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    Wood Magazine Issue #191

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    Wood Magazine Issue #191

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    Wood Magazine number 191

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    Wood Magazine number 191

    Copyright:

    © All Rights Reserved
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    Download as pdf
    862 views67 pages

    Wood Magazine Issue #191

    Uploaded by

    bangbang63
    Wood Magazine number 191

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    © All Rights Reserved
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    rae h er) Better Homes and Gardens® oe Clamp Rack ps6 BOB era | Cope-cutting Sled |) re Picnic Table p.co eS) (SVointer/Planers Explained pcs OT g)Router Burn Marks p22 & Howto Flieee Wate 1+ (Fonts BASIC-BUILI 20 Make it From Scrap: Votive Holder 24 Quick & Easy Shelf Pin-hole Jig 32 Simple, Shop-made Cope-cutting Sled 34 On the cover: Glass-door Bookcase 56 Holdemall Clamp Rack Thisingenius system accmotatesany dam sy, and pack lta hash it coopaet pce 60 Outdoor Project: Picnic Table 70 Weekend Project: Jewelry Box 76 Turned ie Cream Scoop 18 How to Coil a Bandsaw Blade 30 Wise Buys: Cope-cuting Sleds 41 Choosing From Today's High-tech Screws 66 Tool Test: 12" Jointer/Pia Theme matings apa sk te 1Z widen the space of atypical oe Shop-Praven Products SawStop contac style am, Euto-inge boing ‘ing iter, and me KI J 22.3 Simple Fixes for Router-burned Edges 126 Secrets of Circular-saw Joinery 38 How to Cut Perfect Malf-lap Joints 50 Cabinetmaking Made Easy Save money by bultiag cabinets or anpaere inyour bam, No speci tol requie ‘61 Getting the Most From 2x Lumber 72 Learn the Bases of Bookmatching 74 Tips for Working With Brass Parts 6 Shop Tips 12 Sounding Board 14 Ask WOOD ‘2 What's Ahead July 2009 Athough common in Europe machines that bth joint andplane boards lok fevegn to many ofus on ths side af the pond. W000" magarine Tok itor Bob Hunter explain how the machines work and showchow easly they swith fren joining to planing and back at w ‘wondrtagarine.conyweodcuts Cen peeceete TUDE Jahn Steinbeck had a mitersaw dust elector aseffcent as ths dear acficshel bu by Seog Lito Prarie La. perhaps he wouldnt have writen al those depressing books, At ‘wondmagazine com shopshets youl find mare solution-iled shop photos PF CT PLAN aking for mare autdocr projects help you whe aay =E thesummes? At woodnagazine com/outdoo, yout find aren of plans fr outdoor peojects—from furniture ke {the bistro table at ef to yard structures to bichouses, Each shop proven plan guarantees your sucess. Woodworking guru Marc Adams answers ll yout questions about finshes, how they work, and how to succesfully apply them in this 100-minute video. Dowload it for anly $1995 for the Better Wondworking video brary at woodmagazinecam/videos etter Homes and Gardense wondragiine ccm Weasked our staff: mice - Sure aaa Sele st Dwector Ser Deg Eater « en CRS Rew NEE spyegemdee Techriqrs elor Tale Yc ior anda ‘SdewisoN BORMUNTER mee anion ta heehee Tat Mules Edie Multa Ete See ‘ea eames ‘UIEASFETERS CRAIG RUEGSEGER cut notin, eso Design Ky Auda At Dect sent “oF MeRre Re sels ‘innaaner cio Sean munon Prot apners [MARTY BALDWIN JASON DONNELLY DEAN SHOEPPRER. JAY WILDE ‘Contd ts TM CARL LORNA JOHNSON, ROXANE LaMOONE Tech Conaions JF HAL, 0006 WCxS Wheto ae “Conouing otonan RMA init torah Cotitsing eohessee GARSRLEM TEACHER UMSAROERS | ltt 1 RRR entene BARS PLERLIEA NOIR OAS | vel ‘unLennen ence ieee Go a mondmaganece tor wee ayia wooo agama: PO eat 358, Bose 3600039 ol eter wane ta B ROVERS AND MARKETING ‘BHERGD: TIEN Hig ee at 1500 Ona ODH (esau os Masecrg Manage AMANDA SAANOGT Odea et Ain Manages NEXSTAR y penetra Tecate ANDEAN rt Repos crn Repeating LSA GREENWOOD [Asse TIMBAAROA arn: Sige ec ass Manager AF STLES roan onsurner Markeg Brest TO0D WE sedate Asse Deter Mating ta TOM BORING Stage os re Producion Manage SANDY WILLIAMS ‘oro fete, seting Opens Mage MM RESON {commere Manane? MATT SATO Ver Freer Grop Pitney TOM DAVE eae Adminstration MME RGR Narfacturing BANE HESTON onion ay BRM MAL expe Ses MCRAE BRONSTEN Corporate Maing MAMCY WEBER esas BRTTAWARE hel eng ier MASEL New ls Marketing Series ANDY WHOM mei Tanariam — CT Marah 993-2003) ‘Darcie It occanerally aie walle to cry RTS (a wove pris iby be of bait to ou. you pe Bk ‘sce ination rom these companies by all by ae ease [ecus iow San yourreuest ng uth yur aling belts Magne {Castner Sart, BO. Ban 37482, Boone 1A $0037 0452 Sr pas OP ee UE abtntnniad Eten & ten une ope Eee Ihesuinyemactiocnmerti YOUR CUTS od te tyr sas aut cher The al frctee. yourlage eeu and pn Becate youre messy ard mary each iin orgie separate your geting ral naresterens wah supe ater cae assay tre. Os reciente Grease anceps you ‘rake patsy caer im