M E- NG ING CHAAILER GA RAD N B 12 Essential Milling Tips ® YOUR BEST SOURCE FOR LEARNING NEW SKILLS #170, FEB/MAR 2014 Mobile 3-in-1 Workbench Tablesaw Storage And Outfeed Table Build a Curvy Benchtop Tool Elevator | Built-In Router Table Corner Cabinet ALDER the Chameleon Wood Weekend Project Oogloo Eggcup Giant Finger Joints– Skill-Building Step by Step Recipe Box M E R I C A N O O D W O R K E R . C O M HARBOR FREIGHT TOOLS Quality Tools at Ridiculously Low Prices LIFETIME WARRANTY ON ALL HAND TOOLS! FACTORY DIRECT SAVINGS R ! PE ON SUPER COUPON! SU UP FREE How does Harbor Freight sell great quality CO tools at the lowest prices? We buy direct 20% from the same factories who supply the expensive brands and pass the savings on to you. It’s just that simple! Come in and see for yourself why over 25 million 6 PIECE satisfied customers and leading automotive SCREWDRIVER and consumer magazines keep talking SET OFF about our great quality and unbeatable ITEM 47770/61313 prices. Visit one of our 475 Stores Item 47770 shown Nationwide and use a 20% Off Coupon on one of over 7,000 products*, plus pick up any one of the 2 Free Gifts, up to a $ 99 4VALUE ANY SINGLE ITEM! $5.99 value. • We Will Beat Any Competitor’s Price WITH ANY LIMIT 1 - Save 20% on any one item purchased at our stores or HarborFreight.com or by calling 800-423-2567. *Cannot be used with other discount, coupon, gift cards, Inside PURCHASE Within 1 Year Of Purchase Track Club membership, extended service plans or on any of the following: compressors, generators, tool storage or carts, welders, floor jacks, Towable Ride-On Trencher (Item LIMIT 1 - Cannot be used with other discount, coupon or prior purchase. Coupon good at • No Hassle Return Policy 65162), open box items, in-store event or parking lot sale items. Not valid on prior purchases after 30 days from original purchase date with original receipt. Non-transferable. Original our stores, HarborFreight.com or by calling 800-423-2567. Offer good while supplies last. Shipping & Handling charges may apply if not picked up in-store. Non-transferable. Original • 100% Satisfaction Guaranteed coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. NOBODY BEATS OUR QUALITY, SERVICE AND PRICE! R ! R ! OUND PE ON LOT NO. PE ON DOVETAIL MACHINE ER N! LOT NO. 12" SLIDING COMP SU UP SU UP LE-BEVEL MITER SAW 69684/ 97869/61790 P O DOUB SU UPBlade 6 /9819 4 CO 2 HP INDUSTRIAL CO 6177 WITH LASER GUIDE NEW! O SAVE C Included. $12999 5 MICRON LOT NO. DUST COLLECTOR $100 34102 WINNER 24 Best Value Award 70 GALLON CAPACITY $ 99 The Family Handyman $ 149 99 PRICE REG. $249.99 Item 97869 shown SAVE 28% REG. PRICE $34.99 $ SAVE 170 Item 69684 shown $ 18999 REG. PRICE $299.99 t be used with other discoun calling 800-423-2567. Cannot last. or HarborFreight.com or bypurchase with original receipt. Offer good while supplies day. LIMIT 4 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 3 - Good at our stores es after 30 days from original er per Limit one coupon per custom or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchas coupon must be presented. Valid through 5/28/14. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original R ! R ! 24" CLAMP AND R ! PE ON PE ON PE ON 29 PIECE TITANIUM SU UP 30", 11 DRAWER SU UP CUT EDGE GUIDE SU UP NITRIDE COATED CO ROLLER CABINET CO SAVE LOT NO. 66126 CO DRILL BIT SET INCLUDES: • 6 Drawer Top Chest LOT NO. 67421/61485 46% SAVE 60% Item • 2 Drawer Middle Section shown 67421 LOT NO. 5889/61637 • 3 Drawer Roller Cabinet $ 15499 REG. PRICE $299.99 SAVE $145 $ 99 6 REG. PRICE $12.99 Item 5889 shown 9 $ 99 PRICE REG. $24.99 LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 9 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. R ! 27 LED PORTABLE R ! R ! 2.5 HP, 21 GALLON, PE ON PE ON PE ON SU UP WORKLIGHT/ SU UP SU UP 125 PSI VERTICAL CO FLASHLIGHT CO 10", 12 SPEED CO AIR COMPRESSOR BENCH MOUNT SAVE LOT NO. 67227/ "The Perfect Compressor with SAVE 69567/60566 SAVE DRILL PRESS Powerful, Quiet and Consistent 55% $67 Airflow...Plus We Love the Low $70 LOT NO. 60237/44836 Price" – Street Trucks Magazine Item 67847 shown 2 $ 99 99$169PRICE $ 152 99 PRICE REG. Item 67227 shown $ 69 PRICE REG. Item 60237 shown .99 REG. LOT NO. 67847/ $5.99 $219.99 61454/61693 Requires three AAA batteries (included). LIMIT 8 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Undisputed King of the Gara ge" R ! BENCHTOP ROUTER TABLE R ! PE ON PE ON 900 PEAK/ R ! "The PE ON – Four Wheeler Magazin e SAVE SU UP WITH 1-3/4 HP ROUTER SU UP NEW! 800 RUNNING WATTS U S UP $ 60 CO CO 2 HP (63 CC) CO RAPID PUMP ® M GAS GENERATOR 1.5 TON ALUMINUItem LOT NO. 95380 LOT NO. 66619/ RACING JAC K 68053 WEIGHS 27 LBS. 60338/69381 8999 52/60569 shown $59 LOT NO. 68053/692 99 $ REG. $ SAVE Item 69381 shown 89 99$119 PRICE $85 $ .99 3-1/2 PUMPS LIFTS MOST VEHICLES! be used with other discount calling 800-423-2567. CannotOffer good while supplies last. SAVE $40 REG. PRICE $129.99 9499 REG. PRICE $179.99 or HarborFreight.com or by LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 4 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 4 - Good at our stores after 30 days from original purchase with original receipt. one coupon per customer per day. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases must be presented. Valid through 5/28/14. Limit Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon R ! R ! PE ON 4" PLATE JOINER SUPER COUPON! PE ON SU UP SU UP FREE CO LOT NO. CO 20% 68987/38437 Item 68987 SAVE shown 33% $ 3999 REG. PRICE 1" x 25 FT. TAPE $59.99 MEASURE OFF LIMIT 4 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. ITEM 47737/69080/ 69030/69031 R ! MOVER'S DOLLY PE ON Item 47737 shown SU UP 1000 LB. CAPACITY CO LOT NO. 93888/ 60497/61899 Item 93888 ANY SINGLE ITEM! $ 99 5VALUE shown WITH ANY LIMIT 1 - Save 20% on any one item purchased at our stores or HarborFreight.com or by PURCHASE 7 REG. SAVE $ 99 $14.99 PRICE calling 800-423-2567. *Cannot be used with other discount, coupon, gift cards, Inside Track Club membership, extended service plans or on any of the following: compressors, generators, tool storage or carts, welders, floor jacks, Towable Ride-On Trencher (Item LIMIT 1 - Cannot be used with other discount, coupon or prior purchase. Coupon good at 65162), open box items, in-store event or parking lot sale items. Not valid on prior purchases our stores, HarborFreight.com or by calling 800-423-2567. Offer good while supplies last. 46% after 30 days from original purchase date with original receipt. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Shipping & Handling charges may apply if not picked up in-store. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. R ! 16" VARIABLE SPEED SCROLL SAW R ! R ! 14" OSCILLATING PE ON PE ON EIGHT DRAWER PE ON SPINDLE SANDER SU UP SU UP SU UP CO CO WOOD TOOL CHEST CO LOT NO. 94538 $8999 LOT NO. 93012 SAVE $60 5999 SAVE Item $ $40 59 69257 shown $ 12999 REG. PRICE $ 99 REG. PRICE $149.99 SAVE REG. PRICE $79.99 $99.99 25% LOT NO. 69257/95088 be used with other discount calling 800-423-2567. CannotOffer good while supplies last. or HarborFreight.com or by LIMIT 4 - Good at our stores after 30 days from original purchase with original receipt. coupon per customer per day. LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases must be presented. Valid through 5/28/14. Limit one or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. R ! R ! 500 LB. CAPACITY HE PE ON ALUMINUM OXIDE SANDING PE ON R ! 12" x 33-3/8" WOOD LAT SU UP CO SAVE SPONGES - PACK OF 10 SU UP O ALUMINUM CARGO CARRIER PE ON SU UP WITH REVERSIBLE HEAD COARSE C 41% $1999999 LOT NO. 46751 LOT NO. 92655/ CO 69688/60771 YOUR MEDIUM CHOICE! LOT NO. 46752 SAVE Item 3 $ 49 LOT NO. FINE 46753 $60 92655 shown $ 269 REG. PRICE $ 99 69 $349.99 REG. PRICE $5.99 Item 46752 LOT NO. 34706 shown SAVE REG. PRICE $129.99 $150 be used with other discount calling 800-423-2567. CannotOffer good while supplies last. LIMIT 7 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 3 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or HarborFreight.com or by LIMIT 4 - Good at our stores after 30 days from original purchase with original receipt. coupon per customer per day. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases Valid through 5/28/14. Limit one Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. must be presented. Non-transferable. Original coupon R ! R ! R ! 2.5 HP 12" PLANER PE ON PE ON PE ON U S UP SAVE 28° ANGLE U S UP U S UP CO CO CO $50 FRAMING NAILER "The Price is Irresistible" LOT NO. 95082 – The Family Handyman Magazine LOT NO. MULTIFUNCTION SAVE 68068/69928 POWER TOOL SAVE $80 8 Functions: Sanding, 70% LOT NO. 68861/68303/60428 $ 69 99$119PRICE REG. Remove Grout, Cut Metal, Item 69928 shown .99 Cut Flooring, Cut Plastic, Plunge Cut, Item 68861 Scrape Concrete, Scrape Flooring shown $ 1499 REG. PRICE $49.99 $ 21999 REG. PRICE $299.99 LIMIT 4 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 7 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 4 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. R ! WIRELESS DRIVEWAY R ! R ! 45 WATT SOLAR PANEL KIT PE ON PE ON PE ON SU UP ALERT SYSTEM SU UP 1000 LB. CAPACITY SU UP CO CO SWING-BACK CO LOT NO. 68751/ SAVE LOT NO. 93068/ SAVE TRAILER JACK SAVE 90599 42% LOT NO. $115 69590/ Item 53% 61910 41005/69780 68751 shown $ 1999 Item 93068 shown Item REG. $ 1399 41005 shown PRICE $34.99 $ 14499 REG. PRICE REG. PRICE $29.99 $259.99 LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 7 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 4 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 5/28/14. Limit one coupon per customer per day. 475 Stores Nationwide 56 Power Tool-Friendly Bench Ingenious design meets 49 garage-logic construction. GST # R122988611. 44 49 Modern Plate Rack Keep your favorite china within easy reach. NJ 07646. Palm Coast. 4 merican oodworker. MA and additional mailing offices. Funds).98. $5. All rights reserved. $29.S. Subscription rates: U.S.S. 64 Finger-Joint Table Discover the small tricks to making large joints. Box 420235. Cambridge. American Woodworker®. Niagara Falls. Single-copy $6. P.98. one-year. FL 32142-0235. LLC. Palm Coast. Single-copy. Canada Post Publications Mail Agreement Number 41525524. ON L2E 6V2. 70 Finishing Red Alder 70 Four recipes create 56 70 distinctly different looks. POSTMASTER : Send 74 Oops! change of address notice to American Woodworker®. 64 16 Departments 9 9 Workshop Tips 20 24 16 Well-Equipped Shop 74 20 Turning Wood 24 My Shop Issue #170. 54 Oogloo Eggcup A fun introduction to the whacky world of 54 oogloo.O. (ISSN 1074-9152). Send returns and address changes to American Woodworker®. FL 32142-0235. 44 Curved-Front Drawers 36 Create a perfect curve using ordinary plywood and a two-part bending form. P. PO Box 456. 90 Sherman St.98 (U. Canada one-year. Periodicals postage paid at Boston.O. Box 420235.com FEBRUARY/MARCH 2014 . © 2013 New Track Media LLC. Printed in USA.99. ublished bimonthly by Woodworking Media. LLC.99 (U.. newsstand distribution by Curtis Circulation Company. Canada Postmaster: Send address changes to: American Woodworker. Funds).S. $24. New Milford. 26 ® #170. Foreign surface one-year. a homemade molding material. $29. MA 02140. U. February/March 2014 30 Features 26 12 Tips for Working with Rough Lumber 30 Recipe Box 48 Update a kitchen icon with a contemporary design. 36 Bow Front Corner Cabinet Learn how to add a graceful curve to a basic cabinet. Put a 3000 lbs. REAR LEVELING BLADE with patented geometry fills in potholes. 81734X © 2014 Dual Action Hydraulic Electric Powered 3 Point Hitch Horizontal/Vertical PATENT Call for a FREE DVD and Catalog! PENDING 0% MONTHLY INTEREST * TOLL FREE 888-213-2140 36 MONTHS * FOR DETAILS PLEASE CALL OR VISIT DRLogsplitters. LIMITED TIME OFFER. Tows behind your ATV or Lawn Tractor! Turn A Rough Driveway CARBIDE-TIPPED STEEL SCARIFYING TEETH which are 10X longer-wearing than regular steel to shave down bumps. DR® POWER GRADER POWERED ACTUATOR with static holding strength of Unpaved roads with potholes. check out the Full Line of DR® Log Splitters… anywhere you need it (up to 45 mph). Call for a FREE DVD and Catalog! 0% MONTHLY INTEREST * TOLL FREE 888-213-2140 WIRELESS REMOTE 36 MONTHS CONTROL * FOR DETAILS PLEASE CALL OR VISIT DRpowergrader. and high spots. UTV or tractor. washboard. It’s driveway REMOTE CONTROL allows you to make precise maintenance made easy! adjustments from your towing vehicle. ATV. ROAD TOWABLE With 16" DOT- approved tires you can take the DR® All New Lineup! Before you buy ANY Log Splitter. and wash-outs with loosened material. Tows the scarifying teeth to suit the POWERED ACTUATOR conditions at hand.WORLD’S FASTEST SPLITTER! DR® RapidFire™ Log Splitter PATENT PENDING KINETIC POWER The RapidFire uses twin cast iron flywheels (up to 75 lbs each) to blast logs apart in just one second! FASTEST CYCLE TIME With a full cycle time (split stroke and auto- retract) of just 3 SECONDS. LIMITED TIME OFFER.com ONLINE. ruts. . Into A Smooth Ride. the DR RapidFire is 6X FASTER than typical hydraulic splitters.are a fact of country life.com ONLINE. easily behind your riding mower. — raises and lowers 81733X © 2014 DR Power Grader to work and your bumpy ride is over. ruts and washboard . com/WebExtras AmericanWoodworker. Eagan.com/category/magazine-issues Workbench Tour Contact the editors Email: aweditor@AmericanWoodworker. personal use) without written permission from the publisher. If you would rather we not share information. MN 55121. Rueckwald Denise Donnarumma Get plans for making your own at We make center-guided drawers at V.com/WebExtras AmericanWoodworker. plus shipping and handling. FL 32142-0235. Box 420235. FL 32142-0235. Subscribers: If the Post Office alerts us that your magazine is undeliverable.com/WebExtras of your address label. please write to us at: American Woodworker. No part of this publication may be reproduced by any mechani- Find us on: Check out: cal.awbookstore. Arnett SVP. transmitted. 6 merican oodworker.com See all the features of our new bench in operation (p. See how to make miles of plywood edging (p. Eagan. AmericanWoodworker.com ® #170. cell (630) 336-0916. Please include a copy AmericanWoodworker.O.com/WebExtras Suite 180. American Woodworker may share information about you with repu- Thin-Ripping Jig table companies in order for them to offer you products and services of interest to you. stauster@AmericanWoodworker. 56) at Phone: (952) 948-5890.O. 41) at P. Back Issues Some are available for $6.com/WebExtras Phone: US and Canada (800) 666-3111. Palm Coast. MN 55121 Tim Henning.99 each. P.com/SubInfo Learn how bleach transforms wood at Tune-up required! Find out why at Email: e-mail americanwoodworker@emailcustomerservice. February/March 2014 EDITORIAL Editor Tom Caspar Senior Editor Tim Johnson Contributing Editors Brad Holden Alan Lacer Laurie McKichan Kevin Southwick Chad Stanton Richard Tendick Office Administrator Shelly Jacobsen ART & DESIGN Art Director Joe Gohman Director of Photography Jason Zentner Vice President/Production Barbara Schmitz Zero-Clearance Inserts Free Dresser Plans Production Manager Systems Engineer Michael J. or otherwise copied (with the exception of one-time.com office (708) 606-3358.AmericanWoodworker.P. International (386) 597-4387 Paper mail: American Woodworker Subscriber Service Dept. Palm Coast. Customer Service Department. Box 420235. Suite 180.com/WebExtras Newsstand Consultant TJ Montilli Online Subscription Manager Jodi Lee New Business Manager Joe Izzo Assistant Marketing Manager Hannah di Cicco Renewal and Billing Manager Nekeya Dancy Renewal and Billing Associate Adriana Maldonado ADVERTISING SALES 1285 Corporate Center Drive. 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[email protected] AmericanWoodworker. nor may it be stored in a retrieval system.. Order at www. photographic. we have no further obligation unless we receive a corrected address within one year. making it exceptionally strong with an excellent edge-holding ability. TOP-DISCHARGING is standard on all models.com . PRO-SPEC™ CHIPPER KNIFE is made of forged alloy tool steel. Call for FREE DVD and Catalog! 0% MONTHLY* INTEREST MONTHS 36 TOLL FREE 888-213-2140 * FOR DETAILS PLEASE CALL OR VISIT ONLINE. Most branches can be dropped into the hopper and will self-feed. 81731X © 2014 TRACTOR OWNERS! 3-Point Hitch models also available. step back. for easily collecting discharged chips in a container or cart. and watch it chip branches up to 5 ½" thick! SELF-FEEDING saves time and energy. LIMITED TIME OFFER. WORLD’S 1ST Self-Feeding Chipper For Homeowners Just load a DR® RAPID-FEED™ CHIPPER. DRchipper. OVERSIZED HOPPER accepts limbs with side branches — even small trees — with less time spent pruning. instead of you having to force-feed them. SANDING CAPACITY Sand 19” in a single pass. as thick as 4”. 38” in a double pass UÊ ÀÜÃiÊÌÊiÊ>ÌÊÜÜÜ°iiÛ>iÞ°V Sand as thin as 1/32”. Catalog is Now Available. T H E N E W STA N DA R D I N D R U M SA N D I N G 19-38 Drum Sander Only the 19-38 has these ExcepƟonal SuperMax Features! Indexed alignment seƫng Easy height adjustments Extra-wide conveyor Drum will never go ȟout of alignmentȟ More space for easy access to abrasive wrap Only $1399 incl. as The Only short as 2-1/4” Award Winning UÊ``ÊÌÊÌÊÞÕÀÊiÝÌÊÀ`iÀ Variable Speed Conveyor 0-10 FPM Drum Sander! UÊ. open stand! Check your with your local dealer Our Annual Hardware or order direct. Ü>`ÊÌÊÌÊÞÕÀÊ*>`® Drive Motor TEFC 1-3/4 HP Power Requirements 110V 20 amp 1-800-683-8170 www. (800) 367-3591 americanfabricfilter.com Can Your Old Dust Collector Work Better Than A New One? We Design & Fabricate Custom Filter Bags That REALLY WORK! Yes. With Optimized Filters From… • Optimum Performance • Low Maintenance Find • Custom Designs • Cleaner Air • Longer Life ® • Economical • Best Size & Fit on • Proudly Made In USA Scan to Check out our website American Fabric Filter Co.com .leevalley. D. John Cusimano Terrific Tips Win Terrific Tools! | We’ll give you a $100 gift card for every original workshop tip we publish. First. using a clamp. I’ve started measuring and marking the exact maximum opening of my clamps. using a tape. so I know just what they’re capable of handling. This strategy could backfire in a number of ways: You can forget to actually add the body dimension. opened the jaws clamp them together. Alejandro Balbis Clamp I. there’s the quick and dirty method of bend- PHOTOS COURTESY OF CONTRIBUTOR ing the tape into the corner. MN 55121. and then sure their total length. The Terrific Tip winner receives a $250 gift card. 1285 Corporate Center Drive. THE ACTUAL OPENING CAPACITY of a clamp is valu- PHOTO COURTESY OF CONTRIBUTOR able information going into a glue-up. Workshop Tips Clever Ideas From Our Readers Terrific Tip! Measuring with a Clamp ACCURATELY MEASURING the inside of a cabinet to fit a shelf isn’t all that easy. Third. Knowing this PHOTOGRAPHY: JASON ZENTNER UNLESS NOTED information avoids a lot of trial and error—especially if the dimensions of your workpiece are close to the full capacity of a clamp (which often seems to be the case). I think I invented a fourth. FEBRUARY/MARCH 2014 merican oodworker. measured the jaws from outer face to outer face. with and without their work protecting pads. Simple! Here’s what I did: I switched one of my quick. the body measure- ment may not be all that accurate. One EDITOR: BRAD HOLDEN Terrific Tip is featured in each issue. As you know. you could extend the tape without bending it and add the dimension noted on the tape’s body to the reading at the tape’s mouth. clamps to the spreader position.com or send it to American Woodworker Workshop Tips. Let me tell you about the shortcomings of the standard methods. you could use the “pinch-stick” method. Second. Eagan. remove the sticks and mea. Suite 180. This method is very accurate. We may edit submissions and use them in all print and electronic media. you’d root around for two small sticks that are shorter than the inside measurement of the cabinet. then explain what I did with the clamp. you can make a mistake in the math. this is a close guess at best. Here. Submissions can’t be returned and become our property upon acceptance and payment. E-mail your tip to
