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    Woodwork 038 1996 04

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    Никола Стевић
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    © All Rights Reserved
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    A MAGAZINE FOR ALL WOODWORKERS WOODWORK Choosing the Best Glue Cutting and btatseet brat Wood Plugs Sharpening- CFLY Stone Grit Py Comparison r aed Attractive © Shelf for Your Fa Giese} =~ |S a t Satcatis = Inletting with Events Bronte) Eva em) Pee eRCe CCE Ley PUR econ’ precision and quality cuts, there is no substitute aa ee eee gee Meee ee DN ae ae ae Eu Ra eek aL Pat ca es CC Reker Seen as performance, because no other blade is manufactured with the same care, strict tolerances and fine materials. The exclusive long-life, titanium-bonded micro-grain carbide tips are ground with special angles, and the laser-cut extra stiff plate is bonded with a thick layer of Teflon® using a special Pee ae eer ea recy ee ems et The LUBS is a precision cut-off saw, ideal for your mitre saw or table saw, for the cutting of natural woods, low pressure ne LC aoe Peer w n ” 96 108 108 ly what you need. [ UO ar) hy 40 A clean, compatible cutting fluid for both oilstones and water stones. 42 A funky exterior—but fire furniture is being crafted inside this shared shop of Andrew Jacobson, Mike Flanagen, and Thornas Starbuck Stockton ON THE COVER Cecil Pierce makes ‘one-piece wood-body planes in Maine. Photo by Peter W. Richardson eles morn as APRIL 1996 NUMBE FEATURES 30 over rirry YEARS A PLANE MAKER AND USER: CECIL PIERCE by Peter W. Richardson 34. SHAKER CUPBOARD OVER DRAWERS by Robert Treanor 40 Hone stones by Carl Dorsch 42 KEEPING A LOW PROFILE: ASHOP THRIVES IN AN OLD CHICKEN COOP by Glenn Gordon 48 DECORATIVE PLUGS by David Loft and Abram Loft 50} 58 MATING TEMPLATES by David Meiland ‘THOUGHTS ON REPAIRING ANTIQUE SETTEES by Voie Marian 60 64 68 Fo GALLERY OF WOODWORK THE KITCHEN SHELF by Gene Thompson ‘THE GLUING GOURMET by Terrie Noll ‘TRAVELING WOODCRAFTER by Bryan Mills DEPARTMENTS 2 COMMENTARY 4 LETTERS 8 TECHNIQUES 17 BACK 18 EVENTS 22 Q&AS 76 — CLASSIFIED 79 ADVERTISERS’ INDEX 30 A thoughfiul message on Cecil Pierce's workshop door: The most versatile ofall tools s the human hind, but it is weak and its fllibe. AB The fine art of euting and installing decorative plugs. 42 ‘Thomas Stockton prepares for 4 layup of veneers. COMMENT é WOODWORK Publisher ‘THOMAS TOLDRIAN Bator JOHN McDONALD Art Director HENRY RASMUSSEN Contributing Editors CARL DORSCH, DAVID DONNELLY, GLENN GORDON, TOME. MOORE, KERRY PIERCE, DEBORAH R. UPSHAW, PATRICK WARNER Mustrator CLAUDIA LYONS Advertising Director STAN MICHELMAN Advertising Coordinator ‘CLARA KERNS, Computer Production GINNY GREENFIELD, PATRICIA O'BRIEN Gireulation ABBY TOLDRIAN LILLIAN A. MUELLER JACQUELYNE KRAMER woopWworK 38 (SSN 4106-300 paid bimony by ow eric 4 gal Dre #3, oat CA ‘5908 epone (48) 2050 Se cs png ip ot Nowra CA 9457 an alton aa ies Copyright© 19 by Ros Periods cA "ihe vevred Reprinting in whole orn par ‘Spree xcept by writen permon Ever: ala a POSTMASTER Send dt hme Wndvr, PO Bo 158 SUBSCRIPTION RATES 51795 one je, 813.00 pours $4500 the yas fn he US and US psec ate nu fg Ca) $24 one yea, 5S to yours 86 Hee yous (parment in US dla) SUBSCRIPTION SERVICES Al subscriptions and subscription comrespondence Should be ured to Wooanork, Cina Dept POs 158, ns, CA 9957 Pee low tat esr chang of adds len ol arena sel now arn, ncn porible n ae Intl foe co re EDITORIAL CONTRIBUTIONS ‘hese are weleome and sould be addr the ior, Wondwork 42 Digeal Drv #5, Neat, CA S15 acsmpanid by rrr peste Al terial el be handled th feavonabe cts homer the abs ase n repens errr oe, ‘Sarverk photons oe mars By the tf Shion the shor expr wera ha he Submited material completely original, that al righ are caren eae cn hat he mei oway ge pon heights fay te pes PRINTED IN U. How did I carve these? fanaa ff th south cust of Aus ead ove fh he 3D Can PS. Ifyou ter caring look “too pf” as ad a few l used CMT’s exclusive mange 3D Router Carver” System What is the 3D Router Carver” System? Where can I learn more? he 90 Router Carver Sytem i aunque patented method of producing inticate carvings quik, 00 rer ou 2D Caner video, a stop-by-top ‘omscal and wi complete repeatabily, Wh the Carver ®t. Carver Temples and your V2" cle demonstration of al of the aystons capa lunge router you ean eave ay iat wooden sage wit desis that rival he work of a professional tos. Or ask or our lee caliog wih nearly carver Infact the 29 Carver System's speed, accuracy and aconomy make k equal atvatve othe pro- four dazan ther templates pls outline of bis, feasenal or the seus amateur Basses your router, the system insides tee kay elements Piao, hand tool and much more! 1) The 30 Carver Bt: A'2" shank, carte ipped V-Greowe Bs oncosod in a 45 guido bushing. A ‘treaded shaft hin tho bits shark allows reese depth adjustment ta op of he V-Groove bit ‘Bu Speicaons: Shak: 12° Cut dete: 34" Cut Angle 48° Cut dept: 8” Gude bushing em: 1.78" 2} Template Holding Frames: Clampod or ackod¥9 You" workpoce, se Hames old te 3D Templates ‘secur in place. 4) Carver Templates: A tctlo 6 templates (wih more inthe works) produce Nos of designs fr eabint ‘ors, pana! door, door als and comer, drawer fons and many ther appleatons How does the system work? sng te 0 Carver easy. The Bt is mata in he roar (12 cat ony) wh he pings mach rm cick o tat the router ean move up and down 2s you routs The 45" bushing fas the ssn to empl. As he Ht gos wider, outer moves dowrmard,s he weave ges We. ‘As he slot ners, th outer moves up and tha grove gts narowor. That it How do | get started? ve mado that oasy, with a great Tioduciory ofr on wo of our most popular designs. Our Classica! sitchen Set includes tempat and holding frames to make the beaut Kicnen Door ‘and Draner Fon! shown a ht plus @ SD (Carve Bt, compat intact and #08 copy ol our 30 Carve video, YouT save 20% i 2 Feplar peas We alo eer Khon Set inv other aosigne, plus pats for ‘ourpanel doors, door as, rostas & moe, obo sure fo ack for our completo catalog ‘S00 spn & nding fr ners we 520.00 ‘To order, call toll-free 24-hours a day: 1-800-531-5559 ‘Toll Free FAX: 1-800-870-7702 you have questions o require antance with Dealer inquiries welcome! or enbort a (513) 9146160 FAX: (13) 891-6289 cur TOOLS, In Canada, cal Toorond Ud. +800387-7005. “he 20 Carer Syeem™ & Templates ae protected by US pant 45,15 65 & ternatona eador Serio #69, me LETTERS ‘Shop-Worthy Cross-Cutting Boat 1am writing in response to the article in Woodwork magazine entitled “Cross- Cutting Boat,” by Tom McFadden (October 1995, # 35, pages 38-39). I rejoiced when I saw the picture of this cross-cutting jig! Seeing this picture brought back many memories in my ‘arly years in woodworking, This was the industry standard in the 1950s, 60s, and 70s, for cross-cutting technology. I hhave been a journeyman cabinetmaker for 30 years and I can say that this is ‘one design that is hard to improve ‘upon. It is a basic concept that is safe, ‘accurate, and very practical In a world that is constantly chang- ing, I am very much in favor of using new technologies in woodworking and ‘enjoy researching different areas. In than furniture. He bought a few hand tools and a lot of 2-by pine, and he built (among other things) a dining-room table that Vikings couldn't conquer, five beds, a Herculean sofa, and a battleship larger shops, much of the machinery today is geared for mass production. Therefore, it is good to see an old design that is still alive and well in smaller shops! —Dennis Delhousay, Norwalk, California ‘ofa coffee table that still sails after more than a quarter of a century. The Why We Work Wood moment we were grown and out of the When you think about it, working with wood doesn’t rank high on the job-security scale as a profession, and as a hobby, it requires special tools, is dan- ‘gerous, takes a long time to learn, and is ‘usually done in a cold garage or a damp basement. Why, then, are thousands of people at this very moment planing, sawing, sanding, bending, and gluing miles and miles of lumber? For some of us, there are practical reasons, reasons of economy or even self-defense, My father, looking around hhis house in the mid-60s, found to his dismay that he had engendered a houseful of boys who were sturdier hhouse, my mother replaced them with delicate antiques, but the coffee table ‘endures in my own living room and 1 hhave yet to find a way to break it There is, of course, a lot more than practical motives behind the building of furniture and other wooden objects, or ‘we would probably find an easier way of ‘getting them, One reason we keep pick- ‘ng up the plane and chisel is probably that most of us have no opportunity in our work, which takes up so much of Continued on page 6 Please write : Letters, Woodwork, 42 Digital Drive, #5, Novato, CA 94949, DOWEL MATE oS + DOWEL MATE for tough joints that are perfectly aligned. The Dowel Mate is the answer. A single step on the foot pedal first clamps the wood & then shoots in two dowel holes. Ar clamp & air feed. RING MASTER aE) + Ana waste a sli deere Saemimeece roel erg eee eee cee ROUTER MATE conwerts portable routers to precision routing machines + Route Faster » More Accurately More Profitably with the All New PANEL TEMPLATE Produce something special! Route decorative ppanel designs in seconds. 