_ THE MACAZINE FOR HOME WOODWORKERS Re fa a CONSIDERING A BARRISTERS ga cla ola BOOKCASE... Pac Re aeRO ‘, to select the right one BOOKCASES ) s AND SHELVES » Construction methods, ? materials to use, and ; planning pointers ft (see page 58) es celeiciaig » MOLDINGS cg ena a your hand at ia san) iy alee ae Ug d ea asee eae Ta and-sawn boxes =< J. i ice j f ...AND THIS es spice jars - MATCHING FILING CABINETBetter Homes and Gardens: ier Lay CLANTON Hanging Estar CHARLES, SOMMERS dst Drecor.L CATIKE Design Eater JES DOWNING feats Eat PEER. STEPHAN HowTo ior MARLEM KEAWET Euan festnques Et: JM BARRETT Fret Buller IAMESE, RO8LNG Cape Deige PERRY A. MARL tance Sopetat OAALENE REYNOLDS. _Bushess Otce Gk sO KOEP#EL_ “een Oonetane: GEORGE GRANSETH Pod “evn: PAULL. NeCLURE Woe Teloor uber JERRY WAPLAN Nata Ader ananer MARK. S. KART Aaverin earesetatnes JMR BFLLUARDO, ‘ANTHONY IMPERATO Maietng Series Bnacer HANCY DALY Pramaton esearch Qrezor THOMAS 8. TROLAND Giron Orectr WLM HUME, Gielen Mossqy BLLAEED Proscion Ore OALESCHENMELBENG Fein Reser Dict C, RAY EATON. Magala up Oces reo Hesitent JAMES A AUTIV Group Vie Presets Fublsteg Dresors ADOLPH AUERBACHER, ‘UTON I BDERSNA | estos! Director DORIS M. EBT (peas CHISTOPHEA M. LENIN ‘paral ews Chsimn otaortE-T WEREDIH resin ADBERT A. BURNETT cate Vie Presint— Corals Severs ACK D. EAM Sioup Pein Mugazne JANES A AUTRY road- ‘aig M,C. MeREYROLDS; Nel Eas ALLEN L EADIAG: Grok FRED SNES Vien Frosiest: Cypeate Restons DONALD L. ‘ARNOLD: Cera Course! an Asian Seay THOMAS G. FISHER; Prod Dendopmert NEIL KUBHNL; Govpante Planing HERB SCHULTE Finance WELIM H. STRAN Amst Ser ‘ets GERALD, THORNTON. “hesuor MUCHAGL A SELL Cone LARD, MARTSOOK Sees noes WOOD MAGAZINE FEBRUARY 1ome 3 Own this classic “Roll Top” OAK DESK from our pre-cut partially assembled Kit. rn-of the- -Top” you've Here's the century Re always wanted. A full ‘ize oak desk (oak ant oak: ener) ov Jou a xtaoctoy vig Ree ju “urs em pre pus, No special tools de, Whe inked Son pomess = magaiiceh rowplece for our none arse —* wath ea tie sat you paid forthe it Send fr detas tithouteligaion 1 pres sin ny fis Caftsman's Comer cag earing he Cl oll Top Dk day oir guy aio 1 xin sane ‘ates — to The First REAL Universal Woodworking Machine Built: Senne oUt easel ieee sais 1 EXOLUSIVE. FEATURES: + Ala ba Teefasan iste ech) + Hoyas ae, drops HP + avaalVolage ivezan zilch + Asin lnk + Spode ot 20 ML 1 ANE Rasen er ened ‘tin eps ta pect be machi) + Rear notin ana obot acne * Fre reusing ae bo cesses Hany peru * Wise ge ms gat + Sates wh 2t<0t + Heaps sls wih rs toe expel = ntl On Ot Sh * enya tar + Side Lethal ar fnd machin? Hele * Re meunange pet + Stag! ginal uingten oder Teena" soto CALL NOW (800) 421-2067 | yous VARRANTY ON WOTOR [Gave Foate ah ro tha rtrior pia iyi] Call. Res: (219) 549-0761 | ' MASTER WOODCRAFT & MACHINE CO. 400 SPRUCE LAKE DR, ?. 0. BOX 69 | %———#_—_*& | HARBOR CITY, Ch SOT10 [Bite eelNew = ORE Eee NEW ER AND INCREASE FLOOR SPACE MOBILE macHINE: BASES Ne } eee li eeaeacas SS =a PLANERSTAND WITH ROLLERS = Better Homes and Gardens. @ *cuner eval grs indeve maple FEBRUARY 1988 WOOD PROFLE RED ALDER: THE WEST COAST'S WEED TREE 33 GOES TO MARKET Once considered a nuisance, this prolific hardwood has earned the respect of many woodworkers ast low-cost, easy-to.work Wood. ISSUE NO, 21 TOOL BUYMANSHIP PLUNGE ROUTERS — GET DOWN ‘TO WORK WITH ONE OF 4 ‘THESE NEW-BREED TOOLS b ady own. router, there may be a plice for one of these versatile tools in your shiop. Our tool experts discuss the features to look for, and we've included a handy buyman: ship chart ONE MAN'S OE-MAN sawauns. 40) An Illinois Woodworker lives out a dream many home craftsmen’ his own lumber on his own backyard sawmill, ROLLERTABLE fsck Sota Subpart é an REATaETOST Aan unimie Renee cee ee oderlewea Wococetort nee De ee ears Se sees cea all by yourself! CALL TODAY! SST RATE (ta) 3e8-8 eS eres 1-800-624-2027 ext. 112 SHOP-TESTED TECHNIQUES 44 MAKE~EM-YOURSELF MOLDINGS You can translorm plain stock into decorative mol: ings with a router and a handful of router bits, 10S ass technique, NOW YOU CAN BULD IT PORTRAIT-PERFECT 48 PICTURE FRAME Want to make 3 f or a fine print eves fashioning a a {you how, step: photograph, you can—by We show TAMINATED LETTER OPENER O4 ‘This inexpensive project proves once again that « ile imagination plus some wood from your scrap bin Gan equal impressive results, WOOD MAGAZINE FEBRUARY 1988WOODWORKERS’ STANDARDS: 5 8 BOOKCASES AND SHELVES Designing new storage shelves can be tricky, We answer your questions about construction methods, materials, hurdware, and more, RAND-SAWN SCALLOP BOXE! 62 Well guarantee you one thing, If you build one of these great-looking treasure chests, you're going, 10 get requests for lows more. THE BARRISTER'S BOOKCASE 66 Few furniture designs hitye stood the test of time as well as the barristers bookcase, Our rendition continues the fine tradition of providing attrac: tive, yet practical book storage in a_minimum amount of spac STACKABLE FILE CABINET TD ‘The perfect companion for the barristers bookcase on page 66,this modalae unit, which ‘can expand as your filing needs grow, makes quick work of organizing your important records and other paperwork, CRAFTSMAN CLOSE-UP A WISCONSIN FISH STORY 76 Rick Beyer’ carvings make bigsplashes, at major competitions. We show and tell why his underwater close-ups bring home the ribbons. TURNING PATTERN, WALNUT SPICE JARS 80 ‘Meet turning expert Phil Brenni se uniquely sha SHORT-SUBJECT FEATURES Editors Angle ... Ask WOOD . ‘Talking Back .... Wood Aneedote ... ‘Tips From Your Shop Old Hand Ways «+ (and Ours) - es Shop Sense Products That Perform Bulletin Board . Wood Quiz... uz WOOD MAGAZINE FEBIUIARY 19881 a. = ELIMINATE YOUR JOINING HASSLES with the latest in plate jointers priced for your budget Porter-Cable $55 festues vertical handle shah tnuger swateh, SUPER TORQUE PD Sek Give wistiedesthadusenest, rom fe for Sey Gartiealadjusrment. miter fence fr preeise matching of maer jomts, dust elector fini cate upped bade $169.95 Virutex (-81 Siding fence adusts for 48°ap oF jot, arrester: fom the top ofthe trorkpice. Arovatiag sdusterquicey sles eye for dhe dtr ate sees. I ‘rian Bae ad earyine 56 $249.00 Kaiser MINI 2D Tis top ofthe line piner Tinpored exelusvely be WS, Jenks The pow fri AEG 600 wat! motor with spine Key Gives the HM owve Blade. Newshp reher Hesse eliminnes mache sve Perbct inis every te, Guide Soto Ad een wi eb Cans $499.00 Pack of HO, Sse8, 10320 Laminate Rollers Bp Extension wall aller $10.95 Se eller $633 Send $2.00 for our complete ‘woodworking catalog, ‘Raaedane wats os TE BE 193) Momma Ave NE Wishing DE 202 TOLL-FREE 1-800-638-6405THe EDITOR'S ANGLE SOMETHING NEW LTS) .-AND ARE WE EXCITED! ver the past three years, the stulf and 1 have met and talked with Hiterally thousands of you loyal readers. We've seen you at woodworking shows and crafts fairs. We have corresponded with lots of you by letter, telephone, and reader questionnaires. And s eral hundred of you have even come to Des Moit 0 take a tour of our shop. So by now, we feel we're ing. to know you pretty well. np, that ye view woolworking Jing hobby, that you wish you had. more time to spend in your shop, and th: you like to build projcets that you can complete in call WEE not a subst ther a companion peri Ww publication w WOODWORKING PROJECTS. Ni c, but looking projects we that’s 36 to 42 projects a year And to nsure the accuracy of our presentation, we will build every project step-by-step in our own shop. IF you're one of the many woodworkers we know who would like (0 have even more project ideas Wo choose from, this is the publication you've been walting for. For information on how to order WEEKEND WOODWORKING PROJECTS, see the inside back cover. Why not give ita try—I think you'll be impressed. Rees AcoToalseppiy he Ter3u.s.22Wast ELKHART, IN 46516 "wats 1-800-552-7604 3%, 1-800-437-2911 ‘While Quantities Last MAKITA Taba So a = Sat 8] waster power Write For Free Catalog Giz. “OMY 0B =CONTROL THE SPEED OF YOUR ROUTER soure arr sem Rarever ne esr Meu in ne moo ee Ya weedeat Sone Sree cueaaer FEATURES: + SPEED ADJUSTABLE FROM FULL EPEED TOO NPM + FULL HORSEPOWER AND TOROUE AF AL EBEEDE * G9 BACK AND FoR FROM any PrE-SET SPEED ‘70 FULL sPcko ar THe FuP OF A SCH OPS WITH ALL ROUTERS 2 HOF LESS + vss vOUR ROUTER A FEATURE ONLY AVAILABLE ‘OV ROUTERS THAT CosT OVER #50.03 EASY TO USE — supvy Lusi €PEE9 CONTROL smo PLUG YOUR OUTER Info he sreea conTROL — TURWDUL FOR Best RESULTS {Speco cero ins ache a ci we worn Ov VOUT EEL OF * REDUCES src E.EcrRoNeALLY Wrrdour RecUeNG TORGUE: SLES eb eucclawan Sra BY MERE VO“TGE ‘To aur by Nasir Charge of Vie Tal Fe sy Oa ~ 24 Hout Orde Servic, Cal 1-800-539-9298 (InPA 1-800-346-751 1,Ext.56) or sencicheck to MLCS, Ltd.,P.0, Box 5305, Rydal, PA 19046 MULTI-FORM MOLDING MAKER #159. MAKES BEAUTIFUL LARGE AND SMALL MOLDINGS "To ardor by Maslareard 6: Vea Tol Free 7 Day—24 Hour Order Sorvice, Cal 1-800-593-9298 (inPA 1-800-346-7511, Ex.58) ‘or send check to MLCS, Ltd, P.O. Box S3DM, Rydal PA 19046 it bu U1 In Th TALKING BAGK of mail we rec | every letter, but we pron | Send your correspondence to: Letters Editor, Better Homes and Gardens® WOOD? Magazine, Locust at 17th, Des Moines, IA 50336. We the rear wheels of the dragster (“Rubber Band. Powered Dragst find the proper size. tubes e | them over the eear wheels and they worked per feeily “inexp racing flag with the pennies saved. Ifo easy. 1 ‘TWO APPLES FOR THE PRICE OF ONE No, 15 (February 1987, pgs. 48-49). Whi them red like an apple, with gre stem. On some she’ bored % holes in the sides to 14, you showed how 10 mments, criticism, suggestions - even an occasional compliment, The volume ve makes it impossible to answer ise to do our level best. INDING NEW DRAGSTER “SLICKS” arched high and low for rubber bands to fit ” April. 1987. pg. 84) and coulda’ 10, we decitled to try bike inner Into cross sections Yd wide. We slipped. rovided a very interesting look, and were so, ive we were able 10 add colored tape as a Joan & Ea Burger, Lenbartsvile, Pa, nd locating rubber bands for the dragsters quite ed a local restaurant to save the rubber inds from lobster claws. In one week I had more in_enough for my projects. Marl: Bartvowiske, Warrenvilie, Ml, ave built several of your apple banks from issue 1em, my wile noticed that the i moved also looked like an apple, So, she painted en sind brown Serum cee Richard Nallyburton, Batley, SC. RIGHT WAY TO REPLACE BROKEN SCREWS your October 1987 issue “Ti “move nen you plugged the hole with "column on page broken screw, dowel and appeared to use anew serew the sume length as the dowel. It seems to me that for greater strength, the new serew should be longer than 1 Loren R. King, Starling Hodge, Mich, Right, Loren. When possible, use et replacement rrew fonger than the dowel insert so it extends into the workpiece beyond the glued dowel ip 8 Continued on pace 12— WOOD MAGAZINE FEBRUARY 1988| TALKING BAGH _ KIT BUILDERS NOT WOODWORKERS? In your October issue you ask, "Do Real Wood: | workers Build from Kits?” After reading the a it seems that you do think kit builders are re woodworkers Thave made several hundred clocks this year. I sell and make a good living kit builder? He is someone who puts then puts it in a corner and tells e he made it, Paul &. Chapman, Amberst, N¥. | RETROFIT PROGRAM FOR ROCKWELL RADIAL ARM SAWS Delta International Machinery Corporation, formerly the Rockwell International Power Too! Division, has initiated a safety retrofit program. They will supply irm retrofit kit for units of Rockwell 12" radial arm saws manufactured from December 1976 through covered are: 33-790, 3, 33-793 with ‘numbers IM-7800 through LJ-1273. 