[email protected] 9 . but it’s time consuming and awkward. Most people would solve this problem one of three ways. until they just touched the cabinet’s sides. giving me better leverage without tiring my ers if this is a beneficial practice. Workshop Tips continued Tailstock PHOTO COURTESY OF CONTRIBUTOR PHOTO COURTESY OF CONTRIBUTOR Flip Your Glue Comfy Handle ALL WOODWORKING GLUES contain a mixture of ingredi- I HAD A HARD TIME turning the handle on my lathe’s ents that are held in suspension. you’d never have to flip it. In order for these glues to tailstock when drilling into hard wood with a Forst. Necessity being the mother of invention. Using a chunk of scrap. I was told that frequent hand. dict that? Richard Helgeson Ken Sharrah Square Drive Extractor STRIPPED PHILLIPS HEAD screws aren’t always easily removed using a screw extractor—espe- cially if you can’t recall where you last tucked it away. Step 1 Step 2 Step 3 Richard Tendick 10 merican oodworker. tools having this type of handle. You can then install the bit in a driver and turn the Stripped pped pp ed Phillips P qu uaarre Square e screw out. I found another solution to this pesky prob- lem using something that I always have lying around: a square-drive bit. If the diameter of the handle. It works so well that I’ve made balls for all of my rotation does indeed prevent settling. these enlarged it by adding a wooden ball. Of course. Just buy them from a craft store. I’ve started the habit of flip- ball. Just pound the bit into the screw’s head until you feel it bite. when I need to drill on bottle doesn’t have a flat top. To safeguard against this. this mixture needs to stay in suspen- ner bit. I turned a 2-1/4” dia. if you thought you’d go through your glue If you like this idea. then drilled a hole into it slightly larger than the ping my glue bottles every time I come in the shop. I put the bottle upside down the lathe. If your glue stays in the bottle for a long time. so I sion. The handle is small and uncomfortable. ingredients can settle to the bottom. This works great as long as the screw’s screw head drive bit head isn’t harder than the bit. But who can pre- any balls at all. When I asked one of the major glue manufactur- my palm. perform as intended. you really don’t have to turn fast enough.com FEBRUARY/MARCH 2014 . It fits nicely in in a can. Now. I slip the ball over the handle. To make the storage slots. 3" 12" 2" Wood block 2 2"" 9 9" Storage Part A section Cabinet hinges 3" Cover PHOTO COURTESY OF CONTRIBUTOR Data 12" 2" 5-1/8" sheet R. This allows the lid to flip all the way down so it’s much easier to access the blades. The original box used butt hinges.com 11 . you’ll need a stack of thin plywood cut as shown in the illus- trations. purpose and when it was last sharpened. The sheet tells me all the information I need about each blade.com/WebExtras FEBRUARY/MARCH 2014 merican oodworker. The original box held six blades. you need 11 A parts and 10 B parts. 2 2"" 9 9" P B Part Blade Box PROPER SAW BLADE STORAGE not only keeps your blades organized. alternating A’s and B’s. I found that it was too easy to bump them against a hinge when putting in or taking out a blade. mine has room for ten. I used cabinet hinges. such as kerf width. This project is a variation on one I found in an old issue of American Woodworker. Pierre Falzon See how to build the original box at AmericanWoodworker. glue all these parts together in a stack. I also numbered each blade and attached a “data sheet” with numbers corresponding to each blade inside the box’s lid. Starting with an A. it also helps keep a blade’s teeth from getting dinged. It’s simply a hinged plywood box with slots to separate and organize the blades. For storing ten blades. I covered the hinges with a piece of wood to protect the blades’ teeth. Here’s my simple. The long block is tape on one end to act as hinges. Kelly Neumann Mark Thiel Hinge Flattener MOUNTING DOORS using a common type of self- Steel closing hinge is frustrating. steel rod and insert Sp Sp Sprung one inside each hinge. Here’s a way to prop open the hinges while you mount the door: Cut short pieces of 3/8" dia. I prefer to roll A FEATHERBOARD is an important accessory for a table- it on instead of spraying it on. When attached to the door dowel only. Workshop Tips continued Handle cutout PHOTO COURTESY OF CONTRIBUTOR PHOTO COURTESY OF CONTRIBUTOR EExtension spring Tape hinge Contact Cement Cover Think Spring WHEN APPLYING CONTACT CEMENT. Also. I attached the liners with two pieces of masking one long and one short wooden block. but metal ones are better. There’s not as much saw. They’re “sprung” (see right photo). laminate chips in your I’ve always had with this type of featherboard is adjust- glue spell disaster. providing both accuracy and a measure of safety. I recessed these ends debris and keep it from skinning over. I came up with this variation using a 3/4" x 3" exten- posable roller tray liners to avoid clean-up. wandering away from the fence. Extension springs have a loop at ing liners seal up well enough to protect the glue from one end and a hook at the other. I fastened the spring between cover. and the short block flexes notch for the roller’s handle on the other end. if you’re wood with thin fingers sawn into the end. The spring makes to me that I could also use an upside-down liner as a adjustment less critical. I clean-up. often use one when ripping to keep a workpiece from There are drawbacks to this method. and I don’t have to deal with overspray. When you’re done mounting the h hinge door. these hinges don’t lay flat. ing it to provide the pressure I want. This feature makes it next to impossible to hold the door in the proper position. open it. against the workpiece. Mainly. The mat. apply pressure to straighten out the hinge and simultaneously drill pilot Steel dowel holes for the screws. low-tech solution. I also made a small for clamping the jig to my saw. Fred Burne 12 merican oodworker. Since I use dis. a shop-made featherboard is just a piece of skinning over between applications. it occurred sion spring from the hardware store. the glue needs to be covered to keep it from Typically. The props will drop right out. Wood dowels work OK for this. The problem trimming laminate nearby.com FEBRUARY/MARCH 2014 . into the blocks and then screwed them in place. however. T-bolt They’re attached to the base using three butt hinges. So easy to make on a lathe. was carefully designed to ensure uniqueness and reliability.95 $13. a gift that will be hard for any hunting or target-shooting enthusiast to put down.55 $11. Support Hinge Helping Hand surface “I NEED THREE HANDS!” I don’t know how many times I’ve said this when working in the shop.95 $13.95 $12. I take whatever is handy! Serge Duclos “Wow! You made a Bolt Action Pen?” The World’s First Bolt Action Pen Kit. It seems like I always need an aid to hold up the other Leg 1 end of something. The two legs are 2" x 13". no one will believe you made something of this quality in 15 minutes. Discover the joy of making this irrestibly fun Bolt Action pen. To build it. Call or go online for a FREE Pen Making DVD! Item# 1-4 5-24 25+ Chrome #PKCP8010 $12. they don’t serve any pur- pose at all.75 SAVE 16% . Base My riser block is 4" wide x 36" long.95 $12.05 $12. This riser block solves that problem. I’ve often used stacked blocks of Leg 2 PHOTOS COURTESY OF CONTRIBUTOR wood. and made from 3/4" plywood. Chrome and Gun P Action website n ou r Metal.15 Bolt action handle Gun Metal #PKCP8020 $12.15 ut our Antique Brass #PKCP8040 $14. this one is built from scrap. Every detail. from the one of a kind bolt-action mechanism to the precision-engineered components. In case you were wondering about the dadoes in the legs.95 Check oini and M new m Bolt 3 Bolt Action Pen Kit Starter Package Magnu en Kits You get one of each pen in 24kt Gold. I’d rarely find pieces at hand to get the exact height I needed. Unless it was my lucky day.95 $12.05 $11. first mill a 1/8" x 1/2" recess centered in the base’s bottom for the head of the T-bolt. plus the drill bit and 2pc Bushing Set o #PKCPBAPAK SAVE $8 Only $42.95 $13.95 $12.95 and retracts the refill! Patented Black Enamel #PKCP8030 $13.15 smoothly advances 24kt Gold #PKCP8000 $14. but that was a hassle. Then rout a 1/4" through-slot for the T-bolt’s body. It’s infinitely adjustable anywhere between 1-1/2" and 13-1/2". Like many of my jigs. A jig knob and T-bolt lock the jig at whatever height I need. This is a portable vise with a built- in clamp for attaching it to a bench. The tracks are higher than my permanent vise. and mating holes through the table’s As a precaution. so I can remove the bug. Dry Bench glue Make a notch through all of the strips in align- ment with your saw’s miter gauge slot. sometimes a second face vise is needed. While Glue 5/16" thick x 1-1/4" square spacers they may seem innocuous. An invisible blob can put a nasty dent in a mounting holes through the tracks’ ends and workpiece placed or clamped on your bench. Cut a centered 3/4" wide by 1/4" deep groove in one 2" face of each piece. drift. Bolt the tracks in place. DROPPING GLUE BLOBS on a bench is inevitable. when I need my work closer to my eyes. each with a rabbet along one edge. down the center of the grooves. The notch Blob needs to be dimensioned so that when the tracks are mounted to the table. the auxiliary vise is very handy when you ARE YOU less than pleased with your bandsaw need support at both ends of a long workpiece. they can cause problems after in between each pair of mounting strips. Workshop Tips continued PHOTOS COURTESY OF CONTRIBUTOR Notch for miter gaugee PHOTOS COURTESY OF CONTRIBUTOR Auxiliary Vise A SINGLE FACE VISE is typi. Bandsaw Fence Obviously. straight piece of hard maple over my bench to find the The only downside—and I’m still looking for blobs. Sometimes the board will actually pop off a blob. This vise doesn’t mount like a traditional face vise Spacer Space with a mounting flange that’s milled to be fastened to the underside of the bench. To make the tracks. Although that’s vise mounting usually enough. Rip each of these pieces in half. Fence cal on most woodworking Underside of benches. cut two pieces of hard- wood 2" x 1-1/4" and the same length as your table’s width. every so often I run the edge of a edges. your miter gauge’s bar Detector can pass through. fence I need to re-square it to the blade. You can lock it in place at any angle using Charles Mak T-bolts and jig knobs. such as when I’m A slotted fence provides adjustment for blade sawing dovetails. Also. an fence? This simple shop-made fence and track unforeseen benefit resulted: Because this vise is significantly system could solve your problem. gers with a scraper or chisel. I bought an inexpensive vise just for those times. Tom Caspar Len Urban 14 merican oodworker. but the best solution—is that each time I move the its main purpose is to locate them. This cre- ates the recess for the T-bolt’s head to keep it from turning. spacers. so you have four 7/8" wide strips. Drill they harden. I mounted this one Shop-Made permanently to a piece of hardwood so I could more sol- idly clamp it to my bench. it’s perfect for those times formed by gluing up three pieces of hardwood.com FEBRUARY/MARCH 2014 . 437.995 For more information call 888.Create custom inlays in as little as 15 minutes with an Epilog Laser System! Systems starting at $7.4564 or visit: epiloglaser.com/aww MADEiNUS . 888-337-8600. accurate cuts. I a dimpled low-friction base for rough lumber. 16 merican oodworker. That’s pretty impressive. there are four of them surrounding the blade. The blade appears to be in the full “on” position. I’ve often been disappointed with a jigsaw’s blade drift. This greatly increases stability and accuracy when sion. making inside or outside bevel cuts. Sound like a gimmick? That’s what controlled only with the dial. Festool’s previous model. #561608. solid build and great dust collection. the ability to use your jigsaw in conjunction with Festool | guide rails for straight. $350).) The trigger also locks I thought too. Carvex PSC or (pictured) is undoubtedly the most ingenious. up chips that could scratch a surface. from 1500 standing still.com FEBRUARY/MARCH 2014 . That makes for easy. They include to the blade guide system to help prevent deflection. (Speed on the barrel-grip version is the blade’s speed. and it’s pretty cool. which I’m glad to see. In stro- variable speed either with the trigger or by using a boscopic mode. so you can see precisely when the tip of the The standard baseplate on the Carvex comes with tooth is touching your line. the Trion.com. base is still available. brushless technology also results in cutting applications. #561668. accurate replaceable zero-clearance inserts to greatly reduce cutting. festoolusa. A guide rail adapter base gives you extended battery life. Festool. but the Carvex is an upgrade. if you already have Another notable feature on the Carvex is the LED PHOTOGRAPHY: COURTESY OF MANUFACTURER UNLESS NOTED 18v Festool batteries and want to save a little money. Then I tried it. All of the Carvex models have brushless motors. lengthwise down its center. each offering either a barrel grip or D-handle. You The D-handle version allows you to control the saw’s can have them on. You can also attach SOURCE EDITOR: TOM CASPAR a clever circle. lights. you’re cutting. and longer service life for the tool.and radius-cutting accessory to this base. tearout and inaccuracy. The cordless versions 0° to 45° in either direction with the turn of a wheel. mak- loop base with replaceable felts to prevent scratches on ing them relatively compact and lightweight. The Carvex is available in a corded or cordless ver. off or in stroboscopic mode. $350. It’s adjustable from depending on your preference. According delicate materials. creating two feet to balance $550 (tool only. Carvex PS or Saving my favorite for last. the bevel-cutting base PSB 420 EBQ Corded Jigsaw. good ergonomics. It’s an indispens- able shop staple as is. on. a hard was able to make perpendicular cuts in 3" stock with the fiber ultra-smooth low-friction base which doesn’t pick Carvex. tearout. Speed is variable. the lights flash in synchronization with separate dial. The Well-Equipped Shop by Brad Holden Festool Jigsaw THE JIGSAW is a tool that folks are still striving to improve. Also available are quickly interchangeable bases The folks at Festool have also made improvements designed specifically for different tasks. offer a tool-only option as well. to the manufacturer. With a handful of changes and options. the Carvex is unmis- takably Festool: a tradesman’s delight. It’s hinged PSBC EBQ Cordless Lithium Ion 18V Jigsaw. but most models come up a bit short. With its impeccable fit and finish. A steel baseplate is available for metal. you can literally see each tooth clearly while – 3800 strokes per minute. Festool’s new Carvex jigsaw addresses these problems with Bevel-cutting solid solutions. and a hook-and. com. ly change bits and accessories in a completely dif. Plati- 35. The K5 employs a spring. drill guide block. $140. replaceable brushes. num Edition. It’s a ratcheting. #K5. You still have to slide the clamping head up to your workpiece. securely grip. For starters. ries including a circle cutter/straight edge guide. spring-load- ed affair that’s very simple to use. standard kit as well as ing attachments. The K5 uses stepped drill bit with stop collar. ing guide were hard-to-read indentations. Bottom line: The new K5 features lots of small they’re highlighted white and are much easier to read. A Platinum FEBRUARY/MARCH 2014 merican oodworker. Dremel. spacer lay the bit in a recess and set the stop collar according to block. drill bit setup block. It’s simple. guide for easily repeatable drilling. A quick-attaching loaded knob. The 4200’s EZ Change mechanism is a collet sys- tem that works by pulling back on two spring-loaded SOURCE tabs on either side of the tool. The K5’s drilling guide has also been upgraded in a couple important ways. 6" driver bit and a start- a setting block in conjunction with the drilling guide er screw and plug pack. Kreg Jig K5. but then you just hold the back of the clamping mechanism and raise the large paddle-style handle until you’ve heard two positive clicks. the folks at Kreg have made their Áagship kit even more user-friendly. Initially. Kreg.com. releasing the collet’s grip. Older models were equipped The K5’s support wings also serve as storage boxes with a knurled knob-and-screw to change the height for for bits. The 4200 is powered by a 1. No trial and error. detailer’s grip attachment and sand- ing/grinding attachment. hex-shank the stock sizes engraved next to the recess. angle attachment. there’s the almost-automatically adjust- ing clamping mechanism. ting the bit’s stop collar. instead. The EZ Change mechanism High Performance is compatible with all Dremel accessories. The 4200 standard kit comes with a bevy of accesso. 800-447-8638. allowing infinite adjustment anywhere from 5000 – $130. The folks at Kreg also changed the method for set. I still preferred the old method. screws and accessories. which makes height adjustments quicker.6 amp motor with standard kit.Improved Kreg Jig POCKET HOLE JOINERY has been synonymous with the name Kreg for years—in a good way. This kit includes all of ferent way. you won’t lose much valuable time chang. Edition is also available. adjustable stop. Tool-Free Dremel Dremel’s new EZ Change mechanism lets you quick. Rotary Tool. With the new K5 jig. Their jigs have always been affordable and easy to use. 800-437-3635. And there’s no need to reset the clamping head until you change stock thickness. The dust port swivels different stock thicknesses. It features a variable-speed dial #4200-6/40. positive and quick. right $219. With the new 4200 High Performance the accessories in the Rotary Tool. to name a few. you’d extension wings. 4200 ping the accessory’s shaft. the graduations on the side of the drill. dremel. improvements that make the jig faster and easier to use. On the K5. That’s it. for optimal vacuum hose positioning. nor will you lose the confounded a flex shaft attachment wrench—there isn’t one! and a deluxe case. dust port. adjustable stop can be used on either side of the drilling On older models. The K5 kit includes the base with ratcheting clamp. Releasing the tabs re-engages the collet.com 17 . #4200-8/64. kregtool. On the previous version. but have since come to like SOURCE the K5 way.000 RPM and a separate on/off switch. and ing into a tight recess or an angled corner. belt hook. $68. The 1/4" chisel has a 30° primary bevel. #05S26.40. These chisels’ blades are made from PM-V11. 1". SOURCE Lee Valley & Veritas.com. All have 2° micro-bevels. Other features socket-like stainless-steel ferrule that seats directly on the include tool-free drive depth adjustment. 1/2". $84.60. 800-871-8158. (1/2".com FEBRUARY/MARCH 2014 . dry fire blade’s shoulder. & 1-1/2"). such as the mortises for butt hinges. #05S26. 1-1/2". slippery.04. $74. This is a powdered metal alloy chosen by the folks at Veritas after Hose-Free Nailer very thorough research to find the sweet spot between edge NO HOSE? No compressor? Now that’s an idea retention and ease of sharpening. 18 merican oodworker. some woodworkers find that their shorter length offers improved control. I’ve also done enough fin. The downside is that. set of 3 2" Brad Nailer. leevalley. you better have your belt snugged up tion. Though butt chisels are technically a purpose-made tool. 5/8" to 2" long. ish carpentry to know that I wouldn’t miss lugging and only require final honing before being ready for use. I use them for chopping dovetails. #05S26. As trusting as I’ve become. I still swipe the the firing mode to fire a single nail with each trig. #05S26. $219. PM-V11 sits pleasant surprise. The Well-Equipped Shop continued Veritas Butt Chisels BUTT CHISELS have shorter blades than bench chisels and are generally made in wider sizes. LED work light. I’ve come to realize through It’s also got some serious features that you experience that when the folks at Veritas say flat. They’re typically used for outlining and removing the waste from large areas. set of 6 (all sizes). The new Ryobi One+ 18 volt by Veritas. SOURCE 1/4".24. which cover most woodworking The blades have beveled edges for clearance when work- nailing tasks. ryobitools. however. 3/4". quicker and A2 being significantly more time-consuming.08. with the finish carpenters as well. they mean might not expect at this price point. I know I wouldn’t miss the blades about 3" long.. As for ease of sharpening. albeit a little lbs. blade’s back across a fine stone a couple times just for the ger pull. $105. nails per charge. PM-V11 Butt Chisel. $78. with 01 tool steel taking an edge a little The One+ nailer shoots 18 gauge brad nails. a compressor around or inadvertently dragging a dirty air hose across someone’s furniture. 2".12. 800-525-2579. The handles. or set it to bump fire. $439. The magazine holds 110 nails. #05S26. These new butt chisels from Veritas are beautifully made and a pleasure to use. Each blade is lapped flat. $130. largely because of The hard maple handles have been treated by “torrefac- the battery. while the others are ground at 25°. 05S26. PM-V11 outperformed both A2 and 01 tool steel Brad Nailer with Ryobi’s AirStrike technology is a in edge retention. I think it could be a direct hit for woodworkers and Overall chisel lengths range from 7-1/2" to 8". are nicely contoured and have a domed end to Clearly. 1". You can set flat. but resist chipping from glancing mallet blows. $95. low nail indicator and a from rotating.com. Ryobi. like a dovetail.32. this tool is aimed at the DIY market. about twice as much as its pneumatic cousins. In extensive blind testing I can get behind. the trigger and drive a nail every time you bump The blade and handle are connected with a tang and the nose against your workpiece. between the two. #P320.” This heating process stabilizes the wood and helps an extra hole or two.16. 18V One+ Cordless #05S26. with flats on the tang to prevent the handle lockout. This nailer weighs almost 7 prevent swelling and shrinkage. #05S26. where you hold satisfying proof that I don’t have to spend any time lapping. shoots up to 60 nails per minute and up to 700 The bevel is full width and tapers to a point—a nice touch. noise of a compressor. Multi-Function Router Base A ROUTER BASE can be nothing more than just that: a base.com.com. keter. 888-374-4262. $30. On its own. With the MKIII kit. as is the case with a cen- tered base. A short edge guide that fastens to the base is also available. the CRB7 is a solid. it can be outfitted to help your router perform a multitude of other functions. I thought it’d be a good time to reintroduce the CRB7 for those who don’t know the versatility it can add to your router. where the base size doesn’t count. #17182239. $110. and the ability to cut larger circles. With the launch of the new accessories. Edging/Dowel Trim Kit. Edge Guide/Side Fence Kit. as opposed to just under half. you SOURCE can cut centered or offset mortises. CRB7 MKIII Combination Router Base. You can set it up in no time. you’ll be able to rout perfect circles with a diameter as small as 3/4" to as large as 50". Using a set of posts attached to the base’s underside. the previous dado. There’s a little bit of wobble. It attaches to your router via two rods that go in the slots where you’d attach a stock edge guide. A large base increases stability when you’re routing an edge. well-built accessory. I’d like to see a kit that includes all of the a series of parallel dadoes is a snap.com 19 . The Folding Work Table has a unique pop-open design. The most obvious benefits of the CRB7 are its large sur- face area and that it’s offset. It only weighs 27 lbs. The offset amplifies that stabil- ity by putting about two-thirds of the base on your work sur- face. but the MKIII kit has a couple of important additions: two differ- ent-size guide rods to fit more routers. When you’re done working. FEBRUARY/MARCH 2014 merican oodworker. This micro-adjust feature is also great for use with any clamp-on style edge guide for routing dadoes. use the adjustable anti-tilt leg to provide stability. SOURCE Keter. and according to the manufacturer. Or. Using the micro-adjust wheel. it’ll support up to 1. kit. you can precisely dial right up to a line to adjust circle size. m-powertools. as in the case of the CRB7 MKIII kit from M. routing affordable package.000 lbs. the table and all its parts fold up flat—just under 5" thick—in less than a minute for easy storage. Briefcase Work Table HERE’S A REALLY FRESH TAKE on an old idea. The Keter Fold- ing Work Table is a boon for folks with limited work space who need an auxiliary bench from time to time. $80.Power. as the guide slides in available accessories. It’s 29-3/4" tall—the perfect height for lots of benchtop tools. With the MKIII edge-trim MPower. Folding Work Table. The Keter table has a generous 22" x 34" work area. Another cool feature is the two includ- ed quick clamps. They can be inserted into channels in the work surface for holding your work. as well as a stor- PHOTOS BY JASON ZENTNER age shelf to keep the tools you’re using close at hand. Using a Bottom line: This is a whole pile of jigs in one relatively shop-made guide attached to the base’s underside. ing or plugs. $20. For routing on the edge of a narrow workpiece. but less than you’d expect for a folding plastic table. The CRB7 router base has been around a while. you’re also set up for precise flush-trimming of edge band. page 23). such as the bottom’s shape. Let the glue EDITOR: TIM JOHNSON cure for a day. Choose a faceplate to dedicate to the chuck (see Sources.) Learning to keep the chuck from dictat- ing key aspects of the design. This shop-made trapping chuck will dramatically improve the quality of your work in both of these important areas. It allows full access to the bottom of a bowl or vessel and frees you from limitations caused by a faceplate or any other chuck. is another important skill. rings of different diameters are used to clamp work of different sizes. Turning Wood by Alan Lacer The Trapped Reverse Chuck How to build and use this must-have bowl-turning jig. for chucks 14" to 16". I suggest at least 3" dia. the “bottom” includes the lower outside por- tion of the piece as well as its underside. This chuck securely holds the work. Typically. GOOD CRAFTMANSHIP requires that the bottom of a turned bowl or vessel shows no evidence of how it was mounted. Start by gluing together two thicknesses of 3/4" Baltic birch plywood to make the chuck’s base. diameter and height. 