Professional Documents
Culture Documents
Woodsmith - 063
Woodsmith - 063
63
------------------------------------
$3.50
No.63
EDITOR'S
June, 1989
COLUMN
Sawdust
Ed~or Donald B. Peschke
Design Oireclor Ted Kralicek
ManagingEd~or Douglas L Hicks
_
Editors Douglas M. Lidster
Kent A. Bucklon
Terry J. Strohman
ProjeclDesigner Ken Munkel
TechmcallllUSlratorsDavid KreylJng
Cary Chrlstensen
RodStoakes
Chris Glowacki
CustomerSeMce Sandy Baum, Mgr.
Jackie Stroud
PatKoob
Lisa Thompson
PlOjecISupplies Leslie Ann Gearhart
Computer Operalioos Ken MIner
Adminisb'ativeAssts. Cheryl Scott
Jean Carey
BuildingMaintenance Archie Krause
WOODSMITH STORES
~ratiohs Steve Krohmer
MarketingManager Steve Dozier
StoreManagers:
SI. Loois, MO Jon Behrle
8erI<etey, CI\ Michael DeHaven
Des Moines. 11\ Kent Welsh
WOODSMlTH (ISSN 0164-4114) is published bimonthly (February, April, June,
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by
Woodsmith Publishing Co., 2200 Grand
Ave., Des Moines,IA50312.
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@Copyrlght; 1989 by Woo(jsmijh Publishing Co. All R.ightsAesetVed.
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send us his/her name ari!l address.
Now that I'm on the subject of thin lumber, it's time to say that in the past wl1ve
often avoided projects SPecifically because
they requirethin lumber. Irs noteasyto buy
at lumberyards or even specialitystores. It's
even harder to make it yourself - if you
don't have a thickness planer.
So itwas time to corne up with some.alternatives. The traditional method is to resaw
thicker lumber Into thin pieees and use a
hand plane 10 smooth it to final thickness,
Since Ilike using hand planes, this is the
method I'd choose.
That is, except when planing maple (as r
needed for the toolbox). Talk about aerobic
exercise - hand planing even small pieces
of maple wiUget the or heart pumping.
ltonly took a few boards before I wanted
way to leta motor do the work.Therouter
jig we came up with (shown on page 13)
works great. Even though you have to make
a lot of passes over the sun ace, it comes out
fairlYsmooth. And it cleans up quickly with
a hand scraper and a little sanding.
Am Igetting '<lay, letting a motor do the
work? Maybe I'm just getting practical.
BOO~lATClllNG.One of the nicest effects
you can create when making thin lumber is
bookmatehing. If you need a wide thin
panel, it can be made by resawing a board.in
half and joining (bookmatehing) the two
pieces together.
When Imade the thin panel for the chisel
case (page 8) I resawed a piece of'Y4"thick
walnut that had a nice swirl pattern in the
grain. [fyou have the chance to try this technique. look (or a piece of wood with some
character. Avoid "perfect" pieces with nice
straight grain. I look for a piece with "defects"like knots, orspalting, or acraaygrain
pattern. Although a bookmatched panel
with wild grain is difficldt to plane, it sure
No. 63
.-
FRO
FELLOW
WOODWORKERS
CCLAMP TABLE
SANDPAPER CUnlNG
JIG
piece in po-sition. I
created a simple
'):>oar ..man's" clamp.
6~
113 OR
1/6 SI%
Slims
No. 63
later. start
~" from one edge.
Now rout v-grooves ~" deep
along the layout lines to serve as
a cutting trough for the )mife.
Then Iadded two strips atone
corner to Iorm a stop for the
sandpaper, see drawing. Since
the stop gets in the way of the
knife blade, I cut a kerf through
the stop with a hand saw, aligningthekerfs with the Vgrooves.
To use the sheet cutter, place
a couple of sheets of sandpaper
upside down on the base with a
comer against the stops. Now
cut through the sheets. Move
tbe just-cut edge against the
stops and repeat the cut
GLUING EDGING
PANEL RAnLE
FEATURE
PROJECT
Bookshelf
This bookshelf is easy w build, easy to knock down, and it's sturdy.
So, why should that be surprising? It's all done without using permanent
joinery or hardware w hold the shelves to the end frames .
"
Woodsmith
No. 63
EXPLODED VIEW
STIF~ER
44\1'4
2"
"i
SHElF
,,& H
SHElF
D
."