1 includes successor models: 33-890, 33-89} and 33-893 12” units bearing serial numbers 1J-1274 to MC-6923 and 82K04650 to 83CO4616, No other ‘models are involved in the program. If you own a 12” Rockwell radial arm saw that falls within the above iden You can get a free track arm retrofit kit #424-02.628-0011 by writing to: Rockwell Radi n, Delta Interna tional Machinery Corp, 4290 Memphis, TN 38118, Indicate the model nu number of your saw. —Carotyn R. Gray, | for Delia International Machinery Corp. ‘A FASTER WAY TO SQUARE A MITER GAUGE, Your October, 1987 5 issue, under “Tips,” sug: gested using a framing Actually, Pye found its even quicker to turn the gauge upside do in the guide slot, and, with the setserew loose! press the head against the front (or rear) of the table, and then tighten the screw Jack Pires, Ringwood, Nd Several readers wrote to tell us that they used this technique for squaring up a table saw's miter gauge The method is fast, and providing that the Table edge has been ground square to the guide slot, should be accurate. = Continued on page 14 2 WOOD MAGAZINE, FEBRUARY 1988‘This versatila machine makes ‘cutting inisicato wood patterns easy great for making toys, Jewelry, puzzloo, fretwork, ete, Tho blade Fe iver on both up and down: Soko in smeaih extn i Tocker arm system. re ine system avoiss blade q ge and creates # smoath ii hat virtual \ eliminates sanding, Our saw is \ fagy fo uso an fe fone wh S.east constuction that insures urablity Wa fully support aur product with replacement parts nd repars 1 nedec. Thoussnés sPecincaTions: Scat eonstion + Tveat depth 15" Mine depth of cue — "2" * Stake lath — a ts per minuto — 1725, Tawo Tt 0-45" Wont — ta be Sani Sas Ba + Noter— Howry cuty tally encioed fav cooled TOV 120V Uti, balding — inden nose PENN STATE INDUSTRIES-W 2850 Gomly Rosd * Philadelphia, PA 19154 4-215-878-7600 (Ext. 18) * aa $15.00 tor Blower Option » Vien, MasterCard. Check or Money Order Accoatad ‘Asa'$10.00 fer shipning in Genter US. = Pannayiania recon ada 6% eos ta Professional quality, precision. . . eae Super 15” Scroll Saw -qjntet Comparable value over $500 ony LO shipped complete ready to run dpe at nero enh Sie ti Ir ora aor 1 a # ‘este ment mth “i EL preace {tts the la 4 oun Hed a eee et Hooe “a ft hoe a 30 Bey ny preamnres eto) Guarana Sk ‘Siafaa nce pd ae orany paneaser rere Pre it TALKING athe re Da NOT A MOISTURE BARRIER You do readers 2 disservice when you perpetuate the sayth that you can stabilize wood or seal it from mois- ture by slapping on a finish (“Ask WOOD,” October 1987, py. 89). Some fi blocking water vapor matice what dhe Anish, through (0 the Wood. The US.D.A. Forest Products Labora ssicd 91 wood finishes. Their results indicate that the moisture excluding effectiveness of a finish depends primarily on the film thickness and the solids content of the finish. Thwo-part epoxy paint was found to be the most 2 e more ellective at ‘others, b © always gets elective moisture barrier, followed by solvent-based enamel paint, then solvent and shelhe a wed varnishes, Lacquer 7e much less effective moisture barriers, shies. Near the bottom of the [ penetrating oil finishes, which were found Davie stoun, Emmaus, Pe You can oblain a copy of the FPL. report to which sade Sta refers By aordtng fo: Pore! Proc CAUTION: MIXING HAZARD On page 20 of the October 1987 issue (Shop Tips) the item on “How to Beat the Mixing Game” caught my eye, It isa good tip except for the suggestion that an electric drill be used, and that the beaters be cleaned, in thinner: One spark from the deill or beaters could ignite volatile fumes from certain products and thie nersand cause severe injury to the uscr. Pleaye suggest hat readers use only airpowered tools or hand mix when they're working with flammable products, Tom Stroud, Lynn Haven, Fla, Right you are, Tom. Safety concerns dictate thal we do not use electric or shark-producing tools to mix materials containing volatile ingredients CLOCK KIT MAKER MISSED h ticle, “Do Real Woodworkers Duild from Klis?” WOOD Magazine, October 1987, py. 50, we listed suppliers of clock and furniture kits Unfortu fhately, one firm was inadvertently left off the Uist Please add: Kloekit, RO, Box 629, 53147. The firm olfers a free catalog contacted by calling 1-800-KLOCKIT.® WOOD MAGAZINE. FEIMMUARY 1938MINI FRAME CLAMPS You're gluing up a picture frame and don't have a frame clamp smatl enough to bola it TIP: Make a miniature frame clamp. like the one shown ta the drawing below, You'll need four small inside corner braces, four rubber bands, uuud eight Yi flathead machine is and washers, At h the screws to the braces as shown, to hold the cubber bands. Simply’ position the brices at the frame comers and stretch the rub. her bands between them to bold (AND OURS) bo you hive any good tips you'd Tike to share with our readers? We'll rou $25 for each submission We publish. No shop tips can be returned. Mail your tips to: Locust at 17th, Des Moines, 1A 50336 16 FROM YOUR SHOP \G THE SQUEEZE ON BROKEN LEGS The conventional way of fixing breats in evlindvical furniture loge offen seems ikke more trouble than HS worth: building a jig to bold the leg, when gluing and clamping H wilh a Celamp, TIP: You can do the job just as imps. You'l find 4 wide vitriety of sizes at most auto: supply stores, To avoid marring the piece when tightening the clamps, in strip of eardhated berween und the work at Doolitte, Kirkwood Sex the ela Some table saws bave L-shaped ‘metal fence guties protruding at Just the right beight to inflict pain: Yul cuts and bumps on the beads of wee visitors 10 the shop. also ‘TAPERED TO FI Ms somretimes hard to get wood plugs or dowels to fit snugly into the boles you've drilled for tern, especially if youre working with oftwoods. set of inexpensive spade and grind asfigh¢ taper on their cages, as shown below. Use your tapered. bits, plugs will fit into their holes like a cork into a bottle. But don't overdo itt Just light will suffice: File sight tapers I I to the lower portions of a grown: ups anatomy: TIP: Cut Leshaped sloxs in two tens nis balls, then slip them over the protruding nj SJemny Swenson, Newport News. Va woop siscisznseFROM YOUR SHOP TP (AND OURS) Continued from page 16 PIN THE SAVAGE BAND A band saw blade can turn vicious and inflict nasty bites, should it jump off the wheels during inslat- tation. 1&8 not always easy’ to keep the blade an one wheel while wrapping I around the others) TIP: Gain a hand to help tame the bhde by clipping the blade to one wheel on the saw with two or three clothespins borrowed from the laundry room. This leaves your hands free to slip the blade over the remaining wheel(s). Dawid Webber, Chantilly, Va THIS TRICK LICKS GOOEY STICKERS Who likes to pick auccey ate beard tarremove gummed label on a new tool handle or oiber ttem, then clean off the gunumy restane? TEP: Before pecting, hit the label vith a few squirts of WD-40 lubsi ccant. It quickly dissolves. the adhesive, so you can easily peel off the label. A quick wipe with ar will remove any remaining goo. Caution: Dont try this on unfia ished wood. It may leave 2 residue Joseph White, tus, Ota. 18 INSTALLING BRADS IN A PINCH 13 not easy to bammer breds into 4 picture frame to bold the back: ing 1m place Of course, you could buy a framemaber’s brad setting 1001. But they're expensive for such an infrequent task. IP: Common slip-ioint “water pump” pliers make a good sub- brad-setting tool. To five or six iyers of masking tape around the WW that will contact the Frame. then squeeze the brad into the is shown below. Van Caldwell, Cincinnati, ob10 KLUTZ-FREE NAILING No matier bow carefully you work, Jou often end up banging your [fingers or the matertat when “ariv- ‘tng brads or short finish nails. ‘Tip: Start the nail in the thin end of a narrow shim (cedar shingles work well for this). Use the shim to hold the nail in place until you've driven it nearly all the way into the work, ‘Then, pull the shim off the nail and use a nail set to finish the job. No shims available? Use a short length FEBRUARY 088 14" Bandsaw © Blade size upto wae @ Castiren construction © 156 bos. © %enp $239. (ships eight Collec] ‘e o i Soin oto. t0r IAs carseee Vl > Pai sostnie ‘holes ue $299.00 {ships freight cole) Industrial Dust Collector © 2hp, lv # Two 4" ines 1185 CFM #1 ibs. we $339.00 hips height corey) Dust Collector © Thp, tio #4" inet © Commercial quality © Compact size sex $199,00 [hp & Haig, $30) 15" Scroll Saw © Fullyad) abe © 2" cut dept, ‘h sake Now Free work Storage table A249 value © 25assored blades included $199.00 (orp. & Halg's202)This isn't what you think ! ‘You're probably looking at this machine thinking o yourself, "Oh, its one of those ail in one tools that taka forever io set-up and reall isn't practical.” ‘Think again, This is the Toolmax 7310. The T310is a quality woodworking tool that requires almost no sei-up and meets almost any commercial quality ‘specication for individual equipment. The T310 has 4 Separate motors which ‘power tho 10°Tabie Saw, 1” Spindle Shapor, 12" Jolnter, 12" Planer, ard Moise, you want to save over 90% of tha spacein your shop and up to 60% cf the cost of buying individual equipment, call Toolmax for more information or send $19.95 (VISAMC, AMEX customers cal tollfree 1-800-535-4788 t0 ‘order by phone) for an informative video demonstration ape, TOOLMAX 2430 FRONTST. WEST SACRAMENTO CA 95691 1-800-535-4788 USA 1-800-325-8330 CA of these to make eth CONE Ate tangular frames, you need only be off the 45° setting by a hair’ breadth, and the frame pieces won't meet gauge. By miter pauge, you g selling the ga other, the switeh the ga opposite side of the L ‘The for making box joints. 0", with this Europeandesigned miter ing both faces of the a perte ide iuye also comes with an augjustable Mip-up depth stop for PRODUWSTS From ‘TWO-FACED MITER GAUGE FOR PERE “RIGHT ANGLES Not so ou" ng is slight- ly off the 45° mark. Instesd of ee you simply move the fence from one face 10 the attachment vessory for Kity woodworking machines. the miter wujre now comes. with guide bars other popular table siw mod. els specify a 4008" gu Delta, Setrs, and Taiwanese made Tor Shopsmith, Total Shop, WW Master Wooderafl, order one Mex "Aa! bar Kily Miter Gange, 384.95. ppd; box:joine attachmnent, 599.95. pp from Purris Machmery, 2315 Key Drive, Blue Springs, MO ee bar for GREAT SHAKES If you're into Shaker or even if you rea't—you'll find these giant shaker pegs espe cially suitable for hanging large, heavy items of butky clothing. finished, with a 54 and a Mvediameter hes They're the largest commercially ava Shaker pegs we've seen so far. Us them along with pegs of other sizes to make attractive wall acks, Gant Shateer Pegs, bag of 10 (eat ua 5ODIO) $4.95 pyr: 50 (cat no. 5020) $18.50 ppt; from Woederaft Supply Gorp, AL Attan- tic Ave PO, Box 1009, Woburn, MA 1888. 