anor Sev eanteance ‘The modern replacement for your tape measure and pencil. Unleash the full potential ‘of ALL your saws! 4. cen tana sontence (re encarta ys bene patr gam nr ‘To see these products inaction. ‘visit us online al we kregtoo! com. Shop Tips Helping you work faster, smarter, and safer Instant conversion: tablesaw to downdraft table Here's a quick and easy way to add a downdraft sanding table t0 your dust- collection system. Cut two pieces of hard. woe to Yond Vol8", Then cur two cross pieces from 4" stock and assemble the frame, as shown, topping it with, peeforated hardboard, Lower the blade on your dust: collector.connected tables, remove the throat plate, andl center the dawn- draft table over the opening, Turn your New spin on finishing tables came up with this rotating stand when it was time to put a finish on table. Made from a lazy-Susan bearing sandwiched! betien pieces of Yoel2*-diameter ply wood, I gave it more reoch by ataching Kour pivot extension arms, The arms swing ot to ‘dust collector on, and you've got an instant downdraft table perfect for sanding small parts, = Perko, Mercer Ws hold large projects, and then fold up to stow away. Now I don’t have to-walk, around the workbench; [ simply ratate the workpiece without handing the fresh finish, And I'm abways looking at the project from the bestlit angle, —Homy Orme, Gombe, Ort continue om page 8 Mite Cy tei lg Ed Perko went from being surrounded by people (while helping Fortune 100 ‘companies with emplayee relations) to being surrounded by trees in semi retirement on a laketide acreage. ‘There, he s the model of self sufficiency, clearing the land to build his home ond harvesting trees for the furniture projects he creates in his basement workshop. For submitting this issue's Top Shop Tip, ‘we'llsend some Forrest to Ed's shop inthe woods. A Woodworker, Dado King. and finger joint set are on their way. Edi Pathe. Tell us how you've solved a works stumper. If we print it, you'll get $100 and a copy af 450+ Best-Ever Shop Tips (voodmagazine.corn/450tips). And, Hf your idea gaeners Top Shap Tip honors, ‘we'll abo reward you with a 450. Fs on {ool prize worth atleast $300, 3 ae ee ee 2 with photos or drawings and ‘your daytime phone number, to: Shop Tips, WOOD ine, 1716 Locust St, LS-221, Des Moines, 14'50309-3023. Os, by ‘e-mail: shoptips@weodmagazine.com. Include your contact info in the e-mall Because we try to publish original Lips, please send your tips only to WOOD» magazine. Sorry, submitted ‘materials car’ be returned. WOOD magatine jy 2000 BORNE “Sg, Wood Products, Inc Custom TURNINGS! OER eT ea ‘ond craftsmen with unique wood turnings, table | PC Ree mC TODAS IRC Send us your designs and we'll work with you to create the ‘turning you need. ) F Moking your 7 designs into quality, finished turnings — for your custom projects, SO gsc about promotions, naw products ond waodworking tps ot worw.osbomewood.com Tips Just take a little off the top To avoid running a delicate piece, such a potentially destructive planer, [found a secure the piece while sanding it to thickness, [clamp a Sato recess foutedinserap aking the serollsawn Ch 2007 Issue (0. 180), E + than deal with messy sp 8 WOOD magarine ly 200! eT CN A Mini-Gorilla.” ... Micro-adjust with masking tape Ww NEUES TT CSTs TU BTA a ) a Separates even the fines! sanding dust! Pa) ROTO ETC ey Pe ACT y Oneid ae ha Solving Your Dust Problems Since 1993 Pcie ee TREY Shop Tips Shop-made panel clamps Because I do a lot of frame-and- panel door glue-ups, my harizontal shop space quickly gets taken over by clampedup boards. | can’t afford pricey store-bought stackable clamping systems so | eame up with my own version made from hard maple because of its strength. Heres how Ido I: cut all the parts to size, presdril, then attach the top and bottom to the two ends, | glue and clamp one of the Sex Dari hardwood ends rails in place, Then, I combine the UUnreaded rod, clamping binek, coupler, ruts, and clamp assembly, before gluing ‘on the second ral, Finally, Lapply paste wax or masking tape to-the rails to protect them from glue squeeze out ‘To use the stackable clarnps, lean either screw two clamps toa plece of plywood (as shown), of clamp them down to my workbench, making sure they are square and parallel with each, ‘other [assemble a ghuc-up In the | clamps and use a socket-equipped ‘cordless drill to quickly tighten down | the clamping block, Then E finish Aightening by hand with a socket set. T ean stack the next set of elamps on ‘top of the first and bolt them together ‘witht 4°420 bolts through the end holes. I'm limited only by the number ‘of clamps I build. ory Shee, Han, Nr ker tecary is (WOOD magatine oy 209 Avoiding nail blowout: straight to the point Tread with interest the answer you gave about avoid hall guns WOOD (issue 180, page 92). In my expert cence, whether i's grain oF knots