.... -.,....
-~
_,
.".--
-...::::-..
r0
.eo
1I..
'0''''.--1
STIFFENER
I
/,
"'"
-....:::
S~lF
47'
~
--
.'t--:
~-
S~lF
~
."
SUPPORTDOWEL
'\
STill
A
OVERAll DIMENSIONS:
36',,"H x 47'h'W x 13.,,"D
I'-
I'-
\f.'"
)It
.L
<,
~'."
I I
I
,.......
.,.,'
DIAGRAM
1= ,-
E"
0-
,b: ,
SHELF@)
\ If
""-
~OAK
_
DOWEL
MATERIALS LIST
E
LVA?WA7/v~AW&wyffff~;V~
I SUPPLIES
I
I
I
0
0
Stiles(~)
3/. X 2 36~
Rcolls(4)
2 131~
SheltSup, Dowels (lOH~ x 10%
Shelves(3)
~.x9~-47~
ShelfStltteners(3)
o/.x3~- 44V.
A
B
C
o
E
STilE
A
:
, : \.0:1"
STilE
: '\1-"
SHlF~ENER
~
CUnlNG
W-OlA.
WOOD PLUG
SHELF/DOWEL
~?:::SHELF
-'.t~R,
./ ,,::';' ]"
,.
> .'
~.
7/
SHELF
STIF~NER
6"
, I-
STIFFENER
'8x;1Fh
~wOODSCRew
, ,
"'!I
I,
.....!
6"
-o;J
~l
2'
-1.
STilE
1--
~-
...
.......
_
,
CORNER/STIFFENER
;t."
LUMBER
(S.5Boord ft. 'It.'fhIGk.solid red ook
Olhercholcesmlght be birch o(maple
4 -1hrge II, oaJ(dowel rods. 'I.!-dlo..
or other 'h',dlo. d0wel rods
HARDWARE
1518x l'fhwoodscrews
[::::',,:::"T"":::::":=:'
~~~i~i~~:.':~'
.~~,
",~.::.,:::::*ffX~~:]
..
~'.'DS
~~,~
~
No. 63
Woodsmith
FINISH
MARK AC.A:O$S
sruss
AU.
WITH SQUAR.E
KEEP
~EHDSflU$H
STIli
FIRST: fNSRt
SH.ELFSUPPORT
DOWfl5INTO snLlS ......~ __
RAIL
FOURTH:
TlGHTfN c..clAMPS
ATCORNfRS
NOTE:
SHELF
SUPPORT
DOWELS
FOR DOWll
LNGTH ADD
DISTANCE
BETWEN
SHOULDRS
PLUSHOL!
OE'PTKS
9'AI"
NOTE:
SECOND:
ADD GLUE
to LAP JOINts
Woodsmith
No. 63
SHELVES
RADIUS CUnlNG
One of the best ways to round consi'ilt'flt
comers is with a template and flush-trim
router bit. Make the template by cuuingn
piece of Masonite S" square. Then use 11
compass to layout a 1" radius on one
comer. Cutthe radius oversize, and c~lIr
fulllIclcanlO the lineusinga disc sander.
To use the template, stick ildown on a
comer of tbe workpiece using doublesided carper tape. Now set the height of a
flush-trim bit so the bcaring rides only on
the template. Cut the radius in several
passes, until the bearingridescompletely
around the radius oithe template.
FLUSH
TRIM alT
ON ROUTtR TABLE
r-
8CUTsnffENER
TO
~rrnGHT BEtWEEN
--
9 10useAUGN
~~' \~. ",.x
S.ACE, BLOCK
STIffENER
~
~
~.J
END FRAMES
IS COMP\.fT1!
ASSEMBLY
To keep the shelves from bowing and to prevent tbe whole bookshelf from racking. 1
added stiffeners (E) to the back edge of
each shelf, see Fig. S.
CUTTOSIZil. Start by ripping enough.stock
3W'wide to make three stiffeners. To determine the final length. assemble the bookshelf, and measure the distance between the
end frames along the shelves. Cut the stiff
eners to length by starting a little long. then
sneak up on the finished length. Check Ihe
fil between the end frames after each cut
until you geta snug fi(.
ROUND EDGES. After cutting the stiffeners,
round over the edges and ends, see Fig. Sa.
