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11 TOOLS THAT SIMPLIFY CABINETMAKING,; ISSUE 221 OCTOBER 2013 Better ao and Gardens® THN EUS eye f Plus more great plans Stylish Blanket Chest... Architectural Shelf Brackets... Elegant Accent Table,., Cordless-Drill Station... PURVEYORS OF FINE MACHINERY®, SINCE 1983! Grizzh BO aS ea ree ae ade el Seamneennels 10" CONTRACTOR TARLE SAWS 10° HYBRID TABLE SAW 12" BABY DRUM SANDERS mere dhe subi. (6056) wane ny ans aa = 60713 ss95-00 sate 850° ue some GO459 3695-00 sate 575% 2a urement, acters rowan nese ounce cook "oh G0661 3925-00 sate $875% ~ GO715P oxy °795" ) )\ GO4S9P 5595-00 save °575% ~ =) (TS) 8" soInteRs (EES 15" PLANERS 20" PLANER + Mor 3 HF, 228, single phase, TE + Mtr 3 MP 20, sg shasa + oto: 5HP, 210 sgl shase a { Precsomarood eatin ale i937 1 Preesam grind at ron be Neal ia oe {Moc depth ot = Moc ratbeing ep soe 50 1 fio eiog hg Stunted matador + Min ack thks: =. + Ma set Boss { Cateead sae en iin sac ong + Mia. sae on muon, NS oie Seg deat |: ieyccemsenn SssonPat 1 eed ate 1M 830 FPL + Feedrate8 (cosssrx) esd + Cutoread spect: 00 APM 4 neem Cusperminas: 2000 “fgpoxmate chop went: Bes + Cutrboad ameter 24 (coer So ty! eo (2 + Sat en + igri 21400 oo. GD4SIP}) fon (ooesePa ‘ a aeantoee) era ssa vernon cree mah san |] mus care corres taua | Sewage or GO656P ony *825°° sess |] GOASSP $1095-00 saueS1O50% ss |] * Seroonmteshinnmowaich: §—BZgh, SE GO6S6PX ony °1225° GoassPx ony '1695% — ~"!584 }\ Goasa ssssero sau $1595% a ee een) 14" DELUXE BANDSAW | [Egos 14” ULTIMATE BANDSAW || (TJeq_=) 2 HP DUST COLLECTOR + Moto 1 HF, TE 110/220, + Moo: HP TEC, 4220, : adie te soge herve 100 te ee eons ea awe2 22a te, + Ange a 10, 8.92 + F busin : 5 + Blade se: ion 5 cating eapciyteas 91" apse eric a ties ae a anna ene : Bag capacity: 5.7 cu. f. js tate hoy ie re ‘+ Impollor: 12%" balanced cast cy 1 Me ene Se ee an SY SralserenxseD parma Hea ns + Foon 2975 1) sTiuehegte rR + Porat bose 2/0 x4" ic + Tale tight above for 4 Stier Risst + Aoprosnateshipsing weight | + Taal ght 1 Fane corsn: Dtse Uae - + Apronate sig ht se uma = ais + Blade speeds 1 & 200 FFM ue ° saad Ge + Ste st anew ANso Ne 5 ere a a gee «| rt 25 bs vem se GOSSSLX onty 545% GOSSSLANV $545.00 save 544.5% G102922P 8325-00 save $309% Sou pL Tite LT ge m= fom: Pei near canos 3 OREAT SHOWROOMS! Caer eee eee eee eon £ BE so: 18 Cordless rill Hangout 24 Workbench with Wall Storage Build one or both using oly common tools 30 Elegant Accent Table Don let the curves throw you. A few simple techniques ease construction 34 Kids’ Project: Musical Wood Blocks 36 Blanket Chest 60 Architectural Shelf Brackets These easy-to-make corbels can double asbookends. (64 Offset-turned Candlesticks 4 Pocket hole Tips & Tricks 20 How to Find Affordable Lumber 45. Shop Test: Pocket-hle Jigs ‘50 Tricks and Tips for Better Built-in Cabinets BASIC-BUILT | : 56 Must-have Cabinetmaking Tools AT PROETS MADE SPE. 76 Shop-Proven Products Universal workbench base carbide tipped tuming tools, and mare. 3 Editor's Angle 4 Sounding Board 6 Shop Tips 22 Unvamished Project design ideas surround you a 70 Ask WOOD® 84 What's Ahead woodmagazine.com Better Homes and Gardens® Issue No, 221 TRICKS AND TREATS TO GET YOUR SHOP SHIPSHAPE ARFDIRECTOR WRENS Were giving away downloadable plans forjigs and organizers to make your ‘ shop a safer, moreeffcent pace to work, lus, you'l et dozens of free tps, fi Ee seein Sant ec videos and tol reviews Vist woodmagazine,comi/areatshop every week SENIOR DESIGN EDITOR armtone fiom August 20 to October 2, 2013, for fresh ne info and plans! ercittttog eae EDITORIAL CONTENT.CHIEP pvecomre DEPUTY EDITOR cnet TOOLS EDITOR sonnet CGENERAL-INTERESTEDITOR MAGNO ADMINISTRATIVE ASSISTANT STLNURON ‘CONTRUTING CRAFTSMEN usa na sms, ee rnc sv Se mt ee ‘noToctntts aasaoonn ons ‘SINSS MANAGUR HRN WLUFSN CONSUMER MARKETING DIRECTOR BENSON Downloade plansfortisverante | OSAUMANUC racat tation a Rerinia acon ieee me aap ane eesa rsx oss aes Ee HOMES Ns a ‘EAE CaNTENT ADE tems Ce NANG ER “hike Dv OFack oat CHIEF AEVENUE OecHR Monn Gtr ANON Ont mei i NGL Re a “conrolaTe SALES abun DIRECT MEDIA AMER RAND LICENSING ae SBmeredith tau ano CHEF EXECUTIVE OFPCHR see WIN A SHOP’S WORTH OF JET MACHINES Le) ‘We had such fun giving away $5,000 worth of machines from Jet Tools last summer, we decided to dit again. You can enter every day to wina tabesaw, bandsaw, dil press, joiner, rum sander, and dust collector at woodmagazine.com/jetdreammachines. healers rnin win ie i nt teed tenting ata tose pts ace, a es 3 en HAND cen ane redo elbepin ete oh ad nents orm OBs) SA eS nog ‘eel med nda sage dren > dire, nde athon dares pt Mtnaauenpes DDIM armen at dade ttojacnne taupe igo mipsel f eqs dessa git nae JOIN THE GUILD, GET THE GOODS ‘Nt Woodiarers Guido Amer, prem members get exhsve acest step-by-step project videos dovmoadable plans anda 154 discount on all HOOD Store purchases. Join WWGOA now and take 25% ofthe ‘membership pric! Lam moreat ,go.wwigoa.com/woodpromo. ealsechaohuaropeatnomartyeesayrecartnsst.n fy 2 WOOD magazine October 2013 Get the fit without the hissy Av: after aeathy dove of dotyouselt jhome-improvement experience. I's as if one morn- ing, after years of adding (and removing) walls, installing windows, and trimming out rooms, we suddenty woke up and realized, “Gee, I have all of these skills and tools... what else can Ido with them?” The difference between building walls and constructi the furniture that goes within them boils down to scale and tolerances: Most people would never notice a "error in a wall, but they'll cringe at half that error in reveal ‘These mentalities collide in the world of built-in cabinetry. My first attempt at a built-in was a simple computer desk in an alcove. After carefully measuring the opening where the front edge of the desk would be, I built the desktop to fit it perfectly. During installation, though, I discovered that the alcove narrowed at the back, and the desktop was 3" from the back wall, ended up “persuad- st of the way with a mallet, digging a nice channel into the drywall in the process. For your n builtin, don't be a Dave: Follow the terrific advice from SPP THE Work Saw 3000 1s THE COMPLETE SHARPENING SOLUTION eae TE Uns Moet) - had sucha great response to that sweepstakes, we decided to | aL MINIMA NLD ates give you anothes nce to win the same prize! Enter dails a < Hee Ta Waa Hato oe ‘Sharpen and hone your chsels and plane blades up to2" wide to Src eae Pea IL Active air cooled sharpener with routed air flow and heatsink is RC RT ce eek blades without overheating the tee! ~ no water mess. Ar ubetaveus teat ed CE eee UIE eee ecard ue, reat the sharpest blades you ever tad wth pea, ase, and eeatabty Ne eee Cae ee ee ee) Se Behe Cee gers iad Ces WORK SHARP WATCH worksHarProots.com DEMD Souncty Bea Hold the phone! Young entrepeneur makes a case for his business day own his own shop—instead of sharing the garage with his parents’ cars. Hopefully Steven’s work will inspire others his age to follow his example. In a display of remarkable drive and determination, teenager Steven Oleksak of Phoenix, Arizona, has generated funds for his college education by craft- ing protective wooden smartphone cases (right) using eye-catching exotic and domestic hardwood veneers. He shapes, sands, and finishes each case by hand before wrapping them with leather lace and sealing the package with a custom melted-wax seal. He's established his own website (woodphonecase.com) and has begun supplying his cases to local boutiques. A prolific woodworker, Steven also crafts mother-of-pearl inlaid ping-pong paddles (fr right) and has built a Les Paul-style guitar using only a how-to Juthiery book and guidance from his woodworker uncle. With plans to continue woodworking as he attends college, Steven says his dream is to one Woodworking classes: The tradi Although woodworkers lament the loss of school shop programs, asa high school shop teacher, I can only say that those lasses still exist, andthe kids who take them are as zealous as ever. With just alittle guidance and instruction, ‘my students have achieved some very impressive results, ion continues For example, my class of juniors built these simple deck chairs I designed from inexpensive 2x4 and 2x6 stock (blow), and my freshmen class used the juniors’ cutoffs to make a model ofa Stearman biplane—a great way to lear safe use of the shop tools and cut down on waste Jue Leite Rei Sask Article Updates ‘SketchUp Simplified Just after we went to press with the article “SketchUp Simplified” in issue 220 (September 2013), Trimble released a new version of SketchUp with some ‘minor changes. The free version of the software is now called “SketchUp Make.” (The paid version retains the “SketchUp Pro” moniker) Upon download, users are given access to the Pro version on a 30 day tral basis, after which it will revert to SketchUp Make. Some of the icons now look different than those shown in the article, but retain their keyboard shortcuts and functionality. Toolbars and toolsets have also been modified to make them easier to customize. Find more details about the changes at sketchup.com. ‘Construction-grade Scraper Inissue 219 (july 2013), Drawing 2.0n page 28, Drawing 3 on page 29, and the sourced hardware kit ist a" axle peg %" long. The axle peg should be 4a" in diameter. The kits available at WoOODStore.net come with the cor- rectly sized axle pegs, and the patterns hhave the correct axle peg locations. Freud’s Quadra-Cut™ Cems) et ak emp RS 0 ae «Without The Rework! oy, - "” iter 5 Ideal for Any Project that Requires a Flawless Finish! freud Precisely the best. www. freudtools.com/Quadra-Cut Gauge shows reduction in dust-collection suction Mec rine tp Tp— I tend to leave dust-collection blast gates open after using a machine, ‘now choose yous! Voteonlinenow at and that reduces suction at the next tool used. To provide instant visually ea ase indication ofa drop in suction, I came up with this handy gauge. acme To make one, attach a length of %" clear vinyl tubing to the dust Ea co ncrentiinking collector's pipe within a few fect ofthe dust collector and mount tas Wg shown, Pour a small amount of water (adding a few drops of food coloring makes it easier to see) into the tubing and mark the resting Sencar level of the liquid. With one blast gate open and a clean filter in the dust orpietie collector, turn on the dust collector and mark the maximum suction level next to the tubing. Now, you can spot a drop in suction—caused by extra blast gates open, leaks inthe system, clogged filter media, or s full bags—just by looking at the gauge to see ifthe water level has fallen Fen Wadsworth, Sedalia Cole, \ Dust collector 1 brasspex ‘coupling Fersendng hs sue Top Shop Tin KenrecevesaJe 10" Siding Dual BevelCompound | ‘Maersaw worth $50, DREAM MACHINE HAVEA WoOOD-WORTHY eA Aah Telushomyouvesceda verso Congratulations to Keith R. of Toledo, Ohio, winner of wot rdf gare more than $5,000 in JET Tools! | SSR eeeser aera oh You can still win, too! We're giving | SET Eee le away another set of these tools. | shoptipsewoodmagazine comor ‘hop Tips, WOOD magazine 1716Locust ‘St 15221 Des Moines IA 50309-3023. mig — ter oninetaoyandyoucouleejog al the y= etrrachnesshowmat by Inuary 204 Vist Seren ee theeea te ie woodmagazine.com/jetdreammachines to sign up.Enter Pacowta nyo ereyday fyoulle, toinceaseyourchancesofwining! | Sonysabited ntact ete sorucasecssa ooo secon eternity eset ont easton scp phe Dimension yore “Untnetiseyar pena ea oper Yodo Ss es Coeek 6 WOOD magazine October2013 continue on page 8 THE EVOLUTION OF PERFORMANCE INTRODUCING THE NEW PM1000 TABLE SAW & 2 q —e MeN cres ad Td Renee ee 2 Cicaminaliaiaal pane lod oa) VISIT: POWERMATIC.COM 1 Enon Hed TO LEARN MORE ECT Clogged Filters? The Dust Cobra A unique All-in-One high suction dust collector. ( 70” SP ininches of wc) Perfect for the small shop! a Clu cH 12” planer, 6” jointer, portable table saw, Ene CEU Leec CR ole oe Mite certification - Meets EPA RRP require ments including lead. Approx. 4’ 4” tall OS, and 20°x 20"with Mobile Cart. ‘See Dust Cobra video at ‘wwnw.oneida-air.com FROUGH cury J vonowarens wre souurnae nse Stn la ro poo of aug Curtecduorng wer Tomy hae Oneida ries Sans Dust Collection Sin Soe Saddle that horse for slick support When cutting especialy wide or long pleces, a support on the side ofthe tabkesaw helps make sav, strogglefree cus Heres an inexpensive and effective support equiting just a length of PVC pipe, afew wood scraps, anda sawhorse. rom the scrap, fashion two T-shaped saddles —capabe of holding a length of 2" 1D. PVC pipe firmly in place~that fit smugly over your sawhorse’ top rai. Size the saddles so that the PC pipe stands fish with the top of your tablsaw Pe ge: Mn SADDLE CROSS SECTION MDPC pipe NS Cross brace sides thick spacers forsnug ft [Sawhorse top rai 1 "Bes iumben continued om page 10 8 WOOD magazine Ocrobe 2013, Penn State Industries Top Quality, Great Prices and Expert Advice! 