16" x 43" SWIVEL-HEAD WOOD LATHE with Digital Readout

Motor: 2 HP; 110V. ~ ing l,,- ph " se

PreciS ion groo oo east iron bed & cast iro n legs Swing over bed 16

S'IW~l' TACIIOMUUI: wI~t1AL ItU(l()VT

I " x 8TPI RH headstock spioo'e Mn2 spi~ dle & lailstccic tapers 10 speeds, SCo-2400 RPM

• ApPfol(.

shipP11'l1l we'g ht 300 Ib l .

G0462 REG 149511l""

Sale '44500 • THE ULTIMATE 10" LEFT-TilT

CONTRACTOR STYLE TABLE SAW Motor. 2 liP l tOW220V, S fl!;1"-phase

• PI8Ciwo'lg,ound caS( 11011 table !It ..... h gs • Table SIze 27' x 3~ • Arbor:"" • Cu\tl ng c8paclty: 3'i'- ~ 90.2 '''' @ 45'

• Aipcaptcity; 30" • Approx shipping

wei ght 317lbs.

MAPEl" 100tOOl FACTOity

SHOP FOX Ai.UMA-CLAUIC fnC'

G057. ONLY $77500

14" INDUSTRIAL RESAW BANDSAW MA~INISO

enol ~AeTOIlv Motor: 2 HP; 110VI220V.

• - SIngle-phase, TEFC Pr OCl sion ground c~st Iron la ble si",: 19'1.' x 14'/"," n ble tilt: 8'L, 45'R

Ma~ , cutting he~ht: 10" BLade sile' 106"l X 'f." . >I,'W 81ade speed: 3000 FPM App,o~ sh PP'1I9 _ ,,,hi;

284 11K. (,,_~.: , ~\\{.-~~

G0457 REG ~~

Sale $79500

10" WET SHARPENING SYSTEM

WM~I speed: 90 RPM 220 9r1t yrinding wheel Orrn dlrl{l wheel sile : 10' el ia, • 2" ... ,de Luthe, stro pping wheel size, B" elia, ~ I,,' wide

Inc1udas Ilnillers.o l jig, a"gle ""ide 8r polishing/ho"i"g pa~e

• Approx. shipping we'ght: 42 Ibs, M,u'IN fERMAN"'!

r10010 REG , s189~

Sale ' 15995

10" TILTING ARBOR SUPER HEAVY-DUTY TABLE SAW MOlar J HP, mv, sUlgle-phase, reFC

P' ec'SIOn g'OIJnd cast i' on 'able 2 solid cast !lGn eWnsion wings

' HOP fOX elAttie fErtet

Table Jile w- w ngs attached 21'.40' • Arbor: %" • Cuning capacity: S' l, 26" R • S' 8ndarel 1\1 dado

t8~e Inserts • Approx.

sh'pp,ng weog ht: 420 Ib!i

Motor: 2 HP, 11OVl220v,

si rl{l le·phase, TEfC Pr..:; ision grourld cast IrO Il table SI1e_ 17" square .. 11''- thict

Table tl lt to'L, 45'A Max. ~ uttong he'~I1t : 12" Blade Slle 131"l ~ 'II' , I'W Blade speed", 1700 & 3500 FPM

App,o" ~hlwing .. Ight: 3411 .....

hlAPE III 1st! 8101 rACTORY

G051 3 REG. 9-85'"

Sale '71500

PURVEYORS OF FINE MACHINERY®.

SINCE 1983!

10" JOINTER/ PLANER COMBO Motor: 2\', HP, 220V, sirog le·phase, 3400 RPM Jointer lable s iza , 1 2'~' ~ 4O'~,o"

Cutterhead knilles' 2 HSS Max depth of cut: Jo imer - Yo' Planer · 7',,' M.~ widlh of ~ul.

Joimer - Im~'

• Cutterhead speed: 6500 RPM • PI"ner table sile: 9'1( x 23' ... • • Plane r feed ,ata; 16 FPM

• Appro. sh'pp,ng .... eo"ht 3181bs Pla_ - !;" I,,'

flU SAfETY PUSHAOCICS

G0675 REG. 'JJ-95<"

Sale '99500

10" LEFT-TILT CABINET TABLE SAW with Riving Knife & Extension Rails • Motor J HP, 210'1, Single·phase, THC • PreciSion ground Cas! " on table & ca~ iro, m."~ OOlf. • Table sile W/<! ~ten"on' 27" x 63" • Arbor size' W • Arbor Speed. 4300 RPM

• • App<ox. shiPPIng weight: 644 lbs

G0691

Sale '121500

1'h HP Z STAGE CYCLONE DUST COLLECTOR

• Motor: 1'7 HP; 110f22 GV, al n g l e· p h ~se, TEFC, 3450 RPM

• Air suction capa<;ity: 866 CFM • St~tr c p r as' ur~' 2, 013' • In'3l<e port: 6" ' Impel'er: 13';" • Folty mo br le wlb\)!h:~n casters

• Overall dirnellSions' 38"W ~ 2(,' Ox 68-112' H

" App'oK. d'ipping",e ght: 1931bs.

~"~Fu.1UltnIN ~~ ACOMPAeT~ZEI

G0703 0 ~ INTROOIJCTORY~RtCE $8250 ~

I-BIlO-5e3-4777· 3 GREAT SHOWROOMS!

BELLINGHAM, WA MUNCY, PA

SPRINGFIELD, MO 1!CIINIC"'L S.ElMCE 570-:.40·9~ • FlO:' 800-43.8-%'01

~~Sate GET REDUCED PRICES ON MANY ITEMS & FREE SHIPPING ON OVER 200 MACHINES

NOVEMBER 2nd UNTIL DECEMBER 31st, 2009

GRIZZLY GIFT CERTIFICATESTAKE THE GUESSWORK OUT OF GIVING'

6" PARALLELOGRAM JOINTER with Spiral Cutterhead

• Motor: W, HP. nov/nov Single-phase

• Precision ground cast iron table size: 6" x 55Y,'

• Rabbeting capacity: 'I," • Max_ depth of cut Y,'

• Cutterhead speed: 4850 RPM fREE SAFEty • Center mounted fence system: PUSIt IROCKS

poSitive stops @±45'&90

• Built-in mobile base

• Approx. shipping

weight 362 Ibs,

8 " JOINTER with 2 HP MOTOR 8" JOINTER • Motor: 2 HP. 110V1220V, single-phose, TEFC with Built-In Mobi le Base • Precision ~round cast iron table size: 9'1.' x 75 ' • Motor: 3 HP, 220V, sing l e-ph~se, TEFC, 3450 RPM • Rabbeting capacity: y, ' • Max, depth of cut W • Precision ground cast iron tables size' 9' x 72'h" • Cutterhead knives: 4 HSS • Rabbeting capacity: y,' • Max, depth of cut 'I. ' • Cutterhead speed: 5500 RPM • Cutterhead speed 5000 RPM • Deluxecastironfencesize:38"Lx W,''Wx4' H • Deluxe Cost iron fence size: 35' L x 5"H • Approx, shipping weight 558 Ibs. • Built-in mobile base

• Approx. shipping weight: 5561bs.

G0586 REG.~ G0656 Safe FREE REG. s~ '57500 _ "mv S<Ote'715OO , PUSH

~~-l~~:5~~~'~'~~~~;'~LO~" ~' ;f-i.8J~~~'~~j;~~~~~ 12W' LEAN & MEAN PLANER 15" PLANER with Built-In Mobile Base 20" Motor; 2 HI': l1QV, single-phase Motor: 3 HI': 220V, single-phose MADE IN Mox. cutting height: 6" INeLIIDU Precision ground cast iron Motor: 5 HP. nov, single-phase IW 9001 Feed rate: 32 FPM "MIFE SETTING tables & wings Precision ground cast iron table FACTOII:V

JI~ & WRENC+! Knives: 2 double edged HSS Table SIze: 15" x 20 ' Table size with Cutterhead speed: 10,000 RPM n/ I Max, cutting height: 8" extensions: 20' x 55'1,'

Top mounted return rollers ~ot. Mox_ cutting depth: y,' Max. cutting height 8W Cuts per inch: 52 Feed rate: 16 & 30 FPM Max, cutting depth:

• Approx, shipping Cutterhead speed: Cutterhead speed: weight 781bs. 5000 RPM 5000 RPM

G0505 Built-in mobile base Feed rate: 16 & 20 FPM

• Approx. shipping • Approx_ shipping

weIght 6751bs_ weight: 9091bs.

~EA~Y-PUlV CAST IRON cmm~UCrtoN APJUSTABLE BEP ROLLtRS

G0453 REG. ~ G1033X REG. ~'l4S5w-

-'--_-+--="S,:::<Ote= '::-:8::,50=-' :::' =:-::-::~=-=-I----:s,~<Ote '2245==OOiiUMlSAiiioi PROFESSIONAL SPINDLE SHAPER • U

with Router Bit Adapter Motor: % HP.l10V, single'phase wlreversing switch Precision ground cast iron table siZ€: 15'4' x Spincle cop. under nut 2W

Spindle speed: 8900 RPM "I:~~;' Spindle travel: '/,' '''! Spindle dia.: W Spindle length: 3' Split fence deSign wi sliding wood faces

• Approx_ shipping weight: 172 Ibs,

Motor: 5 HP. 220V, single-phase, TEFC Precision ground cast iron table size: 35Y, ' W x 28"0 Table counterbore: 7' x '/0'0 Spindle travel: 3'1<' Spindle sizes: '/.", l' & I t<' x 7 Y,'L Max. cutter dia: 5';. Spindle speeds: 3600, 5100,8000 & 10,000 RPM

• Approx. shipping weight: 602 Ibs.

G5912Z REG, ·229~

S<Ote'1995°O

Sanding motor: II'> HP, 110V, single·phase

Drum surface speed: 4000 FPM

Conveyor feed rate: variable, 2 12 fPM

Max. Slack dimensions: 36-' W x 4';" thick

Min, board length: 6"

Min. board thickness:

Sanding drum size: 4'

Dust collection port:

Approx, shipping weight: 3541bs.

STAND ALONE DUST COmCTION W/DUST BAG

G0458

ONLY '95000

grizzly. com l lMfTt'O rM~omR 24 HOUR ORDERING • OVER 12,000 PRODUCTS ONLINE!

'0

PROJECTS 18 Shop Project: (lamp Rack 28 Made-from-scrap Bud Vase 30 On the (oyer: Blanket Chest 42 Super-tough Plywood WorkbelKh 54 Surprisingly Simple Mantel (lock 62 To)' h(aYatol

SKILL BUILDERS 22 Fixing an Out-of·square Drawer 18 Work Wid" Stock on Your Dovetail Jig

Ta kt offth ~ l~ mpl~t e d,,,J go h~yono the limi ts of)'OlJr hen[h-mount~ j lq

40 Howa Jointer and Planer5av(' You $$$ Th(»e IWlIlool\ PdY for them~I"'1 in ~hort oruer,

SO 14 Senets for Setting Up Router Bits 66 Make and ImtallBaseboard iI"d (flair Rails

Pan } of our I~"t\ on cUS10m-1r Iflllf.w) }our hump

TOOLS'" MATERIALS 16 Aromatic (I"dar: Mothbuster or Not? 20 Wise Buys: Forstner Bit Sets 24 5 Tools for Fine-fining Joints 58 Tool Test; Tablesaw Bladl's Under SSO 72 Shop-Proven Ploduch

Rldgld hybrid Yble\dw. Laguna Lath~. ~nd 1l1OI'<'.

DEPARTMENTS 6 Sounding BO;Hd 8 Shop Tips

78 Ask WOOD 92 What's Ahead

I

28

on the web wQodmagazine.com

ENTER BEFORE NOV. 30 TO WIN $1 ,000

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NEW VIDEOS : HELP AROUND THE HOUSE You're great in tile \hop, but 1\01'1 about \'Ihen It (omes \0 plumbing. wiring, OJ otlw home honey-do (hores) At w()()dm;JlJ'lzme ,(omihomehov.10, you'll find ckmns of oownloadable videos that show yOJ howl0 do those home rep(lirs ~nd improv~ment)_

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.. " .,

2~,o~me~;~~~~~,~~~,,~; ~;~~~ Only Jr1 dt t he ",me tinle. A re1urn c-feither afthe mi\chine. will be reduced by Sf'cond m ilchine il I only through Authorized D;,trl buto" pMticip~ting in t hi' even\.

Pledse contdCl Woodstock I to lOCilt,. a participating d istribut o r neM you. Offer vill id on purchilses milde between 9/14/09 and 11130/09_

SHOPFOXBIZ 1-800-840-8420 !'Ml.ks" sl\.:.pfux.bl'<: WHOLESAl.F. ONI. Y ,,,. I 1<" \ I 1<.' 'I ''', ~Il"!' t ox ". ",.",,,J "J. ,~" o>t W"""',,, k '" ,. _" " •• , I.

I ~~~ 1""'1

November 2009

,

lett relaxe, in the Mo,,", choir and otto rn"" he buiK for hi; home.

woodmog.,i"."tom

Vol. 26, No.6

,Dl TOR~N-CH I Ef SlttKRIER

Man"9'''9 Editor o.,puty Editoc MARLEN KEMMET DAVE CAMPBELL

A.rt Director Senior De'ign ,do tDr KARL EHLERS K~VtN BOYL~

T.cr.niqu€s ,d'itor rool I< lechni<1ue> Edotor B08 WiLSOI'I BOB HUNTER

Mukimed;" Editor LUCAS PETERS

o.,Ogn Editor JEF~ MERTZ

Mu'timedid ,ditor CRAIG RUEGSEGGER

"'"oc;"te Art Director GR~G S~tt~RS

•

Issue No.1 94

Produo::lior\Iortice Manaqer A.dmin~tral"e "'''''IMIt MARGARET CLOSN~R SHERYL MUNYON

Phot<>gropl1er, JASON DONNelLY, SCOTT LITTLE, J AYW ILD~

OiVg de; igned a,1<I built thi' TIl (dbi""t for h" family '''''rn u,ing cherry ar>d ,t.ined popl .,.,

COI1tributing IIlumator, TIM CAHILL. LORNA JOHNSON. ROXANNE I.eMOINE

T.,hnicol Co",ultM\!, BOB BAKER, DOIJG HIC~S

COI1t"but""l Crilfmm n JIM HEAVEY Contribuliflg Proot"oder> BABS KLEIN. IRA LACH~R.J IM SMDERS

SU8SCRIBERSERVIn Go to woodm"9~z;"'.comih'lp ()( I'",te tu

WOOD rmg.;;ine. P.O. Box 37439, 8"""". IA 50037·0-139

PutMisher MARK L HAG~N

io.4 .,.keting Ma"'~r AMANDA SALHOOT Advert"ing Monqr JACK CHRISTIANSEN

D~ec( Response Adverti''''9 Representative LlSAGRfENWOOD A:5,,,t,,,,t TIM BAAROA

ATLANTA, Navigdte Medi:! DETROIT, RPM A"o<;"tes

Bu;in"" M..-...ger JEFFSTILES ConlUmer M.,r<e(in9 Dir.o(or TODD BIERLE

A,so(idle Direct()( 0/ M.,.keting-N€w"liond TOM DE~RING Production M,009'"' SANDY WILLIAMS

Ad""rti>ing ep.,rolm Mon"9er 11M NELSON E·Comme"" Mana~, MATT SNYDER

v,,~ Pr'~d""tiGroup Pub.,h", TOM DAVIS

MEREDITH PUBUSHING GROUP

Pre,idem JACK GRIffiN b:ecullve Vice P' e<jd""t DOUG OLSON

Chief Rev"""e ()'tice, TOM HAR TY Finan(e " Mmini,trotion MIKE RIGGS

Manufocluring BRlJCE HESTON Comumer M.rketir>g DAVID BALL

C()(porole Sill", MICHAEL BHDWNSlE lN Meredith 360° JEANNINE SHAO COLLINS

Inte,,,tive Medio LAUREN WIENER Corpor.te M"-'eling NANCYWEIER

Rese..-ch BRITTA WARE Ch~ Technology Oft;c", TINASTfIL

~w Med', M"-"t,,'9 "'",Ie" ANDY WILSON [)jre<:t Re>IX)m. <>I1d T,.vel PATTI fDLLO

~meredlth

In Momori. m _ E. r. M~r.d;'h III (1933-2003) Our ;ub<crib." I 't i, oc,.,ic",.1y made avai lobi€ to ,..-efully ",re,ted f~m' whm. product' m.y b. 0/ "ter"t to you. If you prefe' not to receive ir>formotion from these comp,," i'" by moil or by phone, .. e.", 1,( u< know, 'i.oo your .. que't a.fmg with you r """Ing label to Magilline Cum.mer ' . rlli,., P.O, So, 37452, Boone, IA 50017-0452

" (opJrIgIo' Morrrli,n (orp_,on 2009, AU ,I"t' ,,,,,,,.d. Mnt. d 10 til< U.\,A. ~"~I \.01 ..

Rao!I", <on oN., <op<"; of WO~D for r<»l. by ' -"''".1 j .. niI" r..><' ti<n<,.cti(h ,,,,"

woodmagazlne,com 5

It i, I floor" w[){)dwork ~nd wood met~1 or fiberglas> door\,

(oreIS~1! T~chnology provides the deep tones of 3[\ oil-b3>e-d st3in with th~ low odor, 13st drying and e3sy clean-up of a wa\er-b3\ed slain,

In additi o n, th e Advanc~dGrun Phau Resin Dispersion T~chnology ut ilizes environmental ly frie nd ly res on , thM result in a VOC wmpl ia nt product

With i l~ delicious new colors, Ultr3 Max Wood St",n g i ve~ you ~ great look that is a l~o good for the environment.

For mOn! information or a dealer nur you vi.11 www.ugl.comor Cillll·800· 272 ·3235.

SOLinding J~Q(lId Our bulletin board for letters, comments, and timely updates

Try high-yielding cypress for outdoor projects grained and often knot-frt;'t;'. Native to the southeastern United States, cypress might cost a little more than cedar in some parts of the country, but that CO'it can be offset by the high yield of each board. r buy it "green" and then air-dry it to save money.

WOOD

-=.----~-. -=-----~.~

Readers approve of digital WOOD~ magazine editions Thank you for puttlllg online the digital version of WOOD magazine. Now I can make thl;' type a'> large a'i I want, and print Ollt only tho'iC articles that need to go out to the shop. I still like the ink-on-paper ver,>ion a'> well, and plan to make good use of both.

-Bill hJh, New GOJhen, 100

After reading the article "From Knotty to Nice" in b'iue 190 (May 2009), I want to recommend cypress a'i another good wood choice for outdoor projects. I live near dozens of mushroom growers who build their growing racks from cypress became of its excellent resistance to rot in that humid envi­ronment. Cypress is relatively <;traight - Tom Mc,iyGy, Newark, Del. I want to -ay how impres<;ed f am with

the electronic version of your maga­zine. The content is organized in an

6

Turn your best project and technique ideas into CASH!

Have you de'iigned and built a project that you feel othl;'r WOOL>' magazine reader'> would I;'njoy building? \Ve're talking bIg or small projects, simple or complex, for the home, deck, garden, or '>hop. Have you come up with a clever time- or money-saving alternative for getting great reulb ill your ,>hop-perhaps a smarter or safer way to machine parts, cut joints, or get an eye-catching finhh (jU'it to name a ft;'w)!

If so, please take a few minutl;'s to tell us about your project or technique. You can I;'arn up to '>1;'VC'ral hundred dollars if we publish your idea. (And, of course, you'll bl;' tht;' I;'nvy of your woodworking buddies.)

Simply 'iend up to five photO'> and describe your project or tedlllique in 100 words or less. If we choose your idea we'll get back to you for more information, so don't forget to include your e-mail addre" and daytiml;' phone number.

Send your material'> via e-mail to: woodmail~(.woodrnagazine.coIl1; or writl;' to WOOD magazine, 1716 Locu'>t 51., LS-221, Des I\.-Ioines, Iowa 50309.

-WOOD magazine editors

HOW TO REACH US • for woodworking ~dvice:

POll )'OUf woodworking questiOOI Uillnery, finlsn­ing. tools. tumirlg, <:iIJS\ CollectIon, etc.) on one of 16 oollne furuml ilt woodmagazine.(~m/fQrums.

• To contact OUI editors: >end y~r (omml'llts viil e-milll to woodmail@woodmagazine.oom; or wr~e 10

WOOD r'ldgilllTre, 1716locUlt 51., lS--221, Dts MoilN's, IA 50309

• Submiption amlt~nc~: To notIfy us of an oddress change or to g~1 h~1fl WIth )'(lll" subsc:riptNln, vi>!t woo-dmlgazine.com/service. Or write to WOOD milgazin1, P.O. Bo~ 37439, BooTJ€, fA 50037-1)4 J9. PI ~oIse endolt yOUf oddrels lab~ from a recent mog~llne issue,

• To find past articles: 5e! OIJr inde~ ilt woodmagazlnMom/inliu

easily accessible format and the user­friendly navigation buttons make it easy even for those of us who are not so computer·,>avvy.

-Mike Ti!tf[Jult, Dov~r Cent"', Ont

If you subscribe to the print version of WOOD magazine, the digital version is free. Just go to woodmagaline,comldlgitaimag.

WOOD magaZIne editors

Please work safely In order to show you precise details in photos, we frequently remuve safely guards. In your work, be sure to use all safety devices, as well as wearing vision and hearing protection.

-WOOD magazine ,w,/ars

• To order past is~ues and artidM: For poIIlt ilSU ~l of WOOD mag~lilN', our >pedal issu~~ (l" dowriaodobl! ilnkles, VISIt oor oolil1! stor! ilt woodmagaziM.cDIIIIstorl. SoITll' i\\lJt", are sold oot

• Updates to previously published projectl: ror an up-to-date ~\tir\(j ci changes In dimeflsion5 Mld buyill9-gu idt >OlJrCel from is>ue 1 tnruugh todilY, go to woolimaga~mMom/editorial.