MAKE SEVERAl
a.
SPACER
~"DIA.
8lOC~'. WOOD
PlUG
~.
.'
SHElf
,NO
f'AAf''-.' ....!I
~
_/_,:~~
'~
'OUNOOVER
All EDGESON STIffENER
WItH I,..,. ROUNIX)VER BIT
No. 63
lOP
SHElf
LAY UNIT
FACE~OWN
a.
Woodsmith
S HOP
PROJECT
Chisel Case
This case protects your favoTite chisels and doubles as a
working chisel stand. Instead of complicated joinery> this project relies on
a precise fit and understanding the natural movement of wood.
WoodSll.lith
No. 63
EXPLODED VIEW
MATERIALS LIST
TRAY
LID PANEL
A EndBlocl<S(2)
8 Cose Dlvtders(7)
C Bottom Pon~ (1)
D Chlseillesfs (6)
<:ASE
DMDER
I~.9lj. 'AI
'1.xl~1)'1.
'1ax 91;, 12~
~.xll;.\.'.1
UP
E LidPonel ( I)
F Ud SkIes (2)
G Ud-stiftener(I)
CUnlNG
\I.x911.12').1
!l4x212'n
:v., x 9'14 if2
DIAGRAM
1118111
F
LID SIDE
IcW*id
lelel
~ .. " 1(
BOTTOM
PANEL
~I
S" . 16" (.6 ad. Ft.)
A,O,G
SUPPLIES
LUMBER
3.5 sq. ft. !I.thlck walnut
.6 Boord It. '!I.'thick walnut
& FINISH
(2) No. 12X1'I.' Rhoross woodscrews
HARDWARE
TungoD
Postewox
CROSS SECTION
FIRST:(DG' GLU(1WO
~" x $" . 80AROS,
CUT OfF
o PJECE.I
NOTlGRAJN
PAmRNANP
END
BLOCKS
JOINTUNES
10 ;tOUGH
DIMENSION
No. 63
\Y/ oodsmith
CUnlNG
THE GROOVES
10
the rabbets
are cut. divide the space between the rabbets into six equal spaces (or the number of
chisels in your set) with a \4" groove between them. see Fig. 3. Now move the table
PANEL
sander or a sanding block.
ASSEMBLY. After the dividers have been
sanded. fitaod glue them into the grooves in
the end blocks, see Fig. 6. (Make sure that
this assembly is square and that it sits fla~)
II0'IT0MJ>.~t.. After the dividers (B) are
glued inlC)lheend blocks (A), you can make
the bottom panel (C).
Start by edge-gluing enough V."-Ulick
stock to make the bottom panel. see Shop
Notes, page 12.TIle finished size of the bottom panel is the same as the outside dimensions ot the tray that you just glued up, see
Fig. 7. (Our divider tray measured 9l1.," x
12.!".)
CU180rrOM
PANELTOffT
BOTTOM
PANEL
NOTE:
D~VIDER
AUGN
ASSEMBlY
MUST 8!
SQUAR,E
Gl,ur 6OTToM
PANn TO DIVIDERS
fLUSH
ON All
$IOf,S
Woodsmith
No. 63
LID ASSEMBLY
After the lJ'ay as-
sembly is complete
you can begin OJ) tile
lid panel (E). Start
by gluing up enough
stock to make a
panel that's
V4"
wider and 1" longer
than the tray. After it
dries, rip the panel Vt6"wider than the tray.
ASSEMBLEme POCKJo:T.Next, to form the
pocket and lid top, cut the panel into two
parts, see Fig. 8. To determine the length of
Olepocket.measure from the end ofthe tray,
to where the arc begins Onthe divider. Then
ada ~"to allow for trimming.
LID ",'r-,
PANEL
LONG
PO,m
DONor
a.
POCKET
PANEL
GLUE SlOES
TO POCKET
PANEl
_;--
12
CHISEL REST
CUT TOFfT
8,TWEI;N
CASE DIVIDERS
cer TO
FfT
G BETWEEN
UD $IO[S
No. 63
Woodsmirh
11
TIPS
SOME
FRO
OUR
SHOP
Shop Notes
BOOK MATCHING
Wben making the Chisel
Case on page 8, J used a technique called book matching to
create the mirror image grain
pattern on the lid. Book matching refers to how apiece ofstock
is cut and glued back together.
