Wood - May 2016

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    • ALMOST A MILLION SQUARE FEET PACKED TO THE RAFTERS WITH MACHINERY & TOOLS

    • 2 OVERSEAS QUALITY CONTROL OFFICES STAFFED WITH QUALIFIED GRIZZLY ENGINEERS

    • HUGE PARTS FACILITY WITH OVER 1 MILLION PARTS IN STOCK AT ALL TIMES

    • TRAINED SERVICE TECHNICIANS AT BOTH LOCATIONS • MOST ORDERS SHIP THE SAME DAY

    PURVEYORS OF FINE MACHINERY ®, SINCE 1983!

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    FOLLOWUS:17805

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    VIEW VIDEO LIBRARY

    G0555LANV ONLY $555 00

    30 TH ANNIVERSARY

    14" DELUXE BANDSAW• Motor: 1 HP, 110V/220V, single-phase,

    TEFC, 11A/5.5A• Precision-ground cast

    iron table size: 14" sq.• Table tilt: 45º R, 10º L• Cutting capacity/throat: 13 1 ⁄ 2"• Max. cutting height: 6"• Blade size: 921 ⁄ 2"–931 ⁄ 2" L (1 ⁄ 8"–3 ⁄ 4" W)• Blade speeds: 1800 & 3100 FPM• Approx. shipping weight: 247 lbs.

    INCLUDES QUICK-RELEASE BLADETENSION LEVER

    CAST IRON WHEELS

    177335

    14" 1 3 ⁄ 4 HP DELUXE 110V BANDSAW

    • Motor: 13 ⁄ 4 HP, 110V/220V, prewired110V, single-phase, TEFC, 15A⁄ 7.5A

    • Precision-ground castiron table size: 19 3 ⁄ 4" x 143 ⁄ 16" x 11 ⁄ 2" thick

    • Table tilt: 45º R, 8º L• Cutting capacity/throat: 13 3 ⁄ 8"• Max. cutting height: 10"• Blade length: 106"• Blade speed: 3000 FPM• Approx. shipping weight: 284 lbs.

    G0778 ONLY $1150 00

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    10" HYBRID TABLE SAW

    G0771 $795 00 SALE $695 00

    • Motor: 2 HP, 120V/240V, prewired 120V, single-phase, 60 Hz• Amps: 15A at 120V, 7.5A at 240V• Precision-ground cast iron table w/ wings: 40 1 ⁄ 2" W x 27" D• Table height: 353 ⁄ 8"• Footprint: 21" L x 191 ⁄ 2" W• Arbor: 5 ⁄ 8"• Arbor speed: 3450 RPM

    3092372

    • Max. depth of cut:@ 90°–31 ⁄ 4", @ 45°–21 ⁄ 4"

    • Rip cap.: 30" R, 15" L• Overall size:

    571 ⁄ 4" W x 353 ⁄ 8" H x 371 ⁄ 2" D• Approx. shipping weight:

    348 lbs.

    $99$99 shipping lower48states

    T26900 10 Drawer, 52” W ONLY $455 00T26899 8 Drawer, 40” W ONLY

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    T26903 14 Drawer, 52 1 ⁄ 2” W ONLY $795 00

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    T26898 8 Drawer, 26" W ONLY $239 95

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    TOOL CHESTS• Gas Springs • Grease-resistant, cushioned drawer lin• Rubber casters with brakes

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    10" X 18" VARIABLE-SPEED WOOD LATHE• Motor: 1 ⁄ 2 HP, 110V, single-phase, 6A• Swing over bed: 9 3 ⁄ 4"• Swing over tool rest base: 7 1 ⁄ 4"• Distance between centers: 16 3 ⁄ 4"• Tool rest width: 5 3 ⁄ 4"• Spindle size: 1" x 8 TPI RH• Spindle speed: Variable, 650 – 3800 RPM

    • Spindle and tailstock taper: MT#2• Overall dimensions: 37 3 ⁄ 4" L x 12" D x 15" H• Approx. shipping weight: 79 lbs.

    12 1 / 2 " BENCHTOP PLANERWITH BUILT-IN DUST COLLECTION

    G0790 ONLY $289 95$79

    shipping lower48states

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    • Motor: 2 HP, 120V, single-phase, 15A• Max. cutting width: 121 ⁄ 2"• Max. cutting height: 4 1 ⁄ 2"• Max. cutting depth: 1 ⁄ 32"• Feed rate: 26 FPM• Number of knives: 2, reversible HSS

    • Knife size: 121

    ⁄ 2" x1

    ⁄ 2" x1

    ⁄ 16"• Cutterhead speed:8750 RPM

    • Number of cutsper inch: 60

    • Approx. shippingweight: 72 lbs.

    3092372

    G0786 ONLY $385 00$$

    2 HP PORTABLE DUST COLLECTOR

    • Motor: 2 HP, 240V, single-phase, 9A• Air suction capacity: 1360 CFM• Static pressure: 11.3"• Filter rating: 2.5 micron• 6" Inlet and "Y" fitting with two 4" openings• Impeller: 123 ⁄ 4" cast aluminum• Portable base size: 27 1 ⁄ 2" x 471 ⁄ 2"• Upper bag size (dia. x depth):

    191 ⁄ 2" x 471 ⁄ 2"• Lower bag size (dia. x depth):

    191 ⁄ 2" x 33"• Lower bag capacity: 5.7 cubic feet• Powder-coated finish• Height with bags inflated: 94 1 ⁄ 2"• Approximate shipping weight: 137 lbs.

    $79$79 shipping lower48states

    $79$79 shipping lower48states G1029Z2P ONLY $350 00

    2 HP DUST COLLECTOR WITHALUMINUM IMPELLER• Motor: 2HP, 240V, single-phase, 3450 RPM• Motor amp draw: 9 Amps• Air suction capacity: 1550 CFM• Static pressure: 11"

    • 6" inlet has removable "Y" fittingwith two 4" openings• Impeller: 123 ⁄ 4" balanced

    cast aluminum• Bag capacity: 5.7 cubic feet• Standard bag filtration: 2.5 micron• Portable base size: 21 1 ⁄ 4" x 331 ⁄ 2"• Bag size (dia. x depth): 191 ⁄ 2" x 33"• Powder-coated finish• Height with bags inflated: 78"• Approx. shipping weight: 122 lbs.

    G0814 w/ Cabinet Stand ONLY $595 00G0813 w/ KD Stand ONLY

    $

    52500

    • Motor: 1 HP, 110V/220V, single-phase, 14A⁄7A• Prewired voltage: 110V• Table size: 6 5 ⁄ 8" x 473 ⁄ 8"• Number of knives: 3• Cutterhead speed:

    5000 RPM• Cutterhead diameter: 2 1 ⁄ 2"• Maximum depth of cut: 1 ⁄ 8"• Maximum rabbeting depth: 1 ⁄ 2"• Cuts per minute: 15,000• Fence size: 29 1 ⁄ 8" long x 4" high• Approx. shipping

    weight: 262 lbs.

    6" JOINTER WITH KNOCK-DOWN STAND

    AND BUILT-IN MOBILE BASE

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    FREE SHIPPING!to lower 48 states

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    © Copyrigh t Mered ith Corpo ration 2016 All righ ts reserve d Printed in the U S AMeredithC orporationallowsthe purchaserofthi smagazinetophotocopytheinc luded patternssolelyforpersonaluse Anyotherr eproduct ionofthesepatterns isstrictlyprohibit ed

    Our sub scr ibe r l is t i s occa sion al ly m ad e avai lable to careful ly se lected f irm s wb e o f in t e r e s t t o y o u . I f y o u p r e f e r n o t to r e c e i v e in f o r m a t io n f ro m t h e s e c o mp h o n e p l e a s e le t u s k n o w . Se n d y o u r r e q u e s t a lo n g w it h y o u r m a i lin g l a b eServ ice PO Box 37508 Bo o n e IA 50037-0508. xx

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    Issue No.Vol. 33, No. 2May 2016

    Better Homes and Gardens ®

    EDITORIAL C ONTENT C HIEFDAVE CAMPB

    DEPU TY EDITORCRAIG RUEGSEGGER

    ART DIREC TORKARL EHLERS

    DIGITAL C ONT ENT MANAGERLUCAS PET

    SENIOR DESIGN E DIT ORKEVIN BOYLEDESIGN E DIT OR JOHN OLSON

    T OOLS EDIT ORBOB HUNTER

    GENERAL INT EREST EDIT ORNATE GRANZ

    ADMINISTRATIV E ASSISTANTSHERYL MU

    WOOD

    C ONTRIBU TING C RAFTSMEN JIM H EAVEY, M ARK L ANBRIAN SIMMONS, BOB BAKER, BRIAN BERGSPHOTOGRAPHERS CARSON DOWNING, JASON DONC ONTRIBU TING EDITOR LARRY JOHNSTONC ONTRIBU TING ILLU STRATORS TIM CAHILL, LORNA JROXANNE LEMOINE, KURT SCHULTZC ONTRIBU TING DESIGNER ANNA FLICKINGERPROOFREADERS SAM CADY, BABS KLEIN, BILL KR

    ADVERTISING AND MARKETINGV IC E PRESIDENT GROU P PU BLISHER SCOTT MORTIMERGROU P BU SINESS DEV ELOPMENT DIREC TOR CURT BLADEADV E RT I SI NG AC C OU N T E X E C U T I V E DANIEL WELLSONLINE MEDIA K IT WOODMAGAZINE.COM/MEDIA

    T AKING M EASURE

    You’re a doer

    woodmagazine.com

    Dave Campbell [email protected]

    M y wife got me one of those wristbandfitness gadgets that monitors myactivity (“10,000 steps a day!”), soI’ve been out walking more, especially withthe beautiful springtime weather in Iowa. Callme snoopy, but as I navigate the newish neigh-borhood near our house, my eyes seem tolaser-lock on any open garage door, curious ifI can glean a storage or organization idea, Iguess. More often than not, though, I’mstunned by the absolute lack of stuff.

    Where are the shovels, rakes, and spreaderfor taking care of the lawn and garden? Whereare the mechanic’s tools and floor jack fordoing basic service on the car? Where are thesawhorses and DIY tools for painting, plumb-

    ing, and patching drywall?This generation of homeowners does more“hiring” than “doing.” A lawn service keepstheir lawns trimmed and tidy, the car dealersends emails reminding them of needed ser- vice, and angieslist.com provides them withhighly rated handymen.

    While I’ll admit I can’t do much work onmy car anymore (too many computers inmodern vehicles), I still prefer to do most of

    the work around the lawn and house myself,whether it’s knocking down a wall, building anew one, or working on the pipes and wiresthat run inside them.

    That goes for the furniture between thosewalls, too. Mine may not be as perfect as thefactory-made stuff, and it costs more to buildthan to buy, so my brain sometimes asks,“Why?” But my heart knows—it’s the journey,not the destination, that counts for us doers.

    So here’s to you, if you like to do. We’ve gotyour back with another issue chock full ofunique and practical plans. If you’re new towoodworking, check out the latest install-ment of Idea Shop 6 on page 36 , where wehelp fill your garage and build your skills,

    $150 at a time. And if you’ve got a few years’experience under your belt, Jim Heavey’sarticle on page 20 is a must-read.

