NOTES FROM THE SHOP

$3.95

No.71

October, 1990

EDITOR'S

COLUt.1N

r-------------------------~.

Sawdust
Edilor Don.lld B, Peschke
l)e"l!llDirector TIlVulir.k

M31131!ingEditor DoulOas J.. lIiok.

As~If.dilono

Prt.jc.,,\1 Oc~l"f'
IIbJsll':'llo('

Tefl) J. Sll'Ohmnn
Jarne" \1. r)alan
Richard S. POI"'"
Gordon Gni"""
Ken !\lunkcl
DlJ,.id Kre).ijng
en,)' ChriSlt"I\SefI

Rod St... kes

Chris Clo","",ki
Gruph.". (lift...
,., Jon Snyd~r
I.."....'CISU~
Lo.Ji. ,\nn G""mnrt
KelI)' H",dford
SrottRhac! es
Cu5ton,cr Sen.iet! ~1Jn' tindo ;\torn)'"
~u.stonl~>fSt-rvicc l.indn

JC)QCS

Genillfc 8rant;On
A1ic:-Sn\ith
Jennie ~
JAnlC<" Kcrkm~
JozIyn I'tOSli

Jen)' \'ant!inni
ContrnUcr J';)ut E. Gill)'
(Xklkkt."l.-ping linda O'Rourke
N(lv.olit,\drninrslnltbr U~
,\1. LidstCf'
,l\iJrniniS'lrnti,,'j' A"sl~. Lnc..ryJ .1\. Scon
SaJldy &um
s"u'\'t'book J<_ ~Iy.,."
t\enlA. l'Sucktnll
Shop Man.gcr
Curtis
Buifdill~Maiutl'!Lll". Kcn Griffie!>
j\tchic Krnusc

Su\,.

Swre Manteno:

Berkel,,.. CA Michael DeHIIVl'1l

1m. \101I1l'" IA Kent Wel'ill

\Voodsmith

(ll>SN 0104..11141 i. pul>

lished bimonlhll' tr-,b., AVril.Jun,', Aug.,
OCI.. O''C) by W""",,,"lh l'ubli.IIIIIRCo.,
2200 Grand Ave.. O~>Moint:>.1A,0312
\\'tHXIsmilh I" a rcgi~lcrld trademark of

\\'\lUCJstnitb 11tll>lh.}ting Co.

~COPl'rigbt 1990 by II'I)O(!SJnichPubtl,JunM
Company,,\ll right. I'\""""..!
StlbscriptiOIlS:
(Jot! year (6 i:"sut::-.) ::>15.95.
Ty,Q)~ (J2i~
..uc:t') ~ ~,. Canada/foreign.

addS<!.O\)/y..... U.S. luooo;.~1lJ<I"roJl)': S:l.9S.

Second CLassP,>Stng<?PH.h, ~Moin..", IA
and at ,dditiooal om"",
Posunaster: Send l':b..iingt.+of a.ddr(!~sLu
Ilk. Do); tOilS. De..!\t()ill'l.."S~IA50350.

hen I walked into the ~hop. I

couldn't figure out what was Roing
on. Evtoryont \\'3~ju~t :SlandinJ! ihere.Iookillg at ~Plnt.'I}ling~ittinj(c)n tilt tablt' ...uYo"
OUl of rfu- cornvr r,f my ('Yl', l l"3URbl a
glimps<: o[ what looked lik,' a small 1\'
screen. '111t'nI realized it was the prolotype
or thv fligllt li~lll
we had been worhiIl,g on.
TI,e (ronl panel of !I", night lighl ha, a
scene of a cat about to cal('h his dinner. (St.~
the cover of this issue.) It IIIlS amazing 10
~~ ..huy.lItatS(.'iI!.llt: mesmerized C\ eryone. I

CV<"I1
(ound myself,taring .llhe ni~hllighl.
sure that any momcut t}\(' cal would OlaRe
his move.
Ken (uur projt'!!l deslgner) said he had
more fun d('"s:igning that scene than anything he's worked on in
Then he
CaJl1C up

y~.".

with three 1110fe scenes.

::,0

we de-

cided lu redesign the box S() you "<)11 Id sw",

thr ee panels in back and change them
around as you wanted.
'Vell.thm WItS the ~nning
or what has
proved to be a V"ry int&'J'c'!i1illj! b._...;ut-. Evt'ry
year Yo',", try to ltavt, ont' i~"Utdt'V(Jlt-d tel

pro~t< Ihal )'ou can build Rifts ior kid.

and for friends.
TOY ROX,Ahhoul(b "" "er~ aUmt'Sllwr,
itt-d by Ihe night light, ISUPI)I'I"I'lhebigge>1
clt"UL'i1g~ was Ih. IGY box - Ihr onc that
luok.. IiIw a giant bloch (page Ii)
You know Ihe tou~helil p;ll'l about build,
ing the..,. tuy box."? K""ping Ih.m in th..
corrcc-t p<"rspccu\!e. B)o' thal 1 Inean. we..

<tarkd l1ul building them to adult scal~

'!hal didn't work for kids.
\\'e buill the 6"1 one big enoul(h to hold
lOIS of IOYS. But wlwn w~gnlh..,~ up
snlall htrd OIIl'oo<l,,,"ti, kids 10I~,I il (IU~
it ~ecJcarlhc)'
had adifiel'l'nl p<'rslX'<"
tiv~ , .. and shoner arms,
What we nt:eded W3$ 3 small box ["f"nan
kids alld a big box for big kid, 111.t, when
\\'t' ....
am\.' UI> "ith tht jdt~a (If a fal~bulton}
that could be movC<!UI)SOshon aml~could
rea..-h.1I1hl' way in.Thtn
the am" (anel
.11 the ",h,'r parts) ),'1'~"ovcr Ihe n,'XI i,'1\'
years. you could adju'l the falS\' bonum
down. TI", end result ><,<'m"d 10 pi""""

.>

e\~ryone
GWlS. [n addition \()the proj<'Cb<forkid~,

up wilh thret' projtocts tI,at could

be gifts for any age: a music box, a mirror.
and a paper gripJl('r
Asl wa.'lJboultocumplel~ tbeOluskbox,
Wt> cartle

I found II "mall piece of burl veneer and

inlay sirips and couldn't J'('sisladding
them 10 the lid. Then I decided 10 make
another lid and Ity my hand al chip carving
panern in it
Although we don't show it. I also experimented with carving initials in the lid, The
"0111<'

gn'alll1hlg abuuta ~nd.1Ibox likt-llli~ bIlla1

VyU can experiment wilh all sorts of weh

niques - and y~u wind up with ~ry individuali7.ed gifts.
The ",melhing happened wilh the hand
mirror. AI first. Iconcentrated on the basic
ll'rhniques - t1!lUnga blank
share ICI match the shape of

to a circular
the be. elro
gla.-,, mirmr, The next task was to rout oul
a ,("Clion lor till' mirror tn n-sr in.
Ithuughl Ihad done okay, unlil Isawwhat
happened ., th~ mirror was used, Almosl
''\'lry"n. wh.. picked il up placed il back
down with the mirror side.; dC)W1I. All of n\y
attention had b<"'11 on the sidewith the mirror - but th .. back ...ide i...
just as important.
Okay.

alltftll\'f Illirrl.r.

this time

with

carved initialon Ihe back )"Iul'hbeucr.And

1 th')U):hl about making a version with a

burl \t~"'trlnlaJd;l!-.on IIll,>nluSlc

bt)X.

(See

what h~pjlt'n' wl",n you're having fun.)

~ 1-0\\ r\l ES. On. of Ihe most 3Jlla;-Jng
IhinllSIhat's happened in thepast y('ar iSlh~
growth (If Uw \\,",(I.",i/II C(lrnlo", \\'t
"'1artt"(l it u,a wrvic(' to $hc)\\'lhe proja:tsin
Ih" bat'k issu,'s of 1\'(I1)("'",illl and 10 in
dud,' some i"tormation on projecl supplies.
It JU;.l kl,<,p$I,'Towingand now It'S .11"'('
can dn 10 k,'t'P up wilh Ih<:phone ,'aUs and
the mail. Fortunately, we have a weat woup
(,f pet,plc who arc anxious to takt" you r ord~r
and help in any wa)' they can.
11mtgroulI i,growing alf,in, Linda ~Iormw (ourcustmnerS<!rvice rru.nagcr) asked
me if she Ctluldhire a (ell' mort' [lI'Oplc for
the (allSeasoll,I said 'UI'{'- bUlonly if their
ftr:;ln:ct'1<'S bt,gin wilh Ill(' kner-r,
Wouldn't vou know iL sh~ hired Jennie.
J,;njcc, J"rT); and JUl.lyn (whu'~ abo kl10"'"
3sJosh),
.'\lso.... hpo Archie retired, Ken Griffitll
juinC<!u. to hdpoul wilh the buiJdingmnin'
knant'C. (Of couri\c, Ken's wifl' helps nut
somclittl\!~ lUO. Ht"r Ilall1(' i$ Jan. So we're
back on Iho~ -j's' all'in.l
ND.T MAnJNG,
""""mber issue of
1I'""d'''''11t (No. i2) win bt, maill'CI during
Ihe week of Dff"In""r 1. 1!l9O.

'n,,,

"'Qi'' ' ~11

Subscription Que.;tiun:.? C$ll1OXl-3.'l3-5(I75

1I:00llll1II> 5:00pm. Cmtrdl 'l'iIIw, ~'kda)'.

t-;"

71

Contents
ITIps & Techniques

I [] A

I Toy Box

I WIremind.b"iltTwothis(ul.illswble
'l'oy
unth kid"
lid

Specia! Tips Coutes! and. si.r

gl'pal tips fromfet Imru-oodioorkere:
1) COllt(}ur Borinq Jig, 2) A \'i,~1'Helper.
.1} Itouter Table Douels. 4) Pilot Hole
Marker. ,S)~rillg ,Yal H'rPllrh, 6) Hillgl'
,\1ol/tlting Helper.
80:1'

III

su])]Jo113

prerent tbe Iidsjronl slanllnillg dOI('1Iall

lilllefillgers, A lid In makeit easyto T/lnl'1?
WI' pili

I Hand Mirror

ISbopNotes

111211'hi.~l'oldpdHnlld'\IiI'I'Ol'l7lakesuJI
e/e!}ClIII oddition to (lny dresser,
And the carred initial moke thi a 1"'''11
persona! gift,

i 1161 IJ Roulinqc

Hand Mirrt:

puge It

.'light Light

lIage 26

Comer Radius.e) Pho

tOC(1)1I
Transfer. J) Irouinq \ lte(?l'.

4) Hillge Loeator Pin s.

IMusic Box

: 11s1 ~\t(lI/llllln(I'/"I.'1leh

I Paper Gripper

11221

and

all

ill/aiel

(I('cplil strip highlight III!' lid of ihi

cl(lssir :I/u,~il'B(),~,
We look a ('/(e/I'OIiI the 10caIdiner
(Iud (/(miglled 0 Paper Grippertha!

C(1I1/;e

it 0)1 casters.

bu ill ill short order.

I Talking Shop

11241 nrf' /I(lI'e inJ(II'111alioll on a self-ccn-

INight Light

11261

lSoUJ'CeS

11311 Ha rdicare

No, 71

tl'l'illfl hinqe bit. Ptus, Ice look <It

Inyi11gmil board a lid gil'e o feio tipsfor
sultdin!) 01/ (( lathe.
Bllill /1'01/1 solid then'y, thi ,'light
Lighl atlell! a jl'iellllly gloll' 10(Illy
1'00111, AlI(I 1(';(/1/0111' interrhouqeoble
panels. it will (llia7)1to almos! allY mood,
and project

supptiee

neededforthe project in thi il1sl(E',

F_R
__O__
M

Tips & Tee

ques

VISE HELPER

CONTOUR BORING .JIG

.1 often

need to hold lon.l(

boards edge up lor doweling,
holes in contoured leg. or any
odd-shaped workpiec e, J make a
m(.rtisinJ.:. or planing. nul it's
hard t(1 du this with only ante
Jig 10 hold the workpiece S<~
cutely in position 00 the drill OUIthecontouron the band saw vise. So. alon~ \\'Ith the \,l::i4' at
:\ow place the joinled edge 01 one end or mv bench, I use an
pre"," table, reft'r WFig 2,
To makethcjig.] $W' byjoiol' thcjigon the drill press table, ""I Inexpensive mdal ,hdfhrackN
ing nne t1Igc of a 2><6vr 2x8 Oat the workpiece into the cutout al the other end to hold UI' the
2,
long stock, see Jig. I
and square (This provide, " area, and drill, see ~1g.
Lou~'x
C',
Jr,l'llxnu
The bracket houk, imo a --hi'll
,table surface 10 ,it on m)' drill
I),rrell/Klrl,
/f"lfl
standard that' ...rnounu-d on the
press tablc.) '1cXIlraee the con-

When 1need

10 drill

accurate

~4t

F~E_L~L_O~~_l
__W
__O
__O~D__W~O__R_K
__E_R
__S

lour of till" workpiece onto the

jig. keeping the edge 10 be
drilled parallel "ilh the jig',
jointed edge. see tog. I. Thencut

bench leg. These standards

come in many lengt.hs. and aJJo\\
tho>bracket 10 be adjusttd UI' or
down 10suit the siz of the wood
being worked
I covered the top ~dj(e 01the
shelfbrscket with. piece ofsplit
garden hose to prevent marring
the wood, see Fig, Ia,
JollII U. lId}",,,,1t/
Eltgli:1hfull,t .V( U' J. ,'Nt 't

a.
SPi.1TGt1.RON

HOSlOR

PlAStiC TU8t

SUPOV(R
8RA(ktT AD lUSTS

TOP t.DGf
Of BRACKET

to ..cCOMODATIi

.OAltO ""Dm

ROUTER TABLE DOWELS

when I have a projecl that re

To mill rhe square tock Iruo a the router t"ble and the fence.
quire> short lengths of hard, round dowel. press tho stock Now tum the stock 00 and rout
wood dowels, I make my own on a~ain"l the round ....ver bit about 111(' adjacent ...ide, sve Fig. 2.
the router table. sce Fig. I. II 2" frum the Idl end. sec Fig. 1. Then rout the other sides in the
saves 111011CY. and the dowels' Then push Ihe 'lock 10the Idl. same manner. Finally. rut the
grain and color match the "",I 01 stoppirlg about 2" from We rigl11 dowel 10 I('ngth
Slrt'f Barrett
I}", proj",,"
end.This leaves a Jlat surfan' for
I start with a square piece 01 "oldilll( tbe stock .rudy against
Knli*fl,JI. JIUIltat,a
stock the CXJIC'width and thickII('N;.$the desired dQweldiarn e2
1
SECOND:
u-r. but at least four inches
SUDEAlONG

---

I.mger than the desired IcnJ!lh

To make a :Y.-diameh,r dowel.