WOOD m~gadn" Navemi:ter 2009

Shop Tips Helping you work faster, smarter, and !;afer

No-guesswork frames with mitersled modification If rOU\'C ('WI IfiN to lila\.;(' pkWre fram~. '"OU IIlltkr\tand Ihe challenge or sizing 11:(' !came mcmber\ 10 flt vOur photos Ti lill ·~ tx'(au '-C the (111 .... .. 1 Jlll'asurcmcllll~ the l('n<:l h o f the rahl)c1 on thl' ....... k o f t hi' flaml'-h iddcn when l'lIni ng-mil1..in~ II hard to size the frame side" a(cur.ud~

Rut t h" 'pt'('[atfl.ed miler 'It'd makl~ it easy. The hi' to how it wall s: The thi(ln~\ of the fl'nt'c~ IIHltch .. ~ the depth of the pktllrc tramc rabbet. The rabbet over].)p" the 1('I1CC during t he cut.

>" lake the first cut on the rtgh l side of the t(,!lee: then sIVitch to the left !Oelll il to final length For C\X"11 mon,' cfficienq-, mCa5u rt" from the \aW kerf a nd marl. ,-ommo n image 5iz ..... o n th l'" left ' (,!In'', iI\ \ hoWII rhen iu\ t align the fr.lIl tl.' ~toc" so the rablx't crOS'>CS the fl." ncl.' at llw (or red mar" and (ut. Thi~ cmurC'\ that the frame accomodares Ihe pictu re. I" n: ('\'en created an angled ~tophlo(k Ihat clamp~ onto the fence for ma king multiple fram~ of t he same ~ize.

-Brent H,U. IJpmt, Uto/!

Thidne« of fence eqUJts

depth of rd~t

Frame rabbet ""('rlaJ}S fence.

Bandsaw blade badge preserves particulars To remember til!' slats (Sin'. width , teeth pcr melt) of your replacement band~aw blade), Cut th e info from thl' bo.~ (ind affi x it to the coill:'<.! blaul' mlns a t wi\t tie. Wheu y~1 hl\tali the blade m till' ~a\\, hang tlw tag from the b.1nd~~w's door hand le. It\ a helpful rc!eTl'lh;e when you frequent ly change blades for d it feren! Uo,l"S

--k"'" Htm/"I>""l~. \~OOO>l\l.. '-hili

8

•

•

. . . . . . . . . . . 6la~e <!,"IC:JPti~n ~ut ~orl1'pac:a9.e

Tw"t tie . . ,

~. \ : • • I •

: : J: . . . . . <:::iJ. .~ .. ' .. . . .

eo;,,,d ba" d<~", b lolde

Brent HIli onl), ,elu( limtly admits t hat he manaycd so ftwdrl.' pro jecI5 for t he IR S. " I IIslld lly lu,1 say, 'I worked for the govetnmc:nt ." My woodworking prOl ert~ ,Ir e a lo t more fun." Now retired. Brent ha~ refocused hi~ cne'\:jic !. on picture frd mlng. W ith 12 grandchi ldren, he g et~ l ot~ of use from hiS tool-winning Jig, left.

For ~end,ng In t 'lIS ,s.ue·. l o p Shop Ti p, B.ent receIves <II JOS An-Tech 7S0-ER air fil trat ion sys tem. Great '<lb. Brent!

Top tips earn tools! leff us how )'Q,.,'\le ~o l ved J workshop slumper If we print it, YOll'l l \:je t S1 00 and a copy of 450 .. Bes t- Ever Shop Tips (woodmaga;lne COllli4~Otlp~) . And, if yo ur l(l"a gdrocr$ Top Shop Tip honors, wc' 11 a lso rcwald )'ou with i\

too l prizc worth Jt IC:Jst B OO. Send your best id eas, dlong

with photos or d raWings and your dayt ime phone number, to; Shop Tips. WOOD Magazine, 1716 Locu~t St., lS·221 , Dh Moines. IA 50:109-:102:1 Or. by C-Olill!; ~hupIJP' 'WoodmJgazine.com. Ind ude your contact Info in the c ·ma;!.

Becduse we tr), 10 publish ()(iginal tiPS, please ~eod your tips only to WOO£)' maq;tlone Sorry, !iUbm .tted materials Coln'l be returned,

Shop Tips Drum sander adapter breaks thickness barriers I love my drum Slln.k:r lor thlcknthing lumber and ItJ.ving a lolnooth ~urface. But rom(>tim~, I wam the same finish on wOrkPIl'<:t'S larger than 1I~ machine's j " max imum thickness, such as wll l·n ~nd ing don;tails flush on a drawer. So, I adaplcd my drum sander to sand on the lOp of the drum by con structing the box you see at nsfrl. It jll)t fit.s t he bed, wnh t lwends pr":>lrudingdown to "eep it from nloving. It's high enough to accmmnodatc t he OpCTll'd sander.

1b create the slot for the drum, 1 instalk'd J6...grlt l>a IX'f, clamped the box In place, turned on thl: drum (but not the feed belt) and ral-;('d It untlllt touched the undel'lkle of the tabletop­iUS! t'nough to JcJVC a m.lrJ,:. Theil, I rclTlovcd the top, anll I"OlJlOO y. ,,!" slots through the top at elt il l' r elld of t he mark to accommodate Ihe exposed ends of the drum where Ihe sandpllpcr does.n't reach. I replaced the top arK.! $Iowly raised t he '\andlng drum u nt il It pro­truded slightly from t he top.

_Paul Milo, (jltnda~, AliI.

10

">.l"llIng drum

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Magnet! tnpe, and glue ilf hI. brush I u .. <I, .. """,b~ m<tal-handlc<l b"~ "Hpr~a.1 glUt 0<\ wood­>W:llna ;oom~ but I al,,"aYS I<'Cm 10 t ... · ... k 1m blUsh oIf In., bench and Imo 'he .. wdus!.t 1M wOfSt jlOI>sibl. ti,ne' My lOIu· ljO!~ Tal'" ~ ,mall m'1J;n('l to 'hI' gl LK' i>oIt!('"hh m.t>lo.I"K t"pe Th~ bruoh con' roll _'~', Ind .. ~ hn>lle> >Ill clean .""". Shelvc s secure sh!:!lvl:!s I inl\o.lI.,d Wtvlns b<,wt'<" lb" or><" "",11 oj my 8""'g< <hop 10 tol.J: od •• "t.~ ... of u.. unuoeJ '1""'<. Tl"l n '"I:' t'·ttlth!"~ in opon view al~1 ellY I<) '1>01. Ilow=r, illl00 , .. ,-.:, ,,"vents ~n,1 /loi,h .. within ,_" of sm all ho oo, !O I ll<'eded • ""V to rhlkiprooo' 'hem Ttw', when 1 1',,,,,1(1 Wlf(' d""'T ~dv!rlg.l iJK'1\oo'1C«(n1<'r. 11 ro",,,, l n 16" .. ·;JIII,.....'h.· \,'ffl ( •• "a,""'''' <Iud 'I""''''''' .. ,Id Cln ~ ".,i,,1I'-'<I" """11 tI.., Ind"<k<)llIrd"",,, a> """'ll.. t-""", u n Ix: Ioxt."jlll all out-of­.u:h S[lOl"~h J <Imvl~ ","w1 (.II.h {I, .n cyt' 1\(>01,: k><~.

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Shop Tips

Just flip and rip with this thin-strip tip As i was ma"in~ the thtll-)trip lIppi ng guide from til,. (\()q-mlkr 200S iSsu.:' o f WOOD, magazine- ~no_ 187, p.1g{" 63).1 sa" an oppollun lt) \0 "nproH~ it~

efficiency, Afle r atl':Khing thl' m iler-slo t IlIn ner to the h()'l"I, I II IlP •• '<I lhe board in half, and Ihi'n r(';lttachoo the two hol ln-s wl1 h 1 1Inb"" ~ bciore Jdding Iht' nut a nd guide tx>1t t hol t .lcts as a SlOp. \\lith the ~trir width ~I, I poSI tion Ihe table!wlw #;;ncl' and flip the IIg guide out of the way to make the ( ut. I flip the guide had. down agdi n to ~ttiol1 the workpiece and I(' [\CI' fot tlw Ill''''! cut. The !...nob on till' lunged gUlI.!c si mply makes it casi.:'r to flip_

011':" [OIlS!, Mound City; Mo.

12

After '.ettlng fe-<>re \ Il,pout ,ftht·"a)/.

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Unmasking a burn-free edge \'our {oXen! a l tic l ~ 011 rcmo\' lng rQute:! hum m.u"s (July 2009, no 19 1, F"gc 22) was w ry tld l,ruJ, Ilc l;;>\ 11K' lIldhod I Us.<' wht'n template routing,

AIlel c:ulting CkoSl' to Iht' t raced kmplat<' lim: with the b.~nd)J."~ I "!'ply two or thcc;;> layers of Inaskmg t"IX' to

I'm a sole magnet! '10 protect the blade and sole of your hand planes when not In usc, pick up a shed 01 magno.:tic air durt grill ,0Vtl frtlm the halelwar" \tore. Trace th~ ,hape of th.; " lane >ole on tht' magnetic

Ihe: edgc of the templ al~ ix'forc "Hi:>.illg il to tht workplcce, Aft er using a pattern hit to ma"" an Initial pa~~, I {e:lHove the ma~king tape alld 1II00 "e a fi nal shallow pa~~ with the mutl'r, eliminating any hum mOl rh,

-EvrrPlf BIau, ~ flo,

~heel ,mel cut 11 out With scl\sors, Your new nugnetlC cover shields lhe blade and >ole from hump. and [ostks, ...... Tn in the ix)\\om of a looll:x),'I:,

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l"IO:f1 tile llOl!!.! par!;clt~, ~"1 get ""'per rJeJoups with out d~SI clOUtIS Siiwdust. o;Iryw311 (IUS\. Wille-r - none- of lIlem star.:! a Chance agll iMt

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Shop Tips

Spring-enhanced hold-downs r use th is jig in place of a featherhoard \)(3)<6 ' scrap of wocxl to accommodate hold-down on my tablesaw and romer the tah. Then att,lch the ~a~h spring tilble because it's inexpensive and easy with brad nails. Clamped to your fence to make. To huild one, you'll need ,111 the spring action holds the workpiece inexpensive windO'IY \il5h ~pring. You ~ecurely agaimt the table during can get them for ahout SMpair at the feeding. hardware store. Cut it small kerf in a -Dale Robbim. 5tockton, Calif.

Childish solution to brittle chalk Growing tired of my chalk breaking when I tried to mark on rough surface~, I took a l(;'~~on from childrt;'Tl\ crayons. I wr,lPP':'d ma~king t<lpe around the

Mas~mg tape

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chalk to reinforce it. After the chalk WC<lI\ dowll, I jUq kar off a litt l", tape to ex(X)se more. Works like a charm . •

-Io!e 501010(, Indian Springs, Nev,

15

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A ramalic ea~tc rn rcd cedar (J1fllipt1fr1.1 l'itgilli<1lllil ha~ bCl:'n

tho;> traditional choice for bla nket (h~ls and closet linings fo r 8en':I3tI011.\ bet:au'\e 01 Its purported mOlh·repcllant properlit' ,lnd fre sh sn~lI . h It a miracle wooll o r tOO good to be tnl!;'?

Mothbusters1 Two culpyJts commonly <la mag!;' dot h: the ca*maki ng doth!;'s lIl<'th, \howrl bl'lllW, and the webbing clot hes moth. t he'il;' I'I;'(' I USJ\~. ~rnall crillen (about v. I<'ng with a Ih" wing~~"l ll ) don't l\."'SCmbl(' yOur ~ta llda .. J polI,h hght m utils . II yuu St'i.' th..'rn at .. II, II !lily alread~' be 100 late to save your sweaters because n's the I nTv;u:~, Tnt hel t han thl' adult moths, t hnt nlUnd1 un wool, fur, ,11Ki feat hen.

LlFl AND 111\-1~S OF TIlE MOTH

16

Cedar

So how docs aromatic cedar contrib­ute to y<>ur pest-control solution? When concentrated m a tightly-sealed ~p.1ce, such a~ d blank.et dll~~t, th\,' lilpor \ frum th i~ wood specie~ will kill h at(hing moth lan'ae. !lut thme vapors have little or no rif~t on larger la rvae, adult moths, OJ Ic"ggs, amI less effe(t ~ l lI l l n

wid!;'-open areas, such a~ doo;ets, That '>aid, iI has been found that

aromatic cedar blocks bugs no bt'tt t'r tha n si mply sealing u lll n le~tl'\1 duthIe'S i n a plast ic cuntainer ur bund ling them In tapl'\t-up butch!;,T P'lP't".

Skip the finish Top-coating aromatil: U'dar 'iI;',11 ~ In, and Iherc{ore negate~, its in~ect ­

repellent propertie~. But you ,hould also avoid ilpplying ilny stain, paint, or

finish to the nOll-cedar interior surfaces (If II cellar chest. That's becausl;' the rl,'s\n5 111 (Cd,IT share characteri~tics wIth tuqll'nttne, ,mu the solvent-like I'apms can cause oil- and water-based stains, p.1Ints, and fimshC':S to softCIl. nlJking lids (ano clothes) st ick If you include t he opt ional Cl"dar tray i n t he blanket chl:'St on I"~' 30, lean' the inlenor un linishrd.

The cedar.lined bottom line If rou want to give \ 'OUT blanket-chest proi-xt a tra,1lt lonallook (and smell), '>Catch no further than auxlK,lIc t1;'llal. Howevcr, 3\ a pt"St lt:lde, aromat ic tmar lIla~('\ a l.o ("tler pre\'entath'e !lIcdicine th,m it c!0(') an ulthna!e curt', So don't expert umaclcs . •

10 circul ~lot.

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Great Ideas f9LYour Shop ~~~~--,-~~?

Easy-Store

ClaDl Rack W h.'n WI! fir" ran aero's this

ciJlllp.r."K.1i cleslgn, we did a bit of J dO\1b1\> takl!. It holds

clamps by t heir h ,mdl~, not by thl' fixed jaws. ,IS wc'd Sl't"' 11 Loul\tle~~ lIme ... With thi~ "brKkward" dC)lgn. clamps can" fall offltle rack, and It kC'Cl'sthe movable jaw frorn ~Ilding down the bar when hung.

rhe key to bullcling tilts damp llOldel is to minimiz.e tht gap UctwCl!rl the front ,m" bad. pit-en. Thl' light!:'! the opening around the damp handle, tht! more vertical a clamp will hang-J v." gap works I,d!. A slight rOtlnd-ol'er ,llong the top in)lde l'<lgl' o f the fron t mini mizl!' marr ing I h{' cla mp. handle finhh when h.lnging the clamps . •

Hote: P,n'it w ij'll1e!. ,hllp at well ai till)w 1'( 12 otlwr tnjl-Sh{,p fllmeo'/'y viSitilrg 1'I'()()(.hn.J~aji nl'c~~nll \ Jl1 r \\' 2iM)lI

"

r , , , I

'",, " Plio! hok: l " '· d~

i r

L , , .

_8 , 3" Hi wQ()(j .crew 0:""1,,,00 011('1 wall stud

",",,' ,han~ hole., _. __ ~ __ 4\,oonter,unk

Slight tOO tld-over along imide top edge ,"''''-" (

FRONT

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/'

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WOOD .. .., .. , In ~ NcNemb...- 2009

Wise Buys Our Experts Test

Forstner Bit Sets FREUD, #PB 100, $200

16 bu.: ~.· IO 2 1'." in ' ' ,ncrements

Editor rating: * .... **

Editor test-drive: Be fore It'SI il"l9 I h,~ :)f'1, t UJ,f'd d !)el"ll'flC,

1I1€:< pt' lhive WI vi For~ r'l€ l blh III m y

~hup, 4nd gol alung lifll' But what a di\lerf' I1(f' whtlll l>f'g:m lI)1ng Freud's I t dl l~n·ml{l€ bit ;. ' It 's ~ma2 i 119 how my ordin~ry, dleafJ bib lulled me into accepting ~ li tt le lear-out here or ~ li Ltll' burning Ihrrl;' With a lm' '1 I1 f' wavy-I'd¥­rim dpsign, !h f'~c b its I1 I'Vf'1 torf' out any of the wood, thJ! I used fur testing, induding p€~ky vent'€red plywood and Mm. The wavy edgt!s Clit so ) mOulhly and de~n l y arld reqlll rt!d ~o 1,ltle effort tiM! it sUlpri;ed me . They 31w ell! flawlessly o n ilug lt!-d -en tr y holt»

To learn mote: 800 ·334· 4 107; Irf'U(J luuIS.com

- T.,.ted by Chuck "'''',,,,d 13 Y"" 'S a~ Ma)le' Craflsman al WOOD mJ9a.!ine. 35 )e~~ of p.ofes,"on .. , woodWOlking c~o~' iE't\,e

'0

Why buy? A workshop needs Sf'Veral typf'S of d rill b it;: 5tdnddrd twbl, br ad·poin\. and rOr.ltf~r bits. The first two dl ill hole. pr lm anly V..- or less in (Iiamt'ter. But fontner bit> create hole, from . to greater thim " . l hese bi t s no t ooly bore cil'<ll1, p recise hole), but they also e)(cel at aI1g1t"d holt>_1 and counlN\)orl's. and Il' awo U<ll bo ttoms ideal tor inse rting European-style (UP hUl 'lI' >, ch <lir Sl fetcher~ MId ~pi ndlt's, or comml'ffiorati~e coins_ Al lhough you can use them in a h .. ndht'ld dnll, tOi safety imd best results we suggt>st using I" o . larger bllS In a slow·runn,ng d rill prt's~ wilh your wor~pif'Ce clamped 10 tht> lab 11'_ Atll'r le;ling ""gh l b01<1'(1 '>t't~ of Forstne r:., we recomm",nd the Ihree belm"_ AlilealUrf' prmlt"d or Imbf>d(lt'(I d iam ett'r m <lrkings on the ~h<ltl-our prt'fe fence-becaust' m iukln9S rWOilr I ll", ",nd ~ It"ld to wt'ar ovt'r l ime due to 5lLpp<tge in the chuck. HAHN" JVSTEM .,. ..... Topo11he 'ine ,. .. "' .. h(ell~nt q .... hty ."' . Solid 1>I'I'lorm~r 101' lh~ pn, ..

LEE VALLEY, #06J80.13, $79

13 bi t~:

'!," to 1" in ~;." increments

Editor rating: ****

Editor test-drive: Excepl for Ih f' 1 h' bit I use lor cup hlnge \ I rare ly uw Forstne r bits l ar 9~ r

than r So thl5 ~H 0 1 ~mall blh , mad .. in China, ~ulh me ju~t fine, even thOllgh I (<In g f' t more bits for If'H m oney e lse­where. Thew hlgh-speed-steel, ~mooth _

rimmf'd bits proved sharp and accurate as they bored crisp, lear-Dul·free ho le :. In

oa k, walnut, fir, birch plywood, and MD F. They make perfect flat-bottom ho les. With only a ,/. -deep divo t from the centN spur. I also tf'sted Lee Va lley's 16·p it'<:.e 5<"t ot sawtooth bi ts (1 'I, to 3' by 'I.' Incrernen ts, S2 50, #06J80.16), and they performed Nlually well.

To learn more: 800-871-81 58; leevalley,com

-Te~ted by Kevin Boyle

8 Yed" '" ~n edilor at WOOD mdgil line, '12 yea.s 01 wood,.ork,ng e"p"""uce

WOODLINE USA, #WL FR2000, $65

20 b ,U, ,,," to'" In ." Inne ments: 1'/0" to 2" ln ,,," jn( remen t~

Editor rating: ***

Editor test-drive; In Ihf' pa51, I"vt' bought rorstllH bits like rvutt'!' blh Oll f' al a l im e, as needed. But lur th f' P"(I" of it halt-dozen Individ ua l blrs, Igol Wondhne's ChUM-made 20-p' t'(.f' ~el . The 12 bits smalle r than I ' fea ture Sm ooth ( uttl ng rims, wh ile the IMger one:. tl3ve d sawtooth design. Both type:. cut cleanly With no I~M·ou l a~ 1 bored ho les III pille, birch plywood, white Odk. and eVf'n tough· as · na il s h ickory. A~ a bonus, th ~ t ltan lum · nitride coating he lp> 1t'(luce du lli ng fro m 11I'a t build up. They al:.o havl' he~ ·t ippf'(j shanks lo r dna-sli p gl'lP in til l' ( hUCk, Wllh the re<:om mended Sf}et'd pr inlt'd on the ,I hank . •

To lE'arn m o rE': 800 ·472-6950; woodlmt',com

- Te:HW by Bob Wil,oll

S }-ears a~ ~n editor ill WOOv m~g"trnl'. 25 ~cars of .... 00d .... Olk,"9 e~re, i~n(e

•

INTROOUCING OUR NEWEST SAW

Go to sawstop.com!wileapproved alld we'll s.elld her a p<Jl"suasive Informalton KII, mclLJding a OVO that will close the deal.

How to Redo a Misassembled Drawer Don't get bent out of shape over an out-at-square drawer. You've got one last shot at achieving a first-rate fit.

That's some magic trick YOUI newly built drawer pull(>d-levltatlng one of Its corners off rour

workbench [Photo A1. Before \'OU make the whole drawO;' I dISJp~ar. try thb technique for separating lind reassem· bling t he drawer

Your lucky brt!ak Separat ing a glue join: by force works best if rou catch the problem bef(\~ the glue cure completely, so ch~k drawers for flatnts.\ and MlUtlre a.\ soon as yOll

lem(Ne the clamps. You ha"e 1\\'0 options for \\eakenlng glue join ts To soften type-l (noll , \\',lt(>[·rdistailtl yellow glue, thoroughly soak till' joInt with vinegar until you fl'pi the ronno!c­lion fleA. FQr tyr ... -2 or tYp.!-3 ydlol\'

"

glue~, repeatedly soak t he joint with acetone in a well-ventilated area. For an odor-free alternative way to soften all th!~ types., heat the joint with a hair dr~r [Photo 8].

Immooiately after softening the joint, damp one side to your bench. place a scrap block against t he joint, and strike the block wit h jUst enough force 10 separate the parts, as shown "WI\'. IkpeCit for the remCiin ing joints, soaking or heating one and separatIng It ""'forl' mo~'ing on to the next.

Once separated, .... ' nd t he joint parts ~moot h without sandmg to barl' wood, which can throw off the fit. Remove any glul' build-up within dadoes and rabbets that would affect reas..embLy, then sand end grain smooth.

Drawer assembly, take two To avoid repeatIng the same mistakes, check drawer parts fo r Identical lengths of opposIte parts., such as sides. Check that dadO€s and rabbets on all opposite pa rts \\".::re cut the same. Then use a \tra lghtt!dgt' to ensull' your bench top rests dead flat. If it 's nO( fl at, do the Il'assembly work on your table-saw top-prov ld~1 It's flat.