32 different corner designs, a side design and are attachment are available to create unique pars. Router Mate re & UNIVERSAL ROUTER ARC ROUTER ATTACHMENT SYSTEM & outer Not includes + ROUTER ARC ATTACHMENT Cut + THE precision arcs and circles from 9" to UNIVERSAL 50" in diameter with your router. Easily adjustable and precisely repeatable. Adaptable to any portable router. ROUTER SYSTEM tums your router, Into 3 tools + Router Table « Joint Maker » Inverted Pin Router + Ruggedly built — Flat ground table + Many options. Family of Fine Wood Working Machines (ALL MADE IN THE USA) ‘See your woodworking machinery dealer or cal toll free for an informative brochure or the name of the dealer in your area. PORTA-NAILS, INC - PO BOX 1257 - WILMINGTON, NC 28402 - 910-762-6334 - 1-800-634-9281 4 WOODWORK APRIL 1996 Render Sonics #10 Infinitely Variable Power-Feed! Variable Feed Makes The Difference! er into valuable faced round, casing. Put this power-feed tool to itself! Quick! ‘Just a (vist of the di ps as any comps duty machine will puts twice as many cuts-persinch at your planer - from 70 to over 1,000 CPI! This toughest oak at higher 5 "hard-to-work” pieces ‘much more! A valuable c curly maple, knotty cedar, burs, k feature for molding work, where profiles make sanding ‘Change to Mold Morse-Taper" Quick Change C\ npossible st minutes! Unique st-changeover ‘Choose From Three Powerful Modelst Woodmaster introduces the first 18 and 25" Planer/Molders .. with all the Features that have made their 12°medel the most \ersatile Planer/Molder on the market! Send for Free Facts today! attachment lets you gang-rip feed in a fraction of the time it fed passes on an Woodmaster’s Quick-Change Molding Head Powered sanding speeds. up production lets you create custom moldings from any and improves the quality of your work. No with p¢ stock Choose from over 250 standard trim more waves ot cross, grain. scratches. takes for multiple har Separate sanding “head ‘nstals"In just osiary abe saw minutes. and picture frame pattems ... or design your ownt Shop Test Results - "It does an excellent job of planing, on a par with more expensive machines, and even better than some commercial models.” 1-800-821-6651 ext. PC60 Editor, Workbench Magazine Woodmaster Tools, Inc. | Beate ie eee fortne money, Alcor 1431 N. Topping Ave. Dept. PC60 to acknowledge the polite and prompt Kansas City, MO 64120 , E,D, Holt, North Carotina Reader Serie #3 nof daily life, to feel the basic satisfac making something with our hands. Until job specialization became univer- sal in our culture within the past few centuries, there was no lack of opportu- nity in this department. At one time, what you needed and didn’t_ make yourself, your spouse probably had to ‘make, Also, apart from simply filing a practical need in creating the objects they needed for day-to-day use, our forebears must have often felt the ple | _ sure that comes with exercising creativ | ty: we see this in the extra attention to detail on workaday objects of the 18th and 19th centuries. Ths is a pleasure we miss, whether consciously or uncon- sciously, when we don't get it. ‘The other thing we miss in the mass - production age is quality. The things around us—buildings, furniture, cars, you name it—seem built with less care than we remember (accurately or not, depending on our age) from the past, and there doesn’t seem to be much we can do about it, except make things ‘ourselves. At our own workbenches, each of uss in very direct control of the quality of an object that is coming into the world. We are, in some small way, making a contribution with the effort ‘we put into each project, This contribu- tion is to the continuation of crafts- manship as a concept, and if nobody but the craftsman knows about it, that doesn't seem to matter too much, ‘One last reason woodworking and other hand arts are still with us is that they are handed down from generation to generation, We associate the skill with the respected person we learned it from, and the respect carries over. Many of us learned at least a little from our fathers or grandfathers and picked up where they left off, taking extra pride in our projects when we were showing off to them in particular. My grandfather also taught me a thing or be CT eee UT BC) hee Scan nee Y ier erst Peer ery earners Se aie noe n ee Pema 6 WOODWORK APRIL. 1996 a ear a ieee nrerenen eee Reader Service #77 ‘two. A refuugee in wartime, he carried his family from Nazi-occupied Europe and started over in Latin America, over- coming hardships my generation can only imagine. Unable for some time to find work in his profession, he fll back ‘on a number of jobs, among them car~ pentry, My mother remembers him building caskets. On the other end of the spectrum, he built little painted shadow boxes, the kind that create a mild optical illusion through exaggerat- ced perspective. In the back of my mind, woodworking was always somehow linked with the idea of my grandfather falling back on his resources; though trained as a doctor, he was able to turn to more basic hand skills and pull through, We admire this kind of resourcefulness just as we do the self sufficiency of the pioneer days, and we feel just alittle bit of it when we make something of our own. —Kristian Eshelman, Highland Park, New Jersey A Me) Ce Like saving money! Carter Band Saw Guide Conversion Kits for Deta 44° and 20, Mini-Max 18°, Grizzly 1 ‘and 18°, Grob, and Davis start at only $129.00! Get the facts now on Carter Band Saw Guide Conversion Kits to add accuracy and cut costs on your bband saw. Brochure $1.00 PRODUCTS ‘COMPANY, INC. 437 Sorng 8), NE rand (619) 45 Reader Seren #01 Give Yourself Some Breathing Room. MODEL 8-12 MODEL10-16 MODEL 350 "S000" Maga Pon = ‘ecent medical studies show that breathing wood dust, = be hazardous to your health. The JDS AIR-TECH, T ‘2000 will dramatically improve the quality ofthe arin your 1 - workshop. Our units are designed for both home and . industrial use. The Model 350 will clean the air in a 20x20x8 in overall perfomance and. footshop sand ahalftimes per hou. (Models 8-12, and 10-16 handle lager areas) value by Better Homes tsps init 200 sys il emove 99% of and Gardens WOOD, 2#%¢sssndlativemiconand80 ofthe arse, Pats smal as one micron. For the removal of dors fumes and smoke, our optional charcod fers available JDS AIR-TECH 2000" Toplace an order or fr the 00 dealer near you cal tll free 259 1-800-382-2637, And give e yoursefsome beathingroom. MODEL 350 roduct from DSS Manufactured in the US.A. CO M PANY 1-800-382-2637 Reader Serio #65, WOODWORK APRIL 1996 7 EGiN 1 OU ES Shop Solutions ‘Threaded Insert Installation It can be difficult to install threaded inserts square to the work, but I have of the insert. Without disturbing the set-up, replace the pilot-bit with the insert-installa- come up with a solution. tion tool. Thread. | First, make an insert-installation on a nut, washer, || tool, by cutting the head off of a car- and threaded | iage bolt, sized to it into the threaded insert; leave a insert, The actual length of the bolt few bolt threads should be close to the length of the above the nut to pilot-hole drill bit necessary for the allow for backing threaded insert. I prefer a partially off after the threaded bolt—the unthreaded por- insert is installed. tion will be chucked in the drill press. Lower the Installation: Clamp your workpiece ‘onto the drill-press table and drill the insert pilot hole deeper than the length insert down to the work; you can start the Powerul houghis bring powerful ress. Watch our free demonstra tion video on the Robland X31 combination machine ond you wil see the pawerul thought process thet hos gone ino the design ofthis Belgian success sor. Every woodwerke’s dream, conbine © 10! table sow © Cast iron sliding table system 50" tip capacity * 20 seconds to change functions * Moriser * Shoper Put the power in your hands todey. Call 800) 234-1976, for you free demonstction video LAGUNA TOOLS 7265 logina Cnyon Rd, laguna Beach, CA 92651 » FAK 714 497-1346 © 12" Jointer/Planer © 3, SHP motors (German) 8 WOODWORK APRIL 1996 © Send your original technique, along with a photo, a sketch, or a plan: Techniques, Woodwork, 42 Digital Drive, Suite 5, Novato, CA 94949. We will pay $35 for each technique of yours we publish. } threaded insert square to the work by turning the drill press manually. When the insert has a good bite, release the insert too! from the grip of the chuck; then use @ wrench on the ‘nut to drive the insert the rest of the ‘way. The washer acts as a stop, so that the insert rests flush with the surface of the workpiece. —Robert C. Thompson, Golden, Colorado Container for Wood Dust as Filler If you like to make your own wood filler using sawdust and carpenter's ‘Continued on page 10 Woodworking Books for... "the en ART, FREE CATALOG 1-800-378-4060 > Hundreds of Titles » Discounts to 20% > Free Same-day Shipping Wooo workers’ Discount Books ca as Se ender Sento 57 Pop-up TY Play Hide & See Since 1955, the Auton Company has served the H cesign community with J