NO.

70

f,)

4D

NOTES FROM THE SHOP

$3.95

No. 70

Augu~t,1990

1----

EDITC)R'S

---------

COL

U t-1 N

-------1

Sawdust
I dilur Dunald B. P("';Cbko
l),"'\il..tn Ilirl'Ctor Tlod Krn.ticek
~1.tI1:aKlnRf.'dilor l)tMIJD';_\5L HickS
'\~"I~.tn'
~.(Iilot, Tl"m J. Strohmttn
James ~l.
Dolan
Rk ....rd S. Pe...".

Gm-donC.;~
Pro,l(.'\11)(~.)(" KJ_'n\Iunkcl

Irtu.Ir.olon ()a,id ~iing

C""Cb~
Rnd_
Cbn, G""-_
(,rophi<orlu"tClorJon 'myd~
Pruj..'<\ ~~
).... HeAnn Gftrl>an
Cu tonw-rSt"t'\"1(f ~tf Und4l1om.J\\
(UlIOflll't's.-f'\1l1
L.iodaJon~
KoUy Hradford

Seen Rbodes
('rt"neU~8mn.ooon

\ldd E<k>lIrd.
MkSmith
Jennie~
(:ontn,114 r t',aut E. Gta),
IIookk'r)"'ljI Unda O'Rourke
(omputCTOPN'.iliI'n.~ Ktn \tinlT

~etYtorlc ,\dminb.tnlnr

,\dmini_A,,,,,,-

()-~u.o;
~1..Ud~
t"b",yl.\.:.ron
~Baum

!'i-.lUfcebuok

J~.an'l~~
!\tnl \. Buclnon
~",.C\lJ"M

"",,,,~I~
Ru, ding ~t nlenalllx Kn Griffith

Sto..., \tllllllgO"':
B<"fkd<).lA ~lic
.....1 DeIia""D

f>."

~ttllnl
.....
IA

\\'oodsmith

Kent \\'~tsh

flS5~ OI6tHI4I .. pub-

Il!lhl-O bin,oI11hl) (I:fob Apnl. JUDl". ,Ulg ..

Ott, (If"c) b)' \\'.)cx),mllh I)ubti ..hlng Co,.
2200(;rand A~r.l)t~ \toin("~.
L"-S0312
\\ood"""it,h

... a rl'gl' ..trrrd

lrack-mark of

II"uodsmi.h 1\Ib!i>hlnRCo

C-.-nJ:ltI I!KII)bv \\ ooo,mitlt Publ).Jung

(""'.pili)'

AJlIiRht> ........... -.I.

Su~";Ptjqn~()DC' )''It

T" ..... .

Ch l!"''IJ~' $1595.

...... 27 9!il.:anadalForri!:'<>:

><I<! S~"
U !>. fuocb. ~llII" COI1\" Sl.95.
~
{la" ...",.., ...aid .. [le..~11liDe>.L-\
.md I'It ;ed.JllIIOn, tI ~
r)Q~tmD"I'r.~'nd(h,]n~\'uf
addR'''!!' to ,,,T'l'l11
"'" Il, (~xle'lilt, (~'" \'~)\~.lA5W50.
!>ubt.<"riptionQu<-.uon.? CoIl SOG-333-5O'i5
8.-OO:tm141 5:00prn. ((nltal 'TIm",. ~kdal~

h.,, a (ri~"d wh,,', been working on a

Imlnd(ath"rdc",k (ur l1yc3I". Hefinally
RO' it (Ionl. a couph- or weeks ago - and it
wa~worth tlu-wuit
The clock is
"r solid walnut with
walnut burl. and it mccrporatcs a 101 ()(
dcUJiI<. indudinJ( an arched top. four burlcoven-d columns at the corners, and ("U~
tom-cut muldinl!' l"""I)'wh~I'\'
S.-e-inll thaI clock Rol me iOI~~cd
in
building one nw",U But I wanted a de<1J:TI
that I could handk In ....m"thUlg less than

"""k

L2\l~,

l.onglune .ubocrlber, know that we

h,,,, h,ld a 'InlIlRk getting tV(If~I'''/lt/,cut
on ,,'h('dulc' (In (a<t. it gOI :;0 bad that in
IYS7 Illi "tIRt"( '~""\u'","'3..n't mailed tlntil
Ortllb,r.! For 1111"Ila,t 18 months we've
bee-n""rkin~ ".rd 10catch up.
w, fin.III) did it fhi, i'sue (Aul(U$IJ!190)
"ill bc In Ih. "",il on August 1.L (You
...httUlrl rc'(. I\'t' it tn da), to t'Yo'CJweeks later.
d."..n.hllJl on mall d"b'ery in your area.)
I want t thank 'IJU (orb<-inl:patiem while
....,,. re Il}'inl': 10 ~'1
caught up. I know it
ran be frusll1lllnR to have 10 wail for an
I~
bul)'oII"1J!l'1
have lo ailan)' longer.

ib~ dt,j~",I ",uk-don j, ba ........on it

Shak"r Tall C.... Clock, (\\r',e not n'I,r
'''' \, I.. I!kk I'c"",,, as one of the
nn$l CoJt J ....11Shaker de-ign brcau......
lt' Itt" t...m-subo<nb.""lo 1l0ud ..", t)r. He started
a rru,' nprodu<tion.)
" th I SUI" ~o ~bac:k In 1979.Con<idering
The minut I -.wtcd buildrng th,clot: 1<.1 IMI ..., onl) had ". h""b", ribersback then.
"und~I'\'d wh) I had put this projt'Cl utf fllr .lnti 111'\\0we I~,,\t~1>o111~.flOO. he- is oneof
SO lonR. Th4,' 31''''\\'4,'( "'as ....imple. I hav e ill
the (l''A OflR'u,:aI:\nrf,u(ul
way, (t'li thaI u dock like thls wa, a nl.'l"r
\\11\ tho I>I~d ,I.houIN,k? \\'ell. he's
jll'll
;11111 clltlll I.,fl J,'_ .In dSsi~, editor.
proit"l - thai wuuld take months. il nOI
years to complete, (My (riend', 12')'ea' or- \\. hf'lt WI' flr,1 Inll'F'\'1t 'wt'cl Hick. il certainly
deal obviou ...ly had ,lI1 t'fft."t:l UJI nle.)
1...11"'" th.t h,' \\." "'1)' lllmili,,,wilh all the
Bllt. i( ),OU b",,k i1 down, a tall c.",dock
prl'Jt ,(,~ 1110111'.1",'.IJlJ",lrt-d U\"'r Iht ..years..
i...
jU1'<>t b()x(" ...,a('k("Ci on lop of ('3C'hotht"r-

IIu\ I km-'Yo hi "'.I~.ItNl' \\()(xlv.'c)rker

a ba,,, pt'ndululII C.>e. and h('ad ca,..
"II( n h. 10111,,11" Ihot a-u kid It. u -d ,oask
Thr way 'lAt'dl',ignt-d it. lht'rt> art 'IX le'rlt",1 In 11.dofll.\1iat(.t,ri ..Ul\a.. '''It!.O
(ram,, "ith molded ,-<11:'" thaI ....'!l;Il'"atr h..1:0Ihi- fir5t .... "I IOub. Itt bt'l1"ll modifym\'"", IMl"'" main C"a'<"....as .. (.J) it ....tht C1'O"''lli
UlS: hIS I'a,ml
tabl, Soon tht'tt'a!ter
mold",!! at th"IOP and kkkboanl;u tht 001 h"looI 00'" s R'duccd III a ruk-r.
:-';0... h.. Ita a lun ,"Ompk...,,,,,1,,( lools
lorn So. In (\".\ it")
ou c.."aJl rut molding
and makf' box .." y()Ucan buikilhi, ('kick.
and Ih<'abilil) 10 hdp u' pruduce our n.....
C.:lq()\'I-W .....W\llE. \\'to art" in tht
32 page l"Xpandl .... \'{"f'qon of "ood.>f,,tifJr.
proc;.., .. of t:h.tnllln" all o( our ..ub~-ribcJ\"mltH ""
f \It:. .~'" JOining uS b
fik...to.t nt \\. updatnl ,}...ti.'Tt1 I,', J:t.ln.: 10 (,ol'\lon (:.ipPt (;ordoo c-omeo; from aback
t-nablt, u ... to del II If,t elf thing, bt t(l.or and ):round ul bruad<aslj<>umalismand his own
(a,ter wllh ),.,ur ",b"'riptiun lInd. it ",ill " ...d"orking bu,int" And h~ also is al:;o
abo hdp with prCK'
..",i"lI Ordl'" (ur oo.,k ~lll)ngtiJnt' \\'QQ(/I(""t" subscriber.
is....ul~an(ll)mjt"('t~uppli...,~~
11, wa' ~mploy~d (or III year< with Iht
'Ib,' 1I"lyllrobl~111j, Ihal U,,,re will 1><' a \okt 01 Am...k. in \\'a<hinj(lon D.C .. and
chanll(nY~r I)(riod. 8I'1w('('n no" and (or a unw he wu, "om'O;jlOnd,'" at Ihe
Augusl 2(hll ".,. will 'I()' bt> llbll' 10 a(..,,\~t's.... l'nlu'd Nntion~ lIul he also ran his own
)'our, 1l1I1fr,", Jjt /1", rt"(()rd~inlheconlput\.-r:
v.ooden toy coml~~ny. "nd workt'<l as a 6n
j ..h carp('n,("r (or all illlt'nOr d~ign(!T (hls
Note: IIyou h., cr""~ntJ) placcdan ord.r
fur bark i"~ul" or project ~P1)li(.'"!'(n,m U!'o. ....i!e.l.aurit)
th(.~ f\.....
urtl~.ttl' JC()( afft'(1t-d. ~ . if )OU
Th(' fiN thinJ:' rln (iordttn ...li ..t heft" is '0
ha\(." a qU(--4j<m about a m3J' (Jrdl.~.'l4e- 'YliU organi,(' thcl1", ., Tl't:hlliqu("' s<'CIionof
be hal'll)' to n'C' you
l'ood.l!t" tit Riglll Ill'\\' \\t' an- planning a

.("orr....

u~

Ifall got' .... 11"ilh th. rom ,'I""ion.af1('1" ~t"so(c:unll><o;l~forti~ .....ol in b} readers.
AUlllJ-I:"'OIhwr
be abk 10 '<'1\'. you CtMdon \\ill alln'-"-IIK'C tIlt" fi"'t rontest in
b<-11<"r
and (.I"iI~r
the nlOX( i"'ut
~.:xT
Th,' (klobcri!-"lJ(' oi I\'nod
"OIHII IJ. ~-aking o( beuer and fa.-ter
I h3\'(' J,:Tl."at nt'~~
C'OOCl'Tlll_ng thl" publish$" Ih ('10 : I) "ill bc mailed (on time)
ing ~;,(:ht"(lul(.for \"()Ixf~" Ilk
during th< .. ttk ofOctober I, 1990.

,.,n

.,'1.

No 70

LOOK

INSIDE

---=---=------

Contents
1141
Great
L!J

l1ip~
& Techniques
,--...!... __

",,::,,;___;!.::.':":'___l

ITall Case Clock

L---

ii p [rom fellow

wood
,\1ortising Jig.
2)Horizonlal Bonng 011 the Morli.~ing
Table. iI) Spliltl')/lIxPI'I.!;) Quick Tips.
workers: I)Rouler

I~

n'e built

tllIl!

1'al/

Tall Cose Clock

JX.l.Ye6

Hold-DoWII C/(/)II/I

pageJO

Clock out of

CCINf

cherry wood aud designed it to be

u-elcome ill CIIIY hrms. It' ~llre 10 become

:...::.....;._::..:.....
_ __j. ~

a lreaslI rcd "";1'/00'11.

ITalk~Shop
L-__

..:;;_;..._...!...

115) holl'
lI'fgll'l'sfJllleIIJlsjrolli
OI",,ItOPOI1
10 plan thi tock
Ii a power
II

__j

pla nero A lid rr

III iIII'

lI'il

I hi'

pros and

COilS

ofu'Orkillg II'jlit a xabl'('l<aw.

IL:.......::..:!.....:-=.::..;_
Shop Notes

111611)pieceROlllillyAlolIglhe
Edgeafa Work
. ,1.11ill.,. a lid Spline Joint .
.!)

_J.

J)

IRoUcrStand
l..

.llakillg CIII(/[' illg a Feutherboard.

Illsl Athisuelcom
addition
any shop.
adjllslabl<!teig!tl roller dlalld
10

...J

is sill/ pie a lid iIII'rpen! 1'('10bll ild.

IMailbox
'--

1
__l

MAl The frame-and-panel

door of t!till
IIlaillto.r pulle doicn tt: reueal a Call
I"ellielll bill [or letters and magazill(,.~.

ITool~& Techniques 11281 Rippillil

~et

011

lite Table Sail>: flow /0

1111YOIIl'IClIllf';wW III rip board

o.C(;1I rate!Y and

sltjdy

: 130) EI'pry

sltop houtd hare 0. [etr of

/I,l','P ho IIdycl(l /lip s, They're easy to

make and I'('rg rcreotile.

ISources
Nll.70

11311 Hardumre
needed/or

IIlId project supplies

the project in this issue.

W'Kl,hmlth

FRO

:V1 F ELL

\V 0 0 D

\(1 ()

R K ER S

Tips &Tee

ques

ROUTER MORTISING JIG

Fall';! with ha.illl( It) rout 36

Some rouu-r bao;ts,ha"I'

11"rl. ,,tly ,"'1I1t -n-d IIIOrti "', for a

n'('('111 pmJ' "1, I d,vl'lup.d a
simph- ji~ Ihal k..I" tilt' router
bit (.''Illf'rt~ {'V, r l)lt' '"'(,rkPl~"(l'
Ill" Jisc .. (Jnt\i~I~(111\\0 bolts v'X"
u'nd,nl( IIU' I>do .. tI.. ba.,,' plate
olltlt" rotltt'r.....-e It~ 1
n,~,,IK,II.,rndrll, il:<,,, rkpoen' and IIJ'C Ix'id m po-mon by
-lightl) l'1~almJllh.,nuler. refer
10~ill 3

drill c)\'e,I'rsil.t!

I'X

l'(JUfllcrbtlrcrl

isting threaded hoi,,,, 10 (lr'I>' 11CIII~to mount thl' ba~ tf) yellir
r01J1,..r and allow ICtTmmor a(1

in tht router and mount the haw

.,1.11.,'"~ the blt align> wilh the

b"h, and is centered ~"'cll)b,'
tYol" ntlu-m

machiru 1x,1'~Just ",,:n" in ilubolb and ,'U' u(l,h,'lw,,,I,

Ju..iments, see Fig.:!b
lr vour router b...... (I.,\'...n't
Ihen. on the back ....
,tlt fl! the
It II nnmi-e i...
required at thtt
havethreaded hoh, ; <Ill ,an ba ...e, drill two counn rlKJrt d nd til the stock, extend ,h('
make a nl'\\ 00.... (Jut .,f ~.."'" IIar 11(,1('"'0.10 accept tht hed.. lIt Ilk" ",-c,rkl.II,,\"( to ~VPOn Uk" belts
Plexiglas or \1.,..onue I(. dc,
machine bult- on a line I
b, pull,"!! a pK,\,(. or stock in th.
lhi s, ~ tract- and \."'Ut (lui ttll from the axi....
OJthl router ...hat.
\ St II\.1fslhl-..am(thicknK~J.S
~hapcot)l)IJrf""l..tjnJ!b:.,'oj pLitt dk . sev tig. 2. Then epo~}Ih
Ih werkpi".~-ee ~i~.
3.
on the new pia,, TItendrilloo,a
boh-In pIace. _11j!. 2a
1It1I111ardChild
:;. center hole ,or ,11<' bIt. \. XI.
:\( xt, insert a . ,,"....
tra.q.:ht b t
\\' 11,1ffU,. \ 't"r" /JIll

,
"
.

4S'

,..

a,

t:- otA..
<OUN'TtUO.f~
,~.

DUP

'

3
Non:

Ct.AAl.

':7arr IS

WO."""ICf
"NO

<lNltREO
aE1WUN
POStS

("T(NS.ON
StOCK IN

VI"

SOlT 1lIOS ON

lXTlHStON STOCX
IXlIN~tON

InoNOtNDOf

"OC.

WOI:KPtlCt

HORIZONTAL BORING REVISITED

.1m.,d. 1m \lonl-101I rab!.in

\ lunbing T;.blt
(.Iut, t tin
I .bl. ",Ih. 1'1It!

I~.",....~I with lh...an'u"",') and

C'J-;4 "ill) ""hie,h I rein nu" rout
In()rti ..(~
f It)\I,:C'Vt'f, I tUn tlnal]i(' t(1 rtosist
chiclins: yC)U ahelnt anlHhc-r uS(>
I"r lilt' "'"l1i,illll T;.bl,' "hid,
)'()U (;till'cl ltl rill'Iltitlll.

smo II.: , lid 01a pl('('<'.dampillo

III rclau{]" 10Iix'.. rkpM'Ct, "'"
~IJI~ 'lid the I\,rt;ilign .;top a nuter gaug.'!t. k.'('p it JX'rpt'n{{)lIdf \."an be u.."ot.'dt" ,,")ftlful th("
di"ular t .. tilt' hack pand of Ihl'

U ~ou rl1>IJ\.'1thl

1l00d.;" 'I '1:11 h7 and I am

the \Ioni,ing
align Jlrill (;"io,' .",d .In.!t'\'tn('
drill. i,C'dn bt- u"-,,I It. 110,, hori

dq~h
oflht holt
To hdp a1i;!lllh" drill b,t <or'
r\_,\'(]Y.1 ~:ribl-'tl .t \.-"Itlt'rlint' C'f1

(Lt) Inuk,,' <luwl'l

0";II11pl.). To do Ihb.1

simply bolt," 1Il)'I'ntl"lillnllrili

i.t, IIUr}.. Guidt 10 Ih,' b;,,,' piau' ill pla'

ltlnlal bClring. , rt'(l'r you to

\\ "I(Ir/"',III/" \(). J 2. in v.'llirh )'ou

f"I1"". I damp

of the router. ".(. rill. I

lIlt' w"rkpi''\'~ to

Adju"ing Ih,' 1>;"., 1.1.,e lin lilt' lab1.., ,)r rL11np an auxilia')
It'atun'd ,I 11t)ril.cllllal borinR: ji2 'he \iuni,inJ,! "rabl,' u~ ()r <Iown Ruid~ to lilt: labll'. "-4..'(.' r"ig. 3.
th.u i...
'-C)lllt wh." '1111ilar to lh~' local,.,; Ih,' h,i,..hl IIr Ih., orill bit
Om nlor~tip: \\ -hl""fl tx)ring
'>

1
~::::..---.,

,ou
POIIlAUGN
TO .....

_ ....n

",

GU".O

.....

