Nw\!'.W(x)(lsrnitlt.clnu v l . 2 4 / N ,r, 4.

A Publication
ofAugustHomePublishing
No. 142 August,2002 q
Publish€r
Editor
Senior Editor
DonaldB. Peschke
TerryJ. Strohman
Jon Garbison
Sewlusr
Assistant Editor Brian Mccallum
Art Director Todd lambirth et'sfaccil. OLrt(loor projcctsrcally bcirg durable, cedar has another
Senior lllustrators David l&eyling tal(c a bcating.'lltey'r e exposedto advantase- it's lightweight.So ev€n
Dirk Ver St€€g drivingraln,bakingsun,andfrccz;Dg ihorsh these proj€cts look sol;d,
HarlanV Clark cold- condilioDs thatworld dcslroy they'rccas] to pickup andmove.
Graphic Intern NathanRobertson nuny piec€sofindoorturnilLrrc. (Xcoursc,onceyou'vebuilt an oul_
Nowthals not lo saythatyoucan! door project,you'll want it to bok
CREAIIIE RFSOURCES
CnotiP Dift.tot lel Krdiek . hnj..t D.rlor.r K.n Munk l ' have trr|iturc ouls;(k'.It's iust thal soodfor aslonsaspossible. Soweve
Sr Poi., O6rs.^ K.nl ftkn, Ryin Mimick' Porr?.,D6rrr.fl wherrit corlcs to rrllrlir1,/ orldr)r inchdcda shortarticlcon the t)1)eof
chns filch . sr', ca&r.{ slcvccudis, SlrvcJohtre! t sr likc to use.
FtottstuPttr cdyola l:.nd6d Iu-nitrre,vou Dcedto lhiok a bil dif- outdoorfiDisheswe
tcrcntlythanwilh in(loorturnilurc.
SPECIAL PUBI-ICATIONS
Carr.vP DoudnsL.llicks !,4'r ti,.n/ Dotr{l$A nint' Ii' slartcrs,its inportarrl to bc w00DlmltH l0uRs
'lhc
S,niu/Cflphi D.\iS1?t:Chnsclnsrki ! /s\'. ,rditt: Cr{it selcclivcabort lhc lype of nratcdrtl firsl lltx){/s,,ii, ?brr lhis past
Ruc{sc{cer. /srrdr/ dt.r Jocl A tltss ! 6rapli. llvcryoneor
D6irr?6j vu N$yd, Jdrrh.n liikt ' Ediktiol Inkn: cnnry you usc.Ii,r all tht oul r)r pr(iccts Maywasallltal success.
'Ilxccll{]nt,"rnd we
in lhis issuc(lhc l'atio-l'nbl(orrpnsc boardralcd il as 'l'he pre
CIRCTJIATrcN (i thc llcnc| on prsc 14,flD(llhc'l'my hcard srch comDrlrts:rs
S!?crb.r&ni.6 Dietr 5 yBum.NP&,KtdCtE I4C7- 'lllltc wcrc cveobcltcr thanl
oll pal{c 2(i) wc chosc ccdaf. scDtati(nrs
wlJrtuKrsh( 'l M!/hrrdd ltu4lffi Ma,asr k(* i,' i[iN .
.
lt,zd,a /rld. l1ifirk wdl.l' . f,mul r{sr: Ih!{' Ihrln ' Onc nicc ll)n)gabouI c('(lnris it Iosisls cxpcctcd'and Ilach daywasbctto'
Ai iU & A t,iiB ^lonoAt RtbNa Curniqit:rn ' Cin dccry, so it stands Lrpwcll to bcins lhar)thlroncbcfore."
lrrdrrry ,,,,,,4d lcis srhlr nnr{ t Asr cin ^htln iu A^1t8
oul(loot\. And il s conuloDly nv il So wc rc hitlins thc roadagainio
Prld M lr'Mdui. S/ GDrr,r2/ki4'a6 Mx4 Hiyr\ IlnbinFriund
coRPoRAtEsltRvlcDs
VPol I'inam: Mlty R. Schrvr . a)tt l/.r ltubin K
ablc. (W t(,und all thc nr:rt(!.ialwc oclobcr.Wcllbevisilinslhc shopsof
nccdfd fll a l(,calhomc ccnl(t soruc o[ Amcdca'sprcmier wood-
o
llutchin$n' &,4{,!rtr laun'J.'nunN . ,4dtr.pq'd.rMdy ot (oufsc, thcrc's rru ( lo bLril(lirrs workrF, sawmills, and tool factuies
J. thnlt . ,4dr /L..imbhr M{!n l\\rrs . lrtdu.th,h Dir:
ceor{c Chnriehr, . tr,.,Dti. Atlbrita rtdrol: I)d'sL$ M. a n o L r k k u p f o j i c t t h a n l h ( l y p c o f in the southcasternUnited Slates.
lisr.r . ,9ddr,4a,i,i{u r,r Cnsfii,*tridr* . rt M"r:trl,ittr:
r/,s€ sArirt^
'l
ruyA cltL M nlidk wood you usc. ltc projccl ilsclfhns lo Ar(l to top il oft, thc fallcolorsin thc
Iilkd D crk! fu6
Jolssr t N.& M.dr Mg. Gdon C Cdppc ' lv., stlc,4'r bf buill lo last. Wc dosisrc{l thc Droj mountains shouldbc absolutcly spec'
,irr Gr& P.iltr$n . lv., S?rrr,4/ri, : Cnolltluppld ' c c l s i n l h i s ; s s u 0w i t h l h i c k , b o c l y lircrlar that li e of ycar. Iirr nrorc
., C,/i.rl M{ : DavidBn*!s. StrcM. Moo . ., t.Jk ./
rsr{ lll.ssins . t},/.srta/ D.!?/'r42,r rit: Mi.hd Sisll ' parls. (W. used twGby nulirial and iDtororatil)n callJiIn,our tour coordi'
4 C /sr: Ki^l€n Ke lc t Rr.srrid'nr J.innc Jonnson. Itdir 5/4 rlcckins boards tu alnn,stxll thc ralof, at 877-8:llt091:J. Or visit orrr
Ren/DeIi!r4: b!Wthlxl
wod(picLcsitl oof projccls.)Conrbi're websitl]: wuu.woodsnrithTouls.com.
WOODSMTTH IVIAIL ORDDR
aruotio6 Dindat: l\ah B^ktt 'cte sPt!. r'Azjtr'i llu '
zrd,,e sdr NancyJohnson r 1',o?'rLi hJ,Jncs' 7i.r'
sr/rk. R.r.rlohnnyAdenc . /rrn' ,,]sd: N.nq Downrv
! Sr C6r. s.'n f,.A j l ammyTru.kerbrod, Anm cox, furil
Revell,Dtbornh Rich t Cd S.- ^|rti Val.rir Jo Riley,Kinr
Hrlnn . Itadp6.: sylviactroy
that wilh nrinl;sc and tcrronjonltsand
splinod Drilcrs, ard yor havc sl rdy
rrroj('ctsthat willlast f(rryca$.
Ilul don't wofry thll all this hcavy-
'f'^'\
duty constnr.ti{nr will rosrll in a
WOODSMITH STORE heavy-wcii{ht projtct. lll addilion to
Mrri Dav. Lrson . Asr MarrsP'i Tinr Tlr.l.n !.V/a Siz/f,
Ws{t€llslone,Im aencr! try Modi.{tr, Mtrk.lohMn, Ctu:ory
r€u/e .ofts iki vicki Edw.rds

$!'r Linu' ht 'r'h . $r J,n.

Woodsrnith Gallery
Readerd
GoYrlcho?Lr'Au0jHu[hb|i-|'inFcomF!^lLri!|'Llfni Visitother Woodrlni|, sub$ribers'workshops,and see
suha;iDdqn$ sn . oD srs5 rh! rrr i'b !nn'i{ ii n!c)
photosof the projeclsthey'vebuilt.It s all onlinein rhe
!s6/Fd lldd s SrdLud D'Biu! ^lmmdibh Por] new Readers Gauery on the Woodsrtrii/,web sit l
PoroMbikdddrddddr$h '
**w.woodsmi6.com
MoDc'lA 5{r+r9s L4r cn Lmr} We wd1 you to be part of lhe Rcaders
Galeryl To submit photos of your favorite
wond wde web hrrp//ew wodsmis cqr Woods,rilli projects or vjews of your shop.
ftintedinu.sA follow the instructions you'I find at the
Reader'sGallery.

AucusrHoI,G
No. 142
 Cowrsxrs
teolures
P a tT
i oa b l e .......................6
This tablt will hecomethefocal poir.tof anJDatioot d.eck.
ks roundtop andsnrdl baseare thepeicct combination ol
graceandstrengtA. And u,id1., r srep-bl-srep
insmctions,irs
constrltctionwon't throu Jo dnf cr.rtes.

W r a p - A r oBuenndc h.e. .s. . . . . . . . . . . . . . . 1 4

Desiened to comDlamenrrhetabb, thesebenches
hac)etheirown
challenge - uorl<ing
withoddanglcs. Burdonl won1.Thcreara
lotso/ liDsondsimDLligs to makcbuizing themsLraighllotuia.

M o r t i s&eT e n oSno l u t i o. n. .s. . . . . . . . . . 2 2 WtaP.

Here are our fauorrteshaplesredsoirlions f(r mafting nv)rdscdnd Around
tcnon lr)inrs - plm a feo shortcutsthat uill bt you cut thcm Benches
faster, eruier, ancla little nue accurate$.
I w?11

TrayTable .........26
Trercisnothingrric/rlaboardrirsmdlsiderabic,brurirere'sm,rrc
/rererlan/irstmcctstftee)e.\Virl a Aandlc g at cachav|,
olenirr
theRD convnicntly liftsolf rhebascto bccrmca seruingrra1.

W a lSl t o r a gSey s t e m . . . . . . . . . . . .3. .0. . . . . .

Wdnt ro mdximireev€ryinc]rirflolrr shopor garagc?l{cre s a
nrrnqc, loufrlle slsrem that is easl to reanange(t a&l on n
latar). Anrl yu canhavcir builr in ahnosrno rimc.

O u t d oFo irn i s h e s ........34

Hcrefra quickloo/tar rwol)oputuoud,aotfinishes:
extenor
polynretlranesandpencrratineoik. Leamhowto lecifu whicht'in-
irhisflght/or tom nc:rrouiloorprcject.

Deportnenls
T i p&
s T e c h n i q u .e..s. . . . . . . . . . . . . . . . . 4
Wail
Stonge
S'6tel1r
P6se30
No. 142 3
 Tps& Tpcrnu
AdlustobleIenre
\Vhile readlnsyour articlc counlcrbore(l into the
'litbl( '11ti(
Sur' tlt trot\l tcncc,scc lris. lb.
issueNo. 1:lll l decidedit Irinall,v.you (lrn scl lhe
was (inx'tocheck rny saw fcncc b !)0'wilh an All(r \i
Bul after clernirs and wrcncn ano r sqLrafc.
luning the e tire snw.I \br can scc how lh( s.l
realize{llllat my riD fr|cc scr$vs afc rdjusld in lhr
c(trrld r)ol be adjrsl{rl 10 pholr)al ghl.
l ' 0 t r i\ , , 1 , d t r , r r
FREE Whrl I cnded lrp d0irrs \ 1 . , ' ! , / L ii.i ) n \ \ r d & L /
OnlineTips was rrraknr( a lully
irdjLrslrbl(auxiliary i( ce
1r)alla(.h1olhc ri1)I(i)cc.
nglps thesou- As you car sc. ir lris. l,
i l s a j L r s la | i ( t 1 o f i u l ) | .
l n r l N h n l : r l l o w si l l o b c
websileandsign
a(ljLrslc(l irfc so,,x sct
'lh.sc
lreeUpva emal scr(ws. crn l)c
adjlsl(rllo n n l ( s u r 1l l x
i( n(.c is pcrp.n(licuhr lo
f
IlUiklilrs lhc f(rre. is
nothir)J.t nn)r'(than dillirrr
a liw sets oi h,)I.s. Ihr
b a c k( , 1 l h c| u r ( ( f c L (i v . s
'j:nrls
{hrl hol(l lh. scl

l,) rltrch thc :rrxiliary

idr(c l0 my fit) trrr(.. I
us(d a D:rir of l(nrJ..
r|achinc s(rcws lhat afc

lpringClonp Koorie(onnerlor
Snullfrar)res caDboa bear p h o l ob c l o w I { r ( t r r x l l | c I rsc nry shop vacuu r ld- :rge 1i0,:;r, ljls ri,{lr1orr1o
r') clrr]rpoDso currcs. tips of th. clanrt)t{) poirrts. drlsl follcrli(n or x lcw of :r vacuunr hose. All yoLr
'l}(,sf
So I carrrcrp with lhis l)onrlsbil(, nrt0 thf my snralh Duchines.llol have 10 do is enlarse thc
quick motlificnli(nlt0 au w o o d a n d h 0 l i l t h e r r r i l o r llntlingadaptirs cattsotrtt smrll hole on the botloor
ordnr:ry sprirs clampk) lishl whik, lhclrlft (ldcs. l 0 f i l t h r ( l u s lp o r t .
hel| siIlrDlify
thi0ss. llrr ll,rfh \{cll it jLrstso hapDcls /nn,tlJ(llrrnn
As you c.rr sL'1.in thL, )iadr! r'n ( )hi,l thal :r lornr fLrbbefbever- { ) r . r h r r 1I .l i w r n i