    See you in the shop!

    “Hirer” Garage“Doer” Garage

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    2

    PLANS 24LowboyTV Stand Big , b old b ox join ts h igh lig h t the

    tra ition al design ; no jig req u ired .30PatioSet

    Id en tical p arts m a e this m atch ed setasup er-sim p le weeken d b u ild.

    44Mil-SpecAbramsTank You r you n gster wll “ta k” you en d lessly

    w en you b u ild this tou gh wood en toy. 54 Peep-inBirdhouse Get ap eek inside th e world of ou r

    feathered frien d s.68 MemorialBox

    C a ’t turn wood to sae you r sou l?No n eed wth this n o-turn u rn.

    TOOLS TECHNIQUES 36IdeaShop6:StartonStorage Wth on ly 1 5 0 p er p ach eck, you ’ll a d a

    lum b er rak, rou ter, a d rou ter ta le. 40 High-caliberA ccuracywithCalipers If you on ly u se calip ers for ch eckin g the

    thickn ess of p la ed stock, rea this.50 DrawerS lidesDemystified

    Th is gu id e h elps you ch oose a d in stall the righ t slid es for you r p rojec t.

    58 ToolTest:8 Jointers Bigger is b etter. Here’s you r p roof.

    64 HowtoI nstallJointerKnives Skip the d ial ind icator wth this lowtech , n o-fu ss tech n iq u e. 76 Tools&Materials C ordless circ saws a d m ore.

    DEPARTMENTS 1 TakingMeasure Are you a“oer” or a“irer”? 4Wood-WideWeb

    In sp irin g p ics a d h elp ful videos. 6SoundingBoard You r voice, you r p rojec ts, you r shop 12Ask WOOD Ta in g a h esive for g ra ite. 14ShopTips

    Mitersawexten sion s a d m ore. 20Unvarnished

    Just sh u t u p ! 88 What’sAhead Asnea p eek at you r n ext W O O D .

    IN T HIS ISSUE OF

    WOOD®MAY 20 1 6 •ISSU E 23 9

    24

    WOOD magazine Ma 20

    30

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    58

    44

    54

    woodm g zine com

    40

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    4

    Moreofa moviemogul?Subscribetoour YouTubechannelt

    video spacked fullof wood working infoyoutube com /wood

    B IN G E W ATC H

    Howto Flatten You rSh arp en ing Ston es

    Howto Install 3 Typ es ofDrawer Slides in C a in ets

    Rem oving Ru st fromC ast iron Ta les

    Ten sion aBa d sawBla e U sin g the“Flu tter” Meth od

    Im p a t Drivers: HowTheyWork a d W y Y ou Need O e

    W OOD- W IDE W EB WOODMA GA ZIN E C OM

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    WOOD® magazi ne neveruses outside parties to solicitsubscription renewals.The safest,

    easiestway to renew yoursubscription is with a creditcard online at woodm agazine.com /

    m yaccount .Ifyou have questions abouta renew alofferyou’ve received,please callour

    custom erservice line at800 -374-9663,and selectoption 1.W e’re happy to help.

    Source:Septem ber2015 WO OD Pulse Survey

    S raps u lp tu res

    Instead of letting m y w ood scrapslanguish in a pile for years, I turned m y

    grandchildren loose on them . They hada ball creating sculptures using thescraps and hot-m elt glue. I only helpedthem scrollsaw their initials. I’m hopingexperiences like these w ill encouragethem to pursue hobbies that foster theirim agination— like w oodworking!

    — Pierre Falzon ,P ickering ,O nt.

    Fin d th e m ortiseIn issue 235 (October2015), the illustration ofthe HallStorage Bench’sleg on page 60 seem edunclear. What I found:The1⁄4" dim ension appliesonly to the m ortise andthe thickness in front ofthe m ortise (left side ofdraw ing). The thicknessbehind the m ortise (rightside of draw ing) shouldbe1⁄2", not 1⁄4".

    — JeffHall,Lithonia,G a.

    A

    ¼ "

    2 "

    3

    ½

    6 WOOD m ag azin e M ay20

    E-mail [email protected];orw rite to WOOD magazine,1716 LocustSt.,LS-253,Des M oines,IA 50309;orcall800-374-9663,option 2.

    Connect with us

    continued on page 8

    S OUNDING BOARD YO U R V O IC E

    Oak top s y ou r list

    Which w ood species do youuse m ost often in your shop?Oak34

    Pine22

    Cherry11

    Maple11

    Walnut9

    Other13

    Too m an y n ot h esThe exploded view oftheWindow Cabinetin issue237 (Dec/Jan 2015/2016)shows notches cutinto theback ofthe fixed shelves (F).Only the frontedge oftheshelves should be notched.

    — M ichelle W ildes,W ayne,N.J.

    You’re right, Michelle. Addingto the confusion are the pencillines inP otoC , which looklike cutlines, but in factindicate safe gluing area.

    pint erest. com /woodmagazi ne

    twitter .com /WOOD_magazine

    facebook. com/woodmagazi ne

    instagr am.com/woodmagazi ne

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    Ch rle s B rto lo tt

    ofWilliamsville, NewYork,usedmapleandcocoboloforthischeckerboa rd.

    Jim Jen se n ofRochesterHills,Michigan, craftedthischerr ydesk withsteam-bentcurv esforhisdaughter.

    I nprepa rationfortheirfirstgrandchild’sbirth, Ge n e n d Su e B l z ic k ofLafayette,California, builtthi scradlebased ontheplansinissue19 October1987).

    8 WOOD m ag azin e M ay20

    S OUND ING BOA R DYO U R P R O JE C T S

    Sen u s a p h oto of y ou r workW an tto see yourw ork show cased in W O O D ®

    m agazine? Sen d a high -resolution digitalphoto ofyou r

    com pleted projectto w oodm ail@ w oodmagazine.com .

    continued on page 10

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    : [VỲ : [PJR7YV

    -LL[ VM -SĤSLZZ9LWLH[HI SL -\SS:JHSL 3H̀V\[

    4HYRPUN 4LHZ\YPUN

    ; OLYL»Z H YLHZVU Z[VY ̀ Z[PJRZ OH] L I L LU PU\ Z L ZPUJL I L MVYL [ OL I \ PSKPUN VM[OL , N` WPHUW YHT PKZ Th ey ju st c an ’t b e b eat for all sortsof task s wh ere rep eatab ility of m easu rem en tsan d m ark s is c ru c ial. Th at’s wh y th e storystick h as b een an essen tial wood sh op tool forc en tu ries.: [VỲ : [PJR 7YV ; OL < SPT H[L , ] VS[PVU VM; OPZ ; Y\ Z[L K ; VVS Wood p ec k ers n ewSSPRO-9 6 h as all th e featu res an d ac c essoriesy ou ’ ev er wan t. Th e g en erou s 8 len g th is

    ac h iev ed b y fasten in g th ree sec tion s of su p er-rig id trac k tog eth er u sin g c u stom m ac h in edc on n ec tors. Wh en ash orter story stick isn eed ed , th e trac k is q u ic k ly an d easily d isas-sem b led . An arra of fu lly ad ju stab le m easu r-in g an d m arkin g tab s m ak e th e SSPRO-96ex trem ely v ersatile. Th e rem ov ab le en d -stop al-lows in d ex in g off th e ed g e of stoc k . An d alon gth e trac k ed g es, you ’ll fin d laser en g ra edIm p erial an d m etric sc ales.6MMZL[ 4 HYRPUN ; HI Z 4 LHUZ ̧ * LU[LY - PLSK¹ 0Z* V] LYLK Wood p ec k ers all-n ew Offset Mark -in g Tab s allow m ark in g an y wh ere b etweenstoc k ed g es b ec au se th ey step d own th e trac k

    th ick n ess to rest flu sh on th e m aterial. Im ag -in e, n ow y ou c an m ak e p rec ise, rep eatab lem ark s an y wh ere on a4 x 8 sh eet of p ly wood orc ab in et p arts.* HSPWLY 4 HYRPUN ; HI Z - VY 0UZPKL 6\ [ 4 LHZ\ YPUN ( UK 4 HJOPUL : L[\ W With Story Stic k Pro’sC alip er Tab s y ou c an literally “tak e off” th eac tu al d im en sion of acab in et or b ox op en in g orp art th en u se y ou r Story Stic k to set you r sawfen c e for th e p erfec t cu t. Th ese tab s are id ealfor m ak in g p erfec tly siz ed sh elv es, d rawer b ot-tom s, fac e fram e rails, stiles an d m ore.

    ) \ [ ; OH[»Z 5V[ ( SS Y ou c an u se th e SSPRO-9 6to la ou t p rec ise loc ation s for c ab in et p artsin c lu d in g fac e fram e stiles an d rails, p artition s,sh elv es an d d rawers. U se it to m ark p rec ise,rep eatab le loc ation s of c ab in et h ard ware lik e

    d oor h in g es, d rawer slid es an d oth er d ec ora-tiv e h ard ware su c h as k n ob s an d p u lls. Im p or-tan tly, you c an m ark b oth rig h t- an d left-h an d edloc ation s with ou t m ak in g an y tab ad ju stm en ts.* VT WSL[L : [VY` : [PJR 7YV 7HJRHNL Ou rStory Stick Pro-9 6 h as ev ery th in g y ou n eed .In c lu d ed are th e th ree sec tion s of trac k to m ak eu p th e 8-foot len g th , fou r trac k c on n ec tors, fou rstan d ard ed g e m ark in g tab s, two c alip er arm s,fou r offset su rfac e m ark in g tab s for c en ter offield m ark in g , th e en d -stop an d all th e h ard -ware n eed ed for fasten in g tab s an d th e en d -stop .

    Wood p ec k ers, In c . Stron g sv ille, Oh io(80 0 ) 7 5 2-07 25

    See ou r fu ll lin e of Am eric a m a e p rec isionwood work in g tools at wood p ec k .com .

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    W OO D m g z in e M ay20

    Chris designed his 900-square-foot

    casita (Spanish for“sm allhouse”)towork as a shop,butalso to convert

    easily to a guesthouse foreasier

    resale ifhe decides to m ove.

    After n in e m ovesthrough six states inless than 20 years,C hrisFinnerty has becom ean exp ert at outfitting anew shop space.T his onecom bines everything he’slearned.

    O ne trick that’s provenespecially handy throughthe yearsisutilizing beveledcleats for hanging cabinetsand tool-storage boards.T he cleats w ork w ell forfine-tuning a shop setup orreorganizing w ithout m ucheffort. A s a bonus, “If Im ove, I can just take theitem soffthe cleats,unscrewthe cleatsfrom the w all,andhave a clean w allfor betterresale,” C hrissays.

