American Woodworker 149

8/7/2019 American Woodworker 149

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DAZZLIN WH TE MACHI , S , AT MATCHG .Q71SP

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IN TRODUC TORY PRIC EG0513P $49801 7" HEAVY~DUTYBANDSAWIN TRODUC TORY PR IC E$69800

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4/84

25 TH A N N I V E R S A R Y ISSUE

#149, August/September 2010

Features, 7 Handsome Patio Planter

Srrong, simple joinery provides l as ti ng beau ty .39 Keepsake Trunk

It's as special as the treasures Itwill hold.4 Hot Pipe Bending

Shape wood with apropane torch.48 Stickley Bookcase

How to build a strong bookcase withouta back.S Game-Changers

Tools that changed woodworking in the last25 years.

,60 Miter,ed Door FramesMortlse-and-tenon [eints are the best waytogo.The Ultimate Grinding RigGrind more accurately with shop-macetool rests.

67 Origami WoodworkingCreative design and a near-zero laser kerfmake it possible.

68 KeyedCabinet Moldin.gsDoveta led eys allow seasonal movement.

Departments'10 Workshop nps63 Tool Nut72 My Shop7 Tool Talk77 Turning Wood2 Oops!


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and pane l door conslruction,ThIs one of a kind solut ion lows you t o c rea te extondecl tenons far eJC.tradoor )Oint s t l'B ! '19lh. a d J U S t

Q11)OYe WId th fo r d f f 8 l B f 1 t panel thicknesses and choose from a v an ety o f m ate ria l th ic kn es se s fo ryour 5 Ies and ral ls (518' to H/4). Optional add-on cutters nc re ase y our bits' capabi l i t iese ve n m ore , lowing you to crea te glass pane l ncr dO ub le s id ed proflle doors.

Foor prof] as are aval able; R ound O ve r (1 1'997 60 ). O gee ( 99-7 81 ).Round Over B e ad ( .t I9 9 -7 6 3 ), and Beve l (1t99-764).

StandardswbtenonsI n regu la r 314~stockTo find more information. please go to:www.freudtools.com/PremierRaiiandStile

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More On the Web at AmericanWoodworker.com

Projects for Gardener.sS e e p la n s f o r a p la n te r , a 9 -p o t s t a n d a n d a t r e ll i s a twww.AmericanWoodworker.com/WebExtras

Tabletop FastenersL e a r n h o w to m a k e t h e m a twww.AmericanWoodworker.WebExtras

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Game-Changing oolsR a v e a b o u t t o o l s t h a t m a d e o u r l i s t o r l o b b y f o r t o o l s t h a td id n ' t a t www.AmerianWoodworker.com/Webbtras

-s eed Gr dersF o r b u y in g a d v ic e . g o t owww.AmericanWoodworker.(om/WebExtrasI,,",",,,,,,,,,,,

Bending Wood VideoB e n d in g w o o d o ve r a h o t p i p e i s n o s w e a t a twww.AmericanWoodworker.comIWebExtrls

Mitered Door VideoS e e h o w t o m a k e m o r t i s e -a n d -t e n o n J o in ts f o r m i t e re dd o o rs a t AmerkanWoodworker .comIWebbtras

" " ' 1 " " " " " 1 1 ' " 1 . 1 1 " " " - " " ' 1 1 ' . ' 1 ' 16 _.&mert Wo..dwodtar.C'o:m AUGUSTIlHllliIIlU ;10'0
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M a ke s A n d K e e p s W o o d B e a u l i f u JT '"Get Insp ir ed . V is it m inwax.com


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telUte t P technology forsawlng tough woad Kiln Dried Exotic Species Resawing

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Celeb atng 25 YearsTwen ty -f iv e y ears a go, I wa s s tu d yin g fu rn it ure -b u il din gin the m oun ta in s of N orth C arolin a a nd ea ge rly le arn -In g e ve ryth in g I c ou ld a bou t w ood workin g. T ha t sa mey ea r (1 98 5), n ot fa r a wa y In T en ne ss ee , a n oth er w ood -w orke r n am ed Jim Je nn in gs w as p ursu in g h is d rea m a swe ll . J im s ta rt ed Ame ric an Woodwork er out of h is lovefor w ood workin g a nd a de sire to brin g u se fu l a nd ln sp l-ra tio na l w oo dw orkin g In fo rm ation to fe llo w c ra fts me n.

A fte r a fe w y ea rs , J im p as se d th e ta sks o f e ditora nd p ubl is he r to Da vid S lo an in P e nn sy lv an ia . D a vid n urtu re d th e fle dg in gm ag azin e in to a n atio na lly re cog nize d b ra nd . H is te am o f e dito rs p ro du ce ds to rie s t ha t d ee ply in sp ire d wo odwork ers , In clu din g m e . D a vid 's t .e am a ls ocre ate d th e W ood workin g S how s, the firs t ofth elrkln d a nd S la tte d b y som e ofth e b es t w ood wo rke rs In Am eric a.

In 1 99 8, Ame ric an Woodwork er m oved to M in ne sota , a nd th e e ditoria lpen w as passed to Ken Collie r. U nder Ken's leadersh ip a nd a new tea m ofeditors, Ame ric an Woo dwo rk er c on tin ue d its s tro ng tra dition o f p ro du cin gs olid w oo dw orkin g h ow -to a rtic le s, in clu din g p ro je cts , In -d ep th to ol te sts ,(ip s, te ch niq ue s a nd s ho p-im pro veme nt s to rie s. 1 t added up to a rich m ix ofp ra ctic al a nd u se fu l a dvic e. I jo in ed th e Ame ric an Woo dwo rk er team in 2001and beca me ed itor In 2 00 6.

O ve r th e p as t fo ur y ea rs , o ur fo cu s h as rema in ed o n p ro vid in g u se fu l"b uild y ou r s kllls ln fo lT 1 1 atio n. W e 'v e a ls o o pe ne d o ur p a ge s t o a ut ho rs froma rou nd Ame ric a a nd b eyon d. I'm a firm b elie ve r th at th ere is a lot of gre atw oo dw orkin g b ein g p ra ctic ed In s hop s a cro ss th e c ou ntry , a nd Amer icanWoodworker i s t he perfect p la ce fo r w o odwork ers t o te ll th elr s to rie s. W h e th erit 's fo cu se d o n a p ro je ct ('"K ee ps ak eT ru nk ," p ag e 3 9 ), a te ch niq ue ('M lt ere dF rame s;"p age 6 0), fa vo rite to ols ("T oo l N ut,- p age 6 3), o r a n ew w a y to b ulldfum it ure (O rig am i Wo odwork tn g,~ p a ge 6 7 ), Ame ric an Woo dwo rk er remains:T he B est R esou rce for Y ou a nd Y ou r S hop lK ee p th e c hip s fly in g,

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10/84

Wo kshop Tips, C lever Ideas From O ur Readers

Shaper WingsI LOV,E MY$HAPER , but alw a ys w i sh ed I thada bIggertop to h elp balance large parts, R ath er th an buy anew shapen l enlarged th e top by a dd in g h ard w oo dextensions. T he ex te ns iO Fl5 o n th e s Ide s a ll! 1 ~ t hic kan d rwide; th e e xte ns io n on th e from Is 1 th1ck.and6 w i de .

To fa st eJ1 th e exten si ons, I d r il le d and t apped h oles Inth e edg,es of th e ta b le . .T he n .I g lued and screw ed 1" by2" cleats 10 the edges of the e1 lt en slons. 1 u sed a Fo rsmerb it o n th e side extensions and a dado set on th e fronte xte ns io n to c re ate r ec es se s fo r t ig h te nin g the bolts.

John Eng lis h

Terrific TipsWin Terrific Tools!l' , . \ , I , , We 'll giv 'e y ou S 1 00 fo r e ve ry o rigin al orks ho plip we publbh. On Terriflc:Tip is featured n

e ach Is su e .T h e Tem flc T ip w in n er re c eiv es a$250 9 11 tc ar d.

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Workshop Tips conrinut ' f iPressu re Spreade rsGmING READY TO GLUE some p re -fin is hed edg Ingon a hu qe cou nterto p, I rea li1 .e


13/84

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or shop Ti

Faster CleaningHERE 'S A Q UICK W AY TO G ET ALL n lE DUS T OUT o f y ou rmachine's nooks and c rann ies . Mos t s hop va cu um s h aveon e port fo r vac :uuming a nd a second port f or b l ow i ng .Hook up a hose to each port then b lo w an d va cuu m a tth e s am e tim e. Chad S tan t o n

T IR E D O F C H A N G IN GW O R N S A N D PA P E R & D S C S l

D u r a G r i t C a rb 'd e B lo c k s a n d D i s c sL a s t H u n d r e d s o f lim e s lo n g e rT h a n S a n dp a p e r !

Swing-Under Bench Tools RevisitedA T IP IN IS S UE "47 NEEDSSOME CLAR i fi CAT ION . The tipInvolved making a device tos to re smal l stat ionary powertoo ls u nd er y ou r b en ch .P e te r U ng er, th e a uth or o fthe tip, pointed outthatthe d evice w e bu ilt a ndphotographed would workfin e fo r lig htw e ig ht t oo ls ,but heavier tools requiremore stabitity.

Peter 's actual rig isshown at right.He madethe s lo ts in the swinginga rm s q uite lo ng . W h enh e sw in gs th e tool up ,th e p la tform on w hichth e m ot or re sts d ea rs th efront o r th e bench. T henhe s li de s t he platformback. so tha t part o f th eweight of th e motor sitson th e bench i tse lf .

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15/84

Mo is tu re Me te rs M IL ESCRA FT- - -2 Year Warranty

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Start by ripping the ralls to width from 5/4 cedar boards, This project ISmade Withmate nals fro m th e home cen te r

Rout a centered groove inone edge ofeach raU ,to h ou se th e slats,

Rout tenons on the ends of each Sillu si ng a r ab be ti ng b l M ak e one pass oneach ta ce . U se a b ac ker board t o g ui dethe wor Pi ce and p re ve nt b lowout .

Rout rabbets on both edges of th eI ns 'd e s la ts , but on opposite faces, soth e ends look lik e a o z : T he end slab arerabbeted o n only on edge.

Assemble the panels. Sp ac er s b etwee nth e slats create unllbrm g aps. G lue th een d slats f lush w i h th e e nd s of th e ra ils.Nai l rh rest at the lO p and bottom.

,. www

Build e slatted panelsStart by cutting th e rails to length (A -D .A g. A a nd Cu tt in g Ust . page 20) . Jointand square one edge, and th en rip th erails [0 final w idth (P hoto 1 ). W h erep os sib le . r ip off a ny lo os e knots.

R out a centered groov e, 5/16' wide)( 3 /S" deep, on one edge of all th e ralls(P hoto 2). S ligh tly ch am fer th e topedges of th e bottom ralls (but no t th eends), to prom ote w at runoff.

T o m ak e th e slats. plane th e 1x4s to5/S" th ick ness and crosscut th em intow ork able length s. Joint one edge andthen rip e ac h le ng th 3-5/16- wide .