"-

ADJUSTMIHl
'N,,"

ilia,, "ilh lit" d~sir",II(),,1

n""'nny .'It;ldl<'d

/{ A I'",'I_~
..\I D

II, ,,,l~rJ("""il/~ .\'(

.,

.--

1---'-4
HE5C;HT

bas('

CROSS
SECTION

....n

I "'-G

r.bll

". tJ Illakl' Il l'a..it'r to CllaJl.gt"

(roln Ill()rti~IIIRtt) horizontal
UIl'I(\I""J 1,lah
bt.rinu, 1 l"I\'t" it ba!)(." plalt' (or
Sill('t l),.. bf)rinK :h;cion Icn<I'!oI my l'ol1align ami anothprformy
10 p,,,h II... "ock 3W'dY from tlw
Null r. Nt)\\t 1ju~ swit.:h to the

zonlal ll()lt,S
join,s, for

\Ion"","

WO'K"'(l

~~

l;:~j
:;;

STOP

COUAlt
PORTAUGN

lIAS'

AUJCiUAJty

Gum

No. 70


SPLlnER

INSERT

.1 ()""dun' kic'krn'l'kand wood

~t"xt. tracv the outline' (,1 thc'

bin(lill$! ;Ind hu",in,l.t on 1114.1

back
"I m) lablt ""v.' hlad,' wlu-n rip-

original in-ert onto Itlt 1I1:lIlk

and rough cut lt tf.\\ililin L-'I,' of

pinU. I d',i~l ...d a ,pliltl'r that

the Il...neil line. s<'C Fil(. I

work ... belt"r than Ihf' splitter
'1'0 trim the nc"\\ iJl.....
-rt tu till'
that ,'an1e" ith Illy saw, The (.riJ.!~ exact -hap 1)1till' original, I
in..ll ","111"r i'!> thinner titan nt~' used tht' ori~rinal.n.. a tt111plal(".
",v. bl."." hk'll al.lv., Ill,k.,1 Attach it to 01e' nt.:'~ tJl'!'iol'C1 whh

.1i~1I11) after 111, C2SlM'1tapt. Ihen mount a flu ..h

.. oocI, ....s".'SII,, blad. \1)' lit.....trim bit in the route-r and. .. ith
,plitlt"r maintain-, the exact th~ "'.rinl: ridin~ aln"1I the
oriJ:inal in,,n. tnm lhe!I('Wcnc
"idlh "f lhe ... v. kerf.
Til "",k,III, ..pIiO,r.bcein b) to -map.-....... I'g. ta \\ Ilhl)Ula
nlOlklnj.( .1 nt.'\\ into;(n l'IJ (luthi~ Ou"h trim bit. m~
UI "'. ,d the II
n",,, or plane a blank I., the sen until it fit.. the ()~ OIOR
10 do,.' "p

thickru ....'

or Ihl'

tn~...'rt nfX'tlinll

in tlu-"'lA- t.,blt-~, the nt;\\ in-ert

will Ii. n",h v.ilh II", wble top,

To riplh.: blade <101In the n.",

insert, C3n'lull~ ahgn the I"n",'
v.ith Ih(._t~clgt'"f lht-" c.riuin;ll in'

8(AItJNO IttotS

INS{WT
Ul'$4I)[

DOWN

.....

OIUGINAl
INSERT

'I.

\.!..... ~.~ ~

.'

')11

@OJ

,Nt!/' .1.'\.

- _m.
/

SAND

INRRT

I'OINl

ORIGINAl
INSI.T

..I

flACE OUTUN{ ON1'O

ROUGH CUT
TOWT'J'MN 1. Of UHf

.tAI TMlN

l'lllall\ .111make 11{_"3,j('1'lO 24:1

'PUmA

Ii

Ji"

., -

.J>

CAlm

....

into the ...101,see Fig. 3,

"'M
2.PFtUSH
lIT

,~,t.

turning otftht' <03.\\ 'oil hen vou'n- tl't' In''Wtt in iiUld out of un:.::,3\\
tabl v, dnll a fUlj(I'r hole in Uw
.~ fnll1tlh.. <n<ioflh,n,'" in"""
To make the spliuer, rip a nl"'\\Ill~"f1..........F1~,3,
Bme J J"I,tSl",
P""" 01"-lock 10Ih,' ClQd u.id,DC" 01 the <a" blade, I hll1h
:-;,t I f ,'/I,Of,( .." I {ft)rH '"
and 3" long. Sand the "nd thai
"ill be closesr 10 the bl.d, III a f4',/,I,4"'!t \'"" Fur nwn "" "'IIpoint, and then glue the s"lin"r 1'/111/."" Ih, 1l111rt, 111(lllw!li)I,V:

,..-

,_ --~~!~.
-.:)/
"

-en, .......~il(2. Then rip It"

AUOH FtI'fCt
wnMl.DCrOf

a-tG NAllNSlal

Gtu(
DIUU. I'

F1HGU
L_HOU

SIUTlIIt
IN PUla

srum.

evr ro ,"

s.w "::.'"'=-

---'

QUICK TIPS
spraying tl,\ ""4.rt'w~with il tit')
lubrit.~mt (Om' br.mcl IIvail.bl,
Tn ..void Ill<'"". 01 ,x=siv, from ",ood\\'urkins.: l'ilt:d(.J.l~ i,
rf,f,;,," ~ Il..'n dri\:in~ S("r('\\'~ int(l Dri-Coll".) Put tht ,,rtOW.. iUl a
Ilardy".t.d .., I U~I:' a lubric3J1t. n('A~pc.'r and ",lI..lV Iht'lll hlr
J1tis rtdllft' .. ,phi "4(,rkpiech. t\\'() or thrt(" '\c..clnd .... 111"'(1
man~It'd ""n h.ad,. and alai raltlf." the- part,a rl)uplt ttl tllt1("
uf unn'\'t an \\ork. :\J!'-o. and spray .tgain. TIll- ,,<re''''''~ III
bra.~, "'l'rt", ..:tn b( (,30;;il)" be pc,rmanc'l1Il\ lubr .. "II cI broJ.;,(n .and t\4l ..t,--d uti in th(" and \\ill zip inlcllhl' \\I)(xi
.~ ",om oJ ,,~autl"n. kc"C'Pt)ll"
'" orKIHC'\'t'
lJ,bri ... hllJ: .lar~.
numbcoroi <luff "f[ lb~ Huoror il v. ill Iurn
.::c.T('\\ ... ",ilh paraffin e,r brto,...".a.x
}'our"hop inlO a ..kati.1t rink,
can be 1t'tliou....Uld tim"l'on:-umIInrulJ.1I /'n<
ins: ...jn~lloal:ll~rl''A luu~1bt:
II,/,."a.\tl'''t~t'ta

position while lryins:: to tighh'n

tll(,~'scr('W$"'(lsan alm(}~ illl'
pCIS,ible task M)' uld ~''''
joint"'r, lik~ nlallY utdc:r 111ool'1

hand"'" indhiduall). SomeSITTING KNIVIS

lim~,. tit, lubricant :;imply 1311<
oflll"'lhr.ad, b<'lon' th, "'J'('ws Inreplacing m~~lilll"r
kniv~'
rail bt.' '0'\'(1('(1.
after ,harpcninJl. I IUlIlld Ihal
Thi, can b,' ~",ily IIvuiriedby holdinglh~ knivt, in tlw rillhl

.\ ailable IInder ""v~t:l1 brand

name!'. ask at your 10\'31f''1'('1
,upplY>l<lrc.) I PUI lbr,,, ,mall
b(,ad_ 01 the adbesiv~ IlUIIY<lll
Ihe bollom edge of a knill' and

FASTENER LUBE

:-<... 70

Illt'J.l"4'1

it lntc) 1)C)-..iliQI1in the cut

1,,I,..ad. n... Handirack huld

II,.. kniv,,, while I lighlen the

jOlntcn-. has. no ll'vf'lin~ ",,'n'w~

and "",uin's lbat tI"'l'1on~rlwad

",. ruUlI,-d10 gain 3I'n~'10 Ih,'
knivt.,~ ~t't S('r('~... \\'ithoUI
"'vding ~"''' ... 'hen I rolah'
th,' C"lllI,m'3d. lb~ kni\,<" 'hp
t.ul Clf iX,sition,
To keep lbe knr. "" in pIa<". I
f(lund a ~lick)' putl}'-likt rt
u",bl<- ~hesiv~ calk-d lIandi
T.l(k. (:\ole: Thi. produ"1 i,

KI " iJal/t ,.

/',/iJib"

'11'1, Il,." 111''11,'fl" 10

SIND IN Ton
nps
II you v.ould likl' to ~hart' a
lip or idea.. jU<;.1 ~nd il to
11'.00..1 tJ TIp, and Tech-

2200 (;rand A\~.Ot:>

\I"int'5.10"'35OO12.
RI'lU('S,

\\ ~ ...m pay upon publica-

lion SIS 10 ~ll~J (dcl"'nding

on Ih,' publi,hed I,'OJMollhe
lip). 1'"'''''' indude an ex1,I.lntllill" and a ,ketch or
phl)tn (W\"U draw a nt'w one),

HEIRLOOM

PROJECT
--------~--------------------~

Tall Case Clock

Timeless design. Solid cherry.
Brass clock works.
Truly an heirloom project.
~\il
,

e'\<e made a number ,.1 dally ....th all the molding. But
clocks in thl' 1\, 1 .. " cut all me molding with a
",lhshopoverlh<'Y"""
'1~ rOll"...-men SlaCked ilto look
have been designt-d to hanj! on tikt- more romplia1ed piece.
wallorsitona lab.... ButmlSTIIl
'''M)I) Ichose cherry Cor this
Case Clock is mo re than JUst a rlu('k It, all 4/4 stock ~.'.
onx_-piece - it'...an impn Sf\I' thk kl \Iv bill Cor me hard ..'OOI!
piece of furniture. Yd(", sur ca",.. to about $120, (This inprisingly easy to build
dud. , ~"traCorculling around
FRA.'ltf.lo We wer "abkt"k.,,.
the ..ap"'>Od.)
the construction
rt"latlvt'l)
1I(I(I< IUI'. As Cor me clock
simple by de~jgninR the ("1\'" work s, We worked witb the
with similar component
".,,'" & SuIliV-dIl Company of
Much o( me con-trucuon ill !\I1I,,,,,hu,,"Us to put together a
velves making (ram,, with '1>1'1.i.1 kit of the high.quality

molded edges. In fact, then- ansix frames mal divide IIIl' Ih.....
main sectionsofthe~a'< , w<"ll
a< me 0'0"" mold.n!! IIl"l Ih,'
kickboard base,
When you look &1It Illi.... ).
m,' dock is noming m..", than
some frames with boxe '!'o between them, GrantC"d. thj, i-, an
uver-simplification, but it... Iltlt

fur from me lrum.

The main diflkulcy .' maJung
the frames preci<dy. Th,')' haH'
In be CUi to ClC.3<"I" .. .Ih'">'must
be perllOCIIy squa re, and th('y
have 10 be flat. lfyou're on larget
with these little detalls.theclock

bn,,,, dCK'kworks (made in German)') and alllhe hardware you

need to build the clock. see
Sc'UI"CI'. page 31.

"'''".
When finishing projt'ct' bk.. thi, (v.im a lot o( moldengl, I 6k,' to use 3 wipe-on oil
fim'" fhi'time Ichose a tung

oilfinl,h (G en eralF'misbesTwoSt'1l s.,~ll

S~tl"l1l).
DOOMS. The clock pictured 31
~.(thas a gla<. door to display
the bras'
pendulum
and
we.ghts. However. you could
sub-dtuu- a solid-wood panel (or
the Ria". "'-e pogo.> 32.
llRACKEI'. One last detail. Be-

is a 'nap 10build.

causethis is a tall piece o( fumi":QI II)MJ.~'T.At first glance.

turv, it has a high ccnter ol gravyou miRht also expect mat you ity and could be I'asy to tip over.
would need lot of equipment ta To kl'('I) it >;tabl,,,anchor it to a
build a clod, like tltis - Cl'P<'- wall. M'(' drawing below.

WALLauclUT
8""u., II" do<k
h... a h'gl. r,.In- oj
gro,:itll. Ifi' rt"t'On!..
,/'1 e tid
addi~g a
brarkrt t() ancnor
Ih. etoelotJr, ...,,11.
Tld.gi"~lhr rlock
'Iability. and it
.noy gll'e yOl{' pe.ac~
tifm,"d.

W(~"hrncth

salW

lUAClCn

MOHfAO

"_5CtiW
IIACJ((J TO

WAUStUD

rUM(

No. 70

EXPLODED VIEW

MATERIALS

CROWN MOLDING
FRAME E.HEAOCASE

fRAMES (See Page 9 for Details)

A

_0(1)

9,xlb.
a ... '''''''''''~(2)
9,...14.1'<
C t<<IOdCoso ToP (I) Qh. 10

"'<>0 Coso

ac,. (I) ~.

o_Coso

lop( 1m.

1w

HEAD
CASE
DOOR

Qo

@
'v

x"

E f,OI" (I)
f $Id,,1(2)

~)

o'i
(s

KICKBOARD

1M',
I~,

31,. X 161~
'It 4.10

lOWERCASE

~ 1~.16
~a x 8~. x 16
~ pfo,t .. CU1 ro fif
.spry-Cutoft

G ['0"'(1)

H SidO$(2)
I

FRAME ~>'

8oc. (I)
0us1 PoM! (I)

PENDULUM CASE
k SlOes (2)
l 80(- (I)
M
.$1 (2)
N 00.1I(Ms (2)

o
I

I~

..

~., 2.x31"... 2 .tx8~"

w'1dOWSlop(l)

.x

HEAD CASE
P Sid<l$!?)

;.aptv-Cutto"

PENDULUM
CASE

fRAME

\!.
H

,.8

DIal Frome SIIO$(1)

'JIolf 'orne 110 1$ (2)

S
T
U
V

000< S'.IOS(2)
DOOI Rois (2)
58011:>00'0(1)
580tDa Suppa<!(2)

x IS"

I~)
x I~t.
.4 x 2'''10 X JOI,.!

~ 2.<.I~

W Sc,ew 8IociU (2)

~4.2 AX 10'~
~. x 2h X 13'"
~ 51;.4".
~3.5'~

X
t>mo Boord (I)
Y W.ncIOw$'op(l)

,. 13'" x 15'41
x SOIlgn

CROWN MOLOING
Z
(1 f ,on'!lldGs
(I) "' I

Me ' r,oo,/Sidol (1)

4() Rgh

o.ll.x42Rgh

88 AI . ont/Sioc!> (I)
2 x d4 Rgn
CC >P Ius! P>:ncI (I) '. po'; C...t to f
"'< Po-leI (Op' ) "' 9l 28 Rgn
'Cv1t, vn 411 .411 91' Of .. Ptvwood

I
PENDULUM
CASE
DOOR

.x8011gn

fRAME ~(
G
H

SUPPLIES

lOWER CASE

Clockl('I($l)epogq31)
(4l) No 8 x I")' Fh wood$C'9WS

KICK80ARO

fRAME

.:),"
OVERAll DIMENSIONS:
7411Hx. 17' '2'W x 101,".0

CUnlNG

(20) No 8 x 111.AI wocx:lsctews

(28INo./"
I... FhwOOClscrews
(30) Yl 1X00s

Songte !1rQng,~ WindOwgiOSS

Tung oIIliN..1'I

DIAGRAM
H

No, 70

FRAMES
\\1la1

fRAME C
FRAME 0

maJ...~thr- ,luck." lI.,r " ....,1I(1hen..-d th .. bun JOUlI.. til

a morti-e and splint' ,"ou

Ix tWt.. 11 u,ll
of thr J':ln..:: rc. ""tlit"\" thi-, fil.

the' irdlTlt> bee k tel th,' sides, I

cut V.I"nlorti"",- "11 a mortising
\II 'IX frames an, buih th, .....me labll' (formo",,n tIl"joinland
't\a} IIound it most t'(ti"'1\'nl tl) how to build a mortising table,
build them all al unn' mlh, r ~.~. "UtH/lIlt/f/ll ~t.67.)
than (,,It;' at a tint" [ts 1 nt"'(,,1t11
Ah,'" ,utlin)! the mortises 10
thvm lur the clock
CUI I I" '1)l1n(!~ t(, fit the
I cut tl\~ (our <;(>t'li(ln~n,'('(I.(1 "I(.rti!'lt.~,.....
*... l;iJ,:. 2. I used ~la
Cor each frame to t'X<.It1,ilt ,",11l111. (or the ,plin(' ....,
bdo~asS('mbly, (\uk;;',II u
ASSEMBUNG THE
lacln~ P;j~t' for 'llt~ "It .I..ur,"
FIlAMES
m,nl,ol raeh Irame)
Ihen, 10 avoid gtl.ing II'f I0 k,~
jI II,.. frame- <quare. flal
mixed up. llabt~,-d .....i1 and Ilush across it!' jnim .... I
~' -uu 1,Jlh.:tram(\\llhnn-i\,- CLlffipc-d lilt" lrow,...um section
.~ C ur-n:
:01 a time, In piec,. or ply" ood
lll()'1'.. The critical dirm n
....th <qua", corners, see Fi)!:. 3
~ rn -n 'bc- frame' I~lh.
ikgln bl glurng one of Ih,
I 19t~ 111<fmntpl"'" :-,un tr. ",d, JlI<'<" 10 th, front piece,
(uttln~':5 milL'" on the In,nt 1\, XI. IIlu, the back to thi-,
plN:'eo,;,(~ tht" h)n~pouu tc 1')llg front icl( .....~ mbly Then add
pomt measurement (~l".I1!'oIllt
tbc L"t ,iclt
diltlt'n~ions ~v4:nIn ttlt flr,llA
I II l"].Ulllllh. lram,' in plac...
in~""I)ntht n(''(1 Jltl~'
IMI1I"H'l',",'laoll' on l'ithcr side of
StO."i. \:\_'Xt rut ..fllilt r 'UII.n.' 'hi 111111,:1' ji,int ... and 3. bar clamp
,'nd QIcach side ,lj,C'. Ill'" "uldilll! IIw back in place, ""e
trinl ,"a,,'I, fit th""il' Ill.~t''''III III! :1.I ,II..., put w:U'l"'p"runder
1('OJCth";Ih <.:I
rt (Ul at reI'" ,.,dl)Olnt." It ,,"ouIOO1
Ill-I.~ued
Itlth,' ply\\'c,otl
Ih,' burk ,"d. " ... r;~,
Ii,\(. h..... \<)\\' (\11 tlle hlw'~,.1
W.1ITHlGf .... \\11("n lhp Imme
the (r..am\.tit fini .. ht"Ci '" ftttl ann I~ff,mpl(.'tt'. rout the' cll"Curati\ t
Irn;:th 111<"
lf1lgth uf th ..... b3<-k lJ(ulilt .. on tht' (rn"t t"'()J.!~, ~.
pil'("('S ,hould ,>qual thl shoo
I I~ 1 Clkf<orII' Ih,. jlmc<du...,
1'0111110 'hMI~.int d' -..:.,..... b<'- ..oo\\n on tht' ('PPO"lt~ pagt" for

-..id,,..;;;'The.

f'xat.1 fil

the ...orid~Yt,KKI 4.:.1......... i(I,... must

be po:rfecLi)flallind the fran,,'
"lUst bt.' -;quart
FIlAME DISIGN

FRAME B

,,"all}'join('(j in two ",'uy.., II II....

frame is m(,stl) df't~)r.lti\'t. it'...
join.d with miter-, at all four

th ...otherhand.h] th. l,n'S\'t'U

find in 3 ...ell-built ,h.,j 01
drawers, arc u,ualll made ""h
mortise and t('oonjolnt ...
For the ..;ix main lranu

FRAME 0

on

thi~clock I borro .....-d fnom each

of tlu S<: d.,,~'1l'"., hll I I
warned to hid, Ihl t nd gnuu on
the (ruolrl.mlN 1,1Ih,' lr:trnt' -,
so Iu~ mitl'tjtnnt'
~inc("lhr vl ...iblt ,..dJ.!c....tJllht

fram~ hav,-'nl\II.,(. pr.,fih:, 'Ill

liwtn. and Iwanll'fllhi, prnOl., In
fRAME A

"

cSI~Ild aU Ihe WII)' lu II,," Ixwk

edge,; uf Ill, franw,. I u"'t" butt
joints un Il", bflrk ,,'lIml'r,
mUI.~"'('-l1t '-\ll1('C" II't,
Crrunl~ Ja} flat anel ru'c' "'('n\\~d11'

FUMES

tht' Illain'l'('ti~'n....til

'IH' (3~.
nlUt'h '1"(\'
mnc'rt"fl fr(Jnt t'C)rnt rs

then .. ne.'