1-800-377-7297 » www.pennstateind.com Exclusively at Penn State Industries. Patented Bolt action handle smoothly advances and retracts the refill “Wow! You Made a Bolt Action Pen?” Discover the joy of making this completely original and iessibly Original Bolt Action Pens fun Bolt Action pen, a gift that will be hard for any hunting or 7 target-shooting enthusiast to put down, Completely Authentic Every detail from the one of @ kind bott-action mechanism to the ptecision-engineered components, was carefully designed to ensure unig *s5 and reliability. The realistic bolt-action handle smoothly 4am advances and retracts to securely lock the refllin place. Includes a bool action rifle clip and replica 30 caliber cartridge and rose gold tip for added authenticity. You can even reverse the bolt for left handed operation! Easy to Make Chrome epacreovo $1295 $1205 SMNAS $1025 So easy to on lathe, no one will believe you made something Gun Metal PAB 51295 S205 HHS sroIs of this quality in 15 minutes, Requires mandrel, bushings ZakeGold rc 51495 S895 $295 sts (item #PKCP3000BU $5.95) & 3/8" drill bit (Item #PKEXEC-3/8 $3.95) BlackEnamel ¥PKCPHO30 $13.95 $13.05 $1215 $11.25 Our Customers Love Their Bolt Action Pens! Tere es Rod R.of VA wrote, “This pen kit is Awesome - LOVE IT!” LSet SF of ach pan na GS Gist ane nd OeTe Daryell $.of TN wrote, “1am extremely delighted with this pen. plus the 38" dil bit nd 2pc Busing Set The look and feel is remarkable and the craftsmanship is perfect. -HPKCPBAPAK SAVE $8 Only $42.75 SAVE 16% This already has become my bestselling ink pen." Choose from our Original or NEW Mini Bolt Action Pens! ‘Mini Bolt Action Pens NEW (ur New Mini Bolt Action Pens are only "long and feature the same authentic styling and use the same accessories asthe original Easy to start with a FREE DVD! A $20.95 Valu eee Cs as Ou 5 minute instructional pen making DVD is packed with Gu Nadal We rane ECS SRN sass ES all ofthe info you need to start making pens. Order item #OVD 2ekeGold ——ePNCRIOD. $1295 $1195. STLIS $1025 Sa Shop-made circ-saw guide can't stray While don't care for wresting set goods atop my tablesaw to cut them Tasik even more the haste that comes with setting up most cular Saw guldes:al that measuring, offsetting, and praying it comes out fight So built this simple tracked fue that puts the blade in ine with the cutlne every time, To build one, cut pice of MDF wider than your saws ase and as Tonga youl ned to span your sheet soins, Then, cuta wide groove "adeep the kength ofthe MDE Mounta Wide hardwood runner to your sw base to match the groove in the MDF) and wax it with paraffin Mace the runner in the groove, un the saw on and cut the full length of the MDE Now, simply align the edge of the guide wth any catlne, clamp it in place, and run the saw in the groove for an accurate cut ie Holbroc, onaps, MC io WOOD magazine October 2073 = 7 “Yes vYes xNo Yes ( EG : Yes vYes ALL LED LTH} COM ROCKAUTO,LLC (EST. 1999) Sliding bandsaw support makes | cutting large curves easy To shape a curved tabletop I made recently, I could have used a jigsaw that made less-than-furniture-quality cus, or my bandsaw with it tiny table, opted for the bandsaw, but only after coming up with the outboard support system show: The support board glides easily on the roller stands 50 [was able to focus com the accuracy of the cut instead of ‘overcoming the board-on-board friction, A clamp at each end of the support board keeps the whole thing fom accidentally rolling too far and toppling, Dovid Carson Cary NC contin on page 12 woodmagazine.com u Nanofiber eats the competition's dust! (FREE with any Tempest Cyclone!) ‘The best value in dust collection is now the cleanest. ‘QurTempest Cyclone Dust Collectors naw include Nanofibes fie 135 FREE upgrade ( $54 value. Industry leading, Merv 15 rated Nanofibe ters combined with our cyclonic separation process captures 999896 of wood chips and dus particles to below 1/2 micron. You achieve near surgical quality air and cleaner too, whi practically eliminating dust clean up forever In addition, Fempest Cyclones never clog, equite almost no maintenance and come v a5year waranty. - 25up-vsoce. 51055 eT FREE Ducwork Pan sie imocm-si25s erred Pius Save 5100 hen you ssi vm ges Gears purchase any Sees, pees eee 20H Fable 125CF4 $595 se Code WoOD26 SAVE on any system you buy! P3offes a variety of sco and offers on dust collectors too numerous to lit here. We'e your Complete resource for everything you need to get the job done tight!To get the best deal an the system sized perfectly for you shop and number of to's, cal Bill at (215) 676-7606 x16, Penn State Industries Top Quality, Great Prices and Expert Advice! Cal '-800377-7257 to redeem Ofer expres 2/13. Ofer revald nine Pcernecttochnge Clean Air! Clean Hop! Clean oo!st) rele ease Olle) ile Service & Design Demand Brand Kits myoldmasters.com for Teo] lo R Ue Mle so) EVEN -\at sel V ACLS Brolg Pret ouclcien- ence) amare: | tee oe | Seep | | Ascrew-together storage strategy for sanding discs Here's the perfect solution for storing 2" sanding discs used for turning. Clear screw-together containers used for sewing supplies and fishing tackle (60mm clear hhold stacks of sanding discs per fectly, and can be stacked and sorted the side of the container with permanent marker. Bob Horn Vocal Calt 2° sanding dsc Mark git on {ach container. Clear scew-together containers Soften the bite of steel spring clamps Having lost or misplaced a few of the protective plastic ends on my steel mps, | replaced them with short lengths of flexible vinyl tubing (found at home centers) slipped over the clamp jaws set Cron, Manco, Cob 2 WOOD magazine Ociober 2013 > for more Salo tools. , 216 issues of WOOD. Every Project. ts | Every Technique: Every Shop Tip. Every Tool Review. i In less space ¥ than a try square. The WOOD Complete Back Issue Collection Order online at = eazine.com/DVDlibrary or by phone at 888-636-4478 Special pricing for owners of the 27-year collection! ADewoor3 Pocket-hole Pointers Whether you own a pocket-hole jig or are considering buying one. based on our review on page 45, these shop-won insights will help you get more from your jig. 1M Ui fn Prepping the stock want, and then mark the back faces, as for maximum purchase; avoid scre Mabepredie-sauarecits,When show elow lt Resureto also raw _ into end gin, s shown blow ener. Taking ojos arta atfes sh cc appa, sci ts hese Speabines or face frames, square Cuts. middle ll ines up with thestiles, _ Drilling the holes nsute aque ascemblles Set your ‘Then dil pocket holes into the marked | Sethe coect pocket depth. For fables’: blade preclely 90° to the faces o prevent acldentalydriling | strongest ins the sop colar tabletop before cating pars tice, | into the best ace, las Gre [eestor Wed al ne eee Grab the best gran, Dil pocket holes _pllot polit sbould stop 4 rom the cxactly 90° to oe bade, Anything less So sews thead into edge orface grain | workpiece’ end or edge, asshown belo sal ulin gaps or unoquere uns Cheek this ear tne you use the Heo Tp cueadsten Se rie ric outa aly callggtoodes eel Set deptstop collar to contaol depth of counterbore. Pocket hole Pet pant. "7 / ( i et Plan your work, work your plan. After cutting but before drilling, lay out project parts in the orientation you ™ A\\ High speed = cleaner holes. A corded ‘These screws wor'tholdst wellteadedings end dvll bores a cleaner hole than a cordless grain Instead dilthepocketsontherallanddrive ome because of its faster bit speed. crews into edge grain ofthe sie op phot) continued on page 16 1“ WOOD magazine October 2013 New Scandi Plus workbenches + free accessories Perfect for discerning woodworkers! * Advanced Swedish design 100% European Beech * Double row of round %” bench dogs working from both vises * Includes 4 bench dogs with side springs that remain at the height required or drop flush into the dog hole — | | | pt se = I 73°x23", 138 ibs W@DCRAFT Fora free catalog orto find your local Wooderaf Store, visit wooderaft.com ‘or call 800-225- la sock lst Instant reck solid clamping _Selflocking steel plate Rubberised cork self adhe- for full details of in any dog hole or leg Protects your bench sive pods protect your vise range and specifications Excessive tear-out around the pocket could indicate a dull bt. Keep a second bit on hand so you can switch to it when the first begins to dull > Smooth the way. Before drilling, spray the bit with a dry lubricant, such as Bostik DriCote, to reduce drilling friction and prolong sharpness, Repeat after every 20 or so holes. > Clear chips frequently. Pull the bit out when you've reached about half depth to clear the chips; then finish drilling, This reduces friction and bit dulling > Match up diferent thicknesses. When joining boards of two different thick- nesses edge-to-edge or end-to-edge, as shown below, set the pocket-hole depth for the thinner board. If joining boards end-to-face or edge-to-face, such as the table apron to the top, shown far right, set the depth for the thickness of the board with the pockets, regardless of which is thinner, and then use a shorter screw if necessary. y Assembling the joints > Choose the right screws. Coarse- thread pocket screws hold best in softer woods, such as pine, cedar, and poplar, as wel as plywood; use fine-thread screws for hardwoods. Choose the length based on the workpiece thick ness, as shown in the chart above right. ‘Most pocket-hole screws come with, an oversized washer head for increased contact with the pocket shoulder, but you can also get screws with a smaller pan head for use with shallow pockets where a washer head would protrude 16 eral Screw Length cu ou TA TA TAT 1% rr Wr ma Fine thread with pan head Fine thread with washer head Coarse thread with washer head Use ine-thread screws for hardwoods, Use coarse thread screws for softwoods, MOF, particleboard, and plywood above the workpiece surface. For outdoor applications, choose stainless steel or coated screws. Never use drywall screws—they break easily while driving, and their tapered (“bugle”) heads can split the bottoms of the pocket shoulders. > Don’t forget the glue. Screws alone make a plenty-strong pocket-hole joint, ‘but adding glue helps prevent a joint from opening up due to seasonal shrinking and swelling > Clamp before screwing. Clamp across a joint whenever possible [opening Photo], to avoid the parts creeping out of alignment as you snug up the screws. Clamp parts to a perfectly flat surface so the front faces align. (If one of the parts is offset, shim below i, if needed.) ‘When screwing an edge to face, such as the table shown at right, always Clamp the assembly securely before driving screws ‘iy ‘When attaching table aprons to atop allow room forthe screws to movein ther pilot holes asthe top ‘expands and shrinks with humidity changes. To do ‘this drilthe pocket asnormak then drivea screw ‘through as shown (op-Remove the screw and dill, ‘utthe plothole aboutV" larger in diameter. inl, ‘mount the apron-and-leg assembly tothe top. > Learntodrivea clutch. Although handy for driving fasteners, avoid using aan impact driver for driving pocket screws, Because you can't see the screw snug up against the pocket's shoulder, the tool's high torque can easily strip out the screw hole. Instead, use a drill fr cordless screwdriver with an adjust- able clutch, set to pull together joints ‘without stripping out the holes. # WOOD magazine October 2015 aN | iy BUILD YOUR D.LY. SKILLS Learn how to do your own home improvements like a pro! With Penn Foster, you can leam the skills of a professional Carpenter, Plumber, Electrician..just to name a few. And, you can learn these skills online, in a matter of months, Why D.LY.ers Choose Penn Foster for Their Training: Program Content - Leam everything you need to know Affordable - 0% financing and low monthly payments. Flexible - Leain online, when and where you want ‘Supported - Unlimited instructor support with an online community to interact with students, faculty, and alumni ‘Accredited - Regional and national accreditation 1-800-572-1685 ext. 7459 www.PennFoster.edu Online Enter ID# AW8S83T Text “LEARN” to PFEDU to learn more. (Message and data rates may apply.) facebook.com/penntostereducation community:pennfoster.edu & #choose2bmore vd ee See what Penn Foster has to offer: PENN FOSTER CAREER SCHOOL www PennFoster.edu Building Trades + Carpenter + Furniture and Cabinet Maker “Home inspector + Home Remodeling and Repair HVAC Technician Landscaping Technology + Plumber + Residential Electrician Business + Small Business Management Mechanies + Auto Repale Techniclan + Diesel Mechanles + Motorcyle Repair Technician + Small Engine Repair PENN FOSTER COLLEGE www PennFosterCollege.edu Associate Degree Programs + Accounting {Business Management {Computer Information ‘Systems + Construction Technology + Climinal Justice High Schoo! + Benn Foster High School + Penn Foster High School wi Carpentry Concentration + Penn Foster High Schoo! lectical Concentration + Penn Faster High School w! Plumbing Concentvation Technology + Computer Suppor Technician rating with AutoCAD? Electronics Technician PC Maintenance and Repair ‘Web Page Designer Other Exciting Programs + Appliance Repait * Gunsmith Private Investigator Professional Lockemithing + Engineering Technology France * Graphic Design + Human Resources Management * Marketing + PC Maintenance Technology + Retail Management his handy wall-hung holster stores your cordless dal mpact divers and nals while keeping #2306) accessories—especially those pesky battery ae chargers—contained and close at hand. Our design L holds five tools, but can be easily extended to fit a larger tool collection. Before building, make certain your tool handles will fit between the station’ dividers and adjust if necessary. Using ¥" Baltic bizch plywood, first glue and screw together four T-shaped dividers and two L-shaped divider ends. Glue and screw these to the 10x27" lower shelf, eaving a %" reveal around the ends and 1" on the front edge. Glue and screw the "upper shelf assembly atop the lower shelf and attach the back. Finally, sctew the station tothe wall, being A. sure to hit two wall studs, For extra convenienc, a place a power strip on the upper shelf and coll up LF oor the charger cords before plugging them in, ® LENO 5? Divine. (Set back "from frontedge of shelf) FREE reviews to help you choose tools to equip your station: ~ 18x 14 FH. screw Cordless dis woodmagazine.com/drilldrverreviews & ore rere Wedd ate car =. Apert aa oe eee eel ae 16 October 2015 MOON LANDS ON MAN! The skeptics said it couldn’t be done... but our Moon Phase proves that one small step for Stauer is one giant leap for watch lovers! ‘thas always taken scientific skill and artistic wizardry to discover the Moon's secrets. When Galileo Galilei turned, his telescope towards the Moon in 1609, he relied on his knowledge of light and shadow learned as a painter to under- stand the movements of the heavenly orb. We relied on that same paiting of art and science to create one of our most complicated and beautiful movements yet... for an unbelievable price! Previously offered for $399, the stars have finally aligned to make the Stauer Moon Phase Watch available for ONLY $99! Our Moon Phase Watch continues a centuties-old tradition of unlocking the secrets of the Moon with scientific innovation. Many watches add extra func- tions, or complications, to display day and date. But we didn’t stop there. The Moon Phase Watch includes a separate window that showcases the current phase of the Moon, This beautiful addition to the face is no easy feat. Solving the mystery of Moon time, Since earthly time Is measured at regular 12 month intervals, the Moon's ‘month is at odds with our calendar. A lunar month is 29.53 days, so a Moon-phase watch needs to keep time in two totally different ways. That's why antique watch collectors are always quick to bid on this type of complex lunar movement. You'll find them among the rarest and most expensive vintage watches ever sold at auction, Not long ago, one of the most important moon-phase time- pieces fetched an incredible $5.7 million! ‘Our goal was to create a timepiece more accurate and affordable than its ancestors. As you can imagine, an offer this good on a watch this spectacular cannot last forever, How we captured the Moon. We put so much effort into perfecting the mechanics behind this watch, but we didn't forget the aesthetics. The Moon Phase Watch boasts three different complications set in the guillochéed face: a standard monthly calendar, a day of the week indicator, and the moon phase display. Its rose gold-finished case features a hobnail-pattern bezel and a crocodile-embossed, ‘genuine brown leather strap adds the final luxurious detail. Your satisfaction is 100% guaranteed. If you are not thrilled, simply return the timepiece within 30 days for a full refund of the purchase price. This offer is limited to the first 2,499 callers to this ad, so please don’t wait. This kind of watch only comes around once in a blue moon. Stunning little machine! "I am in love with this watch!" — R. M. from Asheville, NC Fused ose go case with hysalic patter dal + Day date, and moon phase ds « Croco cmbosse lather band fs 3 6. A Stauer Exclils Limited to the First 2; to this ad only ‘Stauer Moon Phase Watch $399. ‘Now your Call-In only price $99 «se» Save $300!