R ou 5/16- x 5/16" rabbets on bothedges to m ak e th e Inside slats (E a ndPh oto 3). L eave about 8 lineal feet w ithonly one rabbeted edge, tom ak e th een d slats (F). T he outer edge of each endslat is s qu ar e. B ec au se th e se slats go onopposite ends of th e panel, th e r ab be tsare on th e front face on h alf o f th emand on th e back face of th e oth er h alf.Often, th e b4s will h ave o ne good facean d o ne n ot-so-g ood face. So , w hen youcut th e end slats to fin al len gth , m ak esure th at h alf of th em are rabbeted onth e "good~face a nd h alf a re rabbetedon th ebad~ face. T his ensures th atonly t he " good faces w ill s how on th ecom pleted planrer. C ut all of th e slats tof in al 9- 7 1S " l en gt h .

U se a rabbeting bit to rout centered5/16" x 5/16" tenons on both ends ofeach slat (P hoto 4). A djust th e bit'sh eigh t and mak e test cuts on scrapstock to dial In th e th Ick ness; use th efence to set t h e l eng th . Use a squarely-c ut b ac ker board w ith a screwed-onhandle to su pp ort th e w o rk piece an dprevent blow ing out th e back edge.

A ssem ble each pan el inside--face up.B u t b efo re y ou start. m ill a p Ue o f l/S "x 1x 2' spacers. Lay th e rails on a na tw ork surface. T hen. starting w ith an endslat, slide each slat Into positlon In th eralls ' gro oves. S lip spacers b etw een th eslats at th e top and th e bottom . Installth e rem aining end slat tofmlsh th e job.M a ke sure both end slats are flush withth e ends of h e rails, th at th e assem blyIs s quare, and th at th e Inside faces of allth e pieces a re o ri en te d c or re ct ly .

R em ove .he end s la ts , a pplyw aterproof g lue. such as T Itebond III


19/84

(seeSources ,page 20), and th en g lu ethem into th e ra lls . flu sh w ith th e ends.M ake s ure a ll o f th e In te rn al s la ts a reevenly spaced. T h en n ail t hem to the rails(Photo 5).Iused a BeadLOCKjig t o d ri ll th ecentered 7/S"deep mortises (Photo 6and Sourc es ). L a yo ut I s s imp le . J us t ma rkth e midpoint o f e ac h mortise o n eachra il . 1 -114 f rom th e to p edge on the to pra l ls and 1-314" fro m th e bottom edgeon t he b ot tom rails.The ji g comes withs him s th at a llo w c en te rin g th e m ortis esin s to ck o f d iffe re n t thicknesses.

U se th e o ffc uts from th e 5/4 x 6 rallsto make 1 x 1- ledgers (G) to supportth e planter 's bottom bo ar ds (H ) .Gluea nd na il a ledger to th e in side of b oths ide panel s, positioned a t t he he ig ht youw an t You ca n moun t th e le dg er s o n th ebottom rail a nd s ta ck br icks to positionth e pots, or you can le t th e heigh t of thepots or the a mount of so li that you p lanto u se d ete rm in e th e ledgers' location.Make the legs

M ake th e le gs (J) by r ipping a 40 "leng hof 2x4 imo two p ieces tha t are1 -9 /1 6 " w ide . Plane th e sa wn faces tos qua r e t he stock. Then c ut th e legs tonnallength a n d ro un d o ve ra ll t he edges.

lay on e of th e pane l s on a f la t s u rf aceand posltlon one leg so it protrudes3/4" at th e p an el's to p and I-lIS" a t th ebot tom. T r ans fe r t he mo rt is e l ay ou tmarks from th e p an el to th e .le g.T he nu se th e m a rke d le g t o t rans fe r t he la y ou tl ines to th e o th er legs (Photo 7). Bes ure to lo ca te th e m ortise s so tha t th e. legs'good s ides w lH face ou t In sta ll th ea pp ro pr ia te sh im s in th e BeadLOCK jig t oCen te r t he mortises. a nd th en d rill.

Assemble and fin ishBeadLOCKs up plie s te no n s to ck th atyou simply cut t o l engt h to c re ate th e1-3/4" long lo os e t enons (K ).M i te r on eend ofeachtenon-the end th at g oe sin th e . le g. Install th e loo se te non s w he nyou glue and damp th e legs to th e sidepanels (Photo 8). A fte r th e g lu e h as s et,re p ea t t he p ro ce ss to glue and c l ampth e end panels b et we en t he s id e p a ne ls(Photog).

App l y th e fin is h (P h oto 1 0 ). 1 useda l ightly p igmen te d e xt erio r o il- ba s ed

Crute mortises for loose tenons Inth e ral ls, us n9 a 8 ea dL DC K jig or othermo r ti si ng t oo l. B e ad lOCJ ( tenon stockI 1 t s the unique mo rt is es s how n here.

Glue and clamp the legs to t h e s idepane l s .Swa b g lu e in th e mort ises andon the e nd s o f e ac h p an el. In sta ll th eBeadLOCKtenons ; then . Ins ta llt he legs.

Merk th e legs formortising bytransferr ing the l ayout l in e s from t hepanels . Each l eg w ill h a ve mort is es o ntwo adjacent fuca

Completl the planter by gluing th eend panels between the ilsst'mbledSIdes.

Apply an exter ior stain to edd color and p ro tec t. lon f rom the r a in and sun.P erio dically reap ply e stain t o ma in ta in t he f in is h .AU,,-" STI,e. ".110 III _ ..lmuj,u.Woodw ""....:0"' 19


20/84

s ta in '( seeSou rces) . The p igmen t,p ro vid es a .measure of UV ,protection.so t he fin is h la st s l onge r.

P lac.e th e bottom boards on th e

l edge rs , l ea vi ng 1/4" to 1/2" be tweent hem fo r d ra in age.

U ne th e planter w ith h eavy-dutyplank. poke some drainage holes, and

fil l It with soli; thIs is th e per fec t setupfor a m in ia tu re h erb ga rd en. O r skip th es oli a nd c re ate In sta nt c olo r by fil lin g th ep lan te r w ith potted flowers.

Fig. A ' E xp lod ed V ie w

I

S e e m o r e p ro je c ts fo r g a rd e n e rs a tA m e r i c a nW o o d w o rk e r . c o m /W e b E x t r a s ,Cutting List Omdl l~s :qLx12 In W.1H'8 ' "TPart Name Qty. Material ThxWxLi W t , , - , 2 . . . . . . 1 " 11-1/4" . .. . CI)Sl416B S I d e b o n o m rail 2 CfdMdKting 1xHf4". """ ' .1)5/4x6( fIId10plll 1 C t d I r . . . . , 1 -1 /4 ". 9 -1 Jr (a)S I 4 . 1 1 60 E n d b o t t o m rd 2 C e d a r Wing 1'.3-]14' x9 - In'Ii)S l h 6 1 I s I d t . l6 &d i r1x4 St'rl J . . S / t 6 " x f.7Jr O t . d )

E n d s a . t I ~rll


21/84

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O n e p r o d u c t c a n ' t fi x e v e r y t h in g b u t o n e b r a n d c a n W h a t e e p r o j e c t G o n " a p r o d u c ts w il l d o it n g h t h e f i r s t t im eI n c r e d ib l y s t r o n g a n d r e l i a b le - T h e T o u g h e s t o n P la n e t E a r t h '


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Special Advertising SectionMake Turning E asier E A S Y W O O D T O O L SOwensboro. KY

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Special Advertising Section-

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nd r laMore Pow er! M ore Features! M ore Fun!P a c k e d w i t l l f e a t u re s , t he n e w T u r n cr a f t e r C om m a nd er M i d i L a t h e s a r e th e m o s t a d va n ce d .p llW f f f u l a n d e a s y t o u se la the I n t h e ir e L m . T he s e 1 0 " a n d 1 2 " s w in g w o r k h o o e s w ' lI h e lp~ e a ly , e f f e c t t v e l y a n d a ff O ld a b ly t u m p e n s , b ow l s , s p l r id , v a s es a nd m o r e .A s k a b ou t o u t p e n m a k i n g s t a r t e r s e t s a n d F A R p e n m a k i n g D V D I

tan ' \ odw rk ers 100'e pen turning for it blend ofamazing w ds, k illed c raft a nd q uic k re ult . Butif you're new to th is type of w oodw ork ing. th e w idevariety of equipm ent and acces aries available can beoverwhelming. Thankfully. Penn State Industries hasput together a greal range of tarter ets thai includeeveryth ing you need to tak e th e fir t tep on th e patht a very fun an rewarding h bb '- r a profitablemall busine .One of P enn tate Industri m t popular ets i thAdva nce d P en M a k in g ~ tarte r t, \ h ich includes a] h p, cast-iron base T urncraftcr ommander m idilath e. T hi lath e h as a generou 12' wing, variablepeed control. a work ligh t and a bed with an 18"capa ity. T h e et com es w ith enough accessories,to o l .xupp lie and blank to make 40 lirnline\ ood pen and pencils (P enn tate ' m ,t popularpen lyle). T he T um crafter C omm nder m idi lath ei pm 'errul enough for YOU to move on to moreadvanced turning prejects-s uch as bow l , pindles.and bottle toppers-w h en you are ready.P enn tate Industries also h a a h u e 'de lion of penk it an d w o od a nd ac ry lic m ateria ls, al ng w ith just

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Sect ion stiYour success Is our business

Along Comes Ironwoodcla ssica l m ach in es forth e s ele ctive c ra ftsman

Just when you thought there was no glimmer of exdtement on your horizon, a long comes Ironwood. S tiles S hop S olu IonsIn troduces a line of dassica l equipment for the e lite cra ftsmen who take pride in qua lity workmanshIp. E xplore our hoes 0jointers, p la ne rs a nd sha pe rs a nd discover th e In cre dib le va lu e offe re d by th es e h ea vy -d uty m ac hin es .A t S tlles S hop S Olutions, w e w ant V O U to fee l secu re W ith your ne w in vestm entby providing tw o yea rs of free techntcal s up port a nd on e yea of pa rt s wa rr an tyfor all Ironw ood products. C heck out Ironw ood today.

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If you 've ever een a eNC router in action, you k nowthat it' c ap ab le o f quiddy an d precisely machiningparts and piece 6 r just abou t anyth ing. But, if'f u'rea mall h op ow ner, you 've probab ly h ad eeondth ou gh ts about it s iz e and a ff ur dabi li ty . W e ll, hop bo thas l is tened to request for a more compae andin ex pe ns iv e m a ch in e, with th e arne usability o f th e irlarger machines. And they've delivered.T h e T yro sport a cu tting area ofI8~ x 24~ x randth e cho ice of a 1hp pindle o r a 2-1/4 h p ro ute r. Itis screw driven and rid n profiled linear bearingsfo r m ooth m ovem ent and minimum backlashW ith a sy [ m re olution of O .00025~ it' capable ofvery preci e w ork in a compact pace. I t' good forquickly creating mall, intricate part. It'll easily fiton a' ork bench . 0 y ou d on 't have to w orry about ittaking over your sh op. And w ith ucb pred ion. it canh elp you quick ly add quality and uniquene to yourproduct . P lu I it' big enough fo r cabinet doors anddrawer . It ' th e perfect size for ign hop. And it'great for doing your ow n m illw ork .