    Router

    Expandingrollers

    Dust collectorand separatorHanging wall

    storage

    Overhead door

    Fireextinguisher

    Toolstorage

    Storage

    Toolbox

    Toolbox

    W orkcenterwith drawers

    Bathroom

    ShowerDouble

    sink

    Aircom pressor

    W ork-benchW orkbench

    TV

    Drafting

    Drillpress

    Clam pracks

    hardboardtoolstorage

    hardboardtoolstorage

    sm all-binstorage

    hardboardtoolstorage

    Drop-dow nvacuum port

    to dustcollector

    Tablesaw

    Planer

    Belt/spindlesander

    3 8 '

    2 3'10 "

    G rinder

    M itersaw

    W hiteboard

    M obile toolstorage

    Stereo

    Shopvacuum

    SOU N DIN GBOA R DY O U R S H O P

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    Sh o w u sy o u r s h o pSend high resolutiondigitalp hotosofyourshop tow ood m ail@

    w ood m aga zine.comandwemayshowcaseitinthemagazine!

    o o d m a g a z in e c o m

    “It’s really distracting to work atthis drafting table,” Chris says jokingly. “I’ve gota view rightup into the Arizona foothills. Ifthis was a hom e, this bum p-outwould be a perfectspotforakitchen table.”

    Rolling up the 9×10'overhead doorreveals Chris’shop garage. Here, he can cutdown sheetgoods forhis woodworking projects orw ork on otherhobbies, including his ’63 Corvette and’07 Harley-Davidson StreetGlide.

    A lthough it’s a fully functional w ood-w orking shop, C hris also considers it hism an cave:“It’s notu nusualfor m e to spendthe entire evening in the shop.I’ve gota T V,a stereo,and a bathroom .There’snotm uch Idon’thave.”

    Chris lifted six cabinets from hanging cleats in his old basem entshop and relocated them to hiscurrentshop—this tim e using a differentarrangem ent.

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    A

    Q

    A SK W OOY OU R Q U E S TI ONS

    f Seek in g a vic e fromoth er wood workers?wood m a azine.com /foru m s

    Or d rop u s a e m al.ask wood @wood m a azin e.com

    12

    G o for serious adhesion w henattaching a granite topI have a granite rem nant left over from akitchen rem odel,and w anttouse itasa top fora coffee table.M y challenge:H ow do Iattachthe slab to m y table assem bly? I’m guessingdrilling into the gran ite isnotan option.

    — N eilThackery,A llen da le,M ich.

    You’re correct, N eil; drilling into graniterequires special tools and expertise, andcould fracture the slab if done w rong. Wechecked w ith severalcabinetand countertopinstallers, and they all suggested using anadhesive.So w e asked experts from FranklinInternational(m akersofTitebond adhesives),DA P, and Liquid N ails.T hey allagree thatthe best choice w ould be a polyurethaneconstruction adhesive, such as: TitebondG R EEN choice Prem ium Polyurethane C on-struction A dhesive,DA P Sm artBond H eavy-DutyC onstruction A dhesive,orLiquid N ailsLN -950 Polyurethane A dhesive.

    A lthough your installerm ighthave used asilicone-based productto secureyourkitchencountertops to the cabinets— a popularchoice am ong the installers w e surveyed—ourexperts advise againstthis.Because yourtablew illlikely be in a location w here itm ightbe bum ped or m oved around occasionally,you need the reliability of an adhesive w ithm oregrip than silicone can provide.

    C apture squeeze-out. O utline the base’s foo tprint w ith m asking tap e,an d m ask the ba se too .W ipe aw ay excess ad he sive an d rem ove the tap e be fore the ad hesive dries.

    B ecau se it’s difficu lt to c lam p a n a ssem bly suc h a s this, w eigh do w n the basew ith heavy objects untilthe adhesive has dried for24 hours.

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    Ar m s lid e s o u t

    Do w e l a n d h o leh o ld s u p p o r t b lo c k s

    in p o s it io n

    Sc r e w e n ds u p p o r t b lo c k

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    1 W OO D m agazine Ma

    T ip s earn u p

    to $150.Ifyourtip is the bestofthe issue,itw ins Top Sh op Tip honors,

    and you receive a toolprize w orthatleast $300 .

    Send yourtip,photos ordraw ings,and contactinfo to

    shop tips@ w oo dm agazine.com

    Because w e try to publish originaltips,please send yours only to W OOD ® m agazine.

    continued on page16

    T O PS H O P

    T IP

    S H O P T IPS WORK FASTER , SMARTER , SAFER

    Slick sliding support reaches far,breaks dow n sm all

    For sending this issue’sTop Shop Tip, Pete receivesa W oodpeckers PRL-V2router lift worth $370.

    In m y sm all shop,fixed supports on bothsides of the m itersawwould have taken upm ore space than I have available.Instead,Idevised this slide-out support system to fitm y m itersaw stand. T he support blocks

    drop into the arm s via dowels, m aking itpossible to quick ly disassem ble the supportor m ove it from one side to the other withjust a push.

    — Pete Bu rke, Torrance, Calif.

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    o p Q u a lity , Gre a t Pr ic e s a n d Ex p e r t Ad v ic e1-800-377-7297•www.pennstateind.com

    Boltaction handlem oothly advancesnd retractsthe rell!

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    Co m p le t e ly A u th e n t icEv ery d etal, from th e on e of ak in d b olt-a tion m ec h a ism to th ep rec ision -en g in eered c om p on en ts, was c arefu lly d esig n ed to en su reu n iq u en ess a d relia ility. Th e realistic b olt-a tion h a d le sm ooth lya v a c es a d retra ts to sec u rely loc k th e re ll in p la e. In c lu d es ab olt-a tion ri e c lip a d rep lic a3 0 c alib er cartrid g e a d rose g oldip for a d ed a th en tic ity. Y ou c a ev en rev erse th e b olt for left

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    16 WOODmagazine M

    Makeglue upsfairandsquare

    I m ake qu ite a few cuttin gbo ards, and h ave fou n d th a

    th e fin al glue-up can be frustratin g,particu larly usin g tippy pipe clam psw h ile tryin g to keep all th e parts squ arean d align ed . A clam pin g jig, like th ison e, m akes th e process m uch sim plerThe jig h olds th e clam ps uprigh t, pin sthe glue-up tigh tly again st its side toen sure it goes togeth er squarely, an dprov ides plen ty o f clam pin g surface foraddin g cauls to keep th e glue-up flat.

    — G ene H eim erm an,Perry,Iow a

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    L I M I T E D S E A T I N G ! R E G I S T E RT O D A Y !

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    oodmagazine com

    continu ed on page 18

    Wh en b u ild in g m y k id sa treeh ou se, I ran in to asn ag : I n eed ed n arrow stoc kan d h ad an ex tra 2× 6 tom ak e it, b u t n o tab lesaw tom ak e th e rip cu t D ig g in gth rou g h a p ile of c u toffs, Ifou n d th e p arts n ec essaryto n ail tog eth er a sim p lesad d le jig for a c irc u lar sawTh ou g h cru d e, it k ep t th eb lad e t rack in g t ru e d u r in gth e cu t

    — Justin Shepard, Colum bus, Ohio

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    Convenient work light

    with 18”ex cablem akes it easierto seeeven the m ost intricatework

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    18 WOO magazine Ma

    S HOP T IPS

    T o d o t h i s m o n t h : ✓

    1 . O r ga ize yo ur sa dpa e r dr aw e r by gr it .2 . Che ck t he t ir e s o n yo ur ba dsaw fo r cr a ks o r e xce ssive w e ar . Cl e a , r e cr o w , o r r e pl a e if ne ce ssar y.3 . S har pe n yo ur car d scr a e r s.4 . Che ck yo ur jo int e r knive s fo r nicks. S har pe n o r r e pl a e if ne ce ssar y.5 . E mpt y dust co l l e ct o r a d t a fil t e r s cl e a .

    F o r he l p co mpl e t ing t he se t asks, visit : w o o d m a g a z i n e . c o m / m a y c h e c k l i s t

    Tape trickwarnsofsharpedges whileturningW h en h ollow in g a n atu ral-edge bow l on a lath e, th e bow l’s

    jagged edges tu rn in to a blu r, m ak in g it d ifficu lt to kn ow

    w h en yo u r han d s are gettin g too close.To give m yself clear

    w arn in g, I ap p ly brigh t oran ge du ct tap e to th e bow l’s ed ges.

    T h e tap e is easy to see,an d doesn ’t beat up m y han d s if they

    com e in con tact.

    — James M eier,B atavia,N .Y.

    Holdlogstightasthey

    rideyour resaw jigM any bandsaw resaw jigs requ irescrew in g o r h ot-glu in g the log to th e

    sled to h old it stead y du rin g a cu t.B u t I

    fou n d it easier an d less m essy to sim ply

    clam p th e log in place w ith a o n e-

    h an ded bar clam p.

    — Jon G ilmore,M ilw auke

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    U N VA R N ISH E D S T R A IG H T TA L K F R O M TH E W O O D -W ID E W E B

    2

    Just Shut Up!by Jim Heavey

    W e teach ou r kids that saying “shutup” is inappropriate. But, forw oodw orkers, that phrase is anim portant adm onishm ent to yourself.Thenext tim e you hand a w oodw orking gift tosom eone and they offer sincere thanks, Isuggest saying,“You’re w elcom e.” A nd thenshut up.

    A dm it it:M ost of the tim e this is w henyou offer disclaim ers such as,“No big deal.”Or “Not bad for the first tim e I tried cuttingdovetails.” Or “The finish w ou ld havelooked a little deeper had I used oil.”

    M aybe the recipient said that this m aster-piece m ust have taken you forever.A nd youcounter w ith:“No,it w as actually really easy.I had som e scrap that I w anted to use up,and this seem ed like a good project for it.”

    Shut up!Friends and fam ily know how m uch you

    m ust care about them to have handcrafted agift.D on’t tarnish that sentim ent by deni-grating your w ork.You are a lot better than

    you give yourself credit for,an d those w hoknow you hold your sincerity and crafts-m anship in h igh regard.You m ight just asw ell have said: “This is nothing special.W hen I m ake som ething that’s really notthat good,I think of you .”

    Shut up!A ccepting com plim ents m akes m any

    w oodw orkers uncom fortable, especiallyw hen they are given in person. So w edeflect those kind w ords by m inim izing ouraccom plishm ents.Or m aybe w e are so inse-cure about our skill that w e im m ediatelypoint out ou r flaw s,figu ring that som eone is

    going to see them anyw ay.

    Listen: A nyone w ho looks for im perfec-tion s in another’s w ork only reflects backtheir ow n character flaw s,not your w ood-w orking m istakes.(A t any rate,if that’s thetype of people you’re m aking things for,consider a n ice gift card instead.)

    A t a w oodw orking show aw hile back,anattendee w anted to show m e his subm issionfor the w eekly contest. A s he opened thecardboard package and un w rapped hisentry,he told m e that he had a bit of troublew orking w ith that particular species ofw ood. He explained that the finish w asaffected by the naturaloils in the stock.Heapologized for not backing up the m aterialw hen he cut the dovetails.

    WOOD m ag azine M ay20

    You m ightjustas wellhave said:“This is

    nothing special.W hen Im ake som ething

    that’s really notthatgood,Ithink ofyou.”

    continued on page23

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    Th e Co m p le te OO M a g a z i n eCo lle c tio n o n USB Drive

    w o o d m a g a zin e c o m / a rc h ive 888-636-4478

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    ENGRAVE IT CUT IT MARK IT

    C reating your own inlays, custom cabinets, and photoengravingshasneverbeensoeasy.E pilog’sversatilelasersallow you to etch, engrave, and cutintricate shapesanddesignsinamatterofminutes.