20 Continaisd on page 22 WOOD MAGAZINE. FEURUARY 1988POWERMATIC Mint- Wax Wott Bet Jon Panes FS Jn Per 12105 yore ist , RYOBI SPECIALS ‘hares = Bes {WE Purge MAKITA STATIONARIES Seite 1S (RY BR ee oie Heys ivact Tienes Pane) PORTER CABLE, Seige ini oc ae He SESE ee: Ser rowan T9018 Palpeehcuae iar 2 Tbs hear rwostiics | 1-000-354-9083 The workbench companion The Xylophile’s Company 120 Loudon A+ Lecington KY 40S H/o wah (606) 254-9823 WATCO “The Orginal and Still the Best SH OIL FINISH \Wateo Danish oll Finish ean ba yrue ideal workbench companion oral Mose \yoodtinishingprejacterounatnahouco. Yeu be ‘amazed at tow easy Ws 10 {irish wood beautifully witn Watco,"Tho ‘Guginal Danish Oi, Walco dives wood that natural ane-rubbed loot with long Fasting cu IN the wood. surface contigs, rabitly Ard bocause Wate rot onit ike temporary “tereisnotinisn that ‘wllwear oft Watce Darist Or isideal ot Teinitura,panching, cabinets, doer, tie ware DANISH Olt FINISH ‘an en ‘and. Black Waln workand avenantiaues its anosalator Use on butzher blocks, cutting rs, ensloysaterwateaariesand Gurazin the wood. Choose trom 8 boa 18 ‘and Meu, ‘shades, and (Golden Ock, Frultwood, and WATCO. ‘Sante Mon WATCO-DENNS CORP, Dot BHivt5 207 Wana Bc, Sue jen, C8 40808 PRODUETS Bim DOING BATT AGAINST SAWDUST If you own one of the combi tion machines from Shopsmith ‘Total Shop, oc Master Woodcrait, heres a reinforcement in the war a The Dust Star quickly clamps to the way tubes of A cutout in the you to get your © the hood to Sind bowls and other faceplate turn: | The unit accepts 2 standard vacuum hose, Dust Star, $21.50 ppd. from EEL Plus Inc, 623 Osage. Neodesba. KS 66757 (Kansas resi- dents add 5% sales tax). A SLICK PROTECTANT FOR SAW TABLES: st sawdust eee ctrrsles cise 1 protect tables on saws nd other woodwork Kity Speed contains Kity Speed, 314.95 pp. from Farris Machin: ery, 2315 Keystone Drive, Blue Springs, MO Gi015. J8-ounce can = corninwed ow rage 24 WOOD MAGAZINE FEBRUARY 1988SAE ORT Ne ase te hey ROEM rg. Ce crate Pench Clonee at thet Por eee arate Mey i Ci enero seen siseeiTageastirnetor PE Ea er get on eo ISE-SRI clamps Unig se-ovelngsvive pads pated ar ra CORO eRe ce te Mc aA LO Ca Na TE 'URNITURE SHOWPIECES.- they're suprisingly easy to build {n addiion to cur Rolitop Desk CLASSIC, we havo a_sories tiled WEEKEND WORKSHOP, Inotucions are just as complto as our CLASSIC plars. Rolltop Sask Blan costs $11.09 plus $1.00 sth. Catalog is $1.00 (toe i you request il wth your plans Corde). NY residents must inetd caloo tax. Canadian roeklnts pause roma fost ‘money ordor in US funds < HAMMERNARK ASSOCIATES, P.O, Box 201-W, Floral ark, NY 100c2 ‘Save time call 516-352-5198 with Your Msstorcard or VISA order. PRODUCTS Ffoen “ge THIS SKEW WON'T PUT YOU ON EDGE Does the rectangular blade on your skew ef 1 bit edgy? Tired of filing the dings ‘out of the top of your tool rest? If youlll love the new oval skew from Robert Sorby Ltd,, the En: lish hand-tool special straight down, the tool, you'll notice an oy ed profile rather than the ree: tangy y ‘ed to, The oval shape provides a smoother Fide across the tool rest, and a lows you to rotate the cutting edge 10 any angle without balane- ing the blude on a sharp corner And, its less: ick the tool inpen to ing. strong as its rectangular ts, th blade is = giving greater seusitivity for making finishing cuts, The high-speed ‘steel blade comes tn nd 114° widths, We found three sources for the Sorby oval skew (addresses listed below). Constantine and Wood: craft only i wide skews; Garrett Wade carries all four sizes, Sorby Oval Skew: From about $20 for the "3" width to $36.50 for the TA" width Sources Alert Con. slantine and Son, Inc, 2050 Eastebester Road, Bronx, NY 10461; Woodcraft Supply Gor, 4] Allantic Ave, BO. Box 4000, Woburn, MA 01888; Garrett Wade, 161 Ave. of the Americas, New York, NY 10013. HERUARY 1988CARBIDE TIPPED ROUTER BITS PROFESSIONAL PRODUCTION QUALITY 7000s SOLD TO READERS OF FINE WOODWORKING a Pe pee ee IRD MISE | at aera ee Sata ea jaa Ee Rn gorse | Cae eeael ele lait aitiise ae se ae ae feces elias | 08 Aad | Rees ea is alae ia es pea eie oe oe rae ea ? . eS eTUNE FRAMES, ETC 850) WHEN ORDERING ANY THREE OR NORE DEDUGT $1.00 EACH ‘ALL PRICES POSTAGE PAID + Profeasioral Production Gualty » 4" DalBearing Plt ‘+47 ameter smanke % Tix" Lang + One Pose Construction = Two Pte Talk High Guay Tungsten Garside Tips To order by Mastercard or Viea Toll Free ‘TDay~24 Hour Order Service, Call 1-000-599-9200 (in PA 1-200-246-7511 Ext. 56) ‘orsend chock tor MLES, P.0. Box 40530, Rydal, PA 19046 (Gk ees Waeees yeueqromairarnesd eases rods mer” “Intermediate” or “Advanced ; SegenU mye Your Irorive hobby. We can nlp. Bad loro, consult our experts for answers to your Tmostasked questions, Send your questions to Ask WOOD" Better Homes and Gardens* WOOD Magazine peust a Ph Des Moines, 1A 50836 ite itl be elie for publication SET THE PERFECT ANGLE EVERY TIME the blade of my teble saw to any angle tha | ehoose and have it be correct? The scale on the sav is not accurate enough. [want something 1 can Fay on the. table and against the blade to set the proce angle. ell Langley, Aehermant, Miss or the table of any other ible tool), For the fiest technique (illustrated below), you need a simple protractor, such as the Kind you uyed in geometry class, and a sliding bevel gauge aVailADIE AC MIDSE LOO] SOEs, To use, loosen the Wing nut on the bevel gauge | and then phice the gauge alongside the protractor. Set the gauge at the angle you want, Tighten the _ Wing nut then place the hevel gauge on the saw Frovactor Say blade “ NO \ corse) slang bevel STEP 2 “Tit saw blade tomateh angle ot bevel aauce. Sal siding bevel gauge todesited angle wth a protractor | table and agains: the blade. Adjust the tuntil the blade aligns with the bevel gange matches the angle you've set on the gauge ‘Asa second option, you ean buy prese ‘gauges from tool supplicss. One source, Robert §. | Smith, Inc., Dept. JA87, PO. Box 17330, Phocnix, AZ 85014, offers a set Of six angles for $29.95. To use, simply scleet the desired gauge and postion it ‘on the saw table, Then, adjust the saw blade until rests far against the heveied edge. These ganges work well, but they do limit you to the angke of the gauges provided in the set Gianvestn pegez6) 26 WOOD MAGAZINE FELRUARY’ 198824 SHOWS IN 198 Free Workshops yr 100 Exhibits % Door Prizes *THE WOODWORKING SHOWS* z Bartosth iad [ero Ramet ‘SEE THE WIDEST VARIETY OF WOODWORKING PRODUCTS ALL UNDER ONE ROOF HUNDREDS OF ITEMS Machinery * Power & Hand Tools * Supplies ‘toa Jar 8510" Phoo CiicPaaa NoroRitmend Feb. 867 Rickmend Corto Cabo Fah 12134 Natonal Westen Congls, Derr Grater NOwaukse Fob, 192121 Mowsa onocton Hal tds Mach 456 Curis Hicon Cow. O. Tampa Ne.Calfoma Ma, 25:25:27 SarJosa ConenionCoxtar Anta Api G10 Geng nt Cony. Ct, Atari So,Calfomia Apa ay 1 Los Angeles Aiport Hin NothTems Me 67-8 Dales Comverion Centr hea May 181415 Pheasant unBxgo Hal St Chats Upstais New You May 221-22 RocostorRivorsd Cow. NewYork Jura 17-1819. Nassau Ooun ‘Seminars by lan Kirby - Rogar Gilfe - Bob Rosendahl - Rude Osolnik - and other Master Greftsmen 1-800-826-8257, In Callfornta 213-477-8521. Call for rae brochure, 8:305 Pacis Tima $6 admission with this ad Erase) WOOD PARTS FROM MIDWEST DOWEL WORKS Great Buys oy. con Ss B ‘ORDER NOW FIMe/visa ©) Check Enclosed ‘TotaiCos Nandting Ohio residente ‘si 068 Sen tae FinalCost MIDWEST DOWEL WORKS. 4631 Hutchingon Ra Cincinnati, Ohio 45249, 512-574-0408 ‘gama Day Saps/ Crd tore Hon Factor et state Gusanioed ‘85.00 value with ny order i Bs l (ASK Wage YES, COCOBOLO CAN BE TOXIC Q Pee rec that cocabuio wood ives off tuxte funte when cut. love tbe tanks of the Wood and ‘nave been tenting to da afew things with te Is tt saje fo use cocobolo wood in anytbing that might come in contact with fool? 6 fric Moorehouse, Ft. Huachuca, Aris A. Eric, we called Paul McClure, our wood expert, i he advises cocobolo wood noc be used lor projects ng vessels, bowls, cutting hourds, or other items that hold or come in contact with foods, Here’ the concern: coeobolo (Dalbergia retusa), native t Central America, belongs to the rosewood Family. Ax with most rosewoods, cocobolo contains potentially toxic chemicals, such as acids, alkaloids, | resins, and tannins. These chemicals cause allergic reactions in some individuals on contact, producing an itehy rash similar to poison ivy. The rexctions, mast often come from the dust created while sand ing the wood. A reaction will more likely occur when one perspires, or when the dust might be damp. Using old, seasoned sapwood may help avoid some of these problems. HOME WOODWORKING TRAINING Q. Fhave been a sawdust eater for about five years nou: Some of my projects have turned out, bul too many keep my fireplace blazing on cold nights. Can you suggest a home-study eotarse on wood. working —sometbing presented in a logical, pro | gressivg, solpevaluting manner? | en Henkel, Evendate, Obio A. You have these may work for you, For example, you may attend any number of woodworking sclools and Senna that teach the basics. Setiools rain our Apel, 1987 issie, starting on page #0, Youll find variety pF clases ranging from Two» day seminars to six-week courses. Some woodwork- | rs enjoy planning 2 hobby vacation around a cass Many local high school shop and/or industrial arts: fetches sa lls evening eieek ingGke wilt goin school districts adult education department oe with | the nearest aren college | Recently, Fole)/Bckaw begaa ofering atiomne! | stuuly course, For Information write the firm at 6301 Equitable Re, Dept, 13016, Kansas City, MO 64120. pcre are many good Books avallble on just abOUt any phhse of woodworking cnc could be interested “in vor starters, sce the article suggesting "wood | working books" on pages 58:59 of tie December, _ 1987 Issue, And, dont forget your public ibe 28 WOOD MAGAZINE feveral alternatives, Len, and one of a WUARY 1988mexyouszaancnow nary "| 9111" PAPER SHEETS ee mast eerntren | Pus uincaete pany re Tope rise er8yomr | op. nsinne afin Cine... sraytoe | a3 Bh ree 3 28pk onvournen one t $2500 | NDUSTRIAL Beet oi Syeem | G3. 0 pes aape sre, subred 8.08 ram BRASIVES CO. Fiyar | sisson. | (eee. lope sane yu tle ne eaNah steer Gryaw ... sisraee | west lope pe ; toon ad READING) PAYESI? Gera". siszsiae | Igoe. lope a Zebe st ae at ep ee eee os eg guzee - 7 Giirraive ©. e178 | ans pruning Pape [73:00 sens couroy an BOOP sear use: ei SAVE 55.00 Dido 02 Seteseor. | oa. step asap Tow your nest onoes orszs.o0 on mone; =] OP SeShases | ios. ek eo [ csworcnreccoucs — supraccranses—une sae 5) _° _| 3204..0 1k 19pk CONONEYORDER CicHeck SHO SB ome aid shed Ove} STIKY DISC, Rugged ae A To Ghasencam si” bees Tp ssete ears eae eon on | eer GEAR [er —_ pda El raancet. taseean 18 3 met) 1 eairvoer ss vepeeeh Jo wae J) Geramnenr |! 