Section

T he T yro come w ith Shop bo t's P artW ork s softw are,th e arne oftw are pack aged \ 1 m their largerm ach ines. I t's perfect for learn ing th e basics ofC C mach ining w ith ou t h aving to inve lin a largemach ine. T h is mak e th e Tyro great for h o I andhop programs. T h e T yro could be th e machine thattakes l' ur w oodv ork ing to th e next le l.

o Bot C C for Any Size Shop.W heth er you 're a w eek end w oodw ork er look ing to expand th escope of your projects or a serious craftsman ready to turn yourpassion into a business, Sh opB ot h as an affordable, American-m adesolution for your w oodw ork ing needs. O ur P R Sstandard C N C systemgives you th e performance necessary to tak e your deslqns to th en ext level, w h ile o ur P R Salp ha o ffers p ro fessio nal-g rade sp eed,pow er and accuracy at a fraction of th e cost o f th e big ironmachines.T o get you up and running as quick ly as possible, w e offer severalinstallation and training options, and. w ith som e ofth e besttechnical support in th e Industry and a w orldw ide peer netw ork ,h elp is never more th an a phone call or a mouse click aw ay . ~ ~G ive us a call or visit us online to find outh ow you can becom e a S hopB otter.

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Big News From Forres t

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S H A R E T H EW A R M T

Gtting the Most fromYou rW oo cf .. Buy in g Bu ck sISBN:97&-1-56Sn.460-4P ro du ctCod e: 46O


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40/844CI_.AlftedouW .......... _ Ilu.un' .."TI.... ~".

s . . . . t . . , . . . . . . ....... dthepiece chat maketh e curved l id.These pieces ar ecalled "staves."

Annge ...._In..,and us e tapeto ho ld t hemtogether fo rgluing. Alp o w e rth e assemblyand drizzle glueInto th e openseams. Then d rawthe assemblytogether, usingt3pe to dose theseams and formthe l id.

C a Ai'".... 1'Z'wIdIh.Paddng tape Iselastic, so youca n mab sightadjusImentsto the widthby changingth e amount dtension on thetlpe.1f )'OlI'Udendsup tobeadiffetWICdimensionthan tr, simplyalter the b c a cdimensions tomatch.

Bevel the stavesT h e lid 's b ev ele d s ta ve s fo rm a

faceted a rc h w hen th e y're g lu edt og et he r. ( T h e f ac et s disappear later,when th e top Is rounded.' Cu ttin g th eb evels Is fu ssy , b ecau se even a 1 /1 0'v ar ia nc e I n t h e angle. re pe ate d ove rn ine s tave s, will ch ange th e sh ape oft he l id 's curve a nd It s o ve ra ll w i dth . B utdon't worry. Just plan to build the box tot o ma tc h th e lid 's d imensions , wha t everthey end up to be. T he b eve l angles ar es pe dfic to 1110 ' , so I recommend usinga digital angle fi n der to set u p y ou rtablesaw ( see Sour ces, page 46).

S ta rt b y p la nin g b la nk s fo r th estaves to , 3116" a nd ri pp in g them l/S"o versize I n w i dth . N o te th at th ere areth re e ty pe s o f s ta ve s: maln , transitionaland en d ( A - c . Ag. A . a nd Cu tt in gUst. page 46). S ta ck a nd s tic ke r t" eb la nk s ove rn ig h t. o r lo nge r, to l et t h emaccl imate- toss a ny th at bow or twist.Bev el th e e dg es o f th e " tru e" s ta ve s(P hoto 1 and Ag. B) .Then c.rosscut themto length .Glue the staves together

layout the s ta ve s I n o r de r, w i deside u p, M a ke su re that the t rans it iona ls ta ve s (B )h av e th e s ha llow ( 7.8 1 b ev elto w ard s th e cen ter an d th at th e g ra in ineve ry p ie ce r un s In m e same direct on-this will re du ce th e ris k o f te ar-o ut la te r,w h en th e facets are ro un ded.

Carefully a lig n a ll th e ends a nd m akesure th ere are no g aps betw een staves.T hen secure th e a ss emb ly w i th dearpacking tape ( P h oto 2 ). P l as ti c packingtape work s bet te r than masking tape:I t's more e la stic , s o you can p ull th ejoints t lght,lt r ev ea ls th e e nt tr e j oi nt ,an d it c os ts le ss. Rm . ta pe across bothends an d In t he m iddl e. N e x t. t ap e thelength of each seam . R ub dow n thetape with a plas tic burn ishe r Of a I lb ra Iyc ard . Wh e n y ou lift th e m iddle stave.th e a rc h should au toma ti ca lly fo rm , byh anging dow n on both sides.

F l ip over th e Slave a ss emb ly , s o th eo pen seam s face u p. and drape th ea ss emb ly ove r an upside-down bowl , tofully o pen th e seam s. D rizzle a bead ofglue jnto each op en seam , m ak ing sureth at it g ets all th e way into th e p oin tofth e~ ':T he glue will ge t squeezedaway from th at po int w h en you p ull th e


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assem bly tog eth er. P ull th e assem blyin to a n a rc h, and h old It to geth er bya dd in g m ore b an ds o f p ac kin g tape.Check t he w id th and mak e adjustments.if necessary (Photo] and Ag. 8).Remove t he tape after th e g lu e hasdried.Rout a rounded Up

Mak e a jig (F ig .q to rout a lip fo r theend ca p (0 ) around t he In s id e o ft he lid'sarched ends.

T o ma ke th e Jig, draw vertical andhorfzo nta I lines centered on a 15"square p iece of M DF (Rg. 0 ). S ta ndthe lid on end and p lace it on th e MDF ,so th at its bottom edges rest on th eborizontal line and th e vert lcal l1neb is ec ts th e c.enter stave.

T race bo th sides o f th e l id ' s facetedshape onto th e M O F. U sing th e verticalc en te rl in e, s tr ik e a long arc th atIntersects the points on the Inside edgew h ere th e staves m eellh ls a rc willextend about "'6 " above th e b ottomedge of each of th e five main staves att heir cen te rs .

D raw a vert ic a l line 1 /1 6 "'n sld e th eInner edge of each end s tave . Cont inueth ese lines all the w ay to the bottom ofth e M D F. S trik e a sma l l a rc in side eachc orn er, to ease th e tra nsitio n b etw e enthe large arc and th e vertical line.

P re cls el y c ut out th e arch ed sh apeyou've d ra wn a nd sand It smooth . G lueb lo ck s alon g th e o utside profile toprecisely p ositio n th e lid 0 " th e jig .

S tand the lid on end and clamp itto you r be nch . In stall a flu sh -trim b ill"yo ur ro uter an d set I ts de pth -o f-cu t tomatch the end cap 's th ick ness. C lampthe j ig on the lid and rout th e ra bb et(P hoto 4),Cut finger Joints

Layout th e f inger joJnts on oneend of the lid ( R g. E ), and dearly m aritth e four sock ets th at you' l l be cu tt in gout. Use a dado set and a mi te r ga ll geequipped with a tall sacrifidal fenc e tomake th e cuts (P hoto 5). T h e sock etsare w ide enough to require two passesto complete. P ositio n th e lid against thefence, align th e dado set w ith th e firstlayout line and set th e first sto p b lo ck .Sh ift th e lid to align t he oppos it e layoutline with th e dado set and set the other

u...jig tI D rout.. .m.d...a.a.tinside bothendsdth e fId. ThIsr abbet roundsth e H d ' s insideedge. 50 thatwhen th e end alPI s InsQIIed, th elid w i l l appear tobend around It.

eutlngerjolntsInthe lid. u s m ga miter gaugew fth a ta l l fence.1W o sockeU (oneineach end) ca nbe cut from eachsetup. Reposittanth e watkpieceand the stopblocks lIItercutting each pair .

Round the topb v removingall the highspots.. Use)'OUrhands to findInegutarIdes Inthe CUNe tha tneed additIonIIatb!Itdori.

.".USTIUlln aeu _'..I ,. -r..__ 41


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Tnn_the IId'Jround ..... andf inger locanonsonto e a c h endcap blank.

5nfoutthe6ngersandrounded proftieon each end cap.Use a fine,.toothblade and cut tothe outside edgesof your marks.

Cut finger jointsin tIM boll sides.The setup IsSimIIM totheone used earlier,bu t this time theso ck ets a re o nlylIT wICk!, so y o uonly need onestop block. andyou can c u t fo ursockets from eachsetup.

stop b lo ck. R ais e th e d ad o se t to makea 3/4" deep cu t. Bear aga inst on e stopblock to make (h e lim p a ss a nd again stth e oth er b lo ck to make th e s ec on dp as s. F lip th e lid e nd -fo r-e nd to c ut th esame sock et In th e o th er e nd . T h e nre position th e lid a nd th e stop blocksto CUt th e n ex t so ck e t. Four d i ffe ren tse tu ps a re re qu ire d to c om ple te a Uofthe sockets,Comp'lete the lid

Use a hand p lane to round the lid(Photo 6). Ifyou use a belt sander fo rthis steP. wait u ntil you 've glue d on theen d ca ps.

Pos it ion t he lid o n e ac h end capb la nk, flu sh a t th e bottom. (Note thatth e gra in ru ns ve rt lc aU yo n th e e nd c ap s.I Then t rans fu r the lid's edge p ro fi le(photo 7). C a r e r u l l y bandsaw the profi le.c llttin g o n th e w as te -s id e e dg es of th elin es y ou 've d ra w n [P h oto 8 ).

T h e J o [n ts p ro ba bly w on 't s lid et og eth erp erfe ctfy w h en yo u l irst dry-fitth e end cap. I u se th e bandsaw,chlselsa nd a I" w ide sta tiona ry be lt sa nder tofin e-t un e th e t ro ub le s po ts . When th e fi tis sa.tisfactory, g lu e in the end c ap s a ndsand t he p ro tru d Ing f in ge rs flush,The box

M ea su re th e le ngth a nd w id tho f th e c.omp le ted lid a nd b uild th ebox ttl t hose d lmens lons-changet h e d irn en si on s In th e cutting l istaooor di ng ly , a s necessary. Cut the boxs id es a nd e nd s IE a nd F J ta fin al s iz e.L ayout the finger jo in ts an one of theside p ie ce s ( F ig . F l.T h en cut th e sockets .u sin g a setu p similar to the one usede an le r to c ut the lt d (Photo 9 J. A t e ac hsetting, flip rh e board over and rotateite nd -fo r-e nd to c re ate fo u r p erfe ctlysymmet ric a l f inger s. Be s ure to c uts oc k ets I n b e th s id e p ie ce s b efo re youchange ea ch se tt in g.