uaiity sit systems that ff utize emote contrat. ff Auton has developed 2 Unique ‘rack and pinion’ system that raises and lowers TVs, Celling projectors, “smart waiters computers, bars and pane its. Unie the wobble-prone ‘old fashioned’ scissor is, Auton has produced @ motorized plallorm that gides smooth and quiety On four racks and pinions, which will allow tiling uneven loads, all at the touch of a button Pop-Up Gomputer Pop-Down TV Monitor ‘& Keyboard Motorized ‘Swivel Base Variable Height Panel Litt Table ‘Auton does not manufacture fuente. M Pop-Up TV/Bar The Auton Company manufactures a Ccompiote lin of custom and standard motorized its. AUTON. MOTORIZED LIFT SYSTEMS Pop-Down Projector | InUSA. US and Foreign Patent Pending Reader Sovie #14 Now builders, architeets, interior signers and spocties, Iurniture and eabinet makers, can develop their Creations in homes, offices, ships, icra, conference and hotel facilities. ‘Auton knowin world-wide for the systems that you can recommend with confidence ‘The Auton Company ox 801960 «Valencia, Clfornia (380-1960 + (805) 257-8282 + Ask For ‘Workman + FAX (805) 295-5636 ‘Bevery His (310) 659-1718 Honolus (808) 734-1260 ‘mall TVLIFT@auton com imexnet WWW-hitp:/wirw.auton.com Pop-Down Cating TW slue, here’s a little tip. Put the sawdust in a shaker-top spice bottle (like oregano or thyme comes in). This serves three purposes. First, it’ always ready for use, Second, the holes in the top sift out larger pieces. Third, you can better control how much sawdust you're adding to the mix, so you get just the right consistency. That’s a lot of good from a bottle you'd otherwise throw avray. RB. Himes, Vienna, Ohio Long Life for Tack Rags ‘After using a tack rag, I store it in a Zippered plastic bag to prevent it from drying out. This allows me to use the ‘same tack rag for four or five months, ‘At less than $1 each, a tack rag is fair- ly inexpensive. But 1 probably varnish something 250 days a year. If | were to ‘use a new tack rag each time, it would no longer be inexpensive. Kenny Wilson, Konawa, Oklahoma Join IPM’ Joinery System: m has been fl This on and the sad dovetail increment hi ou wil ever own. B furnitun IPMs aceuracy components aly make every yp SimartFence a you to make Dolly to Handle Plywood Sheets A truck from an abandoned skate- board serves as the base for a dolly to handle plywood sheets. A suitable top is made from two pieces of wood, attached to the truck. Its principal advantage over the usual dollies is that with the wheels at a right angle to the sheet, turning is easier than with the wheels in tandem, —Tom E. Moore, Clarksville, Virginia ULTRA PRECISION L072 Mons CaBineT MAKER'S SYSTEM 1 clo ital. Al eabinet making sd with this ONESystem, JOINTE ' Spstems include all the Joinery us our award inning SmartFence. You don Super Liner for Vice Jaws I affix rectangles cut from draftsmen’s-type drawing pads to the jaws of my woodworker’s vise. I cut two pieces the same size as the vise jaws and then spray one side with spray-can adhesive. Then, 1 put a sheet on each jaw and then close the jaws tightly for a short while, Presto...we now have jaws with a little “give” and some padding, which is much better for clamping ‘wood. This softer surface also protects wood from scratches. Also, I have found that even with best vises the jaws are not exactly parallel. This material distorts just enough to compensate, Drawing pad material is “self-heal- ing” and very durable and washable. Available at drafting supply stores, its inexpensive, Often these stores have giveaway scraps that would suit your Purpose well. —Iay Wallace, Ashland, Oregon ] Continued on page 12 red every tie. Mier sdjusabilty se alls the thousandth ofa inc inerements se frame constreton, drawer design, cgewor and mor JOINTECHS CabinetMaker’s System is sinply the best investment in qual and a very alordable pric NEW VIDEO Learn about veneering & the equip't used Special Price $19, reg. $34 | Affordable VAKuum Systems ‘Air Powored ot Electric VAKuum Pumps Klamping Kits from $ 99 | Veneering Systems from $ 198 Professional Systems from § 499 ‘Add Curved Surfaces to Your Projects Croato Eye-Catching Furniture with (EEE roe mera orto pice tors CALL 1-800-547-5484 Quality VAKuum Products, Inc. 49 Bradford Street, Concord, MA 01742 avin tens Pires Crete ae naa ee ted akan a) Roeea Uae) aD Na eed 5.00 FOR A COMPLETE DALES a ee 10 wooDWORK APRIL 1996 Dorie Tyo dot ant the Fn cats you can get ny pre thn dant ober esi i tee Why Because personaly gatas hat CMI's Max Tt and lr Cas bad il ive te iets peice or rn yom money no gesions 2elded laine etc aide mate ou ad cone = Raker Toathvtua Iyeiminates chipping In plywood and venoer noise an improve performance q ae Carbide tipped C id Miter Blades Table ‘Saw Bia Blades Oe 3 negative | hook! Radial Arm Saw Blades: pistes ston o0_sn 10805 unre sino 2809 1900 -Us-soot ipo 55 —$o100_erian | Tete Ure ca 5 sien sitar] Two-blade Packages. SALE! roa Apa iieswhasiconte $100.5 Our free catalog nese tac are aqg a0] ‘nousands of blades, 6 Sarena tem 1ST. Me see eee 210.00 Tin Kel 7 Fhe $115. [noms aes | 5.0 shiping ding fr ors nde 20000 110.00 807 Ua Gut $138.7 [To order, call toll-free 24-hours a day: ea Uimsceem 1128.2 1-800-531-5559 10-233 | CMT’s Award-Winning ‘Toll Free FAX: 1-800-870-7702 emits ag 49.00 Joint-Master 8” Dado Set 4 moet om [Blade Stifening Collars’ Toor te] fourifB andone Ne" oper The in ee ME sone |S suc easy] 1002408 at et we nani set 30 Mears Bouter Olt FL 34677 lsss00 5'Smutren art $2230 sivo0 |) eu $6840) Sales #179. in Conada eit Toot Trond Ltd 180087-7005 Facer Sonice #17 Self-Squaring Dado Jig This simple guide eliminates the need to square up a straightedge for each cut ‘when routing multiple grooves across a workpiece. It consists of a rectangular piece of hardboard or plywood with two parallel edges, and a Yé-inch lip | attached square to both edges of the | hardboard. | To use the guide, lay out the lines to be routed on the workpiece, then make WE MAKE ABRASI [Standard Abrasive Sheets| ‘CABINET PAPER SOlpk —100/ok 60D $16.70 $30.00 [90 $8t¢a 800 16.60 27.800 [1X42 sles foowmets0c 1450 5000 |X stea FINSHING Papen —_{2,1/2X16 A508 son $11.15 $1890C [a1 ‘Goes cota 220A 1000 $16.706 [orcs a4 seen WETIDRY PAPER OTHER SIZES 220 thru 600 $1556 $26.67C NO LOAD PAPERIwhita) hoo thru 4008 $12.25 $21,250 = 100 SHEETS > OTHER PRODUC: * Wide Bolts*Rolls*Flap Whools *Pump Sleoves*PSA Dises “Router Biis*Wood Glue *Wood BistVolero® Dices *Wood Clamps*Sanding Blocks “Drawer Slides*Hinges* TV Swivels MasterCard, VISA. C.0.D. oF Check SATISFACTION GUARANTEED!!! "CALL FOR FREE CATALOG i -TX 8 NV add appropriate sales tax mm = Continental U.S, sipping add $5.50 = 12. woowoRK APRIL 1996 =>" Econ-Abrasives ANY SIZE, ANY GRITE ABRASIVE BELTS PLEASE SPECIFY GATS Econ-Abrasives P.O, Box Kaeser NATIONAL ORDERING LINE (800)367-4101 2 spacer board that equals the distance from the outside edge of your router base to the edge of the bit you will use, Put the spacer block against the edge of ‘the guide and slide the jig over until the spacer meets a Jayout line. The lip will square the guide to the workpiece. Clamp down the guide, remove the spacer, route, and repeat. —Kristian Eshelman, Highland Park, New Jersey SPACER, 7, Y Line To Be ROUTED Yat Lie. WORKPIECE With 176 pages of inthe business. Wea Another Good Turn ‘Why not re-turn teak bowls found at Goodwill? Our local store sells 10" to 12" bowls for $1.00, Most of the bowls have 4" to %" thick sections and can easily be re-turned|—great for practice. ‘Take time to mount the faceplate in the center, and don’t be afraid to remount the bow! ifits out of balance. Buying the $1 bowl not only provides an evening's turning practice, but it helps the charity, and saves a tree. ‘When you are done, give back a better bowl. —Jerry Hedstrom, Gig Harbor, ‘Washington ‘Sure Footing ‘A shop floor slippery with wood dust is especially dangerous around tools such as a table saw. For safety, | stick several stair tread non-slip strips on the floor along where I stand. —Tom Voss, Davenport, lowa Continued on page 14 ll-color, our Free Catalog isthe biggest o chink ics che bes. We have the high quality woodworking supplies and tools that are nearly impossible to find anymore, Everything ftom 324 $0308 3x27 8608 2X21 9)4 11060a 926 1:106a acne toca tradicional old-style 6x48 3.500a1 hand planes and saws 2 116x80 3:25¢a\ tothe very lates in ‘ON REQUEST ora Free Cal roth dd below or call: Depe. 1062 NY,NY1 800. 800-566-9} Plano, 1X 75086 (2199377978 send usa post modern power tools, or letter with your nd address Garrect Wade Co, 161 6th. Avenue 21-2942 PME en eau cur ie ect ca Ric acm Pee uatcu) the dynamic adding one or Pomel ae) s} PON EIMALSG Reade Seren #85 Stopping Oilstone Slip ‘An oilstone or water stone is ustally ‘mounted in a box or a hollowed block of wood. When you bring it to the bench to sharpen a tool, it will slide about unless you do something to stop it. If you have a regular sharpening place you can fasten it down or fit it between stops, but on the bench you have to use other means, ‘One way is to mount the stone case ‘on a piece of plywood with a block to hook over the edge of the bench (A). Thin sheet cork glued to the bottom (B) should provide enough friction to prevent slipping, It may be sufficient ‘to put strips of leather or rubber across the ends (C). ‘All my tools Should he this good! a The Accu-Miter® isa professional miter gauge that makes perfect angles easily Shot-pin action assures dead-on accuracy for common angles — plus a precise protractor scale for WNednarcanmad pga iat esa Hadegu Soman hoe everything in ‘onus between! = JDS sec COMPANY ‘our ffee #0 Ouch Sq Bh, Sate 200, Cumbia SC 29210 brochure. 