that deflect the nail, a little knowledge about {the nail you're using Is key. Use the tricks shown to guide the nals deflection and avoid blowout Dovid Sch, Medi Ore PNEUMATIC BRAD NAL Nallpoints are chooed Side to side sa nal wail ‘generally Getic eto = PNEUMATIC FINISH NAIL Nudpaintsecipped front ra back so alli! peter detect otto ate Wold naitgun pale ‘with board edge Wossmsgazinecom " FEIN Mutt The Num remodeli \ For over 40 years FEIN has been making osilating tools for professionals and handymen alike, and the FEIN MUuniYasrex is the mose versatile, German engineered and manufactured, che high power motor Is designed for heavy duty, continuous use and operator comfort. A wide selection of accessories Is available for every application. For more information, a free DVD, or to see the complete line of Mu.tiMastens ata dealer near you, cll 1-800-441-9878. or visit us at www.feinus.com. ; ¥ Sounding Board Our bulletin board for letters, comments, and timely updates It’s two ... two ... two doors in one! When designing the door connecting the sunroom and living room in the house he's bullding for hls family, Rick Musselman had a problem: He wanted sweeping “organic” curves on the living-room side and a more traditional paneled look on the sunroom side. He Settled on both. Rick's ingenious solution won him a trip to Italy from Freud in the 1OOD* Magazine Interior Door Contest. ‘To match the different trim in the connected rooms, the shop-teacher- cum-schooladministrator designed the door as two distinct halves. He con- structed the living:xoom side of the door tf right from cherry and maple, then enhanced the organic laok with, chip-carved vines an! leaves, The sunroom side (ew right is constructed of pine, and the two hatves are pinned together with walnut pegs and butterfly ey (below lef, ‘The split design serves function as well as form. Because each half is thick, Rick used common router bits he already had in his home shop. For submitting the winning entry, Rick will take his daughter Erika on four-day, three-night trip for two to Venice, They will be treated to a boat tourof the city as well as a tour of Freud's headquarters in Udine, Haly, by President and CEO of Freud America, Russell Koh. ‘An educator tothe core, Rick is excited to win the contest, but he is more excited by the prospect that fis design might inspire a younger genera- tion of woodworkers, Good work, Ric See more of the exceptional entries in Editor-in-Chief Bill Krier's blog post at wood magazine.com/doorblog. (For wocdworing advice, Fst your wedwerhng questions ney. ishing. too ming. gene woodwork }on ene anne rust woodenagusne cr/erums. I To contact ou editors: Se your comments vine \woodenall-woedmagazne core wie to ‘Wo gat, 1716 aes, 15-221, ex Moines, 145009, ( Sebscipton asitance: Toney usclan ates urge ea gt eth your baci vi Cr wt t WOOD magaie PO Bor 37439, Bae I 5037-0439 Pease eco your ates Libel froma recent magi be. 1 ond past articles: See ourindexatweodmagnzinecomvindes, comers, (io onder pastisowes and artes: Cher patie of 0 mapa cur speci, cx doll aries fren ue 0 ese it car nl ve a voodeagainezomitore, Samm sues ae si ut. [WU pdotes to previously pubshed projects: Fer anup- date ng of angen ders ad beying geile ures fom be hog dy, pte woodmagesinecomiediterial. (WOOD magatine jy 2000 Ack Ask WwooD Answers to your questions from letters, e-mails, and WOOD Online Are wooden illegal? Ad oto test all the toys I make for my grandchildren to ensure that they're lead-free. Ican‘tafford that. What can you tell me about the Consumer Product Safety Improvement Act? —Homaid Achesén, Southport, N.C. f no need to worry about the toys that you P¥e mate for your family, Howard. However, if you sell toys or other products intended for kids under 13, you might want to take a closer look at the Consumer Product Safety Improvement Act (CPSIA). Passed by Congress in reaction to lead-laden toy: feom China, the CPSIA requires manufacturers to test and evtify that any products intended for children aged 12 and ‘under meet the federal content requirements for lead ane, phthalates (a chemical used to soften plastics), Costs for th third-party laboratory testing can range from hundreds to thousands of dollars which has stvall manufacturers calling, for fast reform before they are forced to close their doors. The Consumer Product Safety Commission (CPSC) has been charges! with instituting the procedures necessary for compliance. Flooded with questions and concerns about the new law, the CPSC Issued a one year stay of enforcement, pushing the deadline back to February 10, 2010, to allow sme for clarification of the rules. ‘The lay, which initially passed with ease now has Congress squaring off fora battle with several members calling for the resignation of CPSC Acting Chairman Nancy Nord and others drafting legislation’ to reform the CPSIA, It's too carly