M ark thescekets on a lest e nd p ie ce(P h oto ' 0 ). T h ese so ck etS are w ide, 50you' l l have to set two stops a nd m aketwo passes to c om ple te e ac h o ne . U sethe te st p ie ce to set the stop b locks a ndlest-cut each so ck e t b e fo re y ou c omm itto the re a l e n d p ie ce s. A s w ith th e sidepteces, you can cu t four sockets frome a ch s to p b lo ck s ettin g.

M a ke a supe r- st ro ng 'b ot tom by


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Fig. A Exp loded V iew

''I 6,1 ...Y3 &1f4SS""u (7'YP)

Rg. B L id S taves

T o s e e h o t p ip e b e n d i n g n rs t h a n d , v s i twww.AmerICinWoodwoer.com/WebExtras

aUliun/uPTUUU JOIO _..Imu'ic:u CICI4wwllu._ 45
http://www.americinwoodwoer.com/WebExtrashttp://www.americinwoodwoer.com/WebExtras


46/84

Fig. C Routing Jig F ig. E L id S ockets

Fig. F Front View

SOURCESRockier, www-rodder .com, (BOO) 27"9-4441, Wixey D igita l A ngle G a uge,127487 , S39.99.Mc:Masrer


47/84

Sha wood with propane torch.

H ER E'S A SIM PlE , BUT E ffE CT IVE W AYT O BE N D l'H IN ST OC K (1/4" thick or less).T he on ly t co ls you need are a l eng thof 1-In" g alva niz ed p ip e, a propanetorch . a jig to hold th em both , and a f ir eextinguisher-just i n case. T he pipe Isattached to a flange th rough a hole in3/4" plywood. A j ig secu re ly h olds th epropane torch (P hoto, above). T h is j 1grests on th e bench and damps in a vise.

An y woo ds that ta ke to s te ambending are sultable for h ot pipeb en din g, in clu din g o ak , ash. elm,h ic k or y, b ee ch , birch, m ap e and w alnut.A lth ough th ere are exceptions, m ostsoftwoods and exotic w oods are notg oo d c an did ate s. I n g en er al,a ir -d rie dwood bends more e as ily th an k il n-d rie dwood. Kllndrying ~sets"the adhesivec om po un d b etw ee n th e w ood fibers( called I Ig n n ) in a w ay th at mak es itresistant [.0 the softening e ff ec ts o fheat and moisture. T h is doesn 't m eankiln-dried wood s Im possible to bend;bending It is just more difficult

Always start by making test bends,u.sing ext ra p iece s from th e same batchof blank s th at you've prepared for th ereal McCoy . Having p le nty of ex trablanks is im portant. because you neverk now w here a h dden w eakness migh t

lie , and w atch ing a piece break w henyou don't h ave a spare Is a real bummer.

S oak I nWate r o vern ig ht th e piecesthat yo u p lan to bend. If yo u d on 't h av ea large enough container to complete lyimmerse th e p lec es , w r ap them In asoak ing-w et tow el sealed n a plastic bag.

Ignite th e torch , adjust th e flam e tolow , and dam p th e t or ch I nto p os .iUo non th e cradle. with its nozzle 1ft or 50inside th e p Ipe . I t will take a f ew minu te sfo r th e p pe to g et su ffiC i en tl y hOl Tes tby dripping water on to th e p ip e. If th ew a ter b olls In p la ce , th e p ip e Isn't hotenough. When h e w a ter sk itters off,y ou 're g oo d to g o ( Ph ot o, top right).T o c re ate a tl gh l c ur ve , slowly rockth e strip aga ns th e hot pipe w ith aseesaw motion and a pp ly s te ady. gentlepressure until you feel th e w ood relax.Then In crea se t he p re ss ur e. Whenth e bend I snea r the end of th e strip,h old th e s trip w ith V is e-G r lp p lie rs t oprotect your h and from he hot (really,really h otl) p ip e. T o c re ate a la rg er,more gradua l curve, move he s tripalong th e pipe In1 1 2 " increments,applying flve toten seconds ofpressure in each

by G rrett Glas r

T he p ip e ls r ead y when wa . te r d ro p le tsbounce off th e sur face. If t he d ro pl et s stickan d boil. th e pipe isn't hot enough.

th is bending m ethod resemblesblack smith ing, because each piece 15shaped to fit, one curve at a time.spa Just enough to feel t he s li gh te stbend . C h eck th e fit as you g o ( Ph oto ,above) . To unbend a c ur ve t ha t's to osharp, s imp ly f li p th e strip o ver. T o m ak eS-curves, w ork both sides of t he s t ri p.

T o keep from scorching th e wood,lift th e strip off th e pipe every fifteenseconds (o r any t im e th e s urfa cenear th e pipe begins to look d ry ) a ndq uic kly rewe t itwith a sponge beforecontinuing. A l it tl e scorching is okay Ifthe dam aged surface w ill be h idden. Butscorching c a n a lso ru in a p ie ce ; a tt hevery teast. l t ' l t require addi t iona l sanding.

As w irh s te am bending. spr ingbackis l ikely to o cc ur as th e pieces dry. H owmuch th e p e


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WH EN I'M D ESIGN IN G fUR NIT UR E, Ioften tu m to th e Arts an d Crafts er afo r in sp iratio n. I lo ve th is style. It'ssimple, bu t elegant. When a die ntcommissioned me to build a smallbookcase. I knew exactly what to startw ith : a photograph of a p iece buntby L & J. G . S tick ley around 1 904.

This S ti ck l ey b oo k ca se w asperfect fo r my dlents' modern condo.T h ey w a nted a bookcase with anopen back. so It could be accessedfrom both sides and used as a roomdivider. Ich anged th e Stick ley piece'sdlmens ons and design a bit. but keptth e d i st in c tive lo ok o f i ts s id e p an el s.

A s it turned out, my clientsmoved ju st as Iwas com pleting th eJrbookca se . They didn't need a dividerin th eir new living room, but theydi d need a piece to frt beh ind th eirs ofa . The bookcase w as a natural. It'Sproven to be a ve ry v ersatile d esig n!Mate ials an toolsI b uilt th is book case from quartersaw nwhite oak, the same k ind of woodth at w as used to build most Arts an dC r afts fU rn it ur e. T h is wood~ mostp romin en t featu re 1 5 its ray fleck . b utsome quartersaw n boards have muchb ett er -l oo kin g fig ur e than others. BeforeI g ot started, I set as-ide the best boardsfor th e s de panels and the top.

The double tenons I u sed on th isbookcase can be tr icky to machine.I 've found that th e easIest m eth odIs to make them as loose pieces, lik edowels or biscuits. T his requires a lot ofaccurately machined mort is es , madew ith a plunge router. You can make

your own jigs to guide th erouter, but I u sed the L eighFMT , w h ich I s d esI gn edfo r this k ind of w ork (seeS ou rc es, p ag e 53).ake he joints

Begin by m ak ing the .Iegs(B), C ut th em to final sizeand mark th e best sidesto face front and out R outall th e mortises In th e legs(Photo 1 an d Rg. D ).

M ill all th e rails (C ,D. E. F and K). Be sure10trim a ll of th e side

e.gln by routingdouble mortisesI n th e l eg 5.l'musing a L eigh F M TP ro , a j ig w h ic hhas templates ofvar io us s iz es togulde the router.Many types ofshop-made Jigsca n m ake th es ejoints, too.

Rout similarmortlses!nth e ends of th erai ls . Th is J igh olds w o rk bothhOr izontal ly andvertically.

Mill somelohg,t h in p ie ce s tomake loose ten-ons. R ound th eedges of th esepieces 10 fit th emortises.

Cut the tenonstock Into shortpieces an d gluethem Into th e ra Is .

3


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Fig. A ExplodedView

F o r m o r e i n fo rm a t i o n o n m a k in g t a b l e to p b u tt o n s,g o t o www.AmericanWoodworker.WebExtm

N a e ! s : I)Tman S I O O s h a u I d 1asI1J.lfr l o n g . T h i s ' " r o n e I d I e rtndforplnr_ ~)"'datlnanS 111"nanDMrtNnMmartises.c ) T e n o n S I I J d s h a u I d lit... 2 5 " l a n g o r lW D .,4-til' l o n g .

Cutting istPart Name

A . ,B l e g 5C b Jp e r . .o lo.rrill. fJantIbd. . . . . . ,F lo.r!iii.s i d e, S i d t . . . .H S I I e I t I N c I d I r J t o pJ . . . .l bil~l ....M T e n o n s . u p p e r RI. . . . . . .p T f I I C I M , u p p e r , . . _ . . . .

"LLMO~'y ,,- ~ . I-Y"~]).F ig. 0leg joinery

F ig . B Upper Rai l JoineryY


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Assemble thebookcases s ide ,without glue.Mea5urethedistance betweent he ra llr.. C Uf th eside panels tot h is l eng th .

Cut bisc.uit sJotsin the ends of thes ide pane ls . G l uethe sidestogelher.

Plene the topo f e ac h s id e 50t he Ta li sa nd le gsare f lush. Cutb is cu it s lo ts o nth e inside faceof the t op r ai ls .

Malt.two" an rack in g" ralls,and clamp themtogether. Cut ase ries o f b iscu itslots In thelrends.to m ak e One longgroove. When youseparate t he p ieces ,th e g roove willru n ou t the sideof each piece (seeInset. top left).

gluing the side p anels to t he rai ls -t hejoints th at h ave three b iscu it s. App lyglue only to th e ce nter slo ts, an dleave the ou te r on es dry.This willa llow the p an el to s hrin k a nd swel lwithout b ein g re st ra n ed by glue.

After th e sid es are glued, planeor sand th e top ra il s and le gs sothey're even, Ifnecessary . C u t apair o f b is cu it s lo ts on t he i ns id eedges of the to p rails (Photo 7).Assemble the caseDril l holes an d slots In the ant i- rack ingra ils for fastening the top (A g. B). Theends o f t h e rails have biscuit slots thata re a bit u nu su al. T he se s lo ts a re morel ike grooves- they stop sh y of on e edge,and run an th e w ay out of the otheredge, This d es lg n w i ll a llow you to slideth e piece o ver a b iscu it , a s you 'l l s ee la te r.T h e eas est way to m ake these long slotsI s to damp th e two an ti- ra ck ing rail stogether (Photo 8), and make a numberof regula r p lunge cuts a t ea ch end.

C ut s ing le b iscui t s lo ts In t heuppe_ r fr on t a nd back r ails t ore ce iv e t he a nt i-ra ckin g ra ils . G lu eb is cu it s in t he se s lo ts , and carefUllyremove a ny glue squeeze-out

One more thing before gettingready to glue: Rout slots on th eInside f ac es o f a ll fo ur fro nt a nd backral ls to receive th e woo d b ut to ns (l)that will fasten the top and low ershelf (A g. A ). M ake the buttons froma lo ng piece of stock (A g. C ).

You're ready fo r th e big glue-up.R rs t. p l ace biscuits-without glue-Intoth e ends o f th e anti-racking raUs,a nd cla mp these rails betw een theupper rails (Photo 9). Posit ion th eanti-racking ra il s so they projecta bout 1 14" beyond the ends of m eupper ralls. U se a fram in g s qu are toa lig n th e ends of the up per ra lls.