1-800-382-2637 / SC 803-798-1600 14 woopwoRK APRIL 19%6 The traditional craftsman's way of stopping slip is to have two small spikes projecting from the base (D).. You can make these by driving in nails. Cut each head off to leave enough to filea short spike (E). —Percy Blandford, Stratford, England Snapshots Recall Jigs and Set-ups Take a couple of photographs of your temporary jigs and set-ups. Then file them away for the next time you have a similar task. Use whatever lighting you hhave; incandescent, fluorescent, or sun- light. The color may come out strange, ‘but the information is what counts. Ea —Tom Voss, Davenpor, lowa Continued on page 16 The Joy of Sanding Right!? who would believe a job as tedious and dusty a8 Sanding could be a oy? “Thousands of Pertormax owners do. With their Performax y drum ‘sander. no mote sawdust in thelr faces, no more high and low spots = ‘on their finished pieces. Imagine the satistac- tion of sanding a wide surtaco (up to 48°) 10 within O10" Uniform thickness ‘across its full width, (Or sanding stock as, short as 21/4 with: ‘outa carrier board or ‘outed up tngers. Fantasize sanding to ‘as smooth a surlace 22-44 Pro PERFORMA PRODUCTS, INC, T2251 Notel Ave, Se faumevle MN 55357 (612) 895-3922 1-800-334-4910 [Vaal een ad aera) Reade Sonice #25 iat SOM WRENS ‘even sie uae fom” Syeecusnassaarsaces ———— | jam eaaeostissat ses a feo. exaevsmisssecy woe ——— | [snore vast mow ora aon - sas cabaret wee 30346 ——— 10 saw ‘Saosacsanwesee nual —— | ss oa sce sven ‘ne re BEE — ae SNP Waser ER ‘OSTss ie nvoou a SAGER — -DsTss¥6nvODL OT SHOER ‘Sauron et ‘muveuuaconen swe ‘ wetaocs0oa src \ansrcomeneuecs nef Su woaocaou Boer [DVRUSYERORL Weasel Ropswinaz igen coats ner Dae fects amen Ss vcs Ta Se Tavs coLsAUL TW BAC. wurensa ea 1 cur wre Sa WEAR BDE, Se WASP SANCALYOLADES BOS a Bom Ny ERN. ATION: LNG RLOYOP CORPORATION Racdacou SHED Pond 1-800-338-3384 Cacia Tit ae St Smee _——— an r RDAUL view euNC ———— Sven oP. NEVE Soe PAE ‘Qusuo sewers WSIRT PD ‘iusio waco ow ot —— ‘insuo wet snes SShweiss seesrarch SH FSR UST PU ‘aos remem —— ITWeHPERS S15 PSE 2H a AS RTE Halepenesse 990. aia ——— ‘iPr noe ard —— Tornoe ar ‘sewciseswaaoes Puoreatswochwstoe——— at PASH eT SENOS NA Hasevar sheen el ‘euaesar shost ‘| Theres aw wie wae or asaruswosn nt ‘hnomeA LeexnTACNT — Newponter cen Froownonhocet aici _—————— ‘Sue wie BS PRARUMe wea, cr0a0 ‘anos eemcinasa ‘sks meer San te angina leveweserweeAT cE FINGER ROVER YH SAVER TARE le OER Saver revues TORE OSE RUT pai EXCLUSIVE OFFER Ma an) ‘3 piece ee ac Pee cme are ce sinue cet eee rm rary iy Poesia niet oy PA erga en SGN Ue Ueto eme ree er Ser evsccoan new REDAToR cones WAEYLSS CHUCK ROMAN BATENES, CHURGER case VSR WaREé Evi ‘ar Conse LAWTER WAL HEADS evsinconn cw canTonadscoeaS Ver wits ocx 2st Glu We CASE 1 MN CHRGR. evscok s67 COMER ASTER WSN erancox CORDES imi GL WAG TATERY, SM OIRCER CAS {se ieen FaBinUlEiae > WeSE ‘seco assoRTEDERADG ‘cL NSE ER 2 \WIHCASE asp STARS na 10 ‘De vem cam TPL — Stoots ue,ae 12 Castes Sse or cae weaset sem mee Metra 6 12H BE san WBesuerEA OE. ..n8 Se Henle Saws Bes, Fence © sioner rxsmweg ees. os & Skrmietauawarroce Be Th ZieDSrORLEcION GenuLame seman gio oon Wr OSES Elona One OUR PRICES WILL NOT BE rr Reader Service 462 eraone 721 Gos OAKL nT we BATT — evione fav xt we parrenes orb 7 che saN Wease RAE 12 COMPOUND MITER =n henner. <8 ‘SanooM onsir noe ———e oisena_ a ANGLE ORL myo iAV_s HP COMPRESSOR _. $3000 Tune couroin ca te sono su 26. ‘Sosns mou Gosh cao — ‘Fiarousessecoueen 0 ‘uarosnsaarewaet wide ‘Faas soosn unger os ‘Se ove wakfatPnO Naw oatensae {ib une ROE We — a ‘run Two — Sc ed Pisce sar reoncereauay ss (eswasscoou sapiens GPRLUAY —55 ct Ng later eerie Aol kolg N0200RT ne Jor soceacitt as ruse SAW WE SND — ew ecw Down xr wesses roche ST oes 25° DETAR SAIOAWS 12 FCAST == erage MarIROTeY ToOLWeS a CASTS ‘eocoMn UTE Bien courowouren So ‘scar one sat Sp puna ROUTER Eh | ‘crs HT Wea rte GucT AE fxr oT Bae luasoi 1a cnossoU BADE luewow 12x aTacouso BAe. sib 1 xo mrBFoR an it — euow W x2e AP eu Tea suo 1 Xt cross TAN ERE {Ges Xt aon FERROUS (Deon Xe Yh st FUMES UUssow 19 X50 Te UuNMASOR WOOD Some SWerY DADO WTAE Sam hewesurch an set ‘e sm _ Caan ooo. ra Resting Repaired Chair Tenons ‘Making a good chair-joint repair requires that the old glue be removed ‘before gluing. This usually results in a joint that is loose, especially in older chairs where shrinkage i a factor. A simple procedure to regain a proper fit is to glue veneer strips around the entire circumference of the male joint. ‘The strips are held tightly with hose clamps while glu- ing. Try to use veneers of the same type wood as the chair. Orient the veneer grain in the same direction as the chair grain, Allow ‘overnight drying time, then file or sand the veneered joint for a proper fit to the female socket. —Salvatore F. Pontecorvo, Fort Wayne, Indiana ATip to Minimize Tear-out ‘A back-up board behind a piece of ‘wood being cut is of course a help in ‘minimizing tear-out. But, with the ‘wear-and-tear that occurs from repeat- ‘ed cuts, the back-up board no longer UPDATE YOUR TABLE. lwith EXCALIBUR Ss ue + Units are salable indvidaly or asacomplet ‘stem gunrantet io increase the ascuracy and productivity your tables + sick, easy installation Fits al abl saws + Fence locks om bat front ae rear guide ral al vay stays parle tothe sw blade + sting Table croseut tock wp to 67" wide | OvcrAnn Blade Cover comes with Dust Colleton | oe Fines ‘epee 128079 Mineopt ti + Moc features and accessories than ber systems No stil period Lifetime Guarane {or overall features the Excalibur T-Slot fence comes out frst 210 Bot Steet South Lewiston, NY M82 (45) 291-8190 FAK (416) 286-2076 in the world, and skillfully than ever. Call for your Reader Sori #10 16 WOODWORK APRIL 199 (pom tayo uveanen aa: To eliminate this failing, | hold a strip of hardboard in front of the back-up board. After each cut, I slide the hard- board to put a fresh, uncut surface ‘where the blade will come through. ‘Note: So that the stock being eut ean sit flush against the back-up board, 1 ‘made a 14" dado to allow for the hard- board’s thickness. —R.B. Himes, Vienna, Ohio Ye HaRowanRD sae 24 pack-UP Boao: DoanoTo pe eur sits Saunst Front HARDBGARO 1S HELD IN PLAGE ‘BY HAND AND [5 AovaNceD AS EACH CUT 15 MADE 30 There's ans AFRESH INCUT SURFACE BEHIND THE L100 BEING CUT. aE Ve Your Best Work Starts With Us! With over 4,000 of the finest woodworking tools, Woodcraft can help you work more efficiently Free copy today, 1-800-542- 9115 | @) W@DCRAFT. Reader Service #16 ib Sockke Sona aer75 Aecmreagea ‘AComtmporay Cte se Aatgne ne os oe ia furach—Profe ce ‘Mure bomibc ue Gaeta nerd wil Sm ot MES No Oc worker al ore Er: Vrinson eomnonj Ghat resi Sees Ae one esse Rete Cat ‘Ssreay Dak ay See caer Soames = etn se Bet Sane ‘fumed Gul Cele ‘Cri thellondClne ost LOOMS Serene es acareee ‘The Pura of Pal Levine Bite Lomb RCI Ee ay La ‘Altes ee an ian Cs WeElhinny Finer an Fw they Care Seat. Cie Pa A She stat ete owe ovina wd Order Your Back Issues While They’re Still Available! scm ibentme set | cevas ‘gist, obey [eens mw | erates eee ere | a etn een |e gehen el Pe crteg ning | ERRATIC | Bc Pepeeteeaesret || caetctred ora fare ae rh oo Oe eee pacers Seca eae coe! | ames etc pamemau | te seit a iecoteteesertipe ee eee |e att ESE | ne Rain | me ai ‘naar a KO v Issue 18 sue 24 fe easels a |e Seca win ea om a Se ne [Ragan | Seema eS CE sen oe\hek Or RESP senna nnn | Sebo oie oe acer elo enton ere eerie ee, ee gee FaZa se teat ee apes (oe: leas eee ge [cee renga a ee marae as or Beene | kate Taae mow Aer ese cen eeeere rae (2 pear teen. ec iit vrearnn [eed i See Pat Edvtrds —Cabincemaker | Ive 26 Wevtitemnpma, |Reeizcetent | Ea asceipieatn— riers, |imeaaeeasiore* | Geena oo ceteris pee seeeteca, |Seaaiaie, | tearntlf om nang tein" | Reece” | eatetee Swe Seceaiet | eons ve them [eae fee eee ee eee ee ae eee ae on ee a | Miri feeneaeccertocy (ewer |i a eee Sib jatinterm Se ea er i Speier afer ee manne sideps Neon tw | aue22 Teel Mceeer” [Semoneme (ee a Se ira a ee rg x euro wa gd eo ch money Wonder Vi Mastercard pie sce postage ning) 1 Woedvor Rapin BO Box 185; Wool DiS? Phone 15) 820580 | Foc s) 382 587 ee aan Giy Sule Zp viswce Eepation Spring's? C1#14 Mar/Apr’? 