No. 112
trollopedCornerJig
Not thatlons aso rvhile
makinssomcplaques, i corner, I use my hand
cdnreupwitha qrickjisfor
n)akinssomcdecorative
scallopededscs,Iike the
oneyouseeh the margin
phol{)on thedsht.
'nrejig
isjusta plywood
baservilh a pair of wood
clcalssct at il0', like you
sccin l.'is.1.'llese ck'ats
positionthe workp;eccso
lhes(allopc t in eachcor
ncr cndsup idertical.
Aluminum
Anglelporer
'li)
\\'hon boild;ngthelmlc 1
h r n i s s u o N ol.l 8 , l l b u n d
a n o l h r . ro s e t o f l h e a h r -
nri'n'manglesrrrk.]i h{rlp
:rli!.n lhl] drawef ir.(nlls,I
used lhf cLrloifsas spaccN,
as in thc dnwnrs below
No.112
To cut thc arc on each
held routcr It pivotson a
snrallpin,asshownin fis.
1a.(fhis ph is jusl a nail
with the hcadcut ort)
T0 allow thc rouler to
fit ovcr the pivol Din,
all I didwasto renoveone
of thc screws lrom the
-lhen
basc plat€. lhc pin
fils intothescrewholc.
'lhe
sizeoi the arc will
dcpcnd or whc.e you
usc lh0so spacfls.
all you need lo do is Dlacc
x snrall piccc ir) caclr
lower cofncr Not ollly
does this misc lhc drarler
front, bLrl it also centers
the |iece in drc openins.
placc the pin on the jis,
butyoucanalsomakethe
arcs smallerby position
iDs scrap spacerblocks
againstthecleals,jusl like
]ou scein l'is. 2b.
But beforeyou usethis
tcchniqueon a workpiccc,
youllwanl t{)nrakca tlry
rro on a scrappicce.
'lhis
alkrws you to see
wherethc bil will cut,and
it alsogivesyoua staftirg
andstopt);ng poinl.
I us.. thc spacetl\al(nrs
with sornc doubk si(le(i
lapc t0 l|lnporarily allach
l h c d m w c r i l - o o l s . ' l h e nI
scfcw il in pcn]raflenlly.
'I',lnrirtrr
\ ll, ,tr lrlorr
To rout the piece,I first
clampil downwith a pair
of toggleclamps.Then I
maketwo or threepasses
to cu1allthe waythrough.
ln l.ig-2a,you]l noticeI
start in the lowef corncr
and rout ;n a clockwise
dir€ction,or leftto rishl.
Oncelhc arc is cut, I
canthelrrout a decorative
delailall thcwayaround.
NorS./mu
(]/taldl, ALrL,
If you have an original shop tip, we
would like to hear fiom you and con-
sider publishing your tip in one or
more of our publications.Just write
down your tip and mail it to:
Wood,snrith,Tips and Techniques,
2200 Grard Avenue,Des Moines,
Iowa 50312.Pleaseincludeyour name,
addr€ss, and dal'time phone number
in case rve have any questions. ff you
would like, FA\ it to us at 511282-6741
or s€nd us an email messageat wood,
smith@.roodsmith.com. We lvil pay up
to S200if we publish your tip.
Here'sut outrlocnfiroiectthat'sbuilt
wirhthcsunecmermdoafsmanshiP
asfint, indactrfu,mittre.
o parcd to othcr lypcs oiiurnilure, outdoorpfojccts
are rcally prl to lhc lcst. Itxposure10lhe ullraviolct
raysof lhc son and to extrsnes in heaLard h(midity
nrea ihatthe projccthasto be dcsigned10 lhsianda
-ltis -
l{)(()fabDse. ortdoortablcis up lo thecllallenge
yel its design;sasaflr'aciive asit is slul1ly.
BAtt.Tomdkelhe baseof the tableasslrongaspossi
blc,il s buill asa lh;cktrr e that'sjoincdwith halflaps
and through nn'1ise and tenons.No suryriseshere.
Uftal is suryising is how q icldy tbis basecan go
tosetherwitha fewsimpletipsard shortcuts.
o(IrcoriAr ToP. Bul lhe realattracnon ofthislable(and
thc partlhat haslo withslardmostofthc abuse)is the
rop.flri. i: an'i8ht.id-d ,r}rF drr' .dprur.- " s.ric.
, )it Lrr h1 a tr ry'cluir\/.,r r,ij ',,ltr (.a
rir,rrr tr,,,. ru"r l,l,o(,, ,r rlr canl,rriftirlur
rrrarcli,slrtrclle:.l'ltnsvr! ! or f.rrr l4
oi nafr)w slals.lb rnakcthc mileN ot lhe top namcas
slroDsasthebasethatsupportsit, I adde(la thicksplinc
to cachend.(l-heslatsarc supDortcd by sinrplecleats
addedto theinsideedgesol tbc framc.)
lfbuikling a b;g circularframcscelllsa bil in[midat-
nrg,don'tworry.You'llgetplentyofhelp- lionl setljng
your miter gauscaccurately10assemblinsthe frame
(wi!ha sinslebandclampanda handftl ol screws)1(,
r,,utinsth. circl.wirhan'a'J ro-bu:l,l
lraurnl.lji6
ourDoon llilltH.Thelasll;neofdefensc{qainstthesun
andrain is thc finish.Flere,I useda sparurethanefin-
tt'
ish. Unlike a deck stain$a1 needsto be recoatedevery
year,this typc oi finishis moredurablc.For moreon
choosnrg ootdoorfinishes, seepage:14.
No.l42
 Consfruction
a Details
OVERALLDIMENSIONS:
52"Wx52"Dx29"H

\ir. \
Y ::--'.=

--....---_l

nlL

MATERIALS& SUPPLIEg
FrameSegmenrs (8) 1'b x 51/,- 23 er
B Spines(8) t/rx3'2
c eats(6) tbx %. 19 '9t1
D Center Slat(1) 1\5-42
E slats(4) 1x2tsl6-42
F Slats (2) 1 x 2ttl6 - 44 en
Slats(2) 1 x 2tt/b - 18 eh
H Slats (2) 1 x 2t5/rc- 31 'sh.
I slatsl2) 1 x 2t5/rc- 25 qh
-* UpperRals(2) 1th x 4t/r 463/a
LowerRals (2) 1t/rx4t/r 46i/1tsh
Feet(4) 1 x 4t/, 4t/,
M Legs(4) 2t/2x 3 2l
(28)#8 x 1t/a FhWoodscrews
\2a) #8 x 15/s'FhWoodscrews
(8)#8x2 FhWoodscrews
(8)#8 x 3" FhWoodscrews (Forassembly)

No. 1.12
 a!. @sPrlv€

)h roundavets

@
I
{

@
.'Q
2

Iop Irome
'li)
buikl this oLrt(l(xnlablc. I s(rr(({l
with lhc lot). Ii)r now' lhc soal is lo
bLriklrla|g{, ()cla(o|al irann . rsyou
can sce in lrig. I above.Latcr yoLr,ll
foul lhis []rne nrto r (ircLrhr shrpc
wilh a shollrra(1. tmnrncl.
(Ul I0 noUGH 9 l ut . l h e l o p s { a f l s
oul rs.isht i(lc|ti(al /){r// tiv
, r , r h _ l , l ) l h a ta f . ( L r t l i ) f o L r , r shi r .
trull (.(laf 2x{js. (l ctll my blanks ,f)
5rI i x 2lIr.) I )irxixlirrs on the c()n(li
li(nr ol youf lunhcr. y(trrnraywrnt lo
joi|t and plnnf il so llx lraox crrds
u 0 f l a l a n d i l s c d , { c sx r c n r s h . I \ r l
nolc thrt lhis will a[f(ct thc thi(li
n c s s{ ) i l h c r k l r t s t h a l w i l l b c a d d c d you havc a t)ow.f rlril{r slq il rray s l { nc L r t l e f b i sl ,o I L r s c ( l a d a dbol a ( l (
l a l c r t i )h o k l ( h f s l x t s( | i s . l b ) . h r v c r | r e s f l s l o r )l o r l h i s r n s l ( . ) ir) thf trbl( srw. And lo srlDDorllhf
-lll w o r k l ) n r r . I m : r ( l cx q u i t h s l i ( l i n s
MITIRtil0s. llrst lhiog lo do lr) V ) u l l w a r r ll h c n r ; l c rs : t L r sscr l r s
lh$c scanrHrlsis 10r]rit{r-thocnds, accLrntclyas possibk - it'll nltan carfiasc,which is shownon prsc 21.
rs shown in lri,{. 2. I'or r| cishl l( ss nnr tLrninj..wh.D yoo slu( thc IttafttPLliltg. Ncxl, you c r ctlt th('
sirlcd iramc, you ll llccd lo rotatc Irxnx blnuks losrlhcr And f(n a splirris thnl fi1 in(o tlt(sf slots.
'l'hcrc
yoor orittr sargc 22rl:' (lc|'l-(s. (li q L r i c kl ( s l o l l h c s c l l l , t l y o L rl c e d s lrnn-i to this lhan jrst i{cl
afe a scraDpicfc an(1r 15' triaoslc, lins lhc dirneosi(msril{h(.'li) cn(l rp
as shown iD ihc box al left. wi(h th st(mgrsl jonrl lr)ssilrl(,
W h c r y o l l i - e( o | r f i d . n t t h r t t h c t,ou wx t lhc grrir (nr lh splir)cto
nrit(,f gauge is scl ac.uratcly, yotr f u n d . r o s s t h c j r ) i n l l i n co I r h c l w i r
Foraneightsided&ame, caDadd ao:uxiliafy ienceaodNitcr pi{'ces yo 'rc ghins losctlrcf, :ts
you needto cut an acc!- onc el(l ofo:rchsrrnrelrl. llut beforc showr ill lho m sin t)holo xl risht.
'ller
r^le 22t/r' miter. and you nril( r thc othcr rnd, a(ld a sbp e { lwowryslo nrakc1hes0
here's a quick way to bl(k to tho aLxiliary fence,as splincs.\'ou coukl Dl:rncsome sloclt
checkyour setup.Firsl shown nr liis.2. lbis way. all tl){' d o w Dl o r / ' l h i c l t n | d t l r c nc r ) s s c u t
niter ascrappi€cein hau. picccs r'rxl up exactly the same t h o r ni u t o 2 ' l ( t r r gD i e c c sO . r ii you
Then dry assemblethe lcnsth (which isjrsl as irnporlanl rs dont havc a planei you can cul
pieces n€xt to the rip gcttins the angleconoct). thc|r iiorr lhe ernl ofa scrappiece.
fence,as shown here, (UI SIOIroR sPtltlIs.To make this ( l ' l l s h o w y o uh o w o n p a e e2 1 . )
Ar this poinl, the
rf
Now a 45" triangl€r,ill fraDc as sli)ng as possiblc,I decnl As9tM0tt tRAr,ilr.
jy'r'Llhick framc is feadr- h bc asscmbled-
quickly show you how ed t0 add splincs belwee
accurateyour setupis. thc sesnrenls.-lh€ 1'-dccp slol you and this pfocess will bc a krl less
nccd to cLrlf(' lhis istoo nuch ior a hectic thar you night expccl.Thafs

Nr.Ill
 becausc I slued up thc n.ar e just
two picccsat a tinre,ash t ig.3.
To assenrblethc scanerts, you
Bandcianp pu s inside /y - \
arc going to \rant to use a gluc
lhat s nudc for ouldoorLrse.(l chosc
p o l y u r c t h a i eg l u c . Y o u c a n f i n d
'Dofc n orlrntnm aboul thissluf olr
our ilcb silr. seerisht ur gin.)
'Ii,
hold oach paif of segnrcnts
losrlhcr,I first dfy asstrrbled lhcm
I s i n s a b a r ( l c l a m pB . r 1 1 h eo u l s i d e
co|ncf ten(icd10opco urr.So I crll a
nolclr |ear onc cnd of cach picce.
usins a band saw llxrr I rrlr ,r
scf$r acft,ss lhc j(,i|rlinc o{ cach
r s s c m l t y .a s i n I r i g s . : ln r n li ) i r .( 1 1 ) c
Iolch is parl oi thc wrslc seclion
l h a l w i l l b . r o u ( c da w a yh t c r )
'li
onc mor( notc: avoi(l havi|s
l o l | n n l h c s | l i n c sl a l c r o r r . lp u s h c d
lhc splirx s in so thry wcfc lllsh
wilh thc irsnlc com(r (,ffach j(,ir)r.
'
( l h c s n r a l ls a p st h i s l q , v c s w i l l b c with pipeclahp
vlEW
c')vcrfd by lhc sl ts llt(D ai)
Alfr y,)r hl|ve i{,ur prifs ot scs- - gldo€ eap'
r i r t l s H l L r c (Ul p , y , ) r rc a D U s c t h i s
M r r f l c c h n n l u cl o g h r ( ,l h ( p a i r s
i n l o ( w , )h l l v ( s . l n r l b c t o f c i r l u i I s
I l ( h l l l v (s l r ) s c l h { . Ir ' o u] l w a | l t o
( l r ) l s s r r l r k t i t l l r 1 oc l k r ' l { r h ( i r -
1 l l .( A s y ( t r r. i r r s { r ' i n I . i J rI., l l , n r ! {
t ) ' r ! .r L u ) r t )| l i . w , r 1 i sj l s t l l x , i o f
t n r l l i r At l x , t ) i 1 \ \ ' st , ) $ l l u )
I l y { , r f n ( l u t )l v i t hI l i l l l ( , q r p ,l i l ( . cllrls so tlx slxlswill crxlul)llush r(ldc(llhcf.rkr.s/.r/f1lr.As IDxI
l l ' . ( n r cs h o w ni n l : i s . , l x , 1 h c n y o ul l wilh lhr tol)of lhc ir1nrrc,
rs sh('w| 1i{)rx(l .rrli(!-, it s nradf ir1,n 5/4
wrnl lo plallf lhc cnds with I hrnd nr IiJ...lb (l us.(l 5/4 deckinatrn. dcckins,arrdil s cut to lcnsthlo fil
l r l a n cs , t h c y1 1 f i l l i s h l (. l i c n r (n r b c l Ilx shls. w|ich is aboUtI lhi(.k, nrlolhr lianx (|ia. I).'lhc' brirl
l o n r a k cl l x s t ) l i n e s l ] r x l lr 1 o o . ) sc| t)ase:t5.)'lhr 10gcl llx (.l('lrts allachinsil lo lhc ir:IIc, arls,
ftArt. Wilh thc frr . asscrrrltcd. to fit into thc ianx withoulsat)s,I foundovcrcar)bc roLrt(rlaroun(lils g !e you
lrelhane
i l s t n n c t { ) i r ( l dt h c r 7 L w ' i ( l cf / . ? i s nrilcrcdthc.n(ls at 22rl' (liis.5) lot) iacf (,./ l|lurlathc irsnle oflhc
{ ( l l h a t w i l l s U p p o rlrh c s l a r sa, s i I irndnlt:rclx\llhcnrflushwilh lhc lmnrc. (ltuDembcr11)rnovcthc
I r i s .L V N o n l yn c . d s ; . r ( l c l t si n ; r l l
websiteGolo
bolt(mrofllx lmme,asnr l.is. 6. forlcf clockwiscarouodthe irrsidc
( l w o s e s m e n t sd o l l r ( c d l h c r n ) , cllttl StaL\\tcu rhc .k'als wi'r1 of lhc ft:rnxr. Nowjusl centcrrhc
xnd youll wlnt 10 lhicliD.ssrhc shcd n|d s.fcwcd to th. ifamc, I slal nd scrcwil in place(liis.7)

No.1.12
 al. sEcfloN vtEw
I
@ e

b.

/r.€nt€/td1 b r...pl
prlot pont ot trannet

Iop lrome & Slols

W i l h l 1 l ( , f n r n ( a s s u ) r b l u l D { ll h c
e c r l ( r s l a lc 1 l r t d l { l i n i l s o t x l r n r s .
y o r i 1 , r ( a d y l ( , r l n r l t l xc i f ( l ( i u r n l n l
'llxrr
l | l , t r r l s i ( lr((, l s e , , i l ] 1 , l l b l ( .
l h i s l o l l h ( s l r l s w i l l b , r ( l ( l , r ll 0
l i r e l f a r ( , , x s s h , N n i n l r i s .S .
R0UIIR T R A l t l l l l tIti .u l l ) r ' l o r ' ! i ) r
r'!r r(nrl lx,lfrnf, y(nilllrr({laiirif
l v | u s c l f a r n r ! l - r ) ( t l l l l 1l v i l lc U l
a : l ( j " r r ( l i u s . I j J r ) u ( l , , r r ' 1h r r v ( r
l f u | l | l x l l h i s h r s { . ( 1 ( ' r ' lw o f f y . I l
( ! r l y l i 1 1 ( sa p i ( ( . r ' o iL / ' l ) r r ( l l x ) r f l l
l l | x l l s h , , r 1( l ( ^ v . l l o n R I ( o r x . r s
s l x , w ni n t h , b r ) xh c l o w .
D n l l tN 0 t t .\ \ r i 1 h( l l { l | r r r r r r x l ) r 1 i l l ,
y ( t r ls l i l l n ( 1 1 l1 , )( l l l ! l ' " d i r . l x ) l c
i r l h ( ,r u r t ( T s l a t1 , ): r c ( . I ) l l n p i v ( n
t x ) i r l o l h c l r a r n r r ( ' l .l h i s h ) 1 . l r r s
tr) b. e.rrl( 11ll rxu(lly, so hc sLll1lo
{ l o r l n . { 1 r (c k y ( , u fI n (r s u f . ' M 1 1 s .
N , , 1:( l l y o U i ( . , , / t ) l a r n r i r 1r l({)o s c
a n f l r l ) r ' l l a w i l h l l x , l l b k ) ( l( l o r ' t
w a n l t l x p i v r ) lt r ) i r l h ) 1 . i r rl l x l , ) t ) ,
y,)r roul(l s.r\v x st)rccf 1,)thc b{)t
1 , n n{ , rt l x r c l r ( ! s h l , ( l d l l a h o l ( i
lhc spaclr rnd lh{!r rlnrlthr(ifcl(' )
l i { , n rl h c / , , / / , , , rs i ( l ( , o f l h .t r : n r ( .
RoUlfnl L I]{ lorc yo(r lum on
t h c r ) L r l c f .f i f s l s c l : r ( o u p h s c m l )
I i ( c r s L r n d clfl x f f t r r r ( .a s i n I r i a . 1 ) .