Glue th e c ase (Photo 10) . Again .with 50 man y p ie ce s to ha nd le , u sin gglue with a lo nge r open t ime will reallyhelp. Before t he g lu e dries, loosen th edamps that hold th e an ti -r ack ing r a ilsan d s lid e th es e ra ils b ac k. an in ch or so ,re e nsu re th at they a ren ' i nadve rt en t lyglued in place. When th e glue dries.remove the anti-racking ra ils . Spreadglue an the ends an d sides of thesera il s, s li de them back in p la ce (Photo11 ), a nd damp them to th e sides.


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F i ishlng pG lue up the shelves (H & j) and topC A ) , an d c ut th em to fin al size.Notchth e sh elv es so th ere's a 1116 - ga pbetween th e shelves a nd th e en dpanels (so you can drop th e s he lv es inp la ce ), a nd a s im ila r g a p b etw e en th esh elv es an d th e legs (s o t he s he lv esh ave r oom to expand In width) , Makea plyw ood template for spacing thesh elf pins and drill their h oles. I useb ra ss s le ev es (see S ou rces) to Une th esh elf pin holes; th e sleeves add a nicedecorative touch to th e book case. Installth e sleeves after th e piece is f inished.

I use a th ree-step nnish onw hite oak . R rst. I app l y a y el lowdy e (see Sources). N ext, I wipe onone or tw o coats of Bartley's JetMahogany ge l s ta in , f ol lowed by threeapp licatio ns o f B artleY 5 g el varn lsh ,

M enhe finish is dry, f as te n. t helow er shelf and th e top to th e case(P hoto 1 2_).Center the top on th ecase. U sing a spacer,leave a lIS- gapbetween th e button and th e rails, toallow th e sh elf and top to expand w henth e humidity is high. In addition to th ebuttons, secure th e to p with sc rewsthat go th rough th e anti~racking rails.SOURCESleigh lndustr es, www.felghj1gs . .com. (BOO)6 63 -8 93 2, FMT P ro , $ 92 9, S up er FMT ,$ 44 9.Frank lin In te rnat iona l. www.t l tebond.com.(800) an-4S83, T iteb ond E xtend W o od G lue.57.50 ro r 16 OLWIdget Mfg. Co~WidgetCoLom, (800)an-927D, 114"Anl ique arass Shelf Pins,11 2SO-ATQS, $ 0.2 9 e ac h ; 1/4" An ti qu e B ra ssS helf P in S le eve s, U -2 SC l-A T o-G . SO.1 5 each.H ome sle ad R n ls hln g P ro du cts,www.homesteadflnlshlngproducts .com.T ransF ast lem on Y ellow pow dered dye stain,water soluble. _3287, 525.95/4 QLl l:arttey OasslcReproduct lons ,www.bar tJeycoliect ionLom, (800) 787 2800 ,Jet M ah ogany Gel 51 In ,S 16.7S/q GelV a rn i h , S I6 .7 5/ qL

deslgm fUffiltul to beslmple, honest andd lre ct"Y ou c n s eemore of her wor1 l at-~

Cut biscuit statsn th e upperrails to receivet he ami -r addngr a lls .C lamp thparts togetherusing biSCl.llts,but no glue AUg"the ends of th eupper ralls witheach other.

Glue the caset og et he r. S li deout th e ann-racking railsbefore theglue dries.

Spread glUt! onth e ends andInner edge of theanti-racking ralls,an d slid e th emb ac k in p la ce .C lam p [h e rallsto the Sides.

Fasten the lowersh.n and top. Ilike using shop-made-woodenb utto ns. w h ic hfit Into grooves Int he r ai ls . B .u no nsa dd a da ssvlook-althoughyou have to ge ton y ou r h an dsa nd kn ee s tos ee t h er nl
http://www.felghj1gs..com./http://www.tltebond.com./http://www.homesteadflnlshlngproducts.com./http://www.bartjeycoliectionlom%2C/http://www.bartjeycoliectionlom%2C/http://www.homesteadflnlshlngproducts.com./http://www.tltebond.com./http://www.felghj1gs..com./


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a a 9 e r s by Tim John onTools that changed woodworking in the last 25 years.

ODW ORKING ENTERED THE 21 ST CENTURY ON A ROLL Since1985, when Ame ric an Woodwo rke r appeared on th e scene,w ood worke rs ha ve b en efite d from th e in trod uction of th ou sa nd sof n ew tools to ou tfit t h ei r wo r kshops an d methods t o deve lopt he ir s kil ls . A few o f th es e Id ea s, th e c re am of th e c ro p, lite ra lly(hanged th e w ay w e think about and pa rt idpat e n th ismarve lo us c ra ft. T he y a re g am e c ha ng ers .

T o r a v e a b o u t th e s e t o o l s o r l o b b y f o r t o o l s th a td id n 't m a k e t h is l is t , v i s i tAmericanWoodworker (orn /WebExtras

Low Cost Asian ImportsFIR ST IN TR OD UCE D IN TH E 1 97 05 , Asian-made tools an d mach in ery b ro ught stiffcompetition to th e Amer ic an marketL ow p rice s w ere the In itia l d ra w, a ndth e In cre as ed b uy in g p ower theyp ro vid ed m ad e it muc h e as ie r t o o utfi ta woo dworkin g s ho p. In many c ases .Imported to ols c os t h alf as m uch asSimilar domes tic models .

Powe r 0 0 1 5 from irn po brandssu ch a sM a kita qu ickly d eve lop ed aloya l fol1OVJingbased on Innovativedes ig n, p erfo rmance a nd dura b ilit y.Once avail ab le only by mall order, Je t' sw oo dworkin g m ac hin es now occupyp rime re a l e st at e in woodworkings pe cia lty s to re s nat io nw id e. G r iz zl yIndustr ial became a powerhouse

by developing an enormouswoodworking productl in e . a compr ehen siveon line ca ta log, supe,rstoreshowrooms, a nd a nn ua lscratch and dent tent salesth at h ave customers liningup befo re s un ris e. D ue to th esuccess ofth ese and otherAsian manufac tu re rs , domest icmanufac tu re rs even tua ll ybegan to Import Astan-rnadetools of th eir o wn . In e ffe ct.Aslanmade machine ry l owe redth e price of virtually a ll woodworkingtoo ls , a llOW ing many woodworke rsto f u lf il l a dream that t hey p rev ious lycouldn't afford to pursue.

The .Ben.chtop PlanerBY MAKING IT P OS St8L TO M Ill. ROUG HLUMBER on househo ld c urre nt witha tantalizingly smal l Investment. th ebenchtop p laner changed woodworking.Befo re i ts Introduction in 1 98 5, t h e on lyoptions fo r processing mas hardwoods pe cie s we re t o pay add it ional m il lingcharges a t the lum be rya rd (p er foot andfa e ac h s etu p) o r to s pe nd t ho osa nd sf or a l ar ge s ta t ionary machine. Redudnga b oard 's th ick ness w as p ro blem atic ,a nd usin g seIf-h a rv es te d l umber fo ra nythin g b ut b ow l tumlng was a p ip ed re am. In retrospect. it's safe to say thatth is tool pla ye d a n Im porta nt role In

woodworking's growth in popularityd urin g th e 1 99 0s.

Ryobi's AP 1 0 p laner started th eparty, a nd to da y's b en ch to p m od elsb uild o n th e o rlg n al d es ig n. R ig id lylocking cutterheads wit h indexed,d is po sa ble k ni ve s and 13" width capacitya re n ow the n orm , a nd m ultip le speedsare common , But t he promise o f a cc es sto u nlim ite d lumb er ch oice s for a ne xc ep tio na l p ric e rema in s a s a bench to pp laner's mostbenefida l f ea tu re , a lo ngwith t he oppor tun it y to explore andd ev elo p n ew woo dwork in g s kills .


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ew Tablesaw Safety TechnologyVIRTUA LLY E VE RY W OODW OR KfR KNOW SABOUTTHE "HOTDOG " S A .W . SawStop'sin nov at iv e b la de b ra k e me ch a nl sm(right, [Op), wh ic h s to ps a nd re tra ctsth e b la de w i th in m illis ec on ds w h e ntriggered, is certainly th e biggestw o odw o rk in g n ew s m ak er o f th e pasttwenty-five yea rs .B ut ju st as im po rtan t are tw o recen tim p ro veme nts in b la de g ua rd s ys tems .N ew ta ble sa w s mus t now be equippedwith a r iv ing knife t ha t ris es an d f a l l sw i th th e b la de . A riving knife greatlyre du ce s t he pos si bi lit y o f a k i ck b ac k .wh ich Is th e m ost common cause ofta ble saw I nJ ur ie s. ac co rd in g t o a ! 'K e n t

s tudy conduc ted by th e Cen te r f orIn jU ryRe se ar ch and Po l icy .

A s ec on d n ew re qu ireme ntstipulates that t ab le saw user s must bea ble to remove a nd in sta ll e ith er th eriv in g k n ife o r th e b la de g ua rd a ss emb lyin 30 s ec on ds o r le ss .On saws fromsev er al manu fa ct ur ers , t he b la de gua rda nd a nti-k ic kb ac k p aw l s n ow s im plya tta ch to th e riv in g k n ife (right, bottom).

T h e se imp rovemen ts re pre se nts igni ficant , we lcome advances int ab le saw s af et y. Bu t w e still stronglyen co urag e w o odw o rk ers to u se tw oo th e r s af ety t oo ls t ha t a re n' t so new : ap ush stIck an d a b ra in .

T o s e e t h e S aw S to p b la d e b ra k e i n a c t i o n , v is i tA m e r i c a n W o o d w o r k e r . c o m I W e b E lt r i I s

The Random Orbit SanderBE FOR E. R AN D OM OR BIT SAN D ER S W E RE IN TR OD UC ED in th eearly 19905, s an din g w a s p ure d ru dg ery . E v en th e besto rb ita l s an de rs w o rk ed s low ly ,p ro du ce d d ou ds o f d us t a ndle ft I ns id io u s sw ir lma rk s t ha t r eq ui re d a dd it io na l t ed io ussan din g b y h an d o r w ith a fin ish in g san der to rem ove.

T o da y, a s in gle ra nd om o rb it s an de r c an re pla ce th re ec onve nti on al s ande rs . b ec au se it s s andin g p ad o sdUate sa ndro tates-th e sam e d ual-a ctio n m ovem en t fo un d in I nd ustriala ir s an de rs . T h is m ov em en t c uts a gg re ss iv ely . a lm o s a sfast as a b elt san der, an d th e m ark s I t leav es are m uch le ssnot ic ea bl e t ha n o rb it al swirl marks , v ir tua ll y e lim ina ting th en ee d f or a f in is h in g s ande r. E f fo rtl es s h o e k -a nd -l oop s ty .lesand ing d isc changes , e ff ec tive dust co ll ec ti on , e rgonomicd es ig n a nd low p ric es a re n ow s ta nd ard fe atu re s.