GRAIN I'ATl'ERN. To create a
book-matched panel, select a
piece of wood that has some
figure to it Ilook for an interesting burl or a swirling grain pat-
PLANE IN
DIRECTION OF
AAAOWS IEfOR.
_ ...... G1.UING UP
SlDfGRAlN
POINTS TO BACK OF 80ARD
ing, put the two halves back together as if the piece had never
been cut Now stand them 00
edge and opeo the lWO pieces as
if you were opening a book. The
spine of this "book" becomes
the matched joint.
Note: Open the book (rom the
lOP edge, then try opening' (rom
the bottornedge. Eitherway, the
pieceswiUbe bookmatched, but
the grain pattern will be different. Choose the one with the
most interesting pattern,
PtANJNGl'ROBLEM, Although
matched lumbergives you interesting patterns, itcan bedifficutt
10 plane smooth. The problem is
that after the two pieces are
glued together, the grain of the
pieces runs in opposite directions, see Fig. L If you plane
both pieces of the panel in the
same direction, tbe grain might
12
SPACER
FIRST: DR,vt
~::_:::;:~~~::;:
NAILS
ALONG EOGEOF
ONE PUCE
AP}>I.YWEfGHT
ABOV[JOINT
THIRD: DRIVENAILS
'TO;;;:;;,::,_-,,:~AllONGfOG'
OF 0"'"
PIECE
l~~~~~~~~;;~~
NAlLS
Woodsmith
No. 63
GUIDE STRIPS
SLIGHT ANGLE"
"bottomsout" on therightguide
No. 63
the bit
about Ya"deep and rout the
Start by sticking the workpiece workpiecewitl1 the grain. (Rout
down on thejig base with double- ing across the grain may create
sided carpel tape, see Fig. 2.
swirls on the face.) Then make
mE art, Next, mount anyflat another pass to "plane" the
bottom bil in the router. Aiter stock to final thickness. If there
SOmelesting, !found a:l4" or JI,!". are any swirls left on the surface,
dia straighrbit worked the best, 1use a SCraperto clean them off.
'/4" MASONnt
WlNG
MAKEMumPLf
PASSES WITH
THEORAIN
USE ROUTt~
aASEAS
TEMPLAn
TO LOCAlE
scaEWHOlS
\Voodsmirh
~ ~~~~STOP
FaOM.
CUnlNG INTO RAILS
13
FEATURE
PROJECT
Toolbox
How do you make a toolbox that's both strong and lightweight?
Our solution was to use thin maple and join it with box joints.
We also added a unique laminated handle on top.
14
adjustable box joint jig for either the table saw or the
router table.)
HANDLE. The handle is probably the most unusual
part of this project, The easy way to make a handle is
to cut itoutofa piece of~" stock, But there would be
weak spots at the upper corners where the grain cuts
directly across the corner .
Instead, I laminated the handlefrom three pieces oj
V." stock. The grain on the middle piece runs at right
angles to the face pieces. Likeplywood, this-strengthens the piece in both directions.
WOOD.r built the toolbox from hard maple. It's
strong and will last for years. (nun lumber may be
difficultto obtain,seeTaikingShopand Sources, pages
23 and 24.) Maplecan chip out when planinl1.(For fips
on planing, see Shop Notes, page 12.) Poplar or red
gum wouldalso be good choices. They'renotasstrong
'<IS maple. but lighter and easier to plane.
fINISH. For maximum durability 1decided to apply
two coats of semi-gloss polyurethane to Ibe toolbox.
Woodsmith
No. 63
MAIERIALS
EXPLODED VIEW
OVERALL DIMENSIONS,
CASE
PIVOT
LISI
BLOCKS
A Front/Bock (2)
'I4J<4!14-16
8 Ends(2)
V.x4V.,8
'I. x7~. XHW.
~x !I"15~
!I'. x 1M - 7'1.
V.x I- 15'1.2
C BoHom(I)'
TOP
ANGLID SIO
UD
FRONT
H EndTrayled~(2)
UD
1 Frant/Boc!< (2)
~ x I~- 16
J EndS(2)
V.x3-8
~ x316
K Mgled Sldef(2)
L TopO)
M TopBocking(l~
'I4x4",,-16
'I. X 4'1.2- 15l-2
(1)
V.x8-6(5pes.)
o Box Handle
TRAY
'I. x 1% - 14'~.