Ii you don'l havea Iargelli|rn- Wilh thc har(lboafd basecut bit is in just thc right posifion.
nrelfor routingcircles.youcan b sizo,lhr nrst lhing 1()do is SoI cam€up wilh a shortcut.
buildore h a fcw minuk'swilil layorl anddrilllwo holes.Thlr I slartedby drillinsa r/" dia.
a Diece0i 7r hardboardanda Iirst is ror thc '/." dia. dowel hole that natched thc diaDre
dowel,asshownbclow lhat actsas a pivolpoiDt.lhe ter of the Y2rspiralendmill bil
secondholc will be dilled at I plannedb use-(A straishl bit
the fouter end lo provide will also work as long as it's
accessfor thc bit. ]lre goalis long eDough1(lrout through
ior the nrrirt, c.lgr 0f the bit to thc 1rl:rthickfiame.)
end up 26r from the c?rtzf of Now mount the bit in lhe
the Divotpoint,as in delail b.' routerandset it into this hole
H{rwever, it's a bit awkward - it'll positionyourrouterper-
lo attach the rooter to lhe feclly whilo you mark the
mountingholes(detail'a).
Beforeyoumounltherouter
to $e rrammelbase,ifs a good
idea to enlarse the hole so it's I
easierto seethe bit. Then sim-
ply glue a 1!r-longdowelin the
baseas a pivot point.

No.1,1:
-lhis
way. you wo t rout inlo your
b e c h . ' l h e t { ) g e 1s t a r l e d ,y o u ' l l
have 10l(^ver Lhebit;nh lhe lramc.
A d while rouling. youie goal is lo
irnrirnire chilxut. So here are lhr cc
stepsyorl carrtak--10avoi(lil.
Irirst.ils besl to take /irri fasses.
'Ilkyi?
lfss lili--]1/to chif oul lhan
deet)ofles. (l lowere(l lrly bil only
rlL wilh ea(h pass.)Sccond. movc
lhc fonlef slowlr'.Thc nnnc wood
t h c b i l l i c s l o r c m 0 v c ,l h c m o r c
l i k (l y i l l l l c a f o u t .A x l f i r a l l x l h i s i s
onc ofthosc icw occasiorswhcn Itl
reconnncnd baclifoLrlins. ltn onc

_,--.=--_=_z
thin(. a hand hekl oper ti.)|l is casi
cf lo h(n(l s|cufely. Irlus lhc forlcf
is lxl{l in .h(ck bl, thc lmr ncl.
RoulDovtR & 5A[0.Whcn thccirclc
h a s b c c n r o L r l f d .y o u s l i l l n c c d t o
roul x /s" roundovcf,lhis tinrc in :r
.or,/r f./rntir,6a, dir|cti(nr af ourd
bolh (nrlsnl( r(ls$, as in l:ig. 10.
tlAls. As you can scc in IriLI.fl. all
l h a l s k l l o r ( l ( l l o ( h f l a b l ct o t )a r (
thc shls. Wxrr LIlliIJt thcsc pic.cs
t,, l( r)J{lh,y(nr \!anl thcnr lo fil li{hl
bclw..Il 11x,il.lrrr', rs sh(trv|rin lril].
l b . l i r l \ ! l r r l s r r , r l i r n t u l r u r ti s l h (
s D t ( ! l , t r r r , l h , s l r t s .l l r f r , y , ) u
\ v a r r l ( o r s i s l ( ! r/ls 1 : a t ) s $,ayin. ahlaysji,ll,)wirsthc sx|lx, s i ( k. 1 In ( n ,] , ( n r ' l l f i l l x r| l ( ( 1 1t r )t r i r ) r
l I r ( ,l w o s / r / s l l t l ( n r. i r r h s i ( l ( , , 1 r)forr(lufr, asshownir)l.is.ll. il slishlly rrrrfowcf (r'( v.n .|l a
l h ( , f . r r 1 1 ! c ( t r r k hl b . l n y . i r s i ( ! : IriNt. Isrl llrr blankin rrlacc, D c ws h l l l r x l s a 1 i 1 1 w 1 {n k ' | .( 1 , ) x l i r u
'lhcy
r ' ( ,s i t t n y c u l l o f i n l l L r r g l h . usiraa spac( il. llx!r I r 1 pw i l h o I c s l a rI l i r r l (d, i I I ( r( ! r r t h l l
r li) t),,siti,nr
Ii)r ow, I rrrr-( ly s l lhcnr in t)Lrrc rrafli(\l th( l( nHth,,ll lhc l]lnx,. l h c o l h c r s i s n , s s n o l i . l r l n ( l h l l
rrxt l,) lhc curl(r slal, usinirr/s" Wr.r nrilc ns lhc piicc to l(nsth havirrgirrcortsisllrng.rt)s.)
stlilfffs D.1wc.l llxrD. (l:iJ..l2), I Lrscd a slopbk)chso 1 R o U I I D o Vt D I RG t t .I l ( L ( 1 I l , s l l r l s
Ilx r.rlririrs rrr/s r/,:(;, //. /l .(nrklcullwo slalsrhr sanrclursth. l r - ( r i l r c l x r l 1 0 l l x l a b l , l l x r r J s a l
'1h.n
r c r l l y x r . r ) l r r t r r . hh l f ( 1 . f . ' l h c y i ( Iwoul(lsct the slntir)placc L/s'r-(truxlovcrlhxl s roul.{l or th.
r u r i l ( i r l o n . c h ( , n d .b u t t h i s i s l andbirin workorrihc ocxt. l o r r f x ( . o I c a . h , s l l l r t i | r sw i l h t h f
sta dxrd 15 rritcf an(l shoul(lnt Ileli)11yoLlnrit(f thc laslshl, you c r t r l s . ' l h . r y o L rc a n s c r o v l l l l t h c
J.aivryou any lfoLrbl( l sllrlcd wilh mishtwrnt kr doublcchcrltthrl il s s l a l si n 1 ) l a c e , l n r l l n r ss i n l ] l (s c r c w
the sltorlr,st sla( an(l workcd my l.toinstr)nl wilh cqrrl saDS on cillx!' n r l l x . c n l ( r o f c l ( h . n d ( l : i s .8 r ) .

No.l1? IT
 Boce
The lasl section10buildis the base ilf
thalsupports the1otr. As youcar see E
in l.;g. 13,Lh;scons;stsot a pair ot
cr{)ssshar)ed assenrblies t}n1.recon-
necledby i{)urshrdy legs.
-fln
oushnn'1jsean(ltenonjoirls
and hali lapsmakeror sonrerea1ly
slronsjoineryhere.And i1snot as @
tirrc inlcnsivc as you mishl lhink.
Thcrc arc somcshoftculsyoLrcaD 27
taliclo spccdthin,asup.
(Ut l0 tlzt. I startcdwith lhc
tttt.t (.1)arl(ll.t'ti ,.ril,- /1i/. All

a"r,i l
tourpicccsrrc LLrlfinn2x(islorkl{)
lluishcd wi(llh(.lLlt).lhtinslcad of I
ruttins thc kx{cr rails lo finishcd
Icnslh.I nradcall lhc rrils thc sanx'
size(.1(i:7") t)r now,as showDin
'l
Iris.r1c. hisway,thcjoinffy on rll
i)0f pn,(s willbc i(lcr)tical. @
HALI taP9.'llxfirslthinsI dirlwas
lo cLrlllxhalflaps thalj{)inthr rails.
asyoLr(alr scci| [is. 11.lvilh srrh b. srpEvrEw
l(nrsDn.ces, I lil( lo (u1lhchalilaps
al thf labli slrw.rsinl.rr {la(l('bladf h' .hant . @BAIL
Dlusa linA auxilirryt(rr(f scr(wcd
1(,tlx nrild sIUse.'llx.ll|lsl sl(1)is
l1)ftlisr thc bLrd.1lntilil s exa(lly fr
l)rlltlx thirhftss,nth(.slocl{, asiI
I.i(. Ih (\'oucrn l(sl llx hriJ{lrtol
llx bla(lcl)ycLrttins sonx,crdl:r0s
o|l scrat)pi((.s thrt ar'(,lhc srrrx
lhirkncssls lhf rrils.)
Whfn theblldcls scl,ils lir c (,r
sfl thf stot)blocksolhatalllhrhali
hps will bf i(lrnti(al.llerf, y,nr'll
wr i to nr(,Norcffonrthc cnd{)ilhe
11illoth. /irr shoLrl(hr:rs in l:is.1,1.
'lhis
wry,you cancul bolh shorl- Onc Dui thi ,{. Whcn sctting ilorfi IoP. whel) tlx, hall Lrpsarc
dcrs (nir)rrios 1h{ pn cc cnd-fof'cnd lh. slot) bl)ck, dorr't Iry il) gcl il irr cul, don l lrut awaythc dndo scljust
h.lwccn t)xsscs)rod lhc rcmovc cxaclly lhe d,{ht Dluccor) thc firsl ycl.-nx' ,/)/)f| nLilsncd 10 hnvc n
rlrewasrcin bctwcfu i illttr!l l11t\- l f y . ' l l r f i l c o u l ( l c l r du p a b i t s l o p p y . r/'d('ep l.ltbln'tcul acrossthc cnds,
iDrrlorclllovcthc sto]rlrlock(which Inslearl, il s bctlr'r lo s tak up on rs showD in l.ig. 15. Y( 11wart to
w(,il workthc othcrway). lhe fiurlwi(lth oI thc halfl:rp. snrak u| on lhc final wirlth of this

X?if;ftrtt, o@i,:i?

12 No.142
 rabbct until the piece fits into the
Iramc (andcleals).as in fis. 1s.
fioRll5lt. r\'ow you can put awav /.,.
thc dado blade and besin work on
cutting the o$rtises, as shown in
'l
Iris. 13r. hrough moftisesclur be a
rerl rhallcnsc,t{) cut accumtcly.tsu1
thc oncs hefe shouldn l givc you
a n y p r o b l c m s . ' l h e yc a n b c m a d e
Nith jrrst a ddll prcss and a jig saw,
rs yorr can sec in thc lcft margnr
phot(rarrdthc articlc orr page:3.
Since the walls of thesc n1ortises
$'crc lairly sDnrothaml didrit need ttGs.Irinally,you re rcldy lC)nmke
to bc cl€ane(iwilh a chisel, I deci(l the /.,qsfrv) that conn(cl thc uppcr
cd t() k'ave lhc corncrc rornd l(r). and hwcr assernbln's (lis 1:l).
(lt ll be a I(n quickrr to roLrn(lovef ' I h e s ( l c s s s l a r l o u t a s 4 x 4 p o s t s
that flre rut to finallefiAlh (27') nnd
'nrorc
afc slill fl couDlothi|gs t{) t h e nd p p c dt ( )2 1 l r ' x : 1 " .
do before th( mils can be glll({l (UTltiloflt. 'l herf s nol nnrch to
log('lher, bul now s thc tirnc lo Lul thc lcss. 'lhc firsl lasli is to ctlt
the lower nils to thcir 6nal lcnrlh lcronsto fil thc nnnliscs in lhc l.ails.
(ris. l:lc). Jrrst fcnrcrnbcr t(, cul a As you car)sec iD lri,...l(j. I {li(l th;s
liltlc frurr clch cnd 10koep thc hali wilh a dr(lo bla(lc al thc tablc saw'
hps an(l rrnrliscs centcrod. trsins tho i(lrcc rs a slo|. Ar)d rs I
(Hlllltn txDt. Now lhat the low(T n x r l i u r c d o a r l n i , l h . l c n o n s w c r c
n i l s r I 1 c u l l o l ( ! r r ' 1 hc, h l 1 i l , r ( l s r ( n n r ( k ( l w i l ha f i k l o n r a t c hl h o ( o r -
a 7 r ' ( h a r ) f c f ( l r i s .l : | b ) ,w h i c l lI ( u l rxis (t thc nr(rliscs (lfi!.. l7).
i r l t h c I : r b l (s a w ,U s i n sa 'lir
xiliafy c{n pl( lc lhc 1c8s,I rottcd a
i i r r r r l ( ) s o p l r r ' lt h ( t ) i ( c . r ^ , 'n n r n r k ) v cof n I h c i f c d s c s . ' l h e
I D Dr t I L ' l ] r ( L r s ls t ( t ) b c I ( ) l 1l h ( , lii{rshrins lhe basck)laclhfi it cn
' 1 r i l s . I n l)r ( x s s . r l b k { l i s l o r { l ( l l h . b. s.I1wcd lo thc lot),as in lris. 18.
/i./ l/, 10thc low.f |lrils, as sh)wn NoLISrcn U tRItLAI tTlli!. Oncc
'lhc$
nr liil.Is. Ill rfi(l lllb. af. just lh lablcwasass{rnbl(\I,I d dlk{l ccrr-
l ' t h i r k p i c c c s l h : r l r r f c o t , 1 r l : , , l(i({lholes for an un,lncllarnd n nal,
s . l u n r c a n d s h u l n L r s hw i t l ) t h . sl(l 1slrnd, asnr I.i(. l:i and the Dhoto
c n d so l l h e l ( , r ! c fm i l s . r l d s h l . - l h o s i z co f l h c s ( h o l c sw i l l
l s t t B t tr R r t P l t ( t t . ' l h f i i l s a r c vary. brrt lhr'fc s no nccd to makc
e sy cnough lo tlsstmblc. A c(nrlt( (hcnr tishl. Instcxd, lixrli i(n sonx'
s h o r l c l r r t l p si s a l l y o u ' l l r r e e dt o incxpcnsivcholi srw bils al thchafd
s(cufcthcnr.'l'hcrw r h o o t h c ! . h r e warc skrrc.'l hey'll dojUsl fir)c.
hls dr;ed, )'ou can rout ,r r/s' tlfll9H.Asl onarliinrcdcarlioi lhis ' Iir o*rt ccis fr alorllrl/l
f o L r n d o v coro t h Ch p c d s . s o i l h c lablc was finishe(lwilh scvcrxlcoxls dnJ., 'rd'.,lsrdn.i, i JrilirJ nDr.
i r ) w c f a s s c o r b l ya n d t h c b o l t o n r (n spar llIcthnne. Iior nroro o lhis t,og. I,ldi ir t,. .dltr kjD)s(1.
edscs ol thc uppef rsscmlty. ouldoorfinish, turn lo paso:r1.$ o r . \ f J l l . h , ) l dv r r h r r .