S andin g may s ti llbe a ch ore, b ut to day 's ran dom o rb itsan ders sp eed th e p ro cess an d co rral th e du st.

F o r t i p s o n u s i n g r a n d o m o rb i t s a n d e r s , v i s i tA m e r i c a n W o o d 0 e r .c o m /W e b E x t r a s

The Do-It-AII Dovetail JigJIG S F OR P RO DU CIN G H AL F-B UN D O OV ET AIL S D OM IN AT ED th em ark et I n 1 98 4, w h e n le ig h I nd us trie s 0 12 58 J igw a s I ntro du ce d.T h e 0 1 258 w as a w inner for tw o reasons, First, it createddov et ail s t ha t l oo k ed h a nd c ut, b ec au se they could be variablyspaced-and it create d th em in a frac tio n o f th e tim e th at h an d-d ov et ail in g wou ld r equi re . S ec ond, i n a dd it io n t o h a lf -b li nddov et ail s, t he 0 125 8 c ou ld c re at e s li di ng dov et ai ls a nd t hr oug hd ov eta ils I n s to ck u p to 1 -1 /4 " t h ic k a nd 2 4~w i de . I n s h ort. th e0 12S 8 co uld d o it all.

H a nd-c ut d ov et ail s a re t he u lt ima te s ig n o f c ra ftsman sh ip ,b ur n ot e ve ry w o odw ork e r has th e tim e o r I nc lin atio n top ro du ce th em . T h e L eig h 0 125 8 an d it s successors ( Includingth e c urre nt 0 4R P ro a nd d o-lt-a ll type pgs p roduced by othermanufac tu re rs ), a ll ow woodworker s o f a ll stripes t o c re at ed ov eta ils w i th th e s am e p le as in g a pp ea ra nc e, p re cis o n a nds tru ctu ra l I nte grity a s d ov eta ils th a h av e b ee n c ut by hand

T o r e a d a b o u t o th e r d o v e t a il i n g j i g s a n d t o s e e a c l a s s i cb la n k e t c h e s t b u il t w i th a L e i g h d o v e t a il i n g j i g , v i s i tA m e r i c a n o o d o r e r . c o m /W e b E x t r a s


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E ffectiv e Dust Co lle ctionM AN AGIN G SAW DUST H .AS BEE NIMPORTANT eve r s in ce woodworke rsmo ve d In sid e, a n d e sp e cia lly s in ceth e in ven tion of p ow er too ls . T hedevelopment of por tab le dustc olle ct ors In t he e a rly 19805 provideda n a ttra ctive a ltern ative to thetra dit ion al du stp an a nd broom . T he see a rly c olle ct ors w e re g re a t fo r s uc kin gu p c hip s a nd s ha vin gs d ire ctly fro mthesource, b ut th ey w eren 't soa de pla t c ap tu rin g tln y d us t p artic le s, w hic ha re th e m os t h az ard ou s.

T od a y, fil te r b a gs c a pa b le ofc ap tu rin g p an ic le s a s s ma ll as one

m icron ca n be found on even thelow es t p ric ed d us t c olle cto rs. a ndn ew ly d es ig ne d c omp a ct c olle ct orsp ro vid e s ta t e- of -t he -a rt p e rf ormanc efo r small s ho ps .

E ven the hum ble shop va cuum ha se vo lv ed . S ome a re n ow s pe cific a llyd es ign ed to extra ct the fin e d ustfro m s an de rs a nd o th er p orta blep ow er too ls . G ive n th eir com pa ct s ize,re as on ab le p ric e, a nd b en efits to s ho pa n d h ea lth , it's ea sy to see w hy m anyw oo dw orke rs h ave m ove d a dustc olle ctor to th e top o f th eirm us tbuy-l ist.

T e T..s ty le T ab le saw FenceIT 'S H AR D T O IM AGIN E A T ABL ESAW W IT HOUT AT -ST YL E F EN CE .A nd y et. 25 yea rs ago , most saw s w ere s ad dle d w ith fe nc est ha t w e re c umb ers ome to a dju st b ec au se th ey h ad to lock atboth e nd s of th e fe nc e arm to s ta y in pos it io n . They we ren 'ta lw a ys a cc ura te , e ith er. s o y o u h ad to ke ep a ru le r h an dy .

In 1978. B il l B ie semey eT h a d a b en er Id ea : a fe n ce b ase don a draf tsman's T -square.1 1 5 h ea d wo uld be lo ng enought o c on ta in both lo ck in g p oin ts , s o o nly o ne raU (of squaret ub in g) wo uld be ne ce s sa ry , a n d t he a rm , rig id ly a t ta c he dto th e h ea d, w ou ld be free t o flo a t a c ro ss t he saw t ab le . Thefen ce cou ld b e ca lib ra te d to th e bla de b y a tape measures ca le a t tached to t he ra il, w it h re pe a ta b le a cc ura c y t o 1/64".Adjusting th e fe nc e w ou ld b e a s e a sy a s l ift in g th e lock leverand s li di ng th e h ea d a long the rail.

B le s emey er 's f en ce g a in e d n a tio n al r ec ognit io n in 1982by w inn ng the IW F Cha l lenger s Award . S ix years l a te r,B iesemeyer fences were av a ila b le o n Powenna tlc 's Ic on icModel 6 6 t a ble saws . D e lt a a c qu ir ed B le s emey er 's I -S qu a res ys tem in 1 9 95 . A n d today. smoo th -gl id ing , p r ec is e ly se tt ing .e a sy -lo ck in g T - st yle f en c es a re t he In d us try s ta n d a rd .

Wood-Uu.com AUGUST/jtpnJrUU 01.010

The Cord le ss D rillH E.R E'S H OW TO ST AR T A R EVO LU TIO N: Ju st cut th e cord !B a tte ry -p ow ere d d rills m a y b e th e m ost s ig nific an tIn no va tion of th em aU , beca use they pa ved the w ay fora n e ntire ly n ew dass of w ood workin g too ls th at in clu de se ve ry th in g fro m c irc ula r s aw s to b rad n a ile rs .

T he first c ord le ss d rills (fro m th e la te 7 0 s a nd e arly SOs)offere d lim ite d p ow er, ra n d ow n qu ickly . a nd w ere s lowto recha rge-bu t they sure w ere ha ndy to ha ve! T od ay 'sIIt hlum -io n -p ower ed d rlll- dr iv er s a re I1 g h twe ig h t, c ompac t,a nd p ow erfu l, a nd the y com e in s izes a nd va ria tion sfo r virtu ally e ve ry d rill in g a nd d rivin g ta sk, in du din gs cre w driv ers , im p a ct d riv ers a n d h amme r d rills .

With th e Im prove men t o f ba ttery t@ c hn ology. the n ee dto ke ep a cord ed drill h a nd y h a s v irt ua lly d is ap p ea re d.Amazon .c om cu rr en tly lists near ly 200 co rd le s s d r il ls , w i thp ric es s ta rt in g u nd er 520. D oes a ny m odern shop not ha veat le a st o n e?


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Routers and AccessoriesTW ENTY-FIVE YEA RS AG O, m any w oodw orkers d idjust fine w ithout a router. In those da ys, routers w erep rim arily u se d to cre ate e dge p rofile s. a nd h avin g arou te r th at could p lu nge m ortise s w a a luxury, Today,ro ute rs a re e ss en tia l t oo ls in virtu ally e ve ry s hop .

The main re as on for t he ro llt er's e no rmou spopular ity is its ve rs at ility . R ou te rs a re a va ila ble in a lls izes a nd they're com plem ented by a huge selectionof b its. Jigs, rou ter ta ble s a nd Join t-m akin g m ach ln es ,You ca n ta ke a router to the wo rk , o r In st all it in a ta blea nd b rin g the w ork to it. U se the sm allest router to trimla mina te or round over sha rp edges: use the la rgeitro ute r to ra is e e nt ry -d oor p an els or c re at e a rc hit ec tu ra lm oldin gs. T urn ers m oun t rou ters on la th es. to createH ute s a nd sp ira ls. C NC mach in es de pe nd on rou te rs tomake e ve ry cut.

In a sm all shop . a single rn ld-stze router ca n be usedfor tem pla te routing, p lunge routing, a nd inla y w ork;to c re ate e dg e p ro file s. pkture frames a nd c ab in etm oldings; a nd to com plete com plex w oodw orking join tss uc h a s lo ck m it ers , d ove ta ils , mort is es , te non s, a nd s tile sa nd ra lls. No other woodworking tool, even a t tw ice thep rice. ca n do ha lfa s m uch.

T o s e e a n e a s y - t a -m a k e f u ll y - f e a t u r e d r o u te r t a b l e , v i s i tA m e r i c a n W o o d w o r k e r . c o m lW e b E x tr a s

The Sliding Compound Miter SawW HENTHE FIRS T S LID ING M ITER S AW AP PEARED in 1988 , th era dia l a rm sa w took a ba ck se at. T ha t first s lide r com bin ed

the convenience a nd a ccura cy of a m otorized m iter saww ith the crosscutting ca pa bility of a ra dia l a rm sa w. Itsability to cut from the top of the boa rd Improved sa fety andits In nova tive slid e m ech an ism p erm itte d amp le cu tt in gca pa city w ith less tra ve l tha n a ra dia l a rm sa w required

T oda y's sliders m ake sim ple a nd com pound cuts w ellbeyond 4S ' In both d lrec tions a nd p rovide 1 2" crosscutca pa dty for stock tha t's w ell over 2 " th ick. T he best m odelsfe a tu re u se r- frie nd ly c on tro ls , e a sy -t o- re ad s ca le s, a n da utom atic bla de gua rds tha t com plete ly enclose the bla de.C omp ac t fro nt-t o-b ec k fo otp rin ts re qu ire le ss s pa ce b eh in dthe sa w, a ccnsldera tlon w hen sp ace Is a n issue.

S lid ers a re p orta ble . so the y don 't re quire p erm an en ts hop sp ace. H ow eve r, m an y w oodw orke rs b uild de dica te dsta nds w ith fences a nd supp ort for long stock. to m axim izet he ir s aw 's e ffic ie nc y. S e ve ra l m a nu fa ctu re rs offe r s ta nd stha t p rovide supp ort. ro ll to a Jobsite. a nd colla pse fors tora ge . G ive n the a ccu ra cy a nd p orta bility of slidin gm iter sa ws, It 's no w onder the ra dia l a rm sa w Is nowv ir tu a ll y obsol ete.