(or example. fin;1cut some '1',""
~4'stock 10rough len),<th.
Then. mount a ~., reund-over
bit in the router table. (The
radius of thv round ....ver bit has

10be hallthcdesired dlameterof

gditfJr'~ .\nl(': T/II~'tterll ..

,ilt/lle 1;"Qrk~}7'11'for 1,.. -(iil' PII,..
ter (IO/l'n/s (I I,d Ilft''!I;'' r. (')I thin,'('j" IJi{!('e~,tIlt

stijf/..- t;b1l.~/(.8
I(}()

'J)"lrJ, ax it pl1~.ottS
I'Ofl(I'T Int. 1"0,. CI .Iiy

,J itt I)l( t. l'

\VOOd:;'11itlll\'O, .ttl.
xlita/lty

"."

;"'(,,. tll~
tl} tllJIA',

dIJJf't'I.If.

f,(lf'

ROUND-OVER alT

rENCE

AllOW '" lIA5T '2"

ON tAC.k rN 10
HOUt fKt WORJ(IIrl((

l)le dowel) It's very important

thattheculti.ngedgeofthc bit be
mounted flushwith the table lOP
anti with the ft"nct!'.

No.71

SHOP TIPS CONTEST

"'fallY WrJ<){/""'itil readers tell us they're
very interested in making pr"jecL~ for the
shop. So. for the next few issues, we'll ask
)'l\u Ior tips and techniquescn solvingdi{fer

PILOT HOLE MARKER

Whea joining twu pieces of
wood witll screws. I like to drill a
shank hole in the lop or front
pic"'c and a pilol hole in the an

large to fil through the shank

hole. and thin awls are 100 small
to be accurate. Tosolve the prob-

diameter as th ...
shank hole. 1 hen I
pin punch.
grind down the tip sc
Pin punches arc available at itrnatches the- diame.....
most harrlwflrestorcs.andcome
ter of the pilot hole I
in the same diameters as drill want to dnl!. To do
lhis. drill. hole
IMoug-b a scrap
a.
wood block III<'""111<,
diameter
as the

mark the pilot hole SA) lt's accufall'ly cent e red on w. shank
hole. C .'nttr punches are 100

/
'REOJUUlD

SHANKHOII

with the same pin

lern, I use an altered machinist's

chor piece. But it's difficull to

rAP PUNCH
TO MARK FOR
91101 HOU;:

,/

bits. I buy a punch

ent shop problems.

\Vell read }our tips and ttl' them out Up
to three oith" best tips in each category will
be awarded a Woodtlllitif Master Try
Square. Duplicate orvery similartipswm be
considered in the orderwc receive them.

shankholeandinsert
the pin punch. Then
damp lIlt' IV'Hld
block to the 1001 rest

on the grinder with

the end of the punch
against the sid e of
the grinding wheel.
see Fig. t.

To bC!(in, we want lips on how 10organize

drill bits. Ifyou have a p"aredun' ora fixture
that keeps aU your drill bit lyJX'sand ';;1),"
o.. ranlzed, we want to hear about it,
Well publish the best tips on organizinl1
drill bits in the February 1991 issue 01
lI'oMmith (No. 73). Send your tips (post
marked no later than November 2. 1990) 10
Shop Tips Contest, WCH"J.milli. 2200 Grarld
Ave .. Des Moin...", Iowa 50:112. \1'.11 ,'Or>
tinueto pubtish otherTlpsend Techniques,
too. and pay upon publkation $1510$)00 for
tlI,!!\t' tip" based on the pubUsh,'IIlellgtll.

:-ICXLrotat e th .. punch in Ih..

wuocl block until the tlp b the

GRlND 11' TO
DlAMfTJR OF
Pll,OT HOU

same size as the pilot drill bit,

""'tt BIT

HINGE HELP

wide. A V.".wide dado blade

tighten the small "'-;11R nuts on centered on the thickness of the
my t"r~(xlltl"i1l1 router [able stock will cuuhe slot inom' P.1SS
fence .,,",urdy enough SO the You could also make two passes
fence wouldn't Slip. To solve this with a standard 1rswidrblade.
prnhlcm. 1 built a wing nut
After culling the slot, cui the
wn'llch, !'l'1~rIn Fig. 2. It pro- stock 10 a 1- shape on Ih. band
,'iell>S <0 much rorquc thar you saw. so the hair and ~Iol are al
have 10 be careful nullo snap oU the base of the 1"'. "'1<' Fig. 1.
the winl( nuts.
F"tnally. soften "lithe edges of
T-(. make the

I "'as never able to finger-

No. 71

loose-pin hinges,
First. I :;crev.. lht" 11in~tonto
th~ door. N"XI apply a layer of
carpet tape 10 II", hinlt~I",flhal
tY(fitC:1r E. Sr/! Ul'td""llt r contacts the cabinet
Then. position ~,e
dooron the
$rofl.4.,.'8.11""",s
cabinet and pres, on the hinll('
location

Once tl),' tap'" is finniy

3ll.1llu:d ttl 'h~l"3binl'l. gt."lIl1y

t't"lltnV,'" OIl' llingl' pin and lht'

door. The carpel

a.

Iv!" (I("rp.
Then I widened UIC
op<'ning of the hole

I3bl~ saw. 1 CUI Ibe

slol in th~workpiece
~li" d ....
cp and It,,"

well tighlening the thumbscrews, like those that lock a

fence in place on the back of
the radial am' saw tabl....

3'2"

graill.

the wrench with a router and a Here's another Wlly doublesided carpet tape can be used
V4' round-over bit.
This wrench lighten" %" and around the shop. I use il I" h('lp
smaller wing nuts, IIal", work" accurately aliR'" and attach

NeKt. I bored a 31$'.

diamcler
hol~'
ccnlcr(.~d ill Itl(~('lId

with a c()untersink
bi~...., ~ig.lao
Ne)..l. usillg lh~

[Joyl,m.OMo

To use the pin punch, insert il

WING NUT WRENCH

wrench, J cut scme

:It,,"lhick ~lotk3Y'.!:'"
SCluart'. src fjg. 1.

in the pre-drilled shank hole and

tap thepunc h to mark th~ center
ofdw pilol hole. sc.>Fill. ta.
H(f 1"""'11 S, 01 />")1

"
2

.).- Of., HOLE

hulds the
hinll" leaf securely in place for
pilot hole drilling and outlininl!
fur mortising.
TIlis ICdlOiquc can .lsCl be
used for tighl pin hinge, Nler
pr(~SSiingfinnly on Ihl':' hinge 10'
cation. very C:lI\'fully open Ihe
cloorand $llPPUrt it whi)(\ YOll attach the hiD~C10 Ihe cabinet.
tap"

Jo/", lI'e./",k
11tJulrfi r. (""/ortltln

\XloodstUtth

~J~U_S~T
__F~O_R~_K~l~D_~~S

~ ..

Toy Box
How do you get kids to puc tlleir toys in a to)' box! Make it look
like a roy itself. This one is large enough to hold plenty of toys, yet it has a
false bottom that adjusts so that even tile smallest kids can reach inside.

hiSIO)"box looksso much like ala),. il mighl even

gel used, Apart Iromlooking like .101 of fun. we
tried 10design it with kids in mind. The lids arc SUi>
ported with slow-closing lid supports, so they won'I
slam on little fingers. Curious fingers will also find
rounded edges both inside and out. And, the bottom
rests on adjustable shelf supports so ilcan be raised far
even the shortest arms 10 reach the bouom,
CONSTRCcnOI(. The construction of the box is
fairlysimple. We used maple plywood lor the sides and
added solid maple strips "llhe comers SOwe could
round them over. The front and back have mitered
frames with a large glued-on letter and Dumber.
(WIIO</Rmill,Projec: Supplie8 is offering full-sizepat-

rernstorthe lettersand numbersand acomplete hardware kit for the lOy box. see $oU",.,5, P38<,31.)
HARI)WARF.. There's actually more hardware on
this projt'Ct than meets the eye. The lids are auached
to the sides with piano hinges. and supported with
slow-closing lid supports. There's a false bottom that
restson adjustable shelf supports. And the real bouom
lspositioned toallewroom forcasters (so Mom or Dad
can roll the tov box to where the mess is),
nNISU, On~oftheadvanUlgCSofusingrnapleisth'l
it presents a good surface for painting. I pain led the
boxes with bright priRlarycolors, Afterthepaint dried.
I applied two coats of gloss poiyurelllane varnish 0''''''
the entire toy box 10 protect the paint from chipping.

WoodSOlnh

No,71

EXPLODED VIEW
OVERALL DIMENSIONS:

Q).,_

PULL STRIP

22" W x 22" H x 22" ()

END
CAP

LID
PANEL

-@

EDGII'IG
S11IIP

cb

PIANO

HINGE
STRIP

H~NG(

LEVELING
PAD

__.,-r

@
SIDE
PANEL

FRAME

pes,

@
BonOM

LETTER

EDGING
STRIP

(I." MASONIt)

CASTI'

END PANEL

CUnlNG DIAGRAM

MATERIALS
WOOD PARTS

SUPPUES

A Sldef'onel; (2) >,,, piy. 211>' re x2Qv..

8 End_<2> "'4PY
x 2lV;
C Edg Sin". (4)

D Bottom(l)

20'>,.

'1',. 'If,K 22

ol<.ply2P, x \9},

E FromePcs (8) ",.2,24rg"

f FoIse81m.(I) ""plY.I~.xZl'/4
G UdPooe4 (2) l. ply.~.x 16"-',
H EndCeps(4) ~."l.8'Ir.
I HngeStr1ps(?) 'bXlt,,-2Qlt4
J PIJII Strrpsl2)
'. x 2 Zl~,
K Lav Pods(2)
x h -2

No,71

0, }.

~.9 Boord FI 01'Ir" 4~K mople.

'$1100' ~~'lhlCkmopleplywood
(2pes ).,,' Mosonile 10' x 16'
o

1 Qt. 010$$ polyurethane 1ImI$I1

While enamel speov potrIJ
(2 colors) Enomel sproY po",1
(2) H nges I' .,' x Zllf,'w/scraws
(2) Ud $UppOflS

I~' FrnrSI'InoiIS
(~)Sheorockets

L :
~ ... )C

r::::"

oS 4&10 (1.7 ad. fl.,

Ef

:1

If

jI/.~

E :-3

:t

ALSOUQUlRII),
I SHE.fTC4' .. 81) Of

~.~m(l.

(4) 2' Casters

WooJ;mnh

3 ....

PlYWOOD

4'}OfI." MASONrrt

THE BOX
all four panels. TQ trim the panels to widlh. str.lighl routerbitro cunhcse grooves. (You
pla<'Cthe hardwood edging strip (Cl ur each could use 3 table sawand an adjustable dado
blank against the table saw rip Ienc e and cut blad e set to the thickness of the plywood.)
Ct T ms JIi\IlIU.T. Next. 10 join the end
each panel to. finished width of211fIG". see
panels to the side panels. rout 4"v.ide by
BLANKS.To make second step in Fig. I.
After the panels have been CUI to the same V!-dee p rabbets on the i""ide faces of both
the side panels (A)
and end panels (B) width, the next step is to cut them to length. side panels (A). see Mil. 30.
H(lIT()M. \\1th the side and end paO<.'I~
stan by ('ulting four Start by "utung Ihe side panels (A) to a
blanks of :v."lhlck finished length of WVj". see Fig. 2. Ne~t. complete. the next step is to make the bolo
plywood to a roughwidth uf2'l" and a rough since the end panel,; (R) will sit in v2"-deep tom (D). To determine the size of the botrabbets. cut thcm I" longer than the siele tom. dry clamp tile side and end panels tolength 0(22", see Fi,l(. I.
FJ)(;tN(; STRtPS. To hid. tile edges of tilc panels (2H~")._
Fig. 2.
lIether and measure the inside width and
plywood and allow (or routing a rounded
GK()()\'f:S. Once the <ide and end panels kngth N~xt. add '1'," 10 each dimension so
edge later, Iglul'd :Vi" ~ :l<." hardwood l'dg. have been trimmed to size, the next stel) i...Ih~ botton, will fit into the :WO-d eeepgrooves
ing 10one edge of each pl)'Wood panel. Cul 10cut a groove in each piece to accept the in the panels. The bottom can now be CUt
the todWn!!strips (C) 10 a finished length of bouom of Ihe to), box. Before cutting the from a piece of ",."thick plywood (min"
22" and glue them flush along one edge of grooves. take a minute to oriem the pieces, mc.~~TC'd21V4"x ~").
1SSE.'IRl.l.Begin assembly bygluing one
each blank, see FIg. I. Keep the ends 01tilt.' see ["plodro view, page 7. On the side
end
panel (B) into tile rabbets of the side
panels
(1\).
theedging
stripison
the
botto:
blank and the ends of the strip flush.
1l!tMot,\NH!;. Once the edging strips are On the end panels (B).lhe stripis locatedon panel. (A) to form a U"hapcd subasserubly.
Sh' Fig.4. ;-.Iext.slide in the bouom (D) and
I!lue-dto the blanks, the side and end panels top to hide the exposed plywood edge.
The :y."-deep grOGves are located on tll(' secure the end panel to the sides with IV!"
can be trimmed u) their finished size. The
width of the side and end panels (which is jmntl. fac~",of the panels. I~" up from the finishins: nails see Fig. 40. Finally. glue.
actcallvthe heighIO(th~ box) is the same on bottom edges. see Fig. za, I used a :Y." damp. and nail the ether end panel in place,
Ibegan buil<Ungthe
toy box by making
the four sideand end
panels.