The first glue-up filled the wood pore\, '>0 \wi rch to a non·(ll'fletrat ing adhesh·c, \uch as hl.m inutl'epox)'. Assemble the d ral\d and damp t he sides, front, and b..1Ck as rou normally wouLd. This tlmt'. though, add two more cI"mps to hold the drawer :l.~~mbly against your flat work surface \PhQtQ CJ. Thl'tI chl'"Ck for square . •

" WOOD ... ;og ... In ~ r""""m_ 2009

•

M a.:1I1I10;''<' (ut joints fast. but not Jlway~ an"uIJ te-ly. "I hat's the time to bring in hand tools

because sanding blocks. ( h lsoCi s. a nd p lmes Io;'mo\'o;' wood in thous;lodths o f Lin mch lOr':' snux jo int IPbotI)AI.

If you don't havo;' a ulcw,J. plane- or moulder plane, don't ru sh OUI and buy them-yet. Stall simrlc With a sandIng block you can mJk.;o fOr p\'Hni('!; U,IIl!: scraps, ..amlp<lper, and spraY·,ldh\'5he. Then add a good St.'l: of bevel-edge­bench chisels, t\~ your joinery ~k!H s

improve, save time by supplt'meming )'OU t sanding blocks with well-hO!k'd block and shoulder p I Jtl~,

"

Take your jOints from " not quite" to "super tighC using these basic tools and 'methods,

Sanding blocks: Slow but simple Uses: Reduce tellon Ih itknt;' .... ~ by ~andmg Iht;' ehed..s, a nd m.akt;' t he ~hou l ders e\'en with each ot her [Photo BI; ~moot h scoring from tablesaw·cut rabbets or didoes or stub-tenon ,;rooves for dea ner edges ,l nd a stronger glue JOi nt [PhotoC]; and ad jmt half-l.ap d '->Plhs to mako;' parts fl ush I'or a CUT\ed sanding block to flne-tune coped end, on mold ing, wfap sand­paper around dowels of di ffo;'reot \i~ ... Sllcce~ .. secret<.: Match th(' grit to the amoum of stock to r('move-.'>tart at 80 grit for removing det'p <;cor ... llno;'.'>; 120

Squaf~ between the edg~~ and facl'!'i.

g Ilt w(){ks great for minor tenon rorll'ctlOIl~. Theil match the block ~; le 10 Ihe lob . • o r example, plane a ~rap blod . 10 the Ihk'l; nes~ o f rOUt dado width~; then mount :.aod paper 10 Ihe edge fo r a sanding block that ,..ork, tile ent Ire dado with each pass [Phl)to Cj. Choo-.e h ;l(I\\'Oo(l 'klnJ ing-l'llock ,tock lll3 t will hold l crlsp edge, and attach ~'l1ldp.lper to only One su rface, not dd[oioing (,fee Of edges. That lets ~'ou ,Idlust one dimen,ion of d loint without ,tlf~t l llg lI lt' OIlwrs [Photo 81. Abra'IVI'S on smal l SOl ndlng blocks wear In a hurry, SO chal\ge pdp{'r frequently.

comllmcd 011 page 26

just,Right J.oinery Chisels: The ioint-maker's edge Uses: Trim smooth willb and square t!nd~ on d rilled mortiSo..~ [PhOIO 0 [; on hand-cut dtwelaib, ~hCl.' strail;ht Ijnes lor clean joints and Sh:lVl' pHIS 10 fll the ta ils; sq \lare ~Iupped rahh",ts [PhOIo El Success secrets: Hone lilt' ht'\el ;lnd nallen llie had: for an ed):t' sha rp enough 10 sh;n e th ... t!dirs on YOllr arm.

A ch i!oel follow~ grain as it nll ~ r'Or paring ("uts with the gram, cut from the oppo~ite dir~tion i f \'Ou negln to f~l thl' (:hisei plul~'" iJown inlo Ihl' wood. Where that's not an option, hold the ch isel perp{-ndlcular ILl the grJin and tap it to mak .. V,.' stup CUb. Thl'n remove th l' wood between the stops.

Use the whks! chls~'llhal fits till' joint area you're cutting. To trim the walls of a 2'-wide mortise, for exa mple, two cuts with a 1" m 1'/, ' chlscllenvc cleaner, str,llghter linC5 than four or five cuts with a '!.{-wide chisel.

26

workpleCI! htlp. 90"to the l'dgc.

Block planes: Perfection comes .002" at a time Uses: Flush-trim edge!i on p;!rts jOined Inlh a machined dovetail; c lean up ~wn edges to be glued; chamfer IImoo e nd s a nd panel edges for easy in!.ert ion [Photo Fj; clean up CfU5S-grain ruts, ~uch as mitered ends on hand-sa\\ n frame pieces; trim t'Ilds or edges t hat stand proud of an adlacent wurkpll'C~'; make drawer side edges flush with the d rawer fm nt. Succe.~_~ sec:: .. et.~: Ch{'Ck the plane ~,-,l e for flat ness. The best plane worb only a. well b the sharpness o f the hlade (For a video un how to hone a rawr­sharp edge using sandpaper, go to wood magazine.comJsharpcningv id .) Test the plane's cutting depth on ~rap unW each pass takes a con~htent, translucently thin curl [Photo G1. Before tackllng a workpiece, practice contrOl­ling th e plane balanced on the edg .. or end of a ,/,'-thick practice scrap.

PIIUl!ion lheedge of a scrap blade prOd llW tight cur ls of even thk kneu " om . ide to "de.

Shoulder planes: Tools that work: lying down USII:S: \\IUh hlades that cut a hair wiJer th an the plan(' body, these specialized pla ne~ stra ighten tenon shoulde rs and shave tenon cheeh wi lh ea~. Other uSl~ include ~moothlng dado, rabhet, ;m d IW\OI'e bol to m s, as shuw n l't'lfll"'_ Su ccess '\"ccn: ts : You' ll nften pla ne c ross-grain with thh 1001. making a razor·sha rp blade ""!.ential ror ~uccess. Celli;:>, Ih.: hlJde on Ihe plane bod)' [Photo HJ. T h L'n .ldjusl the cutting dept h to m ake shallow pa...ses I\ith no tear·out [Photo I). Because it cuts fasler than a sanding h!ocL.:, stop frequem ly to te~t· fit parts . •

Sources ShOUld" plane. ~edi1.JmYlouldefpLme oo.05P41.o1 Iwlth ~ h.Ird A2 steel b ~ f",le$s ~peni"9J. m5. Lee Valley lools. 800·871·8158 ",Ietvlli~.com. Block r hine. Ver~al AplOI'1 f'I.1ne no. OSP27.G2, $85 W1t h !Ill A:l bLIdoe, Let Valley Tool •.

WOOD .... a.guln.. N"""mber lOO9

•

•

.IE

ase Curves as gentle as a flower petal surround a glass vase nestled within this simple project.

Cut a base and vase holde r

1 Glue together a vast'·holder blan k from three piec('s of '/.><2

'k><7J/.'

slod: (we used walnut), and trim it to size [Drilwing 1). Cut the ba~ to sl:te.

2cemer and Jtlach the .... ut' holder to the base using double·f,lee<! tape.

Drill and drive fo ur scre ..... ~ IDr,wlngs I and 1]. Copy t il.: Vase Holde. pattern from thl' Ivt'X)/) l'aUelrl) Instr, and spray-mount it to a vase holder sIde.

31m!0I 1i a -'I.: cO\'I;' bit i n a !<lDIe· mounle..! rouler :Iud ~el the fenle

fl ush with the b€'a rlng (tkawlng 2.). CIJrnp stophlocks on the infclod and outfeed fences 'l, lk' from Ihe center of the bit. Then rout stopped COV\!S on t he sides imd end~ of t hl' base IPhoto AI,

4Remove tile vase holder from the base and rout VI" round·overs on

the top edse$ of till' 1)<1 $';>.

Drill long ho les accurat e ly

1 Ch eck yOur ddl1 PI,"SS to ellSure the table align. 9()" to Ih," chuck In all

directions [Photo B]. Clamp on a tall fence shimmeel 90° to the t"h tt!. (See;1. free vieleo on ho\\< to fUlc · t line a drill pr~ .It w(X)(\milg.:u: ine . .-omi<.1rillpress.)

2ln~tall a FOTst ne[ bit t he same size as or '/",' 1,1[g('r t han the gla,s vase

marne!e[ r or the I ',,"·dla metc, gl:'l\'" vase we bought at a hobby , to le (LIbbey *2824), we used J t '!."·di31lli'ter bIt. (Drill a test hole io ,,: rap a nd te-.I·flt the glass vase.) Mar~ t he center of th.;­\ast'·holder ~nd, dnl! center II he\()',v l ho: bit. Cldmp J ()Q0 squaring brace to the f~nce TO s.eCU ft' the pJf l

D EXPLODED VIEW

GLASS VASE I ... • d,am. ~ 7'h'

VASE ~OLDER

\10" round ' O\fe"

"

Add ~ims to ma ke the drill pre~, Idbl t 90" 0 ~ rod ,n Ihe chucK. Check thl' ~lignment In ~ II

directions u~in9 a $qua.e.

D BASE (Bottom view)

4."shoiol'~t", w;,mw.sunl<

3Drtll halfway through the vase hulcl l'r [Photo q. Depending Oil

\'O\l r bI t and drill pfe~~, you may !lc.!d to SlOp to r:l.i)<' the tabl .. .1s yOll drill)<J that the chuck reaches deepI'I into t hl' hole, n .ill un til the b:1 rt"Jch l.'S 3,.· d"t'p. l hl'1l flip t he \.1* holde. O\o:r, "'~pil1J.i t he !kll'lle ~lHface .1g.11IISI the ft: !ll.'l.' Cla mp It in pos.ition and d .W u nt l1 th .. holes meet.

4 R.lnCb.lW till' vas.;> holder ill\(j ~arld to the p.utern hnes. If the holt:s

drilled In St .. p 3 didn't ml'et perfectly­ours Werl' off by le~s than 'Io"-)and thl'lH WIth lOO-grit adhe~i\'e·lxlckl:!<.\

II fence

EZ!I BASE ROUTING DETAil

sam1paper wrapped arr.JlInct a '"l1owel. fake C,l le to maliltalll the hal f round shape on both halve5.J]lcn f in ish · ~nd alllXlfb to 2~O gut

5Rl'COllrtect the two \',lk·holdel halves to the oow. Color th .. OO'iol!

cO\'cs with a blocl permanent marl er to make th em less \' Isible, I hi.'ll apply a dear finish, \\ \'e u;;ed thlt .. 'e (o.lt) of Jer050l \o1ltin IJcquer, ~andi us with 320 ~rit between coats. ) •

Writt.~ by Hob W it,on I'mh ,,,If Me r . < PrOIe<! de<lgn; Kevin Hoyle III'''!''\I<'''' Rounn e Le M" ln" L"m~ John.on

"

Overall dimen$ions: 45"~' wide 19l/." deep ~ 20"1I~ 'fgh

(Country fre1h ver!.ion 21 I1A~' high: Casu.ll COlltcmpor'ary version 2)1/ .. high)

30 woo, N

! j , i I

AT A GLANCE • Lid-stay torsion hingE'<; keep the lid

open at any i\ngle . • Option~ for joinery, base profile, and

wood selection provide custom looks.

Build this chest with your prefer­ence:; for :;tyle ami complexity in mind. The Traditional Amencan

look in mahogany (left) require:; dove­tailed corner joints, cut by hand or with a router jig. To simplify matters. try the Ca~ual Contemporary version in con­tra>ting woods such as ash and walnut (be/ow), with rahbeted corners joined hy plugged screws, The Country Fresh option (be/ow right), shown in pine, also feature:; rabbeted corners. For that stylI;;', we reoommend cut nails to hold the joint together.

If you like the dovetailed look but don't have a jig, challenge yourself by hand-cutting those joints. You might be surprised with how nice your results turn out. Start by cutting practice jOints in scrap, following the steps on these pages. After a few attempts, you should feel ready to show off your new skills. And here's an extra safety net: On pages 34 and 35 you'll find two easy tips for fixing any less-than-perfect joints.

Prep the panels, then cut some tails

1 Glue up material for the front/back (A) and sides (B) [More Resources, page

36) and cut them to size [Materials List, page 36]. When cutting dovetails, it's especially important that the panels be flat and of con:,istent tllickness. If you're building the chest with rabbet joints, refer to Joinery Options on puge 35.

Same chest, different styles

Label each corner and top edge so you can match pieces properly when laying out the dovetails and assembling the joint.

Use a ratio to set a dovetail angle

Set the gauge to V.," more than the panel (A, B) thickness so the pins and tails protrude slightly. Sand them flush after assembly.

You'll often see the angle of a dovetail expressed as a ratio of slope to rise (1 :8, for example) instead of in degrees. Why? Because it's easier to set a bevel gauge using a ratio instead of a degree setting. Here's how. For the 1:8 angle used on the blanket chest, mark a 1"-long segment on the edge of a piece of paper. Then, beginning at one end of the line, draw a perpendicular line 8 " long. Use a straightedge to connect the ends of the two lines to make a triangle, then place your bevel­gauge handle along the edge of the paper and pivot the blade to align with the long line.

2c'amp the front/back (Aj and sides (B) together, label them [Photo Al,

then layout the dovetail spacing on each cnd of the front/back [Drawing 1a].

Different woods and base profiles provide a variety of looks forthe blanket chest. See Joinery Options onpQge 35for detaIls of the rabbet joints used on these versions.

3QU"Ic TIp! GUlIge your layout."\rlw Use a marking gauge instead of a II

pencil to mark baselines. The gauge cuts a clean line that provides a trough for your chisel later and emphasize:, the hand-cut look of the jOint. Set a marking gauge as shown in Photo B; then scribe a baseline across both faces on each end of each panel. Set a bevel gauge to a 1:8 angle as shown in the Shop Tip above. Then extend the dovetail spacing marks from each end of lhe front/back (A) down to the baseline. Mark the waste areas between the tails [Photo C[.

.,

woodrn"g .. ,lne.com

4Clamp a front/back (1\) in a vise orto the front of your bench. Staying on

the waste side of the lines, cut to the baseline on both faces rPhotoD]. 1\ gUide block with a 1:8 angle on the end helps start your nIt accurately [Photo D inset].

5 With a panel facedown on your bench, pres~ a chisel into the base­

line in the waste area between the tails to establish an edge. Then make chop­ping cuts halfway through the panel's