T o s e e a d o - e v e r y th in g m i t e r s a w s t a n d , c h e c k o u tA m @ r i c a n W o o d w o r e r . c o m /W e b E x tr a s


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The Sm all La theBENCHTOP W OOD LATHES HAVE . BEEN AROUND fOREVER ,but In 1 986 , B onnie K lein 's m in i la the sta rted a trend.D esigne d to cre ate je we lry a nd oth er sm all tu rne dobjects. it was c ompact and port a ble . S u d denly ,turning wood didn't re qu ire a la rg e, e xp en sive p ie ceo f ma ch in ery . H ec k. It didn't e ven re qu Ire a sh op .The n otio n of c re atin g In te re stin g items on a t iny,a ffo rd ab le la th e k in dle d n ew In te re st in w oo dt urn ln g,a nd w hen pen-turn ing kits w ere in troduced In thela te 1 98 05 , m in i la th es re ally took off. A ccord ing toIndustry s ou rc es , th ere a re c urren tly te ns of thousands ofactive pen turners In th e U.S.

T he la te st tre nd is for gre ate r ca pa otY , to a llow tu rn ingb ow ls a nd ve ss els up to 12" in diameter in addition to p ensand other sm all ob je cts. S o, m o st m in i lathes have bu lkedup. These new ~midl lathes typlca n y feature c as t I ro nconsrructton, In cre as ed swin g c ap a city , in du ct ion moto rsan d e le ct ro nic v aria b le s pe ed . Bed e xt en s o ns ca n be addedto m any of these la thes, giving them the sp ind le ca pa citY ofa fu ll -.s ize machine.

By com bin ing p orta bllt tY , a mp le ca pa city a nd low cost

Abrasive disc system Wa te r s ton esUser~FriendlySha rpen ing Me thodsW AT ER S TO NE S fiRS T G AIN ED NA TIO NAL A TT ENT ION In th ee arly 1 98Os,w he n th ey w ere fe atu re d In Popu la r S ci e nc emagazine. Before th en , sh arp en in g c his els an d p la ne iro nsw a s a time -c on sum lnq p ro ce ss . Manufa ctu re d by combiningabrasives with a b in de r (u su ally d ay ) [9 c re at e a p oro us ,fria b le s ur fa c e, wa te r s to ne s s imp lif y s ha rp e nin g by cuttingmuch fas te r than o il s to nes .

In 1972 , Sweden's To rgny Jansson p ionee red sharpeningsystems by c ombin in g a n e le ctric d rill, a water-cooledgrind ston e a nd a sim ple s pe ed -re du ction m ech anism toc re ate t he firs t T ormek s lo w-s pe ed w et g rin de r. W ith t heIn tro du ct ion o f a n e le ct ric ally -p ow ere d ve rs io n In 1 9 94 ,To rmek 's s low-speed we t -g rind ing syst em s imp li fi ed" __ .l.mulc&a oodW 'Glk-a:.c:am AUGU$ r I5 I PllM 1.1 2G 1 0

withthe chanceto com plete ceet-looking p rojects In aday or less, t od ay 's sma ll lathesoffer a t emp tin g c pp crtu nlty tn addw ood tum in g to you r w ood workin g skills.

T o s e e a w o r k s h o p d e d ic a t e d to p e n tu r n in g , v is i tA m e r i c a n W o o d w o r k e r . c o m / W e b E x t r a s

, . . . .

W et-grlndlng system

sh arp en in g fo r w o odw ork ers o f any ski ll le ve l, and its successha s sp aw ne d a n um be r of sim ila r d esign s.

T he n ew es t s ha rp en in g s ys tems e lim in ate th e s to nea lt og et he r, In fa vo r o f abrasive d is c s. li ke s low -speed wetg rin de rs , t he se s ys tems make s ha rp e nin g e asy .T h e b igdifference 1 5 t ha t t he se ab ra s iv e d is c s ys tems c re a te k eenedges significantly faster.

F o r s h a r p e n i n g t i p s , r e v i e w s o f a b r a si v e d is c a n d w e tg r in d ir n J s ha rp e n in g s ys te m s , a n d to b ro w s e a h ug e s e le a io no f w a te r s t o n es a n d p o w e r s h a r p e n in g m a c h in e s v is itA m e J ic a n W o o d w o r it e r . ( o m /W e b E x t r a s


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New Joinery MethodsTHERE 'S NO OENYING THE ENDUR ING AP P EAL OFT RA DIT IO NA L JO IN R V , s uc h a s d raw -p in ne d mortis e-a n d- te no n Joi n ts , F Ir st d e . .. .e lop ed for u Ill ra na npu rpos es , t he se jo in ts e....entual ly bee e s ym bols ofe xp ert c ra ftsma n sh ip . W h ile ma ch in es h av e re pla ce dm ost o f th e h an dw ork. tra dition al J oin ery still governsmo st f ur nit ur e c on st ru ct io n.B ut the tim es a re a -cha ngin : th an S 0 innovativen ew J oin ery met ho ds . L ame llo 's c omp re ss ed woo db is cu it a nd b isc uit jo in er re volu tio nize d b uild in g w ithp lyw ood in the late 19 6 05 . Bu t it wasn ' u nt il t we ntyyea rs la ter tha t low -cost b iscu it jo iners m ade thet ec hn olo gy w id ely a va ila b le to woodworkers . At abou tthe sa me tim e, in 1 98 6, the K reg Jig w as Introd uced .T h is t oo l s imp lif ie d pocket s cre w Join ery a nd m a de ita va ila ble a nd a ffo rd ab le to a ll w ood worke rs. T he m ostre cent a dd ition to th e "n ew joinery' grou p ca me jus tfive ye ars a go w ith the in troduct on of F estool's D om in osystem , w hich com bine s m any of the be nefits of dow el,loos e te no n a nd b is cu it jo i n ts .

W hile tra dit iona l jo inery isn 't going a wa y, in m anysitu ation s, th ese n ew meth od s p rovid e u se fu l a nd p ra ctic al

Biscuit JOiner

a lterna tive s. W e 'd love to be a rou nd 1 00 yea rs from now ,to report how the Inno v a ttve n ew qu antum m ortise r w illsu re ly re pla ce th e old -fa sh ion ed la se r m ortlse r th at h asbeen a shop m a nsta y s ince the 2 050 s.

Water-Based FinishesR EG U LA T IO NS L JM IT IN G voe (V OL AT IL E O RG A NIC C OM P OU ND )EM IS SIONS FIRS T A P PEARED ABOUT 1 0 YEARS AG O. Anish lngc omp an ie s re sp on de d w it h t he In tro du ct io n o r w a te r-b as edf in is he s, wh ic h a re c omp le x emu ls io ns o f s olv en t- ba s ed re sin s,w a te r a nd oth er ch em ica ls th at m a ke th e 0 1 1 and wa te r-ge ta lo ng ~ T he se n ew fin is he s p ro ve d c on ve nie nt fo r t he ir s oa p -a nd-w ater de an up , q uick recoa t t im e a nd low od or.

Woodwo rk er s, h oweve r, g a ve t hem m ix ed r ev iews. T y pic a lc on ce rn s w ere t ha t e arly w a te r-b as ed fin is he s w e re le ssd ura ble a nd failed t o Im p art t he ambe r c olo r c ha ra ct eris tico f mos t s olv en t-b a se d fin is he s. A n ls hln g c omp a nie s w ereliste nin g th ou gh , a nd h ave con tin ue d to Im prove th e w orkin gc ha ra c te ris tic s o f t he ir w a te r- ba s ed f in is he s t o mo re c lo se lyma tc h s olve nt-b a se d fin is he s. In fa ct , th ey 've made h ug es trid es . D ura bility is u p a nd ambe r-t on ed w a te r- ba se d fin is he sa re n ow ava ila b le . S an d .a b ilit y. a n ot he r c on ce rn , h a s a l soImproved. As a resu lt , the newest wa te r- ba s ed f in is he s wo rkw ell fo r a ll b ut th e m ost d em a nd in g a pp lic atio ns.

T h e av aila b ilit y o f s olv en t- ba s ed f in is he s h as a lre adyb ee n re st ric te d in s ome s ta te s a nd VOC re gu la tio ns a relike ly to b ec ome in cre a sin gly s tric t. T ha t me an s it's a g oo dId ea t o try ou t th e n ew est w ate r-b as ed fin ish es a nd te ll th em a nu fa du re rs w ha t yo u lik e a nd d islike . Y ou r in pu t w ill le adt o e ve n b et te r fin is hin g p ro du cts .

_UGUHIHPTUII .12010 :w'oodwo .com 59


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ortise and tenonjoints are the best ay 0go.FO R A N EW LO OK in cabinet doors. try ~ lte rin g th e comers. Thiss imple d es !g n,a s e le gant a s a p ic tu re fr ame, c an d rama tic allyc ha ng e th e a pp ea ra nc e o f a c ab in et T h ere 's a p ra ctic al b en efit,too: You'r e n ot te th e re d to stock cope- and- st lc k rou te r b it sa ny more . You c an u se a ny p ro file y ou wish . Routin g th e fr ameIs Just lik em ak ing a m olding. Y ou can m ix a nd m atch a w idevariety of shapes .

Mitered doors h ave to be strong to withstand t h e s tr ai n of

beingconstantly opened an ddosed, so I build them with mortise an d t enon jo in ts .T he p ro cedu re i s t e chn ical it y chal lenging , but It's alsofu n a nd rewarding.


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Start by routing moldings on th e facesofttle doo r' s s ti le s and ra il s. I 'm us ing abeading bi~bu t you GIn use any prof il e bi tyou l ik e .

Sa.w grooves for the paMi. C ut from bothfaces, 50 the groove is exK t ly cen te red. CU ta ll th e pleces IOfinallength-bul withoutmiters.

Mark the ralls for mortising. Measurethe d istance f rom the out sid e edge o r a n yp ie ce t o th e b on om o hh eg ro ov e. T ra ns fe rth is distance to thetop edge and face ofeach ra il .

4Miter the ends of th e I iIUS.Cut exaaIyto th e tip, s o th e o ve rall le ng th of the railsstays th e sam e.

MortJ se th e ra lls . S ta n each morti se onthe m ark ed line, and continue It out theend of th e rail. C u t I h e morti se a s econdtim e, from th e oppo s te face, t o center t

Set up a dado blade In the Iilblesaw forcutting tenons on th e stiles. Raise th e bladelevel wi th [ h e bo tt om edge o f t h e mort is eI n one of th r a i l s .

Mold ings and gro ov esTo begin. mill al l y ou r frame p ie ce s to th e s am e th ic kn es s an dth e sam e w idth. M ake a fe w e xtra pieces. to test setups, Tr im theactual pieces l'longer than t hei r f ina l l ength .

1.Rout the mold in g o n yo ur stile s an d ra ils (Photo 1).It ca ngo o n th e inside o r ou tside edges of th e fram e-w h atevet youlike. Set up a feath erbo ard on yo ur ro uter table to en su re th at allth e c uts a re sm ooth and th e sam e depth .

2 . Cut g roov es fo r t h e panel using a dado set (Photo 2) .For3/4" t h ick doors , Imak e th e g roo ves 1 /4" w ide and 3/8" deep.T h e g ro ov es s hould be exact ly c en te red. The best way t o ensur eth is I s to mak .e o ne cut flip th e p ie ce , a nd cut th e groo ve asec on d tlm e-o nce from e ac h sid e. T h is m ay resu lt I n th e groovebeing a tin y b it w ide r th an 1/4: but that's OK.Centering th eg ro ov es isn 't re qu ire d ( yo u ca n c ut th e g ro ove s o ff c en ter, ifyouw ish ), b ut c uttin g th e ten on s late r w ill be much e as er I fth eg roove s, mort is es and tenons are centered.