,.J

.,-

....

61

@@

TllM
lliIS

"""

SIDE/END
BLANK

'2'

NOTE:

...
t

1MAK.olntl

...

2r

,.

....

.,.

W10TMOF-,'

(a.

tom fNDS

,_

@f

SID
PANEl.

_ SIDE
PANn.

SIDE
PANEL

ENO_
PANn

CROSS SECTION

'11."

SlOf

PAl<Il...,,';'!."""''''''''4~t..

$40'

\OIpANR

',-

'.-

END
PANEL

4
'"

a.

SECOND:
(UT AU. fOUR

STRIP

20'4"

.... lDGING U9

BlANKS 10 RNtSHEO

@EDGING

ltAean

,r:

GLUE ' .... 3-....

OWOOO lDGING

I ST~IPSTO All roUR

PlYWOOD $tANkS

FIRST:

NAIL wrtH 1T'1flNJSH NAIlS

_.1_

-"
BOTTOM

END
PANEL

CIM\P

ACROSS
ENOPANR

....

19~
.."

@
2.1 ."

SUOfItl

BOlTOM

aonOM
'[FOU
/lnActUNG

cmGtNOt'ANR

Woodsmirh

No. il

FRAMES
Onee you've assembled the box.

-~....._
_

FRAME
PIECES

work can begin on

fRAMES ARE 1.1",AIOVt PANEL

the fram e s , The

frames Ili(I(' l)ll~('X~
posed plywood rabbel joints and give

Ihe tov box its building block look.

cvr ~1!A."PIECES. Stan by ripping eight
frame pieces (E) 10 a fillish~d widlll of 2"
and a rough length of 24" Nexl. mil"r thee-nds of the f",rnes so their finished ICIIJ(lh

'

__

Oong ...point to Iong-polnt) equals the dis-

tance a,'m,;" on. end of Ille box. see Fig. 5.

(In my rase this mea.sured 22".) Note: The
lop and side frame pieces will extend 1!Vls"
above Uw end panels (n) so they'll he nush
with the lOp. of 1111' lids once Ihey'ro in81.11."11. r"fcr 10Fig. 18.
...''IT.\CI-i mUtES. After the frames have
be-enmitered to size.theyean be glued to the
ends of Ih,box. Startby Rillingand c1arnpillll
011('

frame piece i1u~l\ to 111<'- bottom uf the

ON.

U'

PAHll

.~
t
NOTE:AU
fRAMi PllelS 2- WlDt.

G\.Ut
BOTTOM
fJtA.M( PIKE

..,..

CUT LLNGTK TO MATCH

..OUT ) ...
ROUNl)o()vtR
ON IOno", Of' ~n[S

'LUSH WITH
80fTPMOF'OX

WlDTM OF BOX

fig. 6.1did thiswith 3 routerand a," roundover bit, (ror more on litis technique. "'-'C
Shop ;\"(lIe~on page 16.) Then. ( USI'd the
same bi! co round over the bottom edges of
Ill. sides, see Fig. Iiand also page 16.

Shop 1"ole: I chose Ill" =II,. round-over bil

frame'S. sc....Fig. 7.111b shoulde'r provides a

crisp edge for masking and I.. inling 11t<
faces of the frames laler.
To rout the decorative edA"~.adjust the
router bil SOil JUSt c1e.ar~the surface of the
end panel (6). see fig. 7. When routing the

box. set' Fig. 5. NexI.glue two upright fr.<rnc because it provides a smooth transition be- inside ed$!e of the frames, move the router in
pieces flush with each side panel Finally. t"'(>ellIh. hardwood edging Slrips and th. a clockwise direction, On the outside edues

I(lu~ Ill,' IIIP fnllJw pieces ill plat ... (I used

C-clamps to hold these.)
ROt Nil OVER EDGES. After the frame
pieces art' glued on.fhe n...xt.tep is 10rout a
radius Ulllh.IOp corners of each frdllle. see

',IlOUN[)"
OV[R.

"""",
P~fct

/.

a,r

O'T'

ADJU5' In
so ffCUAAS

<,

ttOUTINNtR
ANOOUfEk
lOGE OF fltAM

ROUT ClOCKWISf
ON tNNER fOG[

J.. ntt suarAC{

Of'TH'
1'(-1 END PANR

CoL-_

";s_/
,

III

Illywood.lfyou don'l have this biroyou could c,( the frames, move the router in a counteruse a V[" round-over bit.
r1ockwiSt' din'Ction. 5>'<.' Fig. S. Shop NOI~:
IlECOllAn\'F .. 1)(;". After llle!!4" radius is To help keep lh~ rooter fnlOllifJpinginto the
routed, rout a ],1.'\ round-over with ashoulder
panel, Iplaced a :V~"-thicktemporary spacer
un lit. inside and outside edges of the inside 111<'
frame, St'(' !.;g. ~.

SlOt:

use ):." STock:

PANn

TO Ktf, Aouna
eA$( LlV'U.

tNOPANn-

.A

Dr
.3

ROUT COONlUClOCKWiS'

ON OUTfit lOGE

FALSE BOnOM
A ralsebouomcan beadded to make the toy,
accessible {orsmaller children,

The size nf II,,, false bottom

(I')

can be

determined after the box isassembled. Start

by measuring the inside dimensions, >i('t
rig. 9.Then <ublrdctlt," (for the shelfbrackcis) from the width and kngth and cut the
bouom (mine measured I~,"
x 20V,")
Nt!X1.so you ClUJ pull oul the bouom, drill a
l' finger hole, centcn'd 2" from ane t'<lg.

..-

an' dnlk"ll inlO Ill!: inside 61(c (If'l,rh o:nd

pan.1 Ill). see rig'. 10.

No. 71

==-

-...;:

USfRMPUyt

to OIUU.SttlU

20' ...

e!l-,,~

StlEIF 8RACf(]';r.;. '11.... false bonom rt'SL<

On t-shaped shelf brackets. TIlt'se bra<'kcts

are mounted ina seriesor rout v," hol~sIllal

- (,NO PAN[L

FALSE

BOTTOM

l_~~;;:j~~
'" fJNGtR
HOlE

lItACK", HOW

"~

;.,
l

ORllJ. ....

.)... O(P

."

HOlES

'"

~
SHILl'

....am

.............

((

THE LIDS
each other, sec Fig. 12,Then, mark the cenlid. which open up ter of the lid and layout a 3" diameter-circle.
from the center, Next. cut out each half<:ircleand then sand
Each lidconsiSlSof a the-edges smooth, set' FIR. 13.
plywood
panel
IIING STRIP', Wilh the pull strips
edged wilh hard- complete.the next step is 10round over the
wood. sec Fig. II
hinge strips (0 to match the radius on the
LID PAJIoEI.!>,
I comers of the frames, see Fig. 13, Hrr~
began the lids by
[1"'1 delcrnlining the size of the plywood lid
panels (G). To determine the length of the 11
panels. sian by measuring the 1Ilsit/; dislance between th<'two mitered end frames,
Then. subtract V~"
forclearance and l~" for
the two V~wideend caps (H), (1nmy case
the panels were ISl'4" long, S('(' Fog. 11.)
To determine the width of the lid panels.
measure between the (>ILlsuir [:let'S of the
side panels (mine measured 2'~")."0'0\. subtract a 10131ofS'>\/, (4 , (nr two pull strips a),
I "'i' (or two hinw strip> CI). and !-It" for the
center RaP between the lids). Then, divide
this measurement in h:t1f1Dgrllhp width of
each panel (in myca>e.S:~IG"wide). Nowcut
the IWO panels 10 size, see ~1J!,II.
WGING STRIps' TI,e edging strips that
surround the lid panels hide the plywood
NOTt:
,
edges, Iripp<'iI a1IU,e hardwu(ld strips to the
use .1.".. 1.... Sf'O(k
same thickness as tbe plywood &,,"). Then,
FOR H[Nell $TRJP$
cut (OUf end caps (H) to a 6nished width of
A,ND END CAP PlKU
"'." and a rough length of 9" Next. cut two
hinge strips (1) to 3 finished width of :v,"
and a rough length of 21". And finally. cut
Ct.A.~UDS
two pull Strips (J) to a finished width 0(2" 12
TOGfH[R
and a rough lengtl\ of21".
,\ssEMllL \ ,Aflorcullinglhe pieces 10 size.
glue the end caps (1-0ontothcendsofthe lid
panels (G). see Fig, II Once the glue is dr).
trim lhe end caps flush with the "d,Res"f the
plywood. Next, glue th, hinge strips (l) and
pull strips aJ 0010 each lid panel. see ~ig. 11
Then, after the glue dries, trim the strips
flush with the outside edge of the end caps,
The

lOY box

has IWo

IL\i.~DL PliU- The next step is It) CUl a

again. I used Ihe:Y." round-over bit,

SOFrF_' EDGES. Aller rounding OVer the
hinge mrips, I removed the sharp edges on

the lids, T~ do thb. use a 1,1," round-over bit

10 sofien the hand hote in Ute pull strips a).
see Fill. 13. I also rounded over the boUOIl1
Insid~ edges of each tid (except for the botlorn of the hingt strips). SC(' Fig. 13,

PUll n.
STRIP<V/

STRtKE43"
OtAMmR CIRClE

ENO

CAP

_20'."

'cD

HINGE
STRIP

13

A'"

ttOUJ
II<XINJ).()VDl
ON J09 $UVAQ
Of HlNGl STaW

cut our

HAND~

<D

NOTt:

hand bole in the pull strips so kids can open

the lids easily. Clamp ihe lids together with
the ends flush and the pull strips 0) facing

OONOT~NO

OvtalOlIOM
toot Of: HtNGf SntlP

lOUT ~~..
ROUND'()VUt

ON aonOM too(S
ANO HANO HOlE

LEnER & NUMBER

After the lids are complete. the n,'xt SICP is
to CUI oul Ow letter and number that an:
J!lued onto the end panels,
1RA:''SI'ERI',\1TER:\. Stan byenlargingth(
desired pauerns.se ....Exploded \r,ew. page 7.
NeXI. transfer both patterns onto V,thick
Masonite. (I chose Masonite because the
edges lear less than plywood.) I used 3~l's
Sproy Mouni 10 glue the enlarged pattern
directly onto the Mas<>nlle.see fj~.14.

14

15

Ct'T Ot7 l.ETI'ERANO NUlIIIlER. Next. I

used a sabre saw 10 CUI out the letter and

number and then sanded any rough lodges
smooth, see !-ig.15.

10

OWE lT"ItR TO

16".16- PileI
OF- t_." MASONITE

\V""dsnuth

WT OUl e.rnt~ AND

RrMOVI: 'APEA PATTUN

SANOlOG(S
SMOOTH

No,71

FINISH
Before I glued the letter and number 10 the

and the tcucr er number with a bright color.

end panels. I applied a finish 10the loy box. Before the paint can be applied to the face o(
To achieve the took of a kid'sbuilding block. the frames. the edges of the frames must be
the end panels and the (aces o( the frame> masked 0[. see Fig. 16.,. To do Ihis, run a
arc painted.see Fig. 16.
strip of masking tape around the molded
MASK'S!:. 8<'(0"' the end panels can be edges of the frames. Then, mask off the end
painted. the loy box must. be masked 0[.
and side panels. Once this is done. paint ihe
SIan by masking off each end panel (B) raised (ace o( each frame and the leuer or
where the lellcror number will be located In number wah the samecolor, 0 used red and
provide an unfinished surface m glue to. To
do this, center a letter or number on each 16
WHITt
BACKGROUN.D
endpaneland trace [ighllylltt>lIodit, ><'" rrg.
MASKlDOU
17.Then. mask off a rough area within th~
traced outline,
Next, l rnasked off the edge>!'and (aCl'>' o(
the frame pieces, and covered th" rest o(llIe
box with newspaper.
PAJNT PA.'T.LS. After the panels are
masked off, paint can be applied. I sprayed
on IWO coats of white gloss enamel (rom an
aerosol can. After the second coat is dJ)'. remove the masking materials.
PAINT una
PAINT fRAME

blue gl~ss SI>'''Yenamel.)

ATTACH I-""ITER Al<ll mIMRER, 'Vith the
painling complete. remove all rhe masking
materials and lillie Ihe lencr and number
onto the end panels.
APPLY

po'.\'ultf;n."'~.~
Finally. apply IwO

coats of gloss polvurethane to the entire lOy

box (including tilt' painted _J. sanding
1i!(luJI'between the coats.