to predict the outcome for small toymakers, but keep an eye on the CPSC Web sit epsc.gov, for updates. Hidden fees for hidden metals (po The oldmaple tree thet fein my backyards A e just too good for firewood, | the sawyers: I've called seem reluctant to come milll it for me. They quote additional charges inthe event of blade breakage. Should! have to pay fer thelr equipment? ino Feing Riverdale NE A A broken-blade fee is fairly common for sawyers Pro operating portable mills, jimmy. Especially when milling “urban® trees, which considerably raise the odds of hitting embedded metal Did the maple ever hold a treehouse? Has ¢ 10 iL? Did it live along a fenceline where it absorbed barbed wire? These questions are often impos le to answer because trees Large enough te hold useful Jumber are also-ole enough to pre-date their current owners, A one-tree job probably doestrt carn the sawyer enough to risk the expense of a serlously damaged blade, so you ene! up absorbing the cost. ailed a clothes 4 VE A QUESTION? Foran answer to your weedworking question, write to ASK. WOOD, 1716 Locust St L5-221, Des Moines, IA 50303-3023 ore-mall ust askwoedewoodmegazine com, For immagine feedback roe your lellow woodworkers post yout questions on (ne of our woodworking forums at woodmagazine.com/forums We discovered this 38 bullet embedded ina piece of “urban walnut when cutting the wood downto site onthe tables. Ifyou take the plunge and hire sawyer anyway, spring for a handheld metal detector and thoroughly inspect the lumber before and during milling to prevent damage to your own blades or yourself after you start working the wood In. your shop. continued on page 16 WOOD magarine jy 2000 Ask WOOD fralted maple: ‘s what's for dinner jel'm going to make a couple ,2 of cutting boards for family members. Isit safe to use spalted maple where food will be prepared? —Seote Fleming, Barrie, Oat. Aw question, Scott. The dark lines prized in spalted wood are caused by white rot fungus, What the fungus adds in beauty, however, it takes away In hardness, leaving behind soft, punky areas. So right away we'd advise against using it for cutting boards, ‘Whaat about for kitchen items, such as spoons, bowls, and platters? Because sawdust from spalted wood has been: Known to cause severe respiratory or skin reactions, many woodworkers know to take extra precautions, such as. supplementing a dustcollection system a properly fitted dust mask, working with it But does the dang contact with food items where particles fram the wood could be ingested? According te Tom Harrington, professor 16 Random black ines make spalted woed attractive, but can leave soft zones unsult ‘curting boards, of plant pathology at awa State University, the white rat fungus, Hypoxylon deusta, that most commonly ‘causes spalting is not toxic, The lives on the outside of the eee and sends tendrils called lypphae into the ‘wood fo break down the plant an gather nourishment. To protect them selves and their rotting food source, these tendrils produce a protein coating ngus that creates the black lines in the wood andl likely causes the allergic react ‘and irritation when it becomes airborne ‘and lodges in your lungs. ‘Once your wood ba however, the borne protein subsides, est its just going to get digested like all the ‘other proteins that you eal,” says Harrington. is complete, ‘wooo magasine uy 2009 Of course size matters. That’s why we make so many. We've got one in your size. entitled to ObeyCrade!* ‘and 278 others just in case. At GRK we think everybody is Whether your jab deals with wood, metal, eanerete or vinyl, GRK makes an OberGrade™ fastener that enables you to get the job done right... the first time around. IRKFASTENERS- iberGrade THUNDER BAY, ONTARIO, CANADA 000/263-0463 - GRKFASTENERS.COM WW Beveled bottoms for oversized tabletops ve glued upa large tabletop and | want to cut bevels on the underside to give it thinner edges and a more delicate look. Because of the size and weight, I don’t think can manage it safely on my tablesaw or router table. Can you help? = Plane up to AIS wide by 9 all Joba Git Te Texes | I< Roarside planing end moultng of materia easuring os arge Start by constructing an auxiliary router J ise fence mounted to one ede, ' J - 2200 epinde speed “Getteraellleierestedl ie ‘ven tor . © 11-52 FPM variable feed «peed Using double-faced tape, attach one rail tothe edge of + See through top guand for view your workbench and slide the table against i as shown ing altrbeads in acon below. Tape the other two rails together and attach the * Compact machine dimensions: stacked rails to the tabletop about 6” from its edge. (You pene can alter the angle of the bevel by changing this distance, With a straight or spiral bit mounted in the router, make a pass along one end of the tabletop. (Starting with the + tearout on the edges) Double-face-tape a Me spacer to