IGt.kbOOrd(l)

8 Pend...." Case 2)

U~ a moruse

and tenon )

,JUllinx

p"".""

~.'J;..

C HeodCO$C-Iop
I)
o Hood Cose BoI1ClM(

o Lowe< Case loP

f)(

lh ..,

(.l't

BACK

"0 lit fl

(Th,.,

1 PI~"

on Ih('
WIll h ,,'

SIDE

rout all~ ()ftllt' (raIm' bu~":#.

.... ,.2; ,.
....

UNGtHOf

VAJtI[S IV"
'RAMI:

..

Mo.nS[

Sf[ PAGE.

thl"';(o IJfoi1.k-:-.) 1>CJ JlCII

.2; ...

IN lACK

(DOl PAorlUSDlr'la,

""

routl"~

... WlOI MOItftSf

tun JOINT

AU SIX fRAM(5 ARt

IU",T TH[ SAMr WAY
llIl M(ASU"(M(NT$ AND

rronl

IJSllo'(NtT1Sl
AND $PUNl

NOTE:

FIlAME POTS

apan .hc'
BUI Ih, bark, 01 Ih .. Iram, $
ar<fiI.lwch,,,J tn an) oth, r part 1\liN.n the mil\."

\"GUM

\0',(,.

Frames (fJr (,'uS4.'w(,rk .U't' lypi

comers. ~ru\'lurnl tr.tnll$. I.n

fRAME 8

rOnlilt r if ).tlJ I-e- a 0"1 ru-e and

ft11OnJOint)
'tOJiCTl'. \.'I' PU'F.S. Fojoin

loom Pk'<"t of furnnure and 'I<lI

~impl} a .;;.taCk 0( frall'K"'(a'ld \.I"t"

OflP ClNTtaJD
ON TH.t<kNESS
OFS-rOCk

'

aOuNOOVUt
[00($01
$PUNl$lO

m MQltl$tS

WIANO

CLAMP
t S[CTteN
TA llMI

-10.

NOTE:

WAX 'APr.

'XCI$S GlUI

DON"l1tOUT
'ROFtU ON IACK$

Nn.70

FRAME A (1'

This frame ~Il'"

Ih"'kkk "...
board from Ih, 10"" ca...........-e
Ora\\ln~.Cactng (t:I;!t".
('0 rot Ihr profil~
on Ih,' trom
and ..idt....(J(tht, trnmc.rout 3V'!"
cove in ~t'\'('r,,1 pa....
st ... until
th .. rt", .t \-4"'lhic.'k ~lluulcJ(.r
along t)'t out ...i(I~(,f Ihl' (ram""
Cmllllld"lh, prom, by formins: II 1~"d''I)r.,bb,1.IO"lIlh(
J()~('f mu...klv ,'(IJ,:t'. Ihi .. should
1(~i1\'t.t~!!thi{'k,htlUlclc'l
l

------,

<OUN1tl

1.

nail). ,olll'1I I"~ upper inside

2'."

Then "" ..drill tlu- counter-

sunk ,Ilank 11C)h'",.

21.-

.*

_. -,
,
,

.......
I

'toO

""
y~~~------------~

ROUNDOW" INSIOl (DGCSWlfH

t .~

ROUHD--OVU.,T

_ 2', ..
FRAMEC

..,.

f ......

1'. ..
I

,,'

'" "

sunk '''ank hoi,,

above

0""
oflb .. he,d ,.,.,...

AI'
I," ROUN-D-O-V-'-'-.-'T-~""r.

T
,.
1

'6'

It' ,'"

.--+----------,
"0'
FRAME0

flltSl ROUT'1
tOUNOOVtR

I o.

~,
...
.. ,'-

..

N(X1 ItOUt I ...

ROUHO-OVIR

'

2',-

f'n...trill II,, II "nunh''''unk

hok, Sh()"lliin Oi "frrl ,,,~ ",,1]/.
For Ih,' olh"r Irame. prt-drill

\'ight hc)ll'!'<0111),(,n thl' ...ide

pi"ft, - t.nlil tht. six ,hank
"ok. on Ill. fmlll pi....,

STEP
2

b.

Finall)', pn..-drill til(' counter-

l-I'3JIlt" C

STEP
1
C

each bit.

,10;.

'2

I," STRAIGHl 81f

o.

.w.", 10 Ih,' lull d,'Jl(h 01 <-UIor

\\;jY

STtP

,.1._

,.

Covt I"

1,b. ' u.ln

IJIIlo"., ,.,,~~ RuuIbOlh round-

(lht')"'rt' JUM a diU.n-n, ..at).

C)nc' of th. ...I fr me ... i, at'a.:h,.,J 10 Ih, lop of the Io.. or
ca-e, and tht oth. r i..turned
and ~IIJCh<-d10IlKbottom

llAvt ',"
SI4OULO'.

,"

\..~ nltlnu<JVt r bit

the ,tntt

111

,j(.l(' .~~(. Ilf IJl~

framc. U"'lng a

&llt (,1Illl.....
Ir4l11c.
....ar\ roun-d

STEP

'0'

Nt'xI rfUl1 ~tW )i. ""'~ decora,,\'(' mho." abel\t tilt cove, ,,OJ

FRAME D (2)

I,."..
.......

'0'

....Ilc'uld,( eu\ 1hc' (ralTlt'

S,:,'O'"1. <'''mpict, the bull

n(,'t \\ uh u lIl" round-over bit on

b.

SINK

<-

until th~'rt"'"a ~;.rlhKk

Thlc tmOlt .ltt3\ht ....IO th( top ()[

Ihe h<'ltd ., ....
The llullnc,sc- profile j ...
routed In t'Aft ~t' JoIN [om)
a J)(()filearound the upper out-

'._ '.- ..),.*

',. COVI lIT

HOUWI1l4

_ 2'.- _

bouom el' lhr l)l>flduium ('3....

SlI.tpt: Ihe tr.lnll ....bv fil"t n'UI~
ing tfu lit' l'C.\'t' in ",(..eral

FRAME C (1'

.,~------.--~----~~~,
'0'

prnciulunll''1 ....-, and one.for the

1,.-SHANK

". (0Vt

01 Ih,""
('Of (c.r lh~ ItJ)01 the

\~d~cwith ;Il..
,*' round-over bit.

You" ,II nt, d I"u

I):-l"'{_'"

..

!--~------"__---1

FRAME B (2'
lr3JJ1t ...-

f-

, .,'0
...... -

fRAM A

2,,1 '')-~

Prt'-1lrilltllt 6\,(,countersunk
....hank hi, I,''''' ,I'" ,hc,\\ n

- ..-,
,.)

,....-..---

b.

~_~.~ ......t
IS)','"

- 2.',. ...-

I.

NOTE: -----~

:-===:::'1

COUHlL.SUNk

SHANKHOUS

OMITSCRew HOLIS ON ONI P'lCE

Of ,ttAM( '0. IO"OM Of HIADCASE

AIt, ... making all six franw,.

I~
work on the kick
board The kickboard con",Is of. front() and (v'o
.Id"s (f) Stan by ripping
all thre e pieces to a uni-

ctNTta ANO Glr.a

I-....J""'" '0 KI(!lIO....

CUt Sl'\JN[
TO "'

both endsotthe kickboard

front (E) so it's V.' longer
than the (ront o( Frame A
_j~-::'2..J(I6~,' from long-poin! 10
long-point)

,
',.

"

"lTuts. No", miter

,,"

NOTE:
lACK Of fRAME
ISfWSH wm.

J(K;.c.aoAAD

Then miter

the Iron" 01 boll, kkkboard sides (Fl. and

rut off till' backs '" they're ~.Ionger than
tho' "dt"'<lI~r.me A (l0"l.,;('(' Fig. 7
"ORf wn 'I'IJ' . "~Xl.
cuI a kerf aIon~
tho 111l1t-rcd t'()g,~of _b piece. and cut
,plm~'
10 fil the kt rt. .... ~ Fig 6. Glue the
"MInt'S in "be,' and clamp Ihe unn square
\11"\(11 o'R.\.". To complete the kickboard. center Frame A 00 lOP 01 the kick
board and glu' IIin plac~.""" rig. 7

4
c

fRAME A

KICK80ARD
FRONT

...

k'.,

("nn widthof 4". see Fig. 5.

, o

FRAME A

,
KICKBOARD
SIDES

.INsn
ON-fRONT
AND SlOU

~.GlUl'RAMI

-.

OIIfCTl T 10 TOf'
01 KlCaeo.t.RO

Now begin work on the

lower case. SIart by edgeIlluiog boards forthe front
(G) and side panel. (I I).
"'t' Fij!. 8. These panel
,,;11stand on the kickboatd
frame, CUI all the panel, 10
6"", ",ngth (16"). then CUI

the Iront panel

10

final

widlll (l5") so i.-sin"1

(rom the roved edge on

A. see rill 10.
L_l~;:::':_jframe
Tho side panels auach
flu,h ,.ilh Ih" back of the kickboard frame
Il<fotl(Ulling them

10 width,

cut a longue

and Woo,,' J"illlalong lIIe front edges oi the

front and 'id,' panel>. sec Fig. 9.
,\'\s~"H'"I \'~LNow rhe side panels (H)
<w, be CUi 10 final width (IW,"). see Fill. 8.
Tlu-n spread lillie in'ide each groove. and
.Iide Ihe IOngu('cI side panels inlo the
IlroclVrd trom pan.'I. (lamp the case with
pip<' damp' untillll"j!lue dries,
fIlA'WOW "1)(,10.' Aflt'r the glue dries.
roul d""otal;v,' h." chamferakmz the out";cIl' ''()I!t'" or lilt' Imnl pie<.... "'" FIR II
~op th,,h.lml(,,,. 2" from the lop and 001
(lim of tIM' (~t~
\11"\( II \ PPtW Olt,UlE. ,"ow SCt'eW a bull
(t-dIlk' (til<' onr"iIh 14 shank holK)
emothe lop o( the case assembly, cenlerinll
Ih, trame 3CI'l'" Ill" >idcs This should no,ult in a W overhang around the fronl and

lOWfI

11

.,.,.....(l.
"dc'.

st..: fig.

10.The frame should be flush

ollh, bock ,'(III~ofthe lower ease.

)\ST\lJ.o!>'ro KltlillO.\RJ>.Finally. screw

Ih;, ,'mirt 'ui>-a"",mbly 10 the lOPoiFram~

A on II", kickboard, see I"tg. 10.

10

CAi(

....
'0

I,un
~

'" .;

...

,a ..

11.,-

WOODS<UW

-~,f~---l

KJO(BOARD
.,/

No. 70

The pendulum case co".

,,'I,oCtwosides (K) held
In plac.- between a pair of
'Il- frame-s, see FOg. 12.
'IOF-'-romaketheca se
sid e~ (K) start b) edges:lulllJ{ blanks to a rough
width of 8" and length o(
32". Theu trim each 10 a
final width I W' less than
Ih. depth ofFrarne B (7!t,,"

in 01)' case), and 31l';!"

lonl(. '(Iig. 12.
AU(, '''C, F'RA.\lbTO CA.'E SIDE. \\'jth the
...id" pant'l, cut I.) 'il.A;, the case can be as...-mbk-d T.. do thi,. stand one of the -BIram,"" on edge .. ,th iI, back (unshaped)
-ection dolAn 1114.n -..&.and one of the ('3CO(_'
"d,.., nn ..tI~" (I11L'l:n"",,, thatlh e back
,-d~,''''of both I"t'""" art" flush.I ~O\\ poc:ilion the ,id,' pi(-c(' W in from the should er
ollh"lraml', ,,-,<, HI! 13
PIIArr 1101..." l "ng th, pt"t'drilled shank