31

ang~ Mark

D CASE EXPLODED VIEW

--

iI!l LlOCLEAT

~~~~~~~~~~~0:' PreU your chisel in <lit I h~ bdsel,n~ 10 cr~a t~ a yom cu i j line. 5~w ( le an edge. Then, ,~. from the baseline. dlOp down 10 down aboul ha lfway Ihrou9h Ihe pan~1.

45',0 ' ___ ---------1 \it" rub~f bumper

.. . cemered over lopedgeof@

.'

<~~6~lIi f- H, wood sere ....

(,(lolh. lld-stay hinge

m OOVETAIL DETAIL

m LI D PROFILE

Tr,Jdlllon~ 1

Ame"(8" Ch~lt

Cn!U~ 1

Lonlempo'i 'Y ChClt

____ \0" cha.11I ....

i

thicknes~ [PhotoEj. Chip out part of the waSte from the end; then flip the panel and repeat this process [Photo Fl. Work your way back to the baseline, angling the chi-;el ,lightly to undercut the base­line [PhotoGI_

Pin it down

1 Clamp the panels together again to create a box, matching the comer

labels, and with the front/back (Aj against the end grain of the sides (B). Align the inside face~ of the ~ides with the baselines on the inSide faces of the fwnt/back. Using a marJ...ing or crafts knife, scribe the edge~ of the dovetails onto the ends of the sides [Photo HI. Use a square to transfer the marks from the ends of the sides down the inside and outside faces to the baseline.

2Secure a side (Bl in a vise or to the edge of your bench and Cut down to

the baseline, staying ju,t outSide the lines [Photo I]. Remove the bulk of the waste between the pins with a coping saw [Photo J], then use a chisel and

scribed ba~eljne on both

woodm"gazine.com

knlft

Push or pull: See how we saw Senior Design Editor Kevin Boyle made a discovery as he hand-cut the dovetails for the chest: Sometimes the tool you know and love isn't the be>t one for the job. "The Japanese pull saw (dowkil I've favored for years wasn't cutting as straight as I wanted. After the blade wandered off course once too often, I switched to a Western-style gent's saw that cuts on the push stroke_ The thicker blade helped fT·e cut true. I still use my dozuki for lots of jobs when I need a handsaw, but for dovetails, the gent's saw i, now my go -to tool."

Kev in ":;;~~~;;;:~~;;:~~:;::! Japat)~:se II switched to a gent's saw.

33

Clam~ and cauls apply pr~w~ on the front ~no:l b<lck (A), pressing tho! dovel lJilJ Ilghlly to thi ~id.s (8).

D BASE

u'O!'" s<:,ap of plywood thO! ~ ilm.thickrHIn iii the bottom (F) to position the glue blocks IE) below the top edge of thO! basO! (C/O).

451, '

EDOPTlONAl BASE PROFilES

- -------"'.,"- -----

c

Full'llle b~se pJuern COUNTRY·FRESH CHEST BASE

._ 451;,'·-------_ _ _

CASUAl. CONTEMPORARY CHE~T BASE

scrapwood gUide hoald to establish a clean baseline [Photo I(J. Quid Tip! {fjJ l~ufU"' star' lUI 'he! Imsdltu. ij" PlaC"t"' th£' end 0 1 "UUf ,·hlsel in o n(' end of th e- 5("11,",,-"'"<1 W Wh ne. t h ,;n ~I i,j(o

the guide up 10 it anJ cllmp II in ,,;a("l.' [ lu the same tOf the ()th('f ('Ild of th~' gu ide Clam? Ih('" co.'ntu a~ ... ·d l t() pr~

34

vent fh-xing. A. wilh the tai ls. Slightly undercut the ba.elinl' when removmg the rest o f the waste.

3Try dr}-fill ing a joint t-. lake a note of any tight spot~ that pre'\'l'nt the

joint from coming together. Use a chisel 10 trim th...>se edges o f the pi ns to fit tNt.wen the tails. Take your l ime and

Orill countuwnk s ....... hole. th rough the bottom (F), then s<:,ew the bolse ilssembl)! Ie- F) to the use IAtB).

Em FRONT SECTION VIEW

SHOP TIP Patch a pin If }'Oil overtrim II pin, glue o n a patch. then start !rimming again aller the 911,1(' dril!s. The end grain of the patch dis3pp€~r5 in the assembled jOint.

~hi1\'c awa> small amOU1I\s, test ing t ile fit oftl!lI. ~ the Shop Tip 11b.11\' if rou trim :r pin too much. WOf1,: rour way .lround Ihedlest, (jilin!> on(' [oint at it t ime.

4onc(' all four joi n ts t it together, apply glu('" II) t h ... edges of the pins

and glu,' up l li(' box IPhotoL]. Quid ~ Tip! H.t~/If(·~ g1,,.· lip tl".~. DoIl'I \J

bother gluing the face grain of the pim or tails. These surfaces contact end grain-a weak bond. Use clamping cauls behind the pins to draw the joint tight across the full width of the front/back (AJ. Check for square by comparing diagonal measurements.

SAfter the glue dries, sand the pim and tails flush with the adjilC€l1t

face s. Avoid rounding over the corners by clamping a scrap to the adjacent panel, flush with the surface of the panel you're sanding. Quick Tip! Zap (@ gaps. Fix gaps under YJ2" by squeez- ij ing in a small dab of glue, then sand­ing the panel with 220-grit sandpaper. The sanding dust StiCk5 to the glue. cre­ating a patch that blends with the joint's end grain.

Give It a base to stand on

1 Cut two 4><4S' blanks for the base front/back (C) and two 4~22 ' blanks

IIOPTIONAL TRAY

for the base sides (0), Note: The bu.ws (or tile Casuul Camempomry uud Call1ltty Fresll versions arc di((cr~11t width, [MOIteri ­OIls Lists]. Tilt your tablesaw blade to 45° and miter-nit the base pieces to 1 W' lon­ger than the outside dimensions of the ca~e IDrawing 2J.

2~lake a copy of the Traditional Ameri­can Blanket Chest Base Pattern (or t he

pattern for the chest you're building) from the WOOD Patten/.I® insert and spray-adhere it to a piece of Yi' plywood or hardboard. Cut the pattern to shape and sand the edges smooth. Use this template to layout the profile on the ends of the base front/back (C) and sides (D). Cut each profile to rough shape on the bandsaw, then sand and file up to the lines.

3 Rout a profile around the top edges of the base front/back (Cl and sides (D)

fDrawings2a, 2b]. Cut 16 glue blocks (El to size and set 12 of them aside for the moment. Glue up the base with a glue block vertical in each corner, pulling the corners tight with band clamps. Then glue and clamp the remaining glue blocks in place [Photo M, Drawing 2] . A Cut the bottom (F) to fit inside the ~ase (CID/E). Drill one countersunk pilot hole in each horizontal glue block (E) IDrawing 2bJ and screw the base to the bottom.

SFliP the case (A/B) upside down, cen­ter the base (C-F) on it and screw the

base to the case IPhotoN].

Build a drop-proof lid

l Edge-glue stock for the lid (G) and cut it to size. Sand the lid to 150 grit, then

rout a profile around it [Drawing 1c].

~," shank flole. counte"~nk bottom face, with ~ 'I ... " pilot hole

b~mper

Joinery options Instead of dovetails, these versions of the chest use rabbet joints, rein­forced with cut nails or screws.

On the ends of the front/back (A), cut rabbets the same width as the thickness of the sides (B). Lay out the fastener locations, then clamp the front, back, and sides together. For the cut-nail chest, drive the nails. For the screw-and­plug chest, drill counterbores with shank and pilot holes and drive the screws. Glue walnut plugs into the counterbores and sand them flush.

CUT-NAIL JOINERY

::;c ... .~

W ra bbet ./ \4"deep /

-.. -. ., ........ (

1 V>" common standard cut nail

/W'pl~g

c,.,... til x 1)1," F.H. wood screw

"'")CUI Ihu'£- lid cle .. ts (m to ~ize, dll ll L.."Oufl tcrsunk pilot h(')ies and counter­bores IDr ... wing 1b] and screw the cleats to Ihe underside of the lid [Drawing 1]. Do nOI use glue.

3 Screw the lid-sl;!)' torsio ll hinges to tI1.e lid (G) and ellSt' (AlB) IDrawing 1,

PhotoO). We used tI'O tiO- lb hinges with J :UI-Ih h inge in the middle. Hott: The IIl1mlJ,rr n{ InllS6 ''',/lIir ... 1 drptllJ~ 011 the ,j7(' ./Ild wt'ight Of rOllr liol l'~e th~ tor:;;Of!

c,I/rlll.llor pro;'ided uri R(}(~ler'5 web sire (rr)(kier.(lJm) iT needed. Adhere three rub­ber bumpers to the fronl underside of the lld SQ they res t on the front (A) when the lld is cla;ed.

4Remove the hinges, fln iYHal~d Ihe Chesl lo 220 grit , then apply a Illl ish.

We used boiled linseed oil inside and QUI, then applied twO coals of water­b3sed polyurethane 10 Ihe outside. If you won't have a crdar tray In the chest, you can apply the polyurethane inside as well.

Add a cedar tray ~Of a chest that stores clQ(hes or blan­l>elS, con,lder making this tray to sit on Ihe bottom. "!I.fade from aromatic cedar, 1\ helps ward off moths natural ly-and it smells great.

1 Cut the ~lag (I) and cleat) (Jj to size. Houl round-overs where shown in

Dr,wing).

2C1am;> ihe slats (I) and cleats U) together with ~. bet","~n the ~lag.

Drill ("ountersunJ... pilot holes through the cle"t~ ,,-oct into the slats; then screw the tray together [Drllwlng l ]. Add rub­ber bumpers to the bottom oi the cleats to Ilit the tray oif the bottom oi the case. Do not apply a fin ish to the tr<ly '>0 the "roma of the cedar ("al) fi JI thl'chl'st . •

Materials List Traditional American

, ffOn\IbaC~ "" IS\->" .. - 'M B '''' ,-15)0" ,,- '" C- .... ,"""""" .- ,- 45:4' • 0- .... - .- ,- 19,.· • E ",."""" .-,- ,. M , ""- ~. 17\<' 43"'- • G id lO" 19)0" 4S"" "' " lid citalS W , - \41<." •

, , , , "

... " , .... \10" 110" 42" N: 6

"'. 2"'- 16' N: 3

Mat""I" I. key. EM~e·gIuI'd~M­~; ~b;rdl~)'I'IiXId; /'£ -<vomaf't: wttr. Suppll .. : Sp<..,. odh",,",,,,, ISxW" Ratheod WO(lod

screws (30; ti6 If buildi ng opt ional nay), J8:<1 ,," flathead wood screws (9).'11" r~t)ber bumpers (3; 7 if build,n.g opt,onal tray). f<w cut· ... l i-" ~: Add l);' cornmonsUnd.rdo,.c

-"" F. , "'_·IInd-P"g )oInery: Add l20l .8><1 )''-f\aI:hekI '-'OOd!(reon, \1,. wairoJtplugsUOi. Bib: ~," lormn "9""bit for T<aditoONl AmelOAffie<t \1,' ,oo..nd-c)lttf bot lor Comity fw..h cht-sl.4S' chamf" bltio! c.su"t Conlempo!«Y~S1. W rouod-<:Wf bit 10, optional !T3y.

Sources Tonlon hl"!!u: 604b.11k1arj 1"Iinge~(2) no. 21171 (padtd 21. S3799: D-Ib. hd·Wo\V hll1Qe (1) 1"IQ.28B14 [pod: c:I. 11 $19.99.1loc.de<, 800·279-4441. rod.Ieo.com. e", n.ll f! I¥." (l)mI1"OO mIOd«d(2Ol no «4 It 1bJ. S 725, T.tmOnl Nai, 800-835·0121, tremonIn.JOI.<Dm. Wilinut plugl::;O' ftt(top l2Q) ~em 2087S [p.Jd '" 5lll. SH9, Roo:X1e<

Cutting Diagram

Materials List CasualContenlporary Chest

,," , I c...... I \\ I , ft"Or1ti'bad< " IS"'" .. - " B .... ,- 15)4" ,,- " C" bMe fronllback ,-,,- "' S!~' W

0- ...... Jr.' 4"'~ 19!4" W

E ... - .- ,- T • , ""'~ .. lH," 4)~' F

G '" ¥,' 1914" 4510\" e.

" IIdde~ts ,- ,- 14""- W

, "

'p, rt1 in<t~ I!y c~ over~"'. See the ""'ructions. kid d""effi""" ,","'fft<tnt /r(rYI Tr»uOl">!ll AJAa'lCincht>!.

Mllt .... l. lIey' EA-<.-dge-gbd<>lh, A-is.h;W~ BP-bod"lplywood; EW-edge-glued w,~ ....

Materials List Country Fresh Chest

, . \ . '\'" C"." T ,\ I .:' " , ,~- ". 15111" ..- " , .'" ,-IS"" .,- " C" bMtf,OI"It/bd: .. ,- 45',,- • 0- .... "'" ,- ,- 19~- • E ... -. ,- .. ,. , ""~

,- 17\'." 43i!1" .. G ., .. 1901'" 4S"," " " lidcieau ,- ,- 14""

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'I'Irl) 'M ,,"(I,I _W..W~'''''lrIK1.ons. laId~ ,,,,4i!lEterI11'CIII T,~IAmeroun cIwst.

Mal~" 1<*1' £l'--edge-qlued pine P-pone;lI'-borrh -. - - - - -~- -

w,IHen by ClIllg R"eg.eH " with brin B.~ le P'OIKt deoig"· Kevin Bor' . ,",,'t'I!"'A~ Ito.a .... e h Moh.t. ,.,..." .. Johnoo"

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R(LAnD ARTICLE • ""8uId Fk.v'fo\lIyflllll'1N1s""lS~ 163(A.~.uy lOO5) ~

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36

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WOOD m .. g .. ~in!f Novemt>er 20()9

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SO your through dO\'f'\;ai! ilg only a("("('pts boards up to 12" WI(\t>. T h ll

dot'sll.'\ lOl"an you can't u •• ' it h) CIlI joints in palWls as wldc h )OU CHe \0 make. Simply tr~1:' the \.:mpl<lte from the rt"$\rk-\lom of thl.' Jtg b.UE' and take 11 to the panels. Herc's how.

Setting up You'll need !WI) tOuters: onl:' for the dove­tail bit and one for Ille stra!ght hit !hilt cuts the pins. ThiS ellmhhltl;'~ S\\'itchillg bits in ,wd out (Jf <lI'te [,)1.11('[ .. net {L'sct· tin g bit hl'lght5. Also PtL'P.lIC two tl'st boards the sam.' Width and thkknl-S\ as your project part', You'll ('lLt dovetails on Oll\' Ithe tail board) and pins 011 tho: otl1.;r (the pill hoard)

RelllO\'O;' tht: through don;tall Icrllpla te from the jig .1nd rcmO'lt' dny )tops or br,lckcts. tt lakc> IWi) 'p.1Cf'r bloch ,.\lou t .lS long a~ the tcmplatf', 3" wide, and thick .>!laugh to !::<tcnd It:" Into Ih~· $1015 on both edges of ellc H:mplalc. xr~'W on .... bind. 10 Ihe unlierslde of Ih{- tC"llIplalc and 5<"1 thl:' <>IhC'r ~~id ... for ut.w.

38

~Iark a oo-.elinl: on Ihe inside fact- of Ihe tail hoor(\ by sean(\ing ehe pin b()..lrd on end, flu.a with thl: end and edg ... ~ of tht· tall board. Scribe tr.... pin board·~ thickne .. on the tail board.

Clamp tal' test board. \0 opposll ... sides of the spacer block, with thtlr

" " ,

Sp".e r b lo.k

"

Inside fa(\') out, :lUd tlghl to the under" sj~ of t h .... l .... mplae .... [Photo AI. Turn the asst.-mbly h.' mp!.lt .... side up, pi1\(\' t he olhN "P.1C\'f h.:twt1.'n Ilx' pand., then clamp this ,nst:moly in l vj.,e or 10 Ihe trollt of your I.)o..'!lch with till· lail lxloard t,lclng you [Photo81·

clamped to your ri ser-bkKk f~(ek"ps things ~I;pping.

,

11 1 )

T~il bou d

~~:::~~~~~ the I(l.il" Then sel each bit ,0 the pins and tails st,md proud of the panels . Sand them flush "fter assembly.

the router only into slots above marh. Rout slowly enough 10 reduce chip-out but nol so slowly that the wood burns.

Mark pins for removal. Those across from a tailg,,! an "X," leave any pin directly across from a space between tails.

After repositioning the template and clamping the panels tothe spacer, lay out the remaini ng dovetail cuts.

I\ow marl:: with an HX~ the matt'r ;al you intend to rout away. For variahly spaced dovetails, such as those on the blanket chest on prl.s;f 30, don't rout in each dovetail slot. For the blanket chest's 15¥;'-wide panels, for example, we IIJJfked below the first two slots, then skipped one and marked below the fou rth slot IPhoto C], skipped two more and marked below the seventh, then skipped three to mark below the ele~­enth slot.

Finally, set the bit in each rO LJh'r to cut VJ2' below the baseline on the tail board [Photo Cj.

Cutting the joint Rout tht:' tails first lPhotoDj. Then ~witch routers and cut into every slot on the pin side of t he template. Especially when routing the pins. keep the router flat on the template. Tipping creates an uneven edge between the pins.

Loosen the upper clamps and slide the template dOlVn to center the newly cut pins in the slots IPhotoEj . (You may need to tap the ~pacer block with a mallet to

woodm"g.ozine.com

slide the template.) Mark the pins across from a t'lll. Clamp the panels and spacer again, making sure the boards are snug against the template and that their edges are flush; then rout away the marked pins. Depending on the jig, this may leave a small ~liver you can snap off, or you can slide the template again for fur­ther cleanup with the router.

With the pins cleaned up, loosen the upper clamps again and slide the tem­plate so the unrouted edge of the tail board splits a slot in the template [Photo Fl . Make mark'> to complete your tail layout. (For our panels, that wa,; just one ~lot.) Then repeat the routing process to complete the joint.

Fine-tuning the fit Assemble the joint if you can . To dial in a perfect fit, mow the template forward or backward on the spacer. For a too­tight joint, shift the telllplate toward the tall side of the spacer. For a too-loose jOint, move the template toward the pin side. Cut the ends off your test boards and try again until you get a snug fit.

After t he test joint fits properly, rout joints on your project parts. Remember that you rout opposite corner joint ~ on each end of the jig: With the tail side of the jig facing you, the front left and back right joints start on the left end of the jig. The front right and back left start on the right end. (This pub the doveta ils on the front and hack panels_) Before routing your project p ieces, damp them together and label each piece and corner so you keep them straight. .

Wriu. n by Cr .. ig Ruegsegge r WI\h Kevin Hoyle

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($ =DowI1k>3d 11-0, ,md. Nom \~,,,",,.,,,",,Ipb ", /0, • ..-noll fo._ Typ< "\r.ough 00."" , " i" \Oe ", .. ct. boJ:.1

39

-' .--. ,. ~ .. ,

N o matter th~ wooo, the cost pef bwrd foot goes up for every mill ing Stl'P performed by your

lumbo.'f supplier. Stra ight.hnt' rip one edge (SUUE)? i\dd l fL~. Surlacc oolh lace~ (SZS )? Cr:lnk UI) \ 11,.\ pr iet', Surfa(c fOllr sh.lcs tS4S}! You had Ix>rh,r be roll ­Ing In dougll.

L!y the time fully ml!h:d wood \Jidcs Into ~ home-ccnte-r lumber bIn (a f ter being individual!y tagged. ,hrink­wrapp..'<1 . and pallt'l lzed), the COst ha, skyrockett'd. WOf\<:, If tho.:' y,' ·lhk!;' hO.1ld "i1'p~ or cup~, even ~I ightly, you can ', m ill oul the def('C t wIthout going hdow }t', That's why If polys to intercept

wood as carly as possIble In th" milling prOCeSS, from either a local sawmlll or lum~ryard. and mill it your'i<!l l .

Do I need both a jOinter and planer? [n a word: "es. Thuugh tllcy remove wood 1 n Similar ways, <'"le ll tool provides only tlll l!" of th e milli ng L'quatioll . First you fl~tlen Olle face of the bo~rct 011 t he lolnkr. Next, With the flat fat", pressed as"~in st the joi nter len<:'1:!, ;.qtlafl.~ an adja­celli t'dge. And finally, JUdi-;e the oppo­~I t e lace p:ual1d to Ihe first usi ng a plall('r. A few pass ... s \\'111 n.'du(e the board to a uniform Ihid,'l\"S~.

Skip-pl .. n~d

Sawmills ~tI eoitM r .ough·sawn o. skip­plane-d bo~ rds. Skip-p/a r>l!d boards giV1.'YOU .. dll!Me. picture of a board'. g .~ln ~ nd colo ••

WOOD mll911d" " N,"",,,"\I>f,2009

A case study: Banking "bread" while building blanket chests Home·a'nlL'f ( Oli\ Luml>cryard cost of profect$ below break-even-

(rough. sawn)

5197.52 $'lii_,-\'J $JOl.n

SUO.0 5 SSI:US

5tH,j~ ,)4:U 3

• C05tfOf 501id-wood part5 to build the Blanket Chest project on page 30. We placed the savings against a Delta 6" benchtop jointer ($240 at lowes.com) and a Ryobi 13" benchtop planer ($200) at a tota l cost of $440 at the time of writing.

But ca n I affo rd t hem? Again, yes. L{'t's walk tluotlgh the math. We'll use t he Blanket Chest on pagr 30. ~s an example, because it is a medium­Size project constructed primarily of solid wood.

For an apples-Ia.apples comparison, we priced only the primary, solid-wood parts, not the plywood, hardware, optional cedar tray, and any hidden pmts that can be made out of scrap woods or offcuts.

Because home centers typically sell wood in common dimeIl~ioned size>, we came up with a hy-the-board shopping list to pit agam>t our hy-the-hoard-foot lumberyJld order, at ri:.;ht, abnve. \Ve also added a generous 25 pdcent to the lum­beryard order to account for waste in the milling proceSS.

Then we priced several species of lum­ber at a local home center and a local

A planer lets you thickness lumber to the needs of tile project rather than conforming the project to OVer- Or undersize lumber.

w<><>d",agnlne.com

..... et dMtt Ihopping Iltu._.

Ho ... Cpt..,· 8pc 1 .. 6 .. 72' · 4pc b3"48~

4pc 1><6><48'

L~.rd· JObo.Wdf~1 rough·sawn

Instead of pre-dimenSIoned lumber, you'll buy by the board foot at the lumberyard. Board feel is thelhicknessxlenglhxwldlh in Inches divided by 144.

lumberyard. The "Case Study" chart, top, shows the cost differences in red o<ik, ml'ple, <ind pine. Remarkably, the lumberyard oak cost 11'55 than half as much as home-center oak. Ruild only about fOUl projects this size and you'll save enough lumber money to buy an entry-level jointer ,md planer.

Besides saving you money, shopping at a lumberyard opens up new species possibilities. For example, you could upgrade to rough-sawn mahogany from a home center's premium-priced red oak and still save $29.22 per chest. The ash/ walnut comhination descrihed in the plans costs $107.62 less per chest than home-center oak.