3 . Cu t th e s tile s a nd ra ils to th eir lin al.le ng th , b ut d on 'tm ite r th eir e nd s yet

Cut th e mo rtis es4. T he mortises will go In the rails. an d th e te no ns w i ll

go in the stites. They could g o th e o th er way around, too-itreally doesn't matte r. The f ir st step Is to mark th e Inner end ofth e mortises on th e rai ls (Photo 3).The depth of th e g ro ov ede te rm ines t he lo ca tio n o f th is m ark . U s ng a ny p ie ce , set acombination square to th e dIstance IT om th e ou ts de edge tothe b ottom o f th e g ro ov e.. Draw lin es a t th is d is ta nc e on th e topedge an d fa ce o f the ra!Is.

S.lnstall a 1/4" bit I n y our mo rtisin g mac hin e. Adj ust thed ep th -o f-cu t so that th e b it sto ps 3 /8 " above th e ta ble . Adj us tth e fence 50 th e c hisel tid es a ga in st th e b ac k sid e o f th e g ro ove .C u t th e mortlse s, sta rtin g at th e p en dilin e ( Ph oto 4 J. C o n tin ueth e mortise al l the w ay to the end of the ra il, T o ensure th at th emortise Is centered an d th e sam e w idth as th e g ro ove, flip eachpiece aro un d and cu t each m ortise a seco nd tim e, as you didw h en c uttin g th e g ro ov es.

6 . Cu t mit er s on th e e nd s of th e ralls ( Ph oto 5). T h is I s afinicky cut. 50 it's best to creep u p on it by gradual ly read jus tingthe posi tion of a stop blo ck . T h e idea I s to m it er t he comers ofthe ra lls w ith o ut mak in g th e r alls a ny shorter, tip to tip .


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D ado both sides of a scrap piece to fo rma ten on, A djus t the b la de's he igh t until (h etenon slides n cely into h e mortise

Mark the tenon's length. Measure thedistance from th e outside edge of a rail10 th e bo ttom o f t he m ortise. M a rk th fsdistance on the end of th e tenon.

Set the saw 's miter gauge to 45~ , th enm ak e a series of dado cuts on th e sllies toform one side of m e teno n. C ut both endso f e ac h stile, from opposite faces.

Reset the miter gauge's angle In theopposi te d ir ec tion . Cut each tenon'sopposing face.

Pare the saw cut so It's flush w ith th eshoulders.

W a tc h C h a d 's V i d eo o n m a k i n g t h e s e j O i n t s a tA m e r i c a n W o o d w o r k e r . c o m I W e b E x tm

Make two cuts to trim the tenons,

Makethe tenons7 . M ak e th e tenons on th e tablesaw using a 112" w ide dado

set. H rst, adJustthe blade's h eigh t. P lace one of the ralls next toth e blade, th en raise th e b la de u ntil it's even wjth th e b ottomof th e mortise (Photo 6 ). N ex t. using a scrap p iece th at's exactlyth e same thickness a s y ou r r ails a nd s ti le s. s et y ou r mit er g au geto 90" and make a test tenon by dadoing both s id es o f t h e piece(Photo 1). If i t d oesn't fit-and ch ances are It w o n't on the firsttry-cut off the tenon, raise or low er th e blade, and dado a newte non , a ga in m ak ing th e sam e c ut from b oth side s.

8 . Set up you r m ite r g au ge to cut the actual tenons(P hoto 8). Again, start w ith a test piece. S w iv el th e m iter gaug eto 45" , eith er w ay. Fasten a fence to th e miter gauge and c lampa stop block . to the end of th e fence. T he exact poslt:lon of theblock wil l r eq ui re s ome fi ne -t un in g. Use a te st p ie ce th a t's th esame w idth as yo ur stiles an d rails. P ositio n th e stop block soth a YO\J rd ado s et cuts righ t to th e tip of th e tes p iece . Oncethe stop is poSitioned, cut th e stile s. T h is requires more than on ep ass , S ta rt w it h th e stile p ulle d aw ay fr om ( he sto p, then make as er ie s o f over lapping cu ts . C ut both e nd s o f e ac h stile h is way .

1Ii~ www.&mull:_Wood~Lcom AUGU$TI'lPTIMIIR 1010

9 . Reset your miter gauge to rut 45 I n th e oppositedirection (Photo 9) .Aga in , make some test c uts to position th estop block . T h e sh ou lder this cut creates m ust be exactly in th esame plane as th e one you m ade in th e last s tep . Once you're al ls et . cu t th e opposite sid es of all th e tenons.

1 0. C ut th e ten ons to length . R rst, set a combination squareto the distance from th e edge of a stile to th e bottom of amortise (P hoto 10). E xtend the square's blade anoth er 1/32" orso l O r c le ara nc e, th en mark this distance on all th e tenons. S awthe w aste on a bandsaw or by using a handsaw (Photo 11 ).When sawing the m itered po rtio n, stay 1/32" or so away fr omhe shoulders. P are th is cut w ith a ch isel (P hoto 12), and th eJoint 5 complete.


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Tools Our Readers Love1

Spindle SanderSearchAL THOUGH I'VE N EVE R R EA LL YNEEDED rr.t spen six yearssea rchi ng for an o ld, cas t- irono sd lla tln g s pin dle s ander. I f in a llyfou nd th e righl one: a Mall OVS-"made in t he early 19805 .11wl ll li ke lyoutla st m y m ore m od em machines,

A t auction, it w as an uglyduc .k lin g. T he to p wa s heavilyrus red , t he powe r sw it ch w asmiss 09. I t had a t hr ee -phase mo to r,a nd , w o rst o f a ll,m e spindle w asseized. But it came w ith an almost-c omple te se t of spindles and a boxfull of sanding sleeves.

Sack inmy sh op ,l tore themach ine comp le te ly apartRemoving th e rust took a lot ofelbow grease. The s wit ch a nd mot orw ere e asy to replace, but d es pit emy best e ffo rt s, I c ou ld n't fre e t hesp in dle. A loc al m ac hin e sh op c am eto th e rescue.

O ne ne w paint jo b la te r, I'v e g ota mach ine that is q uie t a nd ru nssilky smooth. O nce I l ind the rights pot fo r Max, Iwill be lo ok in g fo rany excuse to us e It I

A la n Scha ff re r

Pu I-Through TablesawMYG R AN DF AT HE R'S 10- C RA FT SM AN T ABlE SAW IS A M OST UN USUA L M AC HIN E. T omak e a crosscut, you snug a board against a fix ed rn lre r gauge, grab a handleabove th e bla de gua rd , a nd Iltefi!lIy pul l the blade through th e wood , It's likea n u ps id e-d ow n ra dia l-a rm sew .ln 1 96 0. w o rk in g on my g rand fa th e r'S c ar pe n-try crew as a 16-year o ld greenhom, Iyanked that handle u ntil m y a rm ached.

According to the manual , t h is t abl esaw Is"particularly designed fo rc ut tin g lo ng p ie ce s; suc h a s raf ters , p lates , studs and joists. Craf tsman calledita "Bulld e( s S aw ; "You co uld m ak e ang led cuts, to o, by p ivot in g th e m it erg au ge a nd s ec urin g it I n a se ries of holes dr il led ln to t he t abl etop . The s aw ' scrosscutting capac i ty Is an amazin g 15-3/8",

That 's not a ll-you could do much more with a Bui lder' s Saw. By loc kin g th eb lade's car riage and u si ng a fence, you c ou ld m ak e rip cuts. You could p lace as tandard m ite r g au ge in to th e right-hand m ite r slot a nd push the wo rk I nto th eb lad e, lik e a re gula r tab lesaw .T h e sa w also acce pte e a dado se t

I'm n ot s ure w hen th is workhorse w as m ade, but I b elieve it dates to th emid-l940s. After my gra nd fa th er p asse d a wa y, It w as le ft to ru st In th e m ilkhouse of a da iry ba rn. I restored it many years la t. er. A lt ho ugh I had to replaces ome g ea rs , it stil i work s f in e .Y ear s a go . p ullin g t ha t h an dle fo r h ou rs on endwasn 't e xa c tly a t hrillin g Job. but a long the way, a y oung k id learned t o lo vewoodworking-the hard way.

G lenn Bo rr eson

INt I ' l l p.1I~ yo.. S 1 0 0 III ,h!!~ ya\l1 faYaif\11!10011.ne w CIt D id ,W I t h f Ib N ".d('fS ,. C anlX t u s bye -rni ll I. ll oo ll 'l . .I ... ,.,l C JI nw o od ....Mh'.cal1l, II ' m ad us atArnt 'f lUn WcIcIdwOIkN, 1285 C I I , pomoe Ctnillf D r I v e . SUl le 1 80 . Uga n. M N 55121 If pgn,bI please ' nd ud l! d l! l1W l p h ot os o f) 'O l lr l oo is .


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T U t imGrind more accurat y

in g R igith sho ..made tool rests.

by Mario Rodriguez

L ET 'S F AC E IT , th e tool rests o n mos t g rin de rs just don'tcu t it . They may be f ine f or sha rpening scissors orlawnmower b la de s. b ut when It com es to woodwor1


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Chisels and Plane IronsM AK IN G A ST RAIGH T E DGE 15 th e biggest p ro blem mos tw o odw ork ers fa ce w h en grinding ch isels and p laneIrons. T hat's because m ost tools ar ider th an th eg rin din g w h e el. s o y ou have to slide e too l from sideto s id e to g rin d its whole fa ce . T h a t's r ea lly h a rd to dow ith a standard tool rest. but a dnch With t h is one,T h e to ol IS se cure ly clam pe d in a comm erda l toolh old er ( se e S ou rc e. rI gh t). w h ic h slid es b ac k a nd fo rth o na l on g p ie ce of electrical tu bin g, Y ou c an lift th e h o ld er

The left tool rest is simply a piece of electrical tubingmoun te d o n a b lo ck .AVe r ita s tool holder fits It perfectly.a nd c an be s li d b ac k and f or th o r lifted o ff a l a ny lime .

off th e tube at any point to i nspect your p rog re ss .T he second problem m ost w oodw ork ers h ave w itha standard tool rest i s f in e-tu nin g th e g rin din g ang le .

P r ec is ely ma tc h in g an exi stin g ang le saves yo u lo ts o f tim eon th e gr inder. This tool re st Is e as y t o a dju st: T o changeth e g rin din g a ng le . y ou j o u s t m ove th e rest In o r OUSOURCEL I! 'e 'Va ll eyToo ls . www .l eeva ll ey .(CN1 '\ , (BOO )871 -8158,Veri .,5Grinding Jig. 1f05M06.01. 524.50.

To adjust the angle of the toot 's bevel , s imply moveth e to ol rest in o r o

American Woodworker 149

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Transcript of American Woodworker 149