Q EndS(2)
V.x I'll.- 6"V,.
R BoHom(I)'
'14X 6. x 14''1,.
S Handle (I)
iI.1 x 2 iii- 147/,e
These pieces are V" plywood,
P Front/Bock (2)
CUnlNG
1,1.... x
DIAGRAM
CROSS SECIION
M
p
p
6
K
A
o
o
,/
ANGlED IAC1<lNG
PIKE LOCI(S lOP
TOGETHER
,,
CATCH
--
REMOAIl!
'eRA.
,,
ONE 24.x
"
ALSOREQUIRlD:
(c, R)
SUPPLIES
lowm
PIANO
HINGE
LUMBER
7 SquGre H. V.' solid maple
0.7 Square H. '11"solid mol'll6
24' x 24' plee Y4' maple 0( blreh ply.
COMpARTMENT CAPACITY:
3'/ ...Dx7!t'J-w'"
1511;2"L
HARDWARE
"
ANGLID
RE.INFORCfiMENT
STRIP
1 Brossplonohlnge(P/'6'X
13')
1Bressbox cctcn with screws
6 No. 6 X :Vd' ro~ndhead
WOOdSCl8WS
, See page 24 for kfflnfaClTlotlen
FINISH
Varnlsh: Solin polyur.efhone
No, 63
Woodsmith
15
CASE
1began work on the the bottom edge of each piece and worked
B01TOM.Next, cut an !,t"deep groove for
toolbox by making up. (The waste atthe topwili be cutoff later.) the II." plywood bottom (C) On all four
~'?
the case. Start by The case end pieces (B) start with a pin at pieces. Position the groove so it cuts
~
cutting a C8$e front the bottom edge and the case front/back through the first pin (en the case front) up
and back (both A) pieces (A) start with a slot. see Fig. la.
from the bottom, see Fig. 1.
and two ends (8)
Procedural Note: l'I'hile the jil(' is set up,
After the groove is cut in all four pieces,
.........._
from II." stock to a you may alsowantto cutthe box joints on the cut the plywood bottom (C) to fit.
rough width of 5". lid and tray pieces (see pages 17 and IS).
ASSJ;AWLY. To clamp the case together, I
see FIg. 1.Then cut
CtrM'OWlDTFJ. Aftercuttingthe box joints, used band clamps and scrap clamping
the front and back pieces (A) 16" long and I trimmed down the case pieces to final blocks, see Fig. 2. Position the blocks just
dIe ends (8) S"long.
width. First rip the case end (B) so the cut beyond the joints at each comer. To keep
Procedural Note: Wbileyou'reselup, you aligns with the top edge of the ni,!lk pin up the top of the case square. Islipped a scrap
can also cut the lid pieces so they're the trom the bottom, see Fig. 1. Then cut the piece of plywood into the case.
exact same lengths, see opposite P'llle.
casefront and back (A) to this same width.
PWG HOLE. After the case is assembled,
BOX JOINI'S. Alter the pieces are cut to
Note: Ifyour dado blade cuts eccuctly II." there's still a little void in theends where the
size. you can cut II." box joints on the ends wide slots, then these pieces will be 4114" bottom groove COmes through one of the
of all four pieces. see Fig. 1.
wide. The important thing is to cui the box joinl pins. To fill it, I glued in a wedge\'Ibeo cutting the box joints J started at pieces so they end with a fuji pin or slot
shaped plug and cut it off flush, see Fig. 2a.
'6"
Tf
Ts.
41'' 1
WASTE
TOP
lOGE
NOTE:
CASE FRONT/BACK
ALLSTOCk
(CUTtwO)
2
~
SCRAPPLYWOOD
---
@
BonOM
PLYWOOD
:V.~~~T~H~IC~K~~~::::~==~:=~~~~~~~
'--cur
a.
CAS. ~
F~f
@~
@K
rTf
rn
CUT
EDGE
(CUTtwO)
TOP
CASE END
'_t)~~~=l
'=========:===!i
CUTGROOVE
AT
THROUGH
FIRST
PIN
N;':"
-l
8"
T5"
4r"t
'l
OFF FLUSH
ClAMP
3
~_J
THIRD:
@)
fRONT/BACK
TRIM
~C~::-
fiRST:
(UTHING
h.
~
,_
~.J'~
END~~
TRIM
1/ .