And if you fed like adding in the optional cedar tray, don't count on find­ing pr.:surfaced aromatic eastern red cedar in a home center. For presurfaced material, you're likely limited to mail­order sources which will add $27 per blJnket ch.:st oYer rough-sawn aromatic cedar from a lumberyard.

Enough math. Time to shop! For our cost comparison, we priced the Ddta 6" henchtop jointer (model jT160,

$240, 800-223-7278, deltJportercable . com) and the Ryobi 13' benchtop planer (model APUm, $200, 800-525-2579, ryobitools.com). These entry models will >erve you well. But spending a little more here can pay big dividends.

For example, stationary jointers' lon­ger, heavier infeed/outfeed tJbles improve accuracy and control on long workpieces. Both the infeed and outfeed tables adjust for fine-tuning the cut. And their more-powerful induction motors last longer than the noisy universal motors on their benchtop counterparts. Pricier, sure. But if you're going to he milling the Jmount of lumber thJt demands such a machine, you'll find it pay~ for itself in due time as wdl.

Now leave this article lying som.:place where your home's hudg.:! maker will >1'1.' it. (Sorry, you're on your own for that motorcycle you've had your eye on.) •

Written by Lucas Peters with Jeff Mer tz

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41

Takes-a-Beating, Budget-Friendly

Workhenc This weekend, build a workbench that's big enough to hold furniture projects, yet portable enough to tuck away.

.,.

W ee! this bench into action fa,,>!. A pair of legs adjus t to suit uneven floors, while dual·

locking casters keep the other end from budging. And you can do it all for around $125 in materials and hardware.

Make the case and frame

42

1 Cut the sides (A), shelf and bottom (B), and top cleats (C) to size [Materi­

als List. pr.We 441. Drill shank holes where shown on the bottom. (I'm tile #8 screws in this project, drill Y'l' shank holes .)

PROJECT HIGHLIGHTS • Overall dim~miom: 57' wTde x 28"

deep x 36" high. • Materials needed: Pine dimensional

lumber and birch plywood, both available at home (ellter,.

• Pocket· hole screws make the face frames easy to assemble.

• Benchtop overhangs let you install a vise later.

Squaring brace~ clamped tathe ca~e (~hown upside down) during glue-up keep the sides (AI perpendkulartathe ~helfand bottom (B).

2With a dado hlade as wide as the plywood thickncs~, cut a dado on

the inside face of (;'ach ,'>id(;' (AJ [Drawing 1J. Add an auxiliary fence to your rip fence and cut the rabbets in th(;' sid(;'s.

3sand the side,,> (A) and the shelf and bottom (B) to 180 grit. Glue and

clamp them [Photo A].

4Drill }1." mounting holes in the top cleats (C) where shown [Drawing 11.

Then glue and clamp them to the sides (Al using ,>quaring brace~.

5 Cut to Sill' the face-frame stiles Wj, top rails (E). and bottom and middle

rails (F). Drill pocket holes on the ends of the top and bottom rails. Then glue and screw the frames on a flat SUI face [Photo BI. After the glue dries. glue and screw the middle raih in place.

6sand the frames to t80 grit. Then glue and clamp them to the case

with the stiles fJush with the sides (Al and the raiJs flush with the bottom (B) and top cleats (C).

Now add the feet

1 Measure the caster height, then rip the foot (G) to that width and cut it

WOOD magazine Nc"""'~r 2009

•

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J ~251/ ••

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20',"

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\100 T. nu\-',-~x ]" < .. "iag@boh

;;'" rubbe< k.>g tip_ A

D~EVElER ASSEMBLY DETAIL

¥O x 3" carriage bo lt

Location of@

t- • '1" (O<.Iflte<bof('

",' deep with a ,~ '- hole 2" det'l) ,etlte,~ if's.dc

I

~.1h.

rill void with ~~ kcm@ ~l>Iant.

"'" ,ubt>e<legtlp Clamp the face ·fr~me r~rr5 (E. F) and Stll"'5 (DJ whil .. d riving the pocket S(lews. A clamp on top of the Join! holds the plecei flush.

10 length !MMerials list l_ C Ui the foot br3C('\ (H) and CJSle r support II) In siz~'.

2u* a jigSdw or oondsaw to CUI the foot (G) to shape; sand '1Ui);)\ t\

[Orawlng 2). Dnll ¥l' cQuntcrborC i a nd }i.' ha l.:>, where shown. Seat the T-nuts In the ~' countcrbnres.

3 Glue and suew the n)ot braces (HJ tn the foot (G). Glue and damp the r(\('lt

aS$ClIlbly (GIH) to the c,]sc, \eavillA a :y..-

["(>\"eal. Glue and screw the caster ~upport

( I) to) the C"d!oe where shown.

Top it off with 2 x4s

1 Cut to length 16 s tJ<l i~h t 2)oo"s for the top 0). l'lane both faces of ('.le I! for

~ rHooth gluing sUfface~ . Then IOlnt or rip aile edge of each to r('move the round-overs and rip th l"ll to width t(l

remove the opposltl' rO\lnd-overs.

Qu;ck Tipf M tWI: fast er than t h e IS) wood. Construction lumber typically ij' contains more moislU r~ than Id!tl·dned hardwoods, alld machining can release new stresses ill t he wood a~ frem ly exposed ~ urfac('s d ry o ut. Allow the wood at lea$t 1 IV" days 10 acclimate to your shop. but gille the top together immediately after planing and ripping th" wood to lim it movement problems.

41

""Make ~IX %,.2,, 12" l1:m1wood cauls 10 £Control stock during glue-up. Place wax paper between the caul~ and top 0). Then glue ,lilt! d amp l iIe lop In two groups of eight bo.lrds {PhotOi C and DI . and rcmO\"c squce:I'.(·· oul Ix'fore 1\ drles.

3Mter the g lu(' dries, pia lie \>o\h faces of t>oth hal\'('S 10 the same t hid,n~

Depending 011 t he fI.lwS in Ihe lumber. t his can be from 1" h) ,~ '/(" \h ld;. W ille surface flaw:. mar n('oo to be fil led with epoxy, as sho"l1 In the Shop Tip b('/ol" . A Glue and clamp the top (l J hal\es ""'ttogether. S3lld the hal\b flush Oil the 1<)1' and ends to 180 gflt. Then rout v." rouml-overs along Ihe edges

You're on a roll

ctamp$ and~ow.

l l'illlsh-sand any rClI1allling spots 1<) 180 grll and apply a finish. (We U)ed

I IVO coalS of oll·based wif>c-on varnish.) Drill and )Clt'W the Cl)ter~ 10 t he caster suppor t (I) about I/;' In fro m t'arh end.

rubber leg ti(h. Fill the area around the bolt heads with ~ilicone caulk 1<) h,)ld the tip~ on the belli head~. After the caulk curb, imert the levelers halfway into the T-nuts in the foot (G).

through IllC lop dcals (C) m,mnting holes Into I he lop Now wheel your new bfmch 10 I he center of yOUT shop and put it to work . •

W"ll~ by Bo b WII,,,,, w ith Jell Me rtz

2l\lilke two levelers by placing the head~ of ,",,), ca rr iage bulb into W 3Center the top Ul on the case. Drill

and drive lag screws and washers PrOIK I des"Jn, Oal . ra"lnlch, Seq uim , Wash Illull,alior\S, R" .... nne Le Moi ne , Lor na Johnson

44

Patching \'olds in the 2 ... .4 top (ollis fOf a tough filer. F ir~t lTl3lr.e a disposable spreader by sandin9 a bevel on a hardboard scrap. Then m l)l S·mlnule epo>eyand force it into Ihe VOids until they're r Ued. Afler lhe epo"'y hardens overn ghl, sand t flush with the top.

Cutting Diagram ._---

'« ~ 48 x gc" S'lCh plywood

( bI! II)

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Materials List ., t . ,

r .. rt Iv..' \k ~ , "'" , sl1e1ffoou om

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F mi , " foot br~CI!S

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W" JO W 27 ' 8P 1

'~" 20W 14~" 81' 2 j±"'W ~ , •

11':1" 4Y,"' 28'

\1':1" 3" 6;'"~·=t± III 4' 28' 3'. 24" 57" LP

M.t"rt~11 k<l)': iIP- budl plywood, !'-plne, Lr-l,m,n.o.~ po ...... SuppMII1: rS>< ,W tt.rheild wood!Ol'!'W~ f8><lY>' '~dwood «fI!W'- lOx)" ("' I;MJI! boIIl (2). ''''''~ ,· liIg sc/pws(4L .14~ " ,0III'Id~ \QeWS (8). I\' T .MlhQ), \I.. w;lsllers J8J, V. 'endef"",1he<s 141 . )" douOk> to.:lung \WI~rl Ul-Irl'1 (2l. Jr.' nbbe< leg lOp' C2I. ~1i(on;>c.;"Jk, 5·m,n\.WquKk-teUepoI(y. 8 1..0. altd btu; d;w;iOJel »' Fo;:nlneJ bit "" ,0\.0fId. ow. b\I, pochet·hoIe Jig and bit ~

•

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IIASE HOI.D£A f Ull-StZE PATTERN

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patlems on thos insert lor irregular-shaped lind proiecI parts.. You can mac" ine all 01"" pr.,;.et p*rta ' '''roo Ihe Malerials l~1 and the d raW Ings a.ccompanying tho proj_ ecl you're building .

.. Copyrigl>t ..... _hCorpor ......... 100\1 All 'i9M' ,.,., .... 'M,.d I~ ,h. U.S A, """,,di,h C"'P. 'h< ""bhh<' 01 WOOD , .. "'" '~ • .., ... , , flo PUf(~' <II 'Ii" 1'"", .. n iM«t '0 pholo<"1')' , .... "",lOt"' """I)- lor f'<"'""", 1 ow. """' "'...,. ' "I"ooun"", <I , ..... pot,..,.m. ",inl)- prot1it:N,,,.;,

JIB PISTON e ......... _¥K"h ol ~ FULL-SIZE PATTERN @

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I" ~. shank 001<>, Yo" ,ound-ow" count~"unk

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FUll-SIZE PATTERN

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WHEElSPACER ___ - ';',- hol~s ~,

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"" ® \.VBOOM PIVOT FULL-SIZE PATTERN

11 needed) 1"<"

Excavator Page 62

I PATTERN to',

t:'. __ -===(2="='='=d'=d=)=~,-==='='=' ====~~ ,~" e ® JIB lEVER 0 .... ---'""" r.oI~ 4 FULL-SIZE PATTERN

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BUCKETSIDE FULL-SIZE PATTERN

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Excavator Page 62

® BOOM SIDE FULL-S IZE PATTERN f2 needed)

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COUNTRY-FRESH BLANKET CHEST BASE FULL-SIZE END PATTERN

©.@

Blanket Chest Page 30

TRADITIONAL AMERICAN BLANKET CHEST BASE FULL-SIZE END PATTERN

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\ CASUAL CONTEMPORARY I

BLANKET CHEST BASE FULL-SIZE END PATTERN

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,

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Jim Heavey of WOOD Magazine

VISIT nn:WOODWORKINGSHOWS.(OM FOR TlrnTS, COI\U'LHE CLASS & VENDOI~ INtO

U 1l1l'!>S}'ou'r(' m.1l.:Ulg II\,U IY Jll\Ilti· pIes ot prOj<X1 P.l tIS. it allllO:»1 alwap lal..es Ie.nger to S(-t up for a

cut than It ~s 10 actually roul t he worJ..pi{'('('. fonunatcly, ()\'N tile- y<."ars we'w discovered shortcuts to lI1aM> IIIOSt St'1lIP<; a breen'

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'&'Shim your fence for disappearing edges }Vhell lOuting ({'rtain t"dgl' profill'~ on yOU! louter table, such a~ thl" door lip shown IIlly),y, the bit removes coough stoc k t hat tile profilw ("{lSi.' no longC"! bears against the o ulfeed fe nce. In these ease~, shim the o lll /cell fence-we atlactll'd j..\z-·thick plastic la lllinai r wilh double-faced 1"1)('-10 prOViul' a bt'anng surfaa' lor t he workpi("<:(' lx'yond the bit. Without this, you'll ('nd lip c ulling a snipr · li .... gnugl' whell t he edb'{' clears the mlttd ferIC':-,

Add a temporary depth stop ... ,) ,'Ioutel bIt hIts II)(' bottom 01 the rollct , you can't tighten it fully, creat­i.ng t he potentIal for till' bit Ie:> fly Qut lI\ USl.'. And wit h some rou ters It's difficult to hold the bit 3tt hl:' correct depth whill' simultanl'ously tighten­ing the coliN nut. To prevent this, slip J snug-fitling O-ring onto Ihe bit shnnk to holl! it lI\ pin(\' whi le yO Ll tighten the nut. You could nlso drop n small ruhber grommet Into the splndtl' to prevent hits from hottoming out. \Vhen you t ighten t he nut tIl<;' ruhber wil l flex as the hit shank draws against It. (You'l l find O.rlng~ and grommets at Il"k)st hardware stores.)

~ Trim only what you need 'f1U$.h trimming sol id-wood • .J/l lng on Ve llcl'rw plywooJ 01 ~IDF is a Rood job for a tr im rOUI"r bct-ause o f lU Sllia U h.l~e and low celllcr o f gral'ity. Bul ewn if you uSC a milhll.l' rOilIer, $('1 Ihc Ix'a ring deplh o f Ihe flush-trim hIt just hel&.> th<- l"lge 10 lX' 11;11111100 . 111is way, if you accidentally lip thc lo uter, you won', c uI ill to l il(· plywood's W IU'(·r And when trimming away OOglllg, roul in l climb·cul d ll1."C lio ll, right 10 I<' ft in th is t':>.all1pl", to aVOid t<>arlng Otlt grain o n the ","ODd edging.

Save wear and tear and get cleaner cuts with incremental routing

When I"lOMiblt', trim away e'(cess materia l from your worLp,l!(\!S !It the ... tabl~w o r bandsaw befort' rout Ing. rraee the profile of t he bit onto your ~t()(l;. to prevent oven;:\ltting, as s!l(]w n, Whether you're routing an edge proflle, slid­In.g d(IVl!tail, or any other task t hat rcmoW's a good bit of wood, doin.g this will ~:I\'e you tIme, wear on your bits a nd router motor. and a pile of shavings.

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, <II1II For a flawle~5 surfac ... , alway-;; It-ave a t iny JfIlount-lW" should do II-for a tina! rolll ing pass to r" mm"\! burn , )( chan",,! marks. On a router table, b.dol'C making the cut, apply ma~k l ng tare to the workpiece ed~ or router­table fe nce. as ~hown (t wo layer\ if the tape l~ ultra-thin). Before the tinal pass, re move the tape for a whlsLer-thin shave. For handheld wnr],;, adhere Iwo or three bmilwss card~ to your rout ... r's s\lbha~e for tlle majority of the romlng, and t hen remove t hem prio r to t h(' fi na l pass .

... Rather than adjust the bit's heighl a~ )"ou rernov\' matenal In~l't'mentd !ly, ~l lt to Ih ... exact heig ht from t il\' sla rt and use remo\ .. bll' shIms on the IJ bl"" su rface. Slack I,lyers o f %" hard­board or plywood o n the table using rlouble-fa':L'<I tap." with cutouts .. round Ill" bit, and then remove <llle la" ,' r Jtlt" each pass. Th is proves l's[lCCial ly helpful if "our rO lltc ~ (II m uter lift is fussy to tIne- tune Ix'cause YOIl set \t onc(.' ,Hld loc I:. It in .

• 51

Achieve dead-on measurements without a ruler

Use lTlachin.::d bla~~ .-":1111' b ,I I' , typkal ly \old in k ih .. fn ml W<' to 1/.0' 111 thid.nes~, h) set b It dep ths wilh dcad-on p n..'C is.ion. ~or ('xamplC', wh('u using a longUC"-and-gruovc­bil sct onY,"-lhi(k slod., Sl'I tht groove Culll"l Yo. h.)m Ihe subbase ur Illblc surflla." a.\ \ Iwwn at ,(~lIt. rh£"n rout tht, longu(" to fit Ihe &I"<-o\e \iliOn Mtup ban' Pilrt ' 1"-4932, $IS. WoIxIcr.lt. soo-nS·llS} orwoodaaft.com .

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.... Mler perfe('Ung a ~etup, CS!X'ci311y for mating Iwo-bit "<'I ups, !i1J(:h as (ope-amJ-\tid.: bil~ m IOngll('-a nd-,l:rlIO.We bits (shown). keep a pIece of lest st()(;k I rOl1l ('ncll bl\ III lise 3~ gauge bi!l(k\ for quick sC"tup on fUlure jobs.

W him ruu tl ng Ihrough d\"'d~ils 0 11 a rou ler jig, liS{' r01l1 ~ aClual w<'r\..pi~"'('S to accurate'ly )('1 Ihe bil 's ctll iing dept h . Erst, tape a plt'~'" <,f WI,t!' onto t h,' fa C(" o[ Ihe w,"kpi<:cc that will mall" wllh lh(' (.n('p .u'li (('UI, le lling II extend I' OT >,0 tT.,m the em\ of the \\,orkpi('C\' /'lexl, sel I he router in position on the jig's tempirM with 111(' 1.>11 lighlt' IWd Itl the cuilet. Lower the bit until It tlllK;h(>\ th e- scrap P1('((' lor <l dead-on setting. If you prefer to make ~l)Ur tails Jnd pin' J liltl.; pwud to lie trimJlled alter J~">embly, .'Imply ll,w.;r the bIt anulher one-eighth 111m of the router's d<..pth.adjustmcllt dial, and then lock the wukr's base .

-, J._ ,

.... . 'tnylime- you' re roulln~ hitlh'<' mortises, unluld the hlllies and Si:: t Ih.:: roul~' r ,)nIO onc IClf 01 elch. rhcl1 luwer the b\t unti l it tuuch,') Ih(' be- Ilchwp 1m the e~'K I I;\lttUlg deplh 101 Iho...:: 11 1118e.\.

Fine-tune settings for spot-on precision

]'I)\.' PIP l>rtween the bit and opening In the Touter's base .... SuJl) <.'t\J~s makes it d illicult to 3C\."llfatcly set a bit's depth by ~talld illg a steel m\e on e nd. insted.d, use a rule with scales md.rl;cd \'ertkally on the ends, preferably in Y.l.l' increme nts. Sttel,u1ts:6" ru~, p;lrt mJ94, S12; 1J" r .... p.lrt~I)4Q<!, S2O; li.lrlvifie Tool. soo.34S·2196 or h~r1l/ihetool.com.

.... M<llly of hxlay's routers come with a cent C' ring conC', used to center tl~ subbase to the spindle. An exactly centefC'd bll proves critical for joiner>' tasks that Involve gUide bushlngs, such <IS dovetails o r hox joints. Without being centered, your joints "I'Iill likely not fit perfectly. If your router didn't come wllh a centering cone, get an aftermarkC't one for less thd n SIO. Routerunttfl"'ll ,_ part 1AA1I5o. S6. Tool Bio,n,966-597·38S0or tooilarlU"Otn.

To p<l\ition J routC'r-tabl.e ten,e flush with a bit's ... bearing oc a p.lrticular point on a bit's pro!lle, get it d oll\.' Ily eyeballing It, and lhf'n tighlt~n down one eml of the fence. Holding a steel rule against both fl.' lKC laces. pivot Ihl.' Joosc. (.Il(j until the rule hi lS the fUJr!.. you want. l1ghl~·n Ih ... orhcr e nd of the fence "hcli the infeed Jltd outfC1.-d tJ.c.es line up l'Iith your r<.'8mr.l!ioll point on the bit

~ When fl ue· tuning a bit's h ... ight with .In abo~"t'-the- t abll' ,Kljuslmeul lool, sudl as th ... o n ... shown iK'r<', mJ.kc;! penCil mark on til ... tahl~' <tnd line 1t up with the scdk's Z{'rO rderenU'. Now when maktng fine .tdlusnncnts up ordown you will dlw,IY' !..now where you hegan, to avoid overshooting the startlng pOint should you have to tJ"ck up . •

Wril1e~ by lIo b Hunt. r with Ke vin Royle ",)<j l eft Me,l.

53

M "rho: you ~dn '\ ~ ;(v..' lim" in a bottle, lJut }OU ran bullo thi~ beautiful d oc\.. to t rOld; its p~r

SJgc. Dreo-s up a 5implc mite red (3<.0.: \\ lth a few ~hop-mad~ moklins~. thcn install ilil lnexpensw", b:attCr~ p()\n'r~.J clod. \\'OI'ks. (See Soureli' on ("1S'- 5"_11,'5 a 8, ,,011 way to pallS a few hou r51n the shop_

Build a case for the fa ce

1 Cut the Iront t,\) and ~;d~.) lit) to It;on~th IMlltefi.ls US" {'o'.<'- $6, DrAW­

ing 1l. \\ith the hlade t illed t<. -i5°, b.~vel -

rip both edge~ of the frollllo bring it to finished width. Then bevel rip o!le edge 01 o;;Jch side tofinisheJ width. Rout ,\ v." rabbet on the oppositt' edge of the sides,

2Lay om on Ihe front IAI lhe hole for the ptt~1Il clod. Illo\"t'menl [Draw­

ing l J D ri ll a st arter hole Inside the lilY­OUi l i ne and cu t just imide the li ne wi l h a ji,.:SilW or sc:rollS3w. SanJ up to the line \\'i l h il d rum 5.amler, testing the lit 0 1 t he clock mOH' ment as you YJ. Notli': To) lI1t1illlmn a Slll(~ fit. ,for, 't I'rt"iS ill til,' "/{II tlm'tIl r!lll~.

AT A GLANCE • Stack router-made profil es to

create attractive moldings . • Fe~ture5 a set.it-and-forget-it

press- in clock movement.

Another option: Redwood burl m.1Ikes ~ striking timepiece.

3/\ssemble the front (AI ~nd sides (S) [Photo AJ. Afle r the glue dries, finish­

.sJfK\ the case (AIR] to 22U grit. presen ing the Shdfl) cOIners at the edges and ends

Time to make moldings

1 Cut the top and bottom (Cl, (ove molding (D), ( ,)p IE), l1')n.:lle block

(Fl, :and 00 ..... IGI to ~1 Zl;". Sef the oos.: asilk (("or tht' 1ll0melli.

2Qlllclt Tip! Hout l'IIds, ,1I1'11 -(S) l'llgl'.~ . Wilen routing profiles, rout V

,)(1&.,5 an e nd lint and l>ack up the ( ut Wlf h J ph..'\.c ("of >C lap IPhotoS]. Any (:h ip" out gl"ls fl",l!led up when routing th~ acli~ ("e nt It},l !; edge, Rout it" coves on IhfL'(> sides OJ Ille top ami bottom (e) ami ':(lW ,noMlng (D), If'aving the bock ~dg(' Mluare [Drawing 2. Photo 81 . Change to a Yl" Ivunu-("'cr bit Jnd ront the ends :lnu cdge~ of t he caplE). N~xl , set up a Vi' core boK Ili t 1'1" abow thi' table and rou t ,I gn)<we JrQund .1 11 fOUl" cdgt:'s of til(' tw)(lIl' [>Iuc\.. (F) lPhotoC].

3A' tilt' t'lbli'SJ\\', trim Yo' from the lowl'r e'nd~ and €'(lg.:~ of the handle

bl<K\.. (1- ) 10 • .-wlng 2, Photo oJ. Back at Ih~ roUle' l 1,lble, rout a \1' round-ove l on th~ und~'lsld(' 0\ the blocl's lop edge [Photo ' I. Then 10lwr the bit and fli p the h:m dll' block o\'~'r 10 compltlt the PfO­file [Dr,wing:!l. A Retrieve the baS<! IC) and rou t %" rab ·

&of'bl' tS Vt,,· deep a round the top <'dge lo..-win921 Sand t he ui m pieces (C-c" 10110 gil l

,.

I -l.

5',.' -diam. MOII""'e,,'

woodmagazine.com

~ b ~c ker board to push ,"" woe.;;;;:;; and back ~p the end - 9r~ln CU t , Start with the bI t low to allow for a final cleaA~p pa".