the jig’s fence and make another pass. Con. he step-andl-repeat process, adding spacers an 1: passes, until the bevel is completed. The bit will some of the beneh-mounted rail on thi rotate the table, remave the spacers from the ig, and repeat for the apposite end and then the edges 11 the bevel smooth with a sanding block or Jom-orbit sander. chiree Woodworking Supply Inc? Soe tas Gea ou see ae Leet wit) Oe ree eure Cen era T ey Asyou adel spacerstathe ia, the bieeuts more ef the bevel, ‘gradually and safely nibbling away the wood, woodmagasine.com 7 coors a Shop How to Coil a Bandsaw } Blade Quickly and safely condense your blades for convenient storage. Watch this technique in action at Wwoodmagazine.com/videos Hold the blade in your gloveahand as shown, with the teeth facing ‘vay form you, Uses fost to hal the blade tothe floor youhave 8 ‘concrete floor, plac cardboard underfoot to protect the teeth : aT ee i J 3 J mone mation, push the blade dawn as youtwist your hand ahall-tum... then continue pushing down as you turn your hand anothethalf-turn, WH Gather together the three loops with your free hand andhold tightly. Securethe Blade in olled form using a binder lip or masking tape, ia WOOD magasine jy 2009 Uncoiling a blade: Spring forward, not back hold one outigsblede col. Exerdyour erms very om your body and spread yo Romjou wnssiony reed sspoucerthue wunced me case Aine esto sealghin Keep yourhands low te protect your face fromthe blade, blade wil into-one big loop, sodon'tbe startied. Wossmsgazine.com 19 Breathe Easier with a , : One Stop Dust Collection Solution With 20 years experience and a superior product line, the experts at Penn State Industries ” will provide you effective solutions fora cleaner shop. ‘2.SHP - 14500 - $905 ‘3.SHP - 1TOOCFM -§1125 S5.0H® - 18000 - $1305 Pipe fr maximum artow Fittings and hoods for most applications in layout of your shop to save you hours f planing Vildo High performance bag-style coletos, a cleaners and rable collectors ideal for any size home shop Penn State Industries Scrapwood Solutions Bright-Idea Candleholder cmbinesalvogedtitsofcxotic Toslapapikasolnta ed, you ca php a ne uc the nga tate Consnittre at chery ame bore. Orgowith single wood suchas the mahopany one bore ight seme 8 holder special ow One blank yields six parts From 4 stotk, cut 24165" a — blank for the top front and back (A), fouataccurnne Lavour r top ends, and top tri (Cin this ote: From each ena ofthe bl [Orawing i, crosseut one op Jength [Materals Lis, pase 28]. Th the top font ard back from opposite edges ofthe blank, From ach blank enn cut the top ends, Use marks on the top surface as shoven brio, to organize teen — ay ra pats as they came from the blank. seesaw ' Iuethe front and back A) tothe stant ae ends (1) [Drawing 2). After the glue oanermt, s, rout 4" round-overs along the undersides of the assembly ends (A,B) is wotive candle- = me Bhexpconen view round-ver OY rund over EXitor trim 7 Partsorganized in their original order ereate SECTION VIEW a frame with an unbroken gain pater 1 rabbet "deep 0 WOOD magarine jy 2000 Cut the top trim (€) to the same ‘widths the top assembly (A) width. Refer to the Shop Tip right to rout rabbets and round-overs on th undersides [Drawing 2a] Sand the top: assembly arid top trim to 220, Assemble the base Cat the base (D) and base sides (E). ‘Then machine Yi" rabbets Ys" deep fon the endls of the base and mating jgrooves on the base sides [Drawing], Sand the base and base sides to 220 grit; then glue the sides to the base and cheek for square. (Center the top assembly (A/) on the base assembly (Dy/E), and clamp jogether, Drill countersunk shank holes in the top ends (8), and pilot holes in the sides (By, and screw them together, Glue and clamp the top trim (C} to the top assembly (A/R} [Drawing 2] Make four copies of the leg (F) front nd scle patterns from the WOOD Pattemse insert, and use spray adhesive toattach them to Yox1%ex10" blank. Banulsaw or serollsaw the legs ta shape, and sand the edges to 220 grit. endeaapacina cos rote upeson hetgs occ | TT hwo left and two right legs, Saw just ‘outside the taper mark, and sand to the line up to 220 grit. ‘Gllac and clamp the legs (F) cen. ered to the base sides (F) [Drawing 2], Sand where needed to 220 grit, ant apply a finish. (We used three coats of satin polyurethane, sanding with, 320-grit sandpaper between coats.) {ten by Bob Wilson with Kevin Boyle thusteions! Ronanie LeMlne: Lorna Hohason Materials List ‘payed ois Sorte aration. Materials key M-opleft-red hea. Supplies 33 fathead re, Prete aalable wordt and gh so. Mis: rac one round owe, ‘aibetng it Rout small parts sa Double your safety precautions when routing small parts, In a Wi-thick sheet of plywood or MDE, dill a hole slightly larger than your it diameter. Center the bit attach the sheet to your rauter table with double-faced tape for a