11

FIRST:

cumo

PAINTFIIA.'IESASDlETTERINUM"BE1!.nle
next SICPis to paint the (act'S orthc frames

"*

ANOFRAMtf-Ael $M\l COlOR

Lm'1'II

WfTHtN
~fANO

t1tAClwrrn
ptNCll

MASK ARtA UNDO:

lT1U. WORE PAJNTINGfAa

'ACIONlY

HARDWARE

The final step Is to attach the lids (with piano

hinges), the lid supports and the casters,
ISSTM.l.IIIN!:ES. Iscrewed piano hinJ(es
on the side panels (A) and then attached the
lids to the hlngcs.Start by Clltting the ) Vz"
wide piano hinges to fit each side panel and
screw them in place, see ~ig. 18. 0 used a
self-centering' hinge bit to drill the hinge
screw holes, SI.'C Talking Shop, page 24).
1.1-:\1-:l UDS. To make positioning of the
tids easier. I fil'$lleveled them nush with the
lOP of the lOybox, Since the lids siton hinges,
IWO leveling pads (K) are attached to the
lop edge of each end panel (B), see Fig. IS.
To do this. cut the pads the same thick
ness as the hinge knuckles (mine measured
r.-.lEVUNG
PAD

.N:/

!1'16"thick) and 2" lonll. Then. center the

pads on the end panelsand nail them in place
will. small brads. see Fig. lSa. Finally, appl)'
a C031of polyurethane (0 IIII' leveling pads.
ATt'M:H IJI)S. One. the pads are in pl:.ce.
the lids can be screwed 10 the hinges. To
mark the hinge screw hole lecatiens in the

IKSTAU. un SlIPPORTS. ()ore" tilt.. lids arr-

fastened. the lid $UpJXlnS can be installed.

The lid supports Ichow have three features

NOles. page 17. Position Ihe lids on Ilw

hinges SOthe sidl'-Io-side gaps and the gap
between the pull strips (J) are the same.
After the end holt' locations arc marked.
drill a pilol hole for each screw. Then. secure
each lit! with IWO No.4 x ~' woodscrews.
NexL driUthe remaining pilol holcswith the
hinge bit and install the rest of the screws.

lI.al I really like. 1~1'Sl,Ihey ease the lids

down slowly Second. thel"l'1! adjustable so
as kids gel older. the lids can close faster.
Third. the supports have a detent position
that "locks" thl' llds open. 1'0 install the sut>pan. I.)'nutthe hole locations on each lid
and end panel (B), S('(' Fig. 19. Then. drill
pilot holes (I used the hinge bit again) and
(asten the supports in place.
c;STAU.~TERS. Finally. 10make the (0)'
box (?"d~yto move around.] installed l-asters
on tile bouom (1), Atl.ach a caster 1V.l' in
from each inside corner. see fig. 20.

19

20

ends of each lid. 1used lccatorplns.seeShcp

',"

CASTER

uo

s('A.EW MING!

TO 'OX F1R.ST.
tMl:N 'OUO

..--HINGE

UYWNG

0,

PAD

-r
:r
f
fl."

THKKNtSS Of

2" ....
uvtuNC PAD MA1CH:ES
TH)Q(Nl$S 01 k:rNaE KNUCJ<U

No.71

3'

"

I' ,..
UI)

SUPPORT

aoTtOM

II

WEEKEND

.)

PROJECT

Hand Mirror
The trick co cucring me lOP of this mirror to a perfect circle
revolves around a silnple pivot /)in. Once )'OU know me secret, ie's an
eas~ weekencl project that makes a great gift.

hert! wert" a couple (If challenges in making' this the distance between lIw bit and the pin. you can rout
IWO conccnmc circles,
hand mirror. First. J had 10 IiRurea waytocunhe
Another chal"'ng~ (and Ihis nn~', optional) Is
outside lOp edge 10 u perfect circle. And then how 10
rout a circular recc.....
s for a roUI10 mirror,
carving rbe iniliAIon Ih. back. To 'carvo"lhe inirial l
The soleuon 10 both or these- problems is 10 use a used a router and straight bi!. and then textured the
pivot pm (In(1 3. router A~~
rOta[j'lg- the router around backgroundb)' h~
On page 15we'"" includedstepthe pin. you can rout perfl..:1 circles. Then, by vllryin~ by-step insrructions fur this procedure

PAnERN

".

>1

.11t"

~h'>;lTl' 11' thiR

,)fJ/./,...-t1 i...../fJr 0 f/1Jltt
"t led

7',.

".;"g

- POINT
3...

'0'
G.I-O

~ CENTER"
POINT

3'.".

lAYO,"

...

2),-1.".

"

-,,(1

fh ~Oit, Tlml ill, iI'" If} Ih' /tl'ld

ill til< ItJl lin i,d ,,'hiU

.
ST~'

--

)";'-)"0)'

0" right ),-r",ljrJl' 'ombing

I",.... rOO'd 'lifIluuuvd P"'"

"")', .U/ oot Il,.. pull!!,." /llld
flip';/OfI'YROIJ,. ho"dlrtut'1ls

ON >~. l)I"qlhf<f
tHICK

II/DU.

Wood.,llilli l'thjecl

IEVlLlOGlA$S
MIRROR Frrs HW

"OCK

SltP'

pli.~
i.(JJJ'I'I"jnglJ!"II'.iz~
pal,
~erJl(l-71d,all (/t'"r;lll-ll'ix <"/)1,(,,,,
/Jtll hilt""" lI8 II'CI1as tI,t Ii< t"
IIlcil1)/I''''I

1I1;(I'(}r. FOr il/QI'6

uiftJ/"I,utiOi"'-' ,"'frill.

11

W.,odSllllth

No.71

NEW ROUTER BASE PLATE

The first >t~pin making the hand mlrroriste
To locate the hoi,'" first mount a \1.1"
replace your muter base plate with a shop- siraighl bil in the rOllt~r. Drill one hoi,'
made plate.The newplate needs to be larger (labelled A) 31,1." from the outside edzc of
than the original so il can tw SC"I over a pivot the bit. see ~ig.I.This hole will be used to
pin. Then it's used lor routing lilt" circular guid~the router when rOlllinl((,"lIUingoul)
shape around tht:- top ()rtht~ hand mirror and 1)1(' cirrutaroutsideedge of the rnirrorblank.
recesses (or the gl~s mirror and carving.
1l,.\SE .'1.A".._1 cut the 11(."'\\ base ptnte from
1 (MAKE.......FROM
. t.4- Pt.fJltGLAS OR
a pic...." 01 v." f'ic"igl:c, (ur use Masonitv) tu
a width 016" and 7'#.' lonll. set' I'il!. I.
Now, center your router's original base
plate over the new pial<'and usc it as a tern)
platt' 10 locate the mounting holes and bit
hole. Then drill these holes and mOllnl the
plate to your router
\
(
PIVOT
HOUA
l'l\fel't umzs. N txt. drill t \.\'0 \lJ6"-dia.
holes (A and B) in the new base plate, " ...
I'ig. 1.111('5(>holes will fit over a pivot pin (17
gallg<'brad) that'sdriven imothewcrkpiece

Nnw drill. second hole (B) :WIn" !rum

the Ige "flh. bit. see Fig. I.This h"le will
be used when rouling the circular recess on
the fronl of the workpiece lor the beveled
glass mirror, and on the back 10 form a
border Ior the-carved initial.

E''iI!'''1!~....,i~(tIT 17
GAUGf JIl
t l''''l!''NO

lRAD

I,,

AeovE

SURFACE

ROUTING STEPS

Anerthe new base plate iscomple; e,you can the hole and into the plywood (or blank). lhen pivot th...muter around the circle until
U$(' this S(>I'IIPto cut out th~ lOPof the hand Then snipofithe brad \1.1" above the "lrf3'~. you reach the stop poim.
mirror and rout the recesses,
01 'r.iIOE EDGE. With the pivot pin in plac,.
RCp{'al this process, lowering the bit I,I~"
)IIRROR 8JA."iK. To make a hand mirror, you're ready to bt.'I.~nrouting. First, cui out (or Iess) berw ee n passse ' until th ... bit CUb
start b)'ct1t1inl(al-'."~hkk blank loa widlh (If the oUlside I'dge of Ihe mirror by making Ihrough the hlank.se -e I'll(. 3a.
71o'!"and length of 13", sec the !'al-m on the repeat passes with the router and a 1 s"
1{01T )IIRROR R,:CE$. Next. to rout lilt'
o,)(lOsit, page Then la), out the pauern on slraighl bit, see ~ig. ~.$ince you don't want recesstorrhe mirror, reset the bit ~'It;"(Jeep.
the blank.
IIIrout acompletecirrle (or you would CUloil and ", .. ition thentherpivct hule (In overth v
brad. \[0\\' rout a r(JlitIJ[~'/t~
cirrk-, sec Fig. 4.
<.( where the circle turns in .J the baoc.IIl'.
(This will rout .. groove !-<-ligll(i)'larger in
:-/''''1, S<'Ithe bil 1,1." deep and drop Ihl" diameter than the gla~ mirror 10 allow (or
base plate hole that's farthest from Ih" bit wood movemem.)
(1101l A) over the pivot pin. Then, tip the
CUlA>; 01 TW ",T, After tlu- perimeter of
router at a slighl angle SOthe bit is directly tile recess was routed. Ireset tilt' router to
nver the start point and lurn on thl'" roUlt'r. t/1't dt'e"p and ~nlf)vt!dtht l)ivOl pin. TIle" I
I'(:(ortuI~g.2. (1"ot...: Ifyou're u:;jllg a plunl(e 4.)c.ule<1 Oul Lllf! ' ..a~ll
(rt-'t'hund. SCc l-;'jg. 5.
rout(t. you , ...onl have to tip th(!' router.)
(Ibis trt'at,>;; a 1I16"-<le('I)
lrough lor glue
"0". slowly plunge the bil iroo Ihe blank. S(j1lC'C2I'<lUI. S('C Fig.Sa)

To kt"Vll therouterbit from CUlling into 111)' the handle). mark start and SIOI' points short

bench when routing all the way through the

blank I scrc"('n the blank (in the waste 5('('.

lion) 10 a pi{Cf.,(plywoodand thcnclamped
the pl),,ood to the bench. sec Fig. 3.
11)"(Yr PIS. N~Xl.driU .1 \116" hole {or the
pivot pin nlllheWllY Ihrough Ihe blank allhe
cenlerpoint olthe eirek. (IIyou aren'tguing
10 carve the back. drill the hol<' onl)' ~s"
deep.)
3 17 gauge brad through

3
I

/'a

a.

t.

I
MJR~OR,lANK

SKOND CUT
DtF'N(S PRIMntR
Of MfsutOR RECESS

FlRST

-.. J

atT--

cur

T1!OUGH

PLYWOOD !lASE

No.71

I,

$1RA1GHT

fOil GlUE

WooJ,nllth

13

FINISHING

.>

THE MIRROR

After the recess for the bevele.! glass mirror

is cleaned Gut.YOU can cut the blank to finn!
<hap e, But first. r roun-d a decerative
chamfer around the (>d.t!e01 the recess,
CHA.\ll'ER. To rout tlte chamfer. r used the
same technique as before (routing with a
pivot pin). see Fig. 6. 10 do Ill;'. drive the
brad back inw the hule in the center of 111<'

POSmoN HOl. rN lASt

PLAit ovtR PlVOl ParNT

a.

mirror 1"C("eSS.
Then mount a Vgroovc bit in the router

and lower the bit to cut V." deep, see Fig. Ga.
(You can't usc a chamfering bit with a bearing since the bearing WOn'1 clear the bouom
ofllte reces s,) Next, pesition the router base
SO the hole c10Sl'St to the bit (Pivol hoie B)
sets over the pivot pin.
Now tum on the router and plunge the bit
inlo lite workpiece. Then rotate therouter in
a counterclockwise direction, 'ntis should
rout a chamfer around thereeesswith a race
that's Yil" wide.
Aiter the chamfer is routed. th e blank can
be removed Cromthe plywood. (Note: Uyou
plan on carving the initial on the back side.
tum the blank over and rout the p(>rimcl(>rof
the carving 8t this time with a slnlight biL
St.... the ~t~b)''';(cp instructions for carving
on the opposite page.)
cur m SIW'F_ Once all of the routing is
complete. the handle can be CUI LOshape On
the band saw. set' FIJl.7.1 slatted by cutting
aboutl!ts" outside the L'YOUI tine.
SAN'!' TO FI~J\t SI-IArat.. Nt">:t. mount it
sanding drum in the drill press and sand up
to the outline onhe handle. see Fig. 8. Don't
sand the circular (top) part of the mirror or
YOU may goUlJcit out o! round.Just sand so
tbere'sasmooth transition between ~te mir

WORK IN

COUN'ltllC,OCI<W1Sf

IlfMOVE fROM

PI.'rWOOO

9
I

t.---------...

"OUT IUUHOst WT1li

I..," ROOHD-OVER lIT

(a.

I~'

ROUNOOvtR

on

(tNllR a.tV'tllO

10
,

GLASS
MJRRCHltN
JlfClSS

a.
,rvlL(O
SHOUlD.'

Gt.ASS MIA.OR
1ttaSSIO $UGHTl'l"

~UNIFORM GAP ~u.

AAOUNO (DOE Of MIRROR

Glut

into the center of the recessed area and

MJRROR DOWN

WITH THIN 8I:,AD

Of $lUCONl $(A\.Am

press il down firmly Into the silicone sealant.

see ~jg.lOa.

14

"

ror circle and the handle. see Fig. Sa.