427 June'94 Simmer’s9 C1415 Mayijune’92 428 Aug'94 | Fal’ss O16 Juy/aug’s2 — Caps Ont'se | Winter'so > Cle17 Sepuoct’92 S80 Devos Spring'90 — leis NowDec'2 — Gast Rb'vs Summer’90 —— C119 JaniFeb°93, 82 Apil'9s Fal'90, 01420 Mav/Apr93, 2433 June’95 Winer'so 11221 May/iane'93 G34 Aug's Spring’ Chezz Juy/ang'vs Gass et'9s | Elsto Summer") — haa} Oct'93) 36 Dec'95, PGsu rar — Gate pe'ss © Gas Feb 6 | | O#l2 Winer’) — e25 be 113 Jan/Feb'92_ [426 April'94______Total Enclosed mak Pot en ie Reha gn to cowie mt | Eee be Eales Beer! Ertan Tenaga alc ne Issue 32 | Ses eeeeete Shree ie aoe Eee FRG Hh WaPo Space Far Caves ranean Pel Dok Ending a ‘aisy Deo Wood CretiopanSpeatstoe ti ary ‘Guise ‘ean i Sad Moan Beophat End atl Wp se Reis {key then -aargcran Cesta th odhorker NE cate rei ‘ow ating Dt ae | oe | ee esac oe ee ee eat) See. Sess oe ey EEE a Rounder lane iene eet. ing Ee Te Pe ee EV ENTS 18 WOODWORK APRIL 1996 FREE $45 IN SHARPENING COUPONS ) D , GOOD ON ALL FORREST OR OTHER MAKES OF CARBIDE : BLADES OR DADO SeTS,Copars Date 12917 Sal rics oo tha 4/306 Mateen Hoa rag rdocans cups bo wth pion ‘The Proof Is In the Cutting Both Woodworker I blades performed very well whether cuting throwgh buter soft ack "The 20 The Best of Wood: Boot 1 WOODWORKER II Foe hk agi a 1 sere wen ALL PURPOSE RIP & CROSSCUT sve attacks we maintained a ‘omy bate mommmens ust BLE ripping a variety of woods on the aa inamisoscr sit HH ‘Powerfl Uinaw and experienced | seer sunaoxane $00 $99 the salle wey ewikching tte ‘This 160 page [A muse 8 $8 {hiner blade alowed very salar yee fd an apna wh ‘book features 35 of the best Deere ee en Sees ester, teh we pot withthe Forrest blades. ‘On solid stock, ripped edges came off our saws vemnooth projects from WOOD» Magazine. You must mention you saw this ‘offer in WOOD» Magazine, ‘when ordering erat in no menicte Offer Expires Apr 30,1996. Pole ‘One book Erosceu carne ou crop sa ean ee sa Hike Bottom Line aa Prd be Jet oheeng CHOPMASTER FOR Tey pe hereas eer SLIDING COMPOUNDS ae Strayer Pere /& MITER SAWS Cour ce na ‘se stern su new sizes AVAILABLE ust sus f) Seen an dome eousentievmurse so $8 Bh | Wroobonmenesran Set 93, pa 5 TEST, Woodworkers Journal 35 p78 ee eteioae ans 8 ER ca obs pete ste mamer Ht WOODWORKER I~ GROSSCUT OX O raga SR For TABLE and RADIAL SAW a ont $8 $18 200 $179 tems ors eR 77 $109 omar aaek (eae 10 a25— Pu 550684) DURALINE HI-A/T FOR TABLE & RADIAL SAWS ALLPLAT FACE = s:vorts singe +14 s7s0000 ‘BLADE DAMPENERS-STIFFENERS FOR BETTER CUTS on all brands of blades, use our lage 1/8" DAMPENERS- MEARE UST SALE Mupamaaek $i) $128 STIFFENERS against one side, race aie Sa $168 o [#..... $21 Fei parmie ase Sor $78 one eaark Sr $18 ir siesaras YER StS ° cnt SMONGER MET WEARER T-ANO LARGER AVAILABLE RSI 091% LOSER LE REDUCES NOISE 50%~75% WE RECOMMEND OUR FACTORY SHARPENING eosin ca yew th MIERO-CHPPED EDGES iB 8 aig gay, SOTHO LAU CACC GE TSS Sp aS ype S15, TSS aren VSSQ 1. oh Ue Eetery Quality is why we're different! wswss ore acounrs avause peabeniteniienety Cae ncaa pS 4, DEALER NOLES WELCOME Reader Serica 2 STEVE WALL LUMBER CO. UPS: Specials eon teow (ha geen. Posen We ak ‘ose Peni as SSSERRAGREEERSSDES AT ena Oar ran eer ra 20 WOODWORK APRIL 1996 LOG RUN SPECIALS 100 bd. ft. Bundle 4/4 Cherry $120, 4/4 Walnut $140 ‘Add $20 for S28 Motor Freight Only FOB Mayodan Sere Pati sr here} ON WEEK-LONG Coro complete brochure April 18 — Oct. 11. 1996 = Carving = Chair Making Finishing ‘ Restoration “= Furniture Making = Joinery “ Cabinet Making Veneering > Turning USTRUCTONS: Dr. Koger Cif. Jinn Ton ‘Stephen ctor Sen Stem, Boas Rely ‘etter lack Healey Jee Day Rel, Jack ‘Abert. Nonroe Robinson, Mich Robanek fre Demerath, Marc Adams School of Woodworking 48, SOON, Franklin IN A615 15175354015 Reader Serves 954 Question & Answer ‘Working with Plywood Since I subscribe to almost every woodworking magazine QL the market, I have had the opportunity to note that there has been a dearth of comments or complaints similar to the one that follows. ‘The manufacturers and producers of plywood under the aegis ‘of the American Plywood Association seem to have decided that the American woodworkers will accept without protest, the imposition of plywood for cabinet work which is less than we ‘have had in the past. We have been bombarded with substitu- tions which, we the users, have not asked for. If we order 3/4" {from our friendly supplier, we will get 18mm, 23/32", 11/16", none of which fits tightly in the dado slot we cut for it. Order 1/4" and what arrives—7/32". To solve the problem we are advised to buy router bits so that we can get a precise dado fit Also, quality of the product has depreciated. Most all ply- The Sane tsar inte poeumat rum on on ie ance 812 thers bce a abekeey vat el te podoton of my Sconerng. Ctra Bo many aan re wor be atone Dest at erage he Wr. AN worst forthe Sand Rie ae wold a nt Send ite sands he bomeranswitou chang be aos, ard ges ta Det an hard sae rh, From te unprnébank tage te completed tap, nye Sand Re touches Doomeangs. ee the acon st ny company as own roma hay operant Word We sale FOR A PRICE LIST AND DETAILED INFORMATION Sand-Réte mascoracronma CALL TOLL-FREE ‘an Industry Leeder Since 1942 Fader Sonic #69, 2 WOODWORK APRIL 1996 © We invite you to send woodworking questions to us: Editor, Woodwork, 42 Digital Dr, #5, Novato, CA 94949, wood I've received recently (BC fir, cabinet-, and shop-birc, to name three) have all been bowed. How do you make a straight ‘cabinet side with bowed or curved material? —Carl Dykman NRE are manufactured in many regions of the world, and much of what is available here is made else- ‘where. Often, domestic species, such as oak and maple, are ‘exported to the manufacturing country in raw form and then. return a3 a finished panel, Panels manufactured overseas are ‘often made in metric thicknesses: ic, 18 millimeters instead ‘of 3/4", Panels manufactured entirely in this country are gen- erally made to the stated nominal thickness. Plywood is manufactured in one of two ways, In the first, the core veneers and the faces are pressed together in one operation. Then the entire panel is sanded in a widebelt ‘machine to level the splices in the face veneers. In the second, the core veneers are pressed together first, without the faces, ‘The core is then puttied to fill any voids, and sanded. Then, the face veneers are applied and the panel is sanded again. Continued o page 24 5 wnodans, Sagas SGIMNOILVN HLMOHD JO SHV3A ZL ‘Spueg 129UeA :soues ‘SY Pe a PCa a = aM Gagainvuvn eager Serves 94 = Denotes New Books a eee boeee te? “Makin Pst Tea Tbe i 512 {rine Queen ame Sol cen $19 ‘rina Fumstae Mater ya AS ‘Ses You Can Coupe Cone $19, ‘Mike Aatgu Fun, er Gus $14 Bl erro Se Wood Saer4 ‘Queen Are Fue (Vaca) $32 ‘Mating Wiser Char urban) 18 ‘Tabi Wins Chat Mungen9 ie Sis 8, tc Frye (Duty) How Bull S0 Clase Furnture uso (Bee $12 BS naa ‘BM Cabcy:Exopas Deng ‘Consrcion Cato S17 ‘Stipa Cbs You Cun S18 ‘io rer Kanban 9 ates and Besta (Lavine) ‘Worig Win Pac Lantnes cy S19 Dultiag Kitchen Caio (Cay) S1¢ ‘Shaver Qosetsan Clots ees $16 Book Skt Fum ten S85 ‘The Bok of Shaker Fare aay 339 arty Wert of Ga Sacley (or) 2 Macenfure 1 &GSuay (oan 52 Mite Anbesc fern Pam Sy $2 (Coord Wei Gnu Sc (on 829 ‘Guu Sule After 1909 (Gry) New Mexcan Fura anma $19 ‘New Meche Fue (yh) $5, Paterna tet Ney Hoods Gees pee BG Chet dein a 8 Nae @Repar Wd Cok Casi 98 ‘Goctruline (8 Ania Dede 18 Timber Bly Tat Sfover avs ‘Rover Pant ech Sas Mad ‘Wood Tec 7s Fare 8S Wood an Tete ioral Wood Koh UUMWeed 12S Weal Sop 13 Ties & sist a Fiawe tenn Dats Yeu ‘Sim Capenty Tech Hao Pr ‘Si Sabtulang@ Make Ketan oh WESTIN eee ike Woche (Wen 3 Boyer Baste Tring (Con) 27 ‘Ting Wooden evey Dit) $12 Base Bow! Torsng (tne) 812 Faas Wenge gee SH Reishi Coane Wood ‘Spang $19 ‘Wien Siuesiooto Spe R16 ‘Ting Mactan Maglaton ‘Vol Heleapte $22 rata ng a 22 or clos Cs an 8 ‘Woturine Fess Cea ov 819 “Tong Niner Wood ten) 15 ‘Thr Claman Woetaer (Ci) 813 Tening Wood an S19 Wondisnng Fret (alan ‘Tumed Bow Design Rafa) $19 Creme Woostmaing Nish 818 fsa Wontrng S17 ‘ser Wcaamen 8) 19 IM y Nato Weiner bc Gtretaten Dae SI4 eying od Ode UUnderetine Wood (ec ‘Ward Weodin Cao in S46 (este Sein Wood na S15 Coos ie nd Mace, Tati Oo 58 He Wiety Me zl 819 Masueo a iy Brea S13 Pre vestap Bek Sa) 0 oes ‘re Xasa eV Word Boxes apse $17 "You Male xsd 34 [nef hint tie Wane apm 8i6 ating tle Sones (Bene $1 Mate Srl Worden Boxes ash S12 Set Wie Sansa Te Wont Book (anda) 832 ‘The Workherch Bok ana) 2 ‘he Toor Book Tags 832, Spec Ad Abe 8 ora Tsks Cains Bie ing S14 ‘Wenn Wondering Cola) $2 Se Updo Wasering Sap sus) $14 Heme Wark Parmer ot he) 814 ‘Shang Wortences Alen) $1 ‘Maile er Tol Comers rhranI9 onde Pacer Tarte ‘Being Hind Tose 83 ‘GMating Sod Moding Mecane 7 Bouse ieecuteeme? ns Wen 13g ry tre ont ff Weed Mees sae Sng daey Toma a ace “he Tae Sm Book (Men 25 “Mastrng WW Machines (Dug) $23 SBaneow Handbook Dopinse) S16 ‘TheNew Roa Hand pian) $16. ‘Tle Sow Tectmgoes (Cie) 816 Rat Arm Sa Tecnu Ce) $16 eo Oe Rl ri 310 {Copl Bok Stony Rowe Tot ‘Techno (Decrtor) 817 oar Handbook ater S14 act Cleon fags? Dl ress Book (Dect) 16 ‘Bae Tuning Ve Ral Ar San abe 1 Nott s55 Vou2590 ‘uv T Caen Git Vale ‘Amesian Mase oa Mae Pere eee ae ‘Wekaop Mat Sh Boag Sep Ae ee) 516 ‘Wootten Sho Ae ‘ook (Dieser) is George Frank S14 ‘Woodie Hondboat (Alem $12 ood Fishing eam) 26 gece ahaa baie oe rane Se eee wt $8 ‘eve (Grape Guide ame Consrcton 28 ‘Toe Timber Pree House (Bese 819 ‘Tatton Stabling (Mowa 822 Bice oar ice 518 Fitteeed Richer trrare Carpet ‘iPoon, Wal an Sian Auer Tes ‘Shown Capeny tu st $Me te Capen Ruan ows Pisettentitisnticret ‘onder Sonice #201 Goin Po ee “aioe Wore W's Gade The Wl Maren Gude i) (Carving MinatueSant anon) $1 sigan Fe eo) arin oj ad ale Fm $2 nig