near-zero-clearance sup- port. Then clamp parts between the Jaws of a handscrew placed flat on the sheet to keep fingers well clear of the bit. & xe ly 2 MeL ec Leeming ty 1-800-377-7297 * www.pennstateind.com Fixing W Make Router Burn Marks Disa IPP, Don't let router burns become a black mark against your skills. Eliminate them as quickly as they appeared. thought you took ev proofing precaution. The ‘wood thought otherwise, And Judging by the scoreh marks on that freshly routed edge, you lost. The only 1g worse would be repeating your ke, 30 lets Figure out what went wrong before we fix the damage. Care beats repair Farst, check for the usual suspects Too much speed. Fast-turning, large bits generate wood-searing, heat, Back off the speed control to sult your bit according to these guidelines: Maximum RPM 24,000 18,000 16,000 12.000 rkshop Goofs & Bae Heavy passes. Take off nom than *%4" of material with each ppass—lesson the final one ‘Slo-0-0-0w paces Io avo hie build-up, feed stack as quickly as possible without leaving chatte Dull bits, Re that have lost th This time for sure Once you've identified the cause, make the symptoms—burn marks—go away. searches, as shown them away i abrasives up D grit If you'll through 180 ge add stain later. Fordark burn marks, rout a fresh profile that removes a thin layer and the burn marks along with it. First, using a hand plane, remove one or two ‘curls from each edge that will ride along a router table fence or bit be fasshown bottom center. It you don't havea han! plane, you can, instead, make a light shaving cut on your tablesaw, as shown above. If you're using a bit with ne bearing ‘on a router table and you can fuelge th part size a hair smaller, move the fence ‘back the thickness of a piece of pape asshawn bottom sight. To do this, clam ‘top blocks to the router table tight against the fence. Loosen and move the fence back enough to insert a piece of paper between the block and fence. Then snug the Fence tight against the paper and stop blocks. ‘Now remove the blocks, and rerout the part at a faster feed rate, This will remove the burn marks with only. minimal change in the part size. Profile sanding blocks help you remove light scorch marks, But you can get equilly good, results using only your fingers. 22 Ablockplane tuned tomake shavings thin — ‘enough to see through removes enough material intwo passes te rout away burns, ‘Backing off the fence just a halr andi necessary, nudging the Bit height up the ‘Same stance willerase these burn marks. WOOD magatine jy 2000 Quick & Easy Jig Shelf-Pin Drilling Jig A foolproof accessory for perfectly positioned holes. he challenge with drilling T shelt-pin holes: aligning them perfectly so the shelf rests level and docs Inexpensh gives you a spoton st column of holes, then automatically positions the remaining holes by registering off the last one drilled. Assemble the jig from scrap stock as shown in the drawing. Lay out the ‘entexpoints for the three evenly spaced holes, The outside holes must be equal distances from the ends of the body. Center the middle hole on the length of the body. Extend a line that passes through al three centerpoints onto each end of the jig to help align the jig when using it. Using brad-point bits in your drill press, carefully drill the holes. Then press an insert and bushing [sce Source] into the center hole to prevent wear from repeated drilling. Find a 14? bolt at least 1" long, and the jig is ready. When laying out the shelf-pin holes fon the project, straw a centerline for each column of holes, as shown in the photo, The distance of the shelf-pin holes from the exlge of the panel is Vtrock, Thanks to Find more shop jig plans at: woodmagazine.com/freeplans * a determined by the Simply tape a spacer to the i toe, else every set of oles will be misaligned, and a shelf will teeter ‘no matter where It’s placed. But don't worry—the [ig gets all four columns off to a perfect start. For the bookcase on page 4, we aligned the bottom edge of the jig \with the bottons edge af each panel, then drilled the first hole. ‘To start the holes farther up a panel, cut a spacer of appropriate thickness and place it below the jig. Hold or elamp the jig to the nel, place the dell hing, and deill the first hole Usrough the jig inte the hole just Grilled in the panel, ancl drill the second hole, Repeat this process to: holes. To drill holes “ni the remain from the oppost edge of rotate the igen for en. WSs hls eh te Gisoucuesaeeenan | in each column mist align exactly with ts three mates, oF | en slide the jig up, drop the bolt —~siihettpinnale vee ras" | ha mse i 1 it “be Ls Source inate 20820 925 hing. no, 29, ‘S29 ee Vey 0-7 FSIS eeleycom (WOOD magerine Distance rom edge otproject ta canter bay 3000 Just-Right Joinery Cut Big-Time. Joints with a Small-Time Saw {your dela sw leoes the sel [aman sheets plywend 10 rough ty to