III u..'OS~ ruG':. Alter the handle was

sanded to final shape. I TOUlt'd3Wil bullnose
profile all the way around Ute entire piece,
see Fig. 9.To do this, mounra ~" round-over
bit in the router table and set itlYIS"above the
table, sec Fog.93.
Then rout both the-top and bouom edges
of the mirror. Ailer routing. lighlly hand
sand the edge 10 remove the Rat spot at the
center. but don't round over the edges.
Here, you wam a crisp line.
FINISII. Before rnountinz the beveled
gtass mirror. Ifinish<d the wood with three
coats of lung oil. Do nat apply finish to the
recessed area where the beveled 111= mirror will be mounted.
GLUE IN ltJRROR. Noll' the beveled gl.",
mirror can be glul-d in place. I used Dow
Silicone Sealaatand applied athin bead onto
the recess. see Fig. 10. (Silicone sealant is
elastic and win allowthewood 10expand and
contract with changes in humidity.)
Finally, position lite beveled gla5s mirror

'-

OU'(lCl'ION

\Voodsmilh

ROUTER

TECHNI

U E

Routing Letters
C

arving an initial on the backof'the rnir- fir.t drnw a centerline down the back of the
rormakes ita morepersonal !tift-yet
mirror through the pivot pin. Next. press the
the carving isn't 311that difficult. In the centerpoint of the leiter pauern down over
steps below, l'vc done almost the whole the pivot pin.Then, align lite centerlines on
job with a router,
the pattern and the mirror back. Now the
Full-size patterns of the INters ai ihe bOI pattern is in position to be glued down.
tom of the paxe are available from
~"'PPtJSG. To enhance the letter. I
Wood.'m,II, Project i'.lfJlp/;eo. see "age 31. stippled ordoued the background with" nail
They come printed with a centerline and set. sec photo. I found that by firmly tapping
centerpoint. so t)1I,y'rc ea$}' to aliRn.
a~" nail set.I created a very tlifferent look
L'!TER AlJGNM""'T. To align Ihe leller, than Ij!t)( from lightly tapping a Itll{' nail set.

So Iry a cUllpl~diffe1"('nlCOmbinationsof nail

set

si1"'~ and

depths on a scrap piece to SL'<!

whichyou like best. Thetrickto agcod back-

ground Is uniform dot placement and depth.

lOUT IN COUNTtR:

CLOC1(WISe OUtKTKm

perimrtrr
1 7'0initio], SCI"'"

of tt t"l'rf'1fAjilr(111
bllll/}; /V ply"""",
IlltYIl,r .~;.(/e
doen. R01~fa ~'/n:"d.rep rii'('(~ by
s(fling 1';''01/1011 "IJ" OIl 'he1'11'011';>1.

Alia" flill~rfXIllpnl in
",II, 2 lililil r"bber ce'~le'~lor Hllmy

1'011t

cj,'t:'J(lQ)ldulll(,

t'lllllf!'

bit, " m,ll,rrn uri

3 .\10/1,tl
eet ~',.' d.,,,. ;IInkr n fYl'r"nlld 1>11$$
outsid
a" lu letter. a.~
n 1/.<1- J(t ;"{lTyl,1

sire. Cut a."Ull"d outsid,.dg" of'thl~tl;lr

Ol'OI17fdt Ilf

'''ilII" "11017'ktlif . Discard bad(gTQu>td.

rlusc

(til!

ty/glf
Cflt
pD.'{slbtl' 'fYi/I,IJld tlJl1"/I,ng flU! lrft(r.

USE EVEN
PUSSURt

-_ ~---H'~'lr11,111sa"le 1/.... ,'OI,If!r

pt" I off let/t;I" IXftt.trJt.
1)lu911;,vJl pill hlJlp "Iitll ~/ir'eY'fro)"t'dt" of
billllk . .4 'W $<lIId reee...xed "' ...'" levfl.

4 ')il..

Rf'11101"

11 ntl /Jt(')!

s.....
"
ofllLe letter. To
Final!, stipple
1/", tne bur};.
5
do
II,,,edg<l8
side a/I'" lIa.l.e! at
6
grt"t
"g -Y.,.~~
)lui'
/1# i!lllt ul/Ute a nd .."btlle.It"I'I' rdg", a/,hr
Holel/lle Ilail.C"I ..
80}lflllhe

letter IInl.1 IhEu'ro,roul/tWd.

f:r q:J{
Q9(S -t u

fll13 C'])

'l\L 0 P
No. 71

1)1'

tili.'./II)W

\'ih)(1(ismnh

1(,1. It~l

sel.
1(ltlll

ft

or ~l/lnIJ~T

/>rightll)fd Inpjirmly

(l

hammer.

I J 1( 9v[
0/ 'W X Y z
15

SOME

TIP

FRO

OUR

S HOP

Shop Notes

ROUTING A CORNER RADIUS

As I was making the To), 130x
(HtPOUT PROBLMS. Since
shown on page 6.1 had to rout a the round-over bit (in this casea
large radius on the comers of 1=:"1" bill terms iheradiusby
each side lrame. Ordinarily you culling ONYI"" the corner ('30 usea band S;.1.W.sabre-saw, or
rather than " 'I'1>tlll(1 lh(l corner
a rasp to rough cut the radius. - there's a tendency (or the
wood 10 splh away on the
and rhen sand it 'moath.
1.)0inl( this freehand workS ouueed side of the workpiece.
fine when you only need 10 Bunhere'sa way to prevent this,
radius a couple ul corners, But and also 10 keep the router (rom
(or the To), Box, I wanted to tipping on the 1,lgc of the frame.
mdiu. all (our corners of both
SCRAP~IND\\1Cn. "lne trick
framcs-s- tight radius cuts alto- involves sandwichin.~ (he workgetlwr. And. since I WUl'1,'d the piece between IwO pieces of
radius to be a perfect arc. I de- scrap, S<.'<' Fig. 1.The router will
cided to make them using a still produce chipout. bUIon the
round-over bit in the router,
SCr-dP pieces, nouhe workpiece.

Shop Note: To rOUIthe radius

router can ride along the bottom

edge of the side piece, bUL still
replacement base oj 114" M. needs support te) avoid tiPI)inll.
sonite for the router. (~1oSt So Ifil a scrap piece in the recess
router bases aren 0, pre-drille-d 10 01the bottom. >1(", Fig. 2.
accept a 1'4" round-over bh.)
To avoid t.he problem of
Tl/P~'R,\MEtOIlo~~,
To rout cbipout. first back-rout the
the radius on the lOp corners of ourleed side. This involves
the frames. first clamp two making the first router pass
square-cornered pieces of scrap across the Iinal inch or two ojthe
across 111~corner, !I<.'C Fig. I. ounccd (rij:!hLhand) end in a
Then rmu the radius in sev ....J right-to-left motion. see Fig. 2a.
Hglll passes. lowering the bit 111cn. when the router is fed
across the workpiece in the
slightly between P3"""".
1l(l1'T()~1
COR.'(ERS.I routed proper direction OcfHo-righl).it
the bouom comers next, bUIdid won't split a chunk off the frame
. fro m ..._
"'J
them a liltlediffcrcmly .Here the asn. esns
tne cut.see+ig.....
on the Toy Box. I first made a

lOp ......

~.ono".

Cl,AMp SCRAP PiECE

ONlOlHSIO[S
Of flWo\E

I
I

I------~~

SCRAP PIECE

AOUT~ROM

ftACk ROUT ONE

lEFT TO IUGMT IN

TO tWO INCK5
iN fROM [ND

S'(V[RAl PASSU

PHOTOCOPY TRANSFER
'Vile!) hearne tin It" tocarve tile
tid for the Music Box. I wanted

COP)', which puts more toner on

to make a few practice designs.

bull didn'twant roredrawthem.

this tech-

the paper.
HO\\

ro. To use

-lque. set the iron on it's highest

llEAT TRAl\SFER. Then I r.... setting and 13Jll' the photocopy
membered a tip that appeared in fate down on the workpiece,
Then, "iron" the back of the
Il'uoditmilil No. 45 in"olving the
use of an iron to transfer a pat- photocopy unttl some of the
tern from a phetocopy. The loner releases (rom the paper.
secret is the tl'Jl(' oftaner phOIONote: This tC<'hniqul'will procopiers use- it's heat sensitive. duce a mirror image. For an exBy reapplying heal some 01 the planalion o( how LO gel a nontonertransfers to theworkpiece. mirrored image (such as for IN
I found it best to make a dark ters). see l\'"od.,milll No. 47.

[6

TAPE PHOlO(OP't
0' PAntRN IN PlACL

SUlReN
ON HlGHlSl
KEATStmNG

-\ ~

APPLY HUlT
.....__,__UNlllOUJUNE

IS TRANSft lD

No.71


IRONING VENEER
Wh,'n nl3h"ing the Musk Box
shown on pag~ 18, I wanted to
dress-up Ihe lid with ~ piece 01
walnut burl \'CI1('('r.

PRORIMS. Applyinll veneers

can be a tlme-eunsuming
process, 1'111'1, ~incethv veneer
is seldom Oat, it has to be Oat
tened before you can usc lt.This
part of the process alone can

take several days.

}\Jso. once thp. veneer is Ral,

it'sglu<>d down and held in place

with a veneerpressuntllthe glue
dries. But. because very little air

the gluc to dry. I came upwith a steam setting is turned off. Note:
technique ror Sj)t.'ftiing up th~ To keep (rom gettinl(l:lu~ un the
drying lime -I used an electric base olthc iron. you may want I"
cover il with aluminum Joil.
clothes iron.
The iron provides a S01.lfCeof
While the iron is wamlin..: un,
heal thaI causes Ole water ill the cut Ihe veneer so it', slightly
larger man 111eworkpiece, Then
glue 10 evaporate qukkly.
IRON. Before appl)'ing the apl'l)' glue LO the workpiece. (I
veneer. turn the iron to a me- use yellow woodworklng glup.)
dium heal settillll (about "cot- Use just enough glue LU "butter"
ton' On my iron). The iton J use the surface, so Ih" grain ~1I('m
is an older model thai doesn't baretyshowsthrough,
have any steam holes in the botTACK0)<1; COR"'.)!. Once the
tom. If you have a newer ,"od~1 glue is applied, alltllnl.lcit
with steam holes. make sure the irnn down theveneer, )'0 do thi....

i""

stan by placing the veneer on

the glut.>dworkpiece. see Fig. I

10 keep the veneer from
moving. I ptaee the iron over one
comer untilt he veneer slays DUI.
Now, with th~ corner "tacked
down." move lb~\iron slowly
back and lonh across the piece
until the glue i.set
""Ie: IA'avingtheircmin plac..,
may eause tlu-veneer to bunt.
finally. Dip the workpiece
over and. u~jnR a sharp knife,
trim th" venver flush with Ill<'

Then.

sides, set: I~!(.2.

cal) ~tto the glue when it's in

the press. it may take ~4 hours

(or the glu~ ludry complc1<'ly.
PAPERRACKED\'El<E~'R.To

KtEP,ftON

CUfvtNt1t

MOVf~oa:

lARGER THAN

VU4(J1
MAYIURN

speed up th,' PI'<XeS$, I took a

WORKPf(CE

couple or short cuts. Fin;l. Iused

a ~I)('r-back.>dn,'xjbl~ veneer,
This type or veneer requires no
flalt~ning. That's because 111(>

veneer is lannnated to a sheet ur

paper which keeps the veneer
Oatand intact,
CU'",C; O~ \'El<f.Ftt. Since I
didn't want tn ""ail 24 haunt (or

.
PI.OltCf
IAS[W1TH
AWMQIIUM fOG.

-X'ACTOOR

APPLY fYIN

COAT OF 'YtLl.OW....... ....._

OTttE1l SHAap
XNlfl

1/

GlUII TO WOlUCl!tt

LOCATOR PINS
.1 came across acommon prob10mwhile Iw~3naching the lids
10 the roy Box case. I had al
ready mounted the binges onto
the cast.' and needed to pre-drill
and screw thelids to the hinws.

TIle probk-m is fUUcan't mark

the hinge hole locations on thc ling offmost of the threads on a

lid once the lid b set in position. couple of extra hiogt screws,
Ineededa way 10locate the exact Then. I ftled the cut ends of 01<
center or Ihe hinlle holes on th, screws to a fine point. S('(' Fig. I.
lids without opening' them up,
t SL"CTIlEPINS.To use tbe lo,\IAI)~ FKOM SCREWS.To do cater pins. place on,' pin in the
this, I madelocator pins by cut- end holes of the hing(' and do,",

the hinge flap, see Fig. 2. Next.

Il<,,,itionthe lid on the case and
press down so the pins leave im-

pressions on the inside or the

lids. Then. open up the lid, remove the locator pins, and drill
the pilot holes.

2
fiRST:
POstT'ION
LID

All

wooo-rAC.O

\I1Sf

Nil. 71

SECOND:
PRESS UD
DOWN TO
MAK[
IMPRlS510N

17

W__E_E
__K_E__N_D

r-

~4I

P_R__O~J~E_C_T

Music Box
You have to plan ahead, even on a small box like chis. The sides are 1'ouced to
shape first. Then you can try your hand at two different styles for the lid.

he real reason I wanted to build thls

music box wasto experiment with two
techniques 1seldom get the chance to tryworking with veneer and chip carving. It was
great fun to try these techniques on tbe

small lid. and J didn't have to wony about a

major effort. (Forrnoreon these techniques,
see Shop NOI."on page 17.)
Another challenge "'11$ trying to figure out
away to g"el the music works to srartwhen I
opened the lid and to stop when I closed the
U The seereus a small pin conn eeted to the
...ire shut-off arm of the music movement,
TIle overall secrm to making this project
go 'llloolhly is 10 make sure everything
works bPI""" the box is assembled. Iwound
updry-assemblingit several time. (with rubber bands) before actually gluing it up.
I also found it best te sand all the inside
surfaces /If/Ort assembly. Then. after the
box is assembled, Iused aspraycan toapply
the finish rather than usin!!: 3 brush.

a.