Aneta oe 32 ‘Satis Sucks ro $13 ‘Woodearver's Wertbok (ald) $4 Bide fre Seb 835 Base Cup Canine (rena 12 rsa Fh Cag (Fe) $8 ving eh Orson Cae) 23 ‘Sing Cara ra io 12 ‘Care oe Caving Sistine 28 Scupung Weod (aes) S34 Reals Decoy (Speins) 816 (Sip Caving re io ‘Gip Carving Pater Caso) $10 Gating Wood Bin) $17 ‘ending With ck Bas $16 ‘Woes Complte Ceara Duar S14 Spasms a inaat ly BD ies Sach Sug atti’ {Hise Serge Sia iin Dan LES Geer Waning rain Ce Wood Spine Wai Shs sca Sttia tis Scr Sew Magic (Lockwood) 1S Tara (Crab) 812 ‘a ny Patan Yas (Gab Bact Pars bones S12 ‘Sue tate Batam nom er ges fr Sri sa SH ‘Sul Sow Pees Poa) $12 ‘The Anel be Solow Spcinan) $19, Sit 12 ‘SndeavnPnerycan ‘Suwa law Pars Span $12 spt Sout Stoxes Pere pci) 12 ‘Gms Srl Pats oti toate cette 3s Niaesedieeen 16 teen, of Cabinemakng Ves S175 Bob Round Sos Tech ie SIS ery Walaa Cait Srp 82 ‘Ray Under ion 588 %x Denotes New Books WOODWORK APRIL 1996 23 ‘The sanding of the core allows the manufacturer to calibrate the core thickness more carefully, and this yields a panel which is closer to specified thickness. Generally, the more ‘expensive panels on the market are manufactured in this way, and have fewer problems with core telegraphing and thick- ness variation, Bowing of plywood is somewhat dependent on species, as well as on the dryness and quality of the core and face ‘veneers. For instance, maple plywood is likely to have a bow to it, And certainly the products of different manufacturers will be of varying quality. In some operations the emphasis is ‘on maximizing production and minimizing costs, while in ‘others products are carefully manufactured for the high-end user. It makes sense to ask questions of your distributor before ‘ordering: What mills do they buy from, and where will your ‘materials be made into a panel? What isthe guaranteed toler= ance for thickness? What grades are the face and the back? Is, there a guarantee against bowing? If you are unable to select ‘material in person at the distributor's warehouse, be particu lar when placing an order, and try to get specifications in ‘writing. As helpful as the person on the phone may be, they probably won't be loading the delivery truck. Also try to buy from the distributors in your area that supply large wood- eee eo eee Po ete eee} working operations, as they generally have better products than those that sel to builders and homeowners, ‘There are a couple of ways to deal with dimension prob- lems. Fist, you can use a dado set and shims to cut grooves for plywood panels. This will allow you to set the width of the ‘cut to exactly match the dimension of the plywood you have. If your operation requires routing instead, often you can ‘make two passes which yield the correct dimension. There are also sources for metrie-dimension and small-fractional (ie, 11/16") router bits. ‘My solution involves using a slightly different material. ‘Many distributors now offer veneered panels with a core of particleboard or medium-density fiberboard (MDF). There are even some composite panels with a standard veneer core and thin layers of particleboard under the faces. These panels, in my experience, are domestically made, tend to be within five-thousandths of an inch of specified thickness, and are extremely flat, In addition, the veneer is very well bonded to the core, and there is less tearout when routing and crosscut- ting, In my atea, these panels cost roughly the same as the best grades of plywood and are the material of choice for me. ‘The disadvantages are weight (almost 100 pounds for a 3/4” x 4' x88" sheet), greater vulnerability to moisture, and the fine Continued on page 26 NO GIMMICKS, NO HYPE dust a Better Product) At a Better Price ‘No mixing Waterproof Extraordinary strength Sands & scrapes easily Expands as it dries 30 Minute open time Exterior/interior use Fully guaranteed Distributor/Dealer inquiries welcome == EXCEL \The First Polyurethane Wood a in America ‘The AmBel Corporation nie Sn P.O. Box 819 Prt Cottonport, LA 71327 POLL aye A Clockmaking Catalog Your Handcrafted Clocks Make Treasured Gifts! Yowrcopate parm Liccotiec. Reta Seo Oe Eee Oran Since wall ae are ere artis fais ores } Sierwonertisorsenate earns | Colo sara ceataeuaamcnon | Sox almemamurenene | Si eee nee poeta tere foorand “MAKING WHEELS Easy”) | Mee.‘ os Jun $1995 and receive thc eatalg ive | esanble and stan shat snp ‘Send for your FREE catalog today. Or eal 200 596-258 | ee =a }Y ROUTER BITS WITH CONFIDENCE! Pot our plunge etsaignteto the tet! age Abert crip sean vit NG RANG ROUTER TE ‘caus scrter em ate ‘cision pang adr a raul umeneoey feng Tox Sty belek pana as Nagase Spcal Savings. Buy Wes separate o get ANY TWO BITS for ONLY 94.9 plus 3.00 Shipping Guaranteed Dele You must meen Or #196, crane $i7.99 SBAGLE| nan or ts mrronts? DEMAND eg e erere ee ee 35, | Woodworking Acces PLUS our ee) pp sancti Be eee cae wes CALL 300-872-2311 ender Sorin #56. The World's Most Perfect Router Joints Start With Good Phone Skills. ‘When you phone our toll-free number and order your etic, complimentary 32-page Leigh catalog youre ‘well on your way to a new level of woodworking crafts- mash. The Leigh Dovetail igs and growing array of accesories remain the universal ‘benchmark for precision, easy-to-use router jiner tools. nd with heaton ofthe Multiple Mortise and Tenon Attachment and now the NEW F Finger Joint Attachment, ‘the ingenious, patented Leigh Jig System sets nen standards for quay versatility and camve- rience. Do what thousands of serious woodworkers. worlide have done already; call us today. Call For Your Free 32-Page Catalog Now! 1-800-663-8932 LSiH Se ee ee et eer eet ee Cong Peer tes Bee ers iis, PO Bo 357, Pet vin, Camda OE 6 "6d 70 Fa 4 GE HH WOODWORK APRIL 1996 25 dust produced in cutting them. However, 1 virtually always, ‘get premium veneers and exact flatness when I buy these panels. They are widely used in the furniture manufacturing industry for these reasons. —David Meiland Te would be reassuring if3/4" plywood actually measured 3/4", but I would not expect this to happen on a regular ‘basis unless you are a lange enough consumer to get the pyl- | wood busines’ attention Instead, 1 plan my joinery strategy around a ballpark thickness. ‘As for housing plywood in a dado, I recommend following, the advice that Tage Frid gave many years ago in his book, Joinery: Do not house the full thickness of a panel into a full- ‘width dado; rather, create a tongue on the ends of the panel. Thus, a 3/4” shelf might have a 1/2" thick tongue, and be housed in a 1/2" wide dado. With two shoulders to resist rack- ing, this is a much stronger joint than a fully housed dado, and there are other advantages. | By creating a tongue- age eee a red re Sed eee ey Meena Reader Service #0 26 WOODWORK APRIL 1996 eal eter oe in-dado joint, you put yourself, not the manufacturer or sup- plies in charge of the joint integrity. Also, should you need to sand the shelf after the tongue is cut, there will be no adverse effect on the fit of the joint, as the dimension of the tongue will be unaffected, {As far as warped plywood goes, I find it a complete frustra- tion, Even so, if you are building cabinets and the degree of ‘watp in the panels isnot severe, a face frame and the back of the cabinet can pull the panel into alignment and hold it there, Proper storage can ensure that a properly manufactured, flat panel remains flat, Because unequal moisture content among the various layers can cause a panel to warp, itis best to store panels with both faces protected from the extreme ‘moisture changes of the surrounding atmosphere. If you have «stack of panels, you can protect the face of the top sheet with a cover sheet. Also, sheets should be properly supported if they are to remain warp-free. Ifyou can dedicate 32 square feet of space, it is best to store sheets in a flat stack and let gravity hold it ‘that way: A. sheet that has significant spans between supports (more than 30") or one that is propped up against the wall will surely sag in time. —Eaitor Continued on page 29 SHAKER PEGS CANDLE CUPS MUG PEGS $15.95 per 100, prepaid Wide selection of other wood products. Catalog $1.00 or free with order. od eae Poa) Brea Benny’s Woodworks P.O. Box 840, Dept. WK14 Shelbyville, TN 37160 1-615-437-2295 1-800-255-1335, a =a) (eae od Earn ‘Shaker Peg Mug Peg nisin Valo BUILD YOUR OWN POWER TOOLS & SAVE! 