* Call now 10 take advansage of this famestc offer: 1-888-277-8416 |: Eo Promotional Code MPW189-02) ant lease mention this code when you cal 14101 Souths Dine We, Dep: MPWIE0.02, Burs, Minne 35357 wirtaercomn Stauer? Smart Luxuries—Surprising Prices” + Pce quotes for Calin Costumes oly vss the oiinal Starcom price, wt «3 ATM water restance M mec oo ie co) oTelo a a Ronegs ye "Your next project calls for quited maple? Dig through the ome-centerbins A Google alert (see More Resources, below) scans the web 24/7 for any item containing standard flasain mapleand you may beewarded for youreffort. you name and sends you an email when ts found. Set alerts tolook for Figured pieces typically don get sorted outfrom the restand costthesame as mentions bout lumber auctions, estate sales, and yard sales that may include less tractive pices ‘woodworking supplies and lumber. Search online orin your regional yellow pages for mils orsawyers Sut, youll Hardwood lumber dealers typically ave price reductions for high-volume have to plane and joint the wood youself, Butte savings are worth. jpurchases—usually beginning at 100 board feet. Don't need that much woodworking dub or guild may have existing connections wit foal mi lumber Combine your order wth fiends or fellow woodworking cub and maybe discounts oo, ‘membersto take advantage of volume discounts. Lear how to set up a Google alert: woodmagazine.com/googlealerts. Fora guide to understanding hardwood lumber grades and board feet, visit woodmagazine.com/shophardwood, Find a local sawyer with ths online directory: woodmagazine.com/findasawyer. 20 WOOD magazine October 2013 Got dreams bigger than your shop? Mek cas is ii isc: ee a Sek ae | phe chad disc cae tLe D ver 100 plans for organizers, z tool stands, lumber racks, and more > videos and slide shows of techniques. > Tours and tips from super-efficient home shops WOOD Plans, Articles, and Video Clips Only $29.95! «and check out these other titles in our Complete Guide series: ie or call 888-636-4478 “Complete Guide" dics conan te and PCcompatbie gel content ADEWDIOIS Surrounded by Design Develop a few simple habits that attune you to design in the world around you. smpahe question I get the most from | Get out and explore yourself which furniture or built-ins ‘my online audience: “Where do — [find that both nature and the man- would work well in the settings. you get your project idea: made world provide lots of inspiration. ‘ Fortunately, in my job asa remodelitig —” My wife and I enjoy going for hikes, Seek out more art and artists contractor and professional wood ‘and:we often find a natural, abstract___Today’s art culture is less pretentious worker, [am exposed to all mariner Of arrangement of trees or rock formations and more accessible than ever. Studying designs, which allows meto soak up interesting. Or we'll go walking in the work of other artists—painters, creativity from other professionals. But different neighborhoods or other parts sculptors, architects, even other [believe that inspiration and answers of town and just absorb the details of woodworkers—will both challenge and to our design challenges are all around the architecture. energize your design senses. Remember, us. So even if you are not in the trades, ‘most disciplines of art and design are here are some things you can do to Attend open houses related because they all exercise sharpen your own design senses. Many towns have a “parade” of new or arrangements of balance, proportion, vintage homes. Attend these to famil- color, and texture. ® Always carry a camera iarize yourself with various styles of Ifyou have a cell phone, you're already architecture and home decor. At the Thowghhshadnofomal ning profesional doing this. Ifnot, today’s point-and- very leas, you will discover which Woodware Ted lpn bow ates his shoot digital cameras are powerful, elements you like and don't like. forthe esto sb aon shares whit he learns ot inexpensive, and very portable. Take Actively spark design ideas by asking __americancrftsmanworkshop.com, cone along at all times to record forms and elements that inspire, such as the parking structure shown at right. Then, ‘organize your photos by category, such as “architectural,” “nature,” etc,, on ‘your computer so you're not left straining your brain searching for a ‘vaguely recalled image. Start a sketchbook ‘As inspiration hits you, get it on paper as soon as possible. Don't get hung up ‘on details, or worry that you can’t draw ‘well; ust get the basic geometric forms scratched out and work on details later. Let the ideas flow without self-critique ‘or editing. Allow one idea to beget another, Variations on a theme may ultimately lead to a left-field design that surprises you. Be sure to revisit your photos and sketches occasionally. Often _Inspredin partby the shape of parking garage he photographed, Tod's rare Chandelier was featured new ideas arise out of old ones, the Museum of the Roclesin Bozeman, Montana. 2 WOOD magazine October 2013 BUILD YOUR FAVORITE ; WORKHORSE FROM WOOD'S iN BEST-SELLING 5 Build the whole series! 5 iC Nil é 9 PRT ADEWDIOTS Wo mkce -to-last nite niter_ and simple to construct, these shop ee will provide years of service. Ho ¢asy-t0-build components—a sturdy workbench and "Tissot vege ah eso t racks—will make your workspace the envy of your friends. The durable MDF benchtop provides a solid, stable ‘worksurface, and an ingenious set of blocks behind the rails turns an ordinary one-hand clamp into a vise, as shown right. Laminate the bench’s top Cut the tops (A) from 5" MDF, making them 1" longer and wider than specified in Drawing 1. From %" pine, cut sixteen 234" blanks, These will later become the leg com- ponents (B, C, DF), but will frst be used as clamping cauls to laminate the top. spite one of the tops (A) on samhorses and use a gle spreader (a cardboard scrap or an old creditcard) to evenly distribute glue over its surface, Set the other top panel onto the first, clamp the panels together [Photo Al, and allow to ry. Move quickly during this step so the ghue doesn’t set up before you get the assembly clamped Use a citcular saw and straightedge to trim one edge of the laminated top straight and smooth [PhotoB|; then, use ‘the same setup to rip the top to final width, Next, trim one end square to the edge, and then cut the top to final length Build the legs and rails 1 Fomthepie blanks used ear, cut each ofthe egcom- ponents (B-E) to length [Drawing 2, Materials List] on the ritersaw. Also, cut a spacer at least 4" long from a S'-wide scrap piece. Begin assembling a leg by covering the top (A) with kraft paper; this keeps glue-ups from sticking to the top. Next, stand an inner leg face (B) on edge on the paper. Glue and clamp an upper leg core (C) and lower leg core (D) to the inner leg with a spacer between them to create the mortise that will hold the end rails (Photo). Remove the spacer when the leg has been securely clamped, and wipe away any glue squeeze-out with a damp rag. After about 30 minutes, the glue-up can be removed from the clamps and set aside. Repeat the process for the remaining legs. When all leg assemblies (C/D/E) have dried, glue and clamp the outside leg faces (B) to them, again using the Clampaboard in place against bench dog (Shop Tip, page 2] or easy face planing, chiseling or sanding See page 27 for details on the clamping blocks, ‘mounted beneath the benchtop. Bisencutop EXPLODED VIEW Distribute clamping force evenly across the tops (A)by clamping pairs ofeg blanks side by side and spaced evenly along the MDF panels woodmagazine.com ‘straight board guides your rcularsaw when trimming the top (A) to with, Camp the board firmly tothe top to prevent from sipping, Assembling the leg pieces (CD, E}on edge keeps ‘one edge aligned. lamp the pats tthe top) and teach other, 25 as eS Tomake the dowels easier toinsert use sandpaper tosighty chamfer thei edgesbefore inserting themintotheholsinthe stretchers HM. Imantainingasoid gp. top (A) to keep edges and faces aligned. Be sure to make two mirrored pairs [Drawing 2} Cut the outer and inner end rails (F,G) to size [Drawing 2}; hen, glue the rails together to make two assemblies. ‘Cut the outer and inner stretchers (H, I) to width, but 2° longer than specified [Drawing 3}. Glue and clamp these parts together with the bottom edges flush, wiping away any glue squeeze-out. Cut these stretchers to finished length when dry. Discard the kraft paper. Use a 3" spade bit to drill two holes where shown in each Jend of the stretchers (H/1) [Drawing 3}. Cut a diameter hardwood dowel into eight 14" lengths and chamfer one end cf each [Photo D]. Apply glue in the holes and insert the dow- els, tapping them flush with a mallet. Bring the bench together 4 Stead camp one eral assembly (6) nto the mar tises of two leg assemblies (B-E) [Drawing 2). Repeat for the other end. Use 616-1ong spacer blocks to position the stretchers (H/1) against the leg assemblies (B-G) and flush with the top ‘edge of the end rails (F/G) [Photo €]; clamp the stretchers in place. Transfer the locations of the dowels installed in the Stretchers (H/D) onto the end rails. Drill ¥is' pilot holes through the end rails, centered on the dowels. The cross grain, of the dowels gives the screws better purchase than the end ‘grain of the stretchers, Next, drive 4%" structural wood screws [Source] through the pilot holes to secure the base assembly together. Sut te end aprons) tse, nd ge them to the ends of the top (A) flush with the top face. After the glue dries, set the top assembly (A/)) on the base. Qos tonne aprons inl with ut 2 ngs han shown [Drawing 3]. Rest them in place on the base, scribe the ends [Photo F], and cut the front/back aprons to final length. Glue the aprons to the top, and glue and screw the aprons J, K) to each other and the base. Bla oi cre bak tine ithe up Doty 1), Jand use a 4 spade or Forstner bit to drill the holes. Quick Tip: Use two squares as visual quides to keep the dill perpen dicular as you dril [Photo G}. Mark the 7° hole locations on one tend apron (J) and the front apron (K) [Drawing 3] and drill them with a spade bit 26 ‘When dilling the plotholes, extend %" dil bit asfar as possible from the dil chuck wil stil nse RENAE Ua Byallowing 1 extrain length ateach end ofthe Upper rontfback aprons, you can set them in postion and scribe their inal dimensions. BENCH END ASSEMBLY (outside face) Add the clamp blocks From ¥-thick hard maple, cut one 2Ms+14" blank for the front clamp blocks (1) anda 1%10" blank forthe end clamp blocks (M). Mates Avoid using pine here because the slots you cut for the clamps will wear out in softer woods. Rip af" centered groove 1" deep along one edge of both blanks [Drawing 4]. Dayo tert amp locks.) on the witerbankand two end clamp blocks (M) on the narrow one [Drawing 4]. Matk the location of the 4" dado on each of the five blocks. ‘Clamp an auxiliary fence to yout tablesaw’s miter gauge, line up ‘a dado layout line with the blade, and crosscut the dadoes with ‘wo or three passes. Repeat for each clamp block. (Cut the taper on each clamp block (L, M) with a jigsaw. Then, crosscut the clamp blocks to final length. (Cut the clamp block mounting cleats (N) to size [Drawing 4] ind glue and screw them to the clamp blocks (L, M). WOOD magazine October 2013 INSTALL CLAMP BLOCKS Cae eae Na n nth To drill perpendicular bench-dogholesinthetop (Al havea helper assist you mp block (/N} toa hoe inthe upper end apron (J then attach inkeeping the dil aligned with one square while you watch the other. the blockto the underside of the benchtop (A #8 119 i screw — mg EBs encH FRAMEWORK ar hole ‘4 groove "deep, centered Flip the workbench upside down on sawhorses. Align each clamp block (L/N, MIN) with a hole in the front and end aprons (J, K) and check the fit of a clamp in each block. Secure each clamp block with screws [Photo H} From 4’ pine, cut the shelf slats (O) to fit between the outer stretchers (H1) [Drawing 1]. Flip the bench back onto tex4av'Fitscrew its legs; then glue the slats to the inner stretchers (1). Turna bar clamp into a vise Instead of pce vse this bench uses shop-made camp - 2 blocks thathod typical one-handrtchetingbar camps inserted though eles inthe bench fot and end avons ight Att emeving thee jam tre bor fits — imothegrooveofnecamp block anther ol pin ‘holds