THE BLANK
The first step in building the music box is to
S01TOMGROOVE.The last step is to rut a cut. Then pcsuion the fence :}'~"from the
make the iron!, back and 'ide piece s. In- W'wide groove forth. bottom nf the music outside of tbe blade. With the inside of the
stead of routing four individual pieces. it's box tOlil into. see Fig. Id. Tocut thisjlToo\'e. blank face down. place the base edge of the
safer to rout a single long blank. then cutoff raise the table saw blade to make a v,"-deep blank against the fence and cut the groove.
Jour l)it'C'"' to length.
(NO vltV/ or IlANX
1'0 make the blank. slart with a Vl'thick
1
rtotl11Jt rAIlE
piece of stock. Rip the stock to a finished
,
a.
b.
'1"
CUTRA'",
FNt(
width of2\1>"and a rough length of24".
a'I. WIDE
,"
ROLI<D OVER EDGE. Alter tho blank is CUI
ttOUI'r(OSET 1..,10 size, rout a II," round-overwith a shoulder
~,."
STRAIGHt
',along one edge. S(.'C Fig. la. Adjust the bit so
.rT ' ..- Alovt
SHOUlDU
r
a "". shoulder Is left on the bottom edge of
TAIU
":
the blank to form the base of the musk box.
SHADOW UNE. After routing the roundINSIDE

.-

I.~In

, ~1"
,

over, the next step is to rout a "shadow line"

around Ihe/"lIoul"id~ cdg~ of the blank. SI!<.'

rig. lb. To do this. I used a W' straight bit,
and adjusted the bit to stick up W' above the
router table. Once the height is set, adjust
the fence >0 the bit routs a !V16"widerabbet
on the outside face o[lh. blank.
11'SERUP.The next step is 10routa lip, on
Ihe rOil "'~idtedge. for lhe Plexiglas dust
covenosit on. sre Fig lc. Since this lip is the
same depth as the shadow line, the height of
the router bit doesn't have 10 be changed.
Simply move the fence over to make a V~
wide rabbet.

18

IO~.~-

'.-

or-IOX
I

2l,"

.......

....

I!::! 1\

d.)

, t'AIlE
SAW

'[Net

',t
_J '." __

\X'ood<mtth

,,41_

fI l'l
Ir' - It

COl
GROOVE.

, ... DttP

;>

No.71

FRONT, BACK, & SIDES

Meralltheculsare
made on the long blank.
the next step is to cut the frontlback pieces
(A) and side pieces (B) 10 their finished
lengths. BUIthere are lwo problems here.
rU'St.)'ou have 10 support and guide till-se
small pieces while mitering the ends 10
length. Second. each pair of pieces has to be
I!".trtctl IIlhe same length.
,\t.'XIlJARY FENCE. The solution 10 both
problems lsto attach an auxiliary fence to the

miter gauge. This fence supports the small

piCC('S.And. by u.;ing a slop block. you can
cut each pair of pieces to exactly the same
length. refer to rig. 3.
ROUGII LENGTHS. Before mitering th,'
pieces. cuuhe twofrontlback pieces (A) to
a IYJug"/('>rgtJl of 6". 81;" ~ig. 2. And the two
side pieces (B)toa rough lengm 0(5".
TRIM TO SIZE.Once the pieces arc cut 10
their rough lengths. lilt the table saw blade

1045' and tnm off (lilt nlll o( all four pieces,

(As you make these cuts, you will also CUI a
kerfln the fence that'sused forthe nextcut.)
To CUI 1],(, pieces to fillallengm. measure
(rom the long-point of me mitered end and
mark me length. see rig. 2. Then adjust the
position ofthe SLOp block by laying the piece
against the fene,' unrilthe mark aligns with
the edge of me kerf in the fence, see Fig. 3a.
Then miter the pieces to length.

AOUGH
LENGTH'"

t
~

ROUGH
5"

fRONT/BACK

-UNG'YH

12PIKUl

ASSEMBLY

Once the fronl/back. and side pieces are

mitered to hmglll. me next step is 10 make
IllC bottom of the music box.
I301TOM.TIlebottom (C) is a piece otsolid
wood that's resawn and planed down to fit
the 11l"winegrooves in Ihe sides of me box.
To determine the length and widm of the
bottom. dry assemble the box, holdinll it together with n rubber band.

ingit 10thewire arm. Then, cenrerthe movemen I in the box and mark.the locationenne
two mounting' holes. see ~ig.4. Disassemble
the box and drill 1'6" mounting holes.

CLUEI r. Finally.

apply glue to the

mitered ends and reassemblethe box with

Ihe bottom (Cl in place. see Fill. 6. (Make

sure mat the pin and arm are connectcd.)

MOVlMfN1'

Now. measure the inside dimensions of

the box. and add the depth of the grooves on
all four sides, To provide extra clearance
during assembly. subtract "'16" (rom the
length and width and cut the bottom 10 size.
KE\"1ND HOlF.. Before assembly. holes
have 10 be drillN! in the bottom and one of
the sides to accommodate the music works.
To make rhe alignment of the pin and me

DfUI,l

t" .. HOlE

'"

rott~N!)
$TtM--=-___

BOTTOM

movement as simple as possible. start by

drilling an OVCrsi7.e hole (\-'l" diameter) in
the bottom (C) for the keywind stemto pass
through, 5(.'<.' rig. 4.
Sill T.()""FPIS.1ltemu~c movement hasa

wire shul-OU arm that

1l10VCS

1I1emusk. On tho:music box this arm is actio

vated ..ilh a shut-oftpin that acts as a swuch
when the lid is opened or-closed.
To mount this pin. drill. 14<"-diahole in
ODeof Ih.. side pieces (B). This hole is located :v." from the tongpoint ofthe mirerand
centered on the top edge of the side piece
fS). see Fig. 5. To allow room 10connect 1I1e
pin 10 thcwire-arm. drill oul a recess on the
inside race of ~le side piece with a Forstner
bit. see rig. 5.
\IOU~TlNGnOtES. Now. dry assemble me

box a).'1lin.pultingthe pin in p1aceand 3n3ch

No. 71

CHKK, THAT ALL

to start or stop

WOtUUNG

Dt't-....

PAR1'S

.MOW FREtl Y

Q..

SHUToOn
PIN

ClNTERMOVtMfNl'

I"'IOX

OlUE

nt,

MfJ(RLO

CORNI;RS lOGll'HlA AND

HCN.D IN PlAtE WITH
RUUER UN.OS

19

THE LID
Next. I began work on Ihr I,t'lhick lid. The

lid (I iSC'U1to the-same dimensions as the

outside dimensions of Ih, box (31/." widr

and 41,;." long). >4'" Fig. 7.
I decided to dress-up tilt' lOll 0(1ll<'music
box with burl veneer and an inlay strip.
<Another option is the carved lid shown on
the opposite pail",}
I'ENEER.The lir.;1 SICI) is to glut th,' burl
veneerto 1l1Ctop ofthe lid (I) .see Fig,7. For
a quick way 10 apply veneers, see Shop
Noles on page 17.
ROt,NO0\ R EJ)1;F.s.11,. next slep is to
round Over the lOP edges oC the lid To do
this. Iused a \I." roundoverbiton therouter
IJlblc.sec Fig. 8.Slart by adju.ling the heigh;
of the Ilitto produce a \lit;" should ...r.
KAKB~'"tUR INU\\. Once the round-over
iscomplele.1 muted asmall rabbet around
the cdgl' of the veneer for the inlay 'lIrip.
Start by marking the widlh of the inlay strip
on the topof the lid. see rlJ1.9.
Next. adjusLa V:!" sLraight bil to cut a rdbbel slighlly shallower than the thickness of
the inlay . ce Fig. 10. (The strip will be

ROtmllrABU
I(NCI

", ...

P.

',,- ROUND-

SHOULDE ..::;.

..,/
-c

~~

7
9

OVERIII

TOP fACE'
DOWN

10
I

SETDlPI'H SLIGHTLY

uss THAN THiCkNESS

Qf-INU,y Sf RIP

./

ADJUST FENCE

S04lTcut$h
TO/MlLK

HOt.O INlAY STlltP

FWSH wmt SHQUU)la
"ND MARK W.OlH

IN.lAY STRIP '-

.....

I,STRA'~ an ..

sanded flush later.) Now.adlust the fence so

I)",bit c,,">jusl up to til<' width mark.
ATIl\~.AYS11lIl~.Afl<-rlh!rabbets are CUI

11

fAPfIN

on all four edges. I mitered the ends of the

inlay slril'" with achisel. To guide the chisel
8145' I made ajig. S<.'C Fig. I L
To iJl~laJ)tht inlay. miter one end, Then

POsmoN

temporarily tape this piece in place. t-:exl

mark theshon poinl ofthemiterwith a knlfe,

see Fig. 12.Align this mark in thejig and cut
it to length.
fInallY.8lue the inlay strips in place and

CUT
CH.4HNl

I'

TO WIDTH

MARK END WRH KNlft

'" tN<Ay

mN (lIT WITHODS-ELaN JIG

sand them flush with the veneer,

FINISHING

TOUCHES

To complete the music box. auacb the lid

and drop in a dust shield made of l'lo"'gl.".
HIXCf.S. The lid isanached 10the box with
two small bull hinges. To mount these
hinges. Ichiseled outtwo mortises inthe top
c~orthebackpiece
(AJ.,..,.,l'ig. I:l. Each
mortise is tile same lenglll as the hinge and
as deep as the hinge knuckle. see Fig. l:la.
t"exi. position the hinge flush with the ill'
"j,/p edge of the m<)rti"".sec Fig. 138.Mark
the hole location s, drill pilot holes with an 18
gauge brad. and screw the hinges in place.
To locate the pilot holes in the lid. fold the
hing<" closed and Slick a piece of doubksided carpel tape on each hinge. see Fig. 13.
Then press the lid down on topofthl" hinges.
Now open the lid. mark the screw hole
locations. and drill the pilol holes.
nxrsn ;~l\'ll
DUSTCO\"ER. Next,I removed
the works and hinges and sprayed on IWO
coals of aerosol Deft Clear \Vood Finish.
Finally. cut a ,,>"thick dust cover from
Plexiglas to rest on the inner lip.

20

10 lOCATE PILOf HOUS-,

USI CARPfT lAPE AND

UO TO HINGES

snoe
...... .-

"' ...

_--.....

CUT PLfXtGlAS
DUst COVllIt TO
srr ON INNfR UP,A#Q.>

.... lttICK
puxtGl,AS

OtJ$l
COVlR

....

"'-,oodsm t th

NIl.71

DESIGN

OPTION

Carved Lid

/lO/(/IIIY

fh, kI.ift ot "

.tt'CP (1;;; )

(J

Ilil'Ut, pIllllllt'

k 'f{/;' (llouy tllf

(IItf

Tlrr"C'l"d cut
tM chip.
2
To moke tillS clIl. spinlht 1<'O"kp'err
a
Hold lite''''i/rar tll~~a"'eo.l/gll'n~
lri/ll'l'lnot'<l

a lig/('.1JI.lltge Illl! tip of tilt' kll{fr f n(,)

tlu: u't))'kpirce . Ttu II U.sill/! y()I~I',It ttJjlb tUt

1'tJ1I1/d.

b,f(J11',wd }J"II tile kl>(" Iowan!.you.

I, Itt!,

RECESSED LID
I had just completed the vc"<'t'rro lid on the
music box, when someone suggested doing
achip-carvcd lid. I thought I'd )live it a try.
I'm not an expert chip carver, so (decided

to ~Ii(,
..k 10 a very simple design. (1'0 transfer

Iho fuUsi7'('pattern .00v". sec Shop Noteson

page 16.)
BCdIU,"" it took me several aucmpts to get
thecarvmgjust nght.! made the lid 10 accept
a drop-in carved panel. This way I could

carve tne design severalumescna longstrip

or wood.then cut out the one thalilhought

looked the best and fit il in the tid recess.

M,,1l'HI"L. I carved the design shown
above in a l-'I"lhickstrip of basswood. Bass-

wood is a 'Oft. almost grainless wood that

carves easily.
C.\IlC;F.. Before Iactually started work on
the lid. I made a j!3UJ1e for laying out the
outline of the recess. see Fij[. I below. ullcr
I used lhisgauj(e as a support for. chisel W
clean up th~t"'gcsof Ih~routed recess, refer
to Fijt..1.

ClIISEI.$1 ~I()RT.Now, to gN a crisp

shoulder around tile recess, 1used 3 chisel
to cut to the layout line. Ilen- again I used 111('
Iayout ,gaURt'. but this Orne as a SUI1PC)r1for
the chisel. !'eO Fig. 4. To get the insert 10iii
tij(hlly. angle the chisel w undercut the
sides oflhe n)Ct'SS slightly. ;\1.'(' Mg. ,Ia.
ROUNDOvtR. Oncevou've finished chiselL\y()I'T.Onceycuvefinishedmaking the mil' the rN:CSS to the line. rout a V," round
gauge. use it 10lay out tile recess on the lOP over with a \Ill:! shoulder around the four
of the If!"lhick lid. see Fig. 2.
edge s clflllc lid. see Fig. 5a.
ROl"TtNG. 'Vilh the ktvuut complete. the
All that's Ieft is to cut the carved panel to
next step is 10 rout a ~I"-deep recess 103C' fit the recess. Then "pply a small amoum (II
lPI lhe carving. sec Fig. 3. To do this. use a glue 10the bottom or the panel and Pr6$ it
\I," straight bit and rout r/os<' to the line.
into place. see Fig. 5.

-,
MAKf OAUGt.1ROM

CUT

SCRAP BlOC)(

1 ~ ...

THI(tC

UO 10 SAME
SlZ AS

aox

CllAN UP 'nil
rOGIS Of
O.
_EClSS WJTH

.""'''

CHJSll
us(

GAUGf AS

'ASUP~

Q.