6" dia. Size the | plywood to make a disc that’s slightly less than the maximum diameter your lathe allows. so it can’t go flying across the shop—a benefit that’s absent from most other such chucks. Use yellow wood glue. (In bowl turning.com FEBRUARY/MARCH 2014 . Then bandsaw the disc. both shop-made and commercial. 4" dia. PHOTOGRAPHY: JASON ZENTNER Make the chuck’s base This chuck has two basic parts: a base on which the work is mounted and a ring to clamp the work to the base. for chucks up to 12". for 18" to 24" and bigger still for lathes with larger capacities. Larger faceplates increase the 20 merican oodworker. Then draw lines (Photo 5). four slowly. shaped sections that are (roughly) equal at first. Then “key” location. make thick Baltic birch plywood. As before. Mark across the face to flatten it. Then flip drill these holes. transfer the of a skew chisel (Photo 2). and ners or splinters. The 1/4" ular to the axis of the lathe. the outermost ring you cut earlier and they depend upon the piece you intend In order to hold the work. the disc space the holes 1" apart down to the 4" to hold. disc on a flat surface. Mark this disc to index its more adjustability. Tack acckk Index Inde In dex marks 4 5 Hardboard rdb rd bo o disc Mount a hardboard disc of the same diameter on top of the Drill through the hardboard disc at every hole in the plywood base. but I end scraper to true the disc (Photo 1). For slightly starting about 1/2" from the rim and (Photo 4). Use a square. over the assembly and use the holes in index marks to the plywood disc and FEBRUARY/MARCH 2014 merican oodworker. Start at on the ring are the two variables. With the lathe running at slow Cut the plywood into discs the same speed (less than 400 rpm). Center the faceplate on the disc and that divide the disc’s face into three pie. rings and larger diameters. Drill 3/8" dia. (Once you start using the chuck. stability of this chuck. so always err Remove the faceplate and place the the base to drill through the hardboard on the larger side. so work lines—this mark will be used to index the same diameter as the base. der. mark. The size of the center hole using a sanding disc mounted in a drill holes along the three lines for the bolts and where the drilled holes are located to make sure the rim has no sharp cor. edges. Finish by power-sanding. Cut the rings from 1/4" or 3/8" must have a flat surface that’s perpendic. Permanently mark one of these you’ll make many more. Skew Sk chisel Sk 1 scraper 2 3 Flatten the face of a large plywood disc Cut shallow grooves to deepen scored Drill holes through the disc on lines that to create the chuck’s base. of solid dividers (see Sources) held flat Attach a hardboard disc to the base to Then use the template to mark the bolt on the tool rest to mark lines every 1/2". using the jig.) Cut four rings poorly and dulls tools quickly. Use a new or very sharp bit. and two half gouge sharp. Then turn the disc to a cylin.com 21 . Lightly scrape lines made with dividers. sure it’s perpendicular to the drill press stock is fine for smaller chucks. table and install a flat sacrificial board tend to go to 3/8" or even 1/2" for larger Then lightly sand the surface. as well as its outside face bit that’s 1/64" larger than the bolts to deepen these lines with the long point (when mounted on the base). mounting the diameter. Scored cor ore ed d lines IIndex In n m marks Square-end Sq quuaare re- e. Add marks to index this disc to the base. using a tack in the center and double-sided tape near the base to create a template for drilling the chuck’s rings. using a bowl gouge. one line of holes to index the rings. I sometimes use a stopping about 4" from the center. skew with its long point down. create a template for making the rings holes for drilling (Photo 6). underneath to eliminate tearout. Plywood turns in size. use a pair Make the rings diameter as the hardboard template. make light cuts and keep your the other parts when building and two-thirds the diameter. that will hold the ring (Photo 3). Orient the divide it into three equal segments. Plan to cut between five and 10 rings mount it. Rings between you! Press the hose on—its natural curl bolts. this chuck. Then cut three 3/8" coarse-thread bolts. If the bolt is slightly too long (so Wear a full-face shield and engage the marks (Photo 10). I knife or scissors. sand all their edges and clearly mark Does the center opening sufficiently Reinstall the faceplate on the chuck’s the index points. to locate the holes on another plywood rings after bolting it and the template on Cut out the waste at the center. using a sharp and wing nuts in 1/2" increments from rings. Lightly tighten the wing nuts to After all the rings are cut. Note: The tub. without contacting the bowl? lash all three pieces together using 3/8" ing’s size will vary with the rings’ thick. secure the work. date on the work with the index marks nut. you’ll need bolts ers and wing nuts. make sure its threaded create each ring. With one washer on the ring under Cut through the plywood disc to the bolt’s head. start by roughly Install the ring and use it to clamp the plastic tubing that’s been split with a centering a bowl on the appropriate bowl to the plywood base using bolts. will hold it in place. Cut the tubing about 1/8" shorter of many different lengths to use with Mark each disc for cutting into rings than the circumference of each hole. For the 14" chuck shown here. too. mark its outside face. groove cut in the base. Run the lathe at Set workpiece rim-down on the chuck the base to install a washer and wing 500 rpm or slower during this process. Vary the center opening’s size Observe how the hose curls. I recommend buying sets of (Photo 7). Template Index m marks Base Large ring SSm m Small rri in in ring C Cee Center TThin-kerf Thh ccutout cuu par pa r parting tool 6 maark m arrkk Index mark oo ood disc Plywood 7 8 Use the template and a brad-point bit Mark the plywood disc for cutting into Cut through the disc to create the rings. Then tubing to line 10 rings.com FEBRUARY/MARCH 2014 . wash. and center it using the circular cut nut. Select the right bolts. lightly and holes in alignment (Photo 11). every bowl is different. washers in each ring. these sizes can be made as necessary. Lay the hose down 2" to 8". Clear plastic tubing Index marks aligned 9 10 11 Line each plywood ring with clear To use the chuck. use additional washers under the wing cut-through disc in place. Some discs will yield two on the back of the curl. making certain the base mounts opening in each ring with 3/8" i.d. with all the (Photo 9). 22 merican oodworker. clear to both its lower outside portion and its flush. You’ll need about 20' of this tioned to allow the bolts to pass through index marks properly oriented. using a thin-kerf part. Lay the hardboard and one of plastic tubing from the hardware store underside? Are the drilled holes posi- the rings on top of the base. the base and installing them on the lathe. Then cut disc. Then decide which its unthreaded shaft appears). Use the chuck portion sufficiently protrudes through ing tool (Photo 8). the small ring to create the large ring. As nearly x 2-1/2" long coarse-thread bolts. utility knife. substitute carriage 12" in 1" increments. it’s OK to tailstock (when possible) to hold the ring to use by placing each likely candi. Index this disc. washers and wing nuts. Then line the center grip the bowl while allowing full access base. ness. If having bolt heads whizzing made rings with openings from 3" to and cut with the blade going away from past is unnerving. Position the work on the padded pipe. $5. right). Rotate the chuck by look of the work’s underside. A few years later already marked the center on the diameter (Photo 13). Router Mat. hand. Dividers. thin walls or delicate rims (above. Then nudge surface. tighten the wing nuts wing nuts. One method is to use a sim. #W1320. the work even if it doesn’t have a center Pull back the tailstock and plan the •Oneway Manufacturing. visit alanlacer.95. you’ll also be changing the you can simply bring up the tailstock work’s height. add details such as beads spot by pushing or tapping at the line’s or lines or any other surprise you may midpoint. Use a scraper to lightly face off the protruding end of the pipe. High spot Rub Ru bb b Rubber pad pa pad 12 Center the bowl with the chuck mounted. the work slightly away from that high hollow a foot. For more the piece. Special Thanks work onto the lathe.com.com. When the work is centered place it the bench. Screw the chuck and mounted and bring up the tailstock center. It’s helpful to have portion of the work and finalize its base in a book written in the 1960s. is centered (or very nearly centered) the to complete the work. Thin-Kerf Parting Tool #10336. mark (Photo 12). 4". as opposed to a fully flat •Grizzly Imports. Place a pencil on the tool rest and bowl or vessel to sit on a rim. Then remove the information. base to remove mounting holes on the refined this idea. If you cut in at the Hawaiian turner Jack Straka developed and underside.95.95. to align the hole on its underside with tions. With this chuck you can deep. slowly move it forward to mark the high footed or not. There’s no need to run SOURCES and move the work within the chuck the lathe very fast during these opera. Mount Unusual Shapes This chuck can be used to mount work with natural edges. machine. 135403. FEBRUARY/MARCH 2014 merican oodworker. the tailstock’s center. bolts and ring. $35. Then underside. Gently tap it as PVC pipe necessary and then tighten the wing nuts. spot on the rotating work. Then glue on a 1/8" thick piece of textured rubber (such as a router mat) with CA glue. install a ring and you’re ready to go. grizzly. left). Finish-sand Alan Lacer is a turner. 8" $114. it’s fairly easy to center portion of the work as necessary. Rotate the chuck and test wish to give the viewer. You can also again with the pencil. Thre Th hre reaad d Threaded du dule ule l 40 Schedule rod Mark the high spot.95. 13 You can also mount tall work by using threaded rod with washers and nuts on both ends (above. 800-523-4777. Fortunately.com. 3" $46. Faceplate.95.95. I like a oneway.50. ple center finder (see Sources). Wis. Most other reverse chucking Use this chuck to create a hollow base with a systems don’t have this capability. as you have a lot of mass on the packardwoodworks.com 23 . Center Finder #135510. •Packard Woodworks. Finish-sand the newly turned $21. 6". add lines or beads. (or very nearly). Remove the demonstrator and instructor liv- line will travel fully (or mostly) around chuck with the work still attached and ing near River Falls. $52. $10. 800-565-7288. Then center the Finish turning the lower outside Eldon Rebhorn showed a version of this chuck work to the lathe. writer.ca. 800-683-8876. remove screw holes and chuck marks or fully round the bottom. 8".95. whether $68. Cut a groove in the face of the chuck’s base to tightly house a short piece of Schedule 40 (thick-wall) PVC pipe—usually just long enough to raise the work’s rim off the face. When the work fully round the underside. rim. wonderful place to sit while I’m hand sanding or carving). I’ve also set up a workbench and tool space for ask. as I spend time in the shop every where I’m able to teach classes for some of the ladies in the day. In fact. a bath. A workbench | EDITOR: TIM JOHNSON My 1.com FEBRUARY/MARCH 2014 . that my father built from an ash tree he cut down on our yard room and an attached greenhouse with a covered patio (a is one of my favorite places to work. Un. either had to set up and tear down every time I worked in the My father and grandfather were both woodworkers and shop or park the car in the driveway until a project was done. “When are you coming home?” my grandson. shop includes a finishing room. county fair!) I use the Shopsmith’s tablesaw. Now I have a wonderful space certainly a great trade. version that I recently built as a project won ribbons at the working. (A miniature I trimmed its soffit with cutouts of girls enjoying wood. I could build my what I learned by watching them was far better training than dream workshop next door to our house instead. My trusty Shopsmith—which I’ve upgraded by adding There’s also a small alcove with room for a table and chairs. jointer. I never had any woodworking classes. watching as they built In 2007 my husband said that if I’d give up my dream of beautiful projects. I grew up in an era when girls weren’t allowed bench and my Shopsmith tucked into a corner of the garage. I to touch power tools. something that I dreamed about as a child. ft. 24 merican oodworker. My Shop Where Our Readers Live Never Too Late PHOTOGRAPHY: COURTESY OF NANCY BALLANCE Fulfilling a childhood dream. FOR MORE THAN 30 YEARS my workshop consisted of a work. larger tables—is still one of my favorite tools. fortunately. but buying a motorcycle for my 60th birthday. who will carry on the tradition. lathe.000 sq. This was I could have gotten anywhere. I used to sit in their shop for hours. some days my husband calls from the house to community. Submissions saw and a corner storage rack that holds branches I’ve collected cannot be returned and become our property upon for the walking sticks that I carve. Hamilton. bles. Please include your phone number. I’ve also myshop@americanwoodworker. Tell Us About Your Shop Send us photos of your shop. a pair of rolling work ta. It also doubles as a stand for my scroll saw. you’ll receive $100. photos on a disk to My Shop. slides and raises up Email your entry to and down. a downdraft sanding table. the cabinet that houses the miter 1285 Corporate Center Drive. Or mail your description with digital racks and a rolling rack for sheet goods. a layout drawing and disc and drum sander functions most often. Montana FEBRUARY/MARCH 2014 merican oodworker. for shop important to you. including vertical lumber storage photos attached. it for specialized drilling operations such as horizontal boring. American Woodworker. Suite 180.com with digital built many other shop projects.com 25 . Eagan. shop. its Tell us what you make in it and what makes your molder and shaper functions have been replaced by routing. Although I also use a description of what makes your shop interesting. If “My Shop” features your the most part. I retrofitted the Shopsmith’s old tables with a custom-built stand to create a unique worktable that tilts. We may edit submissions Nancy Ballance and use them in all print and electronic media. MN 55121. acceptance and payment. a combination or general-purpose blade does a pretty good job of both ripping and crosscutting. Old-style guards were truly a pain to install and remove. forrestblades. Use your guard! Use your guard!! If you’ve ever traded shop horror stories with other woodworkers.com.com FEBRUARY/MARCH 2014 . I did. I switch to a dedicated blade for ripping. Modern guards are a different story. you won’t have a problem. The slices are about 1/4" thick. consider using a thin-kerf rip blade. 4 Give a Rip All you need is just one tablesaw blade. If I’m working with boards that are more than 1-1/2" thick. SOURCE Forrest Saw Blades.12 1 Safety First Tips for Working with Rough Lumber Use your guard. Pushing the wood is much easier. it requires less power than a standard-kerf blade because it removes 25% less material. a little bit at a time. most convenient and easiest-to-use method I know for reducing drag. Cut them off before you do any other crosscutting. As each slice falls off. too. such as the one shown here. easy to deal with. I’ve tried sprays and powders as well. If you have a contractor’s saw. 26 merican oodworker. usable length of your board. sometimes it’s worth it. so I use mine whenever I I cut off the end of a board can. so but you may also find hairline cracks I can understand why most woodworkers relegated them to a that aren’t clearly visible on the board’s dusty shelf. Should and dulling it. If the slice breaks very easily across the grain. 800- 733-7111. Large checks are easy to see and remove. paraffin is available at most grocery maintain a reasonable feed rate. The vast 2 Beware of Checks by Tom Caspar Cracks in a board’s ends are a common flaw. majority of those accidents would never have happened if a These cracks are also called end checks. but I keep going back to paraffin. so you know the true. 10" Thin-Kerf Woodworker II 30-tooth rip blade. Unlike beeswax or carnauba wax. Perfect for thick PHOTOGRAPHY: JASON ZENTNER wood. A rip blade requires less horsepower from your saw’s motor and less manpower from your muscles. I always keep a small piece of it in my apron pocket. you know how often people are injured by their tablesaws. $107. I hope you will. it won’t contaminate there’s less chance of burning the your wood. and who wants to go 3 Paraffin Lube Rubbing a small amount of paraffin wax on a jointer or planer’s bed is the cheapest. They’re surface or end. WW10307100. stores. any traces of it be left on your wood. just like a seatbelt. I inspect it for checks. through the hassle of changing blades all the time? Well. guard had been on the saw. it probably contains a hairline check. Paraffin isn’t a true wax—it’s made from wood or overheating the blade petroleum—so it’s compatible with almost all finishes. When you can Sold as canning wax. too. like slicing a loaf of bread. right? After all. Feeding the machine is easy! Grain direction irecttio ionn Save money by making your own zero-clearance inserts. too.5 Enlist Your Bandsaw Rip wide rough lumber on the bandsaw—especially when the wood is cupped or twisted. The line means “Start here. a loose piece can get stuck between the blade and the plate. After jointing one face of each board. If you’re the fence before you even start jointing. and where you put pressure depends on whether its original edge was concave or the blade will stall.com 27 . If it falls all the way through. collection—particularly if your blade has a shroud around it. it may come shooting straight back at you. because a bandsaw can’t kick back. here’s another reason to just do it. I rip cuts will remove only a thin slice of wood. None of this will happen on a bandsaw. stop a minute and orient its mark the same way. you’ll know motor. to the planer. If the cut binds. Each time I add a board to the stack.com/WebExtras FEBRUARY/MARCH 2014 merican oodworker. exactly how to handle it on the first pass. but a mark on its end grain won’t be touched until you trim the piece shorter. 7 Switch Throatplates A zero-clearance insert will prevent thin offcuts from dropping down into your saw. the wood will burn. it’s not a bad idea to place your board against Ripping thick stuff requires power. If you can tell thinking of upgrading to a larger bandsaw with a beefy whether its concave or convex right away. This method is much safer than using a tablesaw. Using a standard throatplate. and that’s not a risk worth taking. 6 Check Your Progress Use the fence to make sure your edge is straight when you’re done jointing. You have to hold the board the right way. a loose piece can also clog up your saw’s dust 8 Mark the End Grain When you’re jointing. Ripping an uneven board on a tablesaw may cause an injury. Running a board through a jointer doesn’t automatically make it straight. and if things are convex. In fact. When I wheel the cart over put in a zero-clearance insert. It’s better to check your progress. the grain direction of each board is pointing the same way. I mark it and Standard throatplates are fine most of the time. Learn how at AmericanWoodworker. requiring you to stop and turn off the saw to remove the little offender. really bad. however. using the fence. but if your stack it on a cart. instead. mark each board’s grain direction by drawing a line on its end. than to just assume that everything is going well.” A mark on a board’s face or edge can get erased by a planer or jointer. com. this wastes wood—but it always works. plane here he h e are 3" extra-long on or rip shorter stuff. exactly? Put big rough-sawn board into together. and then start milling. This is an attempt bottom edges of the boards must be sawn or jointed square to fool your planer into and straight. Here are three strategies: extra in width. Tipping isn’t a problem with of a board. This method won’t fix a crooked piece! It’s best to thinking it’s just cutting joint your pieces first. Overlap your boards. These pieces but not always. Start with boards that because it’s unsafe to joint. Stacking four boards together The problem with the gives you a measurement that’s big-board strategy is that the even more accurate. 6" Starrett hook rule. When the board is whole. don’t snipe in the middle Won’t they tip over? Yes and no. Butt your boards end stack that must be milled to a consistent width. Of course. may not balance well. (I prefer using one with a hook on it. Each half seeks a new balance and a new shape. rip the board. The feed rollers will only engage the thickest board. See Source. It’s better to cut a But how much less. however. or boards method usually works. 3. Which means the part on your cutting list. 28 merican oodworker. Thinner boards. Cut off the Snipe snipe when you’re done 11 planing. Sure. leaving the other one stranded. you to move fast when feeding the beast. it’s worth a try—although it’s not a surefire cure. that are over 4" wide. Planing on Edge Run boards on edge through a planer when you have a 2. This method also attempts to fool the machine. both ends. Why? Some boards have a lot SOURCE of stress built up inside them. It won’t work on the first pass.9 Cut Big Boards into Small Pieces You might think that the best strategy for milling rough lumber is to flatten as large a piece as possible. When you $30. the to end. I don’t cut any pieces less than 12" long. 12 It’s hard to predict which boards will react this way. you release some of that stress. rip them about 1/16" extra-wide. more “bit less” is precisely 1/32". so I assume 3 Ways to Beat Snipe every board could present this Planers create snipe by taking an extra-deep cut at the problem. when your boards are different thicknesses. MSC Industrial Supply. Not true. below. beginning or end of a board. so it’s I always cut my individual natural to treat snipe as one of those problems—like the pieces slightly oversize. do they?) This boards that are 3/4" thick or more. this 800-645-7270. Once your boards are all the same thickness.com FEBRUARY/MARCH 2014 . (Planers take them to the planer. It requires should not be planed on edge. right? or less. We just have to adapt and 1/2" extra in length and 1/4" learn to deal with it. If one is off by a little bit. then one long board. one for each on the nose. two will be off by twice as much—which is easier to read on a ruler. thickness—a bit less than 3/4". Cut C 1. mscdirect.91. Many machines do it. adding common cold—that can’t be cured. they measure 1-7/16" individual pieces. from end to end. stress is in balance. 