the clamp in place once inserted, far ight, y These damp block ae designed to werk thin “pe ¥ 1 S100 and lrgensen SD; expandable bar clamps. you XX havea diferent dame, tests tin the locks andmake ‘modifications to the grooves as needed, orinstallalarger By anchoring a J Ee caer enisariere ee ya can then squeeze a rola inthe camper. workpiece between the moving jaw anda bench dog. woodmagazine.com 2 eA Manes i ‘ Beveled 31 wide spacers ripped from scrap deat material consistently space each subsequent wall dleat(Q)as you screw tothe wall Now build some tool storage From 4 pine, cut to size the base wall support (P), wall cleats (Q), shelf (R), shelf cleat (S), shelf braces (7), and brace cleats (U) [Materials List and Drawing 5]. Tilt your tablesaw blade to 45° and rip bevels along the top edge of each wall cleat (Q) and along the bot- tom edge of the shelf cleat (S). spate tests in the wal where you want toatach your wall unit, making sure each end lands on a stud. Then, place the base ‘wall support (P) flush against the floor and screw it to the studs; do not drive screws at the ends yet, as these will be fastened when you install the brace cleats (U). siete oto exo it wal cea) 3 of the floor. {Check for level; then screw it to the studs. Again, do not drive screws, at the ends ofthe cleats. Then, attach the remaining wall cleats (Photo. Aptos the set cet) the she sh wh the shelt’s rear edge [Drawing 5a]. After the glue dries, hang the shelf assembly con the topmost wall cleat and screw the shelf cleat to the studs. Hold the brace cleats (U) flush with the ends of the wall cleats () and screw through them to the wall studs [Photo J, Drawing S|, Screw the shelf braces (I) to the brace cleats, and then drive screws through the shelf (R) ftom above and into the shelf braces Create custom tool holders ‘Now that you've built the workbench and wall-hung tool rack, build individual organizers customizable for Your tools. Use Drawings 6,7 and@ asthe basis for constructing these racks, using beveled cleats to hang them from the mating wal las. Find mote tool racks inthe WOOD Patems insert on page 42. “Tousethe lamp inthe campblacks Bowe youredaberd dogs iepteapeesgee som spoon tote ahaegs cnr manayaroom Sombie das Soougpntesos } roksnbeetA Srey stn Calter ipand Fo. outeasily. = Drive #8x3" screws through thebrace leat (U) andthe ends of te wal cleats [@)and into the underlying wal stud x2 screw Bacon EXPLODED VIEW <— ~ wea FH crew ~ 66 ch wexSFHscrew ye = 7— SIDE VIEW Eictame rack S45" bevel NOTE: xing pina ray other sftwood fo thisclamp ack, le together fou Shoat segments edge c09e the gan uns font ‘obackformaimumstength When diy sand itsmaot then ci holes at he boc othe lots Cute sts uth asa then gue and sere tater s shown. WOOD magazine Orcober2013 Ebpuiers rack saxne NOTE: Ceate the mortises forthe pliers handles by fist cling "holes, end then jigsawing then o rectangular shape: Adapt the spacing fo sult ourto0l Cutting Diagram Texd8x96 Meciumdenaty fiberboard ©: ox 55x 96" Pine (| Nexsia x 95° Pine ex515 x96" Pine (4 ba.) 2 needed) _————— needed) XSI 72 Pine bd.) Oneeded) Om i 5 Tiax96 Pine ©.3bd fe) Co} (oF Sx 9% x96" Pine (67 bd Mix six 24" Maple (7b. ft) ‘woodmagazine.com tenby mike Berger Fodicedby Bob hunter nth ohn Olson Proje dean: John son Ivars Roxanne Mone; emasehacon| DRILL RACK Materials Li A tops 22H GAH WOR 2 B ovteregfacs 2M" OP C wppmegceres IW DP loneriegcons WD ei P E nwerlagtaces 2K SSP F owerenda WS PD © imerendeais WS DWP 2 Hr ourersvothers SP 1 inerstetches i aN 6S PD J endaprons SDH PO Ke tronvbackapors W566) FD 1 frnecompblocks YP 2 AW M3 ME enddamptlocks 1 aT 2 N_campblockclests 20 es (Osha * o P_basewalsupport Xt 3h" 66" Pt 2 walleas 23 CR shelf met sheet oP Tse aces ap 2 U bracedeats are? sty ct vei Sete suction. ‘Materials keys MOF medium dens Nberboard, pine, N-mape Supplies: £12 F, screws (10), 4852" FH scree (54,8520 FH, scres 3), 48:3" FH, screns 0, ‘dome 36ong. Bits spade spade brad-pointt. Source Fasteners: FstnMaster 4" structural wood screws (lowescom no 194877, 12 per pck driver bit ined), Elegant ‘hen WOODS Design Editor Jol Olson frst showed me this English Arts and Crafts-style table, the graceflly curved leg rails, tapered legs, and wedged top ad me thinking i would be complicated to build. But great looks don't always mean difficult construction: After John showed me his simple ‘methods for shaping assembly, Iwas realy to cv in 1 think you will be, 00. ie Nate Granzow General-nterest Editor I Wx27 Daze H Materials cost $58, First, make three legs From 1M’ cherry (if you can't find cherry of this thickness, slue up blanks from thinner stock), cut the legs (A) to. size [Materials List]. With the legs’ 2'-wide face down on the table- saw’s top, rip bevels where shown to form a hexagonal leg [Drawing 1, Photo Al. Lay out the tapers on the top end of each leg [Drawing 2, Phot xy Out mortises on the inside faces of each leg (A) [Drawing 3]. Cut the '-deep mortises with a mortiser, or use a drill press and chisels. (See More Resources for free videos on making the legs) Drawa taperline on one inside face of a leg (A) linking the ‘bottom to a comer of the hexago- nal outline on the leg’s top. Cut the marked taper on the bandsaw [Phato¢}. Plane or sand the band- sawn taper flat and smooth. Then, repeat for the remaining tapers. Do this for each leg. 30 WOOD magazine October 203 ‘After marking the beveled cuts onthe bottom of, ache, tityourtablesaw blade to 30°and cut them. lip the piece end fr end after each ut Bhs ano pain ASSEMBLY saa sane Before marking the tapers onthe legs A) orient thebest looking faces outward, Mark narrow indicating the inside facet serveas a reminder Bhs verait Now, cut the sweeping rails Cat the rails (B) 10 size [Materials List), Miter the ends to 221%, keeping them parallel, Mark and cut centered ¥4'thick tenons in both ends of each rail using a %' dado set in a tablesaw [Oraw- ing 3, Photo 0), ear eg Tityourbandsnwstable so the blade ainswth the outline onthe leq'stop Cut each e's taper. Draualine forthe agjacent taper and ct agai, Set yout miter gauge t022'= and cur one cheek (ofthe alls (8) tenons. Adjust the gauge the ‘opposite 22's and cu the ether cheeks. Mark the rail (B) tenons! width (see Rail Pattern in. the WOOD Putters insert on page 41), and then bandsaw along the lines. Dry-assemble the legs and rails to check the tenons’ fit in the legs’ (A) mortises. Make adjustments as necessary—lightly sanding the tenon faces if the fit is too snug, for example. Following the Rail Pattern, make a template from poster board, Use the template to lay out the shape of each rail (B). Bandsaw the rails to shape [Photo€}, a CS acer ‘When bandsavvng the ral (8) curves cut "outside the layout line Then, tape thera face-to-face and stack sand fr identical pieces, sand to smooth the curves, and then rout 4" chamfers along the rail edges. Glue a rail (B) to two legs (A) [Photo |. Alter this assembly dries, glue a second rail and third leg to the assem- bly Installing the last rail may require gently stretching the legs apart. Add a classy circular top Bore 4" holes 116" deep in the top of each leg (A) [Drawing 2, Photo 6], keeping the bit centered on the leg. {Cut three 236" lengths of 4° dowel Bandsaw a \'-long slot centered in ne end of each dowel, Glue the dowels, slotted end up, into the 4" holes in the table legs (A), as shown in Drawing 4, aligning the dowels’ slots parallel with one another, (See “Theno-fastener way to securea tabletop” on the next page) Bss ov 2 fo (© of 3 contrasting wood [Materials List]. (We used spalted maple) With a beam compass, lay out a 27° circle on the top [Drawing 4), Cut the top to rough shape with a jigsaw, and clean the edge using a router, straight bit, and trammel. (See More Resources t0 learn how to build and use router trammel) Center the legiatl assembly (A/B) on the top and trace around the dowels [Photo Hi]. Bore %" through holes in the marked locations. ‘Quick Tip! Clamp a scrap backer behind ‘each hole to prevent unsightly chip-out. ‘Chamfer the top and bottom edges fot the top (C) [Drawing 4}. Place the top on the leg assembly (A/B), tapping it ‘down until it seats on top of the legs (A). Secure the top with walnut wedges glued and lightly hammered into place. After the glue dries, trim the wedges and pro- truding dowels flush with the top, and finis-sand the table to 220 grit. 2 See Place two scrapnood spacers between the legs (A) and run a clamp diagonally across the assembly to keep everything square during lamp-up. Biexecoveo view i 1 chamfers WOOD magazine October 2013 Trea Oar Psa Thegainettiow, runs perpen theslosinthe dowels ld, \ X ‘When boring the centered hole in the top of each leg, mark the 1/4"holedepth _Place the leg assembly (A/B) dowel side down on the underside of the top (C), ‘on the bit shank using a piece of masking tape. ‘Then, mark the leg locations by tracing around the dowel ends. Apply a clear finish, We brushed on three coats of shellac, sanding The no-fastener way to secure a tabletop between coats with a 320-grit sponge ® To ensure yourtable'stop (©) ce, tae stays imi fastened tothe eee a ‘leg assembly (A/B) even with ocr hn ton seasonal changesin uit, first aig the dowel sot so they face the same ection | ‘prior to gluing the dowels | Intothelegs Then when Z transferring the dowel s location onto te tabletop align the leg assembly 30 the dowel slotsare perpendicular Z © 3 tothetabletops grin 3) Expansion and contractonin z the tabletop wll occur much £m ___F7 dam. 1 pore acrosets with than ts “peu yan teas ceernte Materials ky. Chery -dge gdp arrangement, that expansion © rane wilpsheqalyaganstihe. wedge. dawel Sa Spe Y2'chrydovel twolegssetfuthestapart _gnetation Bitandbinde formerbiS'canf rk! elatve tothe abetop, x 4 Sight bse. wt stb tng tied movementand reducing the ele possiblity ofthe es nts Cutting Diagram ‘breaking apart. Zz a) Vix 74 36° Cherry (40d. ft) Cer > Fora FREE video on making the mortises in the table’ legs, visit woodmagazine.com/accentmortises > Fora FREE video on tapering the table's legs, see woodmagazine.com/accenttablelegs For free instruction on how to build and use a router trammel, visit i woodmagazine.com/cutlargecircles 2x Tux TF Spalted maple bd. 2) 254°D stiles require grooves in both edges [Drawing 2). Tip! Use a featherboard to ensure ‘lean and consistent-width grooves. Buy ‘commercially made one or make your own as shown at woodmagazine.com/featherboard. mp In your tablesaw, set up a6" dado Doiade %" above the saw table, and attach an auxiliary face to the rip fence. WOOD magazine October 2013 sive assemavy inside face) groove "deep, centered ox ¥ Qt } “Slot centered" from bottom edge VY) warodve groove Lp iesroove ph seamen centered Retrieve the scrap you planed earlier with the rails and stiles, and cut a 44" Jong tenon on one end and test the fit in a stile. Make any needed adjustments; woodmagazinecom “Slot centered 4" fom bottom edge Seat lore long E *siot and slobiscu then cut tenons on the ends of the rails (GA, E, P) and front/back center stiles {G) to fit the grooves you previously cut [PhotoB, Drawing 3) Cutgooves inthe rails and sles by making a deep rpcut to either side of center lip the piece end forendand make a second ip. ‘Adjustan auikary wood ip fence to just touch the dado set, Cutone side ofthe tenon fipthe piece face for face, and cut agai, ©@ = ©®© xO) OOw ZO) TENON, Begs w'deep 7 Clamp together adjacent egs and stiles with thelr ops fuss then usea square to markthe centerlines of mating mortises. Position on your bench the legs (A) Pend stiles (B) in their ultimate orien- tation. Mark mortise locations on these pieces [Drawing 4 (Quick Tip! To ensure that the mortises in thelegsand stiles ine up precisely, mark mat- ing pieces at the same time (Photo C]. Build the self-centering loose-tenon- joinery fig described on page 52 in WOODe issue 218 (May 2013) (download the free article at woodmagazine.com/ 2isloosetenon), Cut a 4x1'¥e opening {nits top. Outfit your plunge router with 2% upcut spiral bit and’ guide bush- ing. Modify the jig with a 4 spacer as shown in Phote B, and cut the three ‘mortises in the face of the legs (A) that ‘will face the side assemblies. Then, swap in a % spacer and rout the two mortises in the faces of the legs (A) that face the front/back assemblies [Photo E]. ‘Cut the mortises in the stiles (B)—no spacers required; the jig automati- cally centers the mortises. Now assemble the carcase From poplar cutoffs, make twenty Yoxl¥ex4" loose tenons using the methods described in the jig article mentioned in Step 5 above. Make the ‘tenons a hair thick and sand them for a snug fit. After dry-assembling to check the fit, glue loose tenons into the mor tises in each stile (B), then glue two stiles to each leg (A) [Drawing 1} SB out to sae the side panels) and front/back panels (I) [Materials List) Glue together each side panel with its rails (C, D) [Drawing 1]. Glue each front/ back panel to its adjoining rails (B, and center stile (G) [Drawing 2. 