2otencn mover aie aunaee roe H"2u-caasg conan PROT Liver FROM sock INDUSTRIAL ABRASIVES CO.» 649. ath ST. » READING, PA 10512 COPED ggg sg toa tee Pare rd UR MN El treo ae On) eae a ae Ber 49 aluminum oxide, first quality, with bump-free splices, “EVER-LAST” Belts from... Joo, BRASIVES CO. ToC ef uretl sanding for each dozen ordered. All belts, QUALITY PRODUCT SIGE 150 Woon ANEEDETE O: the hearth, flickering flames dance across golden wood Tn a corner of the room, @ canary twitiers a fareivel! 10 day- light. The master of the house, his body lest in the bitlowy confines ed's yellow color and sheen feta favorite for inlays Can you solve “The Mystery of the Open Hearth”? of bis club chain, sets bis mind adrift in the peace of the moment ‘as a-coconultite fragrance caresses bis nose Shorilyy the caanery will fall from its porch, The boely of the rhuster will sink back in helpless sluniber: And, in the fivelight, the strangest burglary tn bistory will begin. Could even the famed Sherlock Holmes solve this mystery we've Created? Perhaps not, unless he had been schooled in the world’s wood. Only a dendrologist (one who stud Jes trees) might suspect hat it was the beautiful wood, once Favored by med furnituremakers Sheraton and Hepplewhite, that produced the ao matic smoke to seekite the mi send a canary to eternity Is doubiful chav satinwood's dubious distinction as a natural Sedative was well known by early woodworkers, Instead, its fame came from a unique, golden yellow color and satiny sheen, The satinwood popular in the 1800s was Zanthoxyium elephan- ted from the West In tt smells like coconuts when worked oF burned. However, ently exploitation of the species has made it unavailable t day. The use is East Indian, or C wood (Chloroxyion swietenia), a species with the same color, sheen, and sedative prope the ‘without the smell, Don't inwood as a remedy hough. Due ta lim. ited quantities it sells for over $2 a aT a aa | ay Calor WOOD MAGAZINE FEBRUARY 1988THE NAGAZINE FOR HOME WOODWORKERS T= a transfor: RED ALDER before staining to avoid the Northwest log: Wert gral. may mle ging country. A tree tong 2 waterbised Be en eae The West Coast’s weed | tenis crs ling is finally becoming ea eneE Rod akleé the Facinc coats adhere readily. ‘coast’s most abun¢ hardwood, has been around for a least jaillon ome ofc too great of numbers. Timber producers called iva weed because this ts-grower pops up tn burned or logged out forest areas, sometimes menacing the growth of commercially important Softwood seedlings ‘Over time, though, for: esters began to realize Something special about red alder Ie resist a wi fire's consuming flames. “Taking advantage of this, Uses in woodworking | Due to red alder’s stabil: | ind good gluing prope | erties, manuficiurers often use it as plywood core stock, Because it requires litle cleanup sanding, the wood fats ‘favorite for factory-male, mass pro- duced turnings. Youll find this wood being used | on the West Coast for ing, doors, millwork, unfinished furnicure, and | even waterbed frames, At home, you can use red alder for practically project calling for hardwood. Ie urns and and is hard il strong enough for furniture aid casework. | fire breaks to protect stands of conifers. Toe alter loggers harvest th sands, they tum 10 the red alder for logs to sup- ply a steadily developing | Imarker demand andor walnut | Red alder has gained setae when exposed toain | respect as an absorbent However, the brightness | Cost and availability ' Now that red alder has | | reach-apeak height of | ingseasoninp. The woods | become appreciated asf 130! and 36" maximum — | straight, close grain has woodwerking stock, and | diameter subtle figure. is light to ship, its aval You could easily mis ability fas spread from ake red alder for sspen or | Working properties | the West Cosst to the birch because of its At 28 Ibs. per cub smooth, very light gray | dry red alder w fication | bark with mowed mark- | about qwo-thirds less than | lar and willow make red All along its coastal ings often spotted by Feil oak. A ie harder | alder less ttkely 10 be from Alsska to California, | moss Ihe leaves appear | than butternut and not | found in the East. redalder (Admus rubra) | similar, too, except red | quite as strong as mahog: Red alder comes in five seldom grows alone, It | alder are nearly twice as. | any, the wood works eas- | grades. Selects and better, urs in groves | Jong and coated with ly even with hand tools, | the finest grade, costs less short haits on the under- | Waecepts mals andserews | than $2 per board foot. — | c foot, | Midwest, Competition fiom woods such as pop: on slopes, where soil is side. In the fall, the still- readily, and holds them And, you can often find: moist and fertile. In per- green leaves swirl to the | well. The wood | red alder boards up to. | feet conditions, such as | ground. Teputation for gl to 3" thick around Washington's Red alder’ yellowish. We recommend 1 seal | truseation: Seve Schindler — | Puget Sound, red alders | whit wood quickly | er or shellac wash coat | Photographs Bob C | WOOD NAGAZI fe TEDRUARY 19885 33PLUNGE ores GET DOWN TO ON OTN ONE OF THESE NAc S Even if you already own a router, consider this: With a plunge router, you can start and end cuts in the middle of your workpiece without ever having to remove the tool from the woods st $0, if you like to plunge right into a project, here’s a router you can do it with! D TOOLS ‘ou just can't beat a plunge router for all sorts of interior routing: blind mortises. and dhdoes, cutoms, template routing and frechand routing techniques, such as inlay work and sign making, If you've ever tried to do any of these jobs with 4 conventional rout er youknow how tough they can be starters, you have to balance the router on the edge of the base, start the motor, then carciully tilt the bit to the stock. And you hope the bit hits the target without chewing up too much surrounding wood or your template in the process Not so witha plunge router: Why? Because the ¢ assembly slides up and down Cagitinst spring tension Jon two posts atlached to the base. To make the plunge, youset the baseon the stock, turn-on the motor, release the Jocking lever, and push down on the handles, driving the bit arrow: straight into the wood, Then, you lock the motor down aguinst the pre set depth stop, and make your cut When done routing, release the locking lever and retract the bit by easing up on the handles. Steaight in, Straight out — a much safer way to rout And, with the motor and bit assembly locked in the “down” position, 2 plunge router works just like « conventional one As versatile as plunge routers are they do have a few drawbacks. One is higher cost, You'll usually get more horsepower for your money if pal router. You greater selection of sizes, prices, and optional features with the conventional tools Except for the two large Elu models, we found the depth- adjustment mechanism on_ plunge models harder (0 set and fine than on most ordinary especially if you have the router in water table. routers don't perform as well for edge routing, Most models have a large he base which doest pro: h stability for edge-rowting narrow pieces and at corners. You ¢an minimize the problem by in: stalling a template guide ada with a smaller opening, Despite these few inconveniences, we consider the advantage of having, the plunge feature well worth the 4 cher WOOD MAGAZINE HEURUARY 1988HOW MUCH ROUTER DO YOU NEED? You'll notice in the photos at righ, that the plunge routers we tested fit into wo basic groups: beavy duty (2.0 3 hp.) and fight duty (% (© 1 hp.. The heavyweights. include the Bosch 1611, Ela. 3337 and 3348. Hitachi TR.12, Makita 3612BR, and Ryobi R501. We feel that these tools have plenty of pow €€ (Or just about any routing job weil ever do in our shop. With this power comes a greater variety in bit choices. The big units come with ¥2" collets, but they also accept sleeves for 44" and bits. “The light-duty routers take VY" bits only. The bigger units also have deeper plunge capacity than the lit tle guys In fact, we think they're the best of any router for © ‘deep datloes and mortises in a Ble pass; also for making cutout stock up to 4" thick. With a fe weights cost about twice as tite light-duty, I-hp. models If you do mostly medium: 16 light-duty routing, go with one fof the small ones. These include the Elu 3303 and 3304, Makita 3620 (sce chart), Hitachi TRS, Metabo IT 508, and Ryobi R151 and K-50 model Unlike their big brothers, these lightweight, easily maneuverable tools give you better control for precision work. Al Neilson at Ryobi suggests that their Yehp. 8-30 would he perteet for fine detail work, such as inlays. Buymanship Note: With these plunge routers, when we sa) lightaduly,” were not implying cheup consouction. Untive other groups of tools we've rested, even ibe smattest routers have plenty of power for their size, and contain igh -qiuality materials throughout For example, all feature cast aluminum lower motoribearing housings and ball-bearing moor construction. Hyobi 50 THE BIG BOYS Bosch 1611 RyObE R-II ru 3308 Metabo Kr 508 3PLUNGE ROUTERS READY TO BUY? CONSIDER THESE FEATURES [100K FoR SMOOTH PLUNGING ACTION While checking out these routers, the first thing you'll probably want to do is plunge them up and down a fow times. Does the router have a smooth, stick free plunging wetion? Also test for slop’ (side-to-side movement) between the posts and router body, To do this, have a friend hold the base firmly agsinse a flat surface while you rock the body by the handles. Jn our tests, the Ely and Makita routers had the smoothest overall plunge action. The plunge mectic nism on the Bosch 1611 had ly more slop than we'd like to se But we were testing an early prowo type. Gary Compton at Bosch in: forms us that their engineers intend (0 correct this problem before the foUler Roes into production, These levers or knobs enable you {0 lock the router body in any posi tion on the posts. Ryobi, Hitachi, We) Makita have manual levers. You push down with your thumb to lock, pull up with your index finger to unlock, (See photo below) If you don't lock these: levers fiemly, they may vibrate loose, We found THREE CHOICES IN PLUNGE LOCKS: We Prefer Self-Locking Levers the Makita lever somewhat cumber- some {0 operate, due to its close position to the ON/OFF switch On the Metabo and small Flu routers, you lock the plunge mech- anism by twisting one of the knob type handles, as shown in the photo. below. They're real conv use. But you may accidentally loosen the handle while using the router or picking it up. We favor the spring loaded, self locking levers on the Boseh (shown ) and large Eli routers, To ick the lever you push dow your thumb; release the lever and it locks the router awmomatl- cally in that position, belo espa Tae Spring-aciuated fever auromatically. leeks when you release your dium, We found this type the easiest to use: Youll notice that most of these tools haye a base plate with one or more flat sides. This feature enables you to rout closet to adjoining ver- tical Surfaces. For example if you're making a sink curout ina counter: op, the lat side allows you to rout closer to the backsplash, It also makes it easier to follow guide boards clamped t the stock wien cutting dados and other mortises. ‘You faye two choices in base slives: serewon and, stickon (see photo av right). We prefer the 36 ROUTER BASES: We Like Screw-On ‘Type screw-on shoes because we like to remove them to use as a template for making our own subbases, In terms of versatility, the small Ryobi R-50 has a distinct advantage. Ryobi ises the sime motor assem bly for their Yehp, standard rower (R530), laminaie trimmer (TR-30U), and tilcbase laminate uimmer (70). So, you can buy one tool, and alld the bases of tie other three a accessories, They're easily inter- changed. Ryobi also sells an offset Tuminate trimmer base for this tit, Stfclcon base shoe, at left, peels off ase for replacement. We prefer the nccew-on type, shown at rine For detail, see dis- cussion afer. WOOD MAGAZINE FEDRUARY 1988Check to see how easily you can Tip the ON/OFF switch—withour letting go of the router handles. On the Hitachi TR-12, you have to re- move your sight hand to operate the switch, We found this inconv nient, You have to do the same with ON/OFF SWITCHES: Are They Easy To Operate? the Ryobi R50, But its small si makes switch operation casier Switch types include toggles, rockers, slide switches, and ciggers, shown in the photos berow We found the handle-mounted trigger switch (Bosch, Ryobi R501 and RASL) the safest and most conve hnient 10 operate—unless you plan fo use the tool in a router table. ‘The other switch cypes can be Left on when the router isn’t in use. So, the (ool could start up unexpect edly when you plug in the cord. Exposed toggle switch an get turned on by accident, ‘even while the rowier isa’ being used. On the Miaehi TRa2, you hhave to let go of the righ hand handle to rocker switch. uikes the slide ‘operite. ciuate the The handle position on the iu 3303 and. 3304 models We found the tisger-type switches on the Ryobi and Tosch routers the easiest shard ‘Comfort may not be everything, when choosing a rourer, but sor anil ramped hands are no. fun, You can get a feel for the han- ‘les while shopping. To test, place the ronter ona surface at about the GETTING A HANDLE ON COMFORT Same height as your workbench. ‘Then plunge ita few times at ditier- ent distances from your body. How does it feel? We prefer large, elongated han: les over the small, ball-shaped Knobs, Largerhancles provide better Control, especially om the heavier routers, Our ftyorites? The handles On the Hose, Hirachi, and Makita, We'd lkcto sec larger bandlesonthe Irg El moxtels (4347 and 3348), DEPTH ADJUSTMENTS: How They Work ‘On most of these routers, the depth-adjustment mechanism works pretty much like the one on the small Elu shown at right ‘To set the depth, you first have to insert the bit so its bottom aligns flush with the router hase, Next, you drop the adjust= ment cod ‘onto the depth:stop. Screw, noting the indicator po- sition on the depth scale. Then, slide the rod up a distance 10 equal the depth of cut you wnt 10 make, and lock it in phuce with a thumb screw. ‘All routers but the Metabo have turret stops with three po: sitions, enabling you to make ‘multiple passes for deep cuts without having to re gauge each time. The Metabo stop has one position only We found the depth adjust ment on the large Blu routers heads above the others (see photo at far right). It features fack-and:pinon adjustment, ing knob, and a. sliding tor 16 reset the Most of the routers have depth scales graduated in feae- tions of an inch, The Boyeh seale reads im fractions of an inch and metric; the Makita in metric only. eft The laege Flu (right) has a ore sophisticated mechanism. iPLUNGE ROUTERS | ACCESSORIES: Standard Or Optional? [As Vo you might guess ‘cessories. W . all of these ers come with collet wrenches (required to change bits). And, most include edge guid rd a adjustable edge guide: hand Eh routers ‘The Hitachi TR-12 offers ir most generous standard accessory ickage of all: wrenches, collet sleeves, edge guide, trimmer guide, and i ¥2"adlameter straight bit Refer 1 Ue buymanship chart belou' for standard and optional accessories cach company offers for their routers. When comparing the sturdy, on the the es, also compare the acces Sories that come standard with each tool, And ccmember to figure all of the accessories you'll need or want imto the overall price of the router, For example, if you buy a 2° rout er, you'll probably want to get a4 collet sleeve: PLUNGE ROUTERS: VITAL STATISTICS 3 Hoar (4) anal ee (1) itt (8) ‘atoeung evr oem borer ono fieerined macmun Bt roe da- rae vith apr CH oma quer izhig fng’ease H. Timmer quite | ‘hic seve J ell save 4. Ree gue. Tenpite quae. 7. Mary ois sound 103 low manatee pre: Litre on te a a a be [os B i ‘aa rea [oreoo |e fool» | u [2 fafmfufsn ial or fo fee[Ah) c | ae toe “aw [zz0m | fea] w [anne |s [alm] 7 fis so F Se vo a0 [2soo [uv 0) | [om [a frm s [sm [av] se 6 sum [aw |s fw | 0 | am [on fo oe | reson oroce |: | 5 w fw la 7 "s2 al eo 6a (| st lox fe] [REP | ee ot rsh [avon [ fos) a | |e fo fom [asm | 28P | si es) se xa |=] caf ee [5 ise faa|aa| a PRRE] se ett esm0 BMO| a [6 | au fa [im] fox |—| se fimfical a | ace 7 su | seis, [eso fisefas| w | [2 [a é fox st [a zs — [ARS] sie | 1 as 9 vi oa D. Sait GE Ae Gis say ool a LEGSlp ny ase enemy) « Roum a topn, Paste mans tm! tate 8, Ao arabe wit sear bse 9 Noneletnie vision ls) aval (om) 10, Hew irtoducon: ex opposite pe. MANUFACTURERS Li fie See rai iw Dem NB 2862 vate /LUNGE ROUTERS Fer oi of Amaia Maui 8a. a est 1 ede Wer aot omnes cx Sut (any 2840007 fnaetrs seh Power Toe USA. Us uaade co. Nant bake (ast Wiser gees GA S03 Bac 287 (aysaie Viet a3 (te oa By Aner ar eamaers ene Te 0106 fra res 2 ‘icon, Or Pore ‘wg. 5686“Today, youll find quite afew power tools with elecironie variablespeed control, But Elwand Ryobi offer the ‘only plunge routers with this: fea ture, We tried out the Blu 3304 hp) and 3338 (2% hp.), shown, in the photos on page 35 ‘The new variablespeed, 3 hp. Ryobi RE-GDO (shown at righ?) ‘wasn't available in time to test for this report, but should be on the market by the time you read it, along with a nonelectronic version (R600), Youll find the specs for it in the buymanship chart on the next page, We understand that Freud also has 4 $-hp, electronic router in the works, which may be available later this year We like this fealure a lot. Not ‘only can you dial the speed you ‘want, but the electronics maintain a constant speed under varying loads by monitoring pm and feeding volt- age as needled: AS result, you're less likely t0 bog down the motor THREE NEW ROUTERS Too Late To Classify as we were wrapping up this we discovered three more companies rushing to plunge routers on the m fortunately, protorype units weren available for us 1 test in our shop. But the manufacturers did provide us with the inside scoop on their Priced at about $55, plunge router (an vallable later this yea, WOOD MAGAZINE FEDRUARY 1988 ELECTRONIC SPEED CONTROL: Nice! The clectronies also include “softstart® circuit that smoothly’ ac Celerates the motor up to specd at Stariyp, So, these routers don’t jerk in your hands when you sart them, Slower startup als extends the life of the switch, motor, and bearings. We consider variable speed espe- cially useful on the large routers (Ryobi and Thu 3338). Here’ shy Seyeral manufacturers now sell Jarge profile router bits, suelt as 4” raised-panel cuticrs. Hut these bits, because of their size, really aren't designed to cuit at the very high speeds most singlespeed routers tun (20,000 to 24,000 rpm). With a variable-speed router you can close: ly match the listed speed ratings for these large bits for optimum perfor. mance and safe operation. Speed Controlalso comenin handy formak: ing Slow, finisli cuts in hardwoods, ‘These routers have an infinitely ‘variable speed control: 8,000 to 20,000 rpm on the El 3348; 8,000 new introductions, (Prices tures may be subject to el Jepson This heavy-duty ‘Taiwanese import (model 7412) will sporta 3-hp., 1 amp motor, with a running speed of 28,000 rpm. Its similar to the Maki {a 361 2BR in appearance and spect fications. Priced at $299, the Jepson plunge router should offer plenty of horsepower for the money. 4 ‘guide and roller guide as standard accessories. the time you read this article. Kress Made in West Germany, the chp. 45-amp Kress (model K-18) will Lone Of 16 portable power Is 10 be imported by Kress Tools of America in early "88, Features ttt clude variable-speed control (8,000 to 24,000 rpm), # 1.8" plunge depth, snd a three-position depth stop. In addition, its designed so you can remove the base and-use the to 24000 rpm on the Eu 3304; 10,000 10 22,000 rpm on the Ryobi REGO, The speed control dial on the Ryobi hias six reference settings, with corresponding applications listed in the owners manual and on achat att New from Ryobi te REGO electronic sariablespeed router: AC3 hp. its thelr Dikguest unti: Ryeb Faso offers the same tool winhou the electevnies (R600). er motor asa straight die grinder Kress ‘Tools expects the router 10 etail for about $12 Skil ‘This well-known of cons, €F to0!s plans to introduce a new 1yehp. router (model 1855) later this year. This 8.5amp tool, shown at Leff, will run at 25,000. spm, and plunge depth. Although me handles should be an im eat over the s 60 other plunge routers Other specs: a Mat top and a shaft lock for casy, one-wrench bit changing, 4" collet, manually oper ated plunge lock lever, single Sposition depth stop, 6” cord, h dle-mounted rocker switch, and a depth seale gradusted in metrie and Yaa" increments. Skil expects the lool to list for about $125. @& ler handles it George Graney ss Bab Calter 9ONE MAN'S ONE- Darrell Mattson, an indus- trious Illinois woodworker, lives out a dream many craftsman share—being a sawyer at his own backyard sawmill. lean, six.foottall Darrell Mattson lived when pio. neers settled Illinois prai- ries, he would have been called a “Jack of all trades.” At 42, he an experienced auto and truck me: chanic, a licensed pilot and fight instructor, a locksmith, carpenter, woodworker, and, since 1983, 2 sawyer with his own mill, Explains Darrell: “I try to be self-sufficient.” When Darrell and his wife, Con- bought five acres just outside (erling, Illinois, three years ago, they began to practice what Darrell has always preached. He drilled the well for water, Rows of evergee they planted will somed: them shade and windbreak, or e Christmas trves (0 sell. A tennis court-size garden yields vegetables from spring through fall, Chickens provide eggs, haye traded Iabor har ghum for gallons of sweet syrup. And, with his sawmill, Darrell cu boards for framing, fencing, and constructing outbuildings, such a the stable for his daughter Colleen Appaloosa horse, He also uses bi home-sawed hardwood for making clocks and furniture, ‘With 3 one-man, backyard sawmill, Darrell Mattson rips wood for his woodwo projects as well as nomiinal-size boards for CIRCULAR SAWMILL ANATOMY T probably should have lived eras | 8 100 years ago, when people bad to c do all these things," Darrell says halfjokingly. Then, more seriously, “Cd rather make ‘or install some- thing myself than have it done. This if something goes wrong, 1 ow t0 Mx I.” ‘That philosophy was responsible for Darrell’ decision to buy a saw mill. Sure, he planned to save money on dimension lumber and woodworking stock. But, there was good measure of just wanting to w