__.,:J,.
;_...,
a.
TOFJT
NOT~-'"
4::.:.......
45' ANGLE
CASE
lj '"''r-)
'"!:."
-I-_.~
~"4
~
ClEAT TO
FIT 8ACK
jy
P1.YWO
IIOTTOM
TRIM STRJ:
MITE.
CORNERS"
.j-.
1-...
OD OFCAS(
MntR
'Ii'_'-
p- ~
_
I....
I!--
.~
-L,3
END
TRAY LEDGE
UTtwO)
~_R~EI?.~
Woodsmitb
;....-
1'\
...."..
a.
~GlUEfLUSH
01 END
mAY
LEDGES
""ONT
'"Il
UPSIDEDOWN
16
TO fiT
(NJ)$ OF
CASE
.t
,"
Ll
CLEAT
HINGE
CASE
BACK
~
FRONT TRAY
LEDGE
SECOND:
MITER FRONT UbG
TO FIT INSIDE CASE
No. 63
LID FRAME
r-5~---------------------------------------------------'
1.
UD FRONT/BACK
(CUTTWO)
,-------------------------,
1~
.."
I'i'\
ROUGH
1------------1.NOTE:
Q.
UD ENDS
1f
COTTO
UOEND
MAtCH CASE
-r
CUT45' ~L
....,~-TOAUGN
CUT45"
ANGLS OFF
WITH COftNrR
CORNERS
CUlTO
MATCH CASE
MARKWHERi IND
MflTS fRONT/BACK.
THEN RIPUD
fRONT/BACK
AT22.,.,'
UD
CLAMPING
FRONT/BACK
LID TOP
No. 63
ANGLED
WASn
END VIEW
SIDE
22~'
LID TOP
UVEL
SECOND:
CUT 22'h"
'EVl1SO
2'\0'
W10TH
MA'~ES
ANGLE
ONEND
lEVa.
~r~...
ANGLED SIDES
,n
OPfN~NG
BnwtE'N ANGlED SIDES
10
UD HINGE
CLEAT
Q.
ct:;t==='=O=TT",O.,M,::Of=U::D=::j
\
',
UD HINGE
CLfAT
"'.
(NAMEIR
TOP
SACKING
".--
NOTE:
""--~
LtD UPSIDE
TOP
BACKING
4S'
ANGLE
"
DOWN
Wooosmith
17
HINGE
Afterthe lid is completed. it's attached to the
case with a piano hinge.
CUTIlNG TI:IESINGE. Istarted by cutting a
1Vlsltwidepiano hinge to length. To determine the length, three things should beconsidered: the length mustbeshonerthan the
case; both ends should be cut at knuckle
joint lines; and the distance from the end of
the hinge to the first screw hole should be
uniform on both ends. In my case. I cut the
hinge 13"long. see Fig. 11.
mNGE~IORl1SE. Aftercuttingthe hinge to
length, you can cut a matching mortise in
11
I-.J
AFTER. ROUTlHO,
aEUNIFORM
a,
ClAN UP TO
AT 80TH
LAYOUTUNf
ENOS
HINGE MOUNTING
To mount tile hinge, Istarted by Sllrewiug
one hinge leaf to the mortise in the lid.
Then. stick a narrow strip of doublesided carpet !ape on Ilte top back edge of
the case. Now. set the lid on top of the
case so it's in the dosed position.
Next, carefully open the lid a little
ways, reach inside, and press the binge
leaf down tight against the carpet tape.
Then open the lid all the way and put a
block of wood under the lid 10support it.
Now driU holes for the hinge screws by
driUing through the holes in the hinge
leaf and righl on through the carpet tape.
seedrawing. Fil\ally. remove the!ape and
screw the leaf down tight.
.n.
WRHCtiJHL
J.
PIANO
HINGE
DRilL 8IT
CARm
TAPE
CUT HINGE
ATKNUCKU
JOlNT UNE
CASE
-.
,
Uo
TRAY
,.------,
13
12
I--....Jv
..L
""
'>!;J TRAY FRONT / BACK
(CUT IWO)
a,
GLUEHANDl
TO BOTrOM
"'T
,;-.' 2"
'I'l"
CENTtR
HANOU:
ON TRAY
.OTTO~jWA$"
GROOV
Ih DEEP
b.