CUTTING DIAGRAM
r 5'h e6' cedat (Two Bo.tdt) 1 \ 511' 96" cedar (sl4Decking Twa soadtNeedeo)

1r/, t 511' 96' aedat (fwa soads)

'th' x 3t/1 - 96 Cedar (Iwa Boads)

I ffi 1' \ st/i 96 cedar (st4 Deckihg)

1 t 5t/? 96" C.dat l5l4 Decking lwa BoadsNeedeo)

N!.lll 13
 Wnep,ARot-ttrtoBrNqus
Therearebtsofanflesbuiblnn*wsekttle
benclws.Butwecmne
n mak.dleprocedme
upwith soluduts xnyisinfly srrai!.rfonuard.

hen it wastime to designseating

for the patio table on page 6, I
wantedto "breakoutsideofthe borc"
A squa.re b€nchwouldhavebeentoo
plain,anda chairtoo complicated,So
I carneupwi$ awedge€haped bench
that looks like it wlaps around the
outside of the table - with a seat
thadsbuilt with the sarnefralne and
slat constructionasthe top.
Each bench has quite a few odd
angles,but don't let that worry you,
There are enoughsimplejigs and
tips so that you don't have to fuss
]vith complicatedsetupsor wresde
]vith shifting assemblies.
Note:I built four ofthesebenches,
but ifyou needa couplemore seats,
you could 6t up to six cornfortably SIATltlflt. To build the benches,I shaped.This meansthe iont and
around the patio table. (Keep in started with the seats.As I men- backanglesaren'tthe 6ame.Still,
mind that the materialsandsupplies tioned, they're desigled to match youwon'tfindtldsto bea probl€m.
list below and the cutting dia$am the table. But instead of a round A singlejig worksfor bothangles.
on page15are for of, benchonly) ftame, these seatsare sort of pie Butmoreonthatin a minute.

mattRtalt & SuPPltEg

A F r a mBea c(k1 )
B Frame
C Frame
D Frame
Front
Sides
(1)
(2)
Splines (4)
lYrxslb-338h.
1Yrx3- 15ryh.
1Y2x3-21tsh.
Y2x4tsh.-2
fa SIDE

E cleats(2) t/,x %- 121a

F Slats (1) 1 \Z%-21 ryh.
G Slats (1) 1x2% - 19ryh.
H Slats (1) 1x2la - 16eh. SIDE
I Slats(1) 1 x 2./a- 14tsh.
J EackLegHalves (4) 11/,xZY,- 16Y,
K FrontLegHalves (4) thx2heh. - 16y2
L LegSplines(4) la x 3/a- 161/2
M FrontApron(1) 1 x3 - 1O3/a
l'f BackApron(1) 1x3-22515
O SideAprons (2) 1x3-147A
(8)#8 x lZa" FhWoodscrews
(8)#8 x 15ls"FhWoodscrews
(9)#8x3" Fhwoodscrews

Woodsmidr No.142
 (UIr0 slzt-'l-obesin.the /;?,i.
beck(.4),.lrottt( U), and si.t.s (C)
(?n bccLrtl{rft)ughlcrsth,asin lis.
:a. Lilie ihe fr"nreof the table,the
blankfor the backstnrlsou1exlra
wirlc fof the curve you'll cut lalef
(Iis. 1a). tsultle irontard si(lescan
be ppcdr0 nnishcdwidrh (3,').To
nralicsrrc theyie ilat ard n consis
tcntthiclnress, youmaywanllojoirt
andplaoelhescblanks,bul thiswill
alicctthe sizcofthe clealslatcr
IN|TIn
nD5.With the tr-aDrc picces
roushedoul, thc trsl lhins 1()do is
to miter thcir cnds.tsecruseot thc
shapcoilhe ftrlnc,thcrcarclwo dif-
lcrc|t ar(lcs to cllt here (1J,1" and
56"),ar)dyou wrnt themlo bc as
accurateas possiblcso thc ifamc
gocstog{:lherwithorl anygaps.
Forlunatcly.there's n casylo-
buikl sle(llhat will alnmslcnsur{:
a{(.trracy. Il s shownin l.is.2 abovc,
bul Ihcfes a ht rrn)rcon how t()
buikiarrdosclhc slodon |agc 20.
(UT9L0llon sPtttil!_ Wilh lhc cnds
ol lhc frnr ( picLosnri(rcd, tho
nexlslft)is l{)cul thoslolson Ihc
r|r(ls thar will hol(l lhc r/r,'rhi(.k
sr)lincs,rs shownin l.iss. I andlJ.
( l hcs. splin.slvillslf.DAthcn thc *E:-!'
Nore centet
c,rrxls r d |l lp alil.rr th. t)i(ccs
as bla.k .nd ba.l
piae whh line
you{luc llx Iirnx hsctixr)
Ilyor'vexlftidy builtllx oul(loof
labk, IhcnyoLrknowexrcllyhow
lhisis donc.Lr iact,lhcsa x jiswill
wo { jrlstfioef(,rlhcscr,.alrxpiccos,
cvcnlhorrshlhesc:rrctwo(liiicrfr)i h:rpp.n, lhcff s sonl( sh:rDiru{you holi's dri111\1 lj{;i rpar1.Iin llx pivol
an,llcs,rs ir I.is.iJ.Iir-nroreon this w i l l r r c ( l t o d o 1 0t h c b r r l i p i c o c , l l s p o i r r t ,I r a ; l . d l h r o r u { ho n c o l t h c
jis (a|d oll cLrltinsthc st|(nrscst you can sc|' in |iJl. la. h o l f s i I l l o a s m a l ls c f t p b l o c l ia n d
sDlincs possiblc), turr to pase21. -ll)
l a y o t t h c c L r r v co l rl h c b { k . l cancl lirlrcdlhc bll)ohlo my bonch.
IHAPIBA(fi. At thisDoint,lhc hool nrade a sirD c beanr rornpass, as (As you Lan scf i lii,l. ,1.I dfew x
andskle flaDrcpicccsarc rcadyt{) s h o w ni n | i g . , 1 . ' l ' h i si s j 0 s r a l h i ' r lilrc rlurA nry l)clr(]hso it was oas)r
be nsscnrbled. Brt bcforerhal ca slrir) oi r/$r' har(lbo fd with lw(, to alisl rhe ccntor oftlx, bacli pi.cc
withlhe pivotDoi0l.)
CUITINO DIAGRAM Now c('|rlcflbo back rrieccon thf
liuc and |ositidr i1 so ;t ll cnd Lrp5'
wnle.-lhcn alicr you (lm!v tho c fve
you can cut il oul wilh lhc band saw
(,rjis saw)and sandir sl]roolh.
Irc lasl sleDis lo crcate the han
'lb
1- t sUr' - 96' Cedar(5t4 De.king) dle 0pcnirg (l.ig. 1a). do this.
simply drillhvo l" (lia.holcs an(lcul
oul the wasle betweer theur wilh a
jis saw' Yor can e;lher rout the r/r'
roundovcr ar-oundthe opcning now
or wait until you r0ul the edges oi
lhe iralne aJler assenrbly.

No.142 t5
 SeotFrome& Slols
llv no$: rrrr shrukl havc four'llanrc FF
r:2.--
,!ffi.r!:,L.yi,i*
ltane --
picccsandsomesphresllratari' K'rdy
to bc asscmbl{al. llul l.athcrlhmshrr
'i,i::;' f'
u p o n c c o r D e ra t a l i r n c ( l i k c I d i d
with rhc lableliure). cachscatllanrc
is slu(d ur)rll at oncf in a sinrplc
rsscmblynrrrr, asvou can sct in lris.
;. It ll onlv ltLkf r rrimtr to buikl.flrd
vou Uonly ncr(la sirsle clanrpt(, pull
rllli,orrofncNofIh(fi-rnx'losfthcrl
A S S t M Bf 0I Y R l l . ' 1 - hf ci | s ll h i r r gI d i ( l
wrs (h) assd blf r fixnn rxtscl il
d r a h r s r p i r r c o f h x r d b o x r ( 1l l.c l l
I glucd s(fap l)i...s r(xl r) thr
f i - : n n fs i ( k s r n ( l f i o r r ( l d ' | l x ^ ( t h r
i r - r n x . s ,i l d ( r ' s n1 b c f o r ( a t x 1 1 ) r a

q I l ( n t t ) a f l r ) f t h (l i n r r )
lhrls alllhdl isro il. lnrl brli,rl
y ( t r rg l u ( u t ) y o L l j i s l l i x r x . i l s a
-jF=--; 1 I r ( ! xi (l l (a 1 or t ) t t y a . o r l o l l ) r f r l l l ' r
w r x l r ) l l x l i ) r 1 ) rl i.k e ! , n r s ( ! i n l l r (
r r x r ! . i r r ) l r ) 1 ,r)l k l i . i\
A s s l l t l Btl R l A l l l fI.l v ( r r l h n r l I . hl l r { '
L r r r r r c a l l vs i r r r t r l i lsnt h r s s c r r r I l r .
I s l x { r k l l ) , , j r t , n r l l w o l h i r l J s .l : i f s l .
; r sy o L re r L Ist r t i n l ' i t r .5 i r ,1 h ( b r t r l i
. 1 ) f i r ' r sa r ( n I l l r r n l l l o r i r i L I Ctrxl r '
f)
l i \ 1 l l : I i r l ( l r u l s { ) l t l ) .A l l L n n c o f
rx!s r|n,g,)i! lr)hrv. l rirlirs (Lrl
, , . l l u r i r j r l s lr I n I r 1 l ( .
'llx,
r n h ! ' l h i l t l { )r r r ( r r l i o ins l h i r i
v o r w r r l l r Jr ! ) s i l i { ) rtrh ( s t ) l i r !s : o
1 l l ) 1 . l l u s h t ! i 1 1l rl x i , , . r / , ' . o . r x ! s
( | i ! . ; r ) . ' l l r i s w r y . r ( , r Lr v ' r ' I I ' r v ( '
a r ! l r i n u r r il t l ( )( l ) k r t ( t .
n o u N Dt D G I 5l l h ( 1 r l l i ( r h r ( l n :
(lfn!l. Ilai(l oul rd flrl llx .rfv.s
,)r 1h( eofrxfs (lil].;;t) lltItt I
f o l l 1 ( { Il o u r n l ) v ( ! s o I l h , i n s i ( l (I r l llxrr so lll 5/l (l(r'ltirs borrds $ i l I l l x l x n l , ) n ] , 1 1 1. i|s i r l i e . 7 r L .
'll)
{)Lrliid( (!ls.s oi thr lrarrr(. xs \ r J l | ' l l[ i ( x s s h l s ! v i l ]o x l u t ) I u s h 5tAIs. frnnlt( 1r lh( s1rl. rll
s h { , w ni r 1 : i { s (. i a | l ( l ( i a . $ i 1 l rl l i . l 0 t ) o l l l x h l r n l . l l r a l i l ( . i l i s l r Jr ( k l { l r { s l i r l ' . I ( l i ( l
t t A T( t t A I 5 l.' , l o w! o u u r n n ) r r k ' 1 h ( I r r i l ( , r . ( ll h ( . r r ( l s , ) l l x ' . L r l s l l ) l s b ! s ( l l i r e l h ( n r i I I ) h . ( ' $ i 1/ sh
, r,ri s //il llrrl will bc rtlr.hrll lo w i l h l ! i . s l r r j i ! t t h r l I l | s ( { lj o r t h r s p r r ( r s l r ){ l l l x ! r L t ) sr.s s h ^ ! r r i n
'llkrr
t h i . i n l . p x , c c s , t ss h 0 w ni n l r i s . 7 . l i r r r ( ( r ( f t ! 1 ( )t ) r U C2 0 ) . l l u r l lfi( s l r n r f k ( 1 1l l t l ( ! r ! l h
'lh.
i r r t r n l r | l l t h i r r g i sl h r l : " o u s i r . s(lr{.(l llt cl('rls jn l)li(1, flu\h d r , / i n ] t k ,o i I l h . s (a l I ' r ' i t r ' x r r ( l c l r l

ac)sLAf
l

lll N o .l l l
 the slatsto thesela),outmarks.(the
slals are cut to lensrh to fit tighr
belweenthesides,asin Fis.8b.)
Oncethe slatsare nrirercd,the
top edsescanbe roundedover,and
you can auachtheD to rhe cl€als
with a screwatcachend (Fjg.sa). @

BASE
lvilh theseatofthebcnchco pletc,
it s tinreto work on rhe base.Ir
nralches theshaDcof thescalfrnnrc,
soI hadt0 makeachoicercuraglcd
tenons(,-ntortises)or rnakcrtrctess
anglcd.I decirledto nuke angledlegs
oul oj h{o halvcs0iis. 9),md it tr0.ncd
ool casiefthanI expccred.
ttc tiAtvrs.'lir niake thc legs, I
startcd by cutlins cighl ktcotical
blaDksffoln "rwolly' srock.'fhc
ionl lcgswill achrallyendup I li(lc
turrowcibulwithlheblanks allthe
sanrc,youll only ncedro rmlc one
sclupid- lhc morliscs,asin l.'is.l0a.
INoRT|9rs.With cight nnnliscs t0
cu1 lar calh bonch,I wanto(lrhc
faslcslnrcthodpossibtc. SoI uscda
spiralcr)dnill bi1ar rhc drill press,
asin Iris.10.lhisralics I Iirrte
fixx.c
scl p IiDx. bur thc chc.ksof rhc
ir)r,1iscs cn(lupcl(all,solhcfrJs no
t t
nf(ri I(,s.t i)|1youf chiscts.oin- 2'
21/1
nn)n''nrIlrrs, sc. p sf 22.)
(uI T09zr.Wilhthcnr(11isfs.ut,
yoLrcansctasi(li'f{)tlr Di(,c(,s for the
t
/x'.t ,? ,(/r4- (./1,whilc yoo cut I
lh( /;!r1 /.v r.r/f.s (l(/ r0 finishc(t
widrh(2 ). Justb( surcyou don,r
lri r lho fac(,withrhc|nn1isc. -l
l . i l l . 1 1 . h c n p o s i l i m t h c t c o c cl o Wilh lho bnckhr{s bevfld, yoll
rtvtt tDGtt.'lhcncxt stcp is t0 leavc a 5ldr shouklor bclwcer
rhc canrelrosiliorrthc lence(l.ig. l1b)
brvcl onr cdsc oi cach tl]s (lhc biado and fcnce (|i,r. lla).
Now andbevelthe fiont less.Asainyou
cdscopDositc the nnn-risc). As )'ou youi(] rcady 10 cut rLc back lrss. wrnt tlre Drortisesa1opDosile cnds
canscei l.ig.9:r,rhoan!.tcsfof rhc -lle back lcss arc crrr on odse,
and wilh cachpairoi less,bul this tiure,
irontandbacklegsrrc djifcrcrr,bllr you wanl to r]rnkL's[fe lhat
'sctup each Ihot!..r oflhepicce;sdownon lhe
one is all you n.,edro r)irlic. l ( r f a r e c u t w i t h l h e m o r l i s e r l tablc, which is whar makes this
Tilt the sawblade34,,,as shownin opposileends,rs shown in Irig.
ll. ansleriiiicrentiroln the backlegs.