12

PENDULUM CASt

~~~!~
% '5 ;ii "~

13

_4t'

FRAME
B

\."IN-HT

_ 1',

...;?
_~.

Jh WOOOSCRlW$

PENDUL~~'CASE SIDE

FRAME B

CASE
SIDE

1141 .c!., ~'."

.....J

Non:

fWSt<

LOWER
CASE

At
lAC.

"it,,.
"i(_'rt1W, Then al'nclllhc

other "idr- piece.

"1111' ",,,'ulld "8" frame attach es at the
other ,-nd "I the case assembly in the same
manner l'his Irarne mirrors the first (nun ..
- till" ... ,v,'mold,'" .odg., uf both frames
la'ft' t(~w.trdeach other and into ~ case
(lPtnillt{.....''t. 1-1J.!_ 13.

Non:
SlOES

ut

flUSH

","T\t_J__J,(, ("10 ID\\"'ER

~F .. No".'th(

pendulum c.... can be ",,,,,,ed in place ento

till" lcwc-r (.1'4.' ",ilh Xo s x 1\-~ At woud+
...
c:n~s."""-"_'
l-iJ( 1..

FRAME B

'10M 5H04Ju>(a
Off"'MI

hoi,, in the fram.-<asguid,,,,. drill piIot:hok-;

for both " .... w,. :""" screw the Irame 10 the
side
with IWo ~o. It x It!!' Fh wood-

<,

wrrn

.........
lACK Of

FRAME B

PLYWOOD BACKS
Oo<~ u...pendulum r.,, h3.' been attached
101h< low(r C3"'.~,' plywood backs can be
-.:nw,rl intn rablx-I> routed around Ih,'
back
01 I><llh l'J,"'.
HOl'T R.t\Bll..'"J',. First, la}' the entire assembty 13(:(' down across a pair of sawhorM.....-OIl'" rout a "4"-drep and ViS"widv
rahbl'l "mund all ("ur inside ..tIges of both
(a... "I)Inllll1'. ",. Fill. IS. I did this ",ilh d
~la"rnbbt'lllll~ bil in the router, <Form" re on

,<1",'<

lS

16
.l

0,

..

PEN
DUlUM
CASE
BACK

"

I ~

flaJ.:'

earh elf Lht.,,(C.IP. ninll"-.td (,."Ut a Io\\-er ca.'"'C

back(I).mdap<:ndulumrnse
back(L) 10
fillrum ~" pl)'Wood.
Abo owa'un' and cuI a dUSl panel (J) 10
lay tl.,1in th~ bonom 01 Ihl.'kickboard 3....
",mb!) , ""!-II( 15.
\1T\(1I I'A~H.'.
In'I.lllhe dUSI pantl
(..ith ~ brnd') . nd both l-a"..back, (....ith
~o. 6. ~."
I'h wood<cr~w,;).see fig. 16.

Nll.70

_l, __

'6:1t I,"

',. auos

If,)

\\ ith a rhi ...l and mallet, square up th("

ruuruJt'tl \'"(;,m('""f C3Ch clfme rabbets,
ll"T 1'\' ..' .....\Ct'" nlta~ure the size UI

f h WOODSCttlW

rouunu on 1)1\' ,-dJ,!(" ofaw rkpiece.sce Shop

\:()1t -.

fl

LOWER
CASE
BACK

10W0tCA5(

1Acx.

....,.,

(J

sou... , u_ .OUNo(D

LOWER CASE
DUST PANEL

CORN'IS wnH CHISll

11

HEAD CASE
11I~h..."" case is made up
/

"'POrated
b} a dial frame. and at(ached 10 two bullnose
fram4 '- see f.lg. 17.
IIEAIl'Ill"", Bewn b)
,'dlll'-gluing IWO head
~i<1<"!1(P). and trimming
to I W' less than the
d"plh of Fram e D (Sir!
wid...). and 151,1," long,

01 "" 0 ..;d ..... (I')

17

FRAMEC

:- OVOtKA.NGS
SID'S 1 'l" 2'

r~
~

SOfTEN

'10,..'
IHSIOf

..

IOGr
WIll<

.,"

HEAD
CASE
SIDES

D[(P
ON SO'CCI(

b_

0""

DIAL

..,,1.,-

,.

fltAME
flAILS

,,-

"WOOD

0vutH.U<G

KRfW\

,..,...1
1--...-'
0

',-

INsn
fltAME 0

18

a.

"'AD

II. I''''
rh WOOosc.tw

CA5I

'RAMI 0

K(l' rlUSH ~
IN lACK
Of CAs-rs

\1(.. ..."

PlNOUlIJ.M

(A$(

~inalJy.>Cfl"ft
the h,....1 (n". to the lOPof Ihe pendulum
case. -..('(-tlg. 11'\.
~'RF\I"UPE'Olll

1':1,"

I."
ClNTfllO

<!

tIOUND

I."

,IT MOImS(S

..- MO.""--~...

~,ftt'n the Iront inSldc edge of the

Cramewith a''- round-overbit.see Fig. 17
,\.",E""I \ SIan a'~mblinR
the head

gluinl( Ih. din! tram e between the

two head ,in", (I') Clamp the t:..haped assembly '" thc' pk",<, are Oush at the top,
bottom. mullnllll.
AI"'r Ih, glu, dries, ",'n:w the bullnose
Iramc" ( and Il) 10 Ih~ IfIP and 0011"'" 01
this ,u1>.''''lObly. "" Fig. ITh_(Note: The
bullnoseprofile lan-lhe..arne direction.)
I"t....uion ,},(.trarm ...~ they're Ilush with
Ih,llf'aci'I<It, (1') at the back. and cenrered
from "d,' to -ide, Then driU pilol holes
IhrouRh IIje- ,hank holr- inthe framE'S. and
"'4-Tn\ tht trnn'l ....to the ...ide pieces,

,-j

'\C)\\-.

1'3"" b)

a.

ItOUNO ovta IOClS

Of SJIUHlS 10

_c

DIAL
fRAME
STlLES

"J<'"

ow FR.\ME. The frame

.__.__::..__ -" tltOthold. Ihe clock (a,.., is
built a lilll,' diffll'\:ntl)' than UI('case Crames,
11ha-, mc)rti";'('alltl "plio( jolnt~(ormortise
and tt ntUI joint') at each corner
1 0 make this frame. tir-I CUI """ stiles
(Q) I~'",d,' andISW lon~_Thcncet two
rail~(R)2i1't6"""deand lO~."lon!l (~,)IC:
If) ou'n- 1J'llIg Plf.r1I<.;( and tenonjoints, cut
Ihe ra,I- IOJl)!t'I' 10 allow tor the tenon-c)
11I"n.''''~llble the fr:m c.<;('C ~-18' 17a.

__
r-l ........

,eAM"

,-

ovrltHANG

CROWN MOLDING
'111\'"crown molding

as-

19

,,mb11is made up of three

1 ,h.peel frames, A field f-"'_

first \"I~nK threestrips ul

." ,Ic,,'k loa rouRh k."JIIh
and 601,I...d wridth (or each
L..J.';::,..._ frame Then, on thl~
cove
Iran"' (.\-\) plt'\t-c. rout the same cove and
rabbdlll"ufil,.,on Frame B. reCerI0pagt'9.
~II"

NOTE:

,......

"""(2 AU
fRONTS

1'-,.

,a.

1,I:!l

. -

COVE
fRAME

...AA
17

10 ....

,
'.1
,
f

,-

...

I)".

OVRHAHG

FIElD

fRAME

.-

IN.SEt

mncr ttt~front -oction of each tram..'

lu finallt-nKlh."." ~ig19.llll'n mil~reach

,rdt pi,c,:\'. ,Ind cullu 1"'I1~h.A...s.cmblt> th\~
fraDlc, b~ gilling Ih,' 1"'01and then th.sid,,,,
onlo Ill('tram~ bdow il. see Fig. 19a.

12

RIM fRAME

c.:.....:::. '

fmrne (Z)'land. OJl edge.

" cove lrame (AA) is

routed and by. OaLanel a

rim frame (88) la)'$ 0.1
1'" t'.pc,rthi ... "" rig- 19.
"lake these frames by

roPOf
CItOWN
MOLDING

H("DeAS(
lFRAMt C)
=

NI1_ 70

DOORS

r!lli, The
clock hastwodocrs= head case door that al-

20

lows access to the elock

hands. and a pendulum
C3S"

lot,"

door th.1 allow>

CD-

,....

8'."

~ 2.' ......

--

,....,

13."

t."

I 0

2t.,,"

2t ...

MORnU

...

.10." OEIP

CENTIREO ON

STOC.

(b.
4

)'"J(~'''
AA8eT
'OR GI.ASS

I-t....

SQUARE
UP (ORNERS

'

PENDULUM
CASE DOOR
RAILS

SPUI"ESA.~1))tORTISES.To assemble the

No. 70

[)
..

ts

,,"

2.~c

door rails (R). subtract I~" from the width

01the pendulum case and the head CaSCo see
Fig. 20.

HEAD CASE
DOOR STllfS

...

To determine the length of the pendulum case door rails (N) and head case

positioned 2" Irom the tnp and bonom 01

each door. and mortised into both the case
sides and the frame stiles. SC(' Fig. 22.
Pl'US A.,'l) C.-\TCIlE-".
:-low drill holes in
both frames (or door pulls (~C Fig. 20 (or
locations). Then drill holes lor two door
catches.Finally. installihe pulls and catches.

@-

1 ,
~

2'." j

, ......CASE .DOO

It-nl,'th,see Fig. 20.

wi111'''''0 2" brass buuhinges. Tile' hingesare

1 "."
f

(sa PlNQUl,UM

Now cui 1\\10 pendulum case door stiles

(M) and two head case door stites (Q) to

mMoRmrs

"'l

HEAD CASE
DOOR RAILS

ROUND OYlR lOGES

Of' S9LIN(S TO

[J

t
,

a.

_21,,"_

2' ,,-

access to the weigbts. The

frames (or both doors arc
made using mortise and
spline join!>, and both
frameshavca rabbet along
the in~icl('edg.' to accept a
"-_ '" I glass (or wood) panel,
"_-"'<--=~ srurs A~I) RAIJ.~.Tlw
<files and rails lor both doors are all 21,-,"
wide. To determine the length 01 the door
(mlll(" stiles, subtract ~l! (rom the httiglll 01
the duur opcnlngs, (This allows Vt""clearance above and bdo\\ the finished doers.)

frames. first cui mortises on all the mating

pieces. (I cut all the mortises nn a mortising
table.) Then make eight splines lor the two
frames, see Iig 2(~d.Now damp the frames
flatand square with the >plin'" in place,
1.'smER.\B8lS. IVith the door framesassembled. rut the rabbets that rt'<:civ(>the
1.'13:;" (or solid wood) panels. t used a ","
rabbeting bit in tlw router, ,I'(' Fill. 211b.Cut
these rabbets :y,." deep. 'men use a chisel
and mallet t SQuareup the rnund corners.
~-n)I'IEI' CHA.\tfEHS.TIle! fac c\~ of oolll
frames have a slopped chamferrouted along
the inside edges ofthe rails. and both Wiles
of the stiles. see Fig. 20. With a pencil. mark
the stopping poiOls (ur the inside chamfers
"'x" (romth,' corners. see Fog. lOb. Mark the
Slopping points lor the outside chamfers 2"
Irom the ends orthe Stiles.see Fig. 20b.
t',\NEl STOPS.Aiterrouting uie chamfers,
cut a quarter-round head case window
SLOP(Y) and pendulum case windowstop
(0) from ~''''Ihick srock, see Mil. 21. Note:
Fig. 21 also shows an optional wood panel
(8<.,(' a photo of this opuon 00 page 32).
The zlass panels should be cut 10 fit the
dimensions 01the door openings (less W').
Install them with the-panel stops mitered at
thdrendsand nailed inplace with 1'1' brads.
HA,~Cr..~G111F. DOORS.Each door hangs

CtNTtR AND OQIll

KOUIO FIT

'."

PUll HAROWAAt

(:

RABBETING
iNSIDE
fACt UP

Bit

.J!

OUTSIDE
fACE UP

'",

POSITJON CAtCH

I- PlATEIN UN'
WITH PUll

ePENDULUM

CASEDOOR
STILES

CHAMfER Bl1

.h-4----~

21

,,"
eRAI>S_

WINDOW
STOP

r-"'CO-==~'@@

NOTE:

LAY OUT STOP

POIN'T FOR
CHAWlR WlfH PENCil

22
GLASS

wrNDOW

.j
(OPTIONAL
1 c"

lo".- .J l_
"I

WOOD PANIl)
$0: PHOTO,

PO.;..:' ',.' -,..j

NOTE:
POSRION

.j

f1:INGlS '" fRO,M

TOP AND 10110M
Of OOOIlS

PANEL STOP

j.

1" __

\XlooJsmlth

I3

MOVEMENT

&

CHIMES

t)

ClockWorks
T

he clock works, consists of IWQ major

componenis-c-the movement and the
chime rods. Before you can install these,
center and screw the dock dial (ace on the
back of the dial (ram e.
SIlATB(MRIl.11w cluck movement <ils 0"
a grooved scatboard (U) tIlat straddles a
pair orsupports (\'). ~~ig.
I.To make the
seaiboard, rip a pi(",,, or}( stock to a width
of2~.". ,""cFig. la Thencurluo length to fil
between tile head case sides,
:':ow cut IWO 1I!1"wideand I;s"-deep
grooves (l<erf~)along the length oflhe seatboard to accepi the movement. ~ ~-1l1.la.
The brasschains Ihat support the weights
hang through a slot centered between these
J!roOV~$.1'0form the slot. first drill a pair ot
'1-:1" holes to define the ends of tile slot. see
Fig. lao Complete the $101by connecting
these end holes with Iwo sabre saw cuts,
Tomount the scat board into the ease. drill
:hfi" countersunk holes on each end of the
seatboard. see Fig. Ia, Also. drill a ~j>'hole
ncar one end ror a chime silencing wire

SEA11)()AROS(rPPORTS.Next. 10 support

the seatbeard (11).(.'\Ittwo seatboard supports (V) 5\1-.!," wide and 4:V,tH long. Then

screw the supports to the inside ofthe head

case sides. and the scat board (I)) across the
top clthe supports, see Fig. L
SCREW BI.DCns. In order 10 mount th e
chime board to the bade of the head case, I
attached SCJ'(>W blocks (\V) to the top inside
of the case, see Fig. L CUIthese blocks 3"
wide and 5\"1"long (to match the seatboard
supports). and screw them in place.
CIlIME IIOARII. The chimes are SCf('W(-d
to a chime board (X). which also acts as a
back panel (or the head case. To make this
piece. edge-glue a panel (rom :YiM stock and
cut it to fit in the back ofth" case. see FIg. I
Next. bore :Vtt."holes through the chlme
board to mount the chime block. see F''8 I
Counterborethe holeson the back to accept
the large wash ..rs that come with Ih.
chimes, see Fig. 2. Also drill countersunk
shank holesto mount the chimeboardto the
screw blocks and seatboard support"

INSTAIJ. \\'()RKS. ~()"', set ine clock works

on til<' KJ'()<w<>d scatboard (U). The handshaft should be centered in the dial hole,lfit
isn't, remove and re-cut the supports (\').
To ,l(ld Ih., chimes, first screw the chime
blockonto ihe chime board (>.'). Then screw
thechimeboardtothescrew block. (IV) and
-eatboard ,upport. (V).see fig. I.
m'q' !',\XlI.. After you've line tuned Ole
movement and chimes.topotithe head case
with a dust panel (CC), see fig. 1. Cut this
IIIfil "illli" the crown molding ann screw
(don't ~Iu") it in place - you may need to
remove it to adjust the works, Finally, add a
wall bracket as-shown on page 6.

HEAD CASE
CROSS SEcnON

,
11
CHIM(

... <XI<

sql1w

CHIME
BOARD

BLOCK

._r

DOOR
PUU

,- ,.

o.

SEATlIOARD

~.'" HOf.,E fOA CHIME SlltNC1NG

....

1,

,~.

WIAf

'"

SlAT
"""00
$UPPOIU

CUTOUT WASll

--131',.

14

C:::J;::t:::::===t~~

Woodsmllh

No. iO


I
I

0 ~1 MEN

T SA)\;

~--------------------------

QUE

S T ION

"

____

Talking Shop
PLANING THIN STOCK
./"

,\ nodsmlth j\'f,. ',":f, 110"

IU/t"/'f)'" ,/ lllfo'''!1 II Ilynb, AP~

1"111"", r tu "f ,Iu(', ~ttl('l.tl)

'I,

"0,, Il/flU/lal
""1,1,, "ll/tlllt

tItUk,tfHlf. ,l/ytJU'lIf
s'I,fy" 'lit,I "tIll III

tl,'t1,,, rll

/111 I

"'h"'Hromct I
.1//011 (i. J"I",;;o(,,,

However, I've planed stock I4l

I~~ than W thick on U\(_'.,sicJn.
When duing this l makesu re lh,
knives On thr planer 011" ,harp. II
th.. knives arc dull.lh ..,-bt'al
again<1 Ih .. 'lOck rather than
slice through it
AI,." I exammv <"""h ptec., 01

.\ Pit'}' aIr/'I/fl. ( (1)1,lLflr,,/

1(l tIt",) dn''',,, ~tmrqtu-.lton.1

.. ood and In"'" II In tbe pbn ....

,a]I,-d R)"bllU find (.11"hl'thl,)
.....th~ maj.)nl~ ofl""pbnmg will
li..\ a minimum
thickne .....
~ be done ... 111th. llraln And.
Rlool "'p!ain,iI Ihat it has In do even if I'm planlll": 'tralht
~jlh J)C)tt'llti+d""'I}' problems, grain. I never ,t nd dlrt"''" bentll "lc"(hanica) probk nL'"
hind lhr piaJH'r or look '010 II
~I'"twood grain can , ....itch while it',opt'J'3tm~
din"l1.ic'n~ rnM(lntly.
I r,p<,,'"bl~ lUI Iatl!(
1 AUXlUARY
chunks (If slc,,,..k tt)
PLATfORM
tear 100" Alld 111l' S.lot GVJO!

v.r

thinner n P'<'CC111'1,.

till' " . , Ih,rt is IQ

huld 111l'<hunk, in
pla!..( I've' -ce-en
IHt'\"t" hlow ,11l..ln in

,r:

a I)tallt
Io"f)11 TI("',

m'c.lnnknd a .!

lIll' ,tn. k aliJlTlro dirl'Ctly under

II,, ,'Uttcrh e-ad.
FIII"IIv. In keep the platform
(rom beinlt pulled through the
plalM'f. WUl' a 1 ,k'31 cut from
," plp"'Mod alonR the the bottom fronl t"CI).:l". -ee fig. L
'I'll u,,lh. pblform. hanll Ih.
deal o,,'r th. inf, -c-d <ide of the
I~.tn,'r bed ........ ~1J1.23. Then.
",.kon~ "'1') <hallow CUI,. feed
tIll' 'h~
k lhrouRh .' nonnal.

2
(unUHlAl> "\

ClUT

mlOunumth" kilt........

IllHdt, Irum t141tMasonite 10 keep

SlOt

R~obi"...'olutl()n ,...
ICI

long. "'l' ~iR.I.

Nl'X~ 11111
r- on two <ide guides

'0'

IO'~

~~

AUXIliARY
PLATFORM. I'v..
planed stock very thin by usong
an auxiliary platform, Thi, plat(lrm is placed on lOP 01 Illl' bed
and allows me 10 plane stock 10
asthin as~. 5(.'1.' ~iK,2. (:-'nl.
Youcan'i U' a platform likethis
with 3 planer that has k. d
rolro on the bottem.)
To make the platform, cut a
JII""" 01~.' hardwood pi,,, ood
\-to! narrower and at k-ast 3
longer than the bed Oil our
planer. Forthe RyubiAI'IO.I.'U1
thi> platform l):),' "'ide and Iii'

... ~

,I

1-

,.'

,-

GUIOI
SlOCK

tHIN

fnD

..

.ow.

$10(

GUIDI

USING A SABRE SAW

111("way a s.abrt' " ....j,
liE-ATRllu>-n', I think th"t',
design(c"d t(, c:Ul. filth,,,. tlliUt til, Ih .. main probl<'m wilh ,.brl'