38 Toolset rom center the mores onthe thee= ‘martise face ofeach leg, positon a "spacer against the tapered face of theleg. LEG MORTISE LOCATIONS (Front left leg shown) Dry-fit the legistile assemblies (A/B) Ko the front/back assemblies (EJF/ Gil) [Photo F]. Tie the front/back assem- blies together with the side assemblies (C/D/H), clamp the fit-up, and check it for square. Then, measure the opening for an exact fit of the bottom () ‘Cut the bottom () to size. Set it in place, using spacers to support it Forthe mortisesin the adjacent faces, secure the jig to theleg witha¥'thick pacer against the ‘three-mortise fe. Working wth the parts upside down keps the top tedsofthelegs (Aland the edge of thetop ral) {sh uring sembly. \Witha square ard pencl markacrossthe bottom Uand adjoining alls about every 6"tolocate biscuits. flush with the bottom rails (D, F). Then mark the bottom and bottom rails for biscuit locations [Photo G, Drawing 5]. € Disassemble the chest and cut slots jin the bottom and rails for #0 WOOD magazine October 2013 biscuits, Note: IF you've not alvendy sanded the panels to 220 grit (its always a good idea to finish-sand parts as you make them), now's the time to tackle that task (Quick Tip! Practiceadry-ft with biscuits in the slots before assembling the chest with slue. This helps you figure out how many ‘lamps youl need in what lengths, and how towork most efficient After your practice run, reassemble the carcase with glue and biscuits To make the side bottom trim (K) and front/back bottom trim (L), start with a 443641" poplar blank. With a Ws" round-over bit extended x" above your router-table top, rout a bullnose profile on both edges. Rip a 134"-wide strip off one edge and crosscut that piece to make two side bottom trim (K) pieces. Rout a bullnose profile on the just-sawn edge of the blank, then rip the blank to produce two front/back bottom trim (L) pieces. Glue these pieces to the bottom rails (D, P), trimming them for exact fit [Drawings 1,2} woodmagazine.com sobiscut Slot centered 3° from bottom edge Make copies of the Bracket Pattern, page 41, and use them in cutting cight brackets (M) to shape. Remove the patterns, finish-sand the brackets, and ‘glue them to the bottom trim (K, 1) [Drawings 1 and 2). Time to top it off oa es tontck rin) and lid side trim (0) 2" longer than listed [Materials List, rawing 5]. Rout a partial SHOP TIP Forthe lid rim pieces (N,0) rout the cove profile to lightly less than full depth when you make the pieces. Then, afteryou assemble the trim, complete the cove to full depth with ahandheld outer as shown at right That will cutaway any ‘mismatch where the profile meets at mitered comers, 4 Using pushblocks for safety, cut the cove to within ‘Yeo fulldepth Youll cleanup the remaining ‘material after luing up the tim assembly. Toensure opposing lid trim pieces are the same length, forthe second cutusea stopblock clamped toamitergaugeextension, 44" cove profile along one edge of each trim piece [Photo H ‘ut miters on the ends of the lid im pieces (N, O) [Photol]. Then, cut #10 biscuit slots in the miters and glue together the lid trim assembly [Drawing 5]. Complete the assembly as described in the Shop Tip, below. J hee Ne tam ssertiy YO) to the carcase, being careful to align it evenly on all sides. 39 From at least four boards, edge-glue the lid (P) about 1" wider and longer than specified in the Materials List. Cut the lid to size and rout a bullnose profile along its edges as done earlier on the bottom trim (K, L SHERAILLERS Sher-Coler(in} BE ec une su UCD BAC UDPIN PENETRATING STANDALONE WOOD MAGAZINE CUSTOM MANUAL MATCH BRC COLORAKT. 02 «32. 64 128 fareon = 2 Bi-Blect SIBBA t cagsTut Saat ‘sbi2462iS Se¢hO005 a Here's the pigment mfr the custom stain color based ona sample we crested. ‘Cut the lid cleats (Q) to size. Drill the holes and slots where shown, and screw the cleats to the bottom face of the lid. Finish up Sand any areas that need it to 220 ait. Remove dust and apply a sta We used Sherwin-Williams. custom- tinted Chestnut BAC Wiping Stain and top-coated with satin-finish lacquer (Photo). Cutting Diagram 34x 7/4496 Poplar (53 bd.) Nox 7¥0x 96" Poplar 53d.) @ @ 547! 96" Poplar 53 bd.) © 54x 70x 96" Poplar (5.3 ba.) (2 needed) xsi x AB" Poplar (2 bd ft) 2 needed) Install the hinges on the lid. Have a helper hold the lid in position while you screw the hinges to the lid trim (N). Install the lid chain [Source] to prevent the lid from falling backward [Drawi 5]. Now, gather your blankets and tuck them into their new home. # web Bie Proce Craig Rungpeggeranoha Olson Pret eign tevin Boyle ‘stone tema Johnson vp fete ae ae bcs wee wr Monae ae agin Pa Wien ae at Pad ‘see mde wr wa "Patsy cat esa See tesco. Materials key: 1? laminated pops, ?-poplar P-maple wood E-edgejpined poplar ‘Supplies: #10 bcs [22 #1 flathead screws. Blade and bits Dado set" upetspial "cave and ‘round-over router bis Source ¥ non-mortsehinges (3) a. 28704 $49/pi; Chain 2, 0.30653, $15.39 Rocke, 80077-4481, rocklercom. 40 x48 x48" Maple plywood "x 2448" Maple plywood More Resources P To purchase isues 218 (May 2013), 219 (uly 2013), oF 220 (September 2013) of WOOD Containing the articles on building the bed, dresser, nightstand, and lingerie chest that ‘match ths blanket chest, go to woodmagazine.com/2013issues. To purchase a download of just the bed, dresser/nightstand, or lingerie chest articles, {go to woodmagazine.com/traditionalbedroom. Thinking about lining your chest with cedar? Read this fist: ‘woodmagazine.com/aromatic. > For more bedroom furniture inspiration, visit our reader's gallery at ‘woodmagazine.com/bedrooms, ‘WOOD magazine October 2013 PATTERNS October 2013 Issue 221 Dear Reader: Asa service to you, we've included full-size patterns Cn this insert for irregular-shaped and intricate project parts. You can machine all other project parts using the Materials List and the drawings accompanying the project you're building, epg Meath Caption 20, Aight te SA Mee Cap the aber MOOD at akan the pre spate se pep ee pterescely feel, yeep of hee pattems sty pres Blanket Chest Page 36 BRACKET FULL-SIZE - PATTERN we *. (8needed) a — Ye | ® Sept.2013 yf \ To purchase WOOD issues 218 (May 2013), 219 July 2013), or 220 (September 2013) containing the articles on building the bed, dresser, nightstand, and lingerie chest that match the blanket chest, go to woodmagazine.com/2013issues. ~ To purchase a download of Just the bed, dresser/nightstand, or lingerie chest articles, goto — woodmagazine.com/traditionalbedroom, 1" chamfer ® RAILPATTERN | (3 needed) Accent Table Additional Tool Rack Plans for the Workcenter SQUARE RACK ae NOTE: Cut the squareholding dadoes on your tablesaw before hing the parts eget Vr the ado with nd spacing tut 25° chamfer | SCREWDRIVER RACK ar oO" ay NOTE: Dil the holes forthe screwaiver shanks after gluing up the three boards Vary the hoe iz and spacing to sut your screwarvers. CHISEL RACK NOTE: cut the cise holder dadoes on your ablesaw before slung the parts together Very the dado width and spacing fo suityourchses Built-to-last Workcenter Page 24 Scale 130% for Full-Size Pattern, Shelf Bracket Page 60 we —_— i \ (. alyoud yeioy apisut “ND "OL NUSLivd azis-Tin4 Lava SHC ip es You can't beat these affordable tools | for creating quick, Soveee Fin Ts "5" words describe pocket- hole joinery: simple, speedy, and rong. After using a jig, such as the one shown at left, to bore angled holes, you drive screws to join the mat- ing pieces. That's it! (For more details on how a pocket-hole jig works and tips for using one, read the article on page 14) The screws and the holes that house them typically hide on the inside or back side of a project. Pocket-hole joints excel on cabinet face frames, and they're also a great choice for carcase assemblies, dustpanel frames, drawer boxes, and picture frames, The jigs for making pocket holes with with a drill range in price from $15 to $200, so you might wonder how much jig you really need and which ones work best. We tested 10 widely available jigs, and hhere’s what we learned. What to look for in a jig > Dependable drill guides, The heart of each jig is one or more tubes that guide the bit for drilling holes at about a 15° angle. Most figs use stel guides for long life, but aluminum guides in the Crafts man 29133 and essentially identical Gen: eral Tools E-Z Pro Deluxe 850 wore away during testing, as evidenced by metal shavings in the wood dust, even after bor. ing multiple holes. The Drill Master 96264, despite having steel guides, also continued to produce fine shavings. AIL but the Kreg Mini jig have at least two drill guides, allowing’ you to bore more than one hole without reposition- ing the jig. The Drill Master, Porter-Cable 560 Quiksig, and Steelex D1060 have variable spacing, letting you adjust the uides to best suit your workpieces width. Three fixed guides on Krey’s KAMS give you three spacing options with each placement of the jig. All the jigs except reg’s Mini let you drill two pocket holes in 114% and 2°-wide stock—the two most common widths for cabinet face frames— without repositioning the jg ‘We prefer jigs with centerlines marked oon the guides for quickly aligning work pieces before clamping and drilling. All but the CMT PPJ-002, Craftsman, and General Tools jigs have this feature. > Clean-cutting bits. All the tested jigs use a stepped dill bit, similar to those shown on page 46, that bores both a pocket for the screwhead and a smaller pilot hole for the shank, leaving a shout- er for the screwhead to snug against. A stop collar, secured by a setscrew, limits as shoulders Caftsman’s tapered bit works bes with flathead screws, Althe other jigs use a it that bores 2 Square shoulder forthe washer-head screws. the bit's drilling depth based on the workpiece thickness, All the provided stop collars maintained depth without slipping, but the Kreg and Porter-Cable models were easiest to set. In our testing, the supplied bits from Kreg, Porter-Cable, and Sommerfeld Tools cut Cleanest over the greatest number of holes. The Craftsman, General Tools, and Drill Master bits dulled noticeably while drilling 40 holes, causing workpiece tear- ‘out, shown at top right. Only the Steelex jigcomes without bit; buy one separately for $11, but it does not include a stop col- lar. (Any bit from the other jig-makers would also work) Psimple thickness adjustments. Most woodworkers use pocket-hole screws CMT PPJ-002, $90 888-268-2487, cmtusa.com aa Cag oo ' Topreey set te stop afore eg TI, ple ebm theca ole sie te oa UReworipece thine endhten ese primarily with %-thick material, and ‘we were able to create tight joints in 4° stock with all the test models. Six mod- cls, though, can make pocket holes in ¥" stock. All tested jigs make pocket holes in 1¥4"-thick material as well, but with the Craftsman and General Tools jigs you can't center the screw’s exit point on the workpiece’s thickness, resulting in weaker joints. Porter-Cable’s jig has a unique, goof proof adjustment for workpiece thickness, shown on the next page. With the Sommer- feld 31PC jig, you swap the %" drill guide for a 1°" guide; there's no adjustment for ‘workpiece thicknesses inbetween. > Ease of clamping. The jigs that come with a builtin clamp—Drill Master, Craftsman 29133, $40 800-549-4505, craftsman.com w General Tools E-Z Pro 850, $50 800-697-8665, generaltools.com we Drill Master 96264, $70 800-444-3353, harborfrei ‘Mter 40 holes a Kreg bit made heeft pocket hole in veneered plywood. But after equal testing the Drill Master bit caused substantial tear-out ight). Kreg KAMS, Porter-Cable, and Sommer- feld—work best as benchtop jigs where you bring the workpiece to the ‘CM's jig comes in two parts (drill guide and clamp) that must be mounted to a board. Among those five better-for- benchtop jigs, all but the Porter-Cable require loosening a jam nut before threading the clamp face in or out—a fussy, trial-and-error process. All clamp securely once adjusted. Workpiece sup- ports on the Kreg and Porter-Cable jigs have stops for repeatable workpiece posi- tioning. Should you ever need to drill pocket holes in an assembled or built-in project, the Kreg R3 and KAMS and Sommerfeld jigs work best. The K§MS comes with a WOOD magazine October 2013 TOL aa leo xt twistthe knob tolck nthe setting After dling, release the camp lock to change workpieces. holder into which you slip the dill guide, effectively making ita larger ver- sion of the R3 jig. The Kreg R3 does not come with a clamp, but secures to a workpiece easily with a common one- hhand bar clamp or Kreg’s locking-pliers clamp. Sommerfele’s drill guides. also work like the R3 when removed from the jg. More difference-makers > Driverbits. We prefer a 6"long bit for driving the squaresdrive screws. in pocket holes, because 3° driver bits can cause the drills chuck to contact and mar the workpiece. A 3° bit does prove Kreg Mini, $20 800-447-8638, kregtool.com a Portable drt 0 o guide holder Kreg R3, $40 800-447-8638, kregtoolcom woodmagazine.com handy, though, for driving screws in tight surroundings. The Kreg K#MS, Porter-Cable, and Sommerfeld jigs come with both bits; the CMT, General Tools, and Kreg R3 jigs have just a 6" bit. The other jigs come without a driver bit. > Optional drill guides. Kreg sells spe- Gialized drill guides that fit into the K4MS jig so you can better match the pocket-hole and screw size to the mate- rial thickness, For example, the Micro guide works with 'A'-thick stock and Comes with a smaller drill bit and screws. And the HD guide works with 1!4"-thick stock, using a larger-diameter bit and screw. (See the photo at right.) Tense ra ‘Micro screw (stock) — Regular screw (4-114"stock) i (1% stock) Qo Kreg K4MS Master System, $140 800-447-8638, kregtool.com, Workpiece supportstop ~ Lockin x les == Dust-collection hood Miniig K 7 a PICK A POCKET-HOLE JIG FOR PRECISE, QUICK JOINERY PERFORMANCE RATINGS (1) DRILL GUIDES ‘SECONDARY ] EASE OF CLEARING CHIPS WHILE DRILLING EASE OF STORING JIG AND ACCESSORIES EASE OF PLUGGING DRILLED HOLES WORKPIECE THICKNESS RANGE, INCHES s 3 2 z\s|5 3] 2|2|2 BRAND MODEL 8 ol 2/= or c[ =m [ala] s (CRAFTSMAN Al em |t]2 [A DRILL MASTER a| wim [rats (GENERAL TOOLS EZPRODDELUNE ASO al em |t]2[ a MQKITMINE Clem [Nw] i]s wre 3 = c n[ats AMS MASTERSYSTEM a afals PORTER-CABLE 560 QUIK Fl2[s SOMMERFELD TOOLS [31°C R[2/5 STEELEX 1060 vials 1 2. Optaae 4) Frmlewscin 5. 