O. ENO VIEW b. elo vrew

FRONT Maftite

rygr5)----\:-
F:;{-'W
No. 142
Bose{continued)
\ow tlat lhe bevels hrvt b€| cut
olr thc lqs. yon nrighl l1)i|]i thfylc
fcady to bc gl|({l logelhe. Bul thcfc
'
c s l i l l r ( o U 1 t eo f s l e t ) st o c o n r d c t c .
R o U No0v t R( 0 n N t R . ' l } cl i f s t t h i n g
I di(l was fon( r f(trrr(lovcron lvh:rt
willbc lhe (nrlsi(le cor eN otcarh
l(g bhnl{. ns shr^vr in lris. 12.
( l h c s c h a v e l o b e r ( t r r 1 c dn o w
b . c r u s c t h c b c a f i n sw i l l g c l i n t l x '
way rft(! the lcss arc $scnntc(I.)
.hd0
t h i s . l u s c da 7 i ' f o n n ( l o v c f
l ) i l f r i s c d t { ) i t s i u l l h c i J l h la r ( l s . l
l h ( f t l r c r t , , p o s i t i o nt h ( w o f l t t ) i ( c c
( l : i J a sl.2 a a n d l z b ) . ' l h . i ( l (x l , '
hnh l{ss islhcsllnr|' lhc.urvc ol
t h e f , ) u n d o v r Is h o L r ki n l l ( !s r { 1 w i l l r
l l x l x ) i r t o l l h c b c v r l ( l r i ! r .l 2 ) .
G R o o V tf90 R 5 P L tl 5 . N f r l , I c r r l
sorx six)!fs that will hol(l lh.
stnirxsa . s n r l i s . 1 : 1I.n b , ) l h . a s (s ,
r l x , l x , v (1i r e . r i ( l f s ( n rl l ) ( l r b l ( . b U l
a s y ( t r rc r f i s c r i | l l r i ( S .l l l n f l r ( l l l l b ,
llr. fi)|lt an(lbr(li l( lls arur'l .rl
i!ilh lhc snr)r li'nr, s(llirs. (\itrl
w r r l l l ( g n r ) v c l s r l { ) s (l o l l x c ( ! r
l ( r r ) I 1 h ( ,l ) c v r la s p { , s s i l t ( . )
s P L r x IW s . i r l )l l x . l ] r x ) v {s ( U l ,y o u ,-
. x n n r r l ( l l x l r j r / r L l { , I sl a s i , / r , f .
/ l r r l r r l w i l l l l l i r l h ( J ) r( l l i s . l . l b ) .
I r r l i l n l l x s t ) l i r xs l a r l h c s , l ( r { ) v { r :
t ! i ( , s t n n r s 1 x , f 1$ , ) r i t b ( ' ! i s i b l {
r f l c r x s s . I r l ) l y ,l r x l t h . H f r i r w i l l
'l
f u r r r l r r ! { t h c k ' r r r l h { , 1t h . s t n i r , w h { , 11 ( ., ),t r s n ! t r s s h o w ni n I r i { . l , l Dn cfs lol.rclh cr hrcc blocl{s will
( D o li u ) s s i l s w n l l h .a s b c l i ) f ,) . a r x l t l x N d d n r ) l x n o a ll ( l i . l r c s [ r ( { l 1 , ,I h c p h l l ( ! - l l r . ' hl r f r w i l l
'lh(.Lirrr
A i s r r ! 8 ttrr c s .A l t h i s t ) ( ) i I l .y ( n r 1 ( herc isjrlsl r 7r N1l)lr L c s f t ( n r t o t ro t l h c r s s c n n t y .
'1hc
rl(ly 10{hr( llx k's hrlv( s l,)s{ llr t)|lrlli)r'|lr I x s.l ol six rlr)t(h.(l
r v i l kcyis lhc nol.h;r llx clrnrll
dr Arxlrsril, r olhcf quifli (Lu)rt' bl{,cks lhal .'.xl( pxnll( l .ds{ s so i l l s l ) l o c k s .( l c u t t h i s n o l c h i n o n f
ins ii'rr rrrks this prlrcfss rl !ou (ar rhrrI lhc o(ld'shapf(l b l o c l tr n d t h c n t m ( c ( l i l ( n rt h c o t h c f

\
.. I --l

at.
Frcnt S a n dn d g e t

o
LEG

No.112
 blocks.) To nrakc it. jrst la)' out a
34' angle on onc cdge as shosn ir
1 l.'ig. l4a. ftcn rsc a squarc10clmw
a secondlinc !0" io the firsl. Dithcr
a band sawof a ji.qsaw willwort lbr
co11ir)g a\ray thc rvasle,and thcfc's
oo need10b(,1o0cxacl here.
\vilL lle fo'nl rcady,1|e lcss a|d
splirx,scrn bc elucd togelhcr An(l
rs bflore. (he iofr worls with bollr 22't6"
@
lhr lrnrl and bacli legs.
R o UD I D G I 9W . hen thc glue |as
drn (i, I fenrovt{l th. lcss :rDddnl
sorlt, final sh:rpins.Y)u ll prob,rbl),
n((l to rvoft on the oUtsidccofner asembty seeFiq.16a
ofcach lcs (thc o|e lhtll was follre(l
c:ulnr. All this rrx,L s is smrx)thifis
rny ri(lscs or shoukl(rs o| lhc
nnnxk)vcf wilh a s xlins block (n-
block pl'nc), as shown in liig. 1s.
Y ) L r ' l rl l s o l v a l l o f o u l n s l i J l h (
r ( t r r n d o v uo I l l l r ( , l ( n r sf d s c s l | n d
( r x l so l t h c l ( s s , x s i l l l i i s . l s a ( l h c
t o t ) c n d sr f n r a i ns ( t a f c . )
a P R o r i tN. i ( h r l r c l c r s r o r n p kr e ,
allllrxls l( it is to rrk.lhc aprons
l h r t ( o n n . c l l h f n r .A r d s i n c ca l l l l x

n (xld rnsks rvcrc bUilt int,i lh. c U IT t t l 0 l 9A. l ) o u ll h ( . ( ) n l yt l ) i I s I o MoUilIlilc

[ollt.
']lx
lirslthiogro
l c g s . l | l a p n , n s r r . ( b { ) | l r s ' k ) l o l h ( s c t ) i ( \ l s i s c u l t h c l ' r l ) | r J . t do 10llx aprns is drillthccoLrnt(*
slfrighliin rvlfd as lh y (.angft, as l ' ! r o n s i n t 1 x . n { l s ( ] i i s . l 7 ) . I d i d borf(lshankhoks fof thc scrcws
\ ( { r . r r s { r .i | l I r i g .l ( i l l ) , r v c . l h i sr t t h c l a b k s l l w w i l h n n a u x i l - llral will altachlh. scal:rftrr thc
Lilk lh,. s(.lt shls. I Isc(15/,1 i r f y l i ' n r . x l ( c h e ( l l o l h . n r i l i T brsc hns bfcn asscnrbld ns you
dc(knrs(l ' lhnk) rn(lcutth(,/j?,r/ laaLrgc. Ar)(lsirnl lhc kJnnrsat thc calrsec in liis. l{j,r.this is a prclly
(ll ), ba(li ( N ). ]d]|.tl:,hnrn,ns to) salr k nitlh. I uscd lhc rir) ft!(l ls lr lDn,cclo bc drill;rvJ
lhllnrsh,soI
1 , \, i ? ' . r \ i I I i { l r , r st)l)(l.i(.lh). di(lihisw(nl(at lheddllpfcss.
lAtl ASSIlLY.lhis bnscis lnirly
rasy lo assrrDblc.A sinslc b od
clarur wasall I usc(l1opLrllovcr),-
lhnrs li!.hl,as in |is. 18.Ilul bcfor.
youaddshro,dry assenrblc thc k',ls
andnpronsands(e how wollcvcry
Lhinsnts.'llerc s pfobablya1l{'ast
oneapronshoul(lerlhatwill nee(lto
i be sandcdor Dare(tslishtly..lusl
i r I
k{:epin mind thatthr soal is 10Dull
alllhe . r i!i.r, shoul(lers
lishr.
ADD SIALWhenlhe baschasbeen
I asscnrltcd,all thals lcft is to screw
the scatto lre basc.I loundil easi-
csl to do lhis with thc benchupside
dowr. l})iswaxyor crn seethatthe
ovcrhangis thc samea! the fronl
andsides.{Ihe backhangsoverthe
bascqrite a bit Drore,as;nFis.18a.)
Now the benchis ready ior rhc
finish.And like thc table,I uscd a
sparurethane,but theres moreon
thatin lhe articlcon page3.1.Sl
N o .1 4 2
 I

ff
Norss
SHop
Sledfor Complenenlorylllilers
$Ihen urahins lhe x 2{i. bul if you cant
f r a r D ef o r t h c b c n c h r r r a l i ca 2 6 r r u i ( l cc r l o n
s c a l s o r ) l ) a s c 1 2 . t h c y o u r s a w .l h c b n s c c o u k l
anslcs a1 lhe ifonl and bc rr inch or so smallei
tayautrhe
bacli arc (liflefe|i, as you Ilre liL'yto thf accuracy
can scc in the photo hcfc. ollhe slcd is lo makc sure
'l
his wrrld havc mcanl l h e b a s ci s s q u a r c .l ' h e r r
accLrmlcly *'ltjns thc rrilc| alt you nccd to do is ll'v
g n u g ca l l w o o d d a | g l c s o u t a : l l ' a n g l c l ( t t l r ( '
( : r l , , r ' l r l ) . I i r t . r r r . , t , n , " .A : J , a r. . , r . , ' i r l
t h c s en n s l c sl r c r o r n p l c l : i s . I , I r o l a l c ( ln r ! r r r i l ( r
m c n l n f y ( l l t c y a d d u p t o A a L r s c: | , 1 "a n ( l i p l x ' ( l i t
! X ) ' ) ,I r v a si l h k l o b u i k l r u p s i ( l e( l o w n t o d r : r wl h c
s i r n p l c s l cl dh a l w o o l ( l l l t ( . l l r n A l ( . - l l x r )a l l t h a l s l {f t i s
ratcly flrl bolh aD(l( s lo xltrth a -=----;
withoulhavinJtto |)dic t y slfaight l(Jrrc
furcf a(ljuslnx,ntsirl Irll. flnsh with lhc
-lhc
INITIR tttD. sk{l is l a y o u ll i r r c .r r si n
j u s l r l a r , { cp l y l r o o db a s ( | i s . 2 . (ll (an i
at.
with nr xnJll(rl i(rr( ov( rans lh.
" l w o i y r r l ( I i a l b r s . o o r r ct r x l . )
r D a d co i
(lrig 2).'lh. l)as. ritl(s L A B I I t D G [ te
i , | j , r i r ' lr l . , r i t ' l . i r 1 . : , r . , r P I I ( t s .\ V l , , r r r r r i , \
w h c i t s s h o f l e ( l i r c i s i I s ( h ( j i s , i l s i r n l r t rl r r r l
a s a i n s tt h . l i ' r c c , i l w i l l l o h b f l l h c e ( l ! , s o l l h c
, 1 r r l r , , ! l , , , , f r l r i : 1 . , . / l r . - . . ' \ : r l r r . l l - 1 ,$ i .. r v .
corncNot lhc ln ( ( l ig. y ( t r rk r r o w w h i r h r l l s e is
ll) $Iith lh. lolls cdsc s u t ) t n ) s . dt { , r i ( 1 . r J { r inst
'lh,
rsal|sl lh( lirrcf. il ll .ul lh. f i p l i r ) ( c . w o rk' bul I necd 1{)r]rc ti()n lwo
thc :tnsle lin lh. rd.ir (or pil\r's shool(l b( hbcl(\l l l r i r ) s s .l : i r s t ,s i t r c el h c r c bcfor( nrit.iD}{ thr Insl
r x r s o l l h t i r n m ( l ' i r { . 4 ) . l ( x r ( s p . c i l l l y l h . s n l (s rff lwo si(k pi('ccs,you'll lrncf (1hcback), I (lfy
'l'hc asscurblcdthr' (nhcf lhr(
Notc: bfls. lrrs b as tll y havc(,nc li'rl xl)d rvarl to osc r slop bl0ck
bc bis fnoush so thc oncbackcor crl) $,h.n cullins (h. secord so I coLrl(lsnrnl{ ut) on the
-lhis
pi(.cfs will only slicli prst lTtRPlt(lt VJtr rrl|1a{ly nritli (|is. 4). way, finalhrslh ot (hc l)aclt lof
( n x c d s o .l m r d t n r i r x2 0 know ir(^! thc jis woflts, bolh si(lcswill r|d up thc r satllrcc fil. sI

*=.--

20 No. 1.12
 Splinedl|irer Jig
Addingsplinesis a great
1 way to make a mitered
framestronser,and the
splinesactuallyhelp with
theassenblybecausefiey
keep the frame pieces
dlisned.But on theouldoor
tableandbcnches,the slols
ior thc splinesweretoo
largcto rort wilh a slotcul
terbit.lnstead, I neededto
standeachpieceon eDd
andrun it acrossthe saw'
Tbis procedurealways
Dnkcsnrea litllenervous,
soto makeil saJer, I like to
build a quickjig that sul}
porls the pieces whilc
thcyre pushe(]acrossthc
dado blade, scc phob.
Phrs,thisjis worksior all
lhfeL'aosles;n thc tablc
and bench projects.(lt's
also a sood id€a io havea
zeroclearanceinsert in
your lable saw)
$RnlAGl. Thejigis jusl a
simplecarriaged€signed
to stsaddlethe fenceof the
saw. Two pl'.wood f^ces
arescrewedtoge6erwitl
a pair of spacers in
bctween (Fis. 1). You'll
wantto sizethe spacers so
thecarriaseddessDrooth,
Iy over the rip tence(with
out anysideto-side play). to standa board 0n end to cul a slol on the oppo,
To supportthe pieces.I \r'h€n making the solid site end, as ;n Fis. 2.
addcdthreer%"-dia. dow woodspltr€sf(' the slots, What's important when
cls.'nretwouppcr(lowels rotatingthe workp;cceis
hclp supporl thc work (UI ttolt- Wltencullirg that the sanrefalc stays
picceswhileyou cut thc the slols,simplyhokl (or againstthe jig. This way,
slols on thc cnds. as clarnp) thc tramc blank all the slotswill bc sureto
shownin lhe photoand aIa;nsllhejis. lift: up cvcnif they're)r0i
l,is. 2.'Ihc lhird dowel Aflef cullinglhc slolon centsed cxaclly on the
one cnd, rolatclhc Diccc thickness otlhc picccs.B

$x lrl' NO|E:
Fhs(ew Fa.esate
,a" plywoad

For the stsongestpossiblejoinL the grain

on the splioeshouldrun aclossthe joint-
line (referto the photooDpage9).This is
easyto dowith dl€ splinedmiterjig above.
The frst stepis to qrt a pair of kerfs
aiongthe endof aboard,asshownin l]le
left drawing here.The blade should be
raiseda little morethanthe lnal width of
the kerf. And tlrc jig shouldbe set away
tsomthe bladesolhe splineswill fit snw
in the slots.When both kerfs havebeen
cut, the splinescanbe crossc.uttrom the
blad{s, asin the right drawing.