    T o req u est a b roc h u re, D V D , an d sam p les, c on tac t u s atwww.epiloglaser.com/bhg • [email protected] • 888 437 4564

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    23oodm g zine com

    B efore Ihad even seen h is jew elry box,hehad told m e allthe reasons that I probablyw ouldn’tlike it.

    Itw as actually very w elldone,and I toldhim so. Truth be told, had I entered thatparticular contest, I w ould have taken m y

    projectout of the run ning after seeing his.H e w on handily that w eekend, and hedeserved to.

    T he long-term effects of being so self-criticaland self-effacing getin the w ay ofthejoy that com es w ith w oodw orking. A sidefrom the occasionalscream ing and sw ear-ing, w oodw orking is supp osed to be fun .W hatshould give you pleasure is seeing theappreciative look that you get from thoseyou have chosen to m ake som ething for.Every tim e they look at that clock, night-stand ,or cutting board,they w ill think ofyou.W hile you m ay question your ability,they are in aw e.

    Try this the nexttim e you presentsom e-one w ith a handcrafted item .A fterthe effu-sive and w ell-deserved com plim ents, say,“You’re w elcom e”or “You’re too kind.”

    T hen take a deep breath.Feelthe love.A nd shutup!Trustm e,you’llthan k m e for it.N ow I’ll

    shutup.

    etyoudidn’tnotice th at th e feet of this rec en tly p u b lish ed h u m id or p roject were am ism atch ed size d u e to a rou tin g m istak e. We d idn ’t u se Ph otosh op to fix it. We ju st shu tu p ab ou t it.

    X Jim has been teaching

    and touring with W OOD

    m agazine foralm ost20

    years.You can find him

    in the W OOD booth at

    TheWoodworkingShows

    (thewoodworkingshows

    .com )again thisseason.

    Ongifts, finishflawssometimesescapenotice u n til it’s too late. To th e non wood workerrec ip ien t, th ey’ll escap e d etection forever as lon g as you d on ’t p oin t th em ou t.

    Aside from the

    occasional

    scream ing and

    swearing,

    woodw orking is

    supposed to be fun.

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    24

    V St a nd

    S t r a i g h t f o r w a r d a n d s p a c i o u s

    Ma e high st yled gia t box joint s—no jig needed.T he secr et lies in t he glue up.

    D I M

    E N S I O N S :

    4 8 3 ⁄ 4 "

    L

    ×

    2 0 "

    W

    ×

    2 9 "

    H

    A pproxim atem aterialscost:

    $25046–55"

    ClassofTV

    thatfits

    w ithout

    overhang ing

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    w o o d m a g a z in e c o m

    1 2¾ " 1 8 "

    1 9 "

    18 "

    D

    D

    E

    "round-overs

    "grooves ¼ "deep"from top edge

    #8 x ½ "F.Hscrew

    Tabletop fasteners

    8"

    L

    19 ¼ "

    "round-overs

    4 8"

    S im ple stub tenonsand grooves m ake

    strong doorcorners.

    Adjustable shelf

    Rem ovableshelves

    Enclosed storage

    Big-tim e box jointsrequire no jig;sim ply

    alternate longerand shorterboardsin top,bo om ,andside-panelglueups.

    4 "

    4"S helfpins

    Build w ith atubularsteelbase as shownat left orw itha wooden baseas show n here

    EXPLODED VIEW

    Tip! Edge-glue the

    panels (A,B) in stages,

    two orthree boards ata

    tim e.This helps you keep

    controlofthe end offsets

    and m aintain flush top

    and bottom surfaces.

    f Gettips foredge-gluing panels.woodm agazine.com /

    flattop

    Tip! Align the back

    edges ofthe dividers (C)

    with the inside edges of

    the grooves in the top

    and bottom (A) when

    laying outthe biscuit

    slots.Foreasy,accurate

    alignm ent,slip scrap

    pieces of 1 ⁄4" plywood

    into the grooves.

    A

    AM e a s u r e t h e e n d o f fs e t s p r e c is e lyA board extending too far at one end wilthe other end, crea ting a gap in the box joint.

    ¾ "

    Co n s t ru c t th e c a b in e tN ote: Proper fit ofthe box jointsdependson usingboardsofidenticalwidth and thicknessfor the top,

    bottom ,and sides(A,B).M illallofthese boardsatone tim e for best results.

    1 From3⁄4"stock,cutsix boards 4×47 1⁄4"and

    four 4×48 3⁄4"for the top and bottom (A)[Draw ings 1 and 2 ],and six boards 4×21"andfour 4×19 1⁄2"for the sides (B).

    2 G lue together the boards to m ake the top,bottom (A),and side (B) panels,offset-ting the boards by 3⁄4"atthe ends [ Draw ings 1and 2 , Photo A ].

    3 Edge-glue the dividers (C)[ Materials List ,page 29 ; Draw ing 2 ],and shelves (D ,E)[Exploded View ].

    4Cut the grooves in the top and bottom(A)and the biscuitslots in the top,bot-

    tom ,and dividers (C)[ Draw ings 1 and 2 ].

    5 Finish-sand the inside faces of the topand bottom ,sides,and both faces ofthedividers and shelves.D ry-assem ble A ,B,and C w ith biscuits to check the fit,thendisassem ble the carcase.

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    26

    A fter applying glue to the biscuit slotsand m ating edges, clam p together theA /C assem bly [ Sk ill Bu ild er, Photo B ].

    A pply glue to the box-joint m ating sur-faceson the top/bottom (A )and sides(B).C lam p the sides in position .

    8 D rill 1⁄4" holes centered in the joint fin-gers[ Drawn g 2, Ph oto ].G lue dow elsintothe holesand cut them off[ Ph oto D ].Finish-sand the ou tside ofthe cabinet.

    8 D rillholes for shelfpins in the sides (B)and dividers(C )[ Drawn g 2 ].9 C ut the back (F) to size.Lay out and cutthe w ire opening [ Drawn g 2 ],and finish-sand the back.

    f Getfree plans forsquaring braces and

    benchtop risers.woodm agazine. com /

    bracewoodm agazine. com /

    riserplan

    Set the top/ bottom /divider assem bly on 6 ×6 stock or bench top risers for eas ierclam ping. S qu aring braces ho ld the divide rs perpe nd icular du ring as se m bly.

    B

    SkillB uilderC au l an d sh im sp readc lam p in g p ressu reacross broad p an elsApplying clam ps only at the edges ofw ideassem blies can resu ltin little orno clam pingforce tow ard the m idd le.Ensure ad equa teclam ping across the panelby placing a thinpiece ofscrapw ood— say, 1 ⁄8 " or 1 ⁄4 "— at the

    centerof the glue-up ben eath a caulspann ingthe carcase.

    4 8¾ "

    20"

    #2 0 biscuit slots¾ "

    4 7 ¼ "

    ¼ " groove ¼ " deep in bottomand ½ " deep in top ¼ " from back edge

    4"

    4"

    4"

    14" 20¾ "

    A

    "

    A

    A

    C

    C C

    A

    A

    Shim

    au l

    Squ arin g

    ×

    PART VIEW1

  • 8/16/2019 Wood - May 2016

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    w o o d m g z in e c o m

    21 "

    F

    ¼ "hole 1½ "deep

    #1 8 x1 "brad

    ¼ "dowel1 ½ "long

    20 "

    2"

    2"

    7¾ "3½ "

    A

    ¼ "holes

    "deep

    2"

    2"

    18 "

    B

    6¾ "

    6¾ "

    1 9 ½ "

    19 "12 "

    23 "

    R=1½ "

    2"

    B

    A#2 0 biscuits

    A flu s h -c u t tin g s w t rim s t h e d o w e l s w ithout scarring because the teeth are not set tsides. Put a playing o r business card under a blade w ith se t tee th.

    C o n t r o l d r ill d e p t h w it h s i m p le, nonm arring, w ood stop. Make it by drilling through ascrap that leaves enough bit exposed for your desired depth.

    C D

    A

    B

    CAB INET2

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    28 WOODmagazine Ma 20

    Makeapairofdoors

    1 A sym etricalcorner joints give the doorsa distinctive look and are sim ple to con-struct.C ut the door stiles (G ) and rails (H )to size.E dge-glue the door pan els (I),trimthem to size,and finish-sand them .

    2 G roove the stilesand rails[ Draw ing 3 ]anrabbetone end ofeach part.

    3G lue tw o rails (H ) to a stile (G ), then,

    slide the panelinto the grooves[ Photo EG lue the other stile in place.B uild the otherdoor the sam e w ay.

    4 Bore holes for the hinges [ Source ] in theleftinside stile ofone door and the rightinside stile ofthe other [ Draw ing 3 ].R efer tothe hinge instructions for installationdetails.Finish-sand the doors.

    uildabase

    1 7 ¼ "

    9 "

    1 5 "

    1 "hole½ " deep

    G

    H"rabbets " deep

    European hinge

    3 "

    "

    "centered groove"deep

    G

    H

    I

    2½ "

    11 "

    "rabbets" deep

    Slidethepanelintothedoorgrooveswithoutgluing. A floa ting pan el m ove s with hu m iditycha nges w itho ut cracking or da m aging the fram e

    f If you p la to stanth e TV sta d , a p ly

    stan to th e d oorp a els I) b eforeassem b lin g the d oors.

    Drillhinge clipholesaccuratelywithasimplejig. M ark the hinge loca tion on the side (B),and hold the jig in position to drill the clip holes.

    N ote: To build the steel base as shown in theing photo, fabricate a 48¾ ×20" rectangle osquare tubing with mitered corners. A dd a 6" leach corner. G rind all welds smooth. W eldabout 3" from each corner on the inside of theand back rails to attach the base to the cabiPrime and paint the base. To make the basewood, follow the numbered steps, below .

    f Learn fou r m ethod sfor form ing m ortises

    a d ten on s u sin gvariou s tools.

    wood m a azin e com /m t4wa s

    1 Lam inate 1 1⁄2"-thick stock to m ake blanksfor the base rails (J, K ) and legs (L)[Exploded View ].C ut the parts to size.T hen,cuta groove in each rail(J,K ).

    3 Form the m ortises in the legs (L). T hem ortisesare offsettow ard the outerfacesofeach leg,so m ark each leg for position andm ortise location to m aintain correctorien-tation [ Draw ing 4 ].

    4M ake tenons on the ends of the rails (J,K ) [ Draw ing 4 ], carefully heeding each

    rail’s orientation . M iter-cut the tenons toseatagainsteach other in the leg m ortises.

    5 G lue together the rails (J,K )and legs(L)[Exploded View ]. M easure the diagonals;they m ust be equal to ensure a squareassem bly.C lam p the base.

    6 R ound overthe edgesofthe base [ ExplodedView ]and finish-sand .

    G

    H

    H

    I

    G

    B

    2¼ "

    1¼ "

    1¾ "

    3"

    4"3"

    DOOR(view ed from back)

    3

    E F

    7⁄8 "

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    Cu t t in g Di g r m

    w o o d m a g a z in e c o m

    M te ri ls Lis tFINISHED SIZE

    P rt

    C b in e t

    T W L M atl.