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Tick "a .s.sembly" orr the list

1 On th .. 1<)jJ face of rhe top to, malk hm"!; I' in from each ,'n<l. Then draw

lmes Oll the hack edge)1' from the ends. ro<ltion the top on the Cil:...' (AlIl) [Photo FI, lh .. n drill ~'coutltersunk pilot holes and screw th .. top In plan.', "lOnl'" lint's ct'm..red (Ill til .. ruck L..."'dgl..'S of the top (C) '!lId (on' mold-11Ig (0 ). Then glue and rI,lmp the ((we molding to the top with the ct'nterlmes a ligned ,ml! with their hack <"dges flush [photo GJ. GIlle th .. handlt' block (F) to the ~'ap (F), centt"red. WIll'n t h ... glue has dr1t.>J, drill }II<," holes for ,he handle th rough Ihe top J,so:mbl} (ElF) IOrawing 2). Th£'n drill 'h" countcrl)o.)fE"i for the hanellc nut5.

3vslng double-fan'(\ lap<', tempor,H­Ily celll .. r th .. top assembly (tiFf on

t h" cas(' (A-D). Flip I he as<;cmbly (A-F) over ano drill two countersunk screw holE'S [Drawing 2, Photo HI, ]{~m{)\' .. the tJ I>C .1nd dri\'e <crews (don't use glud to

Sl'cu r ... t he Inp a~mbl)'.

4U~ing t he Sdm .. lll('l hod dS in Step 1 f!"' ''~, 'C"rl'W the Wtom \l:} to the

55

o To provide mOre supportforthe handle block (F) ~s you rout the \'0" round -overs, align the fence with the bearing of the bit.

El PROFILES

,,," round·ov.,,-s

cas£' assembly (A-F); then glue the base (Gl to the bottom. Cut the back (H) to fit betw('en the rabbets in b,l(k of t he case and u Tili a I" finger-pu ll hole [Draw­In91J. Set the back aside for the moment.

__ "'''''~,, ___ ';'"corebox ',,"

Vo"~ , _ I V>" round-over

with a y",·shoukl.... 'It"

~" cove! I 'I," 5Rcmovc the top

assembly (E/F) and apply a fini5h to all parts. (We used boiled linseed oil. topped with a('rosoi ~till pOlyUf(,­thanc,sanuingbctwecn coats with a J20-grit san ding sponge.)

,-=~ .. =.~ ~:;;;:,@c,;;;- ~r-JJ 1 1'>" (Qunt.,,-oore y,"pilot hole"

6After the finish has cured, tUTn the clock

'M" deep with countersunk ~." hole cent",ed

inside

upside' down, drill 'li6" pilot holes for the f(>('t, and dIivc srcd screws to thr('ad the holes before driving the brass 5GeWS [Drawing '1. Secure the handle to the top assembly (E/F) [Drawing 2], then screw the top assembly to t he case. Set tile tillle on t he clock movement, press it into t he case, then add the back (H) and turnbuttons. If al! has gone well, you should finish with time to spare . •

Written by Craiy Ru eg.egger wilh Jeff Mertz Pro],,! d.,ign: Ke vin Boyl~ Illu,tr~!ion>= Ro xann e Le MOine; L!>",~ johns!>n

Cutting Diagram

%. 'J1i. x 72"' Cherry 15 bd ft.) -Plane or re,"w to the thkknesses li,ted in the M~t"'ial, List.

56

Y,x12xll" Birch ~ywood

~~:E~~~~~~~~;':~~ cove top IC) It easy t o ~Iign during glue-up.

" front " " " ,

B' .,~ .. '" " ,

, top!bottom W '" ". , 0 wvemold ill9 W " '"

, , rap .. 3W r , , haroJlebiock .. ,..- ,.' , C ,=, W 5Y4" 9Y4" , " OK' y,- ",. " BB

Materials key: C -cherry; BP-birch plywood. Suppl lt!s: DoubJe..foced t"pe, t&1" flathead wood screws 18~ .8x1 '/i" fl.jlheod wood SCrEW\ 12). Bib: W ,traight. lIi" rOll"id--(l';er, W core--box, yj" r<.>md­over, lio" cove r<lU(ef bits, \'i", l' dn l bit>.

Source Hardware kit (ontains: 5:4" -diom. qwr1z clock nYJVI'meni, br." h"rrle (21<" centers), %<1y," lnss pedestal teet (4), ond ''''''" tumboJtto~ (4). Kit no. 26888, 539.99, ~Iockit SOO·5,6·2548, klodut.com.

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Free "Online Videos" show you how to join it, rout it, and clamp it, at. ..

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and router bits. Two Sets available. #94[1 • + lemplate Set. ...... $169.95 #94-ZL · 11 Template Set .... $269.95

"45 Different Cuts" OUf 45 piece, carbide tipped Router Bit Set includes straight, round over, ch amfer, cove ... 20

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If you can't brin){ )'oursel f to spend S1200n" tablesaw blade, we have good n(:ws for you. \Vc tested n ... arly four dozen rip, crosscut, and mUltipurpose blades-all selling for less

than half that price-a nd found several Ihd! deliver cut qual­Ity almost as good as the Jeadillf( premium blades.

Yeah, but exactly how good are they? There') a rL'ason premIUm-pr iced bla(il's ~USt as 1l1uch J.S they uo; They typica lly perform flaw lessly when paill.'d with <I \\" .... 1-tuned tabksaw. But if yuu're willing to 100 nt, !.and, 0 1 plant away light scoring marks on cnd and oo~e I\ rain- something many of U~ do .:lnyway. regardless of 11'1<' blade used-you can KCt by nicely with the blade) recommended here.

for comparison, we put two proven, premium ¥l-tooth blades-a Forrt's! Woodworker II and Freud [' rl'mier-Fusion N IO--through 11'Io;? samlC' paces as the 5ub-S5(1 blades. and they )01.'\ the standards for what consl:llItes an A grade In each ClIt. AlthouSh none of tbe lesser-priced blades ro~ted acro5Hh~. board A marks, mor.:: than half delivered Bs or h igher.

Key findings • SOlUe blades du il ul1. For most ohhl.' work you'll do with hardwoods and softwOO<!s. a 40-1001h general-purpose or

TEAR-OUT EVALUATION RATINGS teottom plywood fac" shown; cuts made without zero· durance insert)

. f" ••

I .'

f , , I.

RATING:

= = No tear·out on top and bottom faces

, = No t .... '-out on topfue. slight tu,·out 01'1 bottom face

= little to no tea,· outon top face, .Igntfkant teal'out on bottom fa ce

SO· tooth combinat ion blade ddivcrs good to excellen t r,-~ults. But sheet goods, ~lI~'h as veneered plywood and melamine-­coatl.'CI. p.:uticleboard, require cithl'f a premIum multipurpose blade or a speCialty blaUl' (So'lIin); for $65 to S90) made just for thoM! makrials. As evident in the ~rformance chart on the m:xl ".ISt', none of the teSted blade, could nOS'iCllt birch ply­wood without tear in g the grain on the unsupported bottom sidc. HOWC"Cf. rOll can ImprO'o'e the rerformal'lc~ of most of thcS(' bl ade~ by abom onc I(-Her f(rade si mpl)' by llsl ng a zero­dearanc". inSCTt on }'OILr tJb l~w.

• T hin is in. Most 10' blades under SSOcut 0:1 thm kerf mea­surin); between .IZO' and .090'. The only full -ketf blado' that carn(>d our approval Is t h~ Amana Prestige PR lU40 (.134", just OVli'r \4'). Our 1 ¥I-hI' hybrid tablesaw handkd tllat blade with­out oogglng dovm, but kS5Cc-powered 5J,W~ perform best with onc o f the top- ra red Ihin·kerf blades. • Thruwaway bladl.~ !k:caus..· sharpeni ng St'(vlces chargi' dbout $ZO to $35 to rcshaq )(>n a blJde (dep'-'Ildln~ on the n UIll­Ix'r of teeth and the grind geometry), SOllie woodworko'fs dIS­j)OSC of t hese blades after th".y occome dull. And lx'Cau~ tho' carbide tips tend to be smaller than IhoSt: of premIum blades, you' II get fewer ,harpenings If you do go that 100ute.

CtJII/irlUe./ on page 60

CUT-SCORING EVALUATION RATINGS

RATING:

= . Ab~en(e of bli>de mlrks; ;o;nr-fudr

• '" Blade marks r.-qui,e light sandIng

= Dlade mllk~ r.qulre heavy sanding

59

THE BESTTABLESAW BLADES UNDER $50

, " TliltKHAi!OMAPl[ tI<oT!!1(JREDOU

F~£UC

IRWt~

Our recommendations

-, o

.\11 the blades in the ch.trt aoov/' pafOrml2l\ well givell their prICe, but tht! bl.:ld.· .. "tWWfl bdl'''' nudh't.'d ahead of the field to gain our Top Tnol.'m"}r'>~n~nt·

60

d~t>IoIook,<om

1. Pric!> curree! Jt time of ;WII(II pto~lXtkvllnd do not ind .. '" >/lipW." 1'111"" ;ppIi(lb~

Thl' Top Vnlut! honor gc>Cs ILl the GO-hXlth Irwin Classic l5370. Thi .. S~5 CT,}SSCut bl~\1c (,MnNt gr.1ctes of A- or be1\cr in five of ,i x CTO~~C un! ng c~u~go.:lT II'S . •

W"ll.n bv Bob Hunlu wilh 800 B~k~ r

1631?

Grips wood, elevates woodworking Rocl.:leri. new Iknch Cookies arc n-volUliol1 il.ing Ihe w(>{hhop. :dIm. ing fill Sl~bk routing, s,\OJmg ollll! ( "",ins

lYid lOUf tradi lional ( hlm!»_ The .ecH'I) N,m.nurnng rubber P.\Js Ih,,\ pip hoch rho: ]",m ch 3JId

t,lur " MkpILU f,)f wlid holds and ~iml)lc !>Ctl.lp. rlus. we've designL-d rhe {knell Cookie 10 Jouhl ..

~~ ,\ Plujcd sUPIJO(!. It .,!"v.lres yt)ur work for complt"le acees.' \0 fl'fty eJge f<;lr c"-~r finJ,lung ami

edge work. Sturdy. Simple and guar,lIuceJ w hdp you Create with Confidence.

~ , . ....:2... I", " . ,,' .• 'IlL' h' ROl.-kICI.I.:OIll 1 · .s ~-· IH)( · f\ll· l{

AT A GLANCE • Ovr.:r~1I dimen.sions: 19 JIi~' long"

6" w d," ~ 6'1\~' ~lig~l with the bucket at ground level

• Bucket capac'ty: Appro", .00008 cu. yd. (3.75 cu, 111 .)

• Boom reach: 14" • Dig depth: 8'1<" • Erlgine r~ ted at 1 ~dpowcr~

(Ontinuou~ duly

Put this to\' .,nd a pilt 01 !IlJrhk>~ 01 Lego~ III front of l lll ili ren and wa!ch Ihl'm wh,l ... JWJ~ t he time

'.,:oopill..; Jnd m(Jvin~ them. The e"~J­vOl IOr shiilr('S dc,j)(11 ... km ... nt~ "'>ilh Ih,; emllt' in is\ue 1$15 ls.eptl'ml:..:r ZOOS), page 68 More R,wurus, P<IS' <>5].

62

We start with a bucket, then boom

1 hom V.I'-thick sto<:k, cut tile bucket bottom (A) and hucket back (H) to

~il.C [Materials List , pas.: 051. GlUt: the pieces together with the grain runnin,.; In the IoJme diI<2ction [Drawing 1].

2l>.(ak" two copie~ of tht> Bucket Sid. Pattern from the 11'000 J'.lIIerm

in .... n. I~jgl: 46. and ~t one Jside. Trim the othe l along the dashed l ine~ .!round p.UhA and B, and adhere the p.lttclIi 10 the bucket a\..<;cmbly l.-\JK) Cui d\\ dy I hl' m~ide wasil' al tlk- oood:.al'l' [PhotoAJ.

3eul the bucket ~Ide~ (0 to ~J zc alld ilppl~ the remailling B ... (kel SIde Pal­

urn to 0110'. Stack the bucket s id,,-~ wit h t heir edgc\ flush and drill holt"'i \\ht;"re

indicated Cut two LVi" lengths of thr\!ad~d md [Shop Tip, ()Pp(Jsit~L and screw ~ II J,Orll UU! (Hit" one end of each. GIlII' J lld d.l!!lp tile bucket sides to the buc)..et (MRl [PhotoB] .

4MC!\.;<' two copi"~ of the Boom Side P'tt".n ,Ind olle .:opy of U1<2 Jib Pat­

l.rn . "pl,lv-mount them to your stock, 11"'11 ':U\ Jnd ~and the Jib (D) and boom sides I t:, to shape. Spray· mount a copy of the C,b Pattt.'rn to J piece oi l W-lhick stock lOt lammated ~· I1000k) ::Iml ("ut the cab (F) to )h,II"Ie· Drill tbe ho le, where II\dIo.:JIc.J on fhe pallern.~, tbcll.:ham lt'r t he tdg,'). Sand Ihe flJrts to 150 gri t tll('11 glu\' til(' Shall't peg intu a bO('lll

side [Dr,wing ' 1. Nof«: TIJI' peg call SfJ Oil l'ilIk" /J()(IIII ~/d".

WOOD ... ~"...... N<r.rf>mber lOO<>

SAPPIY on e tUpy 0 1 th ~ Jib l llvllr Pat· t llrn and two copIes al lh l: 800m Pivot

Patt@rn to Y.!' stock, and cut till: jib 11:\'l:r (G) dnd boom pi\'ot~ (II) to shape. CUI the lib pl ~ton 'i (I) to ~Il<lpe following the Jib Piston Pattern. Sand :lway t he (':llterm :lnd any mtll rnMI:. 'i IVlth ISO.grit ~and­P;\~1. Cut fl\'~ lengths of t l l readed I'I)d for til" boom IDrawlng II, the n set the bud,~t (M~/C ) , buum Jll~(" S (D, E, G. H, I), and cab (F) dsldl',

Turn your attention to the pivot table

1 CUi tu Sill" and sh J(>e t he pivo t tabl ... (.I), (uu n l\'I~lght (K), and CJ twalk

(Ll, Cut til\' t'ngi ne rover (),f ) to Sill"

10·32 washer , ~

( l O-311ocknut

' ... h ok> '., " dHp

H j~~~~~~~~~~~~~::5 the edge~ ofth'" b ucket IAlB). .od I through 1M- bucket ~;d es le I illi9n ~ them. I

[Drawing 2] and apply a o;,:upy uf tIle Engine Cove r Pattern to it. Dril l the hpl ~)

in the engine cover, counterweight, and pivot tdbl" [Drawing2[: t hen rout round­overs on t he counterweight and engine cover. Glue the smokestack into t h l" engine cover and s.t:'t the cover 3)1(\1.".

2GIUe the catwalk (I.) to till! piv()t tab le Ul wi th th~ top .J.nd front ends

flush lDrawlng 2]. Then, glue .J. bvolll pivot (H) to th e pivot table [Photo C).

",/" ,,, threaded ,oo'\lC0l. ',,"Iong

I()'Jl ""' _ \

1 ()'J2 1Il,,,.>ded ,od " '·Io",·-.~~.)

After tile glue set s, glue the rem<l.in ing boom PJVUI in place [Photo 0].

3(;1t1l: and damp th~ cuunterweight (K) to II,.. pin't tdob!e (J) agd.inst the

boom pivots {HJ and centerC'd side-to­s)d ~. To c~ntt! r the counterweight hole uvel the h()l ~ l!\ tlte pivot t able, push a tJO lt thruugh both hole ~ .

4ASSembJI! till:: jib (OJ. boom sides (El, lib Il'ver (til. and lIb pl~tOns (I) with

t hreaded rod and Jeorn nuts [Drawing l j.

SHOP TIP Cutting threaded rod: It's a snap Cut 4 ., 6 ·, 8-, and lO .gauge threaded rod quid ly J.nd d ...anly with a pair of wire Slfipper/ oJII\'rs Thread the rod Into the appropriately sized hole in the tool. ~Iow, then shear it to length. Twi,t th e rod out 01 the (UttH, and the tool deans up th ~ cut threads. Find Slrlpper!cutters at most hardware and home_improvement stores for about S20.

I ()'J2 ""om nul - .......

'\

po~' I'Ol'l t~ S('(ol'ld boom p,vot (HI. The boom §t>ould mov~ .... Ith Y~fy light r~SlJ t arw::~.

B EXPLODED VIEW

.8~ I" F.H wood ....... -----1'

64

" .. hole, centered

- .. >I. 3' hexhe~d boll

tUf nta blt" tu'I'Ita ble 's teogth.

At (<leh I hl~ <lssctllbly to Ihl'" boom pivots (H). Th{?u screw (don't glue) the cab (F) to tile pll'ol lable (1). This allows for rellu.:l\'illll- lile ,ab to adjusl resistance OIl

the ll0l~lIl ,tIm.

Fabricate a massive chassis

1 ("ul I he rhassls (N) to size and lay (Jul t he t,tpr r~and axle holes on both

~idl'~ IDrawing 3a l. Drill the fV hole and C"Ounlerhor.: (entdl'd on the hottom [Ora ... ingl1· Then cut the t.lper~ and drill the a~le holes [Photo f!J.

2Adhcrc two copies of t he Wheel Space' PaUern to .~·-thicl stock. Cut

the \\hl'cl slXllels (0) to SIze. and dIm til(" holes. Glut' Ihe spacers to Ihe chassis IN ), (cnll'red hetween t hl' t'ods and fl ush at the l>otlolll IDntowing 111.

3C UI the t urntable (P) to size and ("hamrel Ihe top edg.-s [Orillw;ng 2).

(; Iut' and d Unl) the turntable to thl' ("h a:.sis, centel"l:!d. Hter the glue drie, drill througll the tllfntabte, usi n~ the holt' in tll('chassis as a guide.

4 \PrilV-l\lount two copies of th e Whe@1 Cover Pat tern to 1.1' slod, and ..:ut the

wheel ~O\'eIS (Q) to ,Ize and ,hape. GIIII' thl' covers tt) the ch,,,si~ [Drawing 3a, Photo f l

SIf needed, sJnd the axil' pegs to fit sl!ugly II! the Jxlr holo,s ill the chas­

sis IN) :11"1.1 \\"h~eJ ~pac ... rs (0). Cut W from tll (' J..! "long pegs [Or(!lwing31. Test thl' til of th(' wheels and axles, but don't glu(' thrllll!\ place.

Finish and assemble

1 R('lllo-.'(' the wheels, .lxlt'"'i, imd all of th(' hardware and .lppl)",} fj nish. (We

spr.wffi on two CaMS of polyurethane, bumng I)('t\\"~"("n Co.11S with a ,nO-glit ~pong('.) I' " e ll ile fln ish ha., d ried , ("('"as· seml)i(' th(' I)()Oll l (A/BiC, n. [ c..;, I)

using th read lock on a ll acorn nuts. Atla("h t hl' boom aswmbly and Lab (f) to Ilw pt\'ot·tahlt! a,..emhl) IH/J/KJLl.

WOOD ma.guln.. __ 2009

El CHASSIS I" ,ounterbor<! lI<"deepwi tha

'to" hole ,entered m<.ide

DlCHASSIS SIDE VIEW

2PllCC a wheel and a w,uher on each axle peg and ~I\le thl.' pegs in place,

making sure no ~ Iuc ~:ets on the wheels and that the w heels tu rn frl.'l.'ly {Drawing 3] . AftcJ thl.' glue dries, bol t to):ethl.'r the

Lor~t l on of part

cha~sjs a~~mbJy and pivot table/buurn as~embly {Phot o G{. Theil Krew the engine cover (M) in plucc {Drawing 2].

31'1lWCI up the "cllgille~ "illl cookie> and milk, PUlnt the 1m!:; toward the

marbJequan} and let them dig in. . Cutting Diagram

Wnttet' by (.aI9 RU'91'99'~ ""I\h K,.ln 8 .. y l~ ProiKI <lllign " ff Muu III~sl1at<O.~1 R ..... n". l . M .. 'n. l o<na John.on

'ii' _ O.....:@ ®

~. ~ 5'., ~48 ' M .. plell bd. i1.j

, , 'Pla"e 01' r ...... ' .. to the thicknesses lis ted in the lJ.aleria l~ USI

MORE RESOURCES RELATED ARTICLE • "Contr<1lct""Grbdl Mob<IICr-,'III~' 1851~!!pt.2008) S II. D<>woJ<>Od ~iu/II<Ir/OOI'I' ,,(IO(Itr.l\l .. ;,n" . IOil">' l~)r" I'<:< llmolW I .... Typo "or..,." In to. Soo.r<h 00>,)

" c- "" ... - ,- 2W ]". W

0- j. ,- I ,," 6~'· " E- -- w- ,,- 1111," M

,- ub ,,- Ill" 2~' • O· ~blew' W- W- 3' w ,. -- .. ,- " . w ,

J._ pNO!l.>bII! .. ,... ,- w , """""",,,, Ill:" 3))" ,- , L ~w .. ,- ". 3W W

M cnglnICIM .... W ". :Hi." w

, ct\aY;I~ lr,· 3· ,. w O· wheelsplKen .. ,. ,. M , ,. \,,,,,,,Mlok! W· 3" 3" W

0 wheel {overs W m· ,- w

M.ter;al. ke)':M~W warm. Suppl i,,: S!><lt)' ~~ obI" flaIhead wood >aM III fbI" roui>dhurl wood 1=W'(1l, blue nead Io<k 811$: 10.' (<Mod 0'IfII" •• 5" d\arnfut "",I .. bits; " ", 1" l-omf"Ol'! btt>; ~' <II-. bit

Source Wood/ h.,-d",,1n' kit : ConI<WJi~foUo .. i"9wood pa<'~at'ld twdw_l' tolOdemwheels (41.1' .. • axI.!~. Itl tyo" "fI9Ie wII~h 161.'" ... P"!I' 06~ II-. .Sit.11..r peg nl1WJl1lonwa; ...... {'\\Io..r~l«I< n110-3L1odt IlUts l.ll. 10 llaccm .... s l11l. lo.12n"nl4~ lo-12~ 'T ~trHded rod (2), )O·ll_hen (2J. 1Io· 1IIiISher~ 1iil.. "'. w.W>er, 161. ",rhohud belt m ~' Iocknul It. er.... tit no.~ ~2.95 pM <hipping,Meise' HaJtIw.yt~ o¥!~8IJO.441-98Al, metseiwoodhobby.com.

Make Beauli [uJ Baseboards and ChairRails

DIY MOLDING : PART 2 This 15 the , c(ond of two art;ck!s 011 customizing the molding In your home. For tips on m~jdn9 and ins!;!I I­ing door and window trim II~e "\,.11 shown here, see Issue 193 (October 2009) or purdXlsc the Mtlcle by 901119 to woodmag~lln" ()m/dwtr;m.

M 05t of Ihe woo..l trim in tcx!av', homes wa) meant tv be ignored, not a,hulred. If \OU

look around at Ihc )I;,IIlU ~ OO"eboorlh and Chil lI ,ails i,l roul home alld th lnl... I Cl)uI.i .It> oct/a, rOll 'r~ prob.II)ly rlgh r. Making ant..! installing custOUl ba'it'· boords and ~'ha i r raib ,Kids pO! rsonalil ) and \ 'alm." to you r hOll1e

66

Tear out those bland builder-style moldings and install trim that showcases your woodworking skills.

When choosing baseoo:lrd protHes, first decide whether you want a one­piece molding or olle built up frum two o r more pieces [Photo A]. A single mold­ing save-; you time and money, but a built-up moldmg lets you combIne piece~ for a d ramatic, e.'l:t r,l-\\'i \l<' plUfl1e. Then decide between ~tainoo or painted moldings. Stained or d ear-finished moldings need 10 be cuI frum slra ight, dearl'>uod. A layer 01 pai nt, t hough, can hide ine'l:pellSh·e s lock. such as a popla l ~-ap, or an t- IDF bast-board.

There's no ru le dictating \\' hal mold· ing sl7e or style looks be)1 in )our home. In general. a roomy hou"* with c(:illngs highl:r Ihan 8' au"ommooales lrun wid('r than Ihe (u mlTlOn 2,',' baY' board wId th

wooo Magadne """"'''''''''' 1009

D

S"-wide bauboard

To vi,uaHze OOW a room will 1001<. with new molding'i, <;Ompare SlImpiH of Vir IOU~ si z.-.s. Omit lJ>eYKIe molding on (arpeted roomS.

To ht'lp you d~'C i dc " hilt you want, glth~r molding ide;l~ from maga?ines, hlstoril" homes, r..:al ('state open hou'S-e~, and ["ourer hit manufacturers' Web sites. TIltn pick a few styles, moc).: up short samples against a wall [Photo 81, and li\'C with them until yo u sell ie on your favorite s.ize a nd combination.

Uk IXl'IcOOanb, chair rails can he fashioned from a single molding or com­bination of moldiIlg~, A variety of router t)Jh used individually or In pairs ueate Custom chair-rail dl'signs IPhoto C]. In the room ,hOWIl {)ppc.~ir.', we topped a Ix'a<kd chair raIl With a ocaded-cdge stwlf [PMto DI.

Gear up to make moldings Llascboards and ch:lir railS fit between doOJ" .md window casings, so install that trim first [Photo E1. (S~l' Dn' Molding: Fmt 2 011 {XIS" 66.) Wilen e.tlmating and prep,1ring stock to rout for moldin~ jOil\! and plane twO extril StripS for each type of molding 10 allow f(lf rolltlllg t<,ar·Out. m iscuts, and othcr m ishJps.

K'ow set up rour shop to mass-produc~ Illoldmgs Oll! of blJnks at kast 8' long ttO minimize splices on long walls). J"I1at I1l~Jn, table-mOUlltlllg J variable-'p<.~d,

j·hp router that can handle large mold­,ng bits. Then add Infced and outfL'('d supports. feath(·rboards. hold-downs, alld d~t collection [Photo Fl. While routlng. mamtaln a steady feed rate ..... Ithout pau;..es th at k'Jlll' burn marks.