No.142 2l
 &TrNIoNs-
MornsEs
SortrnoNs
& Srnnrcurs
Mortise and tenonjoints
arethe "meatandpotatoes'
of woodworking. They're
strong,easyto make,and
!€rsalile- andmostissues
ol Wood.snLithleature at
leastone projectthat uses
someform oftltis common
woodworkingjoint
As you might imagine,
with having cut, fit, and
assembledso many mor-
florliscg rnd lononr
Rounded
Unlessyou have a dedi-
cated mortising machine
(or drill pressattachment),
the mortisesyou cut will
hav€ round ends.lvhen
using a regular drill bit, I
haveto cleanup tie w"allsof
the mortise anl'way.So I
usualvsqure theendstoo.
But this isn't the only
L To allowlor option. Mortises can also
exces'sll|€,I likg b€ cut with an upcut spiral
end mill bit. (Seebox at
riseslishtbdEeber righL) This tool leavesthe
mortis€ walls smooth,and
sinceI don't needto use
my chisel,I leavethe mor-
tis€ endsround.
tises and tenons, we'v€
run into more than our
shareof problems(aswell
as a I€w mistakes that
n€ededfixins), Someof
the solutionsmeantusing
tools we wouldn't normal-
ly use. Others meant sal-
!"ging a pieceby doing a
litde extra clean up work.
But most of the time, the
best "solution" was one
The nice thing is, you
don't haveto owna plunge
router to be able to use a
spiral end mill bit. lt also
works on a drill press,
which is what I did when
building the $rapatound
bencheson page14.
DtlLlPRISS StltlP.To use
a spiral end mill bit, the
6rst thing you needto do
is iDcreasethe spe€dof
the drilt press to its high-
est setting (300G5000
RPM).Ther set the depth
of the bit so it will stop
slightly d"€per than the
length of th€ tenon, as in
F r o n r p i el cl ,ei l , i . i i i i a
'Woodsmith
that let us avoidthe prob-
lem the next tim€ around.
Sohere are someofour
favorite solutions and
shortcuts.And whether
Fig. 1. (Ihis allows room
for excessglue, asyou can
s€ein the left margin.)
Next, I like to create a
channelthrt will trap the
workpiec$ so they canbe
slid back and forth easily
without shiftingin or out I
did this with a fence rnd
three scrap pieces, as in
Fig. 2. Two pieces act as
stops and are clampedat
eachend of the ddll press
fence. The third scmp
piececreatesthe channel.
Ifs clampedto the font of
the stopsto hold the work-
pieceagarnstthe fence,
you'v€createda few mor-
tis€ and tenon joints or a
few dozen,l'm sure you'll
find somethingto useon
your nercprojecr.
(UTlOnTlSt.To cut the
mortises,l drill a hole
with the bit at eachend.
Then you can lower the
bit %rrand slide the piece
bsck andfortl, (Youhave
to hold the ftill presshan.
dle with one hard and
slide the piece with the
otherJ Removethe waste
in %r' passes until the
mortis€ is roughedout.
Latet after cuttrng the
tenon to fit the mortise,
you can round over the
edgesquickly with a sand'
ing block or a mill tle, as
shownin Fig. 3.
No.142
 lorge, ThroughlUlortise3
T h e b a s eo l t h c l a b l e o n d f i l l p r c s sB
. ulmthcrlhan At this poirt, i'ou can
paJteli has throLrghmof (lrillins overtappinsholes, square Lrpthe co' ncrc of
3
ln nscs.as showr in the maf
sirrphok).Ilercsa slx)rlcut
loLr can 1ry lhe De\l limc
\ u , r l .\ - , r . r . , - l i t " r l r i .
ddll a hole jn eachcorre,l t h c r ) ! r 1 i s c . O r y o L rc a r
rsshownir liig. t bcb$r
Non you caD fclr)ve
r l" . j , . r , t u i , \ t ' , ] i r l
lcave thcm rorlnd (likc I
dkl herc) rnd then latcf
rftnd r)vcr the edgcs ol
"*N

focut or)a lalgc$odtt)icrc. DIy gclti|g oul you, J,! Urc tenons with a nrill tle
L i k e r t y p i c a lr n o f r i s c , s w andcu ing aldrg thr 0r sandius bl(xl{, as in
thrs one slafls out at thf layoLrrlirx,s.as in l.is. :t. lril{.:l on pnse2ll.

Centeringthe illortise
M ( n( i s c s: u f a f t n)(s ll h u y s l ) w h o l ( , ( 1 r i , jl.) N r ^ v U i l ) w i r ( k . r i I l l o l l k l l r s lh o l ( . ) li |l(l slial)liy
'lhflr
sirn-
f ( ! ' 1 ( ! 1 { l, , n l l r l l h i r l i r x s s thr l)i(rl rf(, n(lrnd (t tl l l v , 1 1cra l s . ( l h r c ( l I I . s ply nIn t this ln)rcss
o f l h w , r l i t r i ( r r ' ,a n d l t I y i r s r c , ) n ( l t r o t , ., , v c r t h r . o i 1 w { lr) , ) l ( ,lsl ! 1 . l h c ( l r i l l u n l j l l i r { l w ) h 0 l ( , sl i r ) ( 1 | t )
1 , )b . r s | c ( u f a l c x s I c l , r f i l s t ( 1 \ l o f s t | r f 1 ) i 1r v i l l l ) i l i s , , t c ( i r l r r ( r lc r r c t l y , t x r l ( \ 1 l l : N , , wy o u k r ) { , \ a
w l ) r r s . l l i n { L r pt h ( d r i l l w ) i b ( s l b . . n s ( . i lw , ' r ' r r r ( l v l n rr ( ! r l l o l r l i u s lt l l l h c ( l f i l lb i l i s c r r ) l ( r r { 1 .
t m s s . I l s s u r lr l ( n( a s i ( r
1
!
l , ) s (l l l l I l r t i n J l t , i ( \ rt , )i l l
( n f ( 1 1 l vi J! , n i v ( l r i l ( J rt l x
l r ( | ) r r i t l i ( . s | r 1l l,l r .J l l ( r 1
,-t- -
I s i i t rI w i t h l s . n t ) l ) i ( \ 1 ,
thrt s lh( sllr)f lhi{.linrs\
as llx w(nl(t)i1rr'.'lh ) I
f ' ) u r i l r l v. { n t ( { 1 l ( b i 1i r r
l h c D n r l a | l ( ld r i l l I s h l f

tjsinstherightl0olsisjusl leavea tiny gaDbelwcen 0rotlornDhoto).'lloush

asimportantasusingthe cach of the holes you lechnicallyil's a router
righl technique. Hereare drill, as shownin thc top bil, I've used it to cul
the bits we use to make ../ --:==-
boardat risht.
mortjsesin our shop. On the otherhand,the
mortises with a hand
heldplungeroulcrandin
'€9--
DRIIIBlTl. lor ntost Forstner bit can drill lho drill Dress,as shown
mortiscs,Iwill useeither overlappingholes. As in Fig.2 on page22.
a bmd point bit (top you caDs€eio the middle The flutes on an upcut
photo at risht) or a board, this meansnearly bit afe dcsignedto pull
Forstner bit (middle all of the wastecan be the chipsout ofthe mor-
Dhoto).Bothhavecent€r removedwith the drill tise.And because ifs run
poirts that keep the bit biL So there's iess clean at a hisher speed(up to
'I lrom wanderins,but the up work with the chisel. 5000 RrrM),the cheeks
Forstner is easily the SPnaL titDfl|lt 8tTt.The cnd up smooth,so you
besr choice.With a brad otherbit I like to useis an dont need to do any
point bit, you have to upcutspiralend mill bil clean-upwork at aI.
:-=

No.ll:
23
 flluhiple illortises
-llc
uxn e |rot tiscs lhere consisrerttby usi.g a Dail ( i s e ,I l i k c l o c u t a s P a . e ' lisc and (ut thc sPacer1r)
arc to cLrl.the rnorc I \trrrt olsnull scmp bhcks. lhal slipsbclweenthc skrp l b i s s i r c . ( l l ) i s c q u a l sl h e
therr to end up as identical SroP 810((. The fifst a n ( lt h c c n d o I l h t w o f k r u r o f t i ssc l e r t g t h D i , r s
as possible.lf all the mor- bbck acts as a s(ol).tts rrr p i e c ea. s i n | i S . 2 . t h c d i r n x ' r e r o l t h cb i l . )
tiscsafe (h--san]c.then fil Fis. L lt s clampc(l Lothc Iinrdins the lelrsth of Aftcf drilhrs thc sec
lins thc lenooslalcf uill be l c n c . t o c s l r b l i s l r t h c lhis spaccr is e:tsy now 0 d shoul(lei jLrstrcnnve
s h o u l { l e r t h a ts t ; r i r f s l l h x t y 0 1 rh a v r r n ( o l l h c thc sparcr ar)d drill ov.r
So rvhcn |rakirg nnrlli fI' n the elrd oflhc boxr(t. h o l ( , sd f i l l c d . J r s L n r c a s hppins hok's back t0 lh(
tPA(tn Bt0C|(.Ir(, lh{' u f c f i ( t r nt h c , . / t 1 o t t h c first holc (o ft'lnovc as
ple nrortises.I nulic sLrr.
l h e s h o u k l c fc u t s w i l l b f o rl l h e n r n '
0 l h c fs h o L r l ( l e h o l cl o l h r f , r ( /o f r h c x n ' mrc| $nstc rs possiblc.

loose Ienons
No rrrllcf how crfcitrlly
yollry1,,worl{.(tr1rsi,nr
a l l ! ' y o L l l (l ] o i n A l o ( 1 x l r l t )
wilh a lcnon lhal is l(x)
l ( n ) s el o r l h f r r r ! l i s c .
v I N t I R .i l v , n i ( w o r 1 i
i n g $ i l h r 1 h r ( n r g hl f r ) { , r r
t h a l w i l l b . v i s i b k '( , l h (
I r n ( , r ri s f . r l l y l , ! ) s ( r , 1 l xl r
you can c|larl{e il wilh
lhiI pi( ccs (,1v.n.cf slicc(l
j | - ( n nr r l ) n u o l s ( r a l ) .a s
I
yorr (an s(! irr lrig. I l
ghc 1h. v.rxl r' lo lIl'
l ( ! r l n r ' s ( . hc(k s r r l ( l s l r r l i l
lo lllth.nrn lrsc
B n O WPI l P I nl i ) r ' h i ( l ( l . D
l ( ! r r r s { ) r ' r ( t r n ( k ( l l {r n n r s
lh. srrrn l.chrrklu( will
w o ( l r s i n s b r ( ^ v r rl ) r r P . r
. u l h 1 , r ni r t r r o c . r vb n , I . x s
slx)wn irr IriJ{ l

Iine-Tuningthe lenon
W h c n d r y a s s c n t l ) l i n gr r l f n o n l ! r r l I v r 1 { ) u n l1 1 ' r t I D l i l i l s n l | s l rw i l h 1 h rn(l t)rf. rwa!'.srrhll shlv
nrul;s tur(l{frronj()irrl,voLr 1)i!-irrs ll$rv 1l)r l{rrr{ iIljs. rcsri g lh fil r)11|n.
n n l i r s r ) i if c . : r si I : i { . I .
'lhis
S , )b , r n - ( . D u l l i r st h c l w o fix will cr.rl( il
wanl (o chc(li lhxl th( s | r i o n I l . r r n r i s r rw h o l t
workpi(1l s cnd u p flush.ll lo( crsi{r lh:rn lrvinli lo pi( rcs rprfl. I vistrrrlly sn ll Jt l) in th( !uflisr.
lhfy\1 nol(xssh{^urinlhl rl!)l) thf,,lrsh lh. {'nd l l u l d , n r ' lw ( r 1 ! . ' l l t j o i r r l
l r k c r r o l fo l l h c s i r . 0 l t h ( '
photo b.low), you ll D.c(l l]llrirrnr l nnnlis. sh{,ul(l('r lhis is lh. r v i l ls l i l l h c p k ' D l ys l f 0 r r s
rr)lln(-tunf the t(rnnr wirh Whrt yrnr wxlt 1()d') 's r n n , L r nol I s l o c l {l h r l h l s I l u t s i r . . t l ) i ' f ( J sr l i l l k
''t)Lry in lhc jolnt i^!,
rrrr)vc clloLrithof lh( 1oP
'lhis
' l c . h D i c x l l t . y o L rc o u l ( l ( n b o t t ( n n )s h o u l . l { o i is cxsy.nough li, yo( ll r(1tl 1,,(al( clfc
rlo lhis i clunill{{ r) lhe llnon lo rllow il lo do wilh r shart)(hiscl.Jtrsl l l \ r t t h ( ' 1 w 0D i ( . c sf d u P
c i t h c r ( h . x ) f t i s r o r t h c s h i ( s l i s h t l vu p t n - d o w r r ) c l a n r t )l l x D i c r ( n r r u s ' flush (luriril xsstnnty.

\u. 1{l
24
 Usinglhe Rip lente !s ! Stop
\ Mn., Iinre=. \hFn .u'ring
(t . n , n s o n r h ce n d . , r ra
wolJ(pi€te,I liketoclampa
stopblockto an auiliary
mitergaueefence,as you
canseein F'ig.l bclow.
tsutdrisisnl alwaysthc
bestsolution_ $me work
preces are too lorg 1{)usc
with an auxiliary fence.
PIus.there are a lot ol
timcswhenI needro cut
irlenticat tenonson picccs
thatare differcntlenslhs.
And if I were to usea slop
I IteppedShoulderr
'li)
cut 1(nons,I oft('nlay
Ihcworkpic(c(lown onrDy
tablcsawandnrakcDnrlli-
plc passcsovcr a dado
bla(lc,usioslhc dr) fcncc
asaslop.-llis is a faslway
tocuttcnors,brl younray
find that thc shoulde$at
llre top andbotlonroi thc
len0nondup uncvcn,asir
lhephotoat righl.
The problonrhere isn't
the procedrrl]. Irslcad,
its us ally a good indica-
tjonthatthe rip fenceisnt
90' to drelablc,as showr
No- 142
bl,tk. IJ hdvpto re,rr il
ier-r"l ,in,-.,u .nn ,rp
wirh the samesizerenon
on eachpi€ce.
In both ot rhesesitua,
ljons.I tnd ir'sa lot easicr
ro use the rip fenceas a
stop,as in Fig. 2_Safcfy
Note:With a typicalcross
cur, yo0 shouid ?ro1use
rhcrip tenccandauiliar),
feDce toscther the
wastepiecccaokick back
at you. Bur rrere,yon re
nor c ltins tlh oh rl.te
in lris. Ibck)w (O| ify(nr
haDtxI 10bc using a sk)t)
block on youf aLrxilinfy
l c n c c ,l h c n t h i s s t o t )i s n l
squarc lo th(' krblc.)
'lhc
r ( a s o o f t n .t h i s i s
thrt whcDcutlirra lh('l{nrg
shoul(lefs whh thc picce
lyios facc down 0n lhc
tablc, thc piccc Lonlacts
thc fenrc ncar the botlqn
( F i s .l ) . B t a s s o o n a s t h e
pjcceis sct on edgo,it con
tacts lhe dp fencc hisher
up, as in Fis. 2. Hcre, rhe
fcnc{: pushes lhc piece
piecc,soyoudor'thavcto
worry aboutkickback.
Thcre are fwo thinss to
keepin nind whenusirg
the fip fencc as a stop_
First, whcn p0silioning
the fence,yor'tl necd k,
Drcasurelo the tar 0eft)
side of the dado blade.
Ard nsyoucanscch l,'is.
2, yoLrstill wantlhe auxil
iary lcncc to extcndpast
the blfldc,so il will sup
port thcwoodfibcllsatrhc
backoi thc cul.
a\{'y lfonrth. blr(|. cfcirt
insa sl(plx\l shr)0ld.rl
tolulloIs.-llx b$t way
to solvc this is to a(ljust
the dp tcnccso il s sqUafc
l0 thc lrblc,alldto do l|is,
yo ll warrlk) ch|'chyoLrr
llul thcrr"sn lcr lnra y
sohrli(r fof lhis probhn
V)u cnDclanu 0r carycl
1,rDca shorl srip lo lhc
lencc,as in lrig. ll. (l'ho
srrir)shoul(lbe just Lallcr
thanlhc tenonshoukle
Basically,this slrip acts
men Duking trial cutsfor
a tenon.loflencuta nrini
tenonon theendofoneof
the pieces.This snall
tenonis longenoughto let
mech€ckfie fit. And ii the
minitenonendsup with a
loosefit in thc N)rtisc, I
cancorrectthc setupand
stjll usethe workpiece-
its not goingro affecrthe
strensthoflhejoint.
rr d r.r,,r ir)(h,irl
likc a short iclrcc, so lhc
preccanvayscirntaclsrl a1
the samc spol. (Or nn.ycr
a n o t h c r s o l L r l i 0 o c, h c c k
oul thc lrp oD pasc,l.)N
 Atfistflarce, tHs
anher
mal seemlike
"gmdcn-umiet1"
out-
dacnnbh. Butthe
meyowfirst
funulles
' cluerhatrhisisno
tabb.
ordinary

ncc yor takc r closcrlmli althis

sniallsi(lc tablc,yo llnoticclhc
toDof thl'tablc liiLsrighl otl to
beconl{a ro|vcni( t scrvinglny.
Ilut thc rcmovirbktray isnl lhc
only fcason (o bLril(lthis srcat
'li
slaft wilh, tho basc of thc
tablc conslructcdwith nntlise
is
and tcoonj{)incry.So its buill to
last, cvcn if it doesgel knocked
arounda bit in theyard.Axljustin
caseyou'vencvertacklcdnnrrtise
and lcnon joinery before,wc'vc
includeda separate lc{hniquearli
cleon page22of &is issuc.
Bul Drobablyone of thc tticcsl
fealuresof this proj€ctis that yoo
$ caneasilybuikl it in a wockelnlAll
dle parlslor thc lablearc ctrl h-dn
threccedardeckiDgboards,which
you shouidbc able1()lrd lrl 'rust
lumberyards or hofie ceDlc's
illltfl. Evenlhoughit woDt ktkc
youlons10builtl,!'o ll slill wall to
protecllhis tabk' with a sood oLri'
-r'-/ doorfinish.Affl picknrganoul(toor
finishcanbe a littlt' colftsins, par-
ticularlyi[ yoll vc neveroscd one
bei()l-e.So on Dasc34 thercs an
ardcleon a iew outdoorfinishcswe
usehetc in our shop.
i.k:.:'.