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Woodworking Mistakes Now you can recover from mistakes that waste stock and can make your woodworking frustrating. Fixing and Avoiding Woodworking Mistakes provides ingenious, practical solutions to help you prevent ‘mistakes in the first place and explains sensible strategies to fix them when they do. ‘You'll find ways to save projects by incorporating mistakes into new design options. And, learn how to deal with stock defects like warp and joinery that doesn’t fit as well as how to repair finishing problems. Most important, this book can restore your confidence and make your woodworking even more enjoyable. awocover sm paces sas: siseiss,mewone, $24.95, At your local bookstore or from: ‘Taunton Direct, Inc., 63S. Main St. P.O. Box 5507, Newtown, CT 06470-5507 1-800-888-8286, operator 263. | vast LAYS, pee send me Woodworking Makes fora asa Uday Ipiidisen fe secon cele ander seth Other wl py 2493p $3 pr nding (Crs oe Can nt POG ETN | Lrnarmeso parnows Ms raya ssc Hime Elvis Claws Dscoves Taunton HOOKS & VIDEOS for ellow enthusiasts jeder Service #11 Ferenc Cereve WOODWORK APRIL 1996 29 Over Fi Years a Plane Maker and User: Cecil Pierce fen Cecil Piece was about W: Pee ae eatree Sr tt ed i pc | for wooden planes, It was then that his uncle took him to see the shipyards in East Boothbay, or rather, invited Cecil to take him since it was Cecil who had a Model T at the time—East Boothbay ‘was some 15 miles away. The trip was to be prophetic. Upon arriving at the first yard, the pair were met by the sight of two outboard joiners planing and 30 WOODWORK APRIL 1996 BY PETER W. RICHARDSON scraping the sides of a newly planed up yacht. The long, thin curls of wood falling from the plane and the fine feathery shavings from the scraper’s turned edge left an indelible mark upon young Cecil’s mind. He resolved then and there that he would master these two simple yet graceful tools, Though it took many years of work to achieve his goal, the tools Cecil cre ates reflect a great deal more than a simple mastery. In fact, Cecil has probably made the only true break- throughs in the design of wooden planes since the invention of the cast steel blade. Cecil’s Background The men in Cecil’s family had been lobstermen in Maine for genera seamen who harvested tions — 4 Completed Template C is a perfect mate with Template A. the cut with the tool running, this part of the task would be simpler.) The final step in preparing Template C is to remove the waste in the center, using a utility knife to cut through the remaining 1/32" of material at the bot- tom of the routed groo the templates are ready for a test fit (see Figure 4). This done, ‘Step Five: Shaping the Workpieces Using the templates to shape the ‘workpieces is straightforward. Mike lays out registration marks on a 3/4" veneered panel, aligns Template A on Template A guides a bearing-overflush- trimming bit to form the table’ center. top oft, and traces around Template A with a pencil. This piece is rough-cut on the band saw and then finished with a flush-trimming router using Template ‘Ato guide the cutter (see Figure 5) A solid-wood octagon is assembled as the blank for the border. Template C is used to strike a circle on the blank, and the router is again used freehand to ‘waste most of the material within the line. Care is taken at this stage to ensure that the depth of the rabbet being cut matches the thickness of the center panel When all material within 1/16” of the Tine has be removed, Template C is fastened on top of the blank and the nish cut is made with a bearing-over flush-trimming bit (see Figure 6). The reward for this careful work is a flawless fit between the two finished pieces (see Figure 7). David Meiland is a cabinetmaker in Oakland, California. Template C guides a bearing-over flush trimming bit, forming the rabbet in the perimeter nosing. The result is a precise fit between the interior panel and the perimeter nosing. WOODWORK APRIL 1996 57 Thoughts On BY vorc U MARIAN | Repairing Antique Settees Delving into two settee repair jobs, one for loose joint | eg, the author reveals ind one for a broken a few lessons about joint placement and grain direction in hair parts, both of which play an important role in the life of seating fee eee eae somebody wil bring nto the shop some old piece that needs mend: ing, and I find myself facing some unexpected challenges, as well as learn- ing something every time, Take for instance the settee that a friend brought in not long ago: Jose, it need The joints are kind of he said. lin “No problem,” I replied, thinking that all Td have to do is pull the joints apart, squeeze some glue into the mor- tises, then clamp it back together and be done. Under closer examination though, it turned out that the piece had 58 WOODWORK APRIL 1996 had that kind of treatment done several times before, and every time, Mr. Fix-it id used some different kind of glue: 1 id some yellow glue followed by epoxy, tified the original hide and finally, wood putty, where joints failed to come together due to the excessive glue buildup. The problem he thing that requ had figured on: was that I had gotten into some- ed more work than I every joint would have to come apart completely, and each mortise and tenon would have to be scraped clean down to the wood, or my glue job wouldn't hold any better than the previous ones. Arrepaired settee awaits finishing. Much of the rear leg has been replaced; the original carving at top has been retained. So, the have to extend to several hours instead. half-an-hour” job would Would the customer still want it done? The lesson I learned was to never give an estimate before thoroughly checking the piece out, and even then, to leave some leeway, as often times one might encounter hidden snags that weren’t previously accounted for. But then, there are also those jobs that are challenging and when done, give you a sense of accomplishment and satisfaction. I was still working on the settee I just described when someone brought in a nearly identical piece, this ‘one with a broken back leg. You will often hear people say “they don't make them like they used to...” ‘True, Some of the furniture made today in fact better built, and I say this thinking of the small shop that makes furniture one piece at a time, like they used to do a hundred or more years. ago. Case in point: both settees were entirely assembled using 3/8" dowels, not the best choice, considering the forces they are subjected to every time someone sits down on them, The hold- would not have weakened the leg as much, and since they don't meet inside, they could have also been made longer. Placing the dowels further apart results in a stronger joint that withstands rack- ing considerably better than the one in the picture, which can almost pivot on that point, the dowels are so close together. Something else that should be taken into consideration is the orientation of the grain in the leg. When making a ture at left shows the new leg in place, ready to finish, While working on old furniture I have also developed a philosophy of sorts, where I think that an honest repair that shows, is better than @ clev- erly hidden but poorly done job. There’s nothing more embarrassing than having some customer return a piece that you repaired and that didn’t last because all that was holding it together was wood putty! How Grain Direction Influences Strength Areas that are circled (a) are susceptible to breaking due to grain runout. The alternatives (b and c) that solve the problem. A window template facilitates the layout as it enables one to see the grain direction in the future leg. ing power of an end-grain glue joint is minimal and the surface of face-to-face grain contact in a doweled joint is con- siderably small compared to that of a conventional mortise-and-tenon, While examining the broken leg of the settee in an attempt to determine ‘what might have caused it to fail, the most apparent reason was the poor placement of the dowels: although the apron is 4” wide, the two dowels are only 1-1/2" apart; and the two pairs meet at 90 degrees inside the leg, as seen in the picture, Staggering them ‘would have been a better solution as it curved chair leg, I might go through a dozen or so boards looking for the one that has the naturally curved grain direction. That is usually found in a board with a knot through it, where the grain curves around the knot. One other aspect to consider, when working on antiques, is that of authen- ticity, and the aim isto keep as much of the original as possible and to avoid altering the design to the same degree. With that in mind, I replaced only part of the leg, and used the original top with its carving, joining it to the new section of leg with a scarf joint, The pic- Anatomy of a Scarf Joint (for repairing broken chair leg) The longer the scarf (d), the longer the glue area and the more the two mat- ing surfaces approach face grain (as opposed to end grain), resulting in a stronger joint. The two cheeks ofthe tip of each mem- ber key in the pieces als, preventing them from sliding away from each other during glue-up and clamping. To cut the joint, 'lay out one side and cut it then use it to lay out its mate by seribing around it ti at this point that I maich and align the grain, some- thing of importance ifthe joint isto hhave visual fluidity. Voicu Marian is a woodworker and artist in Alliance, Ohio, WOODWORK APRIL 1996 59 GaAs aR | © This grouping of chairs isa sampling of the variety display- ed at The Chair Show, held this past October and November of 1995, in Asheville, North Carolina. The national juried ex- hibition of chairs was organized by the Southern Highland Craft Guild. Photos courtesy of The Chair Show. B.A. HARRINGTON Somerville, Massachusetts Federal side chair Cherry, madrone burt veneer, and ebony © The design is based ona chair in Boston’s Museum of Fine Arts (1795-1805, maker un- known). Harrington was impressed by its modern lines and simple orna~ mentation. The chair was built asa graduation requirement from North Bennett Street School JIM RANTALA Cedar, Michigan Windsor high bow sack- back, with footstool © Made of pine and oak while Rantala was living in Texas and did not hhave access to freshly cut maple, Upper and under catriage are all riven stock. Traditional construction techniques were used. Finished with blue-black milk paint. 