rhe most car~fully 101lt~d molding, still need to be "an.led up to 180 grit using pads, sanding !opong~" or LUIl­toured blocks t hat 101\0" t he molding profile. You can stJin the mol<lings bdore imtaHa tion, liS we d id here, but apply a d eal fini sh after cutting ;oi n~s and Pd\ching Il,lil !lnl .. s,

woodmaglldne,com

MIX BITS FOR CUSTOM PROFILES

o Vslr'lg on'" bit lets you crute a symmetrica l plofile. while combinong two diffetent bi ts crute~ this look. jSee Sou.e.,.)

banboard,

COllllllon hand tools help you handle lIlost installations, bUI a mlterSJw makes the job easier. You ' lI Jiso work fast('r using a 15· or 16-gaugt' pn~um'l\ lc nailer wllh 214' or 21,.'.,· naHs to attach trim 10 walls. Use an IS-gauge natler with lW

Remove nails with c::are SOOner or !.:!tel. one of your na ils will ~tnke iI hidden k.nol. drywall nail, or some othw ollHade. Be ready with a paIr of end CUlt('/"5 or pliers designed to grip t;ove n a small ll<lil heild. PIJce iI shim or scrap beside the n.lll to protect the baseboard, and use the stw~ of the p liers to leverage the nail out 01 the wood.

SIMPLE STYUSH CHAIR RAILS

or I Vl' brads to attach moldings to each othe r. You' ll also need a J ' lev.;-I, a 0' or S' stralghtl'<lgt'. lape me;jSUTc, coping saw or jigsaw with iI nal row 20-tooth-pt'r­inch blade, a hammel, fill,) l1all-pulling plicrs. (See the Shop Tip bdnw.)

67

Begin with the baseboards First check walls for severe dips that will create gaps behind baseboards and chair rails [PhotoG]. Then locate wall5tuus to attach the baseboards and chair rails [Photo H]. Mark these plus the chair-rail mounting heights at each stud-typi­cally 36" above the floor.

Follow these general rules when plan­ning your job:

• AVOid coping both ends of a trim piece. That makes It hard to cut aLL urate length5. (Watch a free cope-cutting video at woodmagalint.comjcopecut.)

• Cut baseboards and caps starting with the longest piece5 first. That way, any miscut pieces can be reused else­where in the room.

• On walls longer than your longest piece of trim, join two pieces with a 4S" >carf joint [Photo 1[. Place the joint \ome­where inconspicuous, 5uch as behind an open door, and in front of a stud. Glue the joint ends and then drive IS- or J6-gauge nails through both pieces and into the stud to eliminate gaps.

In a typical room with four inside corners and one entry where you're using moldings with profiles, for exam­ple, first cut the piece for the longest wall using straight-cut ends. Add an extra !-is" to the length of the wall and cut the molding this length. Then bow it slightly, and pop it into place for a snug fit in the corners.

For walls 90° to the long wall, cut coped ends to go against the long-wall molding and squared ends to go against the opposite wall or any doorway casing in between. Only as a last resort would you cut molding for the remClining wall witli cope cuts on both ends.

That's the plan: now let's go to work on the baseboards. Unlikethecontrolled world of the workshop, you'll need to work around drywClIl flaws in most houses. For example, inside wall corners become rounded !Je.cCluse of built-up joint compound. To compensClte, sand a round-over on the inside end grain of your baseboard., to fit these corners. Now fasten the first piece into the wall studs using Cl 15- or 16-gauge nailer.

With no profile to cope-cut for the simple baseboards shown here. simply butt the ends of the adjoining pieces Clgainst your first bilseboard until you've worked your way around the room. On outside corners, miter the end so the imide face ends flush with the Lorner. Then cut the mating miter, glue the joInt, and attach the baseboard with

68

i i befo re you

,I and into a stud.

SHOP TIP Hate miters? Try this mlterless alternative In the same way that corner blocks eliminate mitered door-casing corners, these corner blocb eliminate outside corner miter5 in baseboard molding5. They also with5tand bumps from shoes and vacuums. To make them, cut blanb about 1" to Ph" square, and add a Ji" round-over to the three exposed edges. For a decorative touch, rout the top end on all four faces. Then add either a V." notch for outside corners or chamfer for imide corners to allow for drywall imperfections.

chair rail s.

WOOD m agaIin e NO\I~mt.er 2009

Cope molding ends for gap-free corner joints

IS· Or 16·&~ugc nails. HcinlOrce tl'll' join! with 18·gauge bfilds IPl'lotoJ [.

'low rou"!\' ready to add Ihe C,tp­agaiu Starling on the Jonge-.I ""til and bowIng a ~~.O\·t'(long vieee to fi l. (X'(ilyS<' Irs narrower and l.-ss rlgk! than the oo.S£'boon:l, the cap hid.-.s dip) and cur"~'S In Ihe drywall. So press it flnnly agaInst both the wall and baseboard before fastening it through to the wall 5tlJrls US111g an IS-gauge nailer.

tor ill1>ide corners, rope the ends of caps that \'Iill butt up against yOUr first cap with its square-cul ('nils. To rope-cut an end, firSl IC\'('al 1he tx0(l lf> by culling II 4Sc mitCl, as though mal(lng an inside mitered corner. Theil saw on the waste side Ileal the miter edge usIng a coping saw [Photo KJ or jigsaw' [Phot o Lillnd cop­ing jig. (See SourClu.)

Usc a rasp or a y." dowel wrapped with 80-grit abrasive to match Iht! profile to

the miter (-d ge IPhotoMj. Test the coped end profile ag;liost a ('ap-molding scrap 01 an iO:.lalloo cap IPhclto NI.

Plan tht CdP layout to make a squaw """lit or outside-corrlcr mit(ll on the other ends of any ('ope-cul pieces and WorK your ..... ay arouud the rooul. (for a hard­..... ood floor 1101 ShOWII, install shoe moldings the saml' way to hide gaps between the baseboard and floor.) Thcn, putt)' nail holes to match the \vood.

69

Install wall moldings like a pro Builder and flnllh Cilrpeiller David " I~h of Del MOines SllitreS the 10110'.vUI9 tiPS to help you suctessfuily tns tall oilsebocords and chJ;r r,)lls:

p. When ( ut\lnq baseboards with mi ters on bulh t'm.i$, grauudlly shorten them to the (.orrett len(}th To do thIS, D<IYid bults one end d9aon~ t the stopped blade of his milersaw, hfLS ;lnll SIMh ti le SilW, and cuts all lust a hJ,r at d ' Ime

~. f or w,lIIS th'" meet a! an ""ql (> other thdn 90' on 1I'~ldt' comer), ul:'at t' d bd(k bevel, as shown ,)l far righi, on the b(lS('uo<lrd ends so the front lacE'S bult to<Jether ..... thout 9dps

, In,tead of \Isinq d level to determine t half-filil mounting lines around a room, mNlure up from the floor I'our eyes autom atically lilt' the floor fo r reference to te ll w hether the (J1,, '1 rad ,Ian t s. ~ Cut chJiHJ11 ~ h e lf mite rs Wit h the

top fact' up to m'nlm,.:t' Visible teM-OU\. The chdir fa ll hidt'~ tea r·o ut un th t' unders ide of the she lf.

Now add chair rails Walls t hat ' >'ere fl3 t at Ihe t;oa sehoard~ may stili h ave wavts a t t h a lr-ra l! h clght. Check walls with a st ratg htc~" or taut string. Then p3tch d ip> wUh j(l\ lIt com ­pound ilnd repai nt .

Ik-cauSt.' hoth th~ ch,lJ r tad ~ nd shelf show n have rou tt>d protiles t ha t do [\ 't lend themSelves to COpe-LUI '. m Ite r the im ide and outside .:orncrs, . \ ~ wit h the baseboard. ~gin by m iter cut tIng a ch air ra il tv fit t ho: 10ugC" t wa ll ti rq. Attach t hilt ~~t lon wi th a 1-"- o r 16-gauFe IMII .. r a t t h .. studs marl;ed ~arller,

If the n .. ,t pleLt' goe~ l>e t\\een IWO im,ide cornns. measu r .. lor I.:ng. th and m Iter the enili w ith graduOII cut .. un til )00 achieve a tight fit . I$..--..:- " Insta ll wall mo ldi ng_ m .... a P r( ' ,"' <1/)111 .-.)

70

~ To nit ( hai r- rai l outside (orners, mIte r-cut the workpi t'('_e 5liqhtly oVt'r long ,md hold It 'In po~ition _ Tht'n bull a s.<.rap mite r ag~lnst the workplert' mltt'r ,)nd dU'ck lor gaps. Gradually short en the workpIece unt if you St>t> ,) tight mltt>r and no g;)P~, ;)~ ~hown belvw

m'ter or gap' I , wa ll cau sed by parts wt

MITER CHAIR RAILS SHELVES

; ,ope cu t, ~o in this use you would ,orn ~ ' ~ for an a!tract iv~ joint.

When working from an inside l'Orner to an out side corner, first miter lil e> imide corner end and hold II iI1 position while you mark t he miter location at th .. outside corner. Cut (lfi the waste side of t hat mark until the ollter fit~ 1l11 ~h With the corner.

r hen attach the shell es to the chair fili ls using an IS-gauge hrad nailer on t he lop and to the wal l {w m the fro nt With a IS- Of It>·gaug" na ile r [Photo OJ. Miter inside shelf ( Oll1t' IS to match the cluir-rail cmners [Photo PI. Where the sheli met'ts door 01 wi mk.\,\, t rim, cham­fer the sh elf end to d t'ate a t ran~ll ion

[Photo 0 1 with n,) sharp CUrTI(' rs. With the molding installed, pallh t il"

nail ho lt!l. using oil-rosed wuod pulty. and appl r tWO coats of clear fin ish . •

A (~rp ent e r 's penc,l under '~ :' :~~~'~:':'m he lps you cut a back bevel to odd wall a ~9 l es at in sIde corner'.

ildJoIn lng 0:1001' frame.

l'i'itteM by 80b Wll>on WIth David n . h MOI(l '1)(j dc ~ g n , Kev in Boyle IIllJm~toOOI . Rounne LeM oine. Lo rna John.,on

MORE RESOURCES Ht.LAl EI) ARTICLE • ·$hop.T~Sled 12' Mit~- ~"'" 178(Sepl.ember 2O(1) ~

rREE RELAT[D ARTiClE . 'Nder,Compttl!Ol' COmb(! K~f' l!~ 19(1 (M",

200'i). "'< <J<jm..-p.: ..... c"rn,,,.f .. ,(DtI'Ibo

(~·lItt" ... "' .. ".'I''' ... _J<Jo,_.....,. _,<"", .~ lv' ~ ...... , .. ' )I' ....... ...-- ... ,I .. !.o .... b tJ.,, _)

Sourceii Cha'" r lOil bit ltL ~bllno 99-4n $SSand ~ blroo.99,478, ~S8 ptl(6onArrlmm.ffim;, F·~ Alnl:r1Ci,h~,corn. CotM"9II,. ~por_OlJ151Il. ~14_so.'-""V~1ey Tooh,800 S7131S$or ...... aIoyWITI-

WOOD m~"d .. ., r~r l009

C2009 1,10<:1. Se",,"" S-e430 OF21$)1)4R·' A",en\s<lmOO!

Bob Vila endorses and recommends the famous EdenPURE® portable heater Millions of Americans now saving up to 50% on their heating bills and raving about the "heavenly heat" Does not get hot, cannot start a fire and will not reduce humidity or oxygen

The famous infrared ponable healer, the Eden­PliREt, which can cuI your heating bills by ~p 10 50'1, ha; been greatl} improved

The n.", EdenPURP GEN3 heater heats better, faster. <ave, more on healing bill, and runs al­most siler.1

Th. EdenPURE~ can paj for it,elf in a maHer ofwe.ls and then Itart putting a great deal of ex­tra money In yoor pod.et aft.r thal.

A major cause of res i­dential fires in lhe United States i, portable heaters. But the Ed.nPURE~can­not cau .. a fire ThM il be­cause the advanced in­frared h. aling element ne\er get; to a temperallKC that can i~m:e anything,

The outside of the Ed.nPliRP only getl warm to the tooch so that it ",ill not burn children or pet,.

The EdenPURE~ will also keep you healthy. That h b. cau.e, ~nlike otrer heating ,ource" i! will not reduce humidity or oxygen In the room.

The advanced space­age EdenPURE~ Infrared Portable Healer also heat, the room ev. nly, wall-to­wall and floor-to-ceilmg. And, as you know, most other IX'rtablc heater, on­ly heat an area a few feet around the heate-r.

Unlike other heating source., the EdenPUREt cannot put poi~onom Car­bon monoxide, any type of fumes or any type of harmful radiation into a ,=

Q. What I.s tho origin of this amazing h~atlng element in the Eden­PURE~

A. This ad\'anced heating clement was dis­cowred accident.lly by. man nan-..d John Jooes.

Q. What ad\'antag~s does this advanced in_ frgred heating pJ"(Wess have O,'er other heating source produr\s?

Never be cold again

Cannot start a fire; a child or animal can touch or sit on it without harm

Ploturod "'" i.Bob ~II" de""",t " ti ni lit. f,","us Edt1\­I'tJlII" GENJ Mod o! 1[)()(] It" t, r witlt • 1,"';1\'. II .. "'" bill mO"'1 "" jOur ",.tin~ bill "n il< k •• I'i"~ 1"" 10"1!" w.,., witn 'I><" •• nly nlat".

A, This infrar. d heat­ing process was designed aronnd the thre. malt im­portant con.umer bene­fits: economy,comfort, and safety.

In the EdenPURE'" proc. ", electricity il ~,ed to generate a t} ~ of in­frared real which, in rJrn. crealeS a v. ry safe heat.

Q. Hou' can a per­son cut their healing bill b)' up to 50% "llh the EdenPllRE"'~

A. The EdenPURE~ will heat a room In min­utes. Therefore, you can turn the heat down in your house to as low as 5{) degrees, but the room you are occupying, which h" the E~nPliREf. will be warm and comfort­able. Th. EdenPliRP is portable When you move to another room, it wtll quiclJy heat that rOOm ai­'0 Thi~ Can drastically cut heating bill,. in ,Orne Instances. by up to 50%.

End orinter> ie ..... The Ed.nPUREl will

pay for it.elfin wed." It willleep a great deal of e~tTJ mon. y in J u< . rI pocket. Becau,e of to­day's spiraling gas. oil. propane, .nd other ener­gy co,t,. the EdenPIJRP will provide . v. n g,-"ater ,avings as til. tm-.. goes by.

The EdenPURP ~!er is now greatly improved With no increase in pric~. the n~w Ed~nPURE' has been updated wilh Ihe late,! technology, ,afety. and comfort features to provid. you with even greater comfort, more la\'in~s. and veat> of reli­ability. The EdenPUREfi comcs wtth a comprehen­sive three year warranty along witr. a 60-d.y no questions asked satilhc­tion guarantee - we pay the return ,hipping.

This product has bc~n listed by Underwriter> Laooratoriel.

Testimonials from a few of the millions of satisfied EdenPURE® customers

The EdlnPURE"' has cui"" gas bin to alhird of what it w.staslye .... Leslie Wilsan, Vancouver, WA

The EdlnPURE~ really puis oullhe heal tike a Wllte s~­la. !urnace, tt'. ~ e l ow fre"zi ng outS;". and cozy warm ;nthe rather o~ er la rge Ii~in g room a r~a where t'm us­Ing it. I have .Ir"ad, notio e"" 4(110 60% d'o~ in Ihe cost of my heat:ng biNs. G_ge B" Trl8nglt, N. Y.

r----------------------------------------------------, : SPECIAL READER'S DISCOUNT COUPON : : The price of the E(!enPURP GEN311l00;Jel SilO i~ $372 pl~, $17 ,hipping for : : • total of5389 deli'ered. The GEN3 Model 1000 is $412 pl~; S27 shippmg : : and handling for a tot.l of P99 delivered. P.opl. reading this publication get : 1 • $75 di>count plu. free .hipping and handling and pay only $297 deli\'ered

for the GEN3 Model 500 and $397 delivered forthe GEN3 Modd 1000 if yon order within 10 days. The EdenPIJREt GEN3 comes in the decorator color of black with burled wood accent which goes with any decor. There is I strict limit of 3 unil' .t the di,coun! price - no ex~p!ion' pleas... Check below ",hich model and nu!llb.r vou WJnt o GEN3 Model 500, number __ " GEN3 Model 10CXl number

• To order by phone, c.1I TOLL FREE 1-800-588-5608 Authorization Code EHSI246. Place yoor order by ~,ing your credit card. OperJtOl'. are on duty Monday - Friday 6am - 3am, Saturday 7,m - 12 Midnight and S~nday 7am­llpm, EST.

• To order ooline, ,i,it wwwedenpnre.comernerAlllhorizalionCode: EIIS I2..tti

• To order by mail, by check or credit card, fill out Jnd mail in this coopon. This product carries a 6O-day satisfactioo g~arant"" .If yoo are mx totally sat­isfied return at our eXjX'nse, and your purchase price will be rdi.!nckd - no q~e,tions alhd, Tbere i, also a thre. year warranty.

KAME

ADDRESS

ew Check below to get di..count:

STATE ZIP CODE

o I am ordering within 10 day' of the dat. ofthi, publicalion, tberefore I get a 575 discoont plus free shipping and handling and my pric. is only $297 for GEt'!3 Model 500 and $397 forGEN3 Model lOOJ delivered.

n I am ordering p',l 10 day' of the date ofthi, publication, lherefore T pay shipping and h.andling and full price totaling 5389 forGEN3 Model 500 and $.t99 for GEN3 "lode! 1001

Enclos..d i. 5 in: 0 Cash 0 Credo 0 Mooey Orc",r (/l.lake check payable to BioTech ReseaJ"{'h) or charge my: o VISA 0 MasterCard 0 Am. E'piOptim;; 0 Discov. fiNO\us Account 1\0. Exp. Date

Signature : MAlL TO: : BioTech Re>earch : AmhoriLation Code EHSI2-J.6 : 7800 Whipple AYe. N.W. : Canton,OH-I4767 : ~----------------------------------------------------~

Shop-ProVt!I1 Products About our product tests We It'Sl huooredl of toob and I((esscri~s, but only lnose lh~l e,rn at least three IliI/S f<Jf perfonnan(~ make tile fmal lUI iIIld iIp~ar in 'nil I~tion. Prices are WJrerK at tilE time of artide prodlJ(tiOll alld 00 not illdude shipping, where applkable.

These woodworking wares passed our shop trials

Rldgld replaces flagship tablesaw with a rock-solid winner

I've long thought highly of Ridgid's contractor­style tablesaws, but the company's new granite­topped hybrid model, the R4511, leaves those saws in the dust-and at an attractive price. The HI,' -thick granite tabletop proved worth its weight by deadening vibration while workpiece, glided smoothly across it during cuts. The closed cabinet on stubby legs-complete with Ridgid's built-in Here-U-Lift mobile base with four swiveling casters-noticeably reduced the noise level and dfectively channded dust to the 4" port at the rear, I like its cabinet-mounted trunnion> for easy top-to-blade alignment.lts \l/,_hp motor surprised me brPlowing through tough cuts­even bevel rips in 2"-thick hard maple-without bogging down,

If I could change anrthing about this saw, I'd beef up the 2"-tall, aluminum T-square-style rip fence with taller laminate-or UHMW-covered ,>idebo,[rd,>. And Jlike the quick-rdea,>e '>plilter/ blade-guard assembly; but 10 access it I had to first remove three screws in the throat insert.

Uust before we went to press, we learned that Ridgid had issued a recall for this saw to replace arbor shafts that could potentially break under heavy load. If you bought one of these saws

Granite-Top HybridTablesaw, IIR4511 Perform3nce * * * '" '"

b€fore August 2009, call Ridgid at 866-539-1710 -Tested by Doug HICK., Price $600 or go to ridgid.com to see if your saw qualifies for a formfr J.hop ttocher and Ridgid the recal1.) woodworking magOlineedltor 800_474_3443; ridgld.com

n

Heavyweight lathe turns In impressive showing \Vith Laguna's Platinum Series 18-47 lathe YOIl can turn a workpiece up 10 18" in diameter and 47" long. Despite turning a piece thatlarge, J couldn't bog down its 2-hp, 220-volt motor no matter how hard I tried. I like its digital readout and electronic variable speed that ranges from zero to 3,200 rpm. And when finished shaping a workpiece, its reverse feature comes in handy: I was able to ,and smoother than in just the forward rotation.

The heavy-duty ca'>l-iron legs and ways (500 lbs IOtal weight) ellmi­nated vibration, even when I roughed out a near-capacity bowl blank. This machme sports many big-lathe features, including a 1';" x 8 tpi headstock spindle and 36 mdexing stops, for a mid-size price.

However, there's no handwheel on the headstock. and the locks for the headstock and tailstock sit on the back side of each, making it difficult to reach over to make adjustments. And it comes with a 6" faceplate, which work> well for large turnings, but is just too big for medium to small bowls and vessels.

18" Wood lathe, ,A175017 Performdnce Price LJgun3 TOOl 800-234-1976; lagurKltools,com

* "''''* * 51,855

-T211td by Mar/en ~2mmel, Manoging Editor

Route r-bit set makes no-ca nvas tambour doors Few woooworking tasks prove more tediom and messy than gluing slab to canvas to make tambour roll-up doors. Alter making one years ago, I swore I'd never do it again. And premade tambours cost from about %0 for a b~ad box to nearly ,~200 for a de~k. Nnw, thanks to Amana's three-piece tambour-door router-bit set, there's no glue 01.. C"anva~ involved. You simply shape the slats on a router table, and fit them logether loosely in ball-and­s.xket-type joints. as shown at bottom.

The big profile bit routs both profiles of two slats onto one blank; the ball-tipped bit cuts the socket. The included lj," round-over bit eases the sharp edges on the bottolll ~lat. (tike many woodworkers, I already have a Lj," round-over bit , so Amana could leave this bit out of the set to make il more affordable.) Rip the two slats apart on your tahlesaw, and then fit them together. The finished door slides he,t in it 0/"," groove; if YOl.l don't have a hit thut size, rout it in two passes with a smaHer one.