10 Measuring Thickness Two boards are better than one when you measure thickness.) These boards are the same then cut it into smaller parts. if you get the smaller pieces you cut from it math right! may not remain flat or straight. 60-Day Free Trial. you’ll find FREE TRIAL tthe life stories of masters of the craft. MO 64120 . PLANER stock. 1431 N.com Toll Free 1-800-821-6651 Ext. sander. planer. GANG RIPSAW com or 1-800-876-1822 awbookstore. picture frame 2.com/AMW Like Having a W From the editors of American Woodworker magazine. No more • PEACE OF MIND. OODWORK Lumberyard Right in Your P E O P L E | I D E A S | N E W W O R K Shop! M A G A Z I N E Woodwork Wo W is the only magazine solely ssole devoted to the artistic side of 60-Day wo w woodworking. Made in USA! FREE DVD & BUSINESS G Get your copy now at STARTER KIT! 4..com awbookstore www. Burn SAFELY with the Stainless Steel Portable Burn-Cage™ Perfect For… • Old Leaves and Branches • Sensitive Financial Documents • Burnable House- hold Waste • CLEANER MORE EFFICIENT FIRES. High burn temperatures mean thorough incineration with 81730X © 2014 less residue and ash. rretr retrospectives of their work and the 4-WAY MONEY llate latest in studio art furniture. Quickly CONVERTS to molder. PX62 Woodmaster Tools. Perforated lid and sidewalls maximize airflow and trap burning embers. Topping Ave. 12". turn a $5 board into $75 1. Barrel! SPECIAL OFFER for AMW Readers: SAVE $ 70 Use phone # or URL below to save $70 off list price! 877-220-0691 EXT: SY90 Burncage. • LIGHTWEIGHT and portable. custom work. saw. tongue & groove. Inc. Kansas City.woodmastertools. DRUM SANDER Warranty. MAKER! Now. It’s the UNSAFE Rusty SAFE way to burn. 18" & 25" models. 5-Year 3. MOLDER worth of high-dollar molding in less than one minute! Over 600 patterns plus curved molding. In its pages. on the tabl tablesaw. (Most the wedged tenons—the wedges are fake.Curved-Lid Recipe Box Update a kitchen icon with a contemporary design.com FEBRUARY/MARCH 2014 . in which a fence clamped at ing packets of oatmeal. The same goes for the through mortise-and- drawer. she transferred tenons are cut on the tablesaw. (By the way. when recipes or a drawerful. To get organized. this drawer tenon joints: The mortises are template-routed and the is stuffed absolutely full. for example. blank across the blade at a 90° No cooks in your house. The curved lid may look challenging to make.) Make the lid (A. This may sound crazy. To shape the lid works as a recipe holder inside of the lid. Cutting I designed this box to hold List. you can use this method to hollow a 30 merican oodworker. Don’t worry about fitting the recipes onto 5x8 index cards. but it’s In this case. angle. recipes that are handwritten or clipped from magazines are Shape the curved lid too big to fit on 3x5 cards. whether length provides a short test piece the box holds only a few that will be used later. A. by Richard Tendick EDITOR: TIM JOHNSON | PHOTOGRAPHY: JASON ZENTNER | ILLUSTRATION: FRANK ROHRBACH EVERY RECIPE E my wife clips or copies goes in her “recipe the tablesaw. page 32) from a 1" thick the cards in style. the fence is clamped perpendicular to the actually pretty easy. blank that’s 9" wide and roughly An adjustable clip keeps 13" long. but hold? This box still warrants it’s actually just a variation of the a place on your countertop.” As she’s an inveterate recipe collector. Use it to traditional method for cutting coves tradi store coffee or tea. The you mount the lid. you’ll pass the when it’s open. an anglel to the h blade is used to guide the work. Fig. because most of the work is done on blade. orr single-serv. The blank’s extra the cards in place. Initial cove cov cut 3 4 Extend the initial cove cut to complete the hollowing process. this piece on the blade and attach it ing coving cuts on Make the first cut by sliding the to two miter gauges set at 90°—this blank slowly and deliberately across keeps the fence rigid and holds it per. Two miter gauges Lid Curved blank profile Magnetic clamp 1 2 Start shaping the curved lid by removing excess material from Use a 90° fence to hollow the bottom. whether it’s made a blade with flat-topped teeth to hollow the blank. This reduces the amount of planing you’ll cove at the center by pushing the blank across the blade. Lower the blade wide and slightly more than twice the so that it extends only 1/8" above the length of the blank (Photo 2). raising the blade in magnets switch on and off to provide both strong holding 1/8" increments. Then remove the waste on the terpoint of the exposed portion of top of the lid by making a pair of 15° the blade on the saw’s table and place cuts (Photo 1). To complete the hollowing. the center of the blank on that mark. until you reach the profile line. Start by cutting a shallow the top of the blank.) blade is best. Then mark the cen- pletion. you’ve drawn on the end of the lid. Do not force the switch magnets in a pair of blocks cut by moving too fast. Then make and attach them to the fence. passes. the tablesaw. Raise the blade to the height of the coved profile face for the blank to ride on as its coved shape nears com. table. simply extend the cut to For the smoothest results—and the least sanding—use both edges. Shape the lid’s curved top surface with a block plane and then Reposition the fence. Turn the blank end-for-end to cut both sides. page 35).com 31 . while incrementally raising the blade. Install Mag. the blade while holding it firmly pendicular to the blade. teeth mounted between alternately beveled teeth will also B). curved lid or door of almost any size. lower the blade and make additional smooth the surface by sanding. Then have to do later. work. against the fence. (see Source. Center of the lid by mak. but a combination blade with flat-topped Draw the lid’s profile on both ends of the blank (Fig. make additional passes. A rip from a single piece of wood or coopered. Note: power while cutting and easy adjustability between cuts Adjust the fence as necessary to keep the cove centered. These additional cuts. Build a fence to hollow the blank Move the fence up to meet the blank using a piece of 3/4" plywood that’s 2" Hollow the bottom and lock it in place. Reposition the fence and repeat the process FEBRUARY/MARCH 2014 merican oodworker. Leave 1/2" waste on each side to provide a stable sur. on top of sand the top and then cut the lid to final length. Install setups to finish the job. holes at both blank from each setup by turning the blank end-for-end. A Exploded View 1/4" 1/8" BRASS ROD (TYP. Then cut off the waste on both sides 1/4" up-cut spiral bit to rout the mortises in the end pieces so you can shape the top of the lid (Photo 4). remove the saw your router table to finish routing the slots. Save the a sacrificial board. Position the template on top of the end curved offcut. B E RECIPE CARD HOLDER Lid Profile Cutting List Overall Dimensions: 6-5/8" H x 9-1/4" W x 8" D 13-1/8" Part Name Qty. Then clamp the assembly to your Rout mortises and slots bench.) C B D 3/8" 1/8" BRASS ROD 1/2" Fig. 1/2" of making cuts while slowly raising the blade to match on the template.com FEBRUARY/MARCH 2014 . ends of all four slots. Carefully lay out and the template and repeat the process to rout the remain- drill the four 1/4" dia. (B. Then follow the same procedure as for against the three dowels and use the two sides that touch routing the mortises. A Fig. rout consistent mortises and slots in the box ends (Photo Plunge-rout the first three mortises. Finish. b) Length includes 9/16" long tenons on both ends. using the guide 5. Fig. C). Use these two lines to locate the three the coved profile (Photo 3). move the template’s bottom indexing pin to the and install them in the two holes on the left and the hole fourth (lowest) hole and install a 1/8" up-cut spiral bit in the center. Fig. E). marks and smooth the surface by sanding or by using a Outfit a plunge router with a 5/16" guide bushing and a gooseneck scraper.com/WebExtras a) Cut from a 1" Th x 9" W x 13" L blank. Place each end piece on your bench. ing mortises (Photo 6). After clamping. Place a try square (or a framing square) in your router. piece with its indexing pins firmly registered against the end’s side and bottom. Then flip over to use it for both sides of the box. Then use a 5/16" dia. the dowels to mark perpendicular lines that form an “L” Locate and drill the five 3/16" deep stopped holes for 32 merican oodworker. To rout the slot for the box bot- Then cut three 13/16" long pins from 1/4" dowel stock tom. index pin holes on the template. straight bit and After shaping the inside of the lid. check to make sure all three pins Make a template of 1/2" Baltic birch plywood so you can remain registered. Extend the cut on both sides of the a fence on your drill press and drill 5/16" dia. Material Th x W x L 8" A Lid 1 Cherry 3/8" x 8" x 8" (a) B End 2 Cherry 3/8" x 6-5/8" x 8" C Side 2 Cherry 3/8" x 5-7/8" x 9-1/4" (b) D Bottom 1 Plywood 1/8" x 6-5/8" x 8-1/2" E Wedge 24 Verneer 3/69" x 1/2" x 3/4" Learn to make coved molding on the tablesaw at Notes: AmericanWoodworker. You’ll have to make multiple mortise slots and the long slot for the box bottom. This template has indexing pins that allow you bushing and the slots to guide the cuts. the recipe card retainer on each end piece. push its and a fence to finish the job. remove the stock and use them along with the same amount from the inside corner of arched lid offcut you saved earlier to dial in the lid’s hinge pin location (Photo 7). remove the lid and plane a little off Locate the hinge pin its back inside corner. Lift the lid and see if it to drill the hinge-pin holes. offcut. Drill a 1" deep hinge-pin pieces. Bevel the top wedges are purely Cut tenons edges of both side pieces with the blade Cut the sides (C. Lid Pre-drilled rilllle ed offcut hinge-pin hole Scrap End side piece piece 7 8 Drill a hinge-pin hole in an offcut to test the lid’s operation. so it will hold a recipe card. Then try Cut a pair of side pieces (C) from scrap again. if it doesn’t. don’t bother to round the ends of these tenons—just size them to easy because the bandsaw the curve. Then flip the template. Then rabbet both ends of of the scrap sides and flush with the end each piece to establish the tenon cheeks. Use the same setup to mark the lid’s Cut rough tenons on one end of each tenon joints is curve on the box ends (Photo 8). Clamp each side piece in a vise to mark its rounded FEBRUARY/MARCH 2014 merican oodworker. indexing pins through to the opposite face. Lay Rout mortises in each end piece using both sides of the template. so use your rout the groove for the box bottom. drill press. If it does. It should cant slightly back. and go again. Fitting the wedged the real lid. Stack the end pieces and use the fence and a stop in the box end and into the lid. so they’re identically located. using the drill Press a 3-1/8" length of 1/8" brass rod through the hole press. Install a pin and open the setup. Use Mark the lid’s curved profile on each end piece. Then cut the profile on the outside edge of the line. Spiral Indexing exiing ng Dr D r Drilled up-cut h holes bit pins lette le lete Completed ed slot Guide bushing 5 6 Make a template with slots to cut mortises in the box ends. and width. out the slots and drill holes at both ends. Then insert Make test cuts first. piece at the front and back. When the lid stays up. you’re good to go. stays up and cants slightly back. Then saw or box end to ensure the lid offcut pivots easily. Place the lid offcut on top decorative. As with the scrap sides. Fig.com 33 . fit through the mortises. to a 1/8" drill bit through the hinge hole and tap it to lightly match the tenons’ thickness with the mortises in the end mark the edge of the lid offcut. D) to final length tilted to 17°. This hole must be perpendicular to the each side piece with the blade tilted to 17°. using scrap stock. where it contacts the box. cut the bevel on the top of hole at the mark. using the same scrap stock sides to hold the end piece. Then scrap side. Then use a straight bit Rout the first three mortises. Place the rod against the stop and bend it around a Stop 1/4" dowel. To install the retainer.com/WebExtras 5/16" 1-1/2" 1/8" 5/16" 3/16" Fig. SLOT (TYP. 34 merican oodworker. (TYP. Install the last dowel and bend the rod until it’s parallel. you just 1/4" dowels move the rod forward to the next pair of holes. The bent rod installs in the stopped holes drilled in the box ends. INDEX 2-1/2" 11/16" 11/16" 11/16" 11/16" 9/16" PIN HOLE (TYP. E Mortising Template 11/16" 5/16" W. 4" Bend the rod around the 1/2" dowel 1/2" dowel dow owel el until it’s tangent to the last 1/4" dowel hole. simply squeeze its U-shaped middle. insert a 1/2" dowel. 3/8" 9-1/4" 1/4" 9/16" 8-/1 8" 9/16" 1/16" 1/16" Fig.x 1/8" D. Once the rod is at 90° and tangent to the 1/2" hole.com FEBRUARY/MARCH 2014 . C End Dimensions 1/8" 1/4" Fig.) 1-1/2" 1/4" 1-1/4" 5/16" 9/16" 5-13/16" 6-5/8" 3-5/8" 1-1/2" 1-3/4" 1/4" DIA.) 7/16" 1-1/2" 2" 3" 13/16" 1/8" 1" 1/8" 7/8" 5/16" 11/16" 6-5/8" 11/16" 1-7/8" 6-5/8" 4" 3-1/2" 8" How to Bend a Card Retainer Hold recipe cards upright inside the box by bending 1/8" brass rod around a form.) 5/16" 1-1/4" 1/8" DIA. Complete the job by cutting the rod to length and filing a dull point on each end. 1" 1" Make the form by attaching a stop and drilling holes for dowels in 3/4" plywood. D 17° Side Dimensions 1-1/2" 5/16" Get Phyllis Johnson’s famous 5-7/8" lemon bar recipe at 1-3/4" AmericanWoodworker. As more cards are added. dead edge has no teeth. tenons (Photo 9). Remove the waste Finish-sand the box and apply your favorite finish. so it won’t mar the tenon shoul- d ders. Cut the 1/8" thick plywood bottom (D) to size. Then apply between two strips of walnut veneer. using the drill one piece in each kerf (Photo 10). Then dry- FEBRUARY/MARCH 2014 merican oodworker.) SOURCE •Magswitch. Fake wedge wed edge ge ge 9 10 11 Use the mortises in an end piece to mark Glue fake wedges made from strips of Slightly round the ends after shaping the the rounded tenons on the adjacent veneer in slots cut in the tenons. side piece. mark the hinge-pin loca- veneer.com 35 . Richard Tendick is a retired engineer who loves designing Assemble the box projects and working wood. $34. #8110005. Make two scrap-wood cauls with (E). with grooves cut to house the protruding tenons to tightly clamp the joints. Use cauls Install the lid by tapping home the hinge pins. Then disas- semble the joints and round the end of each tenon to the lines you’ve just marked (Photo 11). wedges flush after the glue has dried. File carefully and stop frequently to check the fit.au.99. Then insert the pins in the holes in the box end and rround the ends of the tenons to fit the mortises. between the tenons using a bandsaw and a chisel—leave (Do not sand or finish the mortises and tenons. MagJig95. pieces are flush before you mark. press. Next. simply grind off the teeth. To create a dead edge. MagJig150.com. Assemble the fitted joints and mark the tenons at the point where they protrude beyond the side. any squeeze-out that occurs during glue-up 1/4" from both ends of each tenon for the fake wedges will be easy to remove. #8110004. bandsaw blade is just wide enough to hold three strips of Position the lid on the box. cut slots finishing.99. ves Grooves Caul 12 13 Glue the box together after pre-finishing all the parts. magswitch. File a point on one end and smooth the other end UUse a chisel and a flat bastard file with a dead edge to flat. Trim the tenons to fit the mortises in the sides. $24.) Cut the glued-up strip into short pieces and glue tions and drill 1" deep hinge-pin holes. Make the wedges by gluing a strip of maple veneer grooves cut to house the protruding tenons.) By pre- the ends of the tenons square for now. Cut two 1-7/16" long hinge pins from 1/8" brass rod. (The kerf of a 1/2" glue and clamp the box together (Photo 12). (A gently tap them into the lid (Photo 13). Make sure the bottom edges of both assemble the box to make sure it fits. Bow Front Corner Cabinet Learn how to add a graceful curve to a basic cabinet. by Chad Stanton THIS PROJECT LOOKS PRETTY SIMPLE, doesn’t it? It’s just a box with two sides and a few shelves. It’s got a curved drawer, too—which isn’t so simple— but let’s skip that for the moment. As I started building a prototype, I thought, “This is no prob- lem at all. It’s just normal cabinetmaking.” Oops. As it turns out, this cabinet isn’t nor- mal: Some of its building steps are best done ILLUSTRATION: FRANK ROHRBACH backwards. Normally you’d build a case first, then build a drawer to fit it. Not here—you make the drawer first, then build the case. Normally you’d make a face frame early on and fasten it to the case. Not here—there isn’t any face frame. The stiles are added separately, after the shelves and drawer are installed. After reversing course a few times, I real- ized that I had learned quite a few new tricks and skills while building the prototype. I gained | PHOTOGRAPHY: JASON ZENTNER experience dealing with irregular shapes, figured out how to build up 3/4" plywood to make it look thicker and perfected a way to make wide edging that’s only 1/16" thick. About that drawer—although it doesn’t hold much, it anchors the whole design by adding visual weight to the bottom of the cabinet. It also anchors the whole building process, in a way. The success of the project depends on making a | drawer front with a perfectly smooth, even curve. EDITOR: TOM CASPAR I enlisted some help to work out a foolproof method that doesn’t require any special tools or equipment (see “Curved-Front Drawers,” page 44). I’m very happy with the results. After strug- gling with the prototype, the actual cabinet went together without a hitch. 36 merican oodworker.com FEBRUARY/MARCH 2014 Assemble the sides Begin by cutting 1 Start by laying out all of the cabinet’s one piece of plywood pieces on one sheet of ply- plywood for wood (Fig. B, page 38). Draw the two both of the sides (A and B) as one unit. Make this cabinet’s sides. large rectangle 1" wider than the two Rout two dadoes sides combined and 1" extra-long. Cut and a rabbet to receive the Side A out two cardboard patterns for all of the cabinet’s shelves triangular pieces (Fig. J). These patterns and subtop, then Side B are slightly oversize, but be sure to create rip the piece into a 3/4" gap between the triangles when two sections, one you lay them out—as shown in Fig. B— for each side. Dado so you have room to turn a jigsaw. Break down the plywood into three sections. Trim the section that contains the side pieces to final length. Using a straightedge as a guide, rout two dadoes in the plywood (Photo 1; Fig. C). These dadoes receive the cabinet’s two fixed shelves (F1 and G1). Rout a rabbet on the top edge of the sides. The rabbet receives the cabinet’s subtop (E1). Rip Cut a 65° angle on the front 2 the plywood into two parts, separating edges of both the two side pieces. Both of them should sides of the cabinet, then be at least 3/8" extra-wide. (Note that rip the pieces to side A is 3/4" narrower than side B.) final width. Mark what will be the front edge of each side, then rip these edges at 65° (Photo 2; Fig. E). Make sure these cuts are straight; the stiles will be glued to these edges later on. Rip the other edge of each side, at 90°, to final width. Using a jigsaw, cut out the feet on the bottom end of each side piece. Drill holes for the shelf pins. Cut biscuit slots about 10" apart for joining the back corner of the sides. Assemble the pieces—without glue— then drill pilot holes for screws between the slots (Photo 3). Glue and screw the two sides together. You could use clamps instead of screws, but clamps Assemble the two sides with 3 might damage the sides’ angled edges. biscuits and screws, using Make the subtop plywood blocks and shelves to hold the Angled This is where things start getting tricky. cabinet square. edge But don’t worry—just follow the proce- dure below and everything will come out right. Start by making a precise wooden template for the shelves and subtop (Fig E). You’ll be cutting and Squaring block Watch Chad put his squaring blocks to use at AmericanWoodworker.com/WebExtras FEBRUARY/MARCH 2014 merican oodworker.com 37 J6 J5 Fig. A Exploded View J1 J4 J3 Cutting List Overall Dimensions: 72" H x 24-7/8" W x 15" D J2 E3 E1 Part Name Qty. Material Th x W x L E2 Case 1-1/4" #8 F.H. A Side 1 1 Plywood 3/4" x 15-7/16" x 70-7/8" B Side 2 1 Plywood 3/4" x 16-3/16" x 70-7/8" C Back 1 Solid wood 3/4" x 3-1/2" x 58-1/4" D Stile 2 Solid wood 3/4" x 2-1/4" x 70-7/8" E1 Subtop 1 Plywood 3/4" x 13-5/8" x 21-15/16" E2 • Buildup 1 Solid wood 3/4" x 2-3/8" x 20" E3 - Edging 1 Solid wood 1/16" x 1-1/2" x 20-3/8" A F1 Shelf 1 1 Plywood 3/4" x 13-5/8" x 21-15/16" B F2 • Buildup 1 1 Solid wood 3/8" x 2-3/8" x 20" F3 • Buildup 2 1 Solid wood 3/8" x 3/4" x 11" F4 • Buildup 3 2 Solid wood 3/8" x 3/4" x 6" #20 F5 - Edging 1 Solid wood 1/16" x 1-1/8" x 20-3/8" BISCUIT G1 Shelf 2 1 Plywood 3/4" x 13-5/8" x 21-15/16" G2 • Buildup 1 Solid wood 5/8" x 2-3/8" x 20" G3 - Edging 1 Solid wood 1/16" x 1-3/8" x 20-3/8" H1 Adjustable shelf 4 Plywood 3/4" x 11-1/2" x 21-3/8" H2 - Edging 4 Solid wood 1/16" x 3/4" x 20-3/8" J1 Top 1 Plywood 3/4" x 15" x 24-15/16" J2 • Buildup 1 1 Solid wood 3/8" x 2-1/2" x 25" D J3 • Buildup 2 1 Solid wood 3/8" x 1-1/2" x 17-5/8" C J4 • Buildup 3 1 Solid wood 3/8" x 1-1/2" x 16-7/8" J5 - Edging, side 2 Solid wood 1/16" x 1-1/8" x 17-5/8" J6 - Edging, front 1 Solid wood 1/16" x 1-1/8" x 25-9/16" Drawer K Front 1 Plywood 1" x 5-1/2" x 20-1/16" (a) L Edging 2 Solid wood 1/8" x 1" x 20-1/16" F3 M Side 1 1 Solid wood 1/2" x 5-3/4" x 13-3/4" N Side 2 1 Solid wood 1/2" x 5-3/4" x 13-1/4" F4 P Bottom 1 Plywood 1/4" x 10-1/2" x 18" Q Guide 1 Solid wood 1/2" x 2-1/2" x 10-3/4" R Guide strip 1 Solid wood 1/4" x 1" x 11-3/4" F1 Notes: F5 (a) Make substrate from five pieces of 1/4" plywood 6" wide by 27" long. G1 R F2 G3 Fig. C Side Details G2 32-5/8" 3-5/8" 15-7/8" ROUGH 16-5/8" ROUGH 15-7/16” FINAL 16-3/16" FINAL To download free plans for this project,1-go /2"to1 3-5/8" AmericanWoodworker.com/SketchUpPlans 3/4" WIDE x 1/4" DEEP RABBET 70-7/8" 1-1/2" 1-1/4" Fig. B Plywood Cutting Diagram 1-3/4" 9-1/4" SHELF PIN HOLE 9-1/4" H1 H1 J1 1-3/4" G1 H1 H1 12-1/4" F1 CUT 1 3/4" WIDE x 1/4" DEEP DADO CUT 2 B 11-7/8" A B A 3-5/8" 5" E1 1/2" 1-1/2" 1/2" 38 merican oodworker.com FEBRUARY/MARCH 2014 but what curvature before Drawer you actually need now is the drawer completing the front front itself (see “Curved-Front Draw. Compare the template to the each other. so choose a material and subtop from that shows pencil lines clearly and is 1/4" MDF. allowing a 1/16" margin on the straight FEBRUARY/MARCH 2014 merican oodworker. When you make a bent lami- nation. Trace the front’s curve. You’ll need to Knowing the drawer front’s theo. there’s Markk Mark no margin for error. if necessary. so drawer front and adjust the template’s their curves must match. know its exact retical radius is a good start. I hope you’ll curve. so they match. it’s impractical to change its shape to match something else. then 7 list. Make the front extra-long. using the dimensions given in the cutting Cut the curve on the bandsaw. Place the front on your template sand down to the and connect the two marks you made line. Since the drawer front is veneered. try to make a drawer front that matches their curve. Place easy to shape. D shows an elegant geometric method for calculating this curve. Place the template in the template in the case. shelf template. Once the front is bent. you must go through the Place the drawer front on the marks 6 process of making the drawer front in you drew on the order to accurately determine its curva. The front is laminated from 1/4" pieces of plywood. Fig. template Now it’s time to hit the pause but- ton. E).sanding a curve on the front edge of the Make a template for the shelves 4 template later on. Before you can go any further.com 39 . Therefore. It works for a cabinet of any size. see that it’s risky to make the shelves first and then. curve for the shelves. trace the outline template of the drawer’s Thinking about this. and make make two marks two marks 11/16" beyond the edges of 11/16" beyond the case (Photo 4.) The drawer’s front (K) sits flush with the Make the front of the drawer before 5 shelves. Place the MDF template on the remaining triangles. the piece usually flattens out a small amount when it comes out of the clamps. Rough-cut all the triangles from the sheet of plywood. such as 1/4" MDF. ers. so once you’ve nailed down the drawer’s curve. the edges of the Shelf cabinet’s sides. template. then Shelf ture—numbers alone won’t work. curve. Set aside the top piece (J1) for now. Making the drawer front before making the shelves is the prudent way to go. you need to know the exact curvature of the Marks M drawer that fits between the shelves. pressed tight to the dadoes and the bottom of both dadoes. not sawn from a giant chunk of wood (Photo 5). later on. then and the drawer cut the template and sand to the line will be flush with (Photo 7).” page 44). The shelves (Photo 6). Exactly how much “spring- back” you’ll get is impossible to predict. (Fig. you’ve also got the proceeding any further. com FEBRUARY/MARCH 2014 .G2 1/4" 1 /2" Fig. 10-1/2" 1/8" SETBACK SIDE Fig. H 1 2-/1 4" (ACTUAL STILE) 24" CURVE OF DRAWER 16" WIDTH OF CABINET AND SHELF FRONTS Fig. 1 8" 2-/ (MARKING BLOCK) G 1. D Curve Layout Fig. L N M BOTTOM OF DADO Exploded View of Drawer P L CABINET SIDE 20-1/2" Q 31-1/2" R. 11/16" SHELF FRONT. G Plan View of Drawer Inside Case CABINET SIDE 1/8" SETBACK DRAWER 5-1/2" 30-1/2" R. 31-1/2"R. 11/16" 65° LESS EDGING K L MARK TEMPLATE MARK 3/4" 70° 1/4" Fig. E Plan View of Shelf Template and Case Fig. K Stile Marking Block SIDE OF CABINET POINT 18" 2-1/2" OUTSIDE EDGE 17"R. M 45° Shelf Details F3 Drawer Details 3/4" F4 3/8" DIA. 65° 3/4" 17" 2-1/2" 16" E 1.F2. F 1 . F 1-1/4" x #8 FH Subtop and 15-1/2" Fig. N DRAWER FRONT Drawer-Front Bending Form STILE 31-1/2" R. P 1-7/8" Drawer-Front 21 " 25" 6" Cutting Jig 40 merican oodworker. 