; . .

No.142
 Construction
I 0 Details
I
I OVERALLDIMENSIONS:
22"W x 16"1x 17"H

NOE: ln soft wood tou ll

have lesstearcLtif the

flatERlALS, SUPPI|ES & CUltl G D|AORAm

A Legs(4) 2x2 - 16
B LonqAprons (2) 1x3t/, 15
C ShodAprons(2) I x3'l:- 12
D Ends(2) 1 x 41/,- 16
E OuterSats(2) 1 x2el6- 15
F l n n esr l a t {s4 ) %x2y6-15
I G cleats(2) %x % - 10
.14)#8 x 1t/a FhWoodscrews

No.U2 21
 -'']

sroEvrEw
{

r E 6I
f
L t l
@ l z n ' l| 2 , ,

Bcse
'Ill
lxbll consistsol lwo parls - x
lolr ir{la blNc.I stlulcdwith thcbasc.
Ils r scl ofl{ss and apfonsjoin.(l
wilh nx'1is.an(l l(rnn jr)ints.Ihl lln
/ . y s f . l l a r c a c l U a l l y t wpoi ( c c s o I I
c . ( l x r d . c k i n ss f t ( { l L r pI o n r a k cl l r (
2" x 2" kr blanks,as in lris. 1.
l l o R l l s t gO. n c ct h c k g s r r ' c u l 1 1 )
s i z c ,l l x n e x l s t l ] ) i s t r ) l a y o u l l l x
nr(tr(iscs.As yoLr(arr scf in lfi,rs. lx
an(l lb. cach nn)ftiscis scl back
'lhis
t r u n l h . o u l ( r -f a t c j r s l a b i l .
websile Golo c f c | t ( s r s n n l l r e v c a lb c t w c c nl l !
k s a n ( l a t ) r o na, s s e c ni n l i g . l b .
Now to rrrrl( lhe rrn)flists, I
l u f n . d l o l l r r '( l d l lD f c s sI. u s c ( l a : l , '
I i n s l n c rb i l a o ( l b c s a D dilliD!.hol s
a l t h ( l o l ) l i n dL o l l d o l t h c n r o f l i s ,
a s y o uc a | s c ci n l r i s . 2 . - l h ' | lt l r ' f c s t
of thcrrxnliv isn dcby(lrillnrsovff-
lapl)iru{hol(s. Axl sin(c c.(lar is a
liltL ioLrshlo chiscl rlctuly, llx cof-
r)erswcr( lcft r,r'ndcd (l'i,jl.2a).
l n r t y , n r ' l l r l s on o l i c c i n I r i s . l b
lhrt thc nr(nliscs arl trradcslighlly
( l c f t xr l h r n l h c l c D i { l ho f l h c l ( ! r o n s .
'l1ris
snrallsapis irnlly cxccss1.Iluc.
rtilofls. Wilh lhc l{',{s .onrdct(,
thc rrfxlDicfcs k) nrakcfor thc baso
atr tllr lorl (t,t\rts (li) nt'tl Nha)t
(/,r,rs f( ). (;{) ahcad and slart by
c ltinj.tthc aDurs t0 sizc.
Now lo cLrllhc ((rxnrson lhc cnds
ol thc rpfons, I Usca da(lobhdc on
thc tablc saw (|iJr.:l). Starl by nr k
ini{r (Lrlon bolh si(l(s,uxl tcsl lhc fi1.
Y()tlrnnsncxliupon thc llt by mising
thc bladc:rn(lrctn alnrs thc proccss.
N r x l a f ( l h s h o u l ( k r( ( t s I ( n l h c
tflr(nrs. All you rx\tl t) do h('|c is
misc lhc bli{lc lo nrakc r r/r rul i!'
l h c l o r ) r n db o l l o r )cr ( l s c s( l ' i s . : l a ) .
'l-1l
h s l s l e t )f u - l h r t ( r r n s i s l o
f o u n . l l h c r r s l i s h l l yt o f i t l h c n n r f
. s y o uc d ) s e ci l r| i s . : t b . l u s . { l
l i s c sA $l
a f i k k , , , , r k c ( t r i c kw ( , r l {o i l h i s .
'1h.
firrals1(1) bffuc asscrnblyis
to cascsofix of lhc cdscs of the l(rs
a n d a r r r , r t s( l : i s . 1 ) . I d i ( l l h i s o n a
routerlabl(,with a r/srro ndi)vcr bi(.
oryor Lan sandlhcnr by hlnxl.
A n d s i n c c i l s s o i t t J { , ) u l s i { l cI,
nradf surc lo assc l)le llx brs.willr
lro cxt0i(n ! rd. JJhr'.

2ll No. 112

T
lroy Top
Onceyou've assembled drebase,yoLr

r0 canturn yourattenton
toptl-ay.-lhe
lo malirg the
iop is madeof six slals
thalafe"capped" olreachend.
cRoovtt.I slarled E/vDO
by cuttirg the .rdJ
frl to final size.
'lhe,r
the oexl siep
i
wastocLrttheg'1rve
along lhe nrsi(le t
cdge.Again,I lurne(l
lo lhe lnble saw wilh a dado blade.
(Sincc thc sroove is narrow, you
coukl also DrakeseveralDasseswith
a rcgularblade.)
As yor can see n) I,'ig.5 and 5a, I
nilrr)edthe workpieccrrourd fof lhe
sccond cul. lhis wLy, tl)e groove is
surc lo bc ccnlcfr(l pcriectly.
IAtDltt.'l}c ncxl slcp is lo nuke
thc handlcopcn;nss.I touDdlhebrsl
way l{) rrakc lhcm was to firsl drill a
txrir ot I dia. holcs, likc yoLrscc itt
Iris. 4b.-lhn go back wilh a jig srw
an{l cul oul lhr waslc in bctweert.
(URvtD PnorlLI.Afi(,f thc handk is
'lllc
conlr)lct., thc lasl dchil f(r'lh. cnd lhcn rul s(rn. diff{ r1nc{s. llx orir1 slalsllrc alisncdwilh thc oLrlcr
l)ieccs;sllr{ curvc(l Dronl{. sl.r/s l/t) afc r f ll l ' thiok to oralch onosnrshwilh1ll| cdsc?urd thchn)cr
- l i )( l f a w
D1 f c , I l ( x ) kf i r y : l { j "x h ! lhc ends.I lLrlto kcepll(, \!ciJ{hlol tlrc slalsspaccdcv('Dlyacrossthc lot).
, D i , , U nf,U 1 ( r ( y ( , uc o u k l u s c l , n f { 1 - lfay rlown, thc nr,.r s/.r/s f./r) arc I,inally,th. r/.{r1sf(;/ thal kccD
b o a f ( l )a D ( ls o n x r | r s k i n , j l r 1 r . l o only 7l' lhick.An(l you caDsceitl |iA. thc lray top alil.rDod carrbc nradc.
-l
.r'll( r "bow lha( I usc (o lm(. oul ,1lr,lhc oul(r sla(s flf( cul or) ,r/, hi sejustallachto lhf rndcNidcof
an xfc,jusl likc you s.c iIl IriJ{.(i. si(k s 10[(rrn a tr'nu). thc 1ol)in bctvcfn thc kgs.
OrR vou(clllx curv. {rilc!(I,cut .lusl lik.wilh llx basc,IroLrnde(l Oncotho tablcis assembhd,il s
il lo shapcarrdthcn san(lil snxrnh. ovcr nll the irrtcr cdqcs bcforc tinroflrr a linish.I rpDliedscvcr-dl
coaLs
5tAIs.Although th. slats thal sit asscDrblinsthc tr)lr.-llx'll shrM thc or an fxtcior finish nn nrorcoD
b c l w . e n l h c c D ( l sk x ) k t h e s a D r ( , lolr lh an cxl(lior-,{farlc r{luc. ortdmr nnishcssccDase:J4.Is

No.142
 Svsrpvt
SArr Sronecp
eu1 to build,md' easyto
systemhasit aLI.h's mexpensiue,
Thissrorage
without gettingctutJ(.nLrtoohox.
yu canadlnt the sheLq,es
insnll. Phl,rs

I t't rlr|s youf snorr(!-grragc

\-/doesrr't havc to llc cxpcnsiveor
d i l f i c u l t .W i l h o f d i n a f y2 x 4 s ,l x 4 s .
anrl a half shcct ol plywood, you ll
havepldrty ofsl(n 1..cin no tir c.
N(n only can this st'sler]r1)| buih
i | l a d a y ,b u t y o uc a na d ( l l oi t a s y o L r f
s l ( n - r g cr r c c d ss r ) w - o r ' f { c o n f i g
U f c i t c : r s i l y: r s y o u fn c . ( l s ( | a n l . I r .
'I-lx,(
rfrjrsL lhfcfbrsic parts to
this sl(n-rgf sysl( r : h(r'izorrlll
r l { a ( s ,v ( ! l i e a l p , ) s l sr. n d ( h r c c ( l i l
!lurl slvl( s ol shrlvfs.
'lhc
p o s l sa n d s h f l v c s x f c r r l a l l
'lhc
lh l u rlsIrl. s h c l v c sf i t i r r t , )
" s l o l s i l l x p { ) s l sb, u l l h y l - ( r ) o l
'lhryi.c
kvcl. lit)rx{l ril slii{htly.
'lhis
i v r y , y o d r ) nl h v c 1 ow o r r y
rb(trrll)xlls (arxl()lhrf r )uxl obj(cls)
f o l l i n J lo f l l h c s h c l l .( ; l . l r v i 1hyo k l s
cvffylh i s asrinsl th( wdl.
'l'hcy
Anrl lhc hodzoDlal clcals?
(lo two thilrss. I'nst, th(y allow you
l{) spacc thc vcflicrl posts rs lar
rl)arl as you waol lhcnr.'lhis m( ans
yor donl hav0 l() fin(l a sl(rd lo
scrcw inl{). (l spaccd In}' posls s,r
tho shelvcscn(lcd up 24' l('rs.)
'thc
srcott(l br|rc[l is lh l whcn
thc clmls rf. tln)ll|tcd lo lll wall,
all tho posls (rl[l :rh(lvcs) will aolu
nuticnlly lirx'up with cach olhci

flatERtALS, SUPPLI:S & CUrllNG DIAORAM

A Uprights(4) 1t/, )t 3tb - 11r/a 1b,,,3r! 96.(Fou Boards @3.sBd. Ft.Ea.h)
B ShelfSupports (36)%x31b- 11t/a
C Cleats (2) rAx3i/s-96
3h" - (sit 1.75Bd. Ft. Ea.h)
D Shelves (7) 3 / a p y . - 1 4 x 2 4 x 31/," 96N Boatdt @
E PegShelfFronts(2) 7! x 3 7.? - 24
)l x 31h' - 96' (Iwo EaaKlt @ 1.75 Bd. ft. Each)
3/4
F PegshelfBases(2) x 23h 22tb c
G Braces (2) % x 2 3 / a - 2 % t/a"
3/p a \ y' 1 0 x 2 4 x 3,h" 96 (ane Board @ 1.7sBd Ft)
H ToolShelf(1)
E
. (158)#8x 1/.4'Fh
Woodscrews
.124 *a x31/z FhWoodscrews Abo needetl:t/a 48 t4s Plwood (haket eight shelves)
. Z.2dia.Dowe 26 ong

30 N o .I l :
,O
Posts
At tbe heart oI lhis Dfojccl arc the
posts.As yoLrcan see in t'is. 1,cach
onccorsistsofa 2x4 r/), rrrl /.{/ tuxl
a sedcsof lx.lsrcll s,/rr,fis /R).
f
'Ihcse
suppofts create evenly
spaccd slots lor thc shctveslo slill
irt{). And to secure lhc shclves
(wilhort any faslcnefs),the ends oI
the supportsare cut al a:1. ansle so
thc shelvcsrill upwafd slig|lly.
(UTTrNcTtir tUppoRIs.\\rilh lhc
u p r i s l ) l sf t r l l o l c n g l h ( 7 l r l , ) . ! , o L l
can bcsil wofli 0r) lhf shcl srp
pofls. I uscd an cxlratong aLrxiti,rr),
lencc on lhc Irilcfgauirc (|i!.a.2)
\irLr rrtul tllc srrppofls10 cnrt up
i(lcnticalso all lhc slols \.!ill iinc o1).
'Iir
d o l h i s . l c l a n r p c ( l sar r ) l ) b l r ) cokr
lhf ril) Icncc a tcw nrrhos in fi.(n)lot
lhc bladc. I'his way. rhcfcs no
chanccoflhc workpicrc bindinl{.
Now,with lhc nrilcfsauac an(lcd
il'. you crn frsiiycut nnlltittr pi({.cs
D y r - l r x ) s i t i u r i n sl h c w o f k p i ( \ r ,
lsair)st lhc slo| bk)ckairl!-ca{h cul. o. b.
N { n c : ' l h ( l o r )a n d b o [ ( ' n s h c t r
supporls hnvc (nri squl(,cn(1. So I
osc thc ilfsl ar)dlasl r)i{,cfscut fi1,|
c r r h b o n f df o f t h r t o p n n ( l b o r r u ) r .
I L-t *
A l l A ( HT I I 5 U P f o R r S O.r r c r y o u I __f_-
h l v ( a l l l h . s h l l s u t ) p i r ' l sr u t , v o r l 5IDE
. r I s c r l \ ! I h 1 ! r r , , l h ( . u l n - i s h l jsi ,l n . @ (D
y o l s ( ! i | l . i r a i.t . S l n r l a t o r ) r . r x t
ar(lworh y0ur way d(trvn.
W h a l y o L rw a n ti s f ( n . r l x , i t rr o b . c ( l s f s , l s s h o \ l l i n l r i s s .I a r ( l l b . difft!( nl r)allfrrr ofsrl1,ws (t:iit ta)
J u s l o o s c (n o u J asho l h r s h c l v ( , s c n n A i s o ,s i l c c l l x i n n . f t ) o s t sh a v c ' l h a l s b f c a u s c t h . n r u l s r c p
shk ir) ( nd out) frsily. A d I ti,un(l s u t ) r x n 1(sn , , / , is t{)
s i ( l c s ,n r a l ( ,s u 1 1 , t r n Dt h c t o r ) so f l l x , p o s l s .I t s j U s l : r
il suxl kk,a lo usc l snul| |i{,c. ol y ( n ro f l c n l t l r c s L r p p ( r . t s
l h c s l l n r i , . s n ] l J l . l 5 " c uo
t l r l h f l o t )n n d b o l t o n l
7r' scfap plywood as n spaccr I hiswry, yoLrwon l Drisrakcn
ty hlv. or rnc posl.asyou cao sec in l.jg.:J.
b c t w c r ' nc a c hs h c l fs u p p otf. ' l i ) p R . sh.lvcs rulal{rl (1,)wn.
I (li(l this at thc tabl{,saw' but yoLr
vcnl splitti0s lh. suppofLs.I Dlaccd \|Lr'li also rrolicclhar th. tr)t)r {1 c o u k l ( r s i l y c u l t h c c o r D c r sw i l h
l h c s c f c w s a b o L r l: 7 , t r r r ] r t h c boltnr) suppoflsafc a
irlt:rchcdwith tl ls saw or evcn wilh a hand saw

a.