    A to /b otto 3⁄4 20 48 ⁄4 EO

    B sides 3⁄4 20 21 EO

    d ividers 3⁄4 1 85⁄8 1 9 ⁄2 EO

    D ce ter shelves 3⁄4 1 85⁄8 1 97⁄8 EO

    E o ter shelves 3⁄4 18 123⁄4 EO

    F b a k 1⁄4 1 97⁄8 47 1⁄4 OP

    Do o r s

    G stiles 3⁄4 2 ⁄2 171⁄4 O

    H rals 3⁄4 2 ⁄2 1 17⁄ 6 O

    I p a els 3⁄8 9 3⁄ 6 1 5 EOB s e

    J fro t/ b a k rals 2 2 48 LO

    K e d rals 2 2 1 9 1⁄4 LO

    L le s 2 2 8 LO

    Prep arestock for thesep a els as d escrib ed in th einstru c tio s.

    Materia ls k ey : EOe ge-g lue oa , OP–oa p lywoo , Ooa , LOla in ate oa .Su pp lies : #8×1⁄2 flathea screws (10 ); # 20 b iscu its (1 2)self-closin g , Euro ea -styleh inges (4); ta leto faste ers (1 0 );# 1 8×1 b ra s; 1⁄4×3 6 oa d owel; shelf p ins (1 6 ).Bits: Sta ke d a oset, 1⁄8 ro n d -oer b it.

    SourceHinge s an d m ou nting plates: Blum 11 0 °, clipsot-c lose, half-c rake , screwo h ing e, nickel fin ish , noB0 7 1 B3 6 5 0 , $ 5 .48 (4); Blu m fra eless, 0 m m , screwom o n tin g p late, no B17 5 H 1 0 , $1 .83 (4); Woo worker’s Harware, 80 0 -3 83 -0 1 3 0 , wwardwareco .

    ¾ "

    ""

    K

    L

    1 "

    1¼ "

    ""

    1¼ "

    2"

    2 "

    4 5º m iter

    1 "-deepm ortise

    "

    "

    Pro uc ed b yLarryJohnston wth Kevin B oyle Proect desig n : Kevin BoyleIllustratio s: Lorna Johnson

    Pu t it a ll t o g e t h e r

    1 M ark thelocationsforhinge-clip m ount-ing holeson each side(B)[ Exploded View ].D rillthe holes [ Photo F ]and test-m ou ntthedoors.R em ovethedoors.

    2Touch up the finish-sanding as neces-sary.A pply afinish to allassem bliesan d

    com pon ents.(W echosesatin polyu rethane.)You can stain and clear-finish the base,orpaintitw ith sem iglossblack enam elforthesteel-baselook.

    3 A fter the finish dries,invertthe cabinet(A –C ) and attach thew ooden base(J–L)w ith tabletop fasteners[ Exploded View ].

    4 Position the back (F)in the rear openingand lift the top edge into the groove inthe top panel (A ).Raise the panel up andletitdrop into the bottom (A )groove.N ailtheback to thedividers[ Draw ing 2 ].

    5 R eattach thedoorsand installtheshelves.Set the T V on top, com ponents on thecen tershelves,and sitback forabreak.

    BASE DE TAIL4

    J K L L

    F

    ¼ x 24 x 48 " Oak plywood

    1 ½ x 5½ x 96 " Oak (4 needed)

    E E ED I* I*

    ¾ x 3 ½ x 1 2 0 " Oak (2 needed)

    C D E H HG G

    ¾ x 5 ½ x 9 6 " Oak (2 needed) *Plane or resaw to the thickness listed in the M aterials List.

    ¾ x 5½ x 96 " Oak (6 needed)

    ¾ x 5 ½ x 9 6 " Oak (4 needed)

    B

    B C

    D

    A

    A

    This project requires 47 boardfeet of 4 /4 oak and 2 2 board

    feet of 6 /4 oak.

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    30 WOODmagazine Ma 2 1

    Build a cushy chair, love seat, and footrest this weekend.f If you p la to b u y c u sh ion s, rather tha m a e on es sized the sa eas ou rs, b e su re to h a e them on h a d b efore b u ild in g these p rojec ts.Wth so m a y retalers on lin e you shou ld b e a le to fin d cu sh ion ssized wth in a in ch or so of th e wd th a d d ep th of ou rs— a d that’sc lose en ou g h . If you ca ’t, you’ll need to twea th e len g th of som ep arts to a com m od ate you r cu shion s. For th is set we p u rch ased seatcu sh ion s m easu rin g 5 1⁄2 th ick , 23 wde, a d 24 d eep . (We rotatedth e cu sh ion s 9 0 ° , ru n n in g th e “eep ” d im en sion a ross the wd th ofthe ch ars/ footrest.) Th e b a k cu shion s m easure 4 ⁄4 thick , 22 ⁄2 wd e,a d 20 d eep .

    Allthreepiecesin thissnazzy m atchingset requ ire the sam e, super-sim pleconstruction and share the great

    m ajorityofcom ponents.T hechairservesasthebasedesign fortheset,so here w e’lltakeyou step-by-step through bu ilding it. Tom ake the other tw o pieces you follow thesam e instructions but m ake the m inorm odification snoted in red bold forthe loveseatand blueitalic forthefootrest.Itcouldn’tbeeasierorfaster!

    Easy chairs

    P tiosetf We b u ilt this setfrom w ite oa , a

    d en se, rot resista twood . Oth er g ood

    wood ch oices inc lud ered wood , c yp ress,

    or c ed ar.

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    37 "

    R= 1¼ "

    10 ¼ "10 ¼ "

    FRONT LEBACK LEG

    4½ "4½ "

    3"

    3"

    A

    2 "

    7 "

    1 " d e c k s c r e w s

    "r o u n d - o v e r

    1 " de ck s c r ew s

    2½ " h e a v y -d u t y ,w e a t h e r -r e s is t a n t

    p o c k e t s c re w s

    5"

    A

    To b u ild a f o o t r e s t ,s u b s t it u t e f ro n t le g sf o r t h e b a c k le g s . A n d ,s k ip t h e b a c k fr a m e .

    A

    To jo in t h e le g s in a m o r e t r a d it io n aw a y , s e e t h e S k ill B u ild e r o n p a g e 3

    As s e m b le t h e p r o je c te n t ir e ly w it h s c r e w s f o ra q u ic k a n d s t u r d y b u ild .

    To b u ild a lo v e s e a t , s im p lyle n g t h e n t h e h o r iz o n t a l p a r t sin t h e b a c k a n d s e a t f ra m ea n d a d d o n e m o re a n d .F

    C

    C

    F

    "r o u n d - o v e r

    ¼ "

    ¼ "

    20"

    1¼ "

    w oodm agazine.com

    EXPLODED VIEW

    First up,the sides

    1 From 8/4 stock (planed to 11⁄2" thick),cut

    oversized blanks for the front and backlegs (A ,B ) [Materials List, Exploded View ] .Layout and cut to shape the legs [Draw ing 1 ] ,thensand sm ooth. Save the cutoffs for the nextstep. Ifbuilding the footrest,m ake four frontlegsandskipthebacklegs.

    LEG VIEW1

    Tip! To make idenmultiples of parts, ma hardboard templaand use that incombination with a1⁄2"-shank flush-trimrouter bit to trim theto final shape.

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    " p lu g¼ " lo n g

    1 " d ec k s c r e w

    F o o t r e s tra il*

    F o o t r e s tra il*

    1 "

    2½ " h e a v y -d u t yw e a t h e r -r e s is t a n t

    p o c k e t s c r e w

    " r o u nd -ov e r s

    * Fo o t r e s t r a ils a r e t h e s a m e a s c h a ir r a ils b u t a r e 1½ " s h o r t e r

    10 ¼ "

    18½ "

    E

    E

    F

    A

    A

    A

    A

    C

    d e c k s c r e w

    32 WOOD m a az in e M ay2

    2 C ut the chair rails (C ) to size and drillpocketholesw hereshow n [Exploded View ].Forthefootrestcuttherails1 1⁄2" shorterthan thechair rails [D rawing 2 ]. A ttach the rails tothe legs [Photo A ], being m indful to m akem irror im ages. For strength and w eather

    FOOTREST2

    Skill B uilderAtim e-tested alternative to pocket screwsD on’tow n a K reg Jig H D and don’tw antto

    plun k dow n $60 to bu y on e? N o problem .

    S im ply join the legs to the side rails w ith

    easy-to-m ake-bu t-stron g loose-m ortise -an d-

    tenon joints.U se a 1 ⁄2 " up cu tspiralbitand

    plunge routerw ith edge guide to cu ta

    centered m ortise 4" long an d 1" dee p in

    each m ating edge/end as show n below left .To m ach ine the loose tenons,startw ith a

    1 ⁄2 "-thick,4"-w ide blank ofoak at least12"

    long.C heck thatitw illfitsnug in the m ortise

    an d adjus t the thickn ess an d w idth as

    necessary.Th en,routa bullnose profile on

    both edges us ing a 1 ⁄4 " round-overbitw ith

    pilotbearing as show n below .C utthe blankinto tenons 1 7 ⁄8 " long, apply w ater-resistant

    glue,and clam p fora jointthatw illlastthe

    life ofyourpatio set.

    resistance, use K reg H eavy-Duty pocketscrew s. (These require use of a K reg JigH D— see kregtool.com .)

    3 Finish-sand the leg/railassem blies,thenround over the outside edges.

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    " p lu g¼ " lo n g

    " p lu g¼ " lo n g

    1 "d e c k s c re w s

    1 " d e c k s c re w

    1 " d ec ks c re w s

    1 " d e c k s c r e w s

    2" ga ps

    10 "

    22½ " fo r s ing les e a t & f o o t r e s t

    4 6½ " f o r lo v e s e a t

    2 4 " f o r s in g le s e a ta n d fo o t r e s t ,

    4 8 " f o r lo v e s e a t

    2 4 " f o r s in g le s e a t & f o o t r e s t 4 8" f o r d o u b le s e a t

    10 "

    2¼ "

    2¼ "

    3"

    22½ "

    2¼ "

    3¼ "

    4"

    E

    F

    I

    I

    H

    2 " a p s

    22½ "

    2¼ "

    1½ "2¼ "

    J

    H

    N ow ,the seat fram e and back

    Cut the seat fram e front/back (D), s(E), and center (F)[Draw ing 3 ]. Ifbuildingthe love seat, cut the fron t/back tw ice aslong,an d cuttw o seatfram ecenters. Wing on a flat surface, clam p and sctogether the seat fram e (D–F) [Draw ing 3

    2 Cut the slats (G) so they fit snug betw ethe seat fram e sides (E). At the satim e, cut the slats you

    ’

    llneed later for thback fram e.Forthefootrestcutonlyfourslats.

    Space the slats evenly and attach thew ith screw s driven through the fram e sides [Draw ing 3 ]. Before screw ingslats to the seat fram e centers (F), drilldeep counterbores at the pilot holes receive wood plugs. Break sharp edgthe fram e as you finish-sand it.