his own boards, too, When it 40 WOOD MAGAZINE FEERUARY 1988came time to buy, Darrell pur. chased a circular sawmill. “Twanted to saw logs the traditional way, and without doing it in a trench with 2 pit saw." he muses, “a circular mill twas as teaditional 2 I could get.” A.NO-FRILLS SAWMILL OUT OF A BOX A gesduate of Foley-Belsaw’s home stucly course on locksmithing, © rell wrote to the same Kansas City, Missouri company whe ume to buy a sawmill, Her about, then ordered their Model M-L4—no-frills simplicity. ‘hts saw, relatively unchanged, has been mar: keted by the firm since 1926, first to Midwest farmers who turned woodlots into cattle barns, then (0 cntreprenuers looking for a busi ness, and now fo growing aumber of woodworkers k Fives in a box, ready to Except for an optional 46" diameter blade with 36 replaceable steel teeth (a 40" blade ix standard), P ell bought the basic package (sec sawinill drawing, opposite page): a 40°x10"-1ong steel carriage with set works that feeds logs to the blade and gigs back, a mandrel assembly for the saw blade, and a headblock and top dog assembly to hold the log. The sawmill cost him about $2,400. The manufacturer offers 2 extri-cost steel hase on which to mount te mill, but Darrell elected to build his own, The M-14 does fot come with a power plant—the bayer must furnish a gasoline oF electric motor, or a tractor with, power take-off (PTO) from th drive train. Set up as instructed, the M- swill saw logs up to 14° long and 20” in diameter (24° diameter with the 46" blade Darrell uses). The blade reaches an operating speed of GOO rpm, and the carriage moves for- ran! 54 fect per minute, Advertise ments sty one man can produce 1,000 board feet of lumber per day. Darrell doesn't. It «hobby WOOD MAGAZINE vytielsaw's M-14. saw FemnUany 19838 SAW MILL Darrell Working in his spare th 200 his sawmill up and running in about two months, For the base, he welded a framework made fro steel Lbeams mobile ho ties. bur It fests on railroad din the ground. Deeply treated posts keep the base iy. And, everything is perfectly power source to mandrel, oftbearer’s table (where boards come to rest after the sliced off the log) to setworks. For accurate sawing, it has to be For power, | started with my tractors PTO, but i€ was too slow.” Darrell explains, “I ended up trad: ing some work in exchange for a six-cylinder Ford engine and trans- mission, | hooked up the transmi sion so it uses reverse gear to turn the drive shaft for the saw blade. "That way, the rpm's are about right, and I get enon Darrell also fah the off hearers bled a simple log deck. Its two wooden arms, though haraly fancy, absorb the shock from loading, logs that the cartlage couldn't take. “T bull the shed roof to protect the ‘mandrel, the saw, and the setworks. Tye also put the engine behind a vwalll, sway from the mandrel, so it runs quieter and I can concentrate ‘on the sawing,” he advises. LEARNING TO SAW FROM A BOOK Not knowing how to do something has never stopped Darrell feom giv ing it a try, and the sawmill was no exception, Everything bes learned sawing logs came from the lchookshe got with the and from hands-on experiencs re still gu round as effortlessly siwed boards, Terms he uses, that have to be understood even by backyard sawyers been squaredt up, or slubbed on at least wo sides dog—device with adjustable spikes to secure a log on the save snill carriage for sawing dog board—the lust full-width board to be sawed ff tos wig back—ro remnt the carrtige buck 10 the starting postion after making ee saw cut hammer—the professional ten- sioning (conditioning) of a circi far sawmill blade with a hammer so that it will expand evenly in use mmmer speed—the operating speed of « sawpitl at which the blade runs true lead—the slight misalignment (imesstered tn fractions of an ineh) fof the saw earbor with the og that Keeps the back edge of the blade prom contacting the tog as it pas ‘ses aul that also counteracts we tendency of the blade to run ont of the cul (see drawing, below) Yar to Ya ted irectonot ogiravett) swage—te technique of shaping suw leet for an even bite by band uit @ hammer and a aie catted SETTING UP FOR SAWING You wouldn't think of ripping stoc! on your table saw without first checking the blade’ alignment and setting the sawmill, With proper lea Dareell 6 on the blade, effortlessly all dy long, y being the same thickness. Improper lead shows up right away. “If lead off bit," the hobby sawyer notes, “boards will be thinner at one end because the blide runs out of the kerf, The blade heats up, too.” ‘On his sawmill, Darrell adjusts Cominuea iONE MAN'S ONE-MAN SAWMILL Darrell uses: 46" dtameter. inserted tooth ssvblade dhat cuts a Ya? here Th 36 steel, style teeth can he replaced individually Jead with bolts on either side of the drive shaft that angle the blade ar- bor in oF out. “For softwood,” he says, “lead should be about’ Vie! Cand can be as much as ¥%"), and for hardwoods and frozen wood, out Yes", Bach ty little different, though, so 1 me: sure the thickness of the then check occasionally” est board, at first looks like improper lead mi actually be dull teeth.” When teeth get dull on a table saw blade, you send it out for sharpening, or re- phce it, With 46"diameter saw- mill blade, you start filing, Darrells blade has 36 removable tecth— when they're too far gone to sharp. cn, he pulls them and inserts new ones, as in photo, above Left “They're called “Type B inserted mHebeugin 100 af hem av, and has used only two. swith the: thieds of them in fon Filing isn't difficult, only: time consuming, “Right now, until I gett ng fig bul [file the teeth by then swage them 10 thei originale" width, In a full of Suing, I'l probably file about three times,” he explains. Swaging a tooth requires a metal waging fool and a ball pen ham- mer One end of the 1001 has two indentations: a slightly concave one 2 Watho ona home sawyer fakes te chanee of hiting metal em- bbedied nthe log. This model ‘through Teg. to spreal and shape the tooth point and a straight one to square it of Darrell says: “All you do is insert the swage on the tooth and tap it” Alla stwyer’ preparation for lead nd sharp teeth would only be in vain, though, if the saw were to hit metal buried in the log. A nail 2 tooth, a spike sheur Tales of hatchet snd ha mer heads, pieces of farm machin- ery, and strands of old barbed wire buiried in large old. trees taken from hedgerows and woodlots give Dar: fell a cold sweat. Many of his logs ‘come from neighboring farms, so hhe goes over every inch of them with @ metal detector (see photo above, center), “On sale, this detec tor cost me about $350, bat it ean Dick out metal with mass as small as a quarter” he says, “I haven't hit anything since | got it." GETTING YO KNOW THE TOP DOGS A light sawmill, such as Darrells M-Li, will produce lumber tut compares favorably to lumber sawed by the most expensive, heavy-duty commercial mill. How: ever for this to happen, the operator must know the equipment from top dogs to boa cable to fi it, and recognize its limits. With his mechanical aptitude and ills, Darrell grasped his role as. a ra heavy logs on the Carriage. Darrell slabs off (wo sides 10 get torest squarely and solidly against sawyer a5 easily as he changes plugs in his Jeep C1. From the timehe lays a log down on the carriage to when he removes the rough-s: hoards, there’ litle wasted motion. Confidence, «d concentration result in the steady, deliberate s ing from log to tog that produces accurately dimensioned stock. A ypical sawing sequence starts by lifting a log onto the de small logs with muscle pow ones with tractor. Then, Darrell rolls it over on the setworks, shown, above, right. “If they don't rock, heavy logs don't really have to be dogged down because their weight will old them steady.” he advises. “Lighter ones, though, need toh dogged for safety, so they won't shill under the saw blac two Pronglike instcuments mounted above the setworks, called the fop dogs, hold the log in place by pres- sing it against the carriage. By eye, rreil lines up the log for the si cut (first cut) by moving the se works closer to or farther away from the blade. “What I try to do,” he tells us,“ saw at flat spot on the log so 1 turn it to rest Mat on the carri Once the log sets against the headblock, Darrell sends it re- EGRUARY 1988Darrell controle throttle and feed eate 36 the sawbade bites into the "dog board.” the hst full-bickness board cut ofa log, caaws each board to! thick, peatedlly into the blade, listening to the engine and the spinning blide speed: “L have t0 maintain hammer speed by either throttling thee up or down, or slowing dow the feed rate. To increase speed, 1 slow down the feed rate—that's how a.guy can get by with a rig like this for even large logs. Just creep the timber through” Darrell is 50 careful about controlling, hammer speed, and not heating up the blade 0 throw olf its tension, that he hy ever had to have the blade profes: sionally rehammered. Fach trip into the blade yields a board measuring "%e" thick (photo above, left). For 4 stock, that ves Darrell ie! to take off on his planer alter the green boards h dried, But before he se: Daccell trims off the irregul!: from the rough-cut with « portable circular saw and a super straightedge made from a 10-Long, steel signpost RIPPING WITH CRUISE CONTROL All the wood Darrell stws ends up, for a time, baking in his solar kiln. A greenhouselike structure made from polyethylene film stretched over a framework, the kiln present ly depends on natural convection to move air over the wood. Accord: WOOD MAGAZINE. FEBRUARY 1988 feet of black walaut. Darrell turned the boards hell save forspectal projects ing to Darrell, he has plans to im rove on iat and inal ayaa that will more efficiently whisk away motstucc 0 intends to modify the powerplant by aiding cruise c trol to govern engine speci!” Right now, | have to listen for the engine to slow down, then quickly crank tp speed or slow down on my feed Darrell face wrinkles 10 the thought, his blue eyes beam on Gisiane focus. A smile starts 29 be tion. “And, I dont imine it would bre har! to book up ae mobile cruise control on the en fine. What Go you think?” linn eeen manufacturers: BAND-SAW MILLS Delta international Machines 249 alplia Dr Piusburgh, PA 15238 WoodMizer Products Div, of Laskowskt linterprises S180 W. 10th Indianapolis, IN 46214 WK: Ross, Ine: 640 stain Se West Hempsteat, NH 03841 HOME SAWMILL OPTIONS Und few years ago, your options for a home sawmill were limited primarily to circular saw mills or those made froma basic chain save “Today, portable mills proliferate as interest in sawing grows Basically, you'll find only three types of mills—cireular, chain ssi, and band saw: Briefly, here's Tow they differ: © Circular sawmills se a round, multitoothed, stationary blade of 30" 10-16" diameter to saw logs fed to it on a traveling car- siage, Setup can be ona permanent hase anchored in the ground, or portable, mounted on a trailer Cost varies from $2,500 (less pow- erunitand base) ro about $14,000 © Chain-saw mills operate with high tpm, lightweight engines, special rip chains, and stabbing {0 saWv at log into boards, The ‘operator, OF the operator and