It,;II'J( II (1'I"~ ;Uf II !>!"'/ootll (',(t~ way you'rl ll...
ing 1l
saws - heal boild,ull on Ih.
',til (,fhl" "'111 J'i I {II'! a luggl'd~ SA'\'I~(; "~SoSII( INC Illt blad~. 1111.'up-an<kiown :l('tion
l('(ll'U (",1, \", I ,11/1 un Ilt)I"tt,
sabre -.;a ....' nlakt'~ u,,,autl-fII,\\ll on InC blad .. product>:; a 10101
11t;llg /1'",,,,/' (),. tR It ""1~(lbr~ sawing ,'U!!; [I., U~I~),.,I tn tilt' friction Th~ blad.. n.v ..r g,I. a
1U"r~
slicinll cul~ mad. bl a band ..han," It) cool down as it,'U"
(;t'JI'gf .\lclrl.u
saw'~ continuc)u'" !c)uJ) bladlo
When you fio>1sian l'UUillJ(,
f~',,~t
(Jill, 11/111./11,,'01,.. This mtan:-. only il ft~ 1,1 lilt'
Ihe bl,d .. ,,;11 CUI str-ughl UUI
II
u'InJ( ,harp blade o:;abre '3'" l(,,h t \, r lou\.'h lilt' bdore lonR il heat' up and
lhat', d""lIn~d lor Ihe la.1<. wood. while a band,.. .. bl.J,. .. ""dcrsoffcourse (...."""iall) on
youn probably nol doing an)- """ ",,'<:1'111 hund,,-.I 1''('lh Ih31 thi-k .. 00<1 or WIld JIT'Iin) Ihal
<au".., the blade In bend
Ihlnll .. ronll ~ x<'epl ma)'be culthrou~h th .. "lid:.
a...kinJlloo much In)m t.ht> (()OJ.
roanl '1."1' AI..... '"""
bn
A ""b". <3" blade CUI' ""'"
...abl\ ...." ....\\-ill fc.lOu"a $3'" bladcsha"'liuk-lIr 0lI- I ""h"n it's allo",'Ii 10find it, o.. n
..Iraljlhl lint" \"1)' 'At'll Ct"...p(..... (ilia! is. the loolh,-.I ,-du" tlllh. palh 01 least reslSlaOC'e Ihruugh
cialIy .Ion~ hnt') Th,' CUi malk blade dot,n', prodUCt a wld"r thc "ood grain.lfyoucan1 "i"lIt
in lhi"k "tll'k i, ollt'n """..ted. k~.rr than the 1'("'lllthr blad,'') the back end of the
<lightly
And )'uu11have a hard time gt"1' But band sa" blad., do h.v~ to compt."nsatA:fur chan)r(c~ ill
ting a Nlbr. sa.. to (ollowalong some ""I. Thi' allow, Ih('1ll 10 Ihe direclion the blade b tray,1
('tIN(' wilh fini,hcd-qualily re- make
,'UI< ",ilhtlul bind ing.lhe blade heats Up and stan,
~ull' 'lll(,'S(' ,1\ort(."onlinR~ cc:n~ ing, which h(ats. 111'lilt' bind"
bl-nding. I'vc es"""ially nOlic.-d
I J.,I' 't lUI"f" n I",,,d ,tt u'
ifllblll,t"I,

It

ito/,n

(J

Icraround

MUtt ::=',,111~

,,,u,,

'.f''4

""w

''til'"''''

Nn. 70

Ihi' !>t'nding when running a

,,<,br.' ... " .donl: a fl)("d position
(stll'h a, allain"" ,traighlcdgc)
or ar(lulld. r.x,d p"in! (as ...ilb a
1r3lnnlc,1 point attac:hnlent),
'OIA'no,", TIle~I practice
IS tf) ~1..tYuut,idc )'our inlendl-d
Ion"ol<ul (''ioUC3Jlalwayssand
UII It> II llll'r,) AI<o. 10 p...... cnt
v..u,(t!'nnR. u"'t'"tht.> widl~ blade
ran and ,.ull l'Ul th~ radius
)'ou nt'l-d
On. nlort'lhinl: A blad~ ..,th
.1arjI numbt'rufw"lh 1)l1' iocb
(abu ' lUI produCt" a <IIlooth
nil l\ul ,",,,,du" can build up in
aliI 11t>'>('II~tll
and ''aUst' friction.
"'I'<";all>' in Ihkk ', ... ok. So

>""

\\ llt'n u...iOKl\ ~bre sa\\, you

rnay l'ilV(O to ~"'l'ri.fi('ea ~moolh

<ul by u.illl'( it ,oa,.".,rblade thaI

runs ''()(,It.'r- and st.rnighlcr.

15

T[P':>

0 ~f E

FRO

~1 OUR

S [-lOP

Shop Notes
ROUTING ON AN EDGE
CI.A].tV C)N SI I-'ll()1(f' '11\l'rt
IVlwn 11x',lun l'Outilll! the rob1x>1' lor th,' back p;!Jwl, 011 the are a couple of way~In WIVl'lhib>
TaU ClI'" l'lot'k. I had troubl<- problem 11 the box OT case b
kt'l'pilllt tilt' router level on the constructed in -uch a way that
narrow t"<1U\: ,.1 tile ca-e,
damps will reach around it. I
lI)ou lJ)' 10 b.lallt"lthe router CiamPODa 2x~block flu<h with
on tht Jlam,,,, t"rlJ:t'o It will probthe edge to be rouI,"' ... ~. till, 2abl\ tJp .. ,..,v.ayorthr,,!h<rand
This provide- an ~xtn I V't' of
dill mte 1M wood .sc '(' Fiji I
support tor the router base
t

AllXlUARY 6.o\S&. The second

method is

10

add an auxilial')

ba' 10 the router, """ hll. 3

Fhe base serves as a bridjl"

across the case to th(" OPJ""ll'
"d. I make this auxili3f)' b;, ...
from a piec~ of ~.' ~Ia"",ule
Merdrillinga hole in th, pial
fOlm forthe bit to come throus:h.

I U.... double-sided carpet tape to

stlck the (Iuxiliary platform 10
Ih, plastic base On my router,
(Or. you can remove your exi,ting b ace and screw the new
platform dir,'Cl1y10 yourrouter.)
Then, rout ~uoqJaI with the n~
base straddlill~ o, erboth edges
of tbe case.

WORI(P1[a;

CAIP(llA"
HotOS IASI

IOG!TOO
NARROW TO
K(lPROunR

BASE
AlOfS

10 IOU""

-"",

STtADY

fDGts
Of CASE

MITER AND SPLINE JOINT

On Ihr klCkboard o( 1M Tall out of a1igntn<nt l1., ~oo damp
Ca-e l10('k I u..."11 miter and
"J)Iint" jOlnl (:\Oll \ <pline Is a
thin pi~n' 01 "nod Ihat runs
o,.",...th, ~'inU Th.. miter joint

thejuin1durio~gtu."U~. \'pline

helps k('(1) Ih,'

pi,"'"

alil.'l1.:d

CL'TTI'(, TilE "ENI'. The

spline filS into k"I1, cut in both

hid,, II", end .,'1".00, BUIIadd a

111<'po-ition of th" rip (,.net'

(,top) .. ill deh.'rmm.: the Iocauon olthe k.-rf. see fig. 13 I pi'\"
{.rto
ttM k, n toward the
heel rather than Ill. point ollh ..
miter, -ee Fig 2
With the 'plin .. near the heel.

O"....

sides of th....joint .\f((r ,'uuinll

the miters. lower til(' blade, but
AO\ \~TA('I;'o ...\ ~Pl.l'. keep il tilted to 15 . Then <lid, Ih"IIP 1",'1 a,likely 10crack 011
Fi(',l , ",ii "" ,In'ngthen, the over the rip (ene.loa,',., ,\ 'lOl'. if 111('joinl is stressed, And by
,oint bnlrovidinR more gluesur- see Fig, I. (NoI.,' Sine,' you',, po,,;tinning it near Ih~ beel, yo"
(ace, A miu-r joint by it-elfi' only nOll'Utting completely IhrotlRh can insert a 10ogcrspliJl~ to pro,
an ('nd~rnin tel end-gnun joint the piece. It's okay to Ust' blllh vide more glue surface
which is 'tnJ<lllrolly wry w.ak
Ill.. miter gaujl," and rip I"lIn' al
~PlISL A(ter CUllinll the
the
sam..
time)
!'it"\'t,nd. IIti1t'r.o. 1t.'ltd to s1ide
k.>I1,. (Ul splin~s to fit in the
'plin" (or a "ou~l, 01reasons

to.

KW

roo

k.l1.. If the o.pIin~...ill be hiddl.'n

in Ih,' finrsht-d proj<'ClllL"" ~l>"
.;.plint.' ...
If the 'I~in, "ill be exposed,
)111U ,.lIl U~lh4.! sam e wood 3.,...
\1.\iOnllt'lclr

For maximum

tht otilt r l)i('\."(."-

<"rnk"h. nil the spline so the

grain run-, perpendicular 10 the
tht joint lint', ~'t,foil{ J.

Abu. to ensure lilat

01('

spline

wnn't l)rl~Vt'nttht:' miter (rom

do>inll ("mpleldy.
I cui the
,~11I1l'a hair ,horlcr than the
Ihwl d"lllh "r bolll k.ris.

nostlOllP

CUt SPUN[
SOOKTlTWS
tMAN OlPJH

U.ICWS

WOUJiI'I(((

'INC.
lIP.....

_0"

WO .. t(PICl

16

SI'tINfOUJN
RUNS

AtltOSS JOINT

---------------~
No. 70


FEATHERBOARD

.To get accurate results when blocktothetopottherunner. Br

usillj( a fence on a table saw. I mitering the end of the stop 30'
like to usc a featherboard,
each way. the featherboard can
A (cathcrboard is designed to be used in two directions.
room for an adjustment slot
apply constant pressure to the
cer rus BlANK. To make the that's added laler.
side of the workpiece. This pres- featherboard, I started with a
SafelY Nole: When using the
sure iscreated bycuuingseveral
"."Ihick blank. abou114 long. table saw 10cut the notches, Lum
long notches in one end of the Nex~ rip illO a finished width of offthe saw and wail for the blade
featherboard. TI,e stock thai re- :r.1oIl" and cut a 30' miter on one 10stop, then pull the stock out,
rmally. cut the fesiherboard
mains. the finger-like barbs. act end, see Fig. 1. The featherlike springs. putting pressure board will be Irimmed II> a to ilSfinished length of 10".
finished length of 10"later.
ADJUSI"ME1-T SI.()T. To allow
against the stock.
B.~ The next step is 10cut the featherboard 10be used with
EXPANDAHI.E RUNNER. The
biggest problem will' a fcather- the barbs. To keep each of the varying widths of stock. cut an adboard is (",ding a way to hold it barbs a uniform length, I justing slo\ near the short edge.
To make the slot, cut a ~16
in place. especiallyon a table saw marked astop tine parallelto and
2:V." from the angled end, see wide groove that extends 5\12
where clamping is difficult
To solve this problem. I made rill. 1. Each o( the barbs is W' (rom the square end of the
a runner that expands to fit tight wide and can be cut with a hand fealherboard. see rig. 1. 11ten
for added strength, cut a small
in the miter gau!:" slot of my table saw. a band saw, ora table saw.
NOle: If you use a table saw. filler block and glue it in place.
saw. refer to Hg.4a. But, thi5 only
raise
the blade 10full height so
RlfNNER. 'Vilh Ihe featherkeeps the runner-in place.
To keep the fcathcrboard the ends ofthenotches will be as board complete. the next step is
from turning, I glued a stop vertical as possible.This creates 10CUIa li"-long runner 10Jil in

f.EAtHEBBOARP

..

miter slot measures

:v." x It",)

Once the runner is cut, the

hole for the boll and the expansion slot are made in one end
see Fill. 2. Thencut the runnerto
a finished length 0(5", see Fig. I.
STOP BlOCK. Next. 10 make
the SlOP, I used the waste from
cutting' the runner 10length. see
Fig. 3. Cut two 30' angles on one
end. trim the stop to lenllth. and
glue it to the lOpof the runner.
Finally, assemble lI,e featherboard and (he runner. see l"g.4.
As the wing nut is tightened
the bolt head forces the sides of
theguide bar against the sidesof
the miter gauge slot. In e[f(.-.:I.
it's wedged tightly in place.

SPACE"Alas
lVtNlY

the miter slot ofyour table saw,

see Fig. 1. (On my table saw the

FIRST;
DR'LL I

>" OlA.

COUNTlISINI(

.,.

SECOND:
DRilL A

HOLE

THROUGH CfN'l'tR OfCOUNftRSINK HOt.f

NOTE:
SIU RUNNER10

rrr MIn. GAuGE SLOT

,,"

THtRD:
CUTA'," KUF
2'." I.ONG CEH1tR.(O

SfE flG.2

RUNNER

FOR DB AJl.$

ONHOU

___,

leur TOUNO'"

AFItIt;

MimiNG '-NO

__

W'~NU1

0,

<::.>. .../

pi

=":'-+~__

'-..___,/

f..!

"---:~

~"'_J
nA)'H(R-

.0----2'\- ..
, -~..j

aOARO

fiRST(VI TWO 30' ANGW

ON lND OF WASTt PIKE
t ....

1l.-

TABlE
SAW
TOP

No, 70

.-

MITERGAUG[

SLOT

17

:.__

_;S:.........:..H.:.......=O:........:_P
_

E C

----------j

Roller Stand
When ripping long boareLs,a roller stand comes in handy.
But how can you build one inex/)ensively? Use PVC pipe for the
rollers. Then add some features to make the stand a joy to use.

he b~

problem wiih ma!<il1jlaroO,-r

<Und is the rollers, Manul3l;Iured roIk"

can gel costly - ~

if you ,..;ml> ,~d
"'Ih more than 00(' roller. And ,hop-mad<'

rollers can be trick, 10make - unlil nov.

Combine PVC pipe \\;th some Sltel rod and

"coden

you',~ gul an l'3,).

'II'Ong. and inexpensive way to make mile" I
u~2""'ia
PVCpipc (used Corplumbil1jldrain
lint") for the rollers and plugged the end, with
wooden toy wheels, And for the axle. I used a
piece of steel rod.

18

lOY wheels and

\\'hen the roller problem wa-, ,,11,,-.1.1 con-

eernrated on buildi1ll! extras into th. -tand

IlEJGKT\IlJ\SDIDT. The roller umt j,
mounted toa large sliding <let" "Ihal fit, in<klta pede;taL By loosening a sinj(I." in!: nut. the
,Iff ve can be adjusted to diff.,.. -nt h~lIIht,
Plu'. for storage, it an be lo,"c"od tn fit und vr
the extension wings o( most table .....w-,
U-:VU.RS. The handiest Ieatun-on tl" roller
stand is the shop-made levelers. Youcan nlC,\,-

the stand aroundth .. "hopand quj"kly .dju't it

for any irregularities in the floor

No. 70

EXPLODED VIEW
30 to 36'

a,

2,-snn 100.
11".-lOHO

OVERAU
DIMENSIONS:

RAT
WASHO

.-"

1.0. PVC ""

2"

x 121.,,"Wx;3O"D

ROLURRAIL@

SUPPORT TIE
CROSS SECTION

....,

ItOtu:.

'2WOODlN

(l

WKlU

<DINNER

> SLEEVE CAP

WlU
rl.D.

' al1',"

srm eoe

IlIAD

PVC""

SUPPORT
ARMS

!:

I
r

INNER
(0, SLEEVE SIDE

cg--.
INNER
SLEEVE END

s"""""
....'.

",'" 'LAT
WASHlIt ~

nr

SUP~T

@)

INNER
SU.IVI SIDI

~,
P(OfSfAl

Slot

<if"'

PEDESTAL
SIDE

PEDESTAL
END

)-,.2CAJW4G1

-....

IIOlf

a.-

FOOT

I WING
HUT

PlAS1lC
wtNONUT

.....

t," ,NUt

...".

~
(.AlltAOI
eOLf

MATERIALS AND SUPPLIES

WOOD PARTS
A >odeSlaIEnd! (2)
e _'aI
Sides (2)
C ....Sleev9End!(2)

0..
E

Sido1C2>

~COIIGCOP(l)
1lI'i$OOrS

C2J

.a.",.-"_

WOOOSCItPN

""l'

eCROSSBAR

CUnlNG
~ :It

r
WOOOSCtlW

DIAGRAM

72 f3 lei.

't.,

~ " 5',, - 72 [2.1 a4. ft.1

k ,

fa:

.,,;~=..;, ::zz~.. , J
'I

,ft I

G ...,. I C2J
H SuPPO<' Arm6(2)

. JI)pOrt TlQS(3)

J ~Rob(2)

SUPPUEs
I 28d f, 0'''-'' IhlCkHo<dMoofe

"S-'01 r.' plywood

N",70

1t.," It 3'

,oo 72"

".614. 't.)

1.... ;" ..9:.:: .. ,,_--.. ,.

E :.;"Y,':0Yl

AlSO RtQU'tt(O;
I, SKIn M a." ....VWOOD

19

r-

THE CENTER SUPPORT

~

~ .....1..

The fir~1 step in

building the roller
stand is to make the
renter ...uppon This

a p.'d""tal
and an inner sleeve,
T" adju,t Ih~ hpi!(hl
uf the rollers. rhe
inner ~1t.'tVt...Iicl....inside the pedesta! and is

.'

11100 patt.'.

held il1l't.u,:(,'with a "'illR nut

1)1.I)l'.""T\1 1 'tartL)d by making lh('
",-d.',ttl lui lIlt' two pedestal end, (A)
(rum I Ihi<'k solid 'lock to a width (If 51rz
and a Itllgth of 2~ rI u"od solid stock because It \\(In', crush a ...(,a....~ly
as pl)'Yoood
9.1.( n thl' \\ln~ nul J .. ti$!htl""1K"d.)
One.th. ,00< are rut. the next step is 10
cut the two IK-de'w ,id~(B).:xoce
thenwon t be an\ rrl ....ure placed 00 Ih( ....(
Pl'''''' I used .' pI)"'fIood. Cut eac h -ide

Pl<,'('II'

'T:
"
I

(a)
PEDESTAL
SIDE

~ T'Ht(_1(

HAlIOWOOO

"

...1,'

AU x,

(!)

'(Ne[

PEDESTAL
END

Hfl

SIO(

1\

','
PlYWOOD

,
_

_, ...

'ND

1
,

support consis.... ()(

'.

PEDESTAl ASSEMBLY

"".10.

r
"
1

",d, bv21~'t1II,,,,'CFiIl.I_

the
,n(l ...and th, !Illdt...cut I() size, the nat ~l'P
l()\(.l ~ '\IJ (,Rf)(l\"." J()I\T. \\'ith

ttls.t,lht"r 1nt.- tricky pan is

kt"l'()iltlr{ Illt'lK."dt ',1011tht sa me size from lOP
10 I~Il1um 10 d" this, I used a tongue and
s:m<'V"l'fIn1""
joint, n'(,'r 10 Fig, 1.
l'''I1)l'' dIldo bhuh' on the table saw, CUI
IINc. l tt' wid .. s:fOO ..C..... on thf" inside faces or
th,"'nd P""'" (1\1,"'" Fig. 2.111<'Sl'groove,
are cui ,lil(hll,' d''('I><'r than the tongue

$1Ol '.

j... Ie. J'nn thil"

~ ...) and ar,' k",Ihod '" the distance from

Ih, Itncr IQth. far side of'the blade is equal
lu th.-thid<nl"" ofth(' ~"'ood <id"" (h"'l
Oll<'" the IlfO'"'''' an' cut, J used a ~,"
dado blad" In cut IOllj(U('"on the ed~ofth.
p1)"ood "d.'S (illto fi' into the grooves, To
l'lll th. tonzuos, 'tart by 3rt3L-hin1l an auxiJi.
ill)' fell<I' In the tlblc saw renee, see rill. 3,
\(lj\I"" tll~ h 1\('(" to make a J, ...}ooglo-ngue
Ihen rni,,' Ih, blade kraduall) umil Ih,'
IQnWIt fit...tht I 1'"gn)()\'~in tbe end pieces,
\lHI,r\l~~T~U)T.
ilrfore Illuinll th e
pi(c"C~''''
tuS:t:ll'tr. r routed a "Jot (or the- adjustment boll In oru- "r .Iw cod piece. (A), To
If)(:nl,1 tilt hl'ln and "'(1pping points of this
Shll,drilllw" hok, centered on the "idlh of