32-/ 2-1/2" J 2 Fig. Fig. Fig. J Pattern Pieces for Roughing Out Top and Shelves STEP 1 STEP 2 STEP 3 18" CENTER J1 Fig. PLUG 1/2" 65° 2-3/8" 1-1/4" BACK 20" CORNER E2. H Top Details 1-1/2" 9" 17-5/8" 4-1/2" BOTTOM 33" J3 OF J 1 J4 6" 1 8" R. com 41 . then glue the edging to each piece (Photo 11). shelves. F2. This around the block (Photo 12). with my push stick. Tape is adequate to hold the thin edging in place—you don’t need clamps. When you make the stiles pieces—all the and install them tight up against the same thickness— Edging notches. True the cut surfaces with a file. make sure the angled end into a miter slot. F4 and G2) to each part. The best way to lay out the notches is to use Saw 1/16" thick pieces of front 10 a marking block that’s similar in cross edging for the Stop section to the stiles (Fig. Watch Chad’s thin-ripping jig (Photo 10) in action at AmericanWoodworker. one for template The subtop (E1) and the two fixed the subtop. I glue the make the buildup Buildup stock to a backer piece so there’s plenty flush with the of support—and something to push plywood. using a stop locked you do this. (The block is 1/8" narrower than easily cut multiple the stiles. When method.com/WebExtras FEBRUARY/MARCH 2014 merican oodworker. Plywood shelves (F1 and G1) have front edges shelf that are thicker than 3/4" (Fig. F3. I prefer using the tablesaw to each of the three parts. glue “buildup” pieces bit (E2. Cut the curve at least 1/16" so that it’s an oversize. then mark subtop. Resaw 1/16" thick edging for the subtop and fixed shelves (E3. then trim so the shelves are easier to tip into place. On template. F5 and G3). Use the same block to mark the adjustable shelves. it flush. Trim the front buildups flush (Photo 9). All of these triangular pieces must have notches cut in them to accom- modate the cabinet’s stiles (D). F). Install shelves and the shelves and subtop. Trace the template’s curve on Shape an oversize piece of plywood 8 each piece. Rip the edging about 1/8" wider than the front edges of the subtop and all of the shelves. K). they’ll automatically be proud from one piece of of the cabinet’s sides by 1/8". Also saw edging for the adjustable Add a solid-wood “buildup” piece to 9 shelves (H2) and the cabinet’s top (J5 and J6). of the block is flush with the cabinet’s allows you to side. but a pattern bit to you could also use a bandsaw. subtop. Glue the edging to the shelves and 11 Cut these notches about 1/16" oversize. shape each piece of ply. Trim it flush with a small router. three pieces like wood all the way around to match the this—two for the Shelf template (Photo 8). the shelves and subtop and carefully cut Stock St the notches with a bandsaw.) Remove stock. then use double-faced tape to exact copy of the fasten the template to each piece.sides. then use make edging this thin (Photo 10). To Flush-trim achieve this look. Make the router table. N) and the Stile S marking ma as the cabinet’s dimensions for the support piece used block stiles. screw running Next. The (F3 and F4). 12 Slide the shelves Build the drawer and subtop in The entire procedure for building the place. make the guide (Q) and guide strip (R)—see Fig. you’ll find the that has the exact dimensions for the drawer front’s same dimensions two-part bending form (Fig. These serve to prevent screw passes the drawer from tipping down when through an opened. important. drill a 1/4" hole through the strip about Install the drawer 1/2" in from one end. On page 40. front to back. so the best method is to Screw and make the strip adjustable. Draw a centerline. on the centerline. draw a perpendicular line 1" in from the shelf ’s front edge (this represents the inner edge of the drawer front when the drawer is closed). Across the centerline. on its top face. P). Draw through an a centerline all the way around it. Clamp the strip and align its to the shelf and drill pilot holes for the front edge with screws you’ll use to adjust the strip. The dimensions of the joints receive the stiles. then tighten the screws front and back. shelf (G1). Install the guide with screws— the lower shelf. Cut notches in the back corner of the drawer sides to 13 Fasten a drawer- guide strip to receive the guide. G). Use the shelf. so you can Next. then oversize hole.com FEBRUARY/MARCH 2014 . turn to the guide strip. so their precise location isn’t oversize hole. Trace Notch tch around the notches. then trace drawer is given in “Curved-Front Draw- around a block ers. Determine the exact length of the drawer’s front by placing the front on top of one of the fixed shelves. Here’s how to washer do it: First. Before assembling the drawer’s sides.com/WebExtras 42 merican oodworker. The location of the strip must be very precise. Lower Lo shelf sh Oversize Oversi hole Download free plans for a chest with center-guided drawers at AmericanWoodworker. Replace the shelf. When you trim the front. Run a screw from Remove the upper fixed shelf (F1) underneath to and add some additional buildup pieces secure the strip’s Guide strip front end. M. remove the lower fixed shelf from the cabinet. Drill a 14 Fasten the back end of the strip 1/4" hole about 2" back from the shelf ’s with another front edge. and other drawer details are shown in Fig. be sure to center it front and back. L. then assemble the drawer. you’ll align the drawer as you adjust the strip’s install the guide strip on the lower fixed position. the ends of the drawer should be flush with the notches (Fig. Remove to trim the drawer front and cut its joints the pieces and notch them to (Fig.” page 44. G). Fortunately. He is also the host of the web show Subtop Wood Choppin’Time. Add cleats to Glue the stiles to the cabinet (Photo 16). You can lay C Cleat doesn’t slip. FEBRUARY/MARCH 2014 merican oodworker. Use Mill the stiles. like the tor and a profes.com. Finish the adjust- able shelves by cutting off their back Fasten the top through the 17 corners. Cut the bottom ends of block with an angled edge. Make the back (C) and install it in the cabinet.an extra-long screw in front. the block so it Make the top (Fig. Adjust the drawer until its front is flush with the shelf all the way across. cutting one side at an a long clamping angle (Fig. shelves below. A). alignment. then glue and screw the shelves to the cabinet. laugh and learn. In addition. “Watch. Install the shelf in the cabinet and try out the drawer (Photo 15). then install the rear screw (Photo 14). the stiles to form tapered legs (Fig. The rest of the procedure is Stile similar to building the shelves. sional furniture builder. Fasten the top from under- neath (Photo 17). glue (Photo 13).” says Chad. and you can still tweak the strip. Clamping ng out its front curve in a number of ways. thick. but don’t tighten the and screw the screw all the way. Place the drawer on shelves in place. subtop. add some more screws to lock the strip in position. When Fasten the front end of the strip all is well. but here you’ll need three buildup pieces (J2. glue and screw the subtop in place. both fixed shelves are still removable if you need to adjust anything. Nail it from the front or screw it from behind. Once everything is right. then tighten the screws. block but the best way to ensure that the curve will be smooth and true is to make a 1/4" MDF template first. Make the stiles and glue them to 16 Add the stiles and top the cabinet. but cut it off even with the top of the guide strip Install the 15 shelf and check before installing it—this gives you the the drawer’s maximum amount of holding power operation and for a thin piece of wood. where serious woodworking and light comedy come together. H). Both of these pieces are made from 3/4" Chad plywood built up Stanton is a to look extra- licensed contrac. as you did for the shelves. the strip. J3 and J4) and edging on all three sides (J5 and J6).com 43 . you’ll need to buy or make a is equally simple.com FEBRUARY/MARCH 2014 . cabinetmakers addressed these prob- lems by making the drawer front in two parts. Aug/Sep 2012). However. This article will show you how.) This method works to any cabinet. need a vacuum bag—just a bunch of pipe clamps. Oct/Nov 2008. Cleanup work is minimal. it often requires using a huge piece of wood—a lot of which will end up as waste. Generations ago. tions.Curved-Front Drawers Create a perfect curve using ordinary plywood and a two-part bending form. The method I’ll be showing you isn’t new. cleaning up the saw cuts will require a lot of work.” AW #161. making a perfectly smooth curve even make an unusual requires a lot of cleanup work. not thick solid wood. vacuum bag and the equipment to create the vacuum. by Brad Holden A DRAWER with a bowed front can add a touch of grace Ottoman. and you won’t curved face. drawer like the triangular one More recently. Once you understand the process for mak. Second. and making it requires only a ing. First. and EDITOR: TOM CASPAR When you master veneered its front face. the face of the drawer will have an unpredictable grain pattern. The simplest PHOTOGRAPHY: JASON ZENTNER method is to cut it out of solid wood. There’s very little cleanup work. Before diving in to the nuts and bolts of my method. The substrate is composed of thin lamina- ing this kind of drawer.” AW #138. but since the process. but there are a number of problems with this approach. Third. 44 merican oodworker. and you don’t need any special equipment at all. The method works well. You’ll be making a two-part bending form (rather than a one-part Why use this method? There are many ways to make a curved front. The method I’ll be showing you is very low-tech—you one-part bending form. The joinery used can easily add veneer. extremely well. woodworkers have been using a vac. They built a solid-wood substrate. and could well turn into an ugly bull’s-eye. you can you’re shaping solid wood. laid up like bricks in a wall (see | “Portsmouth Card Table. but it sure has a let’s take a quick look at some other options for making a lot going for it. building the drawer is plain sail. above (see “Bow Front Corner Cabinet.” page uum bag to make curved pieces (see “Morris Chair and 36). too. Their curves are taken Your front doesn’t have to be circular—it could be any directly from the drawing of your drawer front. Build the drawer on paper Before you make even one cut. opposing pressure piece. One pattern is convex. If you’re still on board. Start by screwing an must have a different radius to allow for the thickness of the oversize piece of MDF to the pattern. Mark off the ends of the drawer. front's inside radius. draw a full-size plan of Make the bending form your drawer front. draw The bending form will be composed of two major parts. is actually less than 1/4" thick. the other is concave. using the same I've found that it's best to make both patterns at the centerpoint you used to draw the outside edge. adding layers until the form is as wide as the drawer. calculate the exact thickness of your drawer Both halves of the form must be quite thick—as thick front. convex=inside. then rout it flush. Screw the MDF to a sacrificial board and then use a trammel to draw the two radii. plus at least 1/2" more for tions you use and their precise thickness. trimming. (My and shape. as your drawer front is wide. in the sequence shown to help prevent the stock from sliding Its weight will bend the layers into an almost-complete curve. Concave=outside. using one large piece of 3/4" MDF. form). and you're good to move on. One is concave. looking down from on top. Each pattern Build up the forms one layer at a time. with glue between each Clamp the plywood in the form. Continue drawer front.) making a pattern for each half (Photo 1). Your same time. I’ll be laminat. end-for-end.com 45 . Apply even. make Learn how to accurately rout a large arc at sure you won’t hit any screws with the router and that AmericanWoodworker. The radius of the convex part is the same as the types of curves. Convex radius Pivot vo ot Pattern point Starting Convex p pin radius Space = thickness of drawer cav ave Concave e radius Pieces Pie Pi ecce ess 1 2 routed flush Rout two patterns to begin making a bending form. This process starts with plywood. The radius type of curve. Draw the inside edge of your drawer. 4 2 5 6 1 1/4" plywood 3 C Convex form Batt Ba tten Batten Concave C form 3 4 Place five layers of plywood in the form. This will be determined by the number of lamina. let’s get going. First. such as 3/4" MDF.com/WebExtras both halves of the form are securely fastened to the sac- rificial board. the outside edge of the piece using a compass or trammel. build them up from layers of a material that's easy to cut which add up to make a front that's exactly 1" thick. The best way to make these thick pieces is to ing five layers of 1/4" plywood and one layer of veneer. Next. tric circles. the other is convex. but this only requires a router and a router table. Allow the lamination to cure for at least 24 hours. Slide the other half of the form down between the battens. like most. make a note of each radius. FEBRUARY/MARCH 2014 merican oodworker. drawing now basically consists of sections of two concen- Veneering is a cinch. After you’ve drawn the radii. such as an oval or ellipse—but it’s easier to of the concave part is the same as the front's outside make patterns for a circular bending form than for other radius. strong and perfectly smooth. staying before you even start clamping. adjust the router to cut the prevent the laminations from sliding out of the form dur- larger radius. and trim (see Source. unscrew the patterns from the sacrificial board. battens with packing tape to prevent gluing the lamina- 46 merican oodworker. 6 Joint one edge of the drawer front until it’s straight. For to create a form 6" thick. The number of pieces cave half on the bottom. then rock the piece into the bit. again aligning the bit’s edge with the waste ing glue up. Clamp the form together again. about 1/8" outside the line. full thickness. you can’t use a fence. just includes the pattern. Before gluing. This material is sufficiently flexible First. I cut seven rectangles for each pattern in order form is significantly heavier than the concave half. For finished front and 1/16" narrower than the form’s thick- safety. side of the line. again. cut rectangular pieces of MDF the same width Set up the form vertically.) Add is even more flexible. I'd recommend using bendable plywood. Sawhorses allow plenty of space you'll need will depend. Cut your plywood pieces at least 2" longer than the Because the parts are curved. fasten battens to both sides. The result will the piece is adequately supported and avoids tearing out the be a piece that's stiff. Continue adding and trimming pieces (Photo 2).com FEBRUARY/MARCH 2014 .) Trace the patterns onto each rect. square and smooth. Rough-cut the curves on the bandsaw. cover the form’s curved surfaces and starting pin. Glue and bend the laminations Next. 1/4" home-center plywood to make Build up each half of the form one layer at a time. but if you're bending a radius that's considerably (I didn’t glue the layers together because I wanted to smaller. they'll also keep the form halves in alignment. Joint the ripped edge smooth. veneer. I used five-ply. on the width of your for placing clamps all around. After you’ve cut both radii. the laminations. such as this one. Align the bit’s edge with the waste side of the smaller When the concave part of the form is built up to its radius line and then make the cut in several passes. Paper-backed Pape veneer Glued-up drawer frontt 5 7 Glue veneer to the top of the laminations and place the assembly Rip the front to finished width. of course. The convex half of the drawer. in my pieces with screws. This method ensures that back in the form. with the con- and length as the two patterns. fasten the pattern piece to one of the additional for a drawer front with a large radius (about 30". The battens will Using the same pivot point. case). It’s sold under many trade names another piece under the one you just trimmed. which disassemble them later and save them for scrap. face up. on sawhorses. (Note: The total thickness a drawer front with a large radius. setting the convex half in place does most of the bending angle. page 48) . then trim the additional piece flush. start each cut by holding the workpiece against a ness. The glue will likely cause the laminations to slide. required rabbets tilted at 45°. Resaw and plane the board down to (Photo 3). For a standard rectangular drawer. I'm sure that there are many ways to join drawer sides Smooth the ripped edge on the jointer. Glue and clamp the caps wood from splitting. Or you can build it of the front. it needs to move back and forth to position the square with the face and all the laminations are flush. Use the sled in order. You can make the sled by disassembling the convex When the glue is cured. Continue jointing until the edge is straight. The one without glue is the last to go into the form the front’s curve. 1/8" thick. To minimize this. Make sure the laminations’ ends them flush (Photo 9). which The top and bottom edges of the drawer front should only requires cutting rabbets in the drawer front. Spread an even coat of glue on the top right height and reassembling them. Spread glue on all but one of the lami. fence. im imb mb Climb cuut cut Normal N Noorm rm cut 8 9 Bandsaw 1/8" thick hardwood caps to cover the drawer front’s Trim the caps flush. a little at a time. This three-sided drawer ends. I’m making this front for a triangular drawer (see page 42). ripping all of its pieces to the from the form. leave the drawer front in the form for 24 hours. the front’s ends clear Remove the front from the form and joint one edge the saw’s table by about 1/8". which requires two angled cuts on each end.) Miter Backer gauge and board fence Centerline erliine erli er ne 45° 70° 7 70 Sled ado do Dado set 10 11 Use an arched sled to support the drawer front when you trim its Cut rabbets to receive the drawer’s sides. and then apply clamps. Climb-cut half of each edge to keep the laminations and to protect the veneer. To make the caps.com 47 . one on top of the you’ll need a board that’s wide enough to accommodate other. be capped with 1/8" thick solid wood. Please be careful. Wipe off any excess glue and your tablesaw’s miter gauge. from scratch using the same technique you used to build Clamp the drawer front in the form again to apply even the form. Make the sled just tall enough so that when pressure until the glue dries. Finish tightening each clamp in the same joints requires a convex sled (Photo 10). The FEBRUARY/MARCH 2014 merican oodworker. tions to the form. remove the drawer front half of the bending form. Don't fasten the sled to the (Photo 6). the rabbets would be cut at 90°. you center the drawer front on it. cuts. Glue on the caps and then trim upper half in position. tighten Cut and rabbet the ends the clamps as you would tighten lug nuts on a wheel Trimming the drawer front to final length and cutting its (Photo 4). until the laminations are com. I chose a relatively easy one. nations and place them in the form. to a curved front. Bandsaw the front to finished height minus 1/4" (Photo 7). conjunction with an auxiliary wooden fence attached to pletely pressed together. are lined up. Trace the front’s curve onto the stock and cut When the laminations are all in place. (Climb-cutting means pushing the router in to the top and bottom edges of the drawer front. the same direction as the bit is spinning. set the form’s out the caps (Photo 8). and then apply the face veneer (Photo 5). end-for-end. One of the drawers I made for this story is trian. rod from which you can cut plugs. trim the plugs and sand them flush (Photo 14). then trace its front curve using the centerline on the top of the drawer front. however. 