60 WOODWORK APRIL 196, WILLIAM LOCKE West Roxbury, Massachusetts Reproduction of Langley Boardman armchair Mahogany with cypress crotch veneer, cotton fabric upholstery, and shellac @ Langley Boardman (1774-1833) worked as a cabinetmak- er in Portsmouth, New Hampshire, in the early 19th century. This reproduction was built asa student project at North Bennett Street School, BAYLEY WHARTON Raleigh, North Carolina Kanji chair Curly maple and purpleheart © Though void of upholstery, the Kanji chair derives its comfort from the way it is sculpted to fit the human body. A downward curve on the front of the seat reduces pres- sure to the back of the legs, while the truncated back support follows the shape of the torso in two dimensions. The lower portion of the back is convex to support the lumbar; then as it climbs upward, it makes a smooth transition into @ shallow concave lattice that forms a cradle for the shoulders. ROBERT SONDAY Free Union, Virginia Shaker interpretive rocking chai Pao amarillo e ral color of the wood. Yellow is the natu- used in the chaie— no stains or dyes are used. The chair parts ed, ‘except for the rockers are lathe tut and splat, which are bent laminated for durability. Seat and back of cotton web- bing. CURTIS BUCHANAN Jonesborough, Tennessee Patra’s chair @ Made in the Windsor style, using green wood and 18th entury traditional techniques. Paint finish. BART WALKER Victor, Idaho Lodgepole pine and rawhide rocking chair © Walker handcrafis furniture in a tradi tion from the carly 1900s. Naturally dried pine found dead standing or lying on the forest floor is used to create the pieces, thus reducing the impact on the environment. The woven back and seat of rawhide add a western far. ANDREW PEKLO IIT Woodbury, Connecticut Dining chair Ash and leather © Andrew is an architect and a joiner, WOODWORK APRIL 1996 61 © The sculpeureson these two pages were part ofthis past summers exhib: tion, Wood Sculpture: Craft and Symbolism, put on by the Ohio Designer Craftsmen, The exhibition was held at the Ohio Craft Museum in Columbus, Ohio, According to the curator, James Mellick, “This exhibivion represented at least three generations of wood sculptors from established masters of the craft whom I studied from a distance, to emerging artists fostered by my ion. Many of the sixteen ar own genera 3s from mine states and a province of Canada showed together for the first time, The exhibit was rich in the diversity of style, process, and narrative conten JAMES MELLICK Coluimbus, Ohio Laminated, constructed, carved wood, copper, 65” x 48" x 30 @;. various ways, to symbolize social and political allegory. Savior, 1989, mes Mellick uses the personification of animals, combined in an antelope with arrows piercing the body, draws from the martyr dom of St. Sebastian. Mellick often uses birds as symbols of angels or spiritual guides. When created, the work was a metaphor for the struggle for democracy in South Africa, 62 WOODWORK APRIL 1996 MICHAEL BROLLY Hamburg, Pennsylvania Self Portrait 27" x 16" x10) © The functional sculpture of Michael Brolly employs woodturning in much of it’s form. With a turn of the button, the outer coat of his Self Portrait opens up to “flash” a cartoonish skeletal structure, Brolly says that it expresses the introspection that takes place when dealing with the probler ns of alcohol and being, exposed to the bone, JOHN MCNAUGHTON From the heart Constructed, laminated, and carved wood 80" x22" x 14 ansville, Indiana @ With From the Heart, a chest of drawers inspired by aturn-of-the-cen: tury va McNaughton cele- brates thirty years ‘of marriage (to the same spouse) while paying small homage to the pop artis, Jim Dine, who is known for his paintings and drawings of hearts, ELISA ZYLSTRA Lakewood, Ohio Five shoots Carved and Dyed Wood, 17" x 15" x @ Elisa Zylstra isa recent graduate of the wood sculpture program at Indiana State University. Her rich visual vocabulary draws from her interest in human anatomy and biological forms. Her carved and dyed wood reliefs are like tiny landscapes, microcosms with an clement of the bizarre and make believe. Her metaphor is more physical and celebrates life processes. STEPHEN GEDDES Cincinnati, Ohio Auvers-sut-oise (head of Van Gogh) { metal, 14" x 614" x 10 Laminated, carved wood, forge © Asa product sculptor for Kenner toys, Stephen Geddes is nsible for many of the gures” that parents step on while barefooted. His first love isto express his own observations of fein laminated and carved wood, such as this head of ‘Van Gogh, which is stained as yellow as his famous room in southern France. dimensions, woods used, and photo credit. Send to Gallery, Woodwork, 42 Digital Drive #5, Novato, CA 94949. WOODWORK APRIL 1996 63 The Kitchen Shelf BY GENE THOMPSON Ss years ago, after hearing my ‘wife mention at lunchtime that she had no place for her cook- books, except a kitchen drawer, I went to the shop and made the patterns and built this very handy little shelf. Later I was glad that I made patterns, as we built and sold literally hundreds of these shelves. A tip at this point: We make all of our patterns of 1/8” thick Baltic birch ply- wood, and they hold up for years. Further, I have for a number of years made a pattern for every project. After the bitter experience of having a cus- tomer request another of that shelf you made for me Christmas-before-last, I finally woke up! One thing about this practice, patterns are easy to store, and as the Old Farmer said, “Ya don’t have to feed and water’em.” Now, let’s build the shelf Stock Preparation I chose red oak as the material for the original shelf that I built, as 1 had a good supply on hand at the time. ‘Alternate choices would be black wal- nut, cherry, soft maple, or pine. Logically, your choice should be predi- cated on the finish you plan on using. If you plan on painting the finished shelf, select either pine or soft maple, Any other finish would apply nicely to any of the other choices of wood. Having selected the material which you'll be using, cut the pieces to the sizes as indicated on the drawings, tak- ing care that all cuts are square, and that the thickness is as required. At this point, leave your blanks in rectangular form. Sand al ofthe flat surfaces at this time, as flat sanding after the dovetail ‘machining can ill-affect the fit of your joints. Dovetail Cutting Jig [At this point, build the dovetail cut- ting jig, as shown in Figure 2. While a jig made of MDF or Baltic birch ply- ‘wood would hold up for many sets of shelves, I often use my jigs hundreds of times, and so prefer polycarbonate plastic. Polycarbonate is a very durable ‘material, The thicknesses are uniform and it is readily machinable, yet itis nearly indestructible. (Check the Yellow Pages of your phone directory under the heading “plastic” and look for a display ad for sheet plastic. While the cost of polycarbonate plastic is high ($432.00 for a 4-foot by 8-foot sheet that is 3/8” thick), don’t be alarmed. Almost all of these supply houses have ‘cut-off ends and scrap pieces from big jobs that they custom cut for contrac tors. They sell these cut-offs by the pound and these will suit your purpos- estoa“T”) By the by, youll be able to use this jig in other applications besides the kitchen shelf Joinery Guidelines Using a couple of pieces (or more) of stock of the exact same thicknesses as the workpieces, make some trial cuts of both the male and the female dovetail joints as outlined below, and make trial fits; and if necessary adjust as follows: Female joints—If the joint is too tight, raise the bit slightly. Ifthe joint is too loose, lower the bit slighty 64 WOODWORK APRIL. 1996 Male joint—If the joint is too tight, ‘move the fence away from the bit very slightly. Ifthe joint is too loose, move the fence towards the bit very slightly. Note that these adjustments must sometimes be a paper-thin movement. Female Dovetails ‘The first piece to be machined is the top. Begin by anchoring the dovetail jig to the top blank, clamping both to your ‘workbench, and lining up the centerline that you scribed on the bottom of the jig with a pencil line that is drawn on the workpiece, and with the back edges of the jig and the workpiece even. Install « 3/4" diameter template guide and a 3/8" dovetail bit in you router. TTve found that I get the best results by using a rule of thumb as follows: The diameter of the dovetail bit should always be 1/2 the thickness of the stock bbeing machined. This will give the ulti- ‘mate strength to the joint. Set the depth to cut exactly 3/8" deep into you workpiece. Rule: The depth-of cut should be equal to the diameter of the dovetail bit. With the router running, ‘make one of the cuts, being careful to keep the base of the router tight against the jig during the entire operation. Slow and steady is the manner in which all router operations are made, but espe-

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