a helper, guicle the mill down the length of the log, Extremely porta- ble, chainsaw milly range in price from $600 to about $1,200, © Band-sctw mills wilize a thin (from .032" to 0.090"), horizontal- ly or vertically mounted blade to oe milly feature that feeds logs to the blade, Other smaller, lighter Units take advantage of gravity to ride the length of 3 log positioned at a slight pitch. Some large band- saw mills are trailer mounted; smaller ones can be carried by the operator, Prices start at $2400 and limb to about $10,000, For more information about pertable sawmills, contact these major CIRCULAR SAWMILLS Foley Belsiw Co, 6301 Equitable RU, Dept, 30818) ansis City, MO C120, Mobile Mig. Co, 798 NW, Dunbar Ave, BO. Box 258 Troutdale, OR 97060 CHAIN-SAW MILLS Sperher Tul Works, Ine Box 1 West Caldwell, NJ 07007MAKE 'EM YOURSELF Its Easy With Our Multiple-pass Router Techniques ed with a router, router table, and a few bits, you turn plain stock—of any spe- ies you want—into custom noldings for a fraction of the cost of milled ones. dle. And, you can’t always locate the exact molding profile you need for your project. Most outlets that handle moldings stock only the ‘most commonly’ used designs in the mest popular species—pine, oak, poplar, and mahogany, OF course, woodworkers who own a shaper and a good comple ment of cutters have no pr blems making their own moldings. we've been curious for some ti about whether or not it cally any sense to mill decontive ‘with a router To find out, we asked Design Edhor J g to develop tive ful molding profiles the shop. Then, We rounded up the necessary bits headed for the router table. What did we find ¢ shop test? Two things, actually. First, if you work y, you can, in deed, get good results. And, you ‘can have a fot of fun doing it On the following pages we show you exactly how we made our five ive moldings. Try making more of them to get st feel for how the multiple-pass. proce lure works, Then, once you get the hang of it, try making a few mold: Ings of your own design, during our HERE'S WHAT YOU'LL NEED TO MAKE THE MOLDINGS We recommend at least a Lhp. router, Youlll also need a router ta ble with a 90° fence 3” 10 4" high. The chair rail mold also requires a the cuts (see drawing om ps for details on making one), We chose standard, commonly available bits (0 make Most of the Cuts. But Several cuts require spe Clalized Sears bits (specified in the instructions), You can substitute similar bits from another manufae turer, but you re 1 make some slight adj to the bit height and fence locations: shown on the drawings TIS ON MAKING THE CUTS For cach molding, follow the step-by-step drawings to set the bit for each height and fence posi pass (4 tise). To oF drawin s0 the fenc Notes In ihe drawings we include @ reference dot (+) to help you identify the position of the piece for etch cut. | TABLE EDGING tables with 8-thick tops. back edge of the mold: io dhe wp, Ing enables you ta BASE MOLDING z ‘sige adapts well 10 walls WOOD MAGAZINE FEBRUARY 19882, For a few of the cuts, youlll need Support strips to steady the work: piece while routing, Make them the length of the table, and atiach them with double faced tape 3 Support the ends of long. pieces with auxiliary table supports or rollers. Use a feather board to hold the stock against the fence. 4 You'll get more uniform results im grain pattern and color if you make all your molding from the same board, 5 Allow about 6” waste for each. 8° of material, You're more likely to dip the stock into the bit or move it away from the fence at the beginning oF end of the cut. 6 When making each pass, dont re- ly entirely on the measurements on drawings. Double-check the bit po- sition against the previous cut to make sure they're perfectly aligned. (We sometimes had to make adjust: meats in the fence position or bit height because the previous cut sas slightly off) Use a short picce of stock fo test bit and fence post: tions for exch pass. 7 If you're making several lengths of the same type of molding be sure to run all lengths through each step before changing settings, 3 ‘pply pressure here Start with 9x20" stock. Use a4" slot ‘ulfer bit rout groove alorg cne edge of the piece, where shown on the crawing, ‘Switch to a Sears 1" raisec-pane! it ro. ‘baka, Make tree passos by repostioning fence in 4 increments. Switen (© ae" round-over bt with plo, While cutting, push down on back side of stock to keep it fom recking Start with 2x8/4 stock. Use a 36° beading Bi to make cus whore shown by moving me fence. Match radive of Previous cut Mate the final cut wih a 9%" classical bit, Certred on font erge of fence, as shown onthe drawing Vie rabbet Flip the piece end-forend. Lower bit 10 match radius of previous cul. (Do not ‘change the fance positon.) ‘Switeh to a 14" straight bit ‘and fence position o cuta Yie'x he’ radbet Flop piece as shown, Continued 45ROUTER MOLDINGS PICTURE FRAME, 7 — fe his decoraiive pie- tire feame molding Jooks, you need only two ve ogee bit. And ferein es such of Slart wih 1¥nx29%" siock, Usa Male wo passos by moving 2.34 ogee bit to make cuts for fanen 16 keep top of Bt from Stops 1 through 3, chipping cut the Wood. 6 ees Flip tho piece ordlorond. To Use a" aaght bl. Setferce Switch back to tho 4" oge0 Bit Gut oaurea two passos. Raise ‘mako tho cut, align bit wih and bt height so bit cule sh tomako the cut You may need bt to fll height 10 sot fence, radu of previous ct. with corner of bead tormake two passes. then lower to make first pass. ] 7 8 9) 10 | i Support | lock | +e I [ ai | Fip pace eworend Se % Swick back oe rouse Atach a axvrigh suppor. Poston he Sanh Bo ‘raght bit Jo match height of setting is hoight to match that block to table where shown. cut a Vax’ rabbet, Move previous cut, as shovmn. Of the provious cut ‘Make three passos, fence; make two passes. ue ae WOOD MAGAZINE FHRRUARY 1988CONTINUOUS DRAWER PULL Continuous pulls fake 2 popu alter- ative io haedware on the doorsand deawens ‘contemporary cabi fire. We've designed. thisone to ftstandard ie = re mi i a IE Start with 941 Ye straghi parses by raising bi make ut whera shown Lewer bit to 14" above table height, and repositon fence to [5 6 ad Flip the piece endforend. Use 2. cote box bit wih amas ‘mum protie height of 6. Flip pices end:lorends Do not ‘hango bit ho fion when makng ths cut Use a straight bit, conterod ‘on front aca ef fanco, to cut the Fabbet where shown positon tones and bi 4; again to make cut 2. shown on drawing to make cut it where 9 Til all 10 Yat Yaxve _ "groove | ve eubotato| =lamnate plasti| Align radus of 9° beadieg bit ‘wth faca of lonce to round over butside comars as shown, Reset fence to round over in Side corners of pull cuts 1 and 2). Do not change bit height, Reset fence again 1 round over bottom jp of pull as shown, Do ‘not reset bt height Tp instal, rout a Vax" qroove In top edge of door or drawor front: Glue pullin pace. ContinnietROUTER MOLDINGS PICTURE RAIL Youll most often ace this molding in older homes ‘with tall ceilings, Running, Horizontally about 2! low the ceiling, the rail forms 2 lip for banging pic tues (or displaying chiiaa plates). Youll need a able Saw 10 do step 6. ‘Start with 2x 134" sock. Use a 14? sraigl bitto.cut a "deep groove in the center of the pice. [4 Yithout changing the bi height, move the fence to center ts front face above the rout- ‘Dt, 25 shown Use a Sears 1° bead querterreund tit no, 25563, with piot bearing. You won't need the router table fence fortis step. Psion fence ard adjust bit height to align bit soit machos radius of cut you made in prevcus stp. 5 6 7 | | L Remove the bits pilot Beuing to make this fut, Align bit wth fagius of cut you made in Frovious stop offthe lover projeo ‘shown on the drew ing, to make a flush edge. WOOD MAGAZINE For tho final cut, eo a.%e boading bit (with pilot), Sot force to support the piece, as shown on the drawingCHAIR RAIL Use this molding as a decori- tive accent on walls—and 10 keep the backs of ehairs and ‘ther furniture from snarring o wall coverings. Typically, youd TOPVEW Fun uns molding horizomally, \ | $2536" above floor level. Youll Equal tolergth peed a 45" fence to make the ‘of outer table econ ext #Bxie diywall sciens. Yow'l need a 45° fence on your router table o make this molding. We made the one piclured here rom 1s" pariceboar, 45" emo, 3 al Use Sears 1 radus endcove bt no, Use Sears 1A" found-over bit witout plot, Switen back to a 90° tence. Use a 25826 Start wih xv" sock, Make Switch fo a 45° fence ike tho one shown in straight bit: align it to bottom edge of the [eee the drawing fp ight. radius made in stop 2, |I4 Attach a 7iox'%e" support stip to the table Leave support stip in the samo positon. Flip place enc-br-ené, repostion support tuhere shown. Chamfer edge wih a %' Reposition fence and mak2 ut wih a vs’ strip and fence, and make cat with same Bt Ve-grooving bit. ‘core box bit. used for step 5. Produced by Jinn Rarzett and James R. Downing Photograph: Hob Calmce Mlustations: Advertsing Aes Studio, Ine lke Henry: Bit Zaun WOOD MAGAZINE FEBRUARY 19885 ‘9TRY OUR STACK-MOLDING TECHNIQUE FOR THIS PORTRAIT- PERFECT PICTURE FRAME Finding run-of-the-mill pic- ture frames never seems to be a problem. But, if you want a teuly unique frame that you can build yourself and size to meet your fram- ing requirements, then we've got just the project for you. Note: We machined each molt Jor our 250033" frame from one tong length (we used 12" stock). Bul you might find it easier to handle two shorter lenetbs instead. Kitber way, cut a piece of mabog- any about 10" long and use it asa test piece before machining the Jong lengtts To determine the total tength of each molding nected, simply mea sure the perimeter (ihe total of the four sites) of the tem you plan to Prarne; Wen edd 24 thal figure to allow for miter cuts and waste The Molding Length Chart below lists the figures jor several com mon mati and print sizes MOLDING LENGTH CHART ‘Common Mat and | Total Length of Print Sizes |Malding Neodad| 8x10" 60" Tixia® a texi6° ao 16x20" x24" 20x24" 0 HERE'S HOW TO SHAPE HE MAHOGANY MOLDING F Rip enough 1%"-thick mahogany (ve planed down 112" siock) 10 14 wide for the outer frame parts (A). Grosseut to the length needed CRefer to the note and the Molding eth Chart at Left for help swith this) photo: Her the fullsize the Ass bled: ‘appo page) to white paper or tablettype cardboard. Cut the template shape, and trace the profile onto both ends of the mahogany. pattern of part A (se Note: Study’ the molding drawings carefully as youl need to turn the mabogany several times when making tbe dado and router cuts. To help ensure starting the cuts on the correct end, we marked an °A” ‘on one end and a °B" on the oppo: site end, 3 Faster and. an a a valowide dad Hale %6" above the su saw table Using the setup shown 669 the Step 1 Drswsing and push Slick for safety cut a $4" abbot deep nlomg one edge of the tent sirip. Cheek the cut against the hed profite then make the eut dhogany. plece starting, the end labeled "A." Reposition H fence, and make ‘where shown on tep 2 Drawing 4 Keposition the rip fence again, raise the dado blade, turn the: FIRUARY tonsWG stared wire DADO DETAIL Ye lleosa Fished i 7 ‘Water 6 spline sit 16 cee “45° miler joint Ve dadoos vdeo | ASSEMBLED FRAME DETAIL FULL SIZE Fa Al we [ee smahony | 4 8 7 want | 8 vot xo! c = iivple | 4 slip feathor sping “The lenath ofthese paris varies, seethe ote atthe begining ofthe arkcle. Supplice: carbon paper. 