dado tabla, suchas the pn table parts om pe Sar by pepo 40-tooth regular-kerf blade. Then set the blade 90° to the base plate. ‘Next build the cutting guide shown, befor. Measure from the lett edge of the saw base to the blade (when viewed from the top, add 14", and glue the fence that distance from the right edge of the guide. Glue a cleat 90° to the fence on the underside of the guide, To prepare the guide, place it.on a plece of scrap clamped to your work bench with the right edge overhan the bench, With the left edge of the Circular saw base pressed firmly against the fence, cut off the surplus 4", Now you're ready to start cutting joints ing Remove waste quickly using kerfs Ifyou have multiple workpieces to be laoed the same, clamp the for uniform cuts anda stable surface to support tive guide, Mark where te lao wil start, tien use the mating workpleoe to mark the end of the ct ‘Next adjust the saw blade to-cut the clado- depth plus 15" the thickness of te guide base) Here we're cutting a 90° CUTTING GUIDE FOR CIRCULAR SAWS HARDWOOD CAEAT vex ts This guide handles most oinery cus. but can be downsized for smaller jobs. you're ma cextra-deep cuts, reduce the fence height from 26 Equalto distance from let edge of saw base tothe Blade plas No" to accommedate the saw motor dado as deep as the mating workpie thickness. Test cut a serap piece to ‘confirm the depth. To begin cutting the dado, slide the ‘guide edge to the left-hand mark [Photo: ‘Al. (Clamp the jig to the workpieces, if necessary.) Place the saw base against the fence and make your first outside ccut, Then slide the guide toward the ‘other cut Hine until the right ig base celge Isa bladeawidth distance from the righthand mark, and make the second ‘outside cut [Photo 8} With the joint defined, mow cut kerfs roughly every 16" te 4 apart between the outside kerfs [Photo¢), You can make the kerf slightly farther apart for softwooes, such as this cedar, of closer for hardwoods, such as white oak. continued on page 28 Ey OOO utside ~-eidge line: = ‘After rimming the jig ta size, the right edge Indicates precisely where your blade will cut ‘Slide the edge up to your (WOOD magestne jy 2009 Just-Right J Slide the jg slong ae you saw awaywasteto-Anudge with your fingertips breaks off the keep cutsat aunitorm depth and providea waste between the kerfs, Most should split sable surface foryour saw, lose to the bottoms of te herfs, Cutline. Allow fr the Blade width when saving atthe right outside cut lin Clean up the cuts Alter the final kerf cut, use a ham Or your fingertips (Photo ] tot ‘waste off as close as possi to the bottom of the kerf, Clean up the leftover waste with a chisel at feast 1° wide, Place the chisel bevel side up on the smoothest portion of the dado and y shave off the waste [Photo You'l stil have score lines from the alternating-bevel tet of the blade, the surface beter the matks shoud be smooth The mating workpiece should fit snugly into tine dado without excessive force [Photo FI t's too tight, shave one ski of the dado with your chisel or Sand it using a scrap block with 100-3 abrasive on. one edge. Then glue and ‘Shave away waste with your chisel. working —__- You may not achieve the perfection that’s assemble the joint reinforcing it with fromese eutsde taward the middle toaveld | posblevitha rovterrtablesav, but 3 fasteners as needed. ® porsble taro ‘eeular saw can cu tgheteting Joints. the Use the same jig and technique to cut angles Not all halfaps or notches requite a 90° cut, but you can manage any joint angle quickly and easily ' modified version of the 90° jig. Instead of attaching the fence at 90°, angle and center it on the jig base. Depending on the angle, you may need to extend the fence at the front of the jig to help aiga the saw bate. Use a sliding bevel and protractor to set the fence angle. To give the sw 3 firm footing at you start the eut, move the Underside cleat in 1° from the edge so the jig base Covechangs the workpiece edge. Then make the cuts between your lines as you would for a 90° joint cut 8 W000 magestne jy 2008 Wise Buys Why buy? Our Experts Test I Gac aneata eae ot ere nel asi econ coer stick joints must fit precisely to ensure square, gap-free doors. To pen enc enna ean cates ey ene seco anion tei oat ue lacie pee Te tcl fe eee along the table's fence, which is set flush with the cutter's bearing, Celeesece nesta caer eee Oo Copin SieHs S CREE Editor test-drive: For probably 95 percent of the work you'll do with a coping sled, this bare-bones phenolic made i all you'll ever need. Its. abrasive-coated base and single, adjustable clamp securely bald stock from ¥/" to 14" thick. Ifyou need to ‘make coped cuts on stock wider than 344" ‘or langer than 18%, you should opt for the larger MLCS sled (#9546, $85). You ‘can buy replacement backer blocks for each ‘model, but is easy tomake ‘your own from scrap wood, To