    4 Cut the back fram e top/bottom , and center (H, I, J) to size [Draw ing Assem ble the back fram e just as you the seat fram e. H ere,too,cutthe top/bot-tom extra lon g if you ’re m aking the love

    seat,and cuttw o cen ters.

    w oodm agazine.com

    AA ttac h the rails to the leg s using 2 1 ⁄2 ” he avy-du ty po cket screws (no glue necess ary).P osition the leg cutoffs to eas e

    clam ping.

    A

    C

    Leg cutoff

    D

    FRAM ES3

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    AA

    B B

    CC

    1½x7¼x84"Whiteoak

    1½x5½x72"Whiteoak

    B B

    1½x7¼x84"Whiteoak

    D D E E

    GG

    GG

    GG H

    HI

    I

    ¾ x4¼x96"Whiteoak

    Onechairrequires18 bd.ft.of whiteoakand 12bd.ft.of whiteoak.

    Onefootr est requires7bd.ft.of white oakand 6bd.f t.of white oak.

    Oneloveseatrequires18 bd.ft.of white oakand 22 bd.f t.of white oak.

    ¾ x8½x96"Whiteoak

    GG

    GG

    F

    ¾ x9½x48"Whiteoak

    J

    Put it alltogether

    Retrieve the leg/side rail assem blies(A–C). To one of them glue and clam p aseat fram e (D–G) [Photo B ]. Reinforce w ithscrew s[Exploded View , Draw ing 2 ].

    2Attach the back fram e (G–J) to the back

    leg just as you did the seat fram e,positioning its bottom edge 1⁄2" above the topedge of the seat fram e.

    Retrieve the other leg/railassem bly andglue, clam p, and screw it in place [Photo C ].4 Com plete any finalsanding and apply aprotective finish. We put dow n threecoats of a clear spar varnish to show theattractive grain of the w hite oak.

    34 W OO D m agazine M ay2

    C utting D iagram (chair) M aterials List (chair)FINISHED SIZE

    Part

    Leg/railassem blies

    T W L M atl. Q

    A* frontlegs 1 1 ⁄2" 4 1 ⁄2" 10 1 ⁄4" O

    B* backlegs 1 1 ⁄2" 7 3 ⁄16 " 37 7⁄8" O

    C chairrails 1 1 ⁄2" 5" 20" O

    Seat fram e

    D front/back 3 ⁄4" 4" 24" O

    E sides 3 ⁄4" 4" 22 1 ⁄2" O

    F center 3 ⁄4" 3 1 ⁄4" 22 1 ⁄2" O

    G* slats 3 ⁄4" 3" 22 1 ⁄2" O

    B ack fram e

    H top/bottom 3 ⁄4" 2 1 ⁄4" 24" O

    I sides 3 ⁄4" 2 1 ⁄4" 22 1 ⁄2" O

    J center 3 ⁄4" 1 1 ⁄2" 22 1 ⁄2" O

    *Parts initially cut oversize.See the instructions.

    M a terials ke y: O-oak.S up plies: 15 ⁄8" deck screw s,2 1 ⁄2" heavy-dutyweather-resistantpocketscrews.

    B its: 3 ⁄8"plug cutterand 1 ⁄8" round-over routerbit.

    U se spa cers to po sition the se at fram e w hen attach ing the second leg /railas sem bly.C heck for sym m etricalsp acing on both sides.

    f Though sparvarnishcontains UV inhibitors,

    like anyclearfinish itwilldegrade from sun

    exposure,requiringsanding orstripping and

    reapplication.To lim it

    the effects ofoutdoorexposure,purchase

    coversavailable fromm anyretailers—sim ply

    search online for“patiofurniture covers.”If

    that’snotsom ethingyou wantto do,then

    considerapplying aheavilypigm ented stain

    orpaintform axim umprotection.

    Po sition the sea t fram e 1 ⁄4 " from the front ofthe leg/railasse m bly (A– C) and 1 ⁄4 " from the

    top ed ge o fthe rail(C).

    E

    H

    C

    F

    B

    CProduced by BillK rier with Kevin B oyleProjectdesign: Kevin BoyleProjectbuiltby Brian BergstromIllustrations: Roxanne LeM oine;KurtSchultz

    B

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    With th e Pla s m a CA M ®

    m a c h in e y o u c a n e a s ily

    m a k e im p re s siv e m e ta l a r tp ro d u c ts . G e t s ta r te d w ith

    o u r re a d y -to -c u t a r t d is cc o lle c tio n o r c r e a te

    y o u r o w n d e sig n s f ro mp ic tu re s d ra w in g s

    a n d le tte r in g .

    719)676-2700

    Cut precise

    m etalshapes

    in a ash!

    all tod ay with th is c od e5 X L K P for y ou r fr ee

    d em o v id eo to see wh at y ou c an d owith th is am az in g m ac h in e!

    3 2 % R [ & R OR UDG R & LW\ & 2

    Z Z Z S ODVP DFDP FR P

  • 8/16/2019 Wood - May 2016

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    36 WOO magazine Ma 2 1 6

    Ide a Shop 6:LumberStorage

    andRouting

    f Watch av id eo of thesh op g rown g , up d atedwth ea h p ac h eckwood m a aine com /is6 p rog ress

    W ith a circular saw and the cuttingjigs previou sly m ade,you now cancut sheet goods and dim ensionallum ber straight and square— the found a-tion al skills of w oodw orking. Practice andim provethoseskillsover the nextfew w eeks

    bybuildingm orefixturesforyourshop.T hebudgetforthe secon d fourpaychecksallow sbuying a few m oretools,including a router,one of the m ost versatile item s in a w ood-w orking shop.

  • 8/16/2019 Wood - May 2016

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    w o o d m g z in e c o m

    Blocks supportsheetsforcirc-saw breakdown.

    Bu ild in g p rojec ts req u ires b oard s a d p ly-wood , a d th at req u ires p la es to store th osem aterials. Part of th is p a ch eck b u y s th ep ly wood a d lu m b er to m ak e arollin g rakth at d ou b les as a sh eet-g ood s c u ttin g sta

    f Find plans forthejigs and fixtures shown.woodm agazine.com /ideashop6

    T h e jig s a w w e c h o s e JS 481L G) a c c e p t s T-s hfor quick blad e chan ges, ha s variab le sp ee d for control,an d orbital action for pow ering through tough m aterials.Find review s ofjigsa w s at review atoo l.com .

    tion . Ad d ajig saw a d som e b la es to y ou rcollection for cu ttin g cu rves a d m ak in gin terior c u ts, su ch as th e n otch es in th e cen -ter su p p ort of th e sh eet-g ood s ra k . Ba ka ou t 10 – 15 from th is ch eck .

    Fullsheetsreston rearface.

    Space forfull-widthcutoffs

    With y ou r sh eet good s org a ized , p ick m aterials for awall-m ou n ted ra k to h oldb oard s. Secu red to wall stu d s b y la b oltsth is 2⅑4-a d -p ly wood ra k h old s p len tlu m b er. Ad d alev el to y ou r toolk it to h ey ou p lu m b a d alig n th e ra k s as y ou fth em to th e wall. After th ese sm all ex p en ses,b eef u p y ou r b a k b y a ou t 115 .

    P ayche ck 6

    P ayche ck 5

    Learn through this series of Idea Sh op 6 articles how to set up a shop by w orking w ithin abudge t of $1 50 every tw o w eeks over 26 p ay periods. C oinciding w ith ea ch paycheck, w eprovide online a collection o f related a rticles, plans, and videos at w oodm agazine.com /ideashop6 .

    To receive a n em ailrem inder of tha t po sting, sign up for our new sletter atw oodm agazine.com /new sletter . The first article in this series ran in W OOD® issue 238(M arch 2016). C atch up w ith the previous installm en ts at w oodm agazine.com /ideashop6 .

  • 8/16/2019 Wood - May 2016

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    P y c h e c k 8P y c h e c k 7

    Learn dozens oftricks and tips fora

    handheld and table-m ounted router.

    woodm agazine.com /routing

    8 WOOD m ag azine M ay20

    Getstarted with ahandheld router.

    woodm agazine.com /startrouting

    W atch how this jigand bitw ork together.woodm agazine.com /routdadoes

    Buying Sm art:A m ulti-base rou ter kit es se ntially gives you two tools for the price o fon e.A single m otor fits two ba ses: a sp ring -loa de d plun ge base allow s low ering the spinn ingbit into the w ork to m ake cuts tha t start and/or stop in the m idd le o fa surface. M ount thefixed b ase in a rou ter tab le and qu ickly sw itch the m otor from ha nd he ld w ork to table w ork.

    This Hitach iK M 12V C com es w ith gu ide bushings that thread into the router base a ndguide the bit alon g a p attern to duplicate parts or shap es .

    M otor

    Plunge baseFixedbase

    Bushings

    A m ortising b it’s bearing m atches the diam eter of the cutter (below ). Run the be aringalong a guide, such as the dado jig,a bove,a nd the cutter rem oves m ateriale xactly in line

    w ith the guide .

    Cutter

    Bearing

    GrooveDado

    Dado jig

    Dado jig

    With thischeck and a portion ofthe savingsset aside from previous checks,purchase a

    m ulti-base router kit. A handheld routerperform s dozens of operations.A nd w henyou m ountthe toolundera table w ith the bitextending through, above ,you dram aticallyincrease the router’s usefulness, enablingyou to steady sm allornarrow w orkpieces onthe broad tabletop and guide them along thefence past the bitfor consistentcuts.Routertables don’t com e m uch sim pler than thisversion thatrestson yourfolding saw horses.

    A dd a jig that helps you create m echanicalw oodw orking joints (ones w here the wood

    interlocks),not just glue-and-screw joints,such as those used on the router table andsaw horses. T he super-sim ple tw o-piecedado jig, above , guides a m ortising bit,right , m ounted in a router to plow clean,accurate dadoes and grooves.You then canfitm ating parts (such asa cabinet top,shelf,or divider) into the dado or groove, below .Because you only have to buy a router bit,replenish the nestegg w ith about$130.

    G radually, and steadily, the nest egggrow s, so by paycheck 10 (next issue), itshould cover the costofa tablesaw .T hen,asyou bu ild jigs for the saw,your w oodw ork-

    ing skillsw illreally take off.

    Dado (DAY-doe):A flat-bo ttom ed cha nnelrunn ing across the grain.Groove:A flat-bo ttom ed cha nn el run ning w ith the grain.

    Produced by Craig Ruegsegger with Lucas Peters

  • 8/16/2019 Wood - May 2016

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    D u s t R ig h t ®

    L a t h e D u s t

    Co lle c t io n Sy s t e m

    (52981 ) 49 . 9 9

    M aterialscode 78

    Sign up for our em ails and get

    e v e ry d a y F R E E S H IP P IN G !

    For d etails g o to rck lr.co /6 78 or c all 1-80 0 -279 -44 41 an dm en t ion c od e 6 7 8 at c h ec k ou t .

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    arou n d sp in d le tu rn in g s to c ollec t m ostof th e f in e d u st created wh en c u t tin g orsan d in g , m ak in g y ou r sh op a safer p lac e toCrea te w ith Con fid en ce.