46 etand Co aa cow eos, #000 sa ‘oi, ish STEP 1 STEP 3 Avsliary wood fence WOOD MAGNE FERRUARY’ (98st Continued 31PICTURE FRAME 5 Cat a Vix a" support block the same length as the router table. Using double-faced tape, adhere the support block 10 the router table where shown on the Step 4 Draw: ing below. ‘The support block pre- vents the mahogany piece from 9 beud/quartercound Dit (With out the ball-bearing pilot) to a lablemounted router (See the Buy ing Guide for our source of router bits). With the end labeled "A" to the bit, start the rower, Sow! push the mahogany stock into th bit, and rout 3 rounetover along the inside edge of the molding where shown on the Step 4 Drawing. 6 Relocate the support block on Torend se the end labeled the bit, and round over the oppo: site cage of the mahogany stock where shown onthe step 5 Drawing 7 Remove the support block from the router table, Using the Step 6 Drawing for ret . turn the of the outside edge itch to a Ya" cove bit (with out the ball-bearing pilot), repost tion the router table fence make several routing passes, raising the bit each pass until you reach Ye height, Fea shown on the Step 7 Drawing. NEXT, FORM THE WALNUT MOLDING. T Resaw enough 1Y" walnut for the “thick molding (B). You'll need yo stripy the same length as hoxuny molding. Now, rip amd. crosscut roundover bit (see the Buying Guide for our source) into the collet of your table- ‘mounted router. and rout x round: ‘over on the top and bottom of one edge of each strip to create a bull: nose. Sand the molding smooth, AND NOW, THE MAPLE MOLDING 1 to form the dadoed 0 (C), start by ripping a plece of wiahick maple to 4" wide, Cross: UL IE to the same length as the F apart the entire Jeagih of the maple strip, Attach a Wo blade to. your ny, and cut the Y"deep shown in the photo ars replaced The makes it accurately line up the dado lines with the bkide and alo prevents chip-out.) After cutting all the dadoes, sand the strip smooth, IT's TIME TO ASSEMBLE ‘THE FRAME F Glue and clamp one of the wate ‘hut strips (5) to the mahogany (A), with the bute edges fush (sce the Assenibled Frame De panying the Exploded-View: Draw- ing on the previous page). Allow the glue to dry. (We used wood spacers between the clamp head and moldings to preve the woo) Later, glue and. chimp the maple strip (C) to the w: ‘ogany lamination, with the hack edges flush. (Use a sharp chisel to serape away the excess glue from the dadoes before It ddsies. We found its much harder 1 lo this later after the glue had dried. STEP 4 ‘Yarra support look double taped te table ‘STEP 5 Yax7/s" stuppost Dock doublet lapedto tate 52 WOOD MAGAZINE erremayany rswithout scratching the wood.) Glue and clamp the remaining walnut strip (15) to the maple strip, with its back Mush with that of the rest of the jon, 2 attach a ¥%" dado blade to your table saw arbor, With the end Iabeled °B" facing the, blade, start nd cut a" rabbet 44" ing, the back edge of the the lengths needed for the four frame sides, For perfectly matched comers when making the mitered fauits, cut at the comer of a maple square or dadoed gap where shown fon the Dado Detail on page 5t Use a Vblock jig to cut the spline stot in eich frame conten VBLOCK JIG ‘veshick hardboard glued to guide block {ho nalis or scews) STEP7 | Make several passes to cutcare, rabing ‘he bit each pass STEP 8 Ye dado blade (FEBRUARY tox eeking for square, glue limp the four franie sides together. (We used a and clamp for this.) 5 Using a Veblock jig (see the V- Block Jig Drawing if you don't have fone), cata 4 spline stot 196" deep in each corner of the assembled Frame a shown in the photo at fe/t 6 Cut four feather spl resawed walnut) (0 the size stated on the Exploded-View Drawing, ye the walnut feather splines the spline slots you j corner, Later, after the glue has ried, trim and sand the splines fush with the mahogan APPLYING THE FINISIL T Apply two coats of sanding ce, steel-wooling between coats. Be sure to remove all the ste expecially from between the dadoes before apply We ha beush Meel wool from the frame Gach rutin wa steel WoO.) PT apply two costs of used hieguer), agin st between coats, Mont your artve 3 Yo hang the frame, count Sink two holes on the back side Of the frame where shown onthe Exploded.View Drawing (counter Sinking helps the frame hang Matter fyainst the wall), Now, ten" Seren eyes tno cach countersing String #6 stranded wite from serew tye to screw eye, Hang in a desery ing pce BUYING GUIDE. © 14" round-over bit, Catalog no. TE34104/WDI88, 827,10 plus $3.95 posta ndlines, 375 Beacham Street, Box 6447, Chelsea, MA 02150, or call 800/343-3248. Router bits and arbor set. %" bead /quarterround bit, catalog no. 911725562, $5.49. 13" cove, cattlog no. OHT2557, $5.19. Arbor set to be ised with the bead /quarterround and cove bits, catalog no. 91TT25601, $4.69. Bits and arbor set available at Sears. 1 Designs James K. Dow ph oy calmer, Wil me Hopi 33TURN SCRAP B& STOCK INTO SOMETHING SPECIAL WITH OUR LAMINATED LETTER OPENER Short on gifts but long on serap? If so, you'll find our hardwood opener, with its interesting chevron-patterned handle, real lifesaver, Its hard to bel be so elegant. 1 From %" stock, cut the strips for the handle lamination (A, B, C, D) to the sizes listed in the Bill of Materials. (We specified 11" lengths for these pieces to allow for safety wercutting the lami ation. enough length to the lami: nation to cut handlle pieces for sey eral additional openers. 2 Glue and clamp the strips to- gether stuirstep fashion in the se- quence shown in the Handle Lami: ation Drawing on top of the oppo- site page. Keep the top edges of all the strips flush when clamping. After the glue dries, remove clamps, and serape of the ex glue, Belt-sand the tp and bottom surfices smooth, 3 Position your rad) blade to cut a 43° angle, and miter cut one end of the lamination where shown on the Handle 1 nation Drawing. Now, mark a stop line on the saw table to ensure con: sistent "vide miter cuts (see the photo at right), Cut the number of handle strips desired. eve that something so simple could Mark a stop. dle pieces on the radish am sw: BLADE SECTION Bill of Materials til Se rag — tase —— aera fay, Re pe L [petak[ TOP VIEW Be |e [a [vn fo | ¥e [e [a [valor De [we | [al | % 1 [ok SIDE VIEW. ‘Supplies: Waieo Dai o, #0000 tol woo FULLSIZE PATTERNS BLADE SECTION Conneet the dividing i of the two segments compte patternstairstep fashion {fo minimize waste Third cut ine HANDLE LAMINATION First cut line ‘Second éut line 4 Cat the oak blade (E) to size 5 Glue and clamp the handle pieces to the blade. Align the pieces so they create the pattern shown in the Full Size Top View Drawing 6 Using carbon paper, transfer the Top View of the handle View of the blide to ca (We used the back from a writing et.) Cut the cardboard tem plates to shape. Trace the handle Outline onto the top of the handle and the blade outline onto the side Of the oak blade, Cut the handle and blade to shape on a band saw as shown in the photo at right. 7 Rout a round-over on all edges of the handle, stopping where shown oon the Fullsize Top View. (We used 434" round-over bit chucked into ur table-mounted router) 8 Using the blade pattern on the de Side View as a guide, sand the to shape (we used a belt sander, drum sander would also work the leter opener handle and blade fo a ad saw ited with fi well). When sanding, bevel both edges of the blade to the shape ip to the handle. 9 Finish-sand the completed letter opener. 10 Finish as desired. (We applied several coats of Watco Danish Oil, rubbing lightly between coats swith #0000 steel wool.) Note: After opening a few hundred letters, you may need to “sharpen the blade. To do so, sand with a belt sander or drum sander and then refinish the blade. @® Project Design: Frank Nichols toe Hoping ilusteations Kim Downing, Bil Za WOOD MAGAZINE FEBRUARY 1988ITS YOUR uPROJE re ‘THE SYCAMORE SILVER GHOS Vern Ischiege, 62 home purk auner Manufacturers representative, Ghosts can lurk part-time “award” maker That where Vern found the quar- | Al once carved Woody Hayes! tersciwn sycamore for his classic name on a walnut award. He did the same with “Tmade my model big enough the detail in the made hangs ia Jimmy Conn down to the rose home, and Bobs Hope lose the 2! tall walnut ¢ admits the toughest job was con structing the seats without allow: ing end geain to c pieces of wood, cut them to shape witl ‘the seat with rasps, Veen lined the runni chests with velvet because th hold jewelry instead of tools, eory is to put the weer explains Al, who specializes in limited-edition, lick Whether memorializing a game or ach football starts as four 2x8" Tung oil and wax give the sye: more Silver Giiost the luster and, protection it deserves, Meanwhile, Vern has already started a new pro} fnates them, then tuens the stock cylindrical. He next carves the six urcless wood into a € pigskin. After sanding the He uses paste: wa buffer (0 get the silken fi Al. we have an idea for your next award: A mounted turning g0uge with your n: WOOD MAGAZINE MEBRUARY 1988SiO W/ CAS effort and ingenuity. Our caps are off to you! WELL-SPENT HOURS Wayne Cameron, 30 Saskatoon, Saskeicbewen, Canada Utility company operator Gifts made for Someone special seem 10 (urn out special, 100. fhe hourglass Wayne built for his mother shows how lovingly ‘well he put his spare hours to ne says he chose manio, a wood from Chile, because its color ranges from y and its grain changes from curly to straight, "And if you use a finish of clear oil, then wax, the color remains true,” Wayne advises, WOOD MAGAZINE FEBRUARY 1958 A COFFI Bruce Boyd, 35 Topelea, Kans State property officer Some folks cre by lighting candles Druce says be and his wife light up their life by lighting” their coffee table. $ in the stalled tabletop, this craft Auorescent light The wiring cuns through one of the 2x5" maple legs. The switch rests in an opening i gate framing the stained glass. Bruce edgejoined and doweled The holes left in the top and bottom plates by the lathe face phate screws were put 10 inventive tse. Pegs now fit into the bored out screw holes to secure the which ends up as the “top” when the 9%x4¥5" hourghss is turned over and reset. Wayne found the spindles tough to turn on his lathe, “I had to hold them so they wouldn't vibrate. And any were so thin (¥ Lended up turning half a dozen to get four” Wiyne, your pers off Your mothe e paid fa ‘TABLE THAT SETS THE MOOD, Zax" maple to surround and sup: port the grate. A er framework of maple 1x 1's helps hold up the 30 pounds of iron. Designed for easy disassembly the 45x lewop rests On. cleats screwed into the 1x4 maple sides so it can be lifted up ‘crossed and out, Legs and side boards con: nect by unglued dowels. Bruce applied three coats of poly topped with paste Live can ble sure only age beats exndlest ‘To submit your projects. Send a) 35:mm color slide onfy

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