learn more: 800-533-9298; mleswoodworking.com —Tertd by bab Her, Took & Techniques Ee EAGLE AMERICA, #2100, $80 Editor test-drive: Eagle America makes three coping sleds that wark similarly, but this rigid plastic model isthe one to buy. Its duapad adjustable clamp provides better workpiece holding power, and there's a front guide block for extra support and two easy-fo-grip handles. What | ike best about this nearly 16'-long sled: It glides smoothly over inert plate—which ‘always seems to vibrate slightly out of level—in. my router table, producing, perfect coped ends. To learn more: 800-872-2511; eagleamerica.com Teta by Craig hueprgaer, Mukimeda tase 30 rather make your own sled, youl find plans for one on page 32. ROCKLER, #26595, 560 Editor test-drive: For $25 more than the MLCS sled, Rockler offers a larger phe- rnalc base with nearty double the width capacity, and a front ‘guide block to sandwich the workpiece Against the wood backer block. You also geta larger clamp pad and a front mounted knob for two-handed control (One knock: During assembly, had to deepen the countersunk holes for the handle ‘to fully seat the serews and prevent scratching my router lable, Tolearn more: 800.279.4441; rockler.com Tested by andy Zimmerman ony uid stom tartare and cabinets NTE Editor test-drive: This sleek aluminurn sled is the Lexus of coping sleds. Its three ‘lamps can adjust to hold the workpiece and vrood backer block, which makes changing backer blocks quick and easy, The large, comfortable foam-covered rear handle dampens vibra- tion better than the others. A clear plastic chip shield mounted on posts Fides againet the fence, providing 3 We offset to keep the aluminum base «lear af the bit, However, vyour Fence ust beat least 37" tall to engage this shield if nat, you'll need to ad Staller auailiary fence, To lea more: 877-872-2487: infinitytools.com Tested by Bb Hater WOOD magarine jy 2009 Great Ideas for Your Shop Cope- Cutting Sled Rout rail ends safely and precisely. rocesold suppor: system hes A rout all ends char ighly fio andokt-donne designed nto weir replace afer broming to Gren ee cut sceep dato wide tthe Sout ru oat he router top To eope the eno ral ut the sere the bt hghes than I ou wet cuting the ate on the router tabletop. Clamp a scrap piece of stock the same thickness as your rails ae eee cat een seeac conumnonicats he st your previously routed cs, and adjust the height of the necessary before cutting your rts Project evan: Red Com, ME Pleat tow Get more FREE plans at: woodmagazinecom/freeplans 32 se dare 44 Fong wpe 1" deep. centered inbortorn 2 < al backer stip << Tooale elmp | rox FH. Ww deep | hank hole countersunk ‘onbottom fave wcoumatore w'deep “dN ithe shankhole “Be MF, wood snd certian Fr ariililemctiowe WOOD magarine jy 2000 Dae eM el ES TN oe Ed age r ~ ba —= oll : ee) Se” © mi, Clampa stopblockto the outertablefence Reposition thestopblock, and plungethe _Couls provide fat surfaces for clamping the ‘DE Hromtheleftedgeot the bit Routae’ —_secondbblankonto the bit The blanksendup front stlles(€). The inside faces of the stiles grooveinonlyoneblank withthis setup. anmmerarimagesof each other. (C.D) and side panels (A) should be fash O:: you finish soaking up the handsome look of this project and begin to examine its con struction, you'll discover how simple it isto redwood gi lends the appearanceot sides without the need for cutting diffi- cult joints. Half-lap joints cut on the tablesaw ease door construction, Mul lions adhered to the glass create the look, of fourpane divided-light doors without the pain of fussy moldings. Start with the side panels Cl the case side panels (4) to size [Materials Uist. pase 40, Row and 2 vec228" Ula to get tw Me thick blantsy ther ut the panel trim pices (B) to length from these blanks [Drawing 1], Quick Tip! Stop shee @ Syocrer-ov. Use your ticey to cut © Stllow glue-eliet grooves In the back face of the panel trim pieces to trap ghie before it squeezes out onto the face of the side panel, Giue the pane tim pieces to the side panels, flush with the top and bottom edges. To mate the front stiles (C) and rear stiles (D) start with 6/4 or 8/4 lumber {or laminate wo Lyers of 9° stoce). From thismaterial,cuttwo N20 Blanks. Postion the tablesaw rip fence groove Wr deep centered ue grooves ne Geep,W fom edges Hisioe assemary (RIGHT INSIDE FACE) ¥* from the blade, set the blade "above BJ STILE DETAIL [SIDE DETAIL the tabletop, then cut a kerf in one face a om of each blank, and in oe tl He Fe Fence the scrap te widen the groove. Test the aut sy Rett round over it ae B woedmagarine.com 35 CUTTING CENTERED STUB TENONS IL MARK GROOVE POSITION ON RAILS ML SPACERS KEEP IT SQUARE y epee 4 ef a a ae > 6d ‘Cutserap spacers tofit between the ands (Pi.Useasquare andacrafts knifetotransfer ofthe back rails (F). This prevents

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