  • 8/16/2019 Wood - May 2016

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    WO OD m g z in e M ay204

    Choose your read ou t. From bottom to top:Th is 4" toolreadsin increm ents of.00 05" and .01m m .The 6" m odels showninclude an an alog calipers that provides increm ents of 1 ⁄64"and

    .01 ";digitalin .001 " and .1m m ;an alog tha tread s in .001 ".

    Di l In Ac c u r

    I nside

    j ws

    e n o u g h . Bu t w h e n p re c is io n mtu rn to c a lip e rs .

    With C lip e

  • 8/16/2019 Wood - May 2016

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    oodmagazine com

    B ec a se calip ers p h y sically con ta t th esu rfaes b ein g g a g ed , th ey d eliv erh ar-sp littin g m easu rem en ts y ou ca ’tg et from sigh tin g a ross th e m ark in g s on aru ler or ta e m easu re. Here’s h ow to ch oosea d u se calip ers.

    UnderstandingthetoolTy p ical calip ers op en alittle m ore th a 6 ,alth ou g h 3 a d 4 m od els p rov id e en ou g hc a a ity for m ost wood work in g task s a dstow easier in a sh op a ron . Th e d isp la ,wh eth er a a alog d ial or d ig ital LC D rea -ou t, sh ows m easu rem en ts in fra tion al(1 4 ), d ec im al (in c rem en ts to .0 0 1 ), a d /orm etric (.1 or .0 1 m m ). Fration al rea in g sare m ost u sefu l for wood work in g , b u t d ec i-m al a d m etric scales ca sim p lify m ath .Mark in g s on th e b ar, above, p rov id e q u ickreferen ce, in c lu d in g wh ole-in ch in c rem en ts.

    On d ig ital calip ers, th e LC D sc reen p ro-v id es afast a d p rec ise rea . An d y ou c acon v ert m easu rem en ts from fra tion s tom etric (a d to d ecim al im p erial [.0 0 1 ] onsom e m od els) with th e p u sh of ab u tton . Onth e oth er h a d , a alog calip ers, wh ich wep refer, allow y ou to ey eb all g ra ation sb etween m ark ed in c rem en ts, a d n ev er h a ead ea b attery .

    TakingameasurementWh eth er d ial or d ig ital, all c alip ers work inth e sa e fash ion . First, close th e jaws. If th ed isp la d oesn ’t rea z ero, a ju st th e c alib ration . For a d ial m od el, loosen th e b ez elc la p sc rew, if it h as on e, a d rotate th eb ez el u n til th e z ero on th e sc ale alig n s withth e p oin ter a d retig h ten th e sc rew. For

    Knowhowmanyinchesyouhave For m easurem en ts over 1",rea d full-inch increm en ts on the ba r,a nd ad d the p recisefractionalm easurem entsh ow n o n the dial.This m easurem entreads 1 1 ⁄8".

    Measureoutsidedimension Close the calipe r’s jaw sgently on e ach face of the w orkpiece, and read them easurem ento n the display.

    Gauge insidedimension H old the calipe rs perpend icularto the su rface, and app ly light pressu re to the thum bw hee l

    to find the w idest spa n of the h ole or open ing.

    Full-inchm ark

    A

    B

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    WOOD m a g a z i n e M ay2042

    Wh a t’ th e d iffe re n c eTo quickly find the difference be tw een the thickness o ftw o piece s, or

    the depth of tw o holes, m easu re the thinne ror shallow er of the tw o

    first, be low .Tighten the jaw lock and zero the scale, inset .N ow ,loosen

    SKILL BU ILDERthe lock and m easure the thickeror deeper item , below .The display

    show s the difference be tw een the two, inset .Fast,a ccurate, and no

    m ath required!

    La y o u t lin e s p a r a lle l t o a n e d g e o r e n dO pen the jaw s thede sired dim ension and tighten the jaw lock. Place the stepcontactaga inst the ed ge of the bo ard and m ark along theen d o fthe calipe rs.

    F in d s t e p d i s ta n c ePlace the flat end of the calipe rs o none face ,a nd the step con tact on the rea rof the s lidinghe ad on the other surface .To avoid tilting the calipe rs,press the ba ra gainst the shou lder betwe en the surfaces.

    Stepc

    digitalversions,sim ply pressthe zero resetbutton .

    Before taking m easurem ents, brush thesurfaces of the w orkpiece clean to preventsawdustor other debris from affecting yourreading. Then gently touch the jaw s to thew orkpiece [ PhotosA– ].Forcing the jaw s orthum bw heelcan distortthecaliperand throwoff the reading. If you w ant to preserve the

    m easurem ent after rem oving the tool fromthe w orkpiece (to com pare to anotherw ork-piece, for exam ple),tighten the jaw lock topreventthejaw sfrom m oving.

    In addition to determ ining dim ensions,calipersserve asa layouttool[ PhotoE ].

    W hile you can spend north of $100 oncalipers,you can find a qualitypairsuitableforw oodw orking tasks for$20–$40.

    X Left-handed? Search

    online forleft-handed

    calipers.M ostm odels are

    digital.

    Produced by Mike erger

    CraigRuegsegger

    C D EDe t e rm in e d e p t hRe st the e nd o fthe calipers on the edgeof the hole.E xtend the dep th rod and take yourreadingw hen ittouches the bottom of the h ole.

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    des

    FR E E SH IP P IN GIN C O N T IG U O U S U S A

    1-8 0 0 -533-9 29 8FOR WEB ONLY BARGAINS JOIN THE MLC S E C LU B!

    Solid24 x32 mineralresintopisimpact

    MLCS MerleBand Clam pW ith self-adjusting jaw s!Clampanyshape includingtriaocagns evencircnclu23 'ofsteeband ingEven jointingforceatallconers. 9 0 12 ............ $ 29 .9 5

    SpiralUpcut/Router Bit SetSAVE $17!

    Three piece solidmicrograincarbide routerbitset.Sizes/3/8, and1/2 . 20 0 .......................$ 7 9 .9 5

    NEW!RouterTable Spline J igSAVE $10! Strong, decorative splinejointsreinforcemiterjoints .Thejigfeatur esmelaminecoatedMDF witha14-1/2 longaluminummiterbar that fitsastandar d3/4wide miterslot. 9 5 3 7 .................$ 7 9 .9 5

    Free sh i p p in g on every p rodu ctat M LC Sw oodw orkin g.com !

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    44 WOO magazine Ma 2 1 6

    M il-Spec

    M 1A1 Abram s TankR u m b lin g like th u n d er ac ros s th e b a ttle f ie ldco m e s a ro llin g fo r tre ss , rea d y to s t rike fu nin to th e h e a rts o f its re cipie n t. Th is b u lle tp roo f

    b ru ise r fits the ca rg o b a y o f th e AC-130 sh o w n

    in iss u e 236 No vem b e r 2015), so yo u ca n

    a ird r o p y o u r a r m o r a n y w h e re it’ n e e d e d .

    D

    I M

    E N

    S I O

    N

    S

    1 3

    1 ⁄ 4

    "

    L

    ×

    5 3 ⁄

    4 "

    W

    ×

    4

    1 ⁄ 4

    "

    H

    6tons:w e

    ofan M

    1w oo

    w hee

    this to

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    w o o d m a g a z in e c o m

    EXPLODED VIEW

    Co n s t ru c t th e c h a s s is

    Begin by cutting the chassis (A) blank tosize [ M aterials List ]. Make a copy of theChassis Pattern ( page 49 ) and use it to locatethe 7⁄32" holes on one edge of the blank. Then,adhere the pattern to the opposite edge anddrillthe holes. Bandsaw the chassis to shape,

    cutting just outside the lines and sandingthe cut faces sm ooth. Bore the centered 1"counterbore and drill the 3⁄8" hole whereshow n on the pattern.

    2 Cut the w heelspacers (B) to size [ Draw ing1a ], then drillthe holes and sand the radiion the ends. Glue the spacers to the sides of

    Tip! Save tim e and

    effortby finish-sanding

    parts to 220 gritbefore

    Tip! Learn to applypatternsand rem ovethem .woodm agazine.com /stickysolutions

    Us e t a p e t o c la m p u ps m a ll p a r tsPlace thefen ders (C,D ) top -face-up

    on your w orkbe nch withm itered end s tou ching.App ly pa inter’s tap e

    acros s the m iters, flip theassem bly over, an d app lyglue to the m iters. Pullthejoints tigh t w ith another

    piece of tape and let dry.

    A

    D

    C

    D

    f The M 1A1 features aspecialarm orm ade ofdepleted uranium .

    L

    L

    "hexhead bolt1¾ "long epoxied

    into part"washer

    Turret rotates 3 60°

    I

    H

    G

    "washer Free-turning wheelsprovide m obility."lock nut

    Cannon pivots up and down

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    5 º b e v e l

    " ho le

    5¼ "

    1¼ "

    3¼ "

    2¾ "

    " c h a m f e r

    H

    I

    1 "

    3¼ "

    " g r o o v e s " d e e p" ap a r t

    F

    A C

    E

    C

    x 1 " ax le p eg

    x " axle p eg s

    1¼ " w o o d e n w h e e ls

    x 1 " axle p eg

    46 WOOD m a az in e M ay2

    the chassis (A ),flush w ith the bottom and1 9⁄16" from the chassis’back edge [ Draw ing 1].

    3 To m ake the fenders (C ,D ),first cut tw o1⁄4×1 1⁄8×12" blan ks.Then,tilt your table-saw blade to 15° and m iter-cut them tolength [ Draw ing 1b]. G lue up the fenders[Photo A]. A fter the glue dries,finish-sandthe fenders.A ttach them to the chassis (A )[Photo B].

    4C ut tw o track arm or blanks (E) to sizeand adhere them together w ith double-

    faced tape,keeping the edges and end s flush.A dhere a copy of the Track Arm or Pattern( page 49 ) and cut the dadoes in both pieces.Then,cut the arm or to shape.R em ove thepattern, separate the tw o pieces, and setthem aside.

    5 To safely cut the grooves in the enginegrille (F) [ Draw ing 1],start w ith a 1⁄2× 7⁄8×12"blank. A fter cutting the grooves, trim thegrille to m atch the w idth of the chassis (A ).G lue the grille to the chassis,flush w ith thebottom edge of the top cham fer.

    6 C ut the turret base (G ) and engine cover(H) to size.C ham fer the front edge of the

    turret base [ Draw ing 1].Use a saddle jig onyou r tablesaw to bevel the engine cover’sfront edge.D rillthe holes in the back edge ofthe engine cover [ Draw ing 1c].Sand the tw oparts sm ooth.

    7 G lue the turret base (G ) and engine cover(H) to the chassis assem bly,centered sideto side, w ith the back edge of the enginecover aligned w ith the rear fender joint(C /D ).A fter the glue dries,invert the chassisand ,using the 3⁄8" hole as a gu ide,d rilla 3⁄8"hole through the turret base.

    8 From 11⁄4" dow el,cut tw o hatch covers (I)

    and the com m ander’s hatch (J).G lue onehatch cover centered on the front of thechassis [ Draw ing 1].Set the other tw o piecesaside for now .