8) Ranastankantbewithsopear 00 esaporsep Rextoglecany (0 Strgease Pgs 3.) Aiur (7) Tharbscew (0) Disececiaarahment ———_(R Paaedige ade 1G Pastcrmyoncnoute —W) Nodampiadued (9 Dlgueanisranalke ed) Sores 6) Sel lage daneersces 8) Slog Dsqare cit [NA] Sotapcte (H Heshakeotwhsopcer 6) «ong sqae ive bt [MR) Sotreanmended (0 Laing tsp (7 Spo spate Porter-Cable 560 Quik-Jig, $200 888-848-5175, portercabe.com : “Aes ACCESSORIES (5) | g é 5 |3 7 a5 0 1 8 © = 85 7 7 acrs6 | 3 my 8 /auesae 20 [1 acess | Wis | | A%s, 1H | BCOLMER S36 GH 140 mh | _BDMS36 20 [#1 BLS36 90, ra = [bs 6, Pres cent time af arid poducion 2d do otindude sipping, where apa Sommerfeld Tools 31PC, $90 888-228-9268, sommerfeldtools.com ll guide for "stock woodmagazinecom We found winners at 3 price points The heavy-duty and feature-laden Porter-Cable 560 Quik-Jig ($200) sets itself apart with the quickest, easiest clamping and adjustments for workpiece thick- ness, one-time depth setting on the dail bit, adjustable guide-hole spacing, a ‘vacuum attachment and chip tray. Those features earn it a Top Too! award, But it’s strictly for benchtop use ‘The Kreg K4MS Master System ($140) does all that the Quik-fig does (with slightly less convenient adjustments), works easly on builtins and assemblies, nd sells for $60 less, so it shares Top Tool honors. The K4MS creates clean pocket ‘holes accurately and consistently, and comes with more accessories than any ‘other jig. Save even more by buying just the Ka jg ($100) with a dri bit 6" driver bit, screw and plug assortment, and case. Kreg’ R3 jg, despite its smaller size, makes pocket holes just as well asthe Top Too! jigs, and sells for only $40. You don’t get a clamp, but it works well with most ‘one-hand bar clamps. It’s our Top Value, trey eb er ithe Feeney What comes after the K4? The K5, of course Kreg wi launch its newest pocket holejig, the KS, ater this year. ‘Among the upgrades fromthe KA BA ront mounted clamp lever and uick-postioning damp, MAccessorystorage spacein the support extensions, ‘The wil sell for $140asshownin the photo aright excluding the AutoManx locking pliers amp, 2 $30 accessory, Well test the KS and report our findings ina futureissue of woo. Steelex D1060, $15 ‘800-840-8420, woodstockint.com e e i ere ican re fr ues tus at Jou fi oq fee ee ae vase foes ity andaings soe We shadowed two experienced makers and install- ers of custom cabinetry to bring you simple in pro} tips and tricks that will keep your bull ects (and your sanity) “on the bubble. , = | > PF .c00 mn ihr Buller Nelson Hawbaker uses his own siting postion to determine the critical dimension for the height ofthe knee space na planned desktop. Before you build The design possibilities for builtins are endlless—from bookcases in the den, to a living-room entertainment center, toa set of kitchen cabinets. But even if you know the approximate shape and style of your project, you need to thoroughly survey the built-in’s future home before you touch blade to wood in the shop to ensure a perfect fit, For the initial site survey, you need only a tape measure, pencil, and paper. Your builtin must be designed within the constraints of its location, so your first priority is thoroughly documenting the “critical dimensions”—those inflex- ‘ble measurements that dictate the shape of the project. In most cases, that means knowing the minimum (narrowest, shortest, shallowest) dimensions, Even the best-built homes are rarely square, level, and plumb to the tolerances you might be used to in woodworking, so take measurements at multiple spots: wall could present the same measure- ‘ment at the ceiling and floor level but bulge in the center, surprising you with a narrower-than-expected critical dimension. Critical dimensions include the loca- tions of windows, outlets, vents, sinks, appliances, and other obstacles. But they can also include design standards for woodmagazine.com [Nelson constructed ths floor-to-eling builtin in eight units to enable delivery through a small entryway aswell as onsite assembly. Constructed separately as sngle units, thefaceframeshidethe seams between ‘the carcases, unifying the separate components, desk, seating, and countertop heights, says Nelson Hawbaker, above left, owner of Nelson Hawbaker Building of Dallas Center, lowa The final critical dimensions are dic- tated by the overall space of the install location and the path to it from your shop. Although an 8! bookcase may fit through a 7' doorway on its side, it won't stand up under an 8! ceiling without punching a hole through the drywall. ‘When in doubt, Dave McGrath, owner of Fine Line Woodworks of Bondurant, Iowa (finelinecustomwood.com), makes cardboard mockups that approximate the proposed! size and shape of the fin- ished pieces. He then tests the delivery and installation using the mockups to censure they fit through halls, stairways, tight comers, and doorways, as well as in the installation location itself, adjust- ing dimensions if necessary. Write your critical dimensions on a sketch of the built‘in's location. You should come away with an elevation (front-on) view sketch and a floorplan (top-down) view sketch. Back in the shop, design and build the casework of ‘your project to leave at least i" allow ance between the project and walls. You'll use trim and tricks to fill the gaps after installation. ‘After determining thefloos high point, measure ‘the emaining eight dimensions at that point before extending level ines across the wall. Level the base Countertops, shelves, and worksurfaces, must be level to prevent pencils or eggs from rolling off. This means finding a ‘way to level the base of your built-in, even ifthe floor could qualify asa black- diamond ski slope. ‘To get started, mark a level line about 18" off the floor on the rear wall where the builtins will be installed. Measure from the floor to this line at various points along its length to find and mark the floor’s highest point, above. This point now becomes the reference point at which to measure and mark other critical heights; for example, measure from the floor to countertop level at the high point and extend a level line across. the wall to ensure the cabinet sits at the highest point possibie. 32 Installed along level ine, cleats secured tothe wal's studs provide a solid support and attachment point forthe rear of earcases, Because the cleat does the job of supporting the cabinet, installation becomes a ‘one-man operation, Armed with level reference lines, most pro cabinetmakers don't even rest built: ins on the floor, strictly speaking. Instead, they install a simple “ladder” base, top—a framework of plywood strips leveled with shims and secured to the wall—that will later be covered with trim. An easier but slightly spendier solution: Cleats, above, support the back of the cabinets while adjustable leveling feet, right, support and level the front, We ordered ours from Woodcraft Supply (item no. 145840, $21 for a set of 4, ‘woodcraft.com, 800-225-1153). You should now have a_ perfectly squared case that “floats” plumb and level surrounded by the out-of plumb, not-square, and unlevel walls floor, and ceiling of your house. Time to introduce them to each other. Usethe provided hex urench to level the carcase. Eventually hidden by base trim, the fet remain accessible through holes in the case bottom. =e WOOD magazine October 013 Meeting the wall You hide most bulltins’sins with trim, says Dave. Where builtins meet walls, Cabinetmakers ad “scribes” Any part of the builtin that meets a wall—such a5 stiles or trim-—is designed with extra material tobe shaped to fit the wall "This requires tracing or “scribing® the contours of the wall onto the project partusing ether a specialty scribing tool Buch as the AccuScribe Pro.on page $6, of a simple compass, below. Rabbet or bevel the hidden back side of the materia The reduced material thickness makes easier to shape with a belt sander of block plane A sinall trim piece, bottom left, con forms more readily to. wall contours than the thick face frame, concealing gaps that broadcast imperfections, You can also minimize discrepancies between the builtin and a wall by tran: sitioning with a reveal, bottom right, Leaving a gap between the wall and face frame forces the eye to jump that gap, making it difficult to compare the two. In instances where imperfections in the walls are extreme, or where cabinet installations are unusually large, it may be more convenient to build the wall out with trim to give the built-in a plumb installation location, right. Easerto customize than the bulky cabinets the «columns surounding this fireplace were scribed soonefacehugs the wall whilethe opposite face provides straight and plumb “wal forthe cabinets. Tera oO 3 stile styles that blend into walls (One ofthe x" grooves in the back face ofthe stile postions iton the ‘matching rabbeted ase for scribing, The bevel eases waste removal The simplest gap-concealing option: purposefully lave asmall gap between walland sie. Then conceal witha narow trim piece, pin-nailed in place. The thintrim is easy tofles, concealing wallimperfections. woodmagazine.com Alter trimming away most ofthe waste and sanding tothe line, sifting the Stleto the other groove postions it seamlessly against the wal ‘The reveal between frame and wallraws the eye away rom imperfections, anda close look ull show only wood behind it. Useful where defects are ‘minimal the L-shaped clea also serves asa stop forthe face frame, 53 Countertops that fit contours Countertops trapped between three walls present a unique challenge. Where two sheets of drywall meet in an inside corner, drywallers layer joint compound to hide the seam. This virtually guaran- Enea Hot gle three strips of "ot plywood around the wall perimeter, leaving a small gap between wall and plywood, Use bushing or spacer washerto scribe ‘around the wall ERIN ‘return terminates into the wall at 90° to cap vim attractively, hiding end ‘gran. Cu the smalletur rst and glueit in place onan over length piece that {anthen be more easily sedtof 56 tees a tapered, out-of-square corner, even on even the most exacting framed construction. For walls that are nearly square— especially those that form openings narrower at the rear than the front— wihiteyou cont slongthe cans Countertop ‘the countertop. create a template for scribing from scraps of thin plywood, as shown below. For countertops surrounded by walls with more severe aberrations, you will often have no choice but to leave a gap. That's ‘when trim comes to the rescue, bottom Use belt sanderto andi the template’ scribed ine, Clamp the template ‘onan oversize countertop, and use the washer to scribe the template’s shape. Sand the countertop to thelne, beveling the underside to easeinstalation. ‘Once eutto length and nailed into place, his slender quarterround trim flexes ‘easly to conformto the wall while concealing the gaps between the wall and ‘Wood magazine October 2013 Don’t look down! The last bit of blending to do: floors and ceilings, “Nobody looks down,” says Dave. They just don’t bend over to check baseboards and toe kicks. But they do look up. So while you can fudge the bbase—slightly angling trim to average ut out-of-level floors—you'll have to be NEUE = oar Find FREE step-by-step instructions for a built-in bbookcase/window seat combo at: woodmagazine.com/bulltin TRIM, more creative where the top transitions into an out-of-level ceiling. Dave employs eye-tricking transitions. Multiple layers of trim, below, alternat- ing colors, and shadow-line reveals all create transitions that draw the eye rather than highlighting the discrepan- cies between case and ceiling, In extreme cases, where the ceiling slopes dramatically, design the builtin with a dead space between the case and ceiling, The eye has difficulty comparing level lines when they'te crowned with trim that doesn’t touch the ceiling. Each ayer of rim can be imperceptibly positioned to z ‘gradually “fudge” away an out- ‘of level celing. The shadow lines prevent the eye from noticing. > Leatn to build super simple drawers with a FREE video at ‘wasdmagazine.com/simpledrawers 1 Watch this EREE video to lean about easy drawer installation: oodmagazine.com/drawermount Find 13 pointers fr perfect plywood cuts at -woodmagazine.com/plywoodcuts > Learn how to stain plywood and hardwood to match: woodmagazine.com/colormatching > Fora small fe, download an article on easy face-frame cabinetry: woodmagazine.com/easycab > Or go frameless when you purchase this downloadable article: woodmagazine.comiframelesscab > Find dozens of cabinetmaking articles on a single disc at woodmagazine.com/cabinetry > One WOOD Editor isa litle too in love with his built-ins a: woodmagazine.com/byebyebuiltins 55 From the first cut to the final knob, these tools make building cabinets easier, faster, and more accurate. Get clean carcase cuts from a toothy blade Few materials prove as finicky or frustrating to cut as splinterprone hardwood plywood or melamine-coated particleboard. Rather than sand, patch, or hide tear-out, pick up a Freud Ultimate Plywood & Melamine Blade (thin and standard kerf models available). The 40° alternate top bevel (ATB) angle on the teeth—twice as steep as most crosscutting, blades—shears the wood cleanly, leaving splinter-free cuts. And the high tooth count (96 teeth for 12"-diameter blades, 80, for 10°, and 60 for 7") means each tooth takes tiny bite Ultimate Phywood & Melamine Blade Thin ker: LU79R, 7 $5; 10, $80; 12, $105, Standard ker: LU8OR, 107 $95; 12% 5135 Freud Too's 800-334-4107, reudtools com Scriber draws circles around compasses A compass dragged along the wall transfers (or “scribes") ‘wall irregularities onto the face frame, countertop, and backsplash where they can be beltsanded fora perfect ft. The AccuScribe Pro from FastCap graduates you from the second grade compass, adding multiple articulation points that allow You to squeeze it into tighter spots. The flat base prevents rock. ing as you draw it along a surface. And a built-in sharpener means you'll never have to search for a pointier pencil. All that and it can still draw circles and arcs. Accuerbe Pe, $18 Fastcap 888-443.3748, festeapcom 56 Adjustable shelves in a jiffy A low-dough shelf-pin dling jig gives you fast, no- measure accuracy for stable adjustable shelves. Use the Diillite jg and its 4° selfcentering bit (S-mm version sold separately) to drill the fist shellpin hole; then peg the jig in place through the indexing hole with a dowel or shelf pin and Grill away. No muss. No fuss, No-brainer. Dlite Shel Pin Dring jg, #853, $32 Peachtree Woodworking Supply, Ine £888 512.9069, ptreeusa com WOOD magazine October 2013 Attack clamping tasks from three sides ustom cabinet jobs offen come with custom clamping conundrums, Where barand pipe clarmps cart easly ach (such asa center face-fame tle) turn to Rockers 3a) Face Ievetage for securing the face frame {othe cabinet. You wort turn to this specialist often, but when you need i theres no substitute 3. Way Face Clamp, #39062, $35 Rockler Woodworking & Hardware 800-279-4441, rocker com — High-speed hinge placements ro cabinetmakes love Luropean-style cup hinges because they include enough post-install adjustment to make them ultra-forgiving, Somrmertek's Hinge Boring