C'HISEl
$UCKTlY
TO

UNOlRCUT
(OCf

UD

GLU' CARVEl)
PANEllN

Nu. il

CLOSE
tOOUTUN(

ROUT t ....DEP

\V"od,mlth

Pt.ACI

21

O__N_E__'_E
__V_E__N__I_N_G P__R_O~J_E~C
__T

~"

Paper Gripper
T

down the length of the workpiece. see Fig. I

RIP TO \\1D111.Next. rip the
workpiece (wilh the holes
down) at a 20' angle so the disiance from the edg~ of the board
to the long point of the angle is
I". see Fig, za.

he idea for this project

CAAlefrom a local diner.

After I ordered. the waitress
slipped my order under a holdinll device for the chef, When I
looked at the' device I was ~Irpriscd to find glass marbles
holdiflg the paper I thought it
would be handy to have one of
these grippers to hold drawings
in the shop or the grocery list in

R.>\lIBET~~JRPAf'f:K.

into. I Cut a rabbet along the

angled edge, see I~g. 3. To do
this. leave the blade at 20' nod
lowl!ril!o:V$"abowthetablc. see
Fig. 30. Then move the fence

the kitchen,
The ehall~ng" was designing
the gripper so it would ea~i1y
hold a piece of paper when iI's
slipped into place, but not so
firmly that the paper rips when
pulled out. After some trial and
error. I was able 10 make it work by drilling
a shallow pocket behind each marble.
MARBU HOLDER
I began building Ute gripper by CUlling a
marble holder (A) from 'o/,'thickstock lOa
width of J "'t' and length of 111<'1',
see Fil!. I.

lowardsthe sawblade ihe thkk

ness of the blade.
(ltcould be longtrorshoncr. butlhislcngth
will hold a 8W x 11"piece 01paper,'
ORlI.UIOLES, The marbles are held in~.,
diameter holes set at an angle to the back
plate. It's easiest to drill a series of 'I""gld
holes. and then rip the workpiece at an
angle, Start by drilling ten g'tb"-dcep hoil.,.

BACK PLAn

After rabbeuing the marble holder, I made a

back ptate (8). ~ fig. 4. It's cut from a
pi\,-.,. ()i~"stock. 2"'l' wide and 13Vz"long,

Then. to keep the marbles from gripping

lhl'paperloo tightly. drill a series ofshallow

')'1' holes in lh~ back plate....eer.g. 4.

MARBLE HOLDER

,.

To pro-

vide an area for the paper to slip

,. i'"

11 ."

'..

,
4

ENOVlEW

SET ILAOE
AT 20'

WASTE
1'2"-

BACK PLATE

,.
,"
........MOVE 'INC'(
tOWA8;D II.AOE
AND

22

cur

RAl-SU

co., ...

KID'

""'I>l
AT 20'

.,'

ENOVlEW

-=:I=f'f"'==.,.........=--:;::;:.
'I,. '-__

----,1-;;.
1-.

No. il

HANGING THE GRIPPER

Youcan hang the gripJl("ron the wall by driving SCr<'WSthrough Ih,' back pial,' BUI I
USl'" a ''Y'''em Ih.1 hide. the screws,
This sys\ent Involves c.;ulling a dovetail
groove in the back of the back plate and
screwing a malching doveiall-shaped bar 10
the wall. Then the grip,,,,r slides over the
bar. refer 10 ti~.
II.
OO\'l."AlL GROO\l. To rout the :v.,"wide
groove in the back ofthe back plate (6). s1aJ1
by positioning the router table fence so 3 L:.:"
dovc~1ilbit is centered on the width 01 the
workpiece. see Fig. 5.

HANGING BAR @

tiS'" LONG)

CUT BAA. TO
RTGIlOOV[

a",.

CUT CENTEIt(O CROOvt

IN SfRllS Of PASS(s

PtA,..
KRPOOYnAll
elT ATSAMt

HEiGHT

Now make a series o( passes luming the

workniece end-fer-end between passes.
Move the fence bark slightly between every
other pass, sneaking up on the final width.

IIAl'ICiISt: HAR.Nlcr tllCI,'T't.OVC lseut.the

next step is 10 CIlI a hanging bar (C).

Though me bar needs 10 be '1'16" thick to

match the groove. I found it safer 10 ,Ul(1
with a piece lhal was ~1"
thick and 15"lanK.
l.ater 1resawed it IU thickness.
Without changing the heighl of the
duvetail bit, move the fence IUcover most of

I---'@
HANGING
8AJt

AtTlR atPPlNO.

SNAP Off

1.~OFf
WASTE

/"i~~~

SOvt.....

BACKPlAll

HANGING

_aAR

the bit. Then, make a narrowpassalnng each

t'()ge 01 the stock. sec 1;;g.6,
Check the fil oCthe barunhegrocve.lfit's
a little wid,'. move the (enee back .ligbtlyand
make another pass until the bar jusl slides

tRIM OfF AU. toGES

v.

AT20ANGl{

into the groove.

Once the bar fits the groove. it can be resawn 10 flnal thicknesasee Fig. 7. To hold
the back plate slightly away from the wall.
l'UI the bar a hair thicker Ihan the depth of
the groove in the back plale (Youmay have
10 snap 011a sliver of wood on t-ach edge.)
RE\'EI. EJM;ES. Now ,Iide tlu- bar into the
S:roGve in the back plate and trim all four
~dg"sofboth the bar and the back plate at a
20' angle. see rig. 8.

.....MAlN
$tfOutO CROP

tAPE HOLOS

10

MARWS IN
PlAaOURING
ASSlMBlY

TKROUGHHOU
,

.I." I-fOU

#MaiL(

HOI.O..

ASSEMBLY
Finally.assembly can begin.I started by findin)! some marbles al a local lOy store that

GW(AAU
MARlLE
GAUOE

",'ere fairl)' consistent in diameter.

'IARK1.";S.

For the gripJl("r 10 work prop-

erly. aJlthc marbk-s should be close 10 %"

diameter. To check (or consistency. make n
gauge by drilling a %"diam~ter hole
through 3 piece 01 scrap, see FIg. 9. Once I
lound len marbles that dropped snugly
through the gauge, I placed one marble in

11

IM.aLl HOlDER

MARll.(
HOLOtR

IA(K PlATl-

each hole ef thc bolder (A) and temporarily

taped them in place. sec Iig.10.
ASS~I8U: PAlmi. :-low. glue Ihe lOPedge
01the holder (A) 10 the back Illal,' (R) so it's

centered on thelcllj!\)J and flush with the tOI'

bevel.see ~ig.ll.
....msl~A.~O'10Lr~~~G.
Mlcr as~ml)ling

the parts. I applied lung oil 10 the wood and

then mountedthehangingbar (C) to thewall
..ilh countersunk screws. Finalll'. slide the
back plate over the bar. and slip your

-MARitI:
SUP ,AP(R
UNO!R
MARItS

IUMOvt TApt
-AnfR ASSMBlY

PUll DOwN
TO REMOVE

___

"'ocxt.:r,,1Ifh renewal notice into Lh~wiPlJer.

N". i I

23

AND

COMMENTS

Ta

QUESTIONS

Shop

SELF-CENTERING HINGE BIT

teringdrill bit. This bit Is known
by mlUlY names: \ ...x bit, spring
6, I WIIS faced with tlrilling multi
action hinge bit orself'<X'flwring
pie pilot holes for the piano screws, A'S these screws arc hinge bit. There are t' ..o comhin ...
~. r-iu rnattt'f' 110W car-t'ful tighlcn~ down, the hingl' i~ mon ~z\.~
available. One dnlls
you arc when drilling these pulled out of pusition. see r1l!. I. pilot hol",for Nu. Sand 6scl't'w~
holes, the drill bit can move off
So. what's the best way to drill and the other drills pilot holes
center. It the pilot hole is oU<en perfectly centered holes (or for !'io. 8. 9. and 10 SCI't!WS. (Sc.'C
rer. th. hinge .,ill move when hinges. or anyhardware that has Sources on page 31.1
the screw is installed,
countersunk screw boles?
CONSTRl'cnON. Tho bit eonHINGE MOVE,\tlo.'T.
realUNGE BITS. The solution to sistsof'three main parts.see-Fig.
son the hinJ(e moves has to do thisproblem is a unique self-cen- 2. An outer ca.sc mat's chucked
into a drill A high
speed twist drill bit
1
2
thats held in the
H~G'
1$ ClH'ItIW)
outer case witha set
aut PllOT HOU
t.SO~R
s..'J'(W. And a .prinll
103d"d rr-tractable
inner sleeve.
PlI,OT
1)\\"1'11. Ihe key
HOI(
HINOt
to making this bit
work is tln-lipofthr
inner ...leeve - it's
S!tound tu Lh~same
llGtiftNjNG scuw
CAU$ES HlNGE to
Iwvd as thecoumerSHiFf PO$R1ON
sunk holes in the
hinges. 1'0 drill 3
hole, start by holding the hin,llefinnly

When mounting the hinges

on the Tuy Box. shown on page

with the way hinges are made.

Most hinges have countersunk
SCrew holes \(' accept flathead

TI,,,

mounting hole>. the beveled tip

centers the twist bit perfectly.
"'hen you push down on the bi!.
the Inner sleeve retracts into th.,
outer case as the drill bit enters
the wood.
1)1'11JSn'II\G. The other
thing I like about these bits i,
boweasil)' you can set the depth
of the bit. Simply loosen the
Allen head set screw on the
outercase. andposltion Illl"bittn
in place. Then, as the correct depth. set' Fig. 2.
you in se rt the bit Then. retighten the set screw
into the hinge and drill the pilot holes.

ROUGHING OUT BOARDS

quired Corthe project. Then add
15', toWJ!oCnrdefeersand irreguJ 1(,'(IS lar-shaped boards (those tit at

.1 rf(f'I,t'!/ ~tl)lfrlldot a locnl

Iu",bt'r

Ut1nJ I" IllrA'

l,ol'd/(,'OOd Ior n pfujtrl.

It/)

SO,t"

unh{ld "",l, rutti jIg di(lg)'(l m are tapered or with uneven

a"d nmtrriot li.,,1 1)1fJ11t'

I,allfi

l'dgcs).l!l'm dcafing,,;th pieces

usu! a tos "'~'(l."iltIl i",lteatllt"r that have. unique shape or size.

Sitlce lturtill.}(Jod l'(''nlbt'r i~ 111look (or boards JUSt (or litem.
IlQl CII.'Ull.l'');Jr,,,

J("tlgtJ'$. ,t

l"if/ll,.Of (111(1

ll'~f'I"ditllt

lllat tIll!

wfdp.nJ" boards BJ,olI'" Oil ",,-If

~'tttl'ltg dl(lgrl""
II'ti"fll'/

"(I,f,/ll nl,,"ln~le.Il'Iwllri,'ks
gllli f/~r ,,'ht,' /)/lyi'tg and
layi>tguul boo rd sr
J(J(' P<'7l"/
,l/tll 'Is "'polis. ill J ~l'It'J,'Ot(1
I usually start by sclecung
enough boards to match uie
specified total board (ooUl~ere-

do

24

1')(lJt-:t.T FA"IIJARm'.

OIIl:'C

the lumber is in the shop, there's

a temptation to stan cutting un-

mediately. BUInow's 111('time 10

sit down and take a few minutes figure out what pieces will be cut any of the boards have checked
to carefully study your plans. from which boards. At this puinl ends, cut off any defects before
And ask. where an- theproblem
pieces? \\'hat pieces will be visible?W11"tpieces have to be exactly flat?
Once you're familiar with Ihe
project pieces. the next stC(,is 10

it's like aji~w puzzle and there

are two ways to approach it.
SCAt IlRAWtNI;S.The first
method is to usea scale drawing.
Simply sketch a reduced outline
ofeach board on graph paper. (If

sketching the outliue.)

Next. usc the materials list to
start sketching where the project parts might (it onto the
board. Since most material lists
....
rive finished dimensions fur

No.71

parts. add space lor the saw

kerfs and any jointing orp laning.
II Ihe project has many parts,
you migtn want 10 make a reduced scale template lor each
piece (like the kitchen or bathroom design kits that an- sold).
You can ~.asjly move the parts
.round 10 find what pieces fil
best on which board s.
Scale drawings do have one
limitation though, the boards
are assumed 10be perf,>ct- no
knOIS.taper, or wildgrain.
t,,\,. OlT OS UOJ-utos. Thai's
whv I like the second method,
laying OUIthe pieces directly on

the boards with chalk. If tht'

parts don't fit. I can wipe the
marks off with a damp sponge
and try~"in,
Before marking any boards.
son through them and keep an
eye out for pieces with pleasing

grain pauerns. tse these lor Ihe

hil.ohlyvisibleparts "llh~ proJc'CI
(such as table tOP$and drawer
(roms). The boards with slight
defecrscan be used for parts lhal
won't be seen (interior part s,
drawer backs lind bottoms).
IlOXT ~'ORGkT"ER~'S. When

laying out. mark the pieces "4"

wider alit! 'r.!" lung~r than
needed 10 allow lor kerfs. jointirlg, and squarinz up.

EXAMPLE 1:
"LLPIEctS 00

EXAMPLE 2:
AI,.L Pl(CU frr

NOT flf AND

NOtOMMON
CROSSCUTS

WIIHTWO
COtMOON
C.OSKIIJS

TRJM Off EACH NO

/TO MMO'v'i. CliKKS

Ie:

" ,

..

..

,
Iusually fillin Ill!' large pieces
9
9
~':
!
first so Lbat the cutoffs can be
used (or smaller parts r also try 2~.L.