    Tip! Learn how to buildand use a tablesawsaddle jig to safely cutbevels.

    woodmagazine.com/saddlejigbevels

    ¼ " h o le " d e e p

    5¼ "

    "

    H

    C

    7 "

    15 º be ve ls

    15 º be ve ls

    ¼ "

    "CHASSIS ASSEMBLY1

    FENDERS1b

    ENGINE COVER (rear view)

    1c

    Don ’t let th e wh eels ru b Tem porarily place wheels in thefront and back holes in the chassis (A)before locating thefenderassem bly (C/D).Centerthe fenders,keeping themflush with the top of the chassis and away from the wheels.

    B

    D

    C

    D

    A

    B

    1 " 1 "R= ¼ "

    "" h o le

    4 "

    WHEEL SPACER 1a

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    w o o d m a g a z in e c o m

    F in is h t h e c u t sW ithout ad justing the b andsa w ’s table,crosscut the end s o fthe turret sides, keep ing the bottomfron tof the w orkpiece flat aga inst the tab le.

    T ! Cutthe turretsides(K) and core (L) from one

    blank so the jointlinesdisappear.

    f The M 1A1 cantravelatspeedsup to 45 m iles perhour,propelled by a1,500-horsepow ergas turbine.

    B e g in o n t h e b o t to mB and saw the bevels on the bo ttomof the turret side s (K ),kee ping the b lad e to the ou tside ofthe pa ttern line s. S an d the cu t su rface to the line .

    Tilt the ta b le 15°,then cut along the long edge of thepa tterns.K eep the flat cen ter po rtion of the piece restingon the tab le througho ut the cut.

    K

    L

    OP

    Q

    S3 ¾ "

    ¼ "hole¼ "deep

    "rabbet "deep

    J

    "hole "deep

    "cham fers

    M

    N

    R

    T

    2 ½ "

    ¼ "hole¼ "deep

    Turretrightside

    Turretleft side

    ¼ "

    "

    I

    K

    Q

    "hole ¼ "deep

    "

    ¾ "

    "

    ½ "

    "

    "3½ "

    1"

    6º

    L

    "hole¼ "deep

    ¾ "

    ½ "1 "

    C D E

    K

    TURRET CORE2 a M ACHINE-GU NM O UNT

    2 b

    TURRET ASSEM BLY2

    Ta c k o n a tu r re t

    1 Cutto size the turretsides (K )and cuttheturret core (L) blank 1 1⁄8" longer thanlisted.(U se the cutofffor the cannon base[M ].)A pply the right-and left-side Turret Pat-

    terns to the turretsides,wrapping them overthe edges.D rillthe 1⁄4"holes and shape theturretsides [ Photos C, D,E ].

    2 D rillthe hole in the turretcore (L)[ Draw-ing 2a].Then,w ith the turretcore’s bot-tom face up,hold itbetween the turretsides(K)[ Drawing 2 ],keeping the back edges flush.

    U sing one ofthe sides as a guide,m ark thebevels on the turretcore,then bandsaw andsand to the lines.

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    w o o d m g z in e c o m

    X Dow loa th ese fu ll sizep rinta le p attern s at

    woodmagazine c om23 9patterns

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    50 WOO magazine Ma 2 1

    rawerSlides

    emystified L ike a hovercraft, draw ers m ounted to today’s m etalslidesglide in and ou toftheiropeningsas iffloating ona cushion ofair.Butslidescom e in m any differenttypes,and determ ining w hich to buy can be confusing.H ere’s howto pick the bestone for the job.

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    52 WOO magazine Ma 2

    100 lbslideswillsupport1 00lbs, provided the draw er will, and tha t you screw the slidto hardwood o r plywood per the m anufacturer’s instructions. MDF and o ther com posm aterials w illnot hold screws as w ell.

    f Weig h t ratin g s a p lyto ap ar of slid es if

    installation req u ires ap ar), so two 1 0 0 -lb

    slid es ca n ot ha d le

    20 0 lb s.

    Overtravel

    Full-extension

    ⁄-extension

    ¾ -extension

    ThinkaboutdraweraccessDraw er slides further differ by how far theyallow a draw er to open.Overtravel slides utilize a telescoping designthatletsthe draw er extend beyond the cabi-net. U se them w hen overhanging counter-tops get in the w ay of drawer access.M ake

    sure the cabinet location provides room foropening the draw er fully.Full-extension slides also telescope,allow ingthe full length of the drawer to clear thecabinet.C hoose these w hen you need easyaccess to the rear of the draw er,as in a filedrawer.7⁄8 -extension slides allow the drawer toextend 7⁄8 of its length— a good com prom isebetw een 3⁄4-and full-extension.3 ⁄4 -extension slides,as you m ightguess,allowthe drawer to open 3⁄4 of its length.C hoosethis type of slide w hen unblocked access tothe entire drawer m atters little, or w here

    space lim itshow far a draw er can extend.

    HidethatslideTo con ceal slid esoth erwse visib le fromthe fron t, a d afalsefron t to th e d rawer box,or b u ild ad rawer fron twth alip wder thathe b ox

    screwed todrawerbox.

    False frontsm ask the

    drawerslides.

    WeightheweightoptionsTypicallight-duty slides have w eightratingsup to 75 lbs,m edium -dutyup to 100 lbs,andheavy-duty form orethan 100 lbs, right .

    Longer slides have m ore robustconstruc-tion than shorter ones of the sam e rating.For exam ple, an 18" slide rated for 100 lbsw illbe stouterthan a 16"slide w ith the sam erating. A shorter slide has leverage to itsadvantage.

    With decisions m ade on type,extension,and w eight rating, determ ine the right sizeslide for the project.

    DR AW ER-SLIDE TR AVEL

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    w o o d m a g a z in e c o m

    Me a s u rin g fo r s lid e sTaking accurate m easurem ents ensuresyoubuy slides thatw ork in your cabinet.Followthese tips to m ake sure everything goessm oothly:

    Slides com e in lengths from 10" to 28".Atoo-short slide prevents the draw er fromopening fully,and one that’s too lon g w on’tfit in the cabinet.To determ ine the properlength, m easure the interior depth of thecabinet (behind the face fram e,if there isone)and choose a slide the nextsize shorterthan thatm easurem ent.

    Because the thickness of draw er slidesand the w idth of the draw er opening arefixed,bestpractice isto bu ild the drawerboxto fit the difference betw een the tw o afterassem bling the cabinet.For exam ple,m ostroller slides and side-m ount ball-bearingslides requ ire 1⁄2"ofm ounting space on eachside.To use these in a 12"-w ide draw eropen-ing,bu ild the draw er11"w ide.

    For shallow draw ers or a pu ll-out tray,

    buy a slide no tallerthan the draw eror tray.

    In s t a lla t io n c o n s id e ra t io n sFor fram eless cabinets,just screw the cabi-netprofile to the cabinetside,parallelto thecabinetbottom .O n face-fram e cabinets,thefrontof the slide attaches to the face-fram estile, to photo.To align and secure the rearofthe slide,m anufacturersprovide bracketsand standoffsthatfasten to eitherthe side orback ofthe cabinet.You can also create yourow n standoffsfrom w ood scraps.

    U se the exact type of screw called for orprovided by the m anufacturer, as screw -

    heads that stand too proud can preventslides from m oving sm oothly.M any slidescom e w ith m ultiple holes and slots to allowfine-tuning d raw erposition and accom m o-date a variety ofm ounting options, m iddle photo.A lso, handed slidesm ustm ounton aspecific side, bottom photo; unhanded slides m ounton either side.

    N ow that you kn ow the options,sim plyconsider all installation requirem ents andpick a slide thatbestsuitsthe project.

    Produced by Craig Ruegsegger with M ike Berger

    Illustration: Tim Cahill

    Se c u r e t h e f ro n t o f t h e s lid e t o t h e f a c e fr a m eThe bracket at the rear slides to reachback of the cabinet. This requires a stretcher or cabinet back at least 1 ⁄2 " thick.

    K n o w r ig h t fro m le f tSlide s tha t m us t be ins talled on a specific cabinet side (view ed frthe front of the cab ine t) ha ve tha t de signation stam ped on the m .

    Sc r e w s lo t s a llo w fo r a d ju s t in g d r a w e r p o s it io nin, out,up, an d do w n. With the drawproperly pos itioned, drive screw s into the holes to lock the slide in place.

    f W atch a free videoon installing ball-

    bearing slides.woodm agazine.com /

    sim pledrawer

    So m e fa n c y fu n c t io n sM anufacturers provide severaloptions to add a touch ofluxuryto a draw erslide’s op eration.

    Soft-close slides slow the draw eras itclose s, ensu ring thatitdoesn’tslam .

    Self-closing slides take the conceptfurtherand pullthe draw erclosed w ith justa gentle press on the draw erfront.

    Touch-release slide s do the opp os ite— w ith a touch,the draw er pop s open;us efulforsleek cabinets w ithou tpulls.Progressive m ovem ent slides provide a sm ooth glide because allse gm en ts m ove sim ultan eous ly,ins tead ofhaving one se gm ent reach the end of

    its travelbefore itbegins pulling the next along.

    Detentand locking slide s hold in a setpos ition untilpushed, preven ting uninten ded m ovem ent— idealforsm allap pliance stands orcutting boards.

    f Learn m ore aboutcabinetm aking with these

    videos and articles.woodm agazine.com /

    cabinetm aking

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    54 WOODmagazine Ma 2 1

    See inside

    Birdhouse

    Agreat project toshare with a youngwoodworker, thissim ple bird abodem akes it possible to

    experience the wonderofnature from thecom fort ofyour hom e.

    Just stick it to awindow and wait forfeathered friendsto arrive.

    D

    I

    M

    E

    N

    S

    I

    O

    N

    S

    9 3 ⁄

    4 "

    L ×

    8 1 ⁄

    2 "

    W × 6 3 ⁄

    4 "

    D

    Only

    7 pieces

    to m ake

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    w o o d m g z in e c o m

    EXPLODED VIEW

    Begin by cutting four 1 1⁄2"-thick,7"-square blanks for the body (A). Jointthe faces to ensure they’re flat;any inconsis-tencies willproduce unsightly gaps betw eenlayers. Glue the four blanks together face-to-face and let dry.

    2 Lay out the body or adhere a copy of thepattern ( page 56 ) to the face of the bodyglue-up. Bandsaw it to shape and sand to theline. We found a tall spindle sander (orsanding drum m ounted in a drill press)w orked best for this.

    Next, m iter-cut the roof panels (B)[Exploded View ] and glue them together

    [Photo A ].

    6 "

    1 ¼ "entrance hole

    6 ¾ "

    4 ¾ "

    6 "

    4 5 °m iters

    4 5 °m iter

    4 5 °bevel

    4 " view ing hole " clear acrylic

    Screw-m ounted suction cup

    "

    "

    # 1 6 x 1" brad

    A

    C

    C

    B

    B

    D

    N ote: Ifyou m ustjoint

    the body (A )layers

    thinnerthan 1 1⁄2",that’s

    okay.It’snotgoing to

    affectthe bird’slifestyle

    orthe look ofthe

    birdhouse.

    Wr a p t h e r o o fK ee p the m iter joint be twee n the roof pa ne ls (B)tigh t du ring glue -up byusing painter’s tape to pullthe parts toge ther.

    A

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Hadley Wood News May 2012

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