45°. Cut the curve on the bandsaw. Mark centerlines across the top of the sled and all around the drawer front.com. Drill 3/8" counterbores gular. to match the angle then install the bottom and the other side (Photo 13). If you need to drawer front as a guide. packardforestproducts. When the Cabinet. sides will be fastened to the front with screws. keeping the Assemble the drawer marks aligned as you make your cuts. trimming the front to exact length. Dry fit the parts and make any necessary adjustments. 877-200-4213. 48 merican oodworker. Whenever you make any cuts. make a tick mark on the fence opposite the bottom as a rectangle.com FEBRUARY/MARCH 2014 . which are also angled at 45° Packard Forest Products. fence from the miter gauge and flipped the fence around. G and M. I removed the various types of bendable plywood. it's a good idea Use your drawing to lay out these rabbet cuts and the to clamp the drawer front to the fence. Starting pin 12 Rout a groove for the drawer's bottom using a slotting cutter with a bearing. They're also cut at glue is dry. Glue and screw one side in place and The ends of the drawer are cut at 70°. so the rab. Whenever you rout without a fence. page 40). I made the 45° cuts next. and it required cuts at different angles. Before cutting the first rabbet. move the sled side-to-side (to make overlapping cuts. place the workpiece against a starting pin. Add wooden plugs Trim the plugs and sand them flush. so use a shield to protect the drawer’s sides. for Cut a groove for the drawer's bottom in the front and example). of the stiles next to the drawer (see "Bow Front Corner Glue in the plugs to cover the screwheads. then rotate it to begin the cut. wooden plugs or a 3/8" dowel sides.) marks. Cut the drawer’s the first cut. Even a flush-cut saw can to cover the screwheads. how far you've moved it. so use a shield to protect the workpiece. A playing card with a hole in it works well. then installed a dado SOURCE blade to cut the rabbets. Wooden plug g shield Cutting shie sh ie 13 14 Assemble the drawer using glue and screws. leave marks. (The drawer is Even a flush-trim saw with no set to the teeth can leave essentially a right triangle with two 45° corners. (Photo 11). next cut. to accommodate the drawer sides. All the cuts are 90° for a standard drawer with four Make or buy 3/8" dia. so I'd have a fresh surface to back up the bets need to be sufficiently large to accommodate them. for all of the screws. locations of the screws. Before you make Cut the drawer's sides to finished length. the distance between the lines will show you sides using a slot cutter in your router table (Photo 12)." Figs. I made the 70° cuts first. holes for the six wedged dowels and a 1" dia. | EDITOR: TIM JOHNSON Build a classic Stickley-Style plate rack at AmericanWoodworker. B). | Install a sacrificial board under- PHOTOGRAPHY: JASON ZENTNER neath to minimize tearout. Make the side panels Mill blanks for the side panels (A. you can adjust the design to fit just about any dish—or space. Store dinner plates.com 49 . Need more space? Make your rack wider or taller. page 50). stopped hole for the shelf dowel. Rip them slightly oversize in width and cut them to final length. by Laurie McKichan ARTFUL DESIGN and Tinker- toy-style construction team up to make this eye-catching yet sophisticated dish rack.com/WebExtras FEBRUARY/MARCH 2014 merican oodworker. Bandsaw the curves and then sand to remove the saw marks. salad plates. Drill 3/4" dia. cups. Flip over each blank to locate and drill the 5/8" dia. A. Note: The holes must be identi- cally located in both blanks for the rack to go together properly. A great addition to any kitchen. mugs or bowls. In fact. Complete each side panel by shaping its curved profile. saucers. Locate the ILLUSTRATION: FRANK ROHRBACH large dowel holes and lay out the curved profile on the outside face of each side panel blank (Fig. Modern Plate Rack Keep your favorite china within easy reach. Fig. hole for the front dowel (Photo 1). it dis- plays your favorite dishes in style while keeping them within easy reach for daily use. tion the jig so the dowel extends over 47" R. dowel. Set the front dowel slide the miter gauge forward and posi- 23-1/4" and the shelf dowel aside.) sions can vary from piece to piece. x 1-5/16" W. D 1" P STOP BLOCK 1/4" TH. because the positions of the against the stop block. x E Wedge 12 5/64" x 3/4" x 1-1/8" (d) 1-1/8" L (TYP.) 33-3/4" 1/2" els and the front dowel (B. Note: Dowel dimen. 10-3/16" sure all your 1" dowel stock is the same Hold the jig against the miter gauge 26" diameter.) C L Small plate back rail 1 1" x 2-1/2" x 18-1/2" (c) M Large plate back rail 1 7/8" x 3" x 18-1/2" (c) N Shelf back rail 1 7/8" x 2" x 18-1/2" (c) G P Shelf slat 3 5/8" x 1-13/16" x 18-1/2" (c) M 2-1/2" Notes: 1" DIA. the blade’s leading edge. J b) Length includes 1-1/8" long tenons on both ends. x 1/2"L. MORTISES Sources. Make on the dowel (Photo 2). Use a go/no-go block to 50 merican oodworker. you fasten the jig on the end of the dowel to dial in a 3/4" 9-1/16" to the miter gauge so that it butts against dia.) Part Name Qty. shelf dowel and install a test dowel. rip fence and blade are all blade incrementally and make test cuts 1-5/16" 1-3/4" related. MORTISES The jig consists of a 2-1/2" W x 14" block to the blade’s outside edge. Fasten the jig to the miter gauge 1 " (TYP. K Top back rail 1 7/8" x 1-1/4" x 18-1/2" (c) (TYP. rip fence is set to cut a 1-1/8" long tenon (TYP. x 1-1/4" L.) L fence with a pair of 2" W x 2-1/2" L sure the jig butts against the stop and 8-3/4" attached blocks. BLOCK 1" 3/8" DIA. (Fig. Th x W x L K A Side panel 2 1" x 12" x 37-1/4" 3/4" B Front dowel 1 1" x 19-3/4" (a) C Wedged dowel 6 1" x 19-3/4" (a. Clamp a stop block to the saw’s rip fence so that the 12 " Build B a simple tablesaw jig to cut dowel will butt against the block’s face 16-3/8" round r tenons on the ends of dowels and the jig will butt against its end. b) F D Shelf dowel 1 5/8" x 18-1/2" A 3/4" DIA. (TYP. Set the rip fence to cut the tenons 11-7/16” 13-3/4" by measuring from the face of the stop 1/4" W. Then cut ten. B Side Panel Dimensions 3/4" 8-7/16" 3/4" 1-3/8" 9-1/4" 3" 37-1/4" FENCE 35-1/4" Cut round tenons 35" Cut 1" dowel stock to 19-3/4" lengths 9/16" 2-5/8" to create blanks for the wedged dow- (TYP. In a nutshell.x 1/2"L. Then raise the 1-13/16" jig. Make 10-1/4" (TYP.com FEBRUARY/MARCH 2014 . see a stop clamped to the rip fence when the 3/8" W. 3/4" 1-1/8" Fig. 1-3/8" d) Taper one end to 3/64". A Exploded View Overall Dimensions: 37-1/4" H x 19-1/2" W x 12" D 3/8" TH. at this position. Cutting List Fig. tenon. 2-3/16" (D) to final length. 1-3/16" B Fig. a) Length is oversize. slides freely without contacting the rip hole centered 1" from the bottom and fence.) F Small plate back dowel 12 3/8" x 10" L 2" G Large plate back dowel 12 3/8" x 12-1/2" H H Small plate bottom dowel 12 3/8" x 7-1/2" 3-1/4" J Large plate bottom dowel 12 3/8" x 8-3/4" 3/4" DIA. ( C). page 53). Each block has a 1" dia.) ons on the wedged dowels.. 3-7/16" Setting up the jig takes a bit of trial Slide the jig forward until it butts 3-1/8" and error. Cut flush after assembly. C Tenoning Jig N 1-1/2" 5/8" DIA. E c) Length includes 1/2" long tenons on both ends. C. Cut the 5/8" dia.) the inside edge. Lower the blade. (TYP. (Note: Test from the blade and slide the first dowel cil. Mark Place the indexing jig on the the stop block. a center-to-center on a 3/4" x 9" x 42" length and diameter. Any tearout on the panel’s inside face will a stop block. dowels are straight and you have a flat 3/8" dia. Mark the first hole on every regis. The deeper shoulder first: Turn on the saw. always start with and against both the indexing jig’s fence mark the left tenon. To securely hold each hole on the dowel’s registration line. One dowel requires a second line the dowel spacing with the bowls you against the stop block. fully center the registration line when should fit snugly and slide in and out The first step is to draw a registration you install each dowel. test-fit the tenon (Photo 3). In order to per and attach short lengths of vinyl press at this position. the holes you’ve drilled and installing Next. back the jig away flat surface to work on and a sharp pen. Set the bit to drill assemble this structure. For example. Cut the tenon’s drawn at 90° to the first and one dowel plan to store in the rack. Center the drill bit on the Drill the dowels jig to hold the 1" dowels for drill. rough out the tenon by rotating the tration line. Use the go/no-go side panels. Then clamp the indexing jig to the drill plates in the completed rack. holes precisely spaced 1-3/8" Once you’ve established the tenon’s piece of wood to use as a straightedge. be covered by the dowels. Outside face Stop Tenoning block jijig ttn ner er Forstner bit ep Side an an panel 1 blank 2 Drill holes for the rack’s large dowels through the outside face of Cut tenons on six of the large dowels using a shop-made jig and each side panel blank. Build a V-groove and its pin. A). hold the requires two additional lines. Then smooth the tenon that tenon. V-groove jig and butt the V-groove jig the blade while incrementally rotating it. at 90° and the bowls. Care. the further apart the dowels dowel against the stop block and push 180° (Fig. Then rotate the dowel. too. line the groove with sandpa. so you can keep the drill press. dowels to form the structure that holds dowel. centered 1-3/16" from one the indexing pin. jig’s crosshairs to correctly orient these lines. Lay out oversize and sand them to fit. that was drilled with the same bit used to drill the holes in the Two dowels have additional registration lines. without binding or wobbling.com 51 . 1/4" deep holes—drilling too deep will FEBRUARY/MARCH 2014 merican oodworker. Use the go/no-go jig’s must be spaced. the holes must plumber’s strap across the jig. push the jig against the stop. Then raise the blade and rotate the dowel. mark you’ve drawn to locate the first Holes drilled in the 1" dowels house 3/8" ing (Photo 5). dowel while slowly pulling it away from of the dowel’s tenon shoulders. Go/no-go jig Registration line Straightedge 3 4 Test-fit each tenon using a go/no-go jig—a block with a hole Mark a registration line for drilling holes on five of the dowels. ing jig by attaching a fence parallel to end of the stop. The best line that runs the length of each dowel Build an indexing jig to accurately method is to cut the tenons a tiny bit (Photo 4). length of MDF or plywood. bly.) Complete the index- the jig forward until it butts against the crosshairs to correctly orient these lines. The tenon be accurately located and drilled. install a test dowel in the by sliding the dowel back and forth over dowels correctly oriented for assem. This is easy as long as the space the holes (Photo 6). To size the tenon. reposition the V-groove jig to drill each additional hole. cause problems on the dowels that the mortise for the small plate back rail holes for buttons is optional. Then cut all Make sure to use glue with a long V-groove jig to bandsaw a slot for each the tenons and round them to fit the open time. than the other rails. disassemble the parts and pre- located 5/8" from each end.) Tinkertoy-style assembly The front dowel (B) attaches to the Mill the back rails (K–N) and Start by assembling all the parts without side panels with 3/8" dowels. shoulders on these pieces matches the (see Sources). The dowel is correctly oriented for drilling when the jigs to drill the first hole. Make part liquid urea resin glue that’s perfect from 5/64" thick stock. V-groove jjii jig V-groove jig Indexing Inde Indexing 5 6 jig p pin Center the registration line after installing each dowel in a Use an indexing jig to accurately space the holes. rails. As this assembly 52 merican oodworker. Round the edges of the assembly to heat it up. Make the wedges (E) mortises.com FEBRUARY/MARCH 2014 . This rail mounts ments. Then is set in farther than the mortises for the drill the holes. Countersinking the dowel (Photo 9). slats and the inside faces of holes in all of the wedged dowels’ ten. rack to the wall. So use shelf slats (P) to thickness. (Photo 8). Press the back plate dowels into the back wedged dowels. a two- wedge (Photo 7). 3/8" the small plate back rail (L) is thicker erly. install the back plate dowels in the an easy. I prefer Unibond 800. other back rails. perfect shop). Finally. After making any necessary adjust- dia. add the small plate a series of overlapping holes. Then cut all the sure the length between the tenon for complex assemblies like this one plate dowels (F–J) to final length. Next. Then simply move the indexing pin and measurement from both sides of the line is the same. Using a drill shelf slats on a router table. old-school method for doing Drill holes for the mounting three back wedged dowels without glue this. so if your shop is cool. Install the bit. x 1/2" deep holes in this dowel. Keep each wedged dowel in the final width and length. Back plate ef Stress-relief dowels hole Back wedged 7 8 d dowel Cut a slot that ends in a stress-relief hole in each wedged tenon. Unibond 800 is temper- length between the tenon shoulders ature sensitive. set the fence and drill screws in the small plate back rail. Then use Make sure to locate the holes between bottom dowels and the front wedged a chisel to square the cheeks. drilled holes. Cut mortises and tenons on the wedged dowels (17-1/2" in a just throw an electric blanket over the Locate and cut mortises in the side pan. have multiple registration lines. using a Working on a padded surface. (Note that the plate dowels. press with a fence and a Forstner bit is fence and a 1/4" roundover bit. flush with the back edges of the side pare for gluing by finish-sanding all the use the setup to drill 1/8" stress-relief panels because it’s used to fasten the dowels. Note that glue to make sure everything fits prop- the same setup to drill centered. ons. Locate both V-groove jig. Cut these parts to both side panels. using a file or chisel. els for the rails and slats. Don’t Make sure to orient the slots correctly on the dowels that have use glue. install it (Photo 10). 1 Pint. panels only (Photo 11).com.” You can see you’re happy with the fit. 3/8" dia. Glue also without glue. Leave the leftover Unibond in a 1/2 gallon. When such as Velvit Oil. #21089. #UB-12 (M). Natural. $4. front dowel flush with the sides. 800-382-4109. ont Front dowel Large plate bottom dowels 11 12 Glue the front dowel to the side panels after installing it on the Tap in the wedges along with a bit of glue.10. glue slot. McKichan panel cutouts. The ments as necessary to center the front teeth on a flush-cut saw have no set.. Single panel and clamp the rack together. the side panel cutouts and install with. a flush-cut saw (see Sources). so Laurie dowel and fully seat it in both side they won’t mar the side panel surfaces. the shelf slats and the plate plastic cup with a stick in it. 800-279-4441.50. remove the on/rub-off finish that’s easy to reapply more of her work at front dowel and install the large plate as needed (see Sources).com 53 . the it in. then glue on the remaining side panel and clamp the assembly together. $8. in the rails and slats. 5/8" dia.96. honest and the holes or shave the dowels.59.com. Apply a bit of glue in each • VacuPress. Apply glue and press the dowel assembly into a side panel. Press the FEBRUARY/MARCH 2014 merican oodworker.36.. vacupress. you can remove the clamps Edge. Then glue it to the side • Rockler Woodworking and Hardware. x 3/4" deep holes in from the rack. in the remaining wedged tenons.com. Then Stand the rack up to install the wedges Screw Hole Button. $5. • Velvit Products Company.com. dowel. $23. then trim the wedges and protruding tenons flush with the side panels. the cup. rockler. Glue on the remaining side glue is rigid and can be pulled out of 800-871-8158. direct. When the • Lee Valley & Veritas. Let the glue dry and large plate bottom dowels without glue. Apply glue to the holes for the wedged Install wedges $3. so it’s okay to slightly widen finish that will be easy to maintain. Velvit Oil. leevalley. 1" dia. $23. back rails. lauriemckichan. Then choose a designs furniture to filling. SOURCES string to hold it together. Lay one of the side panels on ris. 36" Cherry Dowel ers to provide clearance for clamps. you may want to tie it with front dowel onto the large plate bot. Then make adjust. #20560. carefully lift the dowel assembly and (Photo 12). Veritas Flush-Cut Saw. using ten the front dowel. out glue the 3/8" dowels that will fas. Cherry 1/2" tenons in the dowel assembly. tom dowels. Unibond 800 is gap.59. Similarly. insert the wedge and lightly tap Unibond 800 resin with medium catalyst. $15. #0K534.com.49. #21063. #21105. isn’t glued. an oil-based wipe.59. Rod.. velvitproducts. bottom dowels without glue. Smallll plate bottom dowels 9 10 Add the small plate bottom dowels and the front wedged dowel. Finish-sand the sides. Cut the wedged tenons and the 920-722-8355. be “simple. Drill 3/8" dia. apply packing tape to the top of the cup and cut around the large hole (Photo 3). then sand and apply three coats of poly. To mold the oogloo. cut into a 2-3/4" x 3-3/4" rectangle. If the air is very dry. It’s too dry to use directly from the box. which readily absorbs liquids. After getting acquainted with oogloo. corn starch 1/4 tsp. a homemade a hard-core woodworker. can you say “oogloo eggcup” three times. lightly spritz the paint. Oogloo Eggcup A fun introduction to I OFTEN START a leisurely day in the shop with a the whacky world of breakfast of toast and a soft-boiled egg. silicone caulk cures very slowly as it absorbs cornstarch with water. then slice off the excess and remove the tape (Photo 9). If you’re making a batch of eggcups. menting soon revealed an awkward problem: Spilled egg is hard to clean up. It’s a homemade material that can be molded into any shape. I’ve always wanted to make a simple set of eggcups of my own design. Here’s how to do it: ILLUSTRATION: FRANK ROHRBACH Start with 3/4" thick cherry. let the oogloo cure for a few hours. a curing agent and and leave it for a few days. Otherwise. then let it sit. but experi- molding material. Once the finish is cured. moisture from the air. Now. Fig.com FEBRUARY/MARCH 2014 . If you form it in a wooden mold. coat a regulation 40 mm Ping- | Pong ball with petroleum jelly and push it into the oogloo PHOTOGRAPHY: JASON ZENTNER (Photo 8). Make the oogloo (Photos 4-6) and spoon it into the cup (Photo 7). But if you mix the silicone with an agent You can thin oogloo with a small amount of mineral spirits if that contains a small amount of moisture. The simplest agent to use is plain old cornstarch. (See “What Is Oogloo?” below. coat the mold with petro- leum jelly first. takes a few hours. Recipe for 1 eggcup however. oil-based paint (optional) 54 merican oodworker. fast? What Is Oogloo? Oogloo is a mixture of 100% silicone caulk. by Richard Tendick Oogloo is the solution. you’ll prob- ably think of dozens of uses for it. Drill the holes. A). Draw the outline of the eggcup on the wood and mark the centers of the two holes (Fig. 100% silicone caulk 3/4 tsp. Normally. To prepare the cornstarch. B). Incorporating oogloo into a wooden cup is easy. Of course. It sticks to both | EDITOR: TOM CASPAR wood and metal.) Dried egg wipes right off this slippery stuff. as oogloo. spread it on a cookie sheet 1/2 oz. Cut out the cup (Photo 1) and round over its edges (Photo 2. the curing process only your project requires it to flow better. you can scrape away the excess and spoon it right away into another cup. Si Silicone Scale Black p paain int paint 4 5 6 Begin making the molding material. then apply tape to outline the eggcup. Mix in a precise amount of slightly damp Add a small amount of enamel paint to called oogloo. Drill two holes in the cup. For safety. slice off the to simulate the shape of an egg. D Do oub blle e-ffa Double-face tape king Packing ig glass llaassss Plexiglass tape e Hole 1 2 3 Cut any shape you want on the bandsaw Round the cup’s edges on a router table. Fig. Coat the excess and remove the tape. amount of silicone into a plastic cup. A Fig. first. Cut the tape to the piece. color the oogloo. 