'- __
18
Woodsmith
GLUEINPWG;
No. 63
HANDLE
The last part to
make is the handle
(0) and the two
blocks that hold the
handle to the lid.
HANDLE BLANK.
Start by laminating a
blank from three
pieces of ~" stock,
see Fig.l4. Cuttbe three pieees3" wideand
6" long. Then cut one of the pieces in half.
Now tum the two half pieces so the grain
runs alright angles to Ihe6"long pieces and
"sandwich" (glue) the half pieces between
the long pieces.
After the glue dries, rip the blank down to
2" wide for the handle and save the waste
piece/or the pivot blocks. Before cutting the
shape ofthe handle, I trimmed the blank to
5\12" long and rounded over the bottom
edges with a 'Va" round-over bit, see Fig. l~.
INSIDE ClnOUT. Next, to form the inside
corners of the handle, drill two :ol"-dia.
holes, llla"from each end, see Fig. IS. Then
layout thelllsideedges oCtbe handle.
Before cutting out the handle, Idrilled
%2"dia. boles in the ends of the handle to
hold pivot pins, see Fig. 153.
CUTOUT SRAPE. Next, cut out the inside
edgesoftliehandlewith a band saw, sec Fig.
16.To finish the shape, trim 45' angles off
the top comers.
ROUND OVER EDGES. To make the handle
morecomfortable to grip, Irounded overthe
top edge and the inside edges, see Fjg.17.
PIVOT BLOCKS. After the handle is
complete, Imade the pivot blocks from the
strip cut off the handle blank. Start by cutting the strip:v,," wide, and then cut 45' angles off the top comers, see Fig. 18. Next,
drill two pilot holes near each end to accept
the mounting screws. Then cut the lll.l"long pivot blocks offboth ends of the strip.
PfNS, The handle is held to the pivot
blocks with pinsmadefrom No.sscrews. To
do this, start by drilling a %2"dia. hole
centered on the inside end of each pivot
block. see Fig. t~.Next, tighten a No.6 x
:V," screw into the hole leaving \I," of the
shankshowing. Thenculoffthescrew head.
MOtlNTlNG 11U! HANDLE. To mount the
handle, first center the handle and pivot
blocks on the topofthe toolbox. Leave about
V16" between the handle and each block to
prevent binding, see Fig. ZOa.
Now, to locate the screw holes, tip the
blocks on their sides and draw lines down
from the two holes in the blocks onto the lid,
see Fig. 20. After drilling shank holes at
these points, tighten the pivot blocks down
to the lid with roundhead wood screws,
CATCH. To complete
the toolbox, 1
centered a catch on the front of the toolbox
and screwed it down, see Fig. 21. Then file
off the screws on the inside of the lid.
No. 63
14
SECOND:
FIRST:CUT'lHREE
,,
.'
,
@
6"
'.-----'
PIECES TO SJzr
11-3-1 B
,
I I
OURTH
RIPOFF 2"
HANDLE PIECES
V4" THICK
WIDEHANDlf
At15TOCK
8LANK
BOX HANDLE
a,
TODRIU HOLE
AT 90', HOLD
BLANK FLAT ON
DRill PRE.S5
WITHClAI.\P
WArn
~~DlA..
HOLES
FOft SMEJ'Y,
17
4$' ANGLE
EDGES
18
NOTE:
PIVOT
BLOCKS
OF PIVOT BLOCKS
AND HAND1.E
NOTE:
CUT 45' ANGLES
OFF COftNERS
21
BOX CATCH
CENTttlCA1CH
ON TOOLBOX
o
UD
Woodsmirh
19
WOODWORKING
TECHNIQUE
MUI;nPIJl PA<;SF_~.Now
irs a matter of
making test cuts to sneak up on the final
depth of cut. While guiding the test piece
with the mltergauge, make thefirstcutwith
theend of the piece against the rip fenee. see
rig. 2. This establishes the shoulder. Then
continue 10 remove the rest of the material
out to the end of the piece.
QUAllIY OF cur. The only problem is the
quality of the cut surface. Theoutside blades
on most stack dado sets have beveled teeth.
The points of these teeth CUIa hair deeper
than the square-cut teeth on the chipper
blades, see Fig. 2. The result is that you get
.-------:7""-,.,..---,
CH[CKrIT enWlN
CUTS UNTIL FWSH
'1.$lCUT
INTlaMfDtATf
----
CUT
FJNA1 CUT
<UJ
20
Ott
..