Jig (below) makes the preinstall process just a5 easy. Three builtin boring bits connected to Hexhead drivers on top ofthe ig precisely locate the 35mm cup hole and 8mm bushing holes. Turn the hex heads with your drill and a socket and press down bore cach hole to perfect dept, Fora loweccost alternative, try the Hingemark igh, which simply and accurately marks the location of the hinge holes Align the lg, tap the three spring-loaded punches to mark the hole centers, and then dil fem on yout drill press. Hinge Boring fig, #8, $180 Sommerfeld Tos fr Wood '88.228-9268, sommerfeldtols com Hingemark, 523 hingemark@sympatic.ca hingemark.com woodmagazine.com Aclamp for flush and flat face frames In a perfect world, your dead-square cabinets slip into place like they’te greased, adjoining face frames aligning seam- lessly. In our world, bulging walls, out-ot-level floors, and moisture-induced wood movement make that a fantasy. The abinet Claw draws together the face frames of two cabinets while simultaneously aligning their faces flush, making it a simple matter to join the cabinets with screws Cabinet law, #8510, 569 per pair Pony Tools 312-666-0640, ajustableclamp com Serew ee j AE 37 Self-centering bits eliminate hinge hassles Tiny screws and hard wood make a bad recipe for precise hinge placement—errant grain can cause the bit to slip off course while drilling the screw holes. If you plan to install butt, barrel, or wrap hinges, pick up a self-centering bit for the sake of your hardware-mounting sanity. The chamfered, spring-loaded sheath on a self-centering bit (commonly called a Vix bit) eliminates hinge creep by locking in the precise center of the hinge’s screw hole while the bit punches a per- fectly sized pilot hole. Vix its set of three hex-drve its, $32 IRs Woodworking xbisonline com sheath Drawer- and slide-mounting made easy ee etre es os fens the slide, one hand holds the screw, and one hand holds the drill. If you're a hand short, pick’ up Kreg’s Magnetic Drawer Slide Mounting Tool. Clamped or held against the face frame, the jig's magnets secure and position metal slides leaving your hands free to screw them in place. ‘The companion product for mounting full-extension drawers, shown on page 56, provides a convenient resting place for the drawer box while you secure the drawer-side slide. Magnetic Drawer Side Mounting Tool, #NZD3, $30, Full Extension Drawer Mounting Brackets, #NZ03-8,$10 Kreg Tool Company 00-447.8638 hregtool com se Thin-kerf dado set for undersized plywood Ifyou use plywood for drawer bottoms and case backs you Know those undersized sheets requie two passes (and ‘thus two setups) of a full-kerf blade to cut a rattle-free groove. ‘The outer blades of Frrests Special: Width Dado King cut that work in half by stacking together for a perfect s'-wide groove. ‘Add any combination of the six magnetic shims or the Ys" hippe for grooves ranging upto slightly wider than Special Width Dado King #Dx02404, $221 Forrest Manufacturing Company, In. 800-733.711,forestblades.com Proper pull placement begins with a. Tita saws and doors compete, dont blow it now with poor pull placement. Rockler’s Drawer Pull Jig It adjustable drawer-pull template lines up on your center mark to precisely locate handle screw holes in six standard spacings, as ‘well as centered.® ‘Drawer Pll jig Template, #35172, 520 Rociler Woodworking & Hardware 800.279.4441, rocker com Show us how you've outfitted your home for family fun: pinball arcade, music studio, video gamer’s paradise, indoor basketball court or playground, model railroad layout, home gym, putting green. .. whatever! We'll feature the best ones in a new special-edition magazine! Send us your materials by 10/1/13; the first 100 to respond receive a Sacre di EREE copy of Great Garage Makeovers magazine, a $6.99 value. AY ¢ 8+10 photos showing the interior of your Family Fun Room, 5~10 close-ups showing off cool features, displays, lighting, floor or wall treatments, problem-solving ideas, storage areas, and fixtures you made or found, Tellus what makes your Family Fun Room great! Email materials to f'unrooms@woodmagazine.com ta Shelf Brackets A five-layer lamination of 34" stock gives these easy-to-make scrollsawn brackets a classic carved appearance. ‘Overall dimensions of one bracket:5}" wide x8" deep x12" high. though the ornate scrollwork on these architectural shelf brackets 14x 10x40" glass, looks tricky, you'll be pleasantly surprised at how easy it is to cut. Only seven simple parts make up each bracket — 48x 1 FH Screw [Drawing 1], so you can build them quickly —S. é . Woead reo Start with a template eS =sS. Cut an 812" piece of 1" hardboard 9" ner ee e or plywood to make a template blank. The template saves making and mounting multiple copies of the pattern to the workpieces DCopy he Src Par inthe WOOD Patterns insert on page 1 and spray-adhere it to the template HlexpLopep view ® blank. (We used 3M Spray Mount Art- Sa tses ine ist’ Adhesive) On ‘Quick Tip! Apply a light coating of spray ‘Center lamination adhesive tothe back of the pattern andietit scaloped yer @ try fr 30 seconds before sticking the patter Bees ‘on the workpiece to allow for repositioning. lamination Subcap Lat st niton aa WOOD magazine October 2013, Sea TY Place the templete flush along the edge and endothe board t trace the patter. Minimize wast by tracing anther patter atthe boars other end. Drill a 4" hole where shown at the Jcenter of the scroll and thread a ‘no. 2 skip-tooth scrollsaw blade through it, (Skip-tooth blades have wider gaps between teeth, which helps reduce fri tion and keep the blade cooler) Install the blade in your saw. [Cut out the inside scrol, keeping the lade on the line. Release the blade from the saw’s upper clamp, remove the template, and reinstall the blade to scrollsaw the outside profile Cut out the bracket parts Begin by cutting five Yx7Mx16" boards to size. Use the template to trace a bracket’s outside profile and inside scroll at one end of a board as shown in Photo. Rotate the template to the diagonally opposite corner of the board and trace the outside profile only. Mark a second board in the same way. ‘These will become the left sides (A) and. scalloped layers (). Quick Tip! Trace the template witha thin- lead mechanical pencil holding it ata sight ‘anglesothe pencilpoint follows the template exactly Flip the template over and trace the side and outside profiles at one end of the third and fourth boards. As in Step 1, above, rotate the pattern to the other end of the board and trace the outside profile. These become the right sides (A) and two scalloped layers (B). woodmagazine.com On the fifth board, trace two outside bracket profiles. These will become the centers (C) for the two brackets. ‘To cut the 3" stock, install a no. 12 kip-tooth scrollsaw blade; then cut all ten bracket layers (A, B, C) along the outside pattern lines. Sand the edges until smooth, ‘On each of the left and right sides (A), drill a %" hole at the scroll cen- ter. Match the sides into two pairs with the pattern tracings facing out, and label them as matching sides. ‘Thread ano. 9 skip-tooth blade rough the hole in one side (A), clamp it in the saw, and adjust the ten- sion. Cut the curves [Photo B]. Cut out the pattern in the other three sides and set all four aside, }On the four scalloped layers (B), extend the cut at each end of the large convex curve where shown on the pattern. Then, lay out the scalloped edge using a penny [Photo C. Scrollsaw the scalloped edges, starting at the outside and sawing into the point from each side. Sand the scallops to 220 grit and set ‘the four pieces aside. Join the layers Refer to the arrangement of layers in Drawing 1. Apply glue to the inside face of each side (A), Keeping it 1" away from the edges of the cutout pattern to prevent squeeze-out into the cutouts. Ramen) anf AeA < Keep steady, moderate pressure onthe workpiece to prevent burning, Forcing ‘the work flexes the bade, causing aessthan-square cut Pye e ty Gq ce Markthe sallops witha penny touching the ‘extended cut and slight) inside the bracket curve. Trace adjoining arcs along the edge. Glue a scalloped layer (B) to each side, creating two left- and two rightside pairs. Remove any squeeze-out in the Cutouts and scallops with a toothpick. Glue a left- and right-side pair (A/B) to each side of each center (C). Remove glue squeeze-out in the scallops. ‘Sand or file the edges of the bracket Hoodies smooth [Photo DI, keeping the edge of the bracket perpendicular to the sides as you work. Make sure the brackets match closely in thickness and contour. Install a Keyhole-slot bit in your Hable-mounted router, adjusting the router table's fence so the bit is centered on the thickness of the bracket. Clamp fone stopblock on the router table's a infeed fence 104" from the edge of the bit, and another on the table's outfeed fence 3 from the edge of the bit. Make the cut [Photo E]. Once you've reached. the outfeed-side stopblock, turn off the router and slide the bracket off the bit along the freshly cut slot. Repeat this process for the other bracket. Then, unclamp the stopblocks and reposition them to cut the second pair of slots: Clamp the infeed stopblock 3" from the edge of the bit and the outfeed 104’ from the edge of the bit. Top off the brackets For each bracket, cut a %x8xSi¢" cap (D) and a ¥x74x44" subcap (B) Rout a 44" cove profile on both ends and the front edge of each cap (D). Switch to a 4" beading router bit and profile both ends and the front edge of ‘each subcap (E) [Drawing]. (Glue the cap (D) and subcap (F) jogether with the back edges flush, centering the subcap on the bottom of the cap. Glue a cap assembly (D/E) to each bracket body, centered side-to-side and flush at the back. Drill and counter- ore holes for #8x1'4" screws where shown, and drive the screws, Plug the screw holes with wood filler or poplar dowels, and sand the cap surface smooth. Finish-sand the brackets to 220 ‘it. Prime and apply a semigloss paint for a soft, aged look (sidebar at right), or apply a stain. We used a custom tint from Sherwin-Williams [Photo F}, and top-coated with three coats of a satin- finish lacquer. Attach the brackets to a wall, sliding the keyhole slots over screws driven into wall studs or suitable anchors. Lay a shelf across the brackets, as shown in Drawing 1. Secure a glass shelf with double-faced tape. Or, install a wood shelf by. screwing it to the brackets instead. # een by Lary bnston Freddy Nate Granzow wih Johan Prec destyJohn Olson Mstatens oma Jehaon oe Sm earaasy brackets ahold look N ‘ Speed up te smoothing process by using more thunsandppe:Tyhagsing away wate tha rasporfie Begin the cut with the tp ofthe bracket against theinfeed fence stopblock and finish the slot against the outfeed-side stopblock. Ifyou chose to paint your brackets, but would ike them to have a worn, classic appearance, lightly break spots along the edges with 220-gtit sandpaper—careful not to overdo the distressing —and accent the distressed spots with dark stan, Apply it lightly to just the bare ‘wood with a small applicator and then wipe it off To enhance the effect leave traces of stain, Jncrevices to simulate patina. Though we painted our brackets one color you could apply multiple coats of different colors Sanding the edges would then reveal layered Colors instead of bare wood. Eicar ano suscar ROCA SHUNT Srer Headstock end Spurcenter Talstock end ve center @mack pencil lines. ‘woodmagazine.com RU Che alle) Took: squarenose scraper Speed: 1200%pm Leave the tool rest in the same position as when roughing the blank to a cylinder. You will stil! have clearance between the biank and the tool rest when mounting the blank on Points C, D, and € in this step. As you begin each cut, move the scraper into the blank slowly. Because the tool won't contact the blank throughout its full rotation, you'll be “turning air” at moments, much «as when rough ing the blank to size. Remount the blank on Points £. Turn the area between the two right-most marks to 1'4" in diameter, top left and drawing, ‘Mount the blank on Points and turn the next area to the left to 14" diameter, tp right. Keep the shoulders ofthe cylin- ders perpendicular to the rounded surfaces. ‘With the blank mounted on Points, turn the next section to 1" diameter, bottom left Finally, remount the blank on Points €, and turn the next area to the left to" in diameter, bottom right. The remaining, block of material next to the headstock becomes the base of the candlestick. Mount on Points D and turn thar, Mount on one, Points E and Spur center © roimscand er: he ae jes ( Mosnton, mths Live ce poms Ean i We a t 1 ms oe + 66 as WOOD magazine October 2013 Vane akc Took Patng too Speed: 1.200 rpm At the right end of the blank, adjacent to the 1!4"-diameter section, make a parting cut, turning down to about a 2° diameter, top tet. Remount the blank on Points A and remove the waste on the bottom of the base (left end) leaving a ¥s-thick base. Tura slight concavity on the bottom so the candlestick rests, only on the outside rim, top right. Sand the bottom to 150 grit; then, remove the candlestick from the lathe. Atthe drill press, drill a Y's" hole 6" deep into Point on the top, bottom left. Complete the parting cut at the top using a woodmagazine.com handsav. Then centered on the Met guide hole you just drilled, bore a 1" hole /" deep into the top, bottom right. Sand the candlestick to 220 grit and apply a finish. To cover all areas evenly, we sprayed on three coats of aerosol satin lac quer. To hold %'-diameter candles, insert a %" copper pipe cap in the top of each candlestick. Light the candles and get ready for glowing reviews of your work. @ oducesby Calg Ruegeggerustn Bian Simmons Moje desir Bn Sons Hutton Loma Johnson ‘Watch FREE video turning tips and techniques at woodmaga: Find dozens of tuned project plans at: ‘woodmagazine.com/turnedprojects. > Read reviews of lathes and turning tools at: ‘woodmagazine.com/lathereviews. | ie Ty, | a 4 o LIFETIME WARRANTY Quality at Ridiculously Low Prices | FACTORY DIRECT TO ccm ih How does Harhor Freight Tools 3PI TANIUM A NITRIDE COATED i HIGH SPEED STEEL ‘STEP DRILLS oe ‘ ‘a et Ee oy sa i ‘SracnsoaRReeTRS LO; POWDER-FREE NITRILE GLOVES "388 = PACK OF 100 DF) nee me GE FA 2 sre Bence 25 uP. 21 CALLON. orn. ae 25 PSI VERTICAL A COMPRESSOR A org sy hice 52158 wooo cniset SET | chu! ‘PITTSBURGH ‘ze drilmaster PE ne ar wa SS (MUEHEL nee ‘cia eae GVER'S DOLLY] 60° WORKBENCH Wirt = FOUR DRAWERS BS rrsounct mmm MBNSSB* RAPID PUMP 11.5 TON ALUMINUM RACING JACK orm diiljmaster ; ORBITAL Oma / tun SANDER P”2 np wousTaal | masntiene! 