7 8 9 Pack the oogloo into the cup’s hole. B Plan View Router Jig FEBRUARY/MARCH 2014 merican oodworker.com 55 . After the oogloo hardens. by squeezing a measured cornstarch. make a handled plate to guide around the large hole. Press a Ping-Pong ball into the oogloo. expose the hole. ball with petroleum jelly. so you don’t have to fish for extension cords to plug in portable power tools. Shorten the top. page 63). The top is long enough to mount a vise at one end and a router at the other.com/WebExtras 56 merican oodworker.com FEBRUARY/MARCH 2014 . a hol- low core door and some hardware. or install drawers or shelves on one side of the cabinet or forgo the tool platforms entirely and just build the bench. Simple construction methods make this bench doable for most woodworkers. especially if you have to share your shop space with cars and other vehicles in a garage. for example. Whether you build the Cadil- See the mobile base lac version shown here or an economy model. Power Tool-Friendly Bench Store and use key benchtop tools on a single mobile unit by Richard Tendick INNOVATIVE FEATURES such as a lever-operated mobile base EDITOR: TIM JOHNSON | PHOTOGRAPHY: JASON ZENTNER | ILLUSTRATION: FRANK ROHRBACH and dual-height pullout tool platforms give this bench a five- star rating. this bench is sure and tool platforms in action at to enhance your woodworking. so you can easily move the bench from the middle of the shop to store it against the wall. The mobile base works just like a floor jack. The tool platforms allow you to pull out stored bench- top machines and raise them to operating position—flush with the top of the bench—in seconds. AmericanWoodworker. You can get these materials at any home center (see Sources). The bench’s modular design is easy to modify to fit your space or tools. You’ll need four sheets of plywood. The benchtop houses a power strip (see Sources. Photo 1). G. The cable for the mobile fasten the plywood to both sides of the door by driving 2-1/2" base passes through the other hole. x 1/4" i. flush at one end and at the back edge. between sheets of plywood (A–C. Cut the 1/2" plywood lever to final dimensions (Fig. with fences attached on both sides. These x 3/4" long steel bushing in this hole. it’s a good idea to remove them after the glue dries. Use screws designed for lever stiles to the middle frame. rails and fill blocks. Make sure the bearing’s inner race is cable and pulleys. Place the 3/4" plywood and drill the two 3/8" dia. For great for this job. This bushing will keep long screws may poke slightly through the 3/4" plywood.com 57 . groove at the front for mounting a power strip. H. The lever raises the bench onto its casters by means of a axle through its bearing. page 58. Use a 90° assembly jig to keep each top long enough to house a router. woodworking (see Sources). Use one hole to bolt the lever on top and clamp it so you can flip over the assembly. so construct a squaring jig to assemble them enough to mount a router at the end. mounted in maple blocks that are bolted on the center frame’s bottom rail (L. Start with the top connected by stretchers and a back to create two 24" wide x The bench top consists of a 30" hollow core door sandwiched 24" deep openings. Install a 3/8" o. Fig D). Cut the 3/4" plywood (Photo 2). holes. (A paint roller works house the lever (K) that operates the bench’s mobile base. rails and fill blocks (F. page 58. A Exploded View 90° jig Rail Fill ow ccore ow Hollow o Stile block door 1 FFi i block Fill 2 Create a sturdy. Le Lever llley Pulleyey blocks ce ce Bearing race Leverr stiles 3 4 Install the lever in the middle frame after attaching the lever Prepare each pulley for mounting in blocks by driving an stiles. The frames sturdy. A 4" wide core spacer (D) makes the bench top long must be square. so the cable from wearing the wooden lever. The middle frame includes two additional stiles (J). Attach the core spacer similarly. Then between the middle rails (Photo 3). The roll pin must be carefully ham- FEBRUARY/MARCH 2014 merican oodworker. Install a 3/8" to the plywood by driving four 1-1/2" screws through the x 3" bolt to keep these the holes aligned when you fasten the solid wood near the door’s corners. The pulleys are steel screen door repair Build the cabinet wheels with 5/32" x 1-1/2" roll pins driven through them to The cabinet consists of three stacked plywood frames that are act as axles (Photo 4). Cut the stiles. frame square. C) Apply glue to the door and spacer. They Apply glue to one side of the door. Fig. flat bench top by fastening plywood sheets on Assemble the cabinet’s frames by stacking and gluing plywood both sides of a hollow core door.d. Cutting Fig. A. Glue on On both sides of the lever. screws all around the perimeter and through the center. clamp these stiles together and use a drill press to plywood. This construction is both flat and block so the lengths of similar pieces are identical. supported on both sides by the vise. B) for the frames to final width and length—use a stop List. Fig. Adding a fill block makes this stiles. The jig is simply a piece of flat 3/4" sheet stock that top and 1/2" plywood bottom wider than the door to create a has one square corner.d.) Lay the glued side of the door on the 1/2" accuracy. the cable passes through pulleys the vise fill strip (E) and install the vise (see Sources). Tack the door drill the 3/8" hole that’s used to mount the lever. #6 x 1-1/4" F.com FEBRUARY/MARCH 2014 3 0° 6 0° . A A Exploded View HOLLOW-CORE B DOOR D E M #8 x 2-1/2" F.) T F G J P Z Q K 1-1/2" CONTINUOUS 3/8" x 3" HINGE BOLT X FERRULE 3" G L M 1/8" CABLE 5/16" x 4" S U Bench Cutting List W CLAMP BOLT Overall Dimensions: 36" H x 84" L x 31-1/8" D V 1/8" WIRE H Y 5/16" x 4" Part Name Qty. C Fig.H. B Cabinet Frame Dimensions D Bench top core spacer 1 Pine 1-3/8" x 4" x 30" E Vise fill strip 1 Pine 1-3/8" x 1-1/8" x 8" 8-3/4" F Stile 12 Plywood 3/4" x 3" x 32-5/8" 3" G G Rail 6 Plywood 3/4" x 3" x 24" H Fill block 6 Plywood 3/4" x 3" x 2" J Middle stile 2 Plywood 3/4" x 3" x 29-1/8" K Lift lever 1 Plywood 1/2" x 3" x 29-1/2" L Pulley block 4 Maple 1-1/4" x 1-1/4" x 3-1/2" M Stretcher 3 Plywood 3/4" x 3" x 54-1/2" N Cleat 3 Plywood 3/4" x 3" x 18" J P Back 1 Plywood 1/2" x 30-5/8" x 54-1/2" 29-1/8" Q End panel 2 Plywood 3/4" x 18" x 30-5/8" 32-5/8" K R Frame face 2 Pine 3/4" x 2-1/4" x 33-3/8" F F S Center face 2 Pine 3/4" x 3/4" x 33-3/8" T Center top fill 1 Pine 3/4" x 3/4" x 3-3/4" 3/8" DIA. 3" 9" 3" 24" 29-1/2" 3-5/8" 3/8" DIA.H. Material Th x W x L CABLE R EYEBOLT A Bench top core 1 Hollow core door 1-3/8" x 30" x 80" 3" SWIVEL CASTER B Bench top bottom 1 Plywood 1/2" x 31-1/8" x 84" C Bench top top 1 Plywood 3/4" x 31-1/8" x 84" Fig./4" 58 merican oodworker. 1 8" 2-/ Z U Center bottom fill 1 Pine 3/4" x 3/4" x 5" V Caster bracket back 2 Pine 3/4" x 4" x 24" W Caster bracket bottom 2 Plywood 3/4" x 4-3/4" x 24" 3-7/8" X Caster bracket brace 4 Plywood 3/4" x 4" x 4" (a) 3" G Y Caster bracket block 2 Plywood 2-1/4" x 3" x 6" (b) Z Lever stop 1 Plywood 1/2" x 1-1/2" x 5" 2" L 1-1/2" Notes: a) Cut diagonally. N SCREW (TYP.) SCREW (TYP. C 2-3/16" Lever and Stop 3/4" Z 1-1/2" 7/8" Dimensions 3" 3 K 5" 1-1/8" 1. b) Stack three 3/4" pieces. 30° Fig. Con- Fig. 24" Continuous h hinge Screwdriver Eyeb bol olt Eyebolt 7 8 Rii block R Riser Install a large eyebolt after building each caster bracket. Attach the end 1-3/4" Y 2-1/4" panels (Q) and the decorative pine facing (R–U). 1-1/4" mered through the pulley to prevent damaging its bearing. the back to complete the job. D Pulley Blocks 5/8"Drill a centered 5/32" hole in one end of each pulley block and 5/16" holes for the mounting bolts. Then bolt the L 5/8" 1-/4" pulley block assemblies on both sides of the bottom rail. 5 K J /8" insert a bolt to keep those holes in alignment while drilling the second hole. 1 1 Assemble the cabinet on a flat surface—you can use the 3-/2" 1-/2" 1 " 3/4" bench top you completed earlier (Photo 6). Attach the caster brackets with the cabinet raised on 1/2" plywood blocks.com 59 . Top stretcher Fig. 24" 6" 6" It’s a good idea to recruit a helper to install the spacers. Install a pulley between each front and rear block. insert a after installing spacers to properly position the frames.d. 6" 3" 9" 4-3/4" Install the mobile base Build the caster brackets (V–Y. Attach bolt after drilling the first hole. G CENTERLINE 2 1/64" DIA.d. 1-1/4" line up. These 5/16" holes must 3/8"o. STEEL blocks) for drilling. E) and install 5/16" x 4" FEBRUARY/MARCH 2014 merican oodworker. A Exploded View Cleat Spacers Pulley P Puu block Bottom Bo B o stretcher ssttr 5 6 Bolt the pulley block assemblies on both sides of the middle Assemble the bench cabinet by attaching stretchers and cleats frame’s bottom rail. When the frames are properly spaced. screw the stretchers (M) V X 4" to the top and bottom. Space the frames 24" apart by using spacers that are rabbeted on both ends. 1 Install a bolt before drilling the remaining holes. x 1/4" i. After drilling the first hole in each pair. G Position one assembly with the pulley centered on the center frame’s bottom rail and drill a hole through the rail (Photo 5). To properly align the holes in the rail. W 3/4" 3" 5/16" DIA. Fig. Fig. E Caster Brackets struct each spacer by fastening a 24" long piece of scrap plywood to a longer piece of plywood. so stack the blocks in pairs (back blocks and front x 3/4"L. Then screw on the cleats (N) and fasten the back (P) to square and stabilize the assembly. BUSHING 5/32" DIA. H.) LL #6 x 1-1/4" 1" FH SCREW (TYP. Material Th x W x L AA Outside slide support 4 Plywood 3/4" x 3" x 24" Fig.) 1" 4" 1-3/8" DeWalt DWE7480 12-7/8" H x 22-1/2" W x 21-3/4" D 1" 1" 4-3/4" CC 2 1" 12-7/8" Build a fence to use 3-1/2" 31-1/4" with the bench top’s router at AmericanWoodworker.H. G Tool Platform Dimensions 9/16" DIA. COUNTERSINK cc) Dimensional changes to accommodate Delta 31-483 Oscillating Spindle HH 3/4" DIA. J Rotating Link Details 15° BB Middle slide support 4 Plywood 3/4" x 3" x 18" JJ CC Inside slide support 4 Plywood 3/4" x 3" x 21" 7/8" 1" GG DD Link 8 Plywood 3/4" x 2" x 7" (aa) 3" EE EE Stop block 4 Plywood 3/4" x 3" x 5-1/2" (bb) FF Platform side 4 Plywood 3/4" x 3" x 18" 1/4" x 2" F. x 7/16" D.com FEBRUARY/MARCH 2014 . Sander: Slide support mounting height: 9-5/8". Support COUNTERBORE bracket brace: 1-1/4" W. COUNTERSINK (TYP. FULL-EXTENSION KK 4" DRAWER SLIDE (TYP. Platform: 15-1/4" W.) 2" FIXED CASTER (TYP. JJ Platform 1 Plywood 1/2" x 18" x 19-1/4" (cc) MACHINE SCREW AND KK Support bracket brace 1 Plywood 3/4" x 3" x 18-1/4" (cc) LOCKNUT DD LL Support bracket plate 2 Plywood 3/4" x 3" x 19-5/8" 1" MM Support bracket leg 2 Plywood 3/4" x 3" x 14-1/2" (cc) 1" 5" 1" Notes: AA BB 1" aa) Ends rounded at 1" radius. bb) Cut front end at 15° angle. FF GG Platform brace 4 Plywood 3/4" x 3" x 13-3/4" MACHINE SCREW 5-1/2" HH Cross brace 1 Plywood 1/2" x 3" x 23-3/4" 1/4" x 1-1/2" F. DD 1/4"WASHER 1/4" DIA. F Fig. Fig. CC 9/16" DIA. Support bracket leg: 9-1/4" L. 60 merican oodworker. H Slide Support Dimensions Tool Platform JJ 2" 1" 4" 2" HH AA 2 1" FF GG 18" 24" 16" BB EE DD CC MM 2" 3" 4" ALUMINUM-ANGLE STOP 200 LB.com/WebExtras 14-7/8" 27-1/4" Tool Platform Cutting List Overall Dimensions: 18-3/8"–23-1/8" H x 24" W x 24" – 54" D 24" 29-1/4" Part Name Qty.) AA BB CC Fig. Then test the lift mecha. and back down through the through the second eyebolt. two cable clamps. bring the end back into the bench and install a side of the cabinet. page 60. Cutting Thread the free end of the cable through the nearest pulley List. simply raise or screw bearing against the opposite side of the middle frame lower the outside slide support’s mounting position inside the to tighten the cable (Photo 10). Draw centerlines for mounting the net to the floor and attach the bench top by driving screws slides on each support and mark the 1" radius ends on each through the cleats. Secure the tensioned cable using second pulley. fence and miter gauge must be through the bushing. Links Middle slili slide su su support Slide supports id de Insidee slide support sid Outsidede slide 11 e slide Inside sliide d support 12 support Lay out the platform assembly’s support slides and links. Then install two cable clamps cabinet and adjust the length of the support bracket’s legs. Feed the cable up to the bushed hole in the lever.com 61 . Then locate the 1/4" dia. J). Fig G. Rotating links raise and this loop by hammering on an aluminum ferrule. To work with other similar saws you may have to make Use an F-style clamp with its head inside the loop and its some alterations. For to hold the tension. Raise the lower the platform between its storage and operating positions. holes on the inside slide tions to install the router plate. Make sure to correctly FEBRUARY/MARCH 2014 merican oodworker. H). DeWalt’s Compact Job Site Tablesaw (Fig. Fig. inside slide supports and on the links. supports (CC. different lengths (Fig. Move the cabi. Loop one end of an 8' length of 1/8" wire capacity drawer slides on each side (see Sources) and rides on cable through the eyebolt on one of the caster brackets. Install the lift lever stop (Z). The spacing between these holes The pullout tool platform extends by means of two 16" 200 lb. cable will stretch like a guitar string and need to be re-ten. down through the other pulley and over removed in order to store the tool. Secure a support bracket with fixed casters. must be the same on all similar pieces. F. Mark Screw the drawer slides to the slide supports. We built simple brackets to the second caster bracket. Correctly locating these holes is critical for the platform’s lift mecha- Assemble the tool platform nism to work properly. F) and the sioned. base on 1/2" plywood blocks. be lowered and its guard. see Sources). Mount slides on centerlines on all of the pieces and locate the bolt holes on the both sides of the middle slide supports. H) and on the links (Photo 11). You have to use cable clamps because the a wider saw. Cut the plywood slide supports (AA–CC. cable clamp to form a loop. Note that the slide supports are nism and make any necessary adjustments. Fig. Then thread the cable through to conveniently store these must-have accessories on the left the eyebolt. link (Fig. Then attach the caster brackets The platform shown shown here is designed for use with (Photo 8). up and through the lever. For a shorter or taller saw. eyebolts (Photo 7). simply widen the cabinet’s opening. Then follow the manufacturer’s instruc. Note that the saw’s blade must (Photo 9). Eyebolt eb e bol olt Looped cable Cable Caa C clamp p Wire cable 9 10 Feed the cable from the caster bracket’s eyebolt through the first Use a woodworking clamp to tighten the cable after looping it pulley. rotating links (DD) to length. ends of the links to a 1" radius (or slightly less) so they won’t Flip over this assembly to attach the cross brace (HH. the mounting height shown 13). flush at the back (Photo slides from rolling back into the bench when you lift or lower 17). 16). extended. Then install stops made from 1" x 1" aluminum angle to the cabinet. flush with the back ends of the middle slide supports. Aluminum-angle stop Link 15° stop p block blo lo Inside In n slide support 3 13 14 Fasten an angled stop block behind the link near the front end of Install shop-made stops to ride on top of the slide supports each inside slide support. inside the cabinet. Remember. round the the links mounted on the two slide assemblies (Photo 15). After attaching both slide supports. countersink or counterbore the holes and drill deep enough automatically fall into place when the assembly is pulled out. Tighten the links so they rotate smoothly. Assemble the bracket and mount the the assembly is pushed in. so the benchtop functions as an outfeed table. Make adjust- bling. Fasten the links and Remove the platform’s outside slide supports and mount their 15° stop blocks (EE) to the inside slide supports (Photo them in the cabinet. Start the assembly by attaching the drawer slides on the supports’ centerlines (Photo 12). without binding or wobbling. Don’t over-tighten. to recess the screw head or locking nut and washer slightly Assemble the platform’s frame (FF. Set the blade height at 1/8". Cut Assemble each set of slide supports and fully extend the a pair of spacers to the proper length and clamp them inside slides. Place each outside slide support on top of these stabilize the pullout assembly (Photo 14). tablesaw. Platform forrm fo m brace Platform lattfo form sside Brace raacce 15 16 Attach the platform frame to the links. Note that the slides mount Install the tool platform in different locations on each support. After all the holes are drilled. These stops keep the spacers. Cut the stop is high enough to ride on the adjacent slide support when legs (MM) extra long. Tighten the bolts so the Stabilize the platform assembly by fastening a horizontal brace links rotate freely. Attach each stop by rotating the ments as necessary to find the correct mounting height for front link up and over to match the stop’s angle. The links at the back end don’t require and automatically fall into place when the slide assembly is fully stop blocks. Pull the platform out of the cabinet just far enough 62 merican oodworker. to the bottom. Drill faces of the inside slide supports. Make sure the to the same length and the plate (LL) 1-1/2" longer. Then fasten it to the frame. without wob. Cut one leg of the angle down to 1/2" on the platform assembly as if it were a drawer. place the angle against Install a support bracket with fixed casters to complete the the fence with a sacrificial piece of wood nested inside and run tool platform (Photo 18). install the rest of the the tool platform. Fasten the stops just tight enough to 2" casters. your saw. Cut the cross brace (KK) mounting holes for screws and attach the stops. GG) and attach it to below the surface. measure the length between the outside Each slide assembly requires four 3-1/2" long stops. With the platform fully recessed the assembly through the saw as if it were a piece of wood. in Figure G is for the DeWalt saw that’s pictured.com FEBRUARY/MARCH 2014 . Photo rub and cause the mechanism to bind. Then flip the assembly again to fasten the platform (JJ). ). #28647. ping to storage height in the case of a kickback. These Heavy-Duty Swivel Caster. duty Full-Extension Drawer Slide. Use spacers to level the supports and position them at the correct height. (You may each). 1-3/8" x 30" x 80". 52". Machine Screw. 10" Compact Job Site Tablesaw. Roll pin. B-C Fir Plywood. #31-483. 1/8" x 8’. 5/16" x 4" (2 req. Washer has holes for screws). 5/32" x 1-1/2” (2 req. 3" (4 req. 5/16" x 4" (4 req. Then install restraints on both sides to and Nut. restraints will help to keep the saw and platform from drop. Heavy Duty Oscillating Bench Spindle Sander.com 63 . These alterations lower the platform’s storage height by 5" • DeWalt. Accommodate a tall tool |1" x 1" x 36". 1/8" (1 req. deltamachinery. Screen Door Repair Fasten the saw to the platform (the base of the DeWalt saw Wheel (2 req.). #8. anchor the saw to the cabinet during use (Photo 19). #8 (4 req. $34 per pair (4 pair req. 1/4" x 1-1/2" (4 req. 16". dewalt. Cable Clamp. 800-433-9258. $519. Heavy- the links and cut the stop blocks to the dotted line (Fig. see Note “cc” on 800-223-7278.69 to $6.H. 800-279-4441. FEBRUARY/MARCH 2014 merican oodworker. Bolt. Power Strip. and cut the legs to length. Hollow Core Door. Trim the platform’s width so it fits between Screws.00. 1/16" (8 req. #68888. $3.). Fixed Casters.99. have to cut slots in the benchtop for the miter gauge’s bar.59 per 100 screws. Square-X Drive Lube Finished its cross brace.).). Minor modifications allow the tool platform to house a Screw Eye. to slide the bracket into position against the inside slide sup. Washer and Lock Nut. Continuous Hinge. the Tool Platform Cutting List (page 60). Spacer Su Support b bracket 17 18 Mount the platform assembly’s outside slide supports in the Install the support bracket to complete the tool platform. Eyebolt. modate the Delta 31-483 Heavy Duty Oscillating Spindle • Delta Power Equipment Corporation. 1/16" x 2’. 1/8" (3 req. Sander shown on page 56 (see Sources).com. 2" (4 req.). 3/8" x 3" (1 req.) Washer and Nut.). #6. 1/2" and 3/4" thickness (2 sheets gauge work properly when the platform is raised. • Rockler Woodworking and Hardware. $89. rockler. Stranded Wire Cable. Shorten the support bracket’s legs and trim the width of Woodworker’s Bench Vise. F. much taller tool (Photo 20).). #DWE7480. Aluminum Ferrule. 1/4" x 2". $379.). Then mark the legs’ exact height. 4x8.com. Richard Tendick is a retired engineer who ports. Mount the platform lower. Remove the bracket loves designing projects and working wood. Then fasten it to the platform. J). #46899. Lower mountingg Eyescrew height Tr Tr Trimmed stop block Gate latch Narrower platform Ferrule 1/16" cable Sho Shorrtte Shortere Narrower wer er 19 20 cross brace legs Anchor the tablesaw to the cabinet with cable and fasten it to Modify the tool platform to accept a taller tool by lowering its the tool platform with screws or brackets to secure it in the event mounting height inside the cabinet and making other minor of a kickback. #29322.com.). Position the saw on the tool platform so it slides in and out SOURCES without touching the cabinet and so the rip fence and miter • Home Center.).).). while maintaining the same operating height. 1-1/2" x 24" (2 req. cabinet. Gate Hook.). 3" (4 req. 1/4" (8 req.). To accom. Aluminum L-Angle.99. changes that allow the links to rotate all the way down. for each). A. Every woodworker is going to ask. next page). like the battlements on a castle wall (Fig. Standard methods won’t work. following the process of making the joints will be much easier. But what if you want really. really big finger joints? Can you imagine making accurate cuts that large? Nope. narrow table to showcase these joints. Once you’ve got this image fixed in your head. “How did you do that?” 64 merican oodworker. | PHOTOGRAPHY: JASON ZENTNER | EDITOR: TOM CASPAR Extra-large finger joints add a distinctive touch to any project. Finger-Joint Table Discover the small tricks by Tom Caspar to making large joints. MOST FINGER JOINTS are pretty small in scale. Now imagine those laminations as having staggered ends.com FEBRUARY/MARCH 2014 . and it can be used on any number of projects. ILLUSTRATION: FRANK ROHRBACH The first trick to making the joints is to think of the project’s parts as a set of three butcherblock tops—thick boards composed of large laminations. I built a long. Here’s a strategy that does work. Or whatever.. which makes them easy to cut on a tablesaw or router table. but you could also use them to make a bench or a desk. When you joint an edge. Let safest approach is to just whack off both ends of every board me explain. depression at the beginning or end of a board. because the finger joints require every (Fig. and ran all my pieces The easiest solution to eliminating snipe works every through a drum sander as well. To fix the problem. I suppose. many planers tend to cut a slight you see any snipe after jointing and planing. The most obvious. when you’re milling not 100% effective. the problem as much wood. is to simply only shows on the surface of the top.Fig.) You may not be depression is called “snipe. until they’re even. while others will be planed—unlike the 3/4" top.com 65 . If your planer sniped. You have to address it earlier. but gaps between your glue joints. you must crosscut your Before we get going. it works. let’s take a detour into the ugly world rough lumber into pieces that are about 6" extra-long. ect. As you know. cut it off. as I said. you may take off more wood at the where every edge to be glued is cut by the jointer. But I’d hesitate to do it when In this project. It can be very subtle. snipe can be a real problem. a little snipe isn’t a big able to see the snipe. x 2-3/8" Notes: a) Rough size: 1-1/4" x 2-5/8" x 48-1/2" C b) Rough size: 1-1/4" x 2-5/8" x 30" A Fig. you’ll be making a much thicker top building this table. but it comes at a price. you joint their edges Alternate strategies for minimizing snipe don’t waste and glue them together. if the planed edges are sniped you’ll get small way around. this method would work fine. C Butcherblock Milling Steps Fig. I used the “butt the pieces end-to-end” the wood. so the deal. On the beginning of the cut than at the end of the cut. Clearly. Th x W x L A Top 9 1-1/4" x 2-3/8" x 48" (a) B Leg 18 1-1/4" x 2-3/8" x 29-1/2" (b) C Dowel 24 1/2" Dia. joint every surface after it has been planed. it may not work in practice. B Doweling Details B 4" 1" 1/2" DIA. First. I hate doing this. but they’re together. But. And in this particular proj. Some of the edges to be glued together will be piece to be exactly the same thickness from end to end. however. jointed. method when building this table. 2-3/8" SHORT PIECE LONG PIECE Snipe matters time. because it Say you’re making a 3/4" thick top from several boards. When all was done. If of snipe. There are yet more ways to deal with snipe (see “12 Tips you can’t fix the snipe problem after the pieces are glued for Working with Rough Lumber. I still FEBRUARY/MARCH 2014 merican oodworker. C). and that (Snipe is usually no more than 3" long. Frankly. But in this project. (Assuming you just plane. After planing the boards to thickness. A Exploded View Cutting List Overall Dimensions: 29-1/2" H x 48" L x 11-1/4" D Part Name Qty. scrape or sand the ends of the sniped boards your jointer doesn’t snipe!) On a regular butcherblock top. wastes a lot of wood.” Usually. you’ll also get finger joints that are too loose. The theory is good. and have done with it. or the other thicker top.” page 26). You just can’t be sure. However. and a stop block to make sure that all of the holes are in the same Repeat the same process for the second table leg and the top. to form the table’s finger joints. before making any cuts to form the fingers. mark both ends of the even-numbered pieces the same thickness. 