th,' "Ilcl piClC.'. st' ..' "-if,!. 5. Jhe center points

CORNER JOINT

(NO

f.,
'Cl

PUING(

GOWN. THEN
MA,I(_( SlVRA,t.

NOTt:
CUI SlOTOH
OH\ YCHt (NO N

of II',.... 11C)I(':-' .tr\~ 7" apart.. willl U}(J-('('Iller

pt,int .,1 tilt' tC~I)I,C,lt b. in..::il. i-'1 (o'in ul((nd.
Tlwn rU11l II,, .I"t on Illl' roul('( lablt- b)

'l'\~:ral....!,al1o...' c"'Ul~.~ Fig. 6.

Finall~.aft,.. Ih, ,1,~ i,cu~til" pffi<Nal
I""",'S ('-\and III cao bo- glued up.

"DiStAl

0'
INNER
SUiEV

2"

zo

J.-

CtN'IIl
art 2.~...
f!tOM '.Hel

SlOE
'-"PlYWQOO

1".1( ....1 ' ... Onc.:e the pedestal i....

.....
)Illpkte. tilt, n~'xtq,t'P ,.. 10make the: inn"'r
...1~"(\1111(""l"t'r ...Jt"t:\t> i....made lite same
way a< th., l"'d<,lal cxct'pt Ih(' pl}"\\ood

ruoOl'rscao bt'llla~n:"'~I~lo~fi~1

SHALLOW PASSU
WITH
STaAtGKT arT

INNER SLEEVEASSEMIIlY

rlUlklrlg

..idt.... arlO In""t:l (rUrll lhl' edg\~of the tnd

1"""",n'l,'flu 1-111
10 Idid Ihis fora couple
o( ,,-aSlIll' 1-11">1,
Ih,-,'<I1!~'0(th<..nd pi"",s
will ill'l lik,- run",'" and k,ocpthe plywood
,id<,(rurn binding, S('COnd,ifneed ~.thCSl'

otta.L 2."
- SlUT l$ToP
HOltS

10

,'V

3" I,'

-===================:::...:==:'

':':'N:S:-"-.:=====~
~" 70

CENTER SUPPORT (cont.)

l'Tn.1-

"'1) 1""(,.'_ To make the inrx-r

..leeve, 5tar1 b} nppanRihe- two omee sleeve

ends (C) 1061inside Ihe pedestal with 1'1 "

~~--------------~
12
r=r.
_1_1J

1-

-.

l[AV1...o 2

f.DiOS[D

11.

NUT

,0rrOI
Of SlOT
ftATW,u,HU

13

DC1U '- HOU

t'HROUGM p,fN11
IUMAt
IOnOM Of SlOT
IN' "CHStAL

...

UTnl\(.1 t, Then.to makethetonzues

ronn

a \'
WOOD

.~.en
~

sca.w.

..y,

, INNER

CAP

" I

2,.-

...

)1.-

:..J

COUNTlR
SUNK
SHANl(.
HOU

l'""s: a dildo hlad!" I CUI the ~.~ons:

lOn~t, In fil illt" lhl' grOO\(,~.
(.1.1 I "'" FIT ~u "\F_ Final!). glu~ the
to

P\ASTK

WINO

on Ih,' end- of th,' plY""',d side-, attach an

"11'lCilia,)(t'n('t'lo thl 'ij"- (~.IlCt".see Fig. 9.

'''',VI. 011' Ihe Rlu~ isdry.tes;

'.-

1hl'ir Ilni"h~'d ~il(' (Jll mv ('a~("thi....was

9 'IIi! wide h) 2:1"1<11111.
'0('<' )il1.
7.)
('N:()()\)- .. 'I~,()''M,~allolthe inner sli-"l!\'lj
pif'C,'('" ( lind I) .If't ('ut 1(, size. lilt." inside
race- ul th, end pi,'(',~(e) are groonod to
3l'"C('pt tht "';~NO. flll' time -et the saw It or,"
10Ih(' tar de of Ih,' "" dad" bIad,' and
cui Ih.
..al' p ~n~\t ......
in bothend pil'Ct"S
I().'" hl1 ~

au(' ,,;i(I, pit"'(~ (1)J(t'lhl'r

'

(AII,..OI
IOU

~J'(.Vl.~t.\\.,,'UI Ill\' " ..It pl}'Wood qdL~ to

oJ

th4"

fit the
lnncr sk-evemto Ih, p('dl'$tal. Itshould slide
without bindinu If ildoc, bind. you "ill have
II, IlL111('or ~nd thl' edacs or m(" outside
ran" ,,(th, mncr ,I,-ev~.nd pieces (e)
inner

...

INstl' IHNOSUfVl
INTO PlDfSJAL.

DtIIlIJHG

uf ck .!falln Xr-xt,cut the-e two piec e-, to

1'"l(1h (23"). ,N' FlK t
"" ~ 1'1t:t t.~.After th~ ends are
cUlnllkI,'(f. Ih,' next ,Iep" to ,,,I the inner
sleeve Mid". (I) Stan by m~.surinl1 th~
in,ill,' width or Ih,' l)lode.tnl. Then subtract
I VI.... Wlwlt a,,,,mbl.od this will give you
V"," ck-aran ce!xlw''<'n11ll' pedestal and the

t'nft

pede-tal alld drill ""uplt-tly through the

inner ...kot' t'

on p;tI1":11 If )'OU prefer to make

your 0"1\ wing nuts, ..... the box below.)
SoUf<X'S

down mto l11(' inner ~1et"\C' "~"AIJ nil l \1'. ~i"ally 10finish oUthe
and 1",-11a x./" ''3lT1al!c bolt throul1h the lnner ,k'l'''', I lldd,od a hardwoodcap. To
lUlU HIR .UIlI ''nIE'TII()IT. Thesliding
inner ...)4"("\'\ ..... hlld In plac:e"Aim a carriage hole, ". fog. 12 Then lap th. head of the make the inn er ~I(""t: cap (E). implycut
boll and 3 "'ns: nlll III <I, t, rmine Ihe ~l<.'3' boh with a h:tm1l11'rIn make sure it's sealed a pi", lit ;'.thll"k -tock til fit Ou>h III the
111en, to 1(1"1> (rom mamnll the .. ood I outsdt_l-dRl~of')'tinJI(r..." ...v, -ee Fist. 13.
uon or thrs bolt. po.. uon the inn....,;l_e :!"
abo,,, th~",od< '~11and ,lamp it .. ith a (- pul a lend. r "ash, r and a '1andard ...,her Th"n drill ''''101, ('Unk 'Cre'" holc~ and
lh('lnn( r(:ap (I- ) IIlluth(' lflrl\"( ,Je.e\'e
4.laJllP..;.ec'" l'ls.: It 'CI~. u....
nga~}Idrill bil. O\"T lh' 1>0,11altd thn'2<k-d Qn. l,,' ""ns: nuL ~~
~nclpi",,(l)
pb...t tht" bll In thl OCItI!)moi tht" ,It.( in the , 1u-cd. I;,l'):c pIa'lll.' handled ",ng nuL_
~l'''1,
(t1k:l,

WING NUT
B~f()r(' I rOllnd the
larg .. plll~1ir wing nub
Ihall u>cd '10 Ihe rollt!T:;tand.1
1)IRlllwd on using shop-mad.
w,x.hnotl,, J111'y"ork",.W('ll." .. decided

THIRD:

FIRST:

DRIVE

O"ILl '" 1I((15S

HOlt '."O(P

~." '~NUT
lNfO HOlf

c.mlortabk

ttM'mto ('xm m{)(("pn 'LIre.

to "lake Ihe ~inK nut ~;l'Si{"r (0

mb.~

Step

2. 'J'hl'n to rt"tlUt'l)Iht'amount of surface-colt

t.,t. 1o"ind..d a 1"Pl'r on Ihe bottom >ide

]\;". 70

,,.

to gripand )'Oucan Ust

10 malt, ... ng nul '1an with :Y.-th~k

'10<1< n,('n oln11 a count ..oort>d hole for a
Tnullo 61 into....."C~l1> 1 Un ~ case 1110.<
"'IngaoW' l-nut .. oIdri1Jnl. 'COUlll... I>o.....
md" W' hole.)
S.'xl.1 cUltapenod 'ide> (onth"band saw)

to ...ll(l! Iht'ln 3' an option for tIlE' roll(r

....anci til (afl I'd rl"'C(,mmt'nd th('m OVlr
...mall nlC'talv.lOJ: null'. Th~ larRe'Wing nul'!\
arenulrt"\.

,',"
,

SECOND:
DtUU

J'

.-

1/".

00"""

tln" u hilI. tJlm"y" lilt- I"rl't- Jilr ti,e T,lI"

If)J It 111"'. 'fh", ,In "l' tltt TU ,(il" pfnrt.

- .--

HOU

tMltOUGH "O(.K

S'tlrt.N!J I ", n $"(1(( x(YtJP blfJtk.

(/rlll (t
,/"'1'
r'lOr~.~\r!,Jt.

2-

1'" "
,h,
2
In" ,In ,.."tl,; .,,/, ~offl'rblu<k TI!~i
sa
Y.
t'tlwr'if]',I"
ai',

I/tllt

"',nflll (I easlf r tl) ht)ld.

IIt/,

"" "'1 " III "

",1 .~,.I111 "/}

lM.)tlQtlxld~of(h,

II "II

1(11U'P~dg(!.:ot.

21

=_

THE BASE
Once the center sup~

pcrt iscomplete.the
next step is to make
the base W support
it Th. base is
made up of two

parts:

the

14

cross-

TH CROSSBARS.

with ~."thick stock, cut two

crossbars (F) 10their finished size. see Fig.
14.Then. position the crossbars so they're
centered and Oush with the bottom of me
outer sleeve. Now. drill four countersunk
screw holes in each crossbar and 5<:"""
them inplace.
FEET. \\11b the crossbars attached. the
next step is 10make the [eel. Imade the feel
(G) from 1Vi'thick stock CUI to a finished
"'id!h of2Vl" and length of30". see Fig. IS.
Next, puuhe feel againsl!he crossbars SO
they extend equal amounts on both ends,
Now. mark where the crossbars intersect
the feet, see f-l8. IS.
Once the feel are marked. CUIthe :Y.",
deep dadoes 10match lhe thickness of the
crossbars f."). see Figs. 16and 16a.
N~l{L J sanded the lOpedge on the ends of
the feel 10a I" radius, see Fig.l7
U."ELE'RS FOR TI'E FEt;r. To keep the
roller stand from rocking on an uneven floor,
I added a leveler on each end of the feel.
These levelers are simply %" x 4" carriage
bolts threaded through a 'I-nut. see FiJl. 11.
To make il easier 10adjusl Lb. levelers, I
threaded Ona plastic wing nut (or tile shopmade wing nut shown on page 21.)
AlTACIITIlE fU'. ~inally.screw the feel
to Ill(' crossbars, sec fig. II!.

..,..
(ClNTtR

bars and the feet,

Starling

15

.ax1' ...
WOODSCUW

oruu

~1.

SUN)(

11........

COUNTU......
$H.AHI("QtU

(ItOSS&AJtS
ONOUTb:
-....:;::---~SllV!ENDS,
fWS-HON
........
y,(_..
eonOM
SPAC( (QUo\UY
ON aOTK tNQS

'"

o.

CtrJOAOQ

-IETWUN
\ p[Nell UHES

18

17

RtMOvt L1VruRS
ANOASSlMW
ONA 'LAl SURfACE

DRlll~'."
CQUNnRSUNK

\ .. C .... aQLT
.'"tONG

SHANK HOL$

'--

ROLLER SUPPORTS
Having completed
the base. I started

"

building tbe supports for the rollers.

Beginbycutting the
~4"'lhick support
arms (II) and support ties (I) to their
finished

dirnen-

sions, see Fig. 19. Then sand a 1Mradius On

II",bottom comers of the support arms.
,,\TfACI-I Ait\tS. ~exl center the arms on

,-

19

o.

"

$AM) I'

RADIUS
OH(NOS
,

,3>,'

(INllR ~
n1S0 N~

. .

SUPPO R.T
S

SUPPORT

TIE

(i)

location oflite SCJ'C'" holes so the top screws

go into the edge or lilt cap (~:)and the lower

22

- ....

....

CD-

theumersleeve, keepingthearmsflushwith
tht' lOP edge af the cap <Ii). Now mark the

ones go into the edges ofthe end pieces (e).

see Fig. 19.Then drill countersunk shank
holes and screw the arms 10the sleeve.
,\1TACHTIES.Tocomplete the roller support. screw lhe three support ties (I) across
the lOPedge of the arms. see Fig. 193.

TOP VIEW

LOWIR scaMS
GO INTO

......

SU PPORr

i~ -
::. l

suppa RT
TI

111."

END PIECES
(AU.SCRlWS

II x 1'.-.

SUPPORT

ARM

WooJsOIlIh

.';

12~.

i
--

I
I

No. iO

ROLLERS
With the rone.- ""1>
port completed. I
....arted working on
the heart of this proit...
'1 -the
rollers,
Each of the fiye
rollers is made (rom
a section o( 2" PVC
pipe. This pipe is
used (or drain lines and is sold by the fOOL
CI'T ROW'H, TO U<I'/(ml. To make the
rollers, Ix,,';nby culling Ihe pipe into five
11"lonl: IUIx.. I cut these 10 length with a
hand saw (or hock saw) and sanded the ends,
WOOUE" \\1I~ll-"'. After filing off the
burrs, Ih, tube-, are plugged 10 support a
rod I plugged Iht>ends "ith 2"'

"""1 ax'"

hardwood 10~ ...~"

see 1'"18.20. These
wheel. come pre-drilJed to the correct size
ior the lII' steel rod that suppOns the rone.-.
NOle: We are offering these wheels
through 11000."",/1 ProJ! Suppl~.see
page 31. Or you can make your own wheels
by using an adju5lable circle cuner.
To make up for any ilTeguJarities on the
inside of Ihe lube, or the outside oi the
wheels. wrap electrician's tape around the
wheels before pushing them in flush to the
ends of the tubes, Then pin them in place
with IWO 17'lfolugewire brads. see Fig.2Oa.
S1Ul AXlE NODS. Next. lO support the
rolle " 1cut6v e pieces oClll' Steel rod. Each
pletti.cut 11'; Iongandinsertedthrougb
the hoI.' in the wheel" Then. to keep the

rollerssp8Ct'CIprolX"riy Iput a %' fiat ..-asher

on each end ofth e rod. see Fig.2Oa.
THE RAILS. Allthar~ left to make ~ the
roDer rails (1) These rails ~ ,;crewed to
the supoort IJl'S (1) and hold the rollers in
place. Using ~."thick stock. cut the rails to
their finished size. then sand a I" radius on
the top comers.see Fig. 21.
Next. drill five 7/16" holes on the inside
face Ot each mil. These holes are :}'8"-deep
and centered 7" apart, see rig. 21.
Finally, screw one of the rails (J) 10the tOP
of the support ties (ll. Then insert the roUer
assembues Into this rail. To keepthe rollers
at the correct height while 1 instaOed the
other rail. I plact'd a II,"-thick temporary
spacer under on(' end. see Fig. 21.
SECOND:

20

INSIIT toUaS A,ND

AnACH 01H0t IU.Il

FIRST:
safW CHI

r "-

llOWlIlAJl

to SUHOI.T,.S

7'

..

.t. .1_
2','2-

....

r!J

r r

1,-

US'TlMPOttARY
SPActRIO

AUONROWRS

DURING ASSlM&l Y

J
SAND
,- RADIUS

ROWR
RAIL

OHlHDS

II., 11.. WOOOSCl!lW>

AnACH IUISH
WITH rHOS 01 TtU

WIDE ROLLER STAND

The roller stand ft'3tured above

works JII'<'~I,but sometimes il
would be nice if il were wider
'Ihe exira width is handy when
wnrkin!! ",;UI pl}'Woodpauels,
In [.",1.you could use both of
these Slllnd, al the same time.
Pusit"'" Ih,' wide roller stand be
hind Ihtsaw Md the narmwone
1II0nl:thl' kit sid e,
Ill,' procedure for buildinll
the wid,' roller 'land doesn't
chans:,. the onh difference ;"
that lour of the pan, have to be
madl'longer, This means you'D
nee-d more l'. -thkk stock, a II).
loot length of I've prpe and
IoURt'!' I.ngth, of~ ,teel rod.
(A h.rd",.r<:, kit is available
through Wood~"llth P""J<CI
S" 1'1,10"" j,l'(> fJ3I!e 31.)

)\;.,. 70

C_~R.-\H!,. The 6rsl pie.:es

that neee-d 10 be I"nlttbl'ned arc
the two c,-o,.,bars (I') Instead 01
11" long, cut Ih('!,e pieces 22"
IOllg.111isl'xtrd Il'nlttb j, needed
to kN'P the I'<.lll'!' stand from ti~

PVC ItOUlRS
""1.ONG ...

$T(RROD

2.2'."lOHG

)
.:>

ping side-to-slde

SI PPORT"F.." :\txt, .dju,t

the Il.'Ilgth 01 tile three -.uppt,n
ties (I) for th< Ionllrr roller< CUI
the~22h
long
ROUIIS. \\ IIh the <upport
lie> CUllO kngth,tht'1lt'X1 "1<'1'''
to cui the Ion~rrolk-rs. f..1Chof
th_fi, ...2"' PVC ron, '""havcto
be 22 lonl:
sml RODS.
f .nall)l, the lalil
pans that need II be cut k>ng,r
are the five til" " ... 1I'<Kb Th<.",.'
rods willll<'t'" to be W ,to '"~
port the Inn!!er rollt'N

WuoJ.smtth

WIDE ROlLER
vtRSION

ClOSS"'"

""LONG

23

WEE

KEN

n r

R 0

J EC T

----------~----------

Mailbox

11 doesn't have a lid. Instead, chIs 1nailbox is designed tvith an inner bin
thaI pivots our. The bin is sized co h()ld magazines and oversized envel()/Jes
w) they don' t have to he folded (or lnangled) to get chenl In and out.

nuU~h
IIKI

"urkioJ!

I' cn"ugh.

My "Id mailbox was

mv favorite woodn,ftJ.!3Z1n(without rolding II and

'mall

10 hold

manllilnllII eVl ry tinwll.";,,.-d, Eill,.rl bad

ttl a ...k 1"'(4 \\{}f)lf/" ..,,*,ttg to reduce the size
of the..r nUlll3nn<-.or I had 10 build a n(""
iar}:.rnwlb", J(h'O<k>dlobuildane ... mailbox

TI... idc'a bchmd Ihl' mailbox is 10build an

ouu r r3."'-(that hou .......an inner bin that aclUallyh,,1<I,Ih,' mali. \\n~ny"u pulldownon
lht' bra ......kl\Clb. lilt' 111"('rbin pi\'UL", out like

Ihc' glo,,' box on ",01 ..-dI'S. Mail can be

in"'n"d c'",ily (without folding it),
)(IIM'II'l.
joinery fur this proj<.'<1is

nw

fairly ,impl" I a-sembled the outer case

wilh bun joinl, and brass 'crews, One
..;;cr(_\\'~are -et into countcrborcs
and
1>luRSlJ'cll() Iln'V('l1llnoisturt> front seeping in
altlng lh,' 'lrt\'-, and l'I)lting the woed.)
RAt ..... r) \, .. t .. The (",nt of the inner bin
S:o.Qrt.",~d up \'-lth a raised panel, 11 )'OU
ha,'c' 'I tried makinz a frame with a raised
panel. lhi...i...
tJ fdirJ~l'asy approach. The
frame I' JOined" uh <.tub I~non<th;u fit into
II","nl< 1:'00', as Ih~pand

n","

I ,h".;e white oak for

the mailbox bc'Cau,,' u ""'..tsd..:ay. Topro'\tICI)) "II

......, the wood, I fmi,h,'<!lh, mailbox ,,;th

1\\.)ft)31, Cit ',lo1r varni ..h. (Spar varnish i"\
(ll....iJ!ltt'fl (clr t.ulc1cK)r U!"C- it's more mois>ture rt",isl.tnllll,Ul t.th,rvami::;hC'$,)
II hardware kil " available for the mailbox, "'c' "',III't"" on pall" 31

MATERIALS
OUTtRCASE
A Sioo$(2)
a 'co (1)
C Bollom(1)

~SInp(1)

SUPPUES
~,.5'2-

d 2

x~I7~.
.x~-I71.
AX '~17.\'4:

INNER BIN
E Sidcs(7)
f Rots(7)

~.x4~.10 'lo

G SIIOsr.

hxl

H PaneI(1)

~.x~

I Bortom(l)
J Bock (1)

~ 2'., 16
, 10-17\'.1

24

",xl ,,1~4

, 10~

15!ilt

60 'lO FI

A INCk

2'

J; '"

Vw'h.re 001(

'hICk Mo:son:'e !or #Y'Ief

cosebOC.
( 0) No 8. I

CUnlNG

DIAGRAM

J_.... II6~. 3,

Ioordl. 1.Sad.. fto lodt)

(1'wo