9 MICRON Dl “ oo COLLECTOR ce se ft Tw mg o Cenc PRESS™ ‘VOLUME, LOW PRESSURE wood aa HIGH SPEED METAL SAW eo PAY GUN KT po g ‘rma 3008 a? RE, PRICE 1.98 res Pes 1/4 TRIM ROUTER ‘UMN ONDE Si 30, 11 DRAWER duillmaster FS (Zine) SPONGES - PACK OF 10 ROLLER CABINET SOARSE ___USENERAL torn 8 CE 5.08 Haulfviaster 12 VOLT MAGNETIC S317 PIECE AIR Toot 4°36" BELT) . « GT KIT 6" DISC SANDER fa A hag, MESSORY AT, 7 {0190.94 210 ) es oS 5 ond ON maul pee CY “iow HEAVY burt FOLDABLE + ooreeriies UTILITY TRAILER Oe ee ee Vics ree eee Ask WOOD Rete tig ety eee ioen erty While'visiting several museums that sowcaso Early American furniture, much of what I saw had ornate cary- ings.['tike to replicate those elements oirmy_furniture pieces, but I don’t have the tools for this. Can you provide me with a “get-started” list of carving tools? Crag Shaw Batimore GiBIg) carving tools are classified as, Jaives, chisels, and gouges. The first twocompare somewhat to common pparingknives and bench chisets, although many carving chisels have dual-beveled cutting edges. For the type of work you want to do, you likely won’t need knives, and you can get by with your bench chisels until you become ‘more accomplished or want to expand your work. Gouges come in two basic ‘shapes: vee and semicircular. The width of each gouge is measured in millimeters at the cutting tip, and the shape of a semicircular gouge, known as the “sweep,” is designated with a “#” symbol and number. The smaller the number, the greater the radius of the circular shape. Curved, or backbent, shanks on some gouges give you better access for carving concave and convex shapes compared with straight-shank tools. ‘To get alist of the most-needed carving tools for a beginner, we posed 70 How to get started in carving? A little “Bird” has the answer ‘your question to acclaimed furniture- maker, author, and educator Lonnie Bird, who teaches carving among many hhand-tool classes at his woodworking school in Tennessee. (Find it at Jonniebird.com.) Lonnie suggests the gouges shown below for carving furniture clement, such as the shell above. You Have a Woodworking Question? Emalittousataskwood@woodmagazine.com Fo festerfeedback fom your fellow woodworkers search foro post your question inthe Ask WOOD Online section of woodmagazine.comiaskwood, or none of ou" topical woodworking forums at woodmagazi questions to Ask WOOD, 1716 Locust 15-221, worms. Youcan also snal-mal s Moines IA 50308-3023, can buy these 10 carving gouges in a set (part no, OST1S ) from Woodcraft for $340: 800-535-4482 or wooderaft.com, ‘As you get more into carving, you'll probably want to expand with double- ‘edged chisels and more gouges. Most ‘carvers, Lonnie says, have dozens of chisels to create specific sizes and shapes. 212mm Gouge — 225mmGouge = | 158mm Gouge i 45 ramm Gouge —_ 87 6mm Gouge — | #7 10mm Gouge sae 111 15mm Gove E mzenmveesouse — \/ ‘25 6mmBackdent Gouge — #25 10mm Backbent Gouge. ——~ continued on page 72 WoOD magazine October 2013 The facts are hard to ignore. OHIO NEM NIKON NOU UUNSHIONMUNKe I Tee Ion ed Wood Glue As the leader in wood glues, we want you to know the truth about polyurethane glue and woodworking. A straightforward comparison between Titebond” IIl Ultimate Wood Glue and polyurethane glue Pentincad Titebond” Il is THE ultimate choice for bonding wood to wood. Period. SR a an enon cd din he USA Oneida Air Systems PE aL Collecting Dust! In WOOD® Magazine’s (May 2013) Air Quality Test the Oneida V-System dust collector was the best at keeping airborn dust levels lowest in the wood shop. eee ace oad) Pee Re ‘Another plus: second quietest, below the threshold of potential hearing loss (85 dB).” WoODe Magazine - May 2013, “Oneida is committed to building the best possible dust collection systems while keeping jobs here in America.” srt rac titer Oni Ste FROUGH cur <= [BE wooonoen wero xs ly Male nthe USA. (Eu ust Collection Systems and Components Since 1983. Oneida Pte Toy Pree Ask WOOD | An Adirondack by any ‘other name is still sweet Affer seeing the Adirondack chair plans in WOOD issue 219 (July 2013), I got to wondering why it’s called that? Can you filme ip/on the history of this iconic chair? — steve Rogers Reo, Nev oddiylenough, Steve, the original chair was not called an Aditondack, but a Westport chair. According to the Adiron- dack Museum in Blue Mountain Lake, N.Y, Thomas Lee fated the chair around 1900. A Bostonian who summered jn Westport on the shores of Lake Champlain, Lee nailed together the outdoor chair from wide planks, incorporating wide arms to hold drinks and plates (bottom photo). ‘Afew years later, Lee shared his chair with Harry Bunnell, a Westport carpenter and hunting friend, suggesting he make some to sell. Without Lee's knowledge, Bunnell filed for and received a patent for the Westport chair in 1906. And according to the museum’s records, Lee did not contest the patent, Over the next two decades, Bunnell built these chairs using knot-free planks of local hemlock and bass- ‘wood. Most were painted green, brown, ot white to provide resistance against the weather, Eventually, other craftsmen. began making chairs similar to the Westport ‘Around the Great Depression, these clear, wide planks became costly and hard to find, so builders started making the chairs from narrower slats, while maintaining the same basic design principles: tilted back and seat; fan-topped back; and wide, flat arms parallel to the ground, Because these chairs were most popular at resorts and vacation homes in and around the Adirondack Mountains, the name ‘evolved to simply Adirondack chairs. Soran et Westport ch Procol te Adeondacr un n The inside scoop on infill planes Whabisansingll plane? They’ Gecutifl, but do they work differ ently tha other planes Isit a type Of tool theta hobby woodworker fk Movin Black Memphis At tS core, Marvin, an infill plane consists of a metal body with wood components tightly fit “infilled”) into the interior voids. These handmade tools come in different styles (smoother, shoulder, miter, and panel), and perform essentially the same functions as antique and ‘modern cast planes. Because most infills, especially pre-World-War-II models, use dense, heavy wood species, such as rose- wood or ebony, they have greater mass to help power through cuts But that’s the only advantage an infill has over a “hollow” castiron plane, With limited, fussy blade adjustments, an infill can be frustrating to use until you become experienced with it, And because you'll pay two to three times more for an infill plane SS than for a n ‘model, wed have a hard time ° recommending you get one. We QUALITY WOODWORKING ToOL: suspect that many people who buy Saas aa Infills treat them as collectibles rather than working tools. Infil smoothing ; plane Includes: Tal esis + Bye Shots + Spark estos +6 Pome Cod h ce oe tay Infil shoulder plane POWER TOOLS, woodmagazine.com a SF Vu Lal Woodcraft Sore Or For A Free Catalog, Visit wooderaft.com Or Cll 1-800-225-4153 EASY CHUCK PUR eeeecrnecentd Beer eget sr De eee! rere) eee Pocket Hole Screws et Install Serews D R ==> 22 = = 1 RE co = T — => iS UVINSIUNA TOR AssRUUY aro wxsmLL- SORES ee Setanta coun ciie tee aes eet ee ere nee sc kWOOD Simple support helps mortise turned or tapered stock [boii preturned legs from an online company to make a tat altered my original plans: Now I want to add Tower stretchers between the legs How can I bore sockets into these tapered segments so the stretches will be parallel wittrtheyypper aprons? Folk the stretchers parallel with your upper aprons, James, you need a simple ig to support the leg s it lies flat | omits square, upper section while drilling the sockets. Slartwith a base of 4" plywood or solid wood slightly | rider and longer than the leg, and attach a pai of short cleats to the edge and end of one corner, where shown helow. Place the lg’s square section against the cleats and clamp itn place. Next, make a V-shaped block to support the leg beneath your layout matks forthe stretcher socket. Attach it to the base with brads or screws 30 the block supports the leg without lifting it. Finally, drill the socket 6m your drill press, at Bottom. Repeat forthe remaining legs (To make a rectangular mortise, simply dill multiple holes ‘of equal depth, using.a fence to keep the jig ina straight Tine. Chisel out th pping holes) 7 WOOD magazine October 2013 Save |i femena vain ines Free Shipping On all Orders! Cnvi wall-mounted room heater consumes less. warms more. energy saving heats aroom for only 4 cents perhour ultra-safe eave unattended 247, cool to touch healthy fanless will not circulate dust or dry the air effective 108% Pure tack Convection gente whole room warmth! silent fanless design, auto dimming power light easy install istalsin mines, no dil equed hardvied and plugin models avalabe stylish slim space saving design ‘only 19" wide by 2" thint economical. safe. simple. 800-807-0107 Limited Time 10% Discount! Coupon Code: WOOD13C10 Router tables & bits at MLCSwoodworking.com "Make Profesional Kitchen Cabinets” Sica shank abide ped tourer bits make case Kitch nan fine furniture cabinet ‘sed panels and deers Unereater #360. $21995 Standard 48387..811495 “Fast Unique Joints” ‘iF en tingas tale Cte ony ose lparemrecreleg wage BSc theo emp Set onl ‘np Set 5406995 Template Settean. $3695 “Don't Stand Stock On Edge” Routwide tok FLAT onthe table with lis in horgontl poston! The Heizontl Benchtop ‘outer Table perfet br raed pnelsand ‘morte and tenon The mer Track ecepesaccesory tops 99767 on $7995 “Tilting Top” Acces tps 04 Cet anges thurcinnetbecat onareprrourer be 97685995 “Mortising Top” Keira” /* cle way t0 ‘cutmortze Sand tenon joins $576.0S79.95 FREE SHIPPING! 2800 533-9298 | @MLCS Shop-Proven Product: These woodworking wares ene Build a rock-solid workbench in no time Key's Universal Bench system makes it fast and easy to build a sturdy workbench, assembly table, finishing table, or tool stand. Just bolt together a set of these 12-gauge, angled:-steel legs and nals fora rock-solid stand, and then screw on a top you make to suit your needs. i's that simple. ‘The legs come in two adjustable heights: 1544-21%4" and 29-35", The rails come in 14", 20°, 28", 44", and 64" lengths, giving you 15 possible footprints from 14x14" to 64x64", In addition to the predrilled assembly holes, the legs and rails have holes for adding shelves or enclosing the sides. ‘We made multiple stands for the WOOD" magazine shop and love them, 4 44x44" stand with a laminated MDF top doubles as a secondary workbench and tablesaw outfeed stand. A 28x44" bench with short legs, locking 3° casters ($60 for a set of four, part no. PRS3090), and "sealed plywood top serves as an assembly and finishing table and nests under the larger bench. We also made a portable table with tall legs for finishing small projects. (No stooping for us tall guys!) Teed tein bye, Universal Bench system ee Performance seem Price Legs Get of 4) $60-80 Price Rails (set of 4). $20-80 Kreg Tool 800-447-8638; kregtookcom Carbide-tipped turning tools start sharp, stay sharp Ive always preferred using high-speed steel turning tools that I could shape and sharpen as needed. But Easy Wood ‘Tools’ catbide-tipped turning chisels impressed me: The insert tips are sharper than I expected, and they held that edge a long time, even when turning dense white oak and maple About our product tests We esthundreds oftoolsandaccestovies,butonythosethateam | at eastheestasfor performance mae thefnal cut andappearin | thissecton. Te products shown here and those that dort make the cut area reviewed at toolreviews.uoodmagazinecom. Prices shown are cuenta the time of arte production anddo notinclude shipping, where applicable se into heaping piles of shavings. For once, it was nice to not have to stop and sharpen the tools—I could just enjoy turning, And when the cutting edge eventually did dull, I simply rotated the cutter to expose a pristine edge. But it’s important to keep in mind that the Easy Wood Tools chisels (like all other carbide-insert tools) are scrapets and, a5 with any scraper, seldom yield turnings as smooth as those created with sharp traditional ‘gouges and skews. So they wont completely replace those tools. Still, there's almost no learning curve, and they'll make a great addition to any turner’ collection. 78 Easy Wood Tools makes chisels with square, round, and diamond-shape replaceable tips. They come in three lengths, and the handles are color coded to the shape of the cutter for quick reference, Tested by Bian Simmons arbide-tipped turning tools Performance Fa RRE Price 90-140 each Easy Wood Tools 866.963.0298. easywoodtools.com NI ‘WOOD magazine October 2013, Leigh dovetails at a value price I've used Leigh dovetail jigs for years with great success, but the knock on them has always been the premium price. So T was glad to test the R9 jg, simply a template you mount to a thick backer board (that you supply). With this setup, you can rout through- dovetail and box joints with a hand- held router, as shown at right, or template-down with a table-mounted router; both work great. ‘The R9 comes with two adjustable side stops for registering the workpieces edge, and three pin plates that mount to the top of the backer board for positioning the machined aluminum template. You can slide it down after routing one set of pins o tals to effectively double the jg’s width capacity without losing registration. The fig makes three sizes of through dove- tails @4’, %«', and 4" pin widths) in boards up to "4c" thick, as well as three sizes of box joints (4, %', and "finger widths) in boards up to % thick, ‘As usual, Leigh provides an excep- tional owner’s manual, clearly written ‘woodmagazine.com with illustrated steps. After setting up the jig, I routed a through-

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