3 4 Drill a 1/2" dia. hole near both ends of each piece.” page 27). mahogany. however. they’ll keep everything in alignment. Start with 6/4 (1-1/2" thick) rough lumber. From here Next. so they will be exactly the same width and table’s top. The dowels aren’t intended to together later on. mark only on one end of the After crosscutting your rough lumber. need to reposition the stop block on the opposite side of the 66 merican oodworker. B). which is the thickness of the top and legs—2-3/8"). rip the pieces odd-numbered pieces with an X. strengthen the joints—they’re registration pins. or tried the (Photo 2). As you plane. Board numbers 1-9 Grain n direction Future mark 1 2 short pieces Begin by trimming all of the pieces for the legs and top about Arrange the pieces in order. On the table’s legs. In addition. Set be able to drill most of the holes using the setup shown in up a long-armed stop block for cutting all of the pieces 1/4" the photo. Note. then mark every other one with an X. then plane the opposite sides until the pieces Next. for two of the “halfway” holes. Plane the opposite on out.) Mill all the pieces for the top (A) and legs (B) forming fingers—mark these pieces with a big X. (I used African 1 through 9. Joint one face of Register with dowels each piece. Use a fence Glue 1/2" dowels into the holes of the even-numbered pieces. In retrospect.com FEBRUARY/MARCH 2014 . joint one edge of each piece. you’ll join are 1-1/4" thick. 2-5/8" wide (1/4" wider than the final dimension.) Number 1/4" extra-long. Trim through the outside pieces (#1 and #9)—just halfway. dowel holes through both ends of each faces of the table’s top and legs. These surfaces will be the inside and outside Drill 1/2" dia. they’re glued up. I wish I had Arrange the pieces to form the table’s top and legs used the “whack off the ends” method instead. with an X. Alternating pieces will get cut shorter later on. You’ll one end of each piece and redraw its grain direction mark. draw Milling and marking a large triangle across the assembly and number each piece. You’ll cut the X pieces shorter later on. each piece. position. To minimize tearout. position the pieces so that their grain all runs the same way. you’ll extra-long. then trim the other end of each one (Photo 1). mark the grain direction of each piece on Fig. had a small amount of snipe. that the holes don’t go all the way both of its ends (see “Mark The End Grain. Oh well. dimension). All of these pieces will be planed as a unit after “joint every planed surface” solution. These are the surfaces that will be glued the pieces with dowels (C). piece of the top and legs using a Forstner bit (Photo 3. On the at the same time. (This is one of the legs. and that will edge so the pieces are 2-1/2" thick (1/8" more than the final be crucial to making tight joints. The dow. but not too tight. Sources). Set up a stop so you remove exactly with light taps of a mallet. Take apart each assembly after cutting. mark one face of each fin- then wipe off all excess glue. On each leg assembly. Make sure your piece of notebook paper. Glue up each section Reassemble the top and legs (Photo 8). they will—but nice and tight els should fit snug.) Position the dowels so they stick out gers thinner by a few thousandths of an inch.) Adjust the router’s Reassemble the top and both legs. without glue. Note: so tight that you won’t be able to assemble them. Clamp of the top and legs are perfectly flush with each other. For the best fit. many commercial I chose to head off this problem by making the leg fin- dowels are shorter. Trim both ends of all the even-numbered pieces from the “finger" with an X. Countersink both sides of each hole. In fact. Cut the dowels to final length ger with an X.003"—the thickness of a final length. Guide the cut using a board with a slot cut into ends. They should stick out less than marked faces with a top-bearing pattern bit (Photo 9. the 2-3/8" (including the kerf cut by the blade)—the target joints are too tight. course. The slot is spaced 9/16" from the edge touching the stock. so the offcut won’t be trapped. far end of each piece. and trim both stock’s thickness). that trimming the X pieces has now created a series Glue dowels through both ends of all the even-num. If you’ve got everything planned FEBRUARY/MARCH 2014 merican oodworker. It’s best to put the stop at the and rout the leg fingers a little bit deeper. You’ll see. The dowels serve to register the pieces together. Take apart the leg assemblies and rout the on the bandsaw (Photo 5). ensures they’ll be flush. Not good! The dowels must be at least 2-1/2" long. table’s top. Mark one face of each legs. as shown in the photo. 5 6 Cut the dowels so they only stick out 9/16" (less than half the Assemble each part of the table. see half the thickness of each piece—9/16" is about right.com 67 . then cut these parts to depth of cut to remove only about . too. This step ensures that all the ends Reassemble the legs and clamp them together. this step it. disassemble the legs thickness for the top and legs. the top assembly together. page 69. If you need to use more force. trimming both ends (Photo 6). to do it. Stack other pieces around the finger to be routed in order to guide the bit. Finger 7 8 Trim one end of all the odd-numbered pieces from the table’s Reassemble both of the table’s legs. drill bit. and try fitting the joints Take apart the assemblies and trim the pieces marked together. blade is set at exactly 90°. The fingers should fit nice and tight bered pieces of the top and legs (Photo 4). (The bit's bearing ensures that you Make the joints won’t cut into the surrounding wood. of fingers and notches. If that’s the case. You should be able to push them home by hand or with an X (Photo 7). the joints may be factory-made fluted dowels. (See Sources. of Let’s start with the legs. use doesn’t leave any room for glue. Here’s how approximately the same length on both sides of each piece. right? Yes. in the notches. Feed FFe e d G Grain direction d di ire re e i dirre di e direction Caul 11 12 Clamp the leg pieces between stout cauls. applied Behlen’s Medium Red Mahogany Non-Grain Raising Stain and brushed on a 1-lb. which is relatively inexpensive. cut shellac seal coat. and even. I made this stool from 6/4 yellow poplar. so the stool wouldn’t tip. Sculpted Finger Joints Large finger joints can be shaped in any number of ways after they’ve been glued together. —Tom Caspar Find out how three types of bleach can transform wood at AmericanWoodworker. for example. but it wasn’t hard.com/WebExtras 68 merican oodworker. I roughed out both of these shapes on the tablesaw. and three coats of Varathane water-based poly. I bleached the wood. Make a Glue all of the leg pieces in one shot. so the legs and top will come out smooth procedure for the other leg and the top. This stool.com FEBRUARY/MARCH 2014 . then stack them one on top of another. Repeat the oriented the same way. The secret to making the convex legs was to leave a 1/4" wide portion uncut at either side. using a series of angled cuts with a dado set. Apply the glue to one piece flat bearing surface by stacking other pieces alongside. Place the clamps Plane both sides of each piece you’ve glued up. with no tearout. To finish the piece. Reducing at a time. which deepened the red color. numbered order. following the the thickness of these fingers will make it easier to glue the joints. as a dry run for making the larger table in this article. Top-bearing pattern bit Paper 9 10 Rout the marked faces a paper-thickness deep (see inset). All the grain is above and below the cauls to apply even pressure. Smoothing the surfaces required a fair amount of sanding. This was followed by a coat of Varathane Cabernet gel stain. features a concave top and convex legs. #18808. Reduce finish the job with sandpaper. It darkened the end grain of the Glue the finger joints finger joints. level them with a router (Photo 15). pattern bit. then place the complete stack on a row of pipe clamps.. glue the top all in one shot. legs in position. clamps aren’t necessary. so you can just slide them together. 1/2" x 2-1/2" grooved and fluted dowels. Put cauls alongside the glue-up. 1/2" dia. then use a small paint roller or equivalent to apply glue to its inside face. that are slightly smaller than each finger (Photo 13). then supported It’s best to glue this type of top in stages. Stack the pieces in order. Glue a piece of notebook paper to one face of each block.com. $5/100. which is essen. Plane both sides of the legs and top (Photo 12). stiff cauls ensure that the hammer. making a pleasing contrast with the rest of To avoid denting the wood. knock off the gluing blocks with a the assembly in the clamps. prepare some softwood blocks the wood. Boy. Scrape off all the excess Level the fingers. But if you work alone. up. The glue may start to set up before you get After the glue dries. After you apply the time. Each of my cauls were composed of three pieces of 3/4" x 6" x 48" red oak glued together. then rout every edge with a 3/16" roun- thinner than 2-3/8". are they stiff ! Large L cauls can really come in handy for gluing a together some blocks to elevate the legs off the floor (allow- large l butcherblock-style top (Photo 11). apply glue to both sides and add it to the stack. Routing should leave them just a hair proud. the better. Place it nearby.) Pick up piece #3. (You only have to pattern bit apply glue to one side of the joint. dover bit. Rubbing them in place • California Dowel and Turnings. If the fingers are proud. $25. To • MLCS. an oil/varnish mixture.com. if they’re proud. run out of time. I taped FEBRUARY/MARCH 2014 merican oodworker. then glue SOURCES the blocks in position. I finished the table with Minwax Antique Oil. The bearing prevents the bit from chewing into the The cauls should be as thick as the pieces you’re gluing support piece. then add more 15 clamps across the top (Photo 11). tial for the final glue-up. And you don’t have to put any glue in the dowel holes. with a router and top-bearing glue before it hardens. Top-bearing aarrin ng Stack piece #2 on top of piece #1. you can glue all nine pieces at the same time (Photo 10). Some of the paper will be left behind. Glue Apply glue and clamp in both directions. Big. devise a method for holding the top and #16509. smack the joint most of the way home with a mallet. make this easy. to remove with hot water and a putty knife. Remove piece #1.. mlcswoodworking. so the fingers will stand 1/32" proud). Pattern Routing Bits. paper-backed softwood blocks on each finger—wherever you may need to apply clamping pressure. Here’s why: ing room for the ends of the pipe clamps). out. caldowel. If you work really fast and have an assistant. $19. 1/32" legs meet the top. but it's easy sides of each half remain absolutely straight. one corner at a time. then jointed. is sufficient. Keep on going in this manner. outside face down. Level the areas where the them from 2-1/2" thick to 2-3/8" thick (or better yet. 866-663-6935. The wider they are. one half at a It the top with a box placed on sawhorses.com 69 . Glue one corner of the table at a time (Photo 14). Paper 13 14 Prepare to glue the table together. 800-533-9298. to start a new pile. 3/4" dia. you may Draw the joint tight with clamps. you could glue. paper face in. it through the planer or fuzziness tic (or knotty). acteristic is one reason red alder is This makes it especially easy to elimi- frequently used for factory-made fur. as red alder Except for its slightly darker color. It’s also stable. PHOTOGRAPHY: JASON ZENTNER hardwoods. red is only moderately dense (similar to alder resembles white birch in appear. nate any minor imperfections that niture. Sanding uniform in color.” This char. However. rus. it’s often referred One of my favorite working prop- to as “poor man’s cherry. occur during construction. is evenly textured. Its figure resembles white birch. with 120 grit removes machine marks glues well and costs less than most surprisingly quickly. The lumber is widely available notice significant tearout when I run and typically sold in two grades. machines cleanly. saw cut red alder with ease. The wood typically because it can be finished to closely turns slightly lighter and more golden resemble many other more expensive over time (Photo 2). 1 Red alder is typically a pale reddish tan color. Finishing Red Alder Four recipes create distinctly by Kevin Southwick different looks. two reasons why it Red alder is especially hard to identify machines so well. 150 grit is per- other hardwoods. Red alder has my work as a furniture restorer and straight grain structure and its surface conservator. I don’t west. and clear (or superior). light in weight. I often hear this question. erties is how easily red alder sands. Red alder is the most abundant My small tablesaw and band- EDITOR: TIM JOHNSON | hardwood timber in the Pacific North. when I rout it.com FEBRUARY/MARCH 2014 . fect for final sanding before finishing. poplar and only two-thirds as dense 70 merican oodworker. In fact. at left). “WHAT KIND OF WOOD IS THIS?” In ance (Photo 1. Exposed to light Linseed oil Water-based poly 2 3 Exposure to light turns red alder derr a slightly lighter golden erenn looks. Water- sure when gluing up a panel can actu. dark color wood tone because it readily accepts with very little blotching. mation to quickly and easily give red to a chameleon: Its natural color can Water-based dyes work extremely alder four distinctive looks. applied (Photo 4). Liquid pigment stains. However. woodwork. stain controller adds richness and ers seem to overlook it. Gel G stain over clear c gel over Liquid oil-based stain Gel oil-based stain Gel stain over clear gel Water-based dye water-based w dye 4 cha Dramatically change red alder’s appearance by using different types of stain. but leaves enough to result lowed by the clear gel as a stain con- descript. even though red alder lodge in the tiny crevices that cover Combining water-based dye with has many positive attributes and is the wood’s surface. Even clear finishes allow result shows the wood’s figure more like other woods. troller and then the gel stain. types of blotching even further. after an application of clear gel used Recipes ety of woods. it dents relatively easily. create two kinds of blotching on ate lighter tones on red alder. In this indistinct figure. or deep red adds a step to the process. I’ve also ated by the type of stain or the way it’s show a texture so uniformly smooth learned that too much clamping pres. Dyes work best best to drill pilot holes and turn the red alder’s middle-of-the-road grain when the goal is to minimize the screws carefully when installing them. be altered to match just about any well to provide intense. dark walnut.com 71 . grainy blotching on luster and shimmer that resemble the Chameleon wood a small scale. while water-based poly minimizes both. It doesn’t darken like cherry does. as cherry). based dyes also work very well to cre- ally bend the boards. because the pigments look of maple or birch. that it can actually shimmer. with red alder: Coarse. pattern can be minimized or exagger. for exam. red alder is similar applying gel stain alone. fol- medium texture make it rather non. so the depth that can make red alder look alder is underappreciated because its stain soaks in unevenly. because red alder’s sur. it’s exactly these in a slightly muddy appearance. blotching. With very little work. Surprisingly. alder’s natural color and grain. so no stain FEBRUARY/MARCH 2014 merican oodworker. This processes create different effects is ral cherry. like an expensive hardwood. controller is needed. n either e n alone or in combination. It’s all kinds of stains. Linseed oil brings out red Clear finishes can create very different tone. a large scale. and blotching on gelled pigment stain and clear gel as very nice to work with. More importantly. neutral color and Using gel stain limits both types of process the dye is applied first. clearly and is more lustrous than on the following page use this infor- In a nutshell. The simple recipes you to alter its appearance (Photo 3). properties that make it possible to Gel stain applied immediately use red alder to imitate a wide vari. but the the secret to making red alder look mahogany. ple. Perhaps red face is not uniformly porous. as a stain controller reduces both Knowing how different stains and red alder can look a lot like natu. wood’s figure and grain in order to so as not to strip the holes. I chose two coats of Zinsser SealCoat varnish. this mahogany look. Step 3 Apply your favorite top coat. . but first using clear gel varnish as a stain This three-step coloring process provides deep. Let dry for an hour. It controller reduces large-scale dark blotches and provides a uses dye for most of the dark reddish color intensity and then more natural-looking and pleasing grain texture. Because the brings out the grain pattern with pigment to imitate a dark red clear gel is used immediately before the gel stain is applied. A top coat of water-based finish quick step to red alder without causing unsightly blotching. Step 2 Apply your favorite top coat. Rub off the excess with dry rags or paper towels. will enhance the look. surface. rustic tone on knotty red alder. Step 1 Generously apply TransTint Dark Mission Brown Dye (mixed in water to the standard strength. label). cut) dye Amber shellac creates a warm. Step 2 Apply the first coat and let dry 20 minutes. The fast dry time of both products the dye colors I’ve tested work well. lustrous colors in one without unsightly blotching. cut. A wipe-on/rub-off finish. Let dry overnight. varnish.com FEBRUARY/MARCH 2014 create richness and depth. work it into the grain for a minute or two and then rub and one coat of General Finishes High Performance off the excess. Water-based dyes work great to add dark. A semi-gloss sheen will help 72 merican oodworker. Polyurethane Water Based Satin Top Coat. rich color. minute to allow for thorough and consistent saturation of the Step 2 Immediately wipe on General Finishes Candlelight Gel surface. a minute to allow for thorough and consistent saturation of the Then apply one coat of satin water-based finish.Red Alder Recipes Knotty pine Dark walnut Amber shellac Water-based (2 lb. a stain that dries as fast as water evaporates. Let dry Stain and thoroughly rub off the excess. Step 1 Generously apply TransTint Reddish Brown Dye (mixed Step 1 Generously apply General Finishes Topcoat clear gel in water to the standard strength. such as Sam Maloof’s Poly/Oil Finish. work it into the grain for a minute or two and then Continue to work in the dye with a damp rag for at least one rub off the excess.b se ba sed sed dye This is an easy method for imitating natural cherry. for an hour. All leaves a pleasant satin sheen. pattern reversal that pigment stains do. process doesn’t require any extra drying time. Continue to work in the dye with a damp rag for at least Step 4 Lightly sand with 400 grit and remove the sanding dust. It’s also nice to work with Step 1 Mix amber shellac at a 2 lb. For the “natural cherry” Step 2 Generously apply General Finishes Topcoat clear gel alder table on page 70. and do not cause the grain can make this finish a one-day process. Step 3 Immediately apply General Finishes Candlelight Gel Stain and thoroughly remove the excess. as directed on the Step 3 Apply the second coat and let dry 20 minutes. as directed on the label). Remove excess with dry rags or paper towels. Natural cherry Dark red mahogany Gel Stain Gel stain stai st an ai Clearr ge g gel el gell ge Clear gel Water-based r-ba r. Step 4 Apply your favorite top coat. Using gel stain alone looks OK. infinitytools.com 5 Epilog Laser www. Church Set of Five! Community Projects 75$&(&873$.osbornewood.$1$ '%$-". www.cookssaw.&$·6)$925.oneida-air. SOCCER Purchase One )$. Wagner Meters www.com 29 Website! partysportspatterns. BOWLING. veneer & turning stock .timberking.bealltool. CHERRY & MORE Osborne Wood Products www.groffslumber. MAPLE. FFriendly rien ri iendl eennndl ddly dl ly se sservice serv erv rvic icee ic . BASKETBALL Fundraisers FOOTBALL.com 8 Shipped to You! Oneida Air Systems www.pennstateind.7(*$0(6 Timberking www. OAK.com 73 Harbor Freight www. 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Crazy Mistakes Woodworkers Make Kamikaze Tailstock of the way—and watched helplessly as it glided I OFTEN WAX finished projects as they spin on my effortlessly down the bed. I gave the 70 lb. I was so excited. A book After removing the old cabinets and installing the that came with it included plans and instructions new ones. so I built the cabinets in them would fit under the new cabinets. American Woodworker. so I decided that new Meanwhile. We may edit submissions and use them in all print and electronic media. I couldn’t my father’s garage shop (he’s an avid woodworker). Unfortunately. Jonathan Lipscomb | EDITOR: TIM “OOPS!” JOHNSON Make your woodworking mistakes pay! Send us your most memorable “What was I thinking?” blunders. Email to: oops@AmericanWoodworker. 74 merican oodworker. figure out what had happened. sailed off the end and lathe. 1285 Corporate Center Drive. ILLUSTRATION: STEVE BJÖRKMAN for building kitchen cabinets. Then I measured the cabinets I’d removed. so it’s natural to wax the lathe’s bed at the same crashed to the concrete floor. none of space at home is limited. My shop appliances back into place. Suite180. Eagan. lathe’s tool-rest banjo and tailstock glide effortlessly. they were stained and finished. (Waxing the bed prevents rust and makes the spindle wheel shattered.) Now the Vise-Grip pliers that substitute for the Unfortunately. Fortunately. I book. I stepped back to admire my handiwork. nothing else was damaged. I built a corner cabinet and two the directions and used the dimensions given in the others. one to go on each side. You’ll receive $100 for each one we print. my wife began moving the countertop upper cabinets would be my next project. Submissions can’t be returned and become our property upon acceptance and payment. tailstock a shove to get it out tailstock carefully. Tim Heil Too Tall I RECENTLY PURCHASED a pocket-hole jig. only its time.com or send to AW Oops!. because I’d followed Over several trips. 99.com/app Pad® isis a tra iPPad iPa Pa traadem dem mark aarrrkk of of Ap Appple llee.SS aannd oth tthe hheer cou oun uunnttri trries. newsstand price).. Digi- tal issues include links to bonus videos and project information. a monthly iPad subscription is $2. a year’s subscription is $24. reg egi g sste gi sttered tteered edd in in th the U.YOUR BEST SOURCE FOR LEARNING NEW SKILLS These and many more titles and plans available at awbookstore.S.. If you’re not a print subscriber. ries ees.com or 1-800-876-1822 Available on n ® ® Apple iPad If you’re a current print subscriber enjoying your free digital edition of AW on a desktop or laptop computer. 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