--~

Be

121

rn WOOOIC'9WS

(.: "lo 7. I , let> t)rasa WOOdSCtews

No Oil
Fhwoooserew5

o 8lden5lC)n spong

l' t)ross ChOn

( ll><OSO"nob
( 1tlJbe Sllicone_'

1) PIn'

spo. vatnl$h

N,I. 70

OUTER CASE
I b.
'I{

~dtbundmg

or 111(' 001("1'

"'

EXPLODED~V~IE~~~V
__ ~~,=

II", mailbox b) makill!: Ill,

...11'..... IO"lakt..'tll,,outer~sides(.\).

CASE TOP

pivot

PANEL

RAIL

"i<l, IUlilt' It'n~ pomt,

"ad,

In a "'''ltlll

a 11...

_"'woooSTILE

INNR BIN
BOTTOM

ERAU DIMENSIONS:
4'W Jt 14' l"H. 512"0

o( 17 '~.

.t, SIDES

AND 1 ' SHANK MOlLS

",

-,

'.'

COUNTt.RaOU

~l.-Ol(P

NOTE.

ROUT1_- CHAMflR
ON AU. (DOIS

PIVOT
SCI!W

c....
""""

I ..

'"

PiVOt
HOU

Wilh til<' r,,"r pi,...., (or II... outer case

clamped 10g('II ... r, <lIilll3:>" pilolholes at all

a...-embly -crew hl\..tlinn~Then SCrt"4't.h~

case tng\tlltr. '4 v "ig. :4b. reJ cover the
screws, lout lit' plu~...trom scrap, Glue the

plu~.n pla,,.and trim 111<'10 flush.

-=-.l
~~-;;H
I
1O.... INQS

USE IA.It Ct.AMPS

to MOlOCASItOGrntO

,.s ,f

..,.;
lACK

~::::::::::::::::::::::=:J

~("'ACKIOOr$~~(~OG~E
__

PIVOT SCREW DETAIL

--------

~-IR.2. Then CUi

0lJU "I," (OUNTUIOUS

OUTER
CASE
SIDE

_.-.;

.",,,,. \11\1'. I (J .. tart ,,"ts(111bly.draw a line

MI)l ~-n~(.IIOU"'. Allhough the hanllt'r
,trill II)) used 10 mount Ih~ mailbox (,,'" ;u:ru"' ....IIH in ..ult' (.Ift el( till' ...i(t~CA) V....in
"xlllod~d view al righl) j, added later, it's [rum lilt tt'll {tllclbottom ends (not th("
l"a...it:r to drill th hnlt~ (or it now, set" Fig. 2. ,h.IIII.-,).,,~ hI!' :\;, Tlu-n.clamp the case
~I.;.o. n,ut J ~"th.JIJUt ron tht'frnnlt~J,~rl~ t(j~c{h\r$(1 tll' hlJ) .tllflbouom pieces align
with ht'(IJtnc.1111JU"S ..... 'tII~. 3.
ofthe' top and bonum. """t' Fig. 2.

f.
WOOl).
S(R1W

SCItlWS

the pif_'('e'"an- 5-l1f

'i('('

x 1' ....

..
G

the outer case

top (8) .1111) bOllom (C) Rip the back I'd!!t
-.0

s.PftING

lC}11111k. u-,workc-an bt1.'Inon

Illl'(l'~OIl 10

OUTER CASE
BOTTOM

INNER
BIN
BACK

screws
near Iltt" bouum (rf)l" ,.r each side, ~'(. fig 1a.
Onc 11ll' 1",1., an- laid out. drill "',"
(_cluntt,rhon -, and ll""' ...hank holes (or lItt,

'IC both

'."'PWO

I(k~atiuno;:c,{ till hul('~ rl)r the lour assembly

\'"XI.drilll'"hul",,(orllle
pi"C)t "'" !'to""", ~ Ihe pi\(,1 o(,:n\\.....allow the
inn, r bin 10 PI"Ol "Ithin the outer case )
\1I"r tbe holt. an' drilled, rout a W
..hmlt , 011 all hul Ilw back I'd!:l"' of both
..,dt f) "\......, '("C fig. I
(\. .... WI \\1) UC1Tn,\1. \\jth lilt- eide-s

WOOOSCftW

(arl' (JI "(I(}' !'>i(It;'anfll'l), them down

~IS" mirron-d ....1 ..,("t. I-ill. I. Now mark tht

,.:r.'"

HANGER
STRIP 'G'

fllttlftl/.

.,,,mhll

.'2.1',
lh ..... SS

..

....an by ('Ullin): I~O ."~lhlrkblanksto a

fini,lu:d w"hh of '>VI' and rough l"ngIh 01
15" Tlu-ncui
a III an~I, .. neach end se th
u,,r.aIlItn~lh''<I"al- I ""i' I"the Iongpoinl'
olllll' anJ:I"d cute, ""'l-!Il. 1.
Aft"r tlw ""KIt, haVe'been CIII. mark the

~~rt'''''~un each ...idv, and the

OUTtR \!)

INNER
IlIN Slot

('3~

__
~

AltON TOP AND

80"OM Of C.. SI.

.1

,1..-

WOOOSC:lt(W

WITH PEN(.lL UNfS

A,NO SCREW TOCETliER

b.

'."

PIVOT
HOI!

... "

.....

fHWOO<>s(RIW

c
1

~~\..d-r~
'\

-,.-..ux;

-,
7-

INNER MAIL BIN

The inner mail bUI
ba~ a front frame
with a raised panel, I
began construction
by ripping the rails
(F) and stiles (G) 10
width of 1114". see
Fig, 4 Then, CUIthe
rails 10 3 length of

UNO'"

101 "1''''

1S'.-

I' .-

G,

pam-l 10 move with changes in humidity.)

Afle, Ih,' ,,'alanl i> applied.apply "POX)' glue
(it's WUICrprc.>1) 10tho!stub tenens on the
rails, and damp the frame around the panel.
J()I~PKY.Th,' fronl frame will be joined to
the sid~. 01III<'inner bin with a double rabbc'ljoinl. 1'0r now, rout a rabbet on the back
edgt'ufllw lranll' slilo's.see $tpp 1 in Fill. 6.
1'11(;"""0 n,' more srepon the front.frame.
To a110" th e inner bin to pivot out v.ithoul
binding. tOUI c,r plane a 10' be>.-elon the I(IP
St ~p2UlF"1I6,
'11)"-, \Vilh the fronl frame complel e.
O(xt cut 1\\ o innerb'tn sides (1:.1 #'I." wide
,U1d10, II, lonll, " ... fig. 7 Th.... CUt3 10'
tapc,on th. -back edge of each side. (lused
th.' band o;a " and planed to the iayoulline.)
Nexl. eu llh~ angle Onthe lOPend o( the
,idl'S by P~'lCing th~ laP<'rcdedge against the
table saw', milcr l!'3u~. see ~Ig.
8.
~'jnally., oul the olher half of the double
rabbel along Ihe fronl m~lt/tedge of each
'iide piece. S<'(' fig. 9.

''''lie........

26

.-

0_
_..

b.

.ANt1

snu

','

STUart_

7'

StU

~i'

,~
It.-

......

a.

RAILS

l' .-

P"".

frame JIfIOOlV"'. see Fig. 4b. (This prevents

water from accumulating bUI allows the

i!'

SnLES

...

;:.

PANEL

tS:~.
I' (1110 !'t,jl,-_"~tu lOV~".

Tlu- next SI('I) i'IO rul a groove 10 hold thr

panvl in plll('r I used table saw 10CUIa
V."wid(' g,OOV(' centered on the inside
l'<hll'S o(th" ,til,,,, and mils. see Fog. ~a.
ro join th, frame 10g..ther, stub tenons
are cut on the end of the mil>, see Fillla. I
did this by CUlllnRrabbets al the ends 01the
mil,. <rt'('ping up onthc IinaI depth of CUI <0
the renl4inlng "ub tenon 61 in the groove.
'tXl.work<an~onthemi~
panel (II) thai fil.;nlo the frame, Toddet
miroo Iht ";7~01 th<- pando dry.cJamp the
fram. 101l"lh('r and measure tht' inside
fram,oP<'nIRJI.Add}."tothesedimensions.
Thi, wa) Ihe panel'. edges will extend !i16"
into tho' JIfIOO""'. Then cut the panel 1(1 size
(minI' nwa",n'" fI.'.io" b)' lS"tll").
Tocut tho'rai.. -d profile on the front of the
panel.tilt II... titbl...saw blade 10II' and set il
1VI" high. M'" SI!.'I) 1in 1lg.5. II helps 10add
a tall auxili.r)' f~nl'''' 10,upport the panel as
iI's po,llI'd Ihrou.l!h 10make the CU~
l\'XI. cui. 'b"wide rabberalong the back
,-dge of Ih,' pand. set' Sll'P 2 in Fig. 5. Thi
form, a 10nJ(Uo'thai fil' Into the grOO\'eS in
the' tram" SIll'ak up on the depth of the rab1k~until th,' longue fits souRly in the tram.:
11""'''''' bUId""'-ll'1 bonom OUL
lS.'E.'IOlv. \Vith the panel COLassembly
can ~
by .ppI~lRJI>iliconeseaJanlinthe

...

1HClUO&HG

rtNONS

... .,.
,

','

' I.-

"

so alAD(
TO 11'

--'r
lOUTll

.:

90'

1lIIt, _AT

.: 1-

I~STaAJGHT lit

10'

J
PAN(l

STEP 2

"-!

..

'

nONT

~,'

.' ~.

__ , -

.~

re
I1>G<OO_

...

ttAUlT f'aOHY
tN:S1Of fOG(

no. 9

,.

fRONT 'ACE

MlTU:OAUGf

10''.10'

5((

'ANn

'"

..

SIDES
~

ya.1 DGf Of ItA& OHlY

c'

STU.tGWT 1fT

... .. ...-

INNER BIN

.-

STtP2

_Of$T1W

_".

.,r

I"

u::::--

I->

STEP t

'IONT

.Ja ~

.......
ON!.y
ONMO<

,"

'''IU '(Nel

--:

aovrlR

tAU.
AU)(.

--I - It,~
-- -

.J._

otI!'

,"

THEeonoM 0' CROOVES

, .. AWA,'t 'ROM (NOS

...

..,

fUll flNet

~yo,'

iliAD 0' $ILKONl SlALANT

... UNa
' .

STEP t

..

NOTE:

.' r

SliOUlDC.

[:

r',

,
I-- "," ...

IIOtITlI
YAA..

flN<1
J

l'

.,.-

1-

t, '

It-

Non:

1tA&UT

(itOHT

(OGlOHlY

SlOf ,-~

"T'
INStOf: FACE

No. 70

ASSEMBLY
To a.<-.m1bk>the inner bin. titsl dry<lamp
lht' <id<~to the front frame assembly. S<'('
fiR. 10.Then drill three holes on each side
and .. :nw the "d<'S to the (rom frame.
IlCtmlM No" lhebottom(l)canbecuUo
l.nRlh to fit between the <ides. Before installing thi, piece, np a 10' bevel on the back
edlW (to match tilt" angled back edge of the
sides), T1WII rill lhis piece to width 10 fil
3Rnin~1the fmnl frame. see Fig. 10.
Secure u.e bouom in place by applying a
bead ul epoxy glur on the (ronl edge and
<erc"ing il in pia<'('lhrough the sides.

IUCK.Onceth~bonomisin~cutlhe
back (J) (rom II.' ~1asoni~to lit and 5CRW
it in platt. see Fig. 10.
rn.l'ill. Bdo", going any further. I sanded
the inner bin and lhe outer case and finished
them with two coats of spar varnish,
IIWUI()~"''I.~F\l8LY.
To mount the inner
bin inside the outer case with the correct
spacing. fiO';llnydown t"o :,thick spacer
strips and place the inner bin on top otthese
strips, see FIR' II.
NMCt.slide thl' outer case over the inner
bin. To create a uniform gap around the

inner bin. Iuw ""m s, To determine the

lhickn,-"" of lh" shun .. pooh the inner bin
against the botlom of the <be. Measure the
gap at the LOpand divide by 2. Then cut four
shims !'Qual to thi~ dimension and place
them asshown in rog.lI, (The inner bin can
becentered on the width of the outercase by

adjusting the pivlll screws later.)

With the shims in place. driB '1'16" holes in
the inner hin for the pivot screws. (Center
the bit lhroURh the hole in the outer case.
see rog. 11.) Then install No. 12 Rh screws
as pivo"'. see PIVOtScI'l'W Detail on page 25.

_-

10

BACK VIEW

-,. ',.

"'SCIttw

INNE.IIIN
BACK
I

SlOI

OVTERCASE

.6. '.,.

EDGEAT 10'

"' SCR(W

St41M OOCKNtS$
(QUAlS

\., TOTAL GAP

~};

~4"SltAC'.

woaK&lHOt

PIVOTHOLI

.~ 1r~

~1~----

(.~a-.-D-O-U-B-lE-RABBET
DETAIl

"" 1'.-

fhSCllW

(I)
INNER BIN
1S0nOM

....
a

rACt DOWN ON

(1'OP Vlrw)

NOTE:
AlJCj.H 1HHO liN aonOM

tlUSH wmi 1On0l4 rOOI

Of ,1tONl .1ItAM[

N.orHOU/

CROSS SECTION OF CASE

HARDWARE
The final "'1'Pbefur. hanl(ing!he mailbox is
10mount the hardware. -ee rill. 12.Aspring

helps the inner bm return into theoutercase.

And a chain kee'P' the inncrbin from pulling

12

sn
TO SfOP~~""~'~N~NU;::::::::::::~~
.,N CHAIN
ATTH('lONT
(DOl

1--' Of nt, OUlU

place,

Nno

KNOBON

TOP fROHf UJl

eMf TO'

OUII(H) (rtr.

Locate and drill screw holes to mount the

<;pringand chain fin the back ofthe inner bin
and inside fnct";olth. outer case sides W.
see FIll. 12. (Youcan vary the spring tension
b)' adjusting where the holes are drilled.)
Nlcr in,lalling the spring and chain. I
mounted Ill. bra"" knobcentered on the top
rail (f) o( th. (ronl !ramo. see Fig. 13.
:-;(,XI. rip a Mnl(er strip (D) to an O\-eraII
height 01 1 ~ ",th a 10' bevel 00 the LOp
~ e, "'" Fi~ 11 Then CUIit LOlength to
match the in,ide width of the outer case,
:':0". mount the hanger strip in the
de<ired location on thO'fronl of the house.
Then sel the mailbox on the hangerstripand
drill pilot holM IhroUlfh the lop outer case
shank hole... lor No. 12 x l~' roundhead
bra" wood..:""".,.. and screw the mailbox in

13

NOTE:

....,

SPRING

MOUNTS IN

CHAtN
I

LOCAnON
ON

oPPOSm
$10'

14

WI A SCRAP Of
WOOD TO LML UN'"

,,!>

','

HANGER

STRIP

"''t. Fill. II

No. 70

li

TOOLS

&

TECHNIQUES

Table Sa\V: Ripping

I

at uic back of the saw. Slide the

II had 10pick Qnl)'on~rea""n

for owning a table saw, it
would be the .billl), 10 rip (cut
with the Itrain). )'\0 other tool in
the shop can rip through stock
as accurately and ...,<a{cly.<tll<'
table saw
Perhaps. because ripping
S<'('IIIS lik(' such a simple operalion (or a lab1.., sa w, it'~ofien
taken (or I!ranl~'().
BUI there's more 10 ripping
thanjus] pu,hing a piece of stock
ihrough the saw.In fact. the IWO
parts 01Ihe table saw (the fence
and the blade) thai make il such
a good ripping machine call also
cause many of th, probl<'msvn-

gaugl' back untilthe ""I'('W head

alignswith the marked tooth.se
rlJl. 3. I\ny ,,",p or bindinl! "ill
indican- how much the blade is
cut of alignment.

To align the blade, loosen the

bolls thai hold the saw trunnion
10 the bouom IIf til<' table TIl<'

trunnion is rbe assembly that

holds Ih( saw arbor (or the
motor on direcl drive saws) 10
th. un(krsid" ofth. saw lable.
Once the blade is aligned, lb.
bolls can be tightened down.

(:'>OIC:For more on this adjustment, see the owner's, manual

(hat came with your table saw.)
AIJc,,,nlF. >'F~"('''-\I'ith the blade aligned.

coumered when ripJ)in~.

QllE.<;110N: \1'/'11 .1",." .f'ICk bllld (1",1
b,t jOl' 11'1'l'I' I "~/; f'" Ihr III f,l~Nlll('?

Rinding is probably the most typical problcm encountered when riptling (Inthe table
saw.

111(,'

problem can

l)fl(,11

be traced

10

alignmenl If the blade and the fence are nOI

parallel 10 each other, the stock can pinch
bt>tv.",nthem, see Fill. LThis notonly causes
burning bill can cause the stock 10kick bock.
TIw problem in gening the blade and the
("nce parallel is determining whether 10 ad-

justlh,' bladc' or th~ fence. Iapproach thi.

problem by using th,' miter gauge sl<>la" a
re(erel1('('-adju~ting I, h the blade and Ihe
(t'ncr- t~.1henlitef gauge slOl.

The firsl step is 10 align the blade 10 the

slol To do this I make a .imple feeler gaug~ the next step 1$10 align the rip fence: to the
miter )!auge slot. Here ag:.in I use the same
that fits in the miter )."'"1:<'~IOL
>"EF.IRG.~I(iE. 11ie feeler "duge i< made shop-made f""ler gauge 10 check the alignup of IWOparts. a runner and an ann The ment of the fence. see FIR.4.
runner is, cut to fit :'11Ug, (but still move
To check Ihe fence. lower the saw blade
(r""ly) in the leu-hand miter gauge s10L below the table.Then, with 1111'(~el"r ,,",URe
Then the ann is attached to tlu- runner so it still in the left-hand miter ~"ul(e slo\. slide
extends 10within '1'0" of Ih(' blade. see ~ig.
2. the fence over to the feel"r j.rauge. ;\ owslide
To make Ihe gaug~ adjustable. simply S('1\'W (he feelprWlugc alons: the slot and checkfor
a roundhead S<'1't'W imo the end o( the ann any gap:; or binding (hal indicates the renee
that is closest 10the blade.
is 0111of alignment, Once nl!llin. check wilh
AJJGNTlIE lll ...\O. In use this gauge. start
your owner's manual to see how to align
b) unplugging IIII' saw and marking one your rip fence.
tooth Qrlll~blade witha (~IItipmarkcr. Th(.'11 Now. both Ihe (enl'rand Ih,' blade should
adjllst the deptlt of the >;<:r('Wso Uti.'head just hi' parallel. (For 010r<' complete information
tooche; the <ideQl1hemarked tooth. see Fig. on adjusting til(> blad(' and Ihe ("nc~ on a
2. :-iow roL11Clite blade 0;0 Ihe n\'lfked lOOth is table saw. "'''' 1I"~"I'lIIiI"
NIJ.5).)

4
8lADE

TOOm
rEN(f:

AN.

.,.

IIW>I
NOT
PA,UUQ

ROUNOHtAD
mUR

ARM

FINCE

SCRW

GAUO(

WOAK flit'S

.'ND$

"".
lUltNS-f

FIRST:

t'>
U

POStltON

rNaso IT

OtR.tCTtOH

tOUCHES

'tW~GAUG6.

~,fftO

mEN I.OCK
MOVf'tnut

GAUG(TO
RUROfSAW

28

aLAD.
ROTATE

MAR.KlO

OUT0'

TOOTH

I1ACK

WooJSll1lth

AUGN
MlNT

No. iO

Qt E...
"O\:

t.

MU'II\C,JI<. Ill<' nJlllUlll jig I u-c is oolh

inll more than I 12.. ide. ~4 p~""'ood
I,,.. ,
,Ied "The trick" findlO!!a way I" hold the
tklHq I ('lIN
<I",!.. "",,urd) 101h, ply"'ood ,1<"<1.
0.,...11..l''OlJ'" 1\. tried \'ariQu,methods,,(
1.' ('('11 ,I " ,A",'
holding (h,' stock In plan. nit" prubk.1n ha.,
j",1 bt.,,,u,, vour -..I" bog- down when rip- bo.'l:n firnlilll a method that ""uId "t'CUn-1)