-Tested byErv Robert" wIlo 1m bffn building proW:ts or.:! testing

1001; ()fWOOD& mogazirlf (Of 18)"orl.

Tambour Door Router Bit Set, 154114 Performance Price Amana Tool Co., 800-445-0077, aman~tool.com

***** $175

continued 011 puge 74

woodmagazin ... com 73

Families Have Soved Up To 50% On Heating (osts And never hove to buy fuel· ,oil, gos, kerO'Sellp., wood - ever tlgail1!

YOlll' Itlltlih witil Hydro-5i1: • Sllllll h~lil'lj (OIlwilh Hrdl~·~1 • Fum"" frM - dLKI fr .. • lif.tlm •• "."III'I. ~O"'I"C wnlr~(h • 5~11, wmphle ,,"U(I <)/ IIW1d • (!tun, n~ l"'lte\, ,",,;rOnfl"lnIBlysof, • U.t.l~l,d • P'~1I\5rmhkd·~ rClidylo <lit • Portublo (IIOY( 01 p ... monon! 1220Y( • WMI. ho<J\. ileolinQ 0< ~ngl, 10"'"

Hydro·S~ i, a high performance individool room fIe<ltirlg ~y,tem fhat can ~ave you hundreds of dolk", in home ncating (osls by replacing old and inefficient heotirlg. It con rcploce or supplement your electri( heat,

s"s or oil furnocc ond woodstovcs. Hydro-Sil rcpr".cnh economy in koting' in<idc lhe

heater is 0 scoled copper chombcr f~lcd wiTh 0 horm!c.s ,ilicone fluid de.igned for heot retention qu"li~es. The fluid i. quickly heeted by" Vtlrying "mount of micro­ma""ged proportional power. Thi, exdu.ive technology greotly increases energy ,ovins'.

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OVer 10 time .. stronger than con_nUonal pefJboard

Shop-Proven Products Irwin's beefy clamps turn in weighty perfo rmance I'~ , enEd 011 Irwin Quick-Gllp one· handed l)at clamps for rears, so l lookoo fonvard to using Irwin's par-diet-jaw clllmps.. The ~eel-reinforced jaws and thick stee!I·l)eam bar did not flex Und('f prCSSUH!. Bul at 61h Ibs for the 24' clamps and 9 lbs for each 48' mod,,1, the ht'ft add~ up when you mov(' a cI~m~d assembly off your b('nch. The mOV'~blc fa .... os dig into the smooth bars when tightened. lea\ing bite minks tllilt ImlX'<I~ m(welllent on later glue.ups. And the Hne handle Ihwads rcquifl' OlOl'e turns 10 lighlcn and 100000n than most other parallel-jil'" clamps.

__ rt>Slt'd bv Bob Ii~~(<,>,: roo.l) Ii; rahr.,'?1fe. Ed,!",

Parallel-Jaw Clamps Performance

( .. ) p

... '

Price 24' clamp, 112026500 SlS 43" cla,.,p, .2026SOt 14S

1""';1\ tl1(lUAriai Tooh 80().~64 ~6; lJWIn.com

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NEW! SHAPE 3 SIDES IN 1 PASS!

COtTtimlt'd 011 PUS" 76

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Visit www.kregtool.com/beaded lodoy 10 watch Ihe video and leorn morel

800,441.8638 www.kregtool.com

Shop-Proven Products Dial in dead-on dadoes, grooves, and rabbets Infinity's PreciSion Router Dado Jig delivers just what it promises: precise dadoes, grooves, and rabbets. This aluminum jig adjusts to fit any strdight­edge guide up to 'I"' thick dnd 2:1"," wide, and glides smoothly against it with ball hearings. Mount the included 'Ii' guide bushing in your TOuter, fit it into the 1ig, and then TOut a channel with the desired bit. Por channels wider than the bit, ~imply usc the micrOdd­juster on the jig to move the router without moving the guide. The scale and cursor all the jig m<lke it edsy to return to this setting later. Go to woodmagaline.com/toolschool for a free video of this jig in action.

-Te,/ed by jMSvec,

a former pro;eft editor and builder a/ WOOD ' mogQ./ine

PI't'cision Router Dado Jig, 'PDJ-' 00 Performar>ee

Price Infinity Cutting Tool , 877-872_2487; infinitytoots.com

Contour sanders lay down smooth g~~~.~!~. Auto,lxxly repair shops have used cove,.t little more pressure stiff-foam (similar to swimmlllg-pool and it enough to get that, too. "noodles") Soft-Sanders for years, hut I had I~ss sueo:ss Oil SlTId]] r()ukd only recently did these cOTltour-sanding profiles (ogt'cs, be.lds, etc). Getting accessories find their way into wood- sandpaper to conform to those small working shops. The kit features six shapes proved too difficult, rounding-distinctly shapt:'d sanding pdds in three over crisp cOIllers instead. densities and includes 80-, 120-, and The supplied s.:llldpaper sticks to the 180-grit adhesIVe-backed sandpapt:r. pads well during sanding. yet peels off

I began my testing by sanding a c.:lsily when changing grits. It proved It:ngth of home-cenkr red-oa\... crown durable as I foldt"<i, wadded, and twisted molding. I used three pads to match the it into variOUS forms, and it did not dIfferent molding contt)urs, and wor\...ed load up with dust or pitch . • my way through the three grits tL)

produce a slippery-smooth surfJCe. Next, I went to work on a cabinet­

door rabed p<lnel. It took only one pdd to match the large cove. To te~t the contour pad's effectiveness, J scribhled pencil lines all along the profile. At first, the abraSive missed the apex of tht:

76

Soft-Sanders

-Tm_d by Bob Hunter, Tods &. Tedrniques Editor

Perform<lnce **** ,-' Price $25 (4-pack replacement smdpaper, $4) Style-Line Corporation 800-752-9863; soft-sanders.com

WOOD rnagolZine Nowmber 100'i'

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Ask WOOD Answers to your questions from letters, e-mai ls, and WOOD 9nline'

Hidden hazards could lurk in broken

Q .. dropped my prQmium tabl~nw blade on the • concrete and the carbide broke off of a tooth. Can I

keep ufoing it? -Todd Hubbard. O(ll;:.mrl, Calif.

Ae ::ihort an~wer, rood: n o. BeSIdes t he ob~'iously darn-• J.b'Cd toot h, othC't te'e th may ha\'c sustained mvisible

damage. The next u:.c ('ould t urn that carbide in to dangerous shrapnel.

flut t~ t hele ally way to salv:tge your Investment? We called several p remium blade manufacturers posing as customers to sec what our OptlUn) werl'.

Not surprisingly, bouncing l blade off of concrete instantly Yoid~ the warran t y-so t here would be no free replacement. And companic) offeled flW altCrnat lWS beyond purchasing a new blade. ' '''h en prompted, most agreed tha t a local ~harpcnlllg service mlgflt he able 10 replace t he carbide tip kSli cxpcmlvcJv t han replac ing the blade.

The repre'>l:lltatlve 01 one tl1anuiact ure r, FOH""t Manuiac­tunng, a~kcd u~ to send in t he bruken blade. T hey offered to check Ihe surround ing teeth tor damage. leplace missi ng carbidl' li~ )traighttn a ll ~ hent teet h. and m ake a lest cuI to ensure everything was in order. They di rected tIS to thei r onli ne pr icl' list. \\'hich had a (kla ilc-d li!'>ting of t lld l lees fo r thl'se l\oCrvicl .... In llddll lon [0 .~hipplng CDstS, cll rblde tip leplau-mem s tatLS at S7 for olle tooth down to $3 each 10 1

Surgery for broken screws

Q_ While I was installing hinges on a cabinet door, the _ he ad of a brass screw broke off. How can I remove

the screw without mak ing a mess of my project? _ Kennl'fh Hill, Troy, Mich

A• The IMI }ou'r~' looking for, Kenneth, is a broken screw . l· ... traCtor. (To buy Olle searl'll for "screw extractor~ at woodcraft.com.) WIWl t lusta lled In a d rill, these diminutive hole sJ.ws ~u l a r(,'lnovable plug of wood trom around the threaded ~hafl (>t t he brni..;.'11 screw. Because their outer diamet('n match ("ommon plug'Lutter SlzC'i, you simply fill t he hole with it plug CUI flmn ,I )CTitJl of the S.ime wmxt, h iding the mistake. One word of caullon : Don't ovcr tigh ten t h(,' chuck when inserting Ihi: ext ractot in your d rill, as you cou ld clUsh t he tube.

Bra_'IS sC rew~ art· fragi li:. On you r next atlemrlt, be sure to pIc-drill a rlOp('fl~ Stud p,lot hole. Then d rive dnd lemove II sleel SClew of the lkunC SIZC <HId thread count In plow the wa) forlhe .-.r<L'\.S \CI ~".·". FmalJ~, tighten t he br.lSS screw b) h;md with a .>(re"d r i~<!r to avoid twistin g otl lhe head .

roltTi/t/led on J>t.lg,· 80

7.

HAVE A QUESTION? Fo r ~n Dn.wer 10 yo~ r woodwork.ng qvestio n. write to ASK WOOD, 171C1 l ocust St " LS·221 , Oes Moin lts. IA 50]09·]023 or e-mail us dt itskwood@woodm;ttgaz lnlt.,om.Forimmediiltl' feedback from )'OUr fdow wooowork,ers, POit your que~tions on one 01 001 woodWorking fOtum~ al ..... oodm;ttguinlt.'omJfOtum5.

Hidoondarn..lge(Q\lld eq ... al dangerous shrapne-l if th i'! blok@l1bLade is ... !Itd aglin befOfe bemg properly re paired.

fnu r 0 1 more teeth . A test Cllt checl..ing fol benl teeth emts an additional S2.5O and st ra igh teni ng a ny henl teeth mSh S2.50 per toot h .

WOOD ... agulne Novemoer 2009

Time travel at the speed of a 1935 Speedster? The 19305 brOught unprecedented innovation in machine-age technol­ogy and materials. Imlustrial designers from the auto industry translated the principles of aerodynamics and streamlining into ('t'('ryday oblects like radIos and toaster~. It was also a decade when an unequaled \'arlety of watch cases and movements Cdme into being. In lieu of h,ll\ds to tell time, one such complication, calkd a jumping ITIt'challls m, utililed numerals o n a "1st vieWed through a windOw. With its strik ing resem­blance to the dilshboMd gaug.;>s and radio dials o f the d~ade, Ihe jump hou r watch was illde&1 " in tUlle" with t ht> times!

n1\~ 51,mer /QJOs /J,I l/mollic deft ly blend .. the mooern functionality of a 21-jcwel alltomatic movement and 3-An,! water reSistance with Ihe

Tmt' to MrKhillt' Art eltht'liCl. the ,It't'~

brlls/led ~!<lill"'-~.~ Il.ee/ .:a~t' i, (k,n 011 tilL

b,ld:, all"wil1g a pt'fJ.. lit tllf inlla w(lfJ..inSl,

~1i ~tinctive, Tetro look o f a jumping dis play (not an actual jumping complica tion). The stainless steel 1 t/2" Cdse is com pk men ted with a black a lli gator-em bossell lea ther band. The band is 9 I/Z' long and will fi t a 7---A 1/2" wri"t.

Tr}' the Staller 1930s D'l<~lltrollic \\fillch for 30 days and if YOll itre not

reccivlllg compliments. please return the walch for a full refund of the purc!la~e price. If you have an Ilpprt'ciation for classic design with pn'clslol1 acc uracy, lilt' 1930~

D,j3JI/rc)llic: W.ltch is buill for you. This watch Is a l imited edi tion, so please llct quickly. Ou r last two li mIted edition watches are totally ~old ou lt

Not AlIllilnbie in Stores St,1\.ICf 19305 Dashtronlc Watch S99 .. Sf,;", ~

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Ask WOOD Shedding some light on fixture placement

Q. I'm in the process of com­• pleting my new shop at

, home, and I have a load offluores­cent lights to install. How should I space them for best effect?

- Bob Crain, Spring Valley, N.Y ..

, A. Congratulations 011 your new . shop, Bob. You need to create

adequate illumination that overlaps to eliminate shadows or dark corners. Referring to the drawing, below, here are some simple rules for doing just that.

Start by measuring the height (A) from your work surfaces to the expected height of the light fixtures. Assuming you plan to install your fixtures in unbroken rows across the ceiling, the distance from the outermost fixture to the wall (8) should be about one half the distance of (A). The distance between fixtures (C) should be about I-J'/I times (A).

For example, a typical 24x24' shop with a 10' ceiling and 36"-high work surfaces gives you a distance of 7' for (A). Three 16' rows of lights (each consisting of two 8' fixtures or four 4' fixtures) spaced 8' apart (C) leaves 4' all around from fixture to wall (8).

Some shadoV\'S can't be avoided, so add task lighting where needed to take care of any workstations that are 51 ill in shadow.

I I,

!

! I

, •

1-· ---------------

80 WOOD magazine '.member 2009

Dead-on dowels dilemma

Q_ Where can 1get properly . sized dowels? When I

buy ¥? dowels, they always ~ltltm to be slightly undersiz@d.

-M,~e Chesler, Champlin, Min"

A _ l Ook no furt her than YOut • router table. ~Ii "('. !>tMI wll h

your choi«(' of <if}. st raish t·gra inoo ~tO( 1.; to .woid t il(' curling rou otten '>CC in 'tore-bought dowels. Joint and plane a t>lanl: down to the d(",,'cl'\ diameter-In )'ou r caS(' v..)< Yo square-then cut it about 3"longcl than the dowel YOli. wll! n('('d.

Imtall a fOund·over bit with a ,aJim half that of You r dowel blank-y,. ' for you~,v, " dow..:! stock. Set the fCI\(:c flu\h to the bit'S bearing. Then, ~{'! the bit hdSh! to make an even roundevc! in your 'toek. Make a te~t r()undovcr 011 a cutoff to veri fy your \etup.

Mark ,IMI and ~IOp lines on aU four faces of the blank about ]' from each cnd. By louting lx'tw('('n t he§.(' marh, you keep the ends ~uare tu act 11 .. guides .\ftcr ealh pa~~ rotate the blank 90° for the next pa'~. r-inalJy cut off 11K' squart· ('nd~ and cut the dnwel to length on yuur band~aw.

'>qua,e ... ut .... d ndu a",~'nsll"~f ... ( •.

Ali",,,, mlfk,willl

(l'I/lIIIU,lf ()II ",1,\\ 82

81

1.1;0,.",,,10; lE"u ... , .. lnll C",,,",..t« With 'he Matf!rial Eatinl8'01 you ean quickly .nd easilY cak:utate Y",ds, Fee l, Incr\IJs. F'Jetlor,. and Meltlrs and rna/ena! costs and a~OIfIIanc..s '" get ~'aet~ tilu matorlalli you need. Pr ovent eebmatitlg ""ors and save tm~...-.J IT"()I"',ey MOd$1 4019

Construdion Maste~ Pro Adva"" .. d " .. "".I""II·F ... "llon Con. truclion_Ma111 Calelliator 1,lijaoll6ij3 more POI'IWf.- bU llt·.r, 9Olltlon s . ir. add ition \(l 100"", r'-""'<J il ,~ Mo;os~ M~Soer f1ro The pMtloCt IOCM ,r your ~WQr1o;jtlg paSeion Indoon project! &.uCI1 as reonOOelrng ... acIding a room. h"""'" prov.des ~e~ for oomJ>,)llnd ml\eori M_ 40115

Home "roiectCal(~ D""lt ·Y .... ~ ... ..,.."1 c,,1,,"''''0II" S'"1ll,fy your n.-nll ""I;lI"OVeIlIIIIl' projects ""'" this ~S<! CII'CJ!.T.or eu"~n tunc:1ion key! I~ you QUICkly and acc..-""'V ina m9B'191 ,~o_ kIr PIOfIl QClnCrele. 1<10. ...... _ and ca<peL Model 8510

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Ask WOOD A pound of panel·busting prevention

Q. After reading about the effects of moisture on . wood movement, "m reluctant to try tablesawn

ra Ised panels. Won't the wedged edges of the panel spread the grooved stile to the breaking point, espe­cially on widll pillnels7

A. Fortunately_ Michael. tlme-Iested. r.l i~,piln"l . constructlon absort» the often puni5hing eflects of

\ea\o I1 <11 wood mOI:(,nl('nt by capturing the movement­prone pa nelln a forgIVing framO!. "' he wedged edge, of Shaker-~t}'le, tablesawn l)3nel~ might!)e ,llinlt' ]eo;s lorgiving than othtl de!>!gns, but Ihe 'tep' to 3\"oid wood mOWDleilt catas trophes are th" ~llIe_

fir\t, make yuur panel from straight-grained, ri ft-~awn or quartersawn wood that has tx:en properly kiln-dried~ which is le~~ prone to mo"ement tha n cat hedral-grained wood. Once in )'Ollr shop, let the wood accli mate for a couple weeks before machInIng It . This allows the wood'; moistllff: content to stablliz(! wit h its ~urroundings.

After mea\uring bctw(!(!11 tll(! groove\ in the rails and '>tiles, cut the ral~ed panel to leave at leasl a '18 ' gap on all sides. This lea\'Cs tIle panel free to Shrink and swell with the changing humIdit y of the sea~on\. To avoid a loo,e or rattling pan"l, Install flexible ~pacer', 'lich as "Space Balls·' (WoodClaft #142284, S6/packase of WO, BO(J-225-1153, woodcraft.com\, In tht> groov('s, or glue or pin-nail the top

82

The wedge 5h~pe of a tableuwn raised paJli'1 i,le« forgiving of wood mo~ment without plannIng for its effects.

and bottom centel of the pallel in the rail. For panel' L8" or more wide, or If the piece will t!xpt!rlencl.' dra~tic challges in humidity, such as a Crc>S,-COUllt ry t rip from Arizona to Florida, deepen the grooves ~ nd/or narrow the panel to allow for e\'ell more swelling.

Fil1Jlly, p~llel sJHink;,se might expo,e.1 '>light gap between the panel profile an d th .. ,tile groove In tabJesawn panels, so stain and fini~h the p~ne l befofe ImerLing it ill the frame to aVOId ,1 dl"",cl tng ullStained Hne . •

WOOD n>.Oguh.e N~be< 200.'1

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~ Blades, Cutting Tools

CMT ORANGE TOOLS Tor, qlJaity hdus:ricJ :"w, lJar',.es aoo r«Jtef t-.<ts nl affc.-ddtffi pieing, Circle No. 180.

EAGLE AMERICA Largest 58lOCt>01l of profess<():1al (1)3I;ly. AIT:erlC:;'1-maGe route-: tiTS ~ 1 OOs of unq.e a=sorfc)S, Circle No. 193.

FORREST MFG. CO., INC. Top qluity bhdos ,,")(.1 r.bdos for GIl lIltle; smoc/h finish Circle No. 206.

FREUD SAW BLADES ~'his 413-~:;ge c:;Ubcj j lustratff ~lC fca~ures JTl baleflts fa- al Fre<,Jd "",,W tl!ol<.les. Circle No. 219.

FREUD ROUTER BITS AI Freud router tits de rEtlYese:1[e(j 11 tris 8L-page ·~a.flk)g,

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MLCS WOODWORKING 8ast qu~. 'I'i, r'OJIl sded'oo. kJw ~nces, &;~crlOr ~ce Froe Sili~'lI;illg' Circle No. 24S.

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Plans and Videos AMERICAN FURNITURE DESIGN CO. 1 so ot Arr\€<1·8a.'s best f,.,-niture "ans, comprPhensive IlSTUCi'01 '1-'00, Cd j o;j Circle No. 336.

MEISEL HARDWARE SPECIALTIES CATALOG ?,COJ+ IlJlI-siLe r,o;a<;[ flans n,;j rwd-to-fhd il5d\'JCf'e, Circle No_ 401.

U-BILD WOODWORKING PLANS SiCiC8 I 848' IllJno:eds of f<)l· siN p'Jns, d(l'linloadfllJe jj:;1S, low p;Yes. Circle No. 435.

86 WOOd Magazine November 2009

ARMOR CRAFTS FUII->;ize 1)l1.11S to bl l id Grades, rocking IlcrSes, c¥.:>ck.l n:)j rn:xe, Also hardwaro:;CJd wood cre'!t SliWi es, Circle No. 556.

THE BEALL TOOL COMPANY Irrventi'le sOlJtiC(ls for sh~ p;oIJems 'i,'00d thm:;(j'>:J bulfng & more Circle No. 558.

GRIZZLY INDUSTRIAL, INC. 12,0C() w(j()jwcrki:-.;) and mPla!w«(\<ing machoos, toos and accesscrips, 1.I:-;:w,-;,taJje rf>c:esl Circle No. 563.

HARTVILLE TOOL CATALOG OIJ<J~y W<XXJwcrk!:1g toos Jrd slIpph!s Jt thl test ~~ces ara<.l1d Circle No. 596.

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MORTISE PAL Matisos m:;de oasy! Circle No. 824.

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Income Opportunities & Education FURNITURE MEDIC OffPfilg irc;:-,m,Sf! 1.::8:13es [0 co.la~fied l1 [hidcJ3~ to perfcrm molJls, o'>-site furn·:II..-fJ rfJ~:;'" & restcrr.,[KJ'1 se<,;CfJS Circle No. 895.

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WOODCRAFT RETAIL FRANCHISE 0-"'1 a Woocl:;raft S10re - frJ llCilises offerBd for stcres auoss II">:! cou:1try. Circle No. 924.

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HYDRO-SIL Unq."", roc:m-by-roc:m heati1g sys:u r, Circle No. 1190.

RADIANT FLOOR COMPANY RooMI Hez,ting Systerns-eesign, m"nufxture;}1d &,18 fcr thlLJIY Circle No. 1301.

ROCK LOCK FASTENING SYSTEMS, INC. Post ,';,nd rn i ilg d lnch,' wn[ lyY(t,v3re thd mnkes it oasy, Circle No. 1308.

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_Tools COOK'S SAW MFG., L.L.C. I 'cr,(!!jP &\'lTTills, Edgers, Sharpe''€<s, &;nd Btooes. Froo CJtz,0g, VKloo avcjtlt:ip, Circle No_ 1480.

THE CRAFTSMAN GALLERY ROlitPl' Boss joinery rf\i';chl1es n'1d o~her qly;lil Y \'iwj"vcrhlg toos and accp:.scr:ps. Circle No. 1495.

DREMEL MULTI-MAX T'1e npw Ummel" M1Jlti·M,-;,x r" Jsclbhlg 100 system. Rrr,f.; r. Rormoo, Restcrc Cin:le No. 1508.

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JET SUPERSAW Cast :ro1 v.~ngs, si rl i,'J GrOSSO.Jt t,·;,bk'l, mk:ro aq ust fruCR Tcrafy e'1OkJsed c:;bOlet Circle No. 1588.

LAGUNA TOOLS Rcc woxt'''a1<.~-.;) rnahCffl Icr prol'Els.simiils J:)j hot:ey;sts, !lwad-'.· .. mi:lg design t:dlds",ws, [l'-cvP";,n q.Ylity mr.dir..,s \'~th u,'Of 2:0 )I:\H c! OXjJCrCoixoe, Circle No. 1593.

MAXNC, INC. Mfl:)Jfa8[urerS Of Amflfioa:1 rmee CNC rl ~ l s. hires n:)j routers .. ",1 z,ffordaCie pr'ccs l Circle No. 1612.

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PENN STATE INDUSTRI5S A"".(I., ..... "9 ;.m' oclJOn. Cc EICIC • CycU"oes. Duclwork and rncJ'I' Ctrc l. No. 204&.

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Curvaceous jewelry box Straightforward constllJCtk:<l hdes b€hild t~ fuv.ing lines of this handwne box. Simple potteTns make 'rt eal), to cut matching [\jrves on the drOl'll'rfroots, pulls, ~d [JS{',

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