Old
fonoarda,uf,back.
Woodsmith
No. 63
CUnlNG
I,
. \
FENCE
l6toW
$HOULOR
II
jI
'1'1I\
I
Ii
KtJ:P nETH
HOLO WORKPIECE
TIGHT A_GAINST
TtNONJIG
DOWN ON--,.<...
SHOULDER
lU ';
l~s,~~,
L
,/
TO CENTER
OF SAW KItF
SECOND:
CUTour
sorroa FLAT
,---WASTE
AGAINST FACE
([bollt
TENON CUnlNG
Thejig Iuse to make the face
cut for an end lap is the same
one used for culling tenons, Its
whole purpose is to hold the
workpiece vertical as it's
guided through the blade.
The jig is designed to
straddle the rip fence. This
holds it.D position and also providesawayloadjustitsposition
in relation to Ule blade,
CIJI'PlECES. The jig consists
of two faces held together with
crosspieces. There'salso avertical stop at the end of the jig.
To make the jig, first rip two
cross pieces to width to match
the thickness of your rip fence,
This width is fairly critical be
cause you want a good friction
fit agalnst the fence when the
face pieces are added.
if the pieces are a hair too
No. 63
clds halfthe
thitkne;;.~.
JIG
narrow, the jig will bind on the
ripfence.
Woodsmith
NOTE:
CUT ALL PIECESFROM
....PLYWOOD
CROSS PI(C[S
VERTICAL STOP
MUST Be 90' C)
MATCH FENCE
TOTA811
THICI(NESS
LO(AtE
SCREWS ABOVE
8LADEPATH
FACE PIECE
21
TECHNIQUE
WOODWORKING
Resawing
S
SCREWAUXlUARY
fENCE T\ RJ':..:E.'Nct:
CqMBINATtQN
SlCOND PASS
1~ 2
ANAL CUTS
22
r1~~~~~~~~
17 _
Woodsmi[h
J....-
.i
.'~~"~~!D
C~;4vm
CUT
a.
SUGHT
'"
I
._
.A:.
/~
:/':;,-
"
')
. ;;,~
/!
I
1-<..'
GUID
'-- __
.=L.LJ
"
Na.63
COMMENTS
AND
QUESTIONS
Talking Shop
THIN LUMBER
is the AP10
to a con
sistemthicklress. Piduredhere
pla'le,' f,"om
LENGTHS.
No. 63
Woodsmirh
23
SUPPLIES
PROJECT
Sources
THIN LUMBER
There are several sources for
thin lumber and we have listed a
fewofthematthe right, Lookfor
the code TL after !be address.
TOOLBOX
TIle hardware that we used on
the Toolbox isavallable through
Woodsmith Project Supplies
or from one of the catalog
sources listed at the right (see
codeTB).
We are also offering all the
thin lumber needed to build the
Toolbox. TIle lumber is all kilndried hard maple. except the
plywood which is IA" birch.
All of the maple has been suo
lace sanded on both sides andall
the edges are cut square.
Since tbe lumber is cut to
special specifications. we are ineluding a new cutting diagram.
Toolbox Hardware
.763100Toolbox
KiL. $5.95
(1) 1V!6" x 13" Brass Piano
Fnngewith Brass Screws.
(1) Box Catch wi!b Screws.
(6) #6 x :y." Rh BrassScrews.
ORDER INFORMATION
BY MAIL
To order by mail. use the form
on the protective cover of this
issue or write your order on a
piece ofpaper, andsend it with
your check or money order
(please include$1.50 shipping
charge with each order). lA.
residents add 4% sales tax.
Send order to:
\Voodsmitb ProjeclSuppUes
P.O. 80,,1.0350
Des "foines, IA50306
BY PHONE
For Caster service use our
Toll Free order line. Phone
orders can be placed Mon.
thru Fri., 8:30 4:30 CST.
Before you call please fiIIout
the order form completely,
VJSA or MC orders only.
1-800-444-7002
AU"", ~ (06 """"./or dIllivery
uft"" 1111811
CATALOGS
TIUJ folwlui'YIg
eo,Upa91ft'$!Vlt'6
Albert Constantine
2050 Eastchester Rd.
BrOIL",NY 10461
TL, T8
24
BLANKET CHEST
UNGERIE DRESSER
Woodsmith
No. 63