pinR <10,,,(1 m,,," yuu need a different hold th, stock no II be vt'Ntik enough to
motor. Ihen- nn' "'(\
..ral factors that affect handl, diff... -m wul(hs and thicknesses,
01

#I,,.

,,(doro>lmylah/. ,u",

or tlcmll"lI It Clrt'Ult
l'
"1')J"ry 114 II er (IN'I'
.1,) t"JfI'/',' bll.~IHq a " ur

I",,, ",11" ,;lW bind" (UIS thrnugh stock.

A""lnilll( thru tlu- bl.ide IIl1d the (ence arc
ali)l"ed and II,.. b~ul,' i,sharp, one simple
solution i~
tu feed tht' ....ock inte the blade at

a ~l,'v.\'rrat,'
It vour .....11n

j ...aJiJ.:nt-d

btad\' yc.u,,' U"'Ull(

Rli' 1II.\I.f., II I I>l:onI" d" .101.,1 ripping.
I u'< a:! ,"".Ih ,am.d, rip bbd e. ,."., Il"th
on 11", blade at(' anlll.'(f lorward more than
on a. {rO"~'\.Il or l,)nlbln~ltion blade -ee
drawlll~ ""k." lb "'lRkd Iet'th mak,'

.too<

bladt

(For mon In(c,rnUltif)Oon a <hop-

made <pb"" ...."'I"'!!e.'.)

The second pr..bk m (lh~ prec... "t:dlling
b<,tw,,n Ih. bl.ld,.n<lth. (I nrc) can u.-.uall)
be traced tll 'In(' 1)1two cau ......
...; Thv work,
pil'c~pull<away ir ..m the (e nee, Orthe oper
:oII1Td... -sn't (oil"" good ripvinlll~hniqll""'.

Don"lnp a pa"~et ..1~J(k th..ll" .1dc-r tharl

"'CUltl"
'OOVI.

il "tonll It', dIU;'uit ,.. keep Ille ",.",.

Irnm bind in!!

...uoo ....

:\~t'r u .... the Inltl'r JCd'tNl and Iht, fenct:

tOJ,:tt"tht"rIAht" rntlkillJ! a II,rt",tJ/~ "ut (II's

NSH THI STOCK

AHOTHI...o
fi<OOUGH

ukay fJn a gT'()CIVt'l,r a dad.),)

K~,'p a 'lIppl) o( pu,h ,Ii..k, fir blocks

hand),. 'l11i, way YOIIwon'l b~ I.",pll'll 10
riJllhin pi,,c, wilhout them.
1>110'1'Ialld IlIlh, "OIIIt .. r Ih. blade. This
wa)' ifth,' Iii,''''' <1,,(, kirk back. )'OU won'l

bt'lll 11,,,''A-d\'

n (" kt- HI Itl...\l, ...... /\ncllrf option" ould

be III II..... Ilun k"r1 np blarl". The><-blades

behind the

the workpiece tiglll a~cull"\t tilt" fence can

oflen 1M'sol",, by U""l! a f,alltcrboard. see
drawillg below. I'flsiliflnthe [.alhemoard in
fron, CIt Ihlt bltlC,It ~ it applies prcssunagain'l Ih,' ,iel, ..f the stock. This khOPS thl.'
..rock tight :~aln ..1 th~' fl"IH.'",_(~,. pagt' 17
for a d,,,,,-ription on how In mak~a l..athe...
board for thv wb~,;aw )
TIlt IU 1..(', hll3ll\'. kickback<'atl ol1<'nbe
pn,\;cntl'fl b) (mp.).,) ins: a 1..-14"lnlpk' rull~

.'",'NO JIO

Ih. -tock ,'urr" II). th.. probk 10 may be the

nUrJlbt'r f.f I,"th 1, kC'j11tel a minimum. BUla

bladrwllh h'lI I<'",h,'an I.av"al"dgj(,'<!t:dlto.
To ",Ivl' Ihi, problem. I often uS(' a I" 0bind,' nl)J'in~I<'dUliqu. 1make Iht' fir.;1"II
t Ij!'~t)Vi'I"V,t' tl-:.inJ: ,I ril)J)i11K blad,. l1\(,.'n I
,unll' b""k and dean up Ihe ('UIIO fini,h,'(f
"idlh "'lill a cro ....
"'l'Ut f)rCUITlbination blad{.

<aw

blade and k....ps the kcrt trom rk"'n~ on the

~E"rnFRRO.\lU).TIle problem of keeping

$'WGHT~UNf

and you'n- ft.'t:'ding

...li....ing flit. th;lt allo", \'(JUtl' (4'Cd quickl).

T" k,"'p Ih" bLl<1" lrum b.-in!!o,"rl03dt:d
..."h "hlp, a' Ih,' 'I,>(k is kd Ihrough. the

mt1aI that's mour 1m III I~

(.1..\\1' .... l'''"lJ.: 31Q1r I f ..hc.p-nladc hl)ld,

I leln', kt 10'(. uf lin v.c.rkp'('" until it has

bt-en pu..ht1J ('11" ,,1, I, I" pa...tht' bladt-.

ha\'c' narro~\-r 1t.'t.:Lh than on ...tandard car

bid,'oW'd bLJdt-...Th" means th~re is I"",

dl)y,,, l'lanll)'. (~l()"" IJ on pa,gt .~J)

,~lht'bt:st
tll('lhod I\r f,~ond\ ct In 1;00.1
til,,) 'n: what

rt....'..tanc:4: "Ill'n l"Uttill~. aJld ~our mol or

makt" llll'" nVPIn~ JI;.!' '!IoU t~ ...

) to use.

,huuldn'l ha"'IO lIork a.' hard (For mort'

on thin k.'ff bl3d, '. ",.,. 1\ I. Ii :\0. ;;3.l

I "'J\I; TIlf Jlt. lou,.. Ihe Jlj(. damp thO'

Sp...,ul ~ 01. Ai')'0\1 1113) hav,,11OIic>1I. wt'
...tllCk do,," to thl AA ~ 'lOC edge f"xtt.'1ld~ don) .JKn. J(WI'\) on Ih" I.1bk,'" llU,,,

}'-lnaJl~ tht' mf)"l 1111pl,nanl thing to f('nlt.:lnbt r IAh,n u"ln~ aal~ VO'4t'f tool~ that
IfUtt',..", IX" ~
((Jr~ouro"'n...;.a{t'l~

b',

dr.1"illR abo1;t
dont ",,.dI>buvo ~.e'~J<1dbOcImnn-~
feIII (6 I~ from the 1'Iea. "'"~ > oUflll1.ll1l wt...n.~....p,,-.ibI.:
b)"dc ( m' .' Ih. "Idth ollh. jig). ;'\OW.IO
rip thc.c.lj.!l' ..IJ .li:t.:ht..NI11ply I>u",h the jiS!' and
the: ..t",," thr~J",).Il.ftk' s;.,...

J1J.! ~

O\l r 0' rtf,:," ')t Iht

nl("11
t 1111 lahk tIi.1-.

Cl\I~,,"O~:r.;

RIP 8LADE

I,i,.-, uJ x/'~'k

~.rt t'Q;QjlJ.~

I r'j' ""('4

," "

",11,/,

x 11j/'tl/,lNzrk til 'lit: If'llt

II
"

"';1 "'1'1" ny. ,"'f IH I III IIr4' 'f X(),"" r,hJlll((ltl'

MO '{PH CJtlAft A $MOOnlEft CUT

I~
L/

"fJlt"

('UII I tl',(Jitl tl,l' 1~l'rlllll III'" 1/', fitlure.!

'11lt"biRJ.!t...1pi.tt'nllail'fc.bll 'm "'hen ripping

un Ih,' lab),' "''' I' ktrk/Nlrk. Kickback 1)('.

cur- wh,'TIIh, btad.ml,'h"" a piece or stock
and Ihn ....' II batk 81IOU. Sioct' a table,.., ....
Ql ESI10\: S.., .'
rh." /
blacl. non, ,,' ai><IUI ~OOOI'JIIIl. don', undrrJ;n .,
, I 'I,
,,,llff lolI/#l",d
01,1.:0 ,""inaatr Ih. ("'n' w1th .. hicb a sa'" blade
:\'."" I 1'1 , 'Qt'lJnn.~t,Umfiq"('tJ
<"311 hurl a JI",, .. f w",'"
.tmJ!lhltdlJi' ...;'"1"' Irl",,'rhn I nJfl tl/,r.
J') poe,,)1) . mo'l kit kb:k can be 1r.l<.1.'d 10
whal'3 ,h, ht-~t 'VI" I" I~t Ih, bfl(J_n/,.. to tl c.nt>c.(tIAOl,)ll .....lbk caliCO("~)mttimesasa'4'
.. , (;,,.", K" ,i!h'
k"rf miKhl d",,' up and pioch thebacko(th"
blade Or Ih,' pi, ..... ~"m.'.
v.edgC<I beI II ('III C,nt "r;11J.:hll-dJ,te on a board. 1 u~ a tol'1:lllh('(( n.'(~uld tIlt> blad~,
~PI.rmw. '1111' probl,m ..(th(' kerf closing
'1r.lIJ(hlhn(' riPJ>ingJig on the tabl(' "3"'.
Ev,'" il }i,,11h.I\I'.' jointt'r it ma), be faster to can bt ....I... d by u,in!! a ,plin~T IM'hindth~
n}) a ''It.liJ,!l'II'1IU('(ln tht' table saw,
bL1<1('.!\ ,plitt"r is u<ually a Oatpiece o(
/COMB'NAno~
B:=:LA=D~E:'__

f(A't'MOao,uO
1110' HOTI' 't, 7)

--"--<!::::J

I,."

PUSH

moe

NOTE:

"'w

29

S HOP

PROJECT

Hold--

mp

hiS is a great little hold-down clamp

that can be mounted to a workbench,
on. drill press table, or as part of a ripping
jig for the table saw, seee photos at righL
The clampisdesigned with onesideolthe

ann shorter than the other. II pivots on a

cylindrical block to allow a range of options
in the thickness of Siock you can damp <up
to 3"), refer to Fig. 2.
The clamp is held in place with a large
wing nut that's screwed onto a 6"long machine boh. see Fig. 2. This machine bolt is
screwed into a Tnut mounted in the tOPof
the workbench or in a jig.
ARM.To make the ann. lay out the pattern
on a 11'l"thick blank as Mo ..n in Fig. 1.
Betore culling out the shape. bore a 7110;"
hole through the lOP of the block for Ute
machine bolt to pass through. see Fig. 3.
Next. cut out \he half circle pivor block
and save this piece. see rig. 4.
To allow the arm 10 pivot around the rnachine bolt <as ,;bOWD in Pig. 2). you need to
bore out a clearance slot, Bore a series of
holes through the bottom of the block all the
way through to the pivot area. see Fig. s.
Now you tan cut the arm to shape on a
band saw. Then clean out the slOi with a
chisel and Jile. To assemble the parts. insert
the machine boluhroegh thearm and screw
it ;'110 a T'mn mounted in ajig or bench. see
Fig. 2. To keep the bolt from going too far.
lock two hex nuts together to form a stop.

..
,

To tighlen down !he arm. you can make

RIPI'L"GJIG.Iused thesedamps to make

a straight-line rippillj! jig, see photo. (For
more on this jig. see page 29.)
BENCIt 1l0U).I)()WNS. They also make
\\'hen using ihisclamp.theidea lsthauhe greathold-downs on a workbench.Just drill
two sides ofthe arm are different lengths for W' holes through the bench top and install
various thicknesses 01 wood. This also ai, T'nuts from below. Or. ifyour bench a1re-ddy
lows you some fleldbilily inwhere the end of has dog holes, slip a long bolt with a large
the arm is placed on the workpiece.
washer up through a dog hole.
your own wing nul out of wood. see page 21.
(Hardware for the damp is available from
II'oodsmilh Project S"ppIiRt. see page 31.)

ARMPAmRN

3~'1

NOTE:
CUT fROM IV,'"

n1ICK STOCK.

',,-

_us
0

-r-

',"

'11.- '--

HOU

,.
DIA-

-'.GRtD_

CROSS
SECTION

SKANl<
WASlt

WAST'

PIVOT
IlOClC

_..t_

.,,-

WORK"IIC E
"

","
NOTE:
SAW HAlf

5 ',"

ClRCI.E
PIVOT BlOCK-

30

Woodsmirh

Nil. 70

_.:P:.........:...R~OJ E C T

_____

SUPPLIES

Sources
~h,odul~ 40. 2"1.0., II" long.
(30) Brad, For Securing Pipe
Tu \l11<e1 s, 17gaugp. l',"long
770150 LarSW Roller Stand
Ilardware Kit.
544.95
l1,i, kit illdudes everything
li't1odabove. but the steel rods
arc 22'I... longand the piecesof
I'VC popeare 2'l' 1011jf.

TALL CASI CLOCK

W" worked with Ih,' Ma.'iOn &

Sulliv,,,, In. 10put logclher 3 kit
of all the h;ord,,;of(' and clock
work, '1<','<1,,1 10 build ih e TaU
Ch...k 1111 p:Jgdi. (Nuw: \I'e
'lrollRly recommend \'OU have
tht' kil in h.U1d""lor c you start
construction (,f lilt. Clock.)
In.. Io"I.", ....jth thi-, lUI are:
(1) 1'-11) Cham f)n"t'n \I,,,...

t:.".

MAILBOX
All ot IlK hard", are needed to
ment, \\ e-tmtnster Chime
build the \ta.lbox shown on
Ip~.y, un th,' qu.utcr bour plu,
pallt 2. i-, a"aitab" ina kil from
a tuU ' -oun, un th, bour). In- Hardware Kit onl) from \1 ..... n \I ,,'n' ot"-ring ''''0 kit" ooe ki. \\'ood~",ith Project Supplies.
ci1ldt .....~leIK\'
Feature, B~, & Sullivan. (Thi-, kill'" ",j' D\'"3I1 to build tht' ~dard size Rolk-1' (-';ot, I" .. kit doe- ,In' include
Wdlltol ~11l'1I'. And Brass, abl e from \Vood,mith I'n,j._,<'t ....'.nd ,huwn on page III and ....00<1. fini-h. waterproof epoxy
l-h;llJl~,
Supplies}
.lIwlh e r kit 10 build the .. ide glu~......10<1 >\CT\'w
plug'<.or wall
(I) ~ondard P"ndutuJ1I \I'ith
Ma.",n & Sum".. n
KnOt'r Sland shown at the bot "ICIuntlOg SCf\'W>.) The silicon,
Ora" Bob. 'Iol~ Th c penrum of page 23. (Note: Th e "'ulanl can be ordered sepa586 Hiwns Cn' ....ell Rnad
dulum b 1II.ld,01lixht colored
\I'~Sl Yarmouth, MAtl~h;;1
""",I. flathead screws for ... ralt'ly.".,..below.
wood. "()U 111UYwant to stain it
(508) 77~lj5 (~:llO/'M tn
Mailbox lIardwure
"fllbly. and electrician's tnpe
IU nMl..h the wood used (or
":30 P'--l Eastern 'lin",)
770200 Mailbox Hardware
.tt. ""t included in either kll.)
your dock ,'a'('
The prices below do not m
Koller Stand Hardware
I:<.it
,,,
S6.95
(I set ) \I'dRllI Filling,
elude ~hippins: and hand linN 77() Ioo Slandard Roller
(10) Nit. 8 x lit." woodsm.ws
(I '<'I) Black Clock Hands, These kits art' ""r Ii...lt-d In t)l~' "land lIardwllJ'C
$.149,
ZinCl'latt'd,l'hillips Flathead
"'rpenhn, Slyl.
\Iason & Sutlivan "'11.11111 [..) Large Plastic \\'ing Nuls (24) \(1. 6 x W' Woodscrews.
.(1) Ilial
(llock race). Choose th...dial you wam, and
Zint I'lal.d. Phillips Flathead
1\ ith ~1elalln..<ert;;,3"
Enameled Aluminum. II' x then order from \1ason ,~ StJ
II Illg~.Threaded To Accept
.(1) \0. 12x 1""\\'oodscreVo's.
II' \I'ilh 91-2" Time Ring livaa U"lIS! Ih~ lollo"'Ulg urd,.,. ~.lfl(ta.rd .; Bolt
Bra~" Slcued Roundhead
(:\"" . A, ...labk- \I'illt .\rabi<- numbers;
"~I -'x4' Carriage Boll.
(11Round B""", Knob. I' Dia,
Or Rnman "um~r1ll' ~
O206X WoocNnithClodt "ith
(Il x2"C~e Boll
(II b'l~n-.jon Sprins:. fi" loD,ll
th4 ,~,,,,, ~Otl .....anl ~ photo Roman ~umernlllial SIr."
I)
fend,,!, Wash;.,.
(1 h,l Bra" Chain
:tbf",\(' ri~hr)
0205.XWood>mithC1ot:k"'ith
765-305 Uo,. s.1kont. Sea~
III W...<het
ani (3-0. tulx-)
__ 83.29
sIn (I -c.a) \:uts
I) 11I..tru<:I'Qn'
~or ;\Iowlting r'lrnbic 'Iumernl Ui.d

""-ro"

'i'j'

'tl')\1

(2

flu,:n1 dJ1d

(>aJr)

Bra"

Chin,,,,_"S

Bull Hiug('s,

.OLU.STAND

r~) iT~Uls

II ardwood \\'heel~ 2"

I)i... " nia. "xlt: Hole
(5) Rod., 11;" " I J1/1o". Cold
(IU)

Opt!n .~ of the hardw.rI' nt~'d"d tn

Widlh.lnt'lud,, 'kn'w,
bwld the RollrrSuinds shown in
(2) I~ra'l' Kn()l.)~.~'S
.. lJia.
this issue is availabl ... Irom
K..II,d.l.inc,Plaled 51",,1
(2) MugOt'Ik !loor Catch('$
\VoodsRlith Proje,'1 SUllplic"
(5) "iec,'" Of PVC Plastic PI"".
Th,' (,,)lowing II(,IIIS arc
n""ded 10 build lh,' Tall Case
ORDER INFORMATION
CIO('k bUI an' "'" included whit 1--this kit
BY MAIL
BY PHONE
\\,.".1 and fini'h IOrlhecaS(' 01
To ord.r b) mail u... the lonn J (Jr laster "",ire u"" our Toll
Iht(..'lcJl(k
enclost!d "'ith cum.1I )~
In" order line. Phuo" orden.
..1alht, ..d v.OIHf"'('n ,. ... and V1'
or
v.:rit~
}our
order
00
a
1=
[."("f>
canbcplat.-ed
~Jondaylhroullh
brad ...,., a,\,,(mblt tht" ("CL~.
olpapt,r.
ands.-nd
...
,ha
,hock
'nd.y.
~:QO
,,\\1 10 5:00 I'M
-stnRk- ...lrtnJl1h windo" ~la.:..""-S
or mon.." unit.,. Ho".de S3.SO (l'rItr.ll sc:.ndard
(0. th(' <loot-<haJxe
Before railing, han" )'our
On~ I \ ~.,nll 1li''Cc of ,tit!..ire bandlinl! and shi_
with each ordcl-.J L~r("<ideat, \ I~\
or Ma>t~ Card ready
(abolll 19 lIaugcl 10 Ix- usro
add
4
saJo>,.l<IX,
CAn-sidcnl.
\IIIllh chimt ,Ut1k:\'r ('!!(.'\." pagc.'
'800-444-7002
add 6.25 >ai" tax. So. nd 10:
111
'Woodsmith Prqj<>c:t Supplict<
\
rt .. to"u,,.Jujilrd.l
'fTY
- '\ III JIICtUnUnl{ l,ard".,o.re lsee
\of
1"n,.

lIbyd
r,)t'httHg.'
P.O. Box 10350
b.ltl'Jrlll~1 JlItgt_' b")
q,n.,. Orfl~. J!dI(J
ne;o
Moin" lA 6(),106
, ,.tl ,":lIt tlrdtr tilt, \\'t~.J,,,,,,
itl,
ll""k II ork~ and
S""n'llp ....2"I,,)n~xl\,.

Ti_.

\ 0'.

l\ ...70

--------

W.~',)..mllh

HOLD-DOWN CLAMP
IVood,mith Project Supplies

i.olf,'rill~ a hardwa,... kit and a

full,i1.('pallern n!'eded 1omake
Iwlthold-doWII cL'Ullpsas sbown
'") IlaK,:m Earh kil inrludes
~"ouRh hardware to make two
daml>" and Iwelve TNuts as
mountirtg ",Ialion"" (\\'000 i>
""I indudlod.)
Clamp Hardware
770300 HoldDo....ll Clamp
Hardware
.._ $6.95
(2) l.arll~ l'(a,.lic Wil1jf~ub
\11th \klalln",rt.. 3" ~

II "'1:'. Thn'3d,od To AtXepi

Standard ~~' Boh
(21 x b~ \1a(hin~ Boh", AlJ.
Thr,d. Hrxhcad
(2)~" \Va,h,",
- (..) '-,,"\lut~
- (12) ~'-rNuts
(2)

I'ull!ii/.t' Arm Pauems

31

~--------------------

---

LA.ST

LOOK

------~~-

Final Details
Tall Case Clock

- ......
~;
~\I/

II 1\ -c

'I"

, ..\ ','ll,IIffl.f' ",,. Ifl".dIT'f,rl r:

t jfT" f t. J 1Hlk. I
J""lun.'(litJli,/jrr",
r: nnd JIIINt'1 ("'N t I(t",), "~ltd III I' ("il
Inflll btl,. Furl'". nUIHI,1 f'Ju.h. I n,"t"J ,,, II"f "",}

Ttl yt,,(

."""1..-,,.
Il('J""

tl,~Tall r(l~'

n/IINnrtJlI(,p.

(-./(1('''- II ,rrtll,t"'lIfI!
lb~,.; "Pt'SlfI" J, (l'Ut'I 8 II

rul d~'alUlld l't}litl rltt'rr"

II 111111/1

(/(HI"

, ,."r r """'111

fir I" .~. Iltt II/,t",,'1J1 1"'/' ,."IIt"r xtalld

n ,fliji rt "I'I f:u(h (" ,,,, jll'f ,.,11''...(flY'
trt I'."!I a 11I1('lIt ('/',,' III If Ilj"N "llllfll1 .

rOil n ,,[11( "/llkt!

"~I
n/II,Oft I"YI fi