i:zl;"i;'3:' -- 1
SECTION

dw:i;r*t
N o .U :
 Posls(continued)
PosrslDt Wiih the postsassenrbled, ils timc
vttw t0 get them readyto mounlon the
wall.-lbform a stronslockingjoini,
+ I (rrt sone haf{tovetailnotchesb thc
Dostsandthcn Dladethe horizontal
I cleatsthe postshangon.
lor(Hts.Don't]cl lhe lulf-dovelail
t notchesthrow you. The fil herc
doesnthaveto bc prccise- youre
bas;cally crealinsa hookon (hepost
so itll be easy1()positionil on the
dcatslaler.asin l'is.6a.
wlral doesneedto bc prccise;s
lhc /.x1rltl of thc nolchcson the
posls.-lheyall nccdto bc kkattical,
so the shclfslolswill linc up wh{:n
lhc poslsarehrns oDthc clenls.
So atter carefullylayingoui the
notches,I cul /xr) licris trn cnch::r
+ (;0" kcrf on t(4)antl onc nl 9{)' on
thc botlqn,asir)I'iss..land44.

I
I Ncxl to quickly fcrrovc mr)slol
lhc wrslc, I i$i(lcd a roulcr ll.(c-
I h:nd bclwecnthc lwo kcfl.s,ns-1tr|
I scc ir lrig.5- Ih(D rsins a Lhis l, 1
1x knockr(l oLrlthc snull wc(lsc l( ft
undcrlltc bcvcle(lkorf (l:is.l,r').
(lt^rs.with all tho notrhcscul,
youcannrnkcthc lwo (/.rir^-| (') lhc
posls will hang oo, as iD iris. {j.
'ihcs('
afr jusl sirnpll lx,ls lhrl arc
b|clcd al(nrAlhcirr) edgcto nutch
t h c n o l c h c s ; DI h ( p o s l s ( I l i , { .( j a ) .
Inrl |(ni{l lhal thoyic nol rs wnl(
as lh. notch opcrrinj..s.
'lh.yi('
riplx{lr lilll{ nrfrowcfsolhc lr)sls
crn lxxrl( ovcf tho ck als casily
o u i T l [ c .A t t h i s D o i r r lt,h c ( h a l s
a n ( l p o s l s c a Db c n x ) u r l c d ( o l l ) {
w a l l . ' l ' o( l o l h i s , I s c r c w c dt h c l o t )
cl(al scvcDftal ironr thc noor nrak-
ir1.ls fc il wxs k v.l lrnd lh l I wxs
hillir)s wirll shxls (liis. (ja).
'lh.
b o l l ( n nc k a l i s n n n r n l { \ l l l x
srnn \(ry, l)ul yor nc(d lo iak.
c x t m ( a n l h a l l h c p o i n tl o D o i Ddl i s _ f'
l a n c t b c l w c c l t h c c l c a t sn r a l c h e s
thc DoiDll(!|oirrt distrncc belwcen
t h c D o t c h ( s .O l h c f w i s c ,l h c p o s t s
will rcsl on orly onc cleal.

a.
SIDE
sEcfloN

b.

l< 221,'
< 2 4 " 7

No.14:
 With the cleatsin place,you call
atbch tle posts (Ftg. 6b). I spaced
the posts22%" apa4 checking for
plumb. This spacingwill alow the
z4rYide shelvesto 6t b€tw€€n^the
supDorrs,irsyou cin seen rlg. oc.
sIttvll
Thelaststepis to maketheshehes.
Tostoreavarie9ofitems,I cameup
withorce shehdesiep$ Anda tl|re€
aresizedto slipeasilyintotheslobin
theposb.Thisway,rearranging the
shelves won'tlreahassle,
Pu t tHRv$. The first set of
ah.eh)es(D) arc platn3/attplryood
panelscutto fit theslots,ash Frg.7.
(Io slideeasily,they'll needto be
slighdyshorterthan 24rr.)Then I
cutaradiusontle frontcornersand
easedtheedgesvdthsandpaper,
?tcsHltYls.The secondshelJI
desienedendsupbeinga srnallbin
with a row of pegpalongthe ftont,
as shownin Flg. 8. This will allo!,r
you to halg up a shopapron,ball
csp€,ot ano<tension cord.Plu6,as
n youcanseein lhephotoatright the
bin h greatfor storingsmallitems
likecansor spraybottles.
Thepegshelves st?rtoutasapeg
s,irefDoseft'J thagscutto fit in the
slots,asin Frg.8. Ifs screwedto a
shelf[ront (E) that's sizedto 6t
betweentherr€s of the posts.But
beforescrewingthe two iogether,I
gIDE SECTIONVIEW
No.142
driled five %irdeep
holesfor the dowelpegs.
To reinJorcethe front,
I addeda singletdangt!
lar ,/aae (G). (Notethat
it's sc-rewedto the tront
through th€ hole lor the
center dowel, as shown
in Flg. 8a.) Fhaly, you
can cut the dowels and
glue them in place.
loot Sflllt. The last
shell was desiSled Ior
hanging handled tools
or baseballbats, like in
the photo at right
me tool shalf (H)
starts out just like the
ones you made ea ier,
But as you can see in
Ftg. 9, this panel has
some deep notches cut
in its front edge.
To form each notch,
frEt dril a l%rr{ia. hole witi a hole
saw as in Fig. 9. Thed to complete
the notch,you canc1ltout the waste
on the band saw or a jig saw (Fig.
9a). Now all that s left is to sandthe
edgesoI eachnotch smooth.
Now that the shelves are com-
plete,they canbe arrangedho\tever
you'd like. And if you changeyour
mind later, don't worry - reconfu-
uring a shelf is just a matter of slid-
ing it out and repositioningiL N
'Woodsmith 33
 Fnusrns
Ourooon
whora,tlnsr fin*hn useTIf you'regoingnbuildm antdnar
Wondering
project
mdwantittnl6t,hne mea couple weusemour shap.
finishes

Outdoorfnishes haveapretty tough

job. Not only do th€y haveto protect
wood from rain aid sunlight - but
they also haveto deal with extseme
tempemhfe charg€s.
To accomplishall this ord let the
beautyof tle woodshow there area
few different claor outdoor6nishes.
They canbe s€parated into twocat-
egories:6lrnfnish€s andpenetrating
oils.They do the samebasicjob but
in two very diJferentways.

f fl fll slls
Filrnfinishesareprobablythemost
faniliar becausetheysiaJethe same
characteristicsas many interior fin-
ishes.They form aclear,hardbarrier
on ,op of the wood.
Polyurethanesare most often
thought of as an interior finish.
However,there are tough, exterior
polyurethanesfor wood expos€dto
tle elements- like doorcor trim.
Exterior{rade polyurethanesare
sometimessold as sparurethaneor
msrine\"dnish.Thes€'hncy'nanes
refer to avery tough fnish originally
designedto be us€don woodenships
expos€dto the harsh and unforgiv-
ing environm€ntof the opensea.
But tlat doesntmeanyoucant use
them on your patiofurnihfe. Ir hcl
they're idealfor this purpose.
Udike interiorpolyurethales,exlF
rior grade polyurethaneshave a
higher amountof "solids.'Sotheygo
on alittle thicker but providea much
ha.rderandmore durablefinish.
There is one other important diJ-
ferenc€.bderior polF rethaneshave
w (ultra-violet)inhibitors to protect
the woodfom the harrnfuleffectsof
the sun.Howevet thesew blockers
do losetheir effectivenessovertime.
Polyurethanes do have another
downside.Wlen the fnish sta.rtsto
wear,you'll need to sand down the
"tooth'
entiresurfaceto glveit some
beforeyou applyanothercoal The
advantageis you'll only have to do
this onceeveryfewyears,
P:ilErmr c ollt
Penetratingoils are just what their
namesuggests.They'rea mixture of
oils alongwith water repellentsand
w blockersthat soak into the sur-
face.These are often sold as "deck
stains"or '\rater sealers,"
Unlike polnrrethanes,penetrating
oils dont form a hard finish. They
help preventwood fom drying out
andkeepwaterfrom soakingin.
The problem with these Vpes of
finishesis that over time they're
slowly absorb€dby the wood until
the surhce is left unprotected.lvhich
meanson avemgp, you'llhaveto rea}
ply the finish everyyear.
But the ad\antageto thesepene
tratingfnishes is that recoatingdo€e
n't requireanyprepwork. Recoatthe
surface,andyou're done,
flfi flGltt flItsrl
Sohow do you choos€the right out-
door fnish for your proj€ct?It really
dependson how big ,nd what tlpe
of project you're building and how
much work you'rewilling to do.
For example,if I was building a
shed or deck, l'd use a penefating
oil - mainly becausethese finishes
arelessexpensiveand easyto apply.
But iJI built a setof patiofurniture
oike I did in this issue) I'd use a
polyuethane.The reasonis simple.
I like furniture, even outdoor furni
ture, to havea smooth,tough finish.
SoI usedthe samefinishingstepsas
if they were going insidemy house.
After appbingacoal let it dry thor'
olEhty.fien sandit lightlybefore
tlif next coat.I repeatedthis for a
minimum of three coats.
Note:All of the outdoorProj€ctsin
this issuewere all tseatedwith Zar's
Satin E erior Polyurettu"e.
As youcanseethereis no mystery
to exteriorfinishes.Youjust needto
choosewhich onesuitsyou best. N

Woodsmith No.142
 Souncrs
0utdoorftloleriols
when you bLrilda project
tlut spendsmostof its time
outdoons, it'sa goodideato
choosethe matenalscare
tully.Hcre aresome$ings
to kccpin mindtor the Dr4
ectsfeahrrcdin thisissue.
w00Ds.'Ihcre arealot0f
woodsyou canbuildwith.
As far as dccayresistance
goesredwood, teak,mahc
gany,cyprcss,and white
oakareall goodchoices-
but dreycanalsobe expen-
sive (andnot all are !om-
monlyavailable).Solor our
projects,wechoseanodrer
decay-resistant wood:
Onc thins to keep in
miffl is that cedaris softl
asdincnsionallunrbcrSo
the 2xti boardswc used
projects, somepiecesoike
the cleatson the top and
seatfrarnesol tie lableand
b€nches)will needto be
sizedbasedon the fl.ttr.rl
dickness of the stock.And
it's alwaysa good ideato
doublecheckthe sizesof
the pi€cesto make sure
th€y'll fit properly.
cl.Utt.Anotherconsider-
ationfor outdoorprojects
is the glueyou'lluse.The
yellowandwhitegluesyou
typicallybuikl with aren'i
intendedfor outdoorappli-
cations.But thereareafew
otheroptjonsto considcr.
For the projectsin this
issue,I decidedto usc a
glue I'vehadsoodrcsults
with ilr thc Dasl:poly
ureth.rneshro.'l'hisgluc
ilall
ORDER
SOURCES
in the OnlineDxtrassec- wood like cedar.(with
tionofour webs;te.) hardcrwoods,solidbrass
A coupleothergood(and screws aren r srrong theJoIIot,,i.?.g
less€xpensive)choicesfor enoughandtendto snapas
an outdoorprojeclwould you'redrivinsthen in.)
be to sea ycllow slue for" $lid brassisnt youronly
'nrcrc
mulat€dfor outdooruse oplbn though. arc
(suchas I')?r'kl;r's Tite- screwsd€signedfor out
bondll) or a plasticresin dooruse.Slainless slccl
slLe. (Plastic
rcsinscomc in .md silicon bronzc arc both
powderform and haveto 8l eat I0r ouldoor projccts,
be mixedwith watcr.) but they'renot as com
s(Rtw!.Likc theglue,you monlyavailablc andcaDbe
also want to be carelul a bit pricey.A lcsscxpen
aboutth€ kindsof srrews s;vechoicefor thcscprd
youuse.'lherearen'tmany ccts would be 10 usc a
srrewsin theoutdoorproj comnioDdeckscrew
'nre
ectsin th's issue,ard lhc Di(: drin( aboutlirrd-
scrcwsaren'lvisible.But iDasupplics fof otll(luf fur-
stll, you./0r l wanllo usc nilurc ;s thal you Lrsrally
standardzinc or brass' donl havr10l(x)kvcry iar.
platcdwoodscrews.'ltcs( Most honr( ccDlcrscafry
justaron'tmeantto bc oul cvcrythinAyou'll nccd,

I wcrc around1r,l:r'x 5Y:".

Ard thc s/4 dcckinswas
closc10lr thick.
S0 why orontionthis?
whc,r b ildinsfurniturc
reactst0 lrrolsturc,so rl
worksdifferentlythanthe
ghrcsyou'reuscdt0. (Fu'
nxnc onl)itlurcuralrcghrc,
checkout thc frcc arliclo
si&'andcanrusl qrickly. lh{Jugh solncoftheopli(nN
IIowcvef,t aditi0nal, I'vc ncnliondl Inay bc
solidbmsswoodscrcws iu0 rvailablconly al wood-
as(nxlcho;cc- al lcaslif woddngsloresor through
yo 'rc wofiing wi ) a "$fi"

SpirolEndf,till Bilr
An pcrltspiralcndnrillbil
is specificallyrlcsisnedkr
cut tnortises.(1'sacluallya
roulerbit,bul canbc rscd
iDa drill pfessthat'ssclal
itshighestspe€d.)
tjnliko l,brstnfr bits. a
sDiralend mill bit pulls
chiDsout of the mortisc,
whicheliminatesheatbuild'
up and clogging.But the
lonsercultins edge (^nd
the hishcr sp.'eds)also
makesftn a clcturercut,
so lhe sidesot the mor-
woodwr)rkins storesof
SpiraleDdnrill bits are lhrough the rnail-ordcr
readily availableal local sourceslislcdat risht.N

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No. 1.t2 35
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