10 align cross-cut line,; in ea ch

board 10make rough cuts more
manageable,
way to get the pieces [rom a 6"
.\.x E,X,\"'Pl.E. Recently I was wide board thai was 1 fctll()llg,
working un a project Ihal re- see fig. 1.
quired the following pieces: (A)
The first time 1 laid it 0111.I
4"x 14" (2 ea) , all 1'1-'<"
x Sh" (.I couldn't tit aU the pieces on lh('
ea.), and (C) J:V." x 16" (3ea,),1 board. Not only that, there
was faced with fll1dingthe best weren't OlDY clear cross-cuts.

"

"

'c

MATERIAlS UST
A
t21 ." xl'"
]
8-(41) 1:).... x6l' ....
C (3)

13~"
II( 16"

.f" :~f'~
!

9
.~~

!
..L

e
C
..f;._._

So Iwiped off tht chalk and

tried again. This lime all tht"
pieces fit, and I could SIan by
cross-cutting the board into
three manageable pieces. Then
it was easy to rip all thc parts
from these three short pieces.

LATHE SANDING

'."'It to br (l/ilt' to gd

gel with ordinary sandpaper.

tny (I"-,,iug proj4:C/s (IS Slllfllllli
And it's easier 10 sand sharp
n I'd likr. Is ther " (!'I,k tn details il ihe roldcd edges enhc
xa "dil,g O)~alatJ'f-'?
paper are crisp.
J do however, use Slikit sand
r:L. Kt'lfct't''''
ZeJiRt,o/J/e, PI l11l$!/I''Il1l1n
paprrquit".
bit, I fold il back-toThe real trick in sanding on Ihe back $0 the grit on one side
latilc is 10gel the lathe and the keeps the sandpaper from slipsandpaper 10 work together ping 0(1 my fingers while the
not against each other, This can other side sands the workpiece
be' don~ by choosing the right
TllI.'I1I<IQI S. Once rhe sandsandpaper and then using cor- paper has been selected. the
reet sanding techniques. (NOt,,: next lhill.c( to consider is techR~membt!r. no amount of sand- nique. Start by removing the tool
ing wiu make up for a roughly rest 5(,' that you don't gel your
rumed picce.)
fingers pinched between the
SANI>P,\J'ER. Before you sand
workpiec e and the tool rest.
3 project. 1I1efir~1 step is 10
N~XI,make sure you're sandchoose th~ COITf'CII)'P"and !-'Til ing in th,> righl direction. You
sandpaper. I use aluminum
should sand with your hand
oxide sandpaper b~caus~ il '(lid", Ihe workpiece - with
.tayssh3rpL'T long('r and doesn't
your fingers (ollowiog the dir<'C
break down from h"al ascluickly liol10(111eworkpiece rotalion.ll
as Ihe other lypeS.
you Sllndon lOPorth. piec. tbe
I gencrally US<' a progressive wl1<>d,'an grab th~ ~l1dpaper
serie" ,,(four grit,; of papt'r: 120, (and your (ing,rs) and can
tSO, lan, and 220. 111i5 work.
..:runch your knU(kJt,.s a.,gains1
wc'lI for most projects and ",111 Ihe spioning wocxt.
produce a smoolh finish. An exShop NOlI" II you own a lathe
ception II) Ihis i< on end gnUn. Ihal has a r ..vcr~abl. motor,
Hel'('. 111olten slart willi 80 or make $Ore your finget> alWllYS
100 griland):o on 10finer grits,
follow the dir('Clion of Ih. work
Many tum!:rs u>~ dothback pi~~tolation.Rt'versillJtalatht!
p;JpCr or put Contact pal"'r ou and sa"ding in both dirc'Ctiom,
Ihe back of sandpaper. BUI fold bends the wood fibt!rs and al
ing IhCS( thick papers docsn'l lows them 10be removed more
leave Ihe crisp ('dges thai you ('asily. n,is can produc(' a very
l nerer

No.71

smooth surface.
'..ATtlE.

$~r.f.I).

With sandpaper in
hand. you're read)'
10 select the lathe
speed. The speed
Ihal I usc for most
sanding is Ibe sam.
thai I've used to
make m}~finish cuts.
However. there arc a
few exceptions 10
thls where
['II
change the speed

or tile lathe.

111slow down the lathe when

I'm sanding faceplate work.
such as plates and bowls. '11<'
rims and edges of Ihis IYP<' or
work can bum v,'ry easily. AI
thnugh the riIll revolves at lh~
same revolutions per olinut(> as

PRf.l',<IRE. 'low that the lathe

speed is set and you're ready 10
sand. one question remains

110" much pressure should b~

applied when sanding?nle best
indicator I know for correct
~ndingpl"f$Surr is h('cll~
If your fingers start heating

the center 01the work, the rim up, you need 10back off the PTI'So
has a grealer vcloci ly and a sure. Excessi\te pressure
larger diameter. This Illt!llns
Iher .. will be more woud in con-

LaCIwith the sandpaper in Ih~

same atnOlmt of liOlt;.

crc-att~fri('ti<Jnand the hcatpnr

duced can bum both the sand-

pal",r and thc wood.

Bl'RXtSHIXG.

Once ille sand-

ingjob is done. thcl'e'sone mol'('

Another lime to decrea$e
spt'ed i. when sanding work <lep Ilik. to do ""ror. finishing.
"'1h small beads Qr sharp eris!> I tum on the lath. and bumi,h
edges. By slowing down you'lI the turned piec(> \\lith its own
be able 10 conlTol how r3t,idly sba"inl!S. Burnishing COnlpaCIS
tb" wood i> removed. It'l 13k~ wood fibets 10producea smooth
long"r lu sand ill this Sj)<.'t.'<l. bUI surface. So I lake a )(l!n.rous
tber~'s legs ofarnanc~ ofremo\'- handful of sltaving:; and prt'S.<
ing a finc detail thai you SpeOI them firmly into tbe piece. l11i.
produces a SOil, smoolh <heen.
considerable lime fom,ing.

'J(',lOdsml[h

15

UST

FOR

KIDS

r-------------~----------------------------~.

Night Light
You can create magic with a scroU sat!.' and a
ChristnUlS tree bulb. And it's lnagic (hat can change /rom season
to season with four interchangeable parrerns.

Ou doni oflen think about projects thai gel

\\000.1 used cherry for all the parts of the night
Iheir cJ.larm from the wood that's lIIi.~ill!l. light. The color and warmth of cherry enhance the
This nigll1lighl is one of those projects. It's a box. glow cast by the tight. And because cherry is closewith solid wood sides. lOp.and bottom. What makes grained. ilCllISwell on a scroll saw.
it interesunzlsthe frontpanel thai screens Ihe lighl
SLPPI.1ES.The lighl fixture is a Christmas treeshining from a small bulb inside.
size (4 wall) bolb that dips tighlly inlo th" base of
\Ve designed this nightlislht with four of these the box. This light bulb fixture, alongwilh a full-size
interchangeable scroll-sawn panels. You can slide drawing of each of the four pan ems (and a piece of
one in front or the lighL and store the others in a felt cloth for the bouom) is available from
compartment in the back ofille box.
"'OOI.I"",ill/ Pmjo!t:i SUpplieK. see SoUI'(t;S. page 31.

26

Woodsmlth

LIGHT DnAIL

EXPLODED VIEW

""

OVl:RAU DIMENSIONS:
9'Hx6"Wx5V. D

PtHCH W1f1fGS Of

UD

tt

UGHT ftXIUIU.
AHO PUSH INTO
UGHTSOARD

@
BACK PANEL

{'

l~

.stORAGE CHAMad

..
@

fOIt txlllA

/'

INttl(kANGfABli

UD BLOCK../'

PANas

,/

DIVIDER. PANel

@
-

INTERCHANGEABLE
PANELS (4)

@
SIDE

-_/

~;'e:

SIDE
O'~~

eo

0,
UGHT

flXTVat

CROSS

SECTION
(.RONT V1fWI

MATERIALS
A tnt&fchOngeobie POneIs (4)~'

8 0Mde, PoI\Ell (I)

C 8oc'< Panel (1)

<
"

o Si005(2)

4'1rAX8

114 x 4'Ir. X 8
lJ "',. x 8

~.x..w.x8

E Base(l)
f UdO)
GUdBtock(l)

\2.5V4.6
'1.1.5114.6

H Ughl Booto (I)

It X2 x <1

~.x2.4

SUPPUE5
(4) No. I)' I' R> woodscrews
lung 001finish

LIGHT BOARD

'---

Felt clolh 6' x 6' (rol.>gh)

Nigh, Ughll(it (see page 31)

CUnlNG DIAGRAM

LIGHT FIXTURE

PHOTO DETAILS

Woodsm1(h

2i

RESAWN PANELS
I started building the planerto reduce the slock to V.". Now, sand six 8"long panels. sec Fig. 2.
nighllitl byculting or plane the saw marks from allthe-panels SO
Shop Note: Instead of resawing solid
six panel blanks
th~y' re each the same finished thickness of stock. you could use plywood (but the plies
(four for the inter- "'4" 111en cross-cut both blanks to produce willshow on the finished pauern panels).
changeable panels,
SECOND:
I~USone dhider panel
1
POSmoN fUK'
2
IM"ETWO
and one back pane!).
SUGtm. ... MORE lltAN
PASStS.
Thcnightlight boxls
' .. FROM 6LADf
FUPOI_
@
L_--,,-__ _j built around these.
WOItkPlra
PANrlS
(NOIORlND
!'Al."'EL SI.A."iK. To make these six \"-111
tCUT'
SIXPtKU
UT'WiEN
J." fHlCX)
thick panel. (A,B & C), r,N rut a piece of
PAS:$tS
~"scoc};.to a final widllt of 43(," and a rounh
length 0(26". see Fig.L
~~\\\' PA..~ELs.Then resa ve this into two
panels Ihat arc each slightly thicker than
V," I used the table saw and mad,' IWO
passes with. sharp blade, see Fig, L You

..

could also use n band saw or thickness

SIDES
Aflcr resowing and V," from the insid~ edge of the blade, and
culting the panels 10 raise the blad,,%" above the table.
size. the next step is
Now make one pass tOCUl a kerf inthe test
to make the grooved piece forming the outside limit or the
<Ides of lite box.
groove.Then tW11 thepiece end-for-end and
StOE BL\,''K Th. cui a kerf near the other edge. When you're
two sides (0) start satisfied with tbe depth of the ken and its
out ." on. blank of distance [rom the edge. rut kerfs on both
:v."thick stock. CUI edges oflit" actual workpiece [ollo,,;ng Ihe
the blank to 3 finished ",dlh of I:It,'and a sante procedure.
rough length of 16....~". see Fig. :1
Nowreposition the (etu..X" and make a --".
PJu\jELC~)\'ES. Next, CUtthree V4"wid(" ond P31SS
on the resi pie,c. SOthe ~I
panels
groovesforthepanelstosddeimo. lusedthe
fii snugly in the grooves in the tt<1 pi!'(('.
table saw with a rip blade to form all the Then make the cuts in tilt! actual workpiece
grooves. l~uIbefore cutung the grooves in to complete the two outside grOO\'C;'"S.
the blank. CIIIa tesl piece the same sire as
Form the groI)V" for Uw divider panel in
the blank 10 check the width and position of thesame w..ry.ntis groove is located 2" from
lite groove.
lite back edge of the box sides. see Fij!. 3.
The llrst grooves In cui art' the two OUI Sl'IJRAGE CI{,\.\IIIER. After the three V.-'
'ide ones. sec Fig. 3.To do Illis. seuhe fence wide groov("~ were cut. 1 cui a I"wide

"slorag(' chamber. see Fig. 3. Do this by

making a series of passes with the rip blade,
OIl'SIDE EI)(;ES. Next, to make thp sides
appear thinner than their actual ~ .. thickness, I trimmed lit" front and back edges
down to W thick, see Fil!. 4. To do litis. sel
the table sa" blade !o'~"(rom the fence and
."'" high. see rig. 5.
BVtJ.NO$~ I'ROf'D._ Aftertrimmingthe outside edges, rout a bullnose profiit-on them
with

01 J'

SECOND: CUT

THIRD: CUT SIOItAGf

t,

AGAJN.SlflNa
TOTRlMmGU

I
;;:

,!!)

CHM\II!Jt

BACK
fOG.

SIDE

".1

."

--~~
...
28

USEruT PlleE
lO<H1C~CUT$.

I)",
<,

AU.GROOVlS

_ ..,.._,. _.w

2"

t c

~.l-l...

....

I~"""':--.

sa atAO'
lltlM _.
'RONT A,ND
BACK (OCfS Of

NOTE:

"

::J..-

~
lUP

fINe.

UlL..---fUF ;'

,
.,.

StM PIECES TO ',," THICK ..

6
ROUNDOVlR
OUTStD( toot"

10tJf1R rABU
'[NC'

',"

ROUNG-OvtR

Bn

---. ....-

Wood,01'th

~." filCH -,

l-

.'-h'
',

1
,

-{- ""J'*

...

into f\I,'O 8'1longsections, see Fig. 3. Then

SUDf SfDE P1Kt

GROQVI

do this. first

nlue the back and divider panels in place

(flu,;h at the tall and bottom) between the
two sides. refer to Exploded \'i,w. fl'lS!" 27.

OUT$IO(
CRooVES

DIVlDER

'1'0

raise the bil V.. high and round over th"

outside edges (groove'" face Itll). ~e Fig. 6.
Then raise the bit V.l' hiJ.!lland round over
the inside edges (groove dQ"w). see Fi)!. t,
PRf._-\SS&\tRL", ~OY,l (''1lllI1l' side l)it..'4.:t

fIRST: CUT lWO

round-ever bit.

BASE & LID

B~gin making lite
.. base and lid 01 the
box by cutting a
blank to a final width
01 SII,", and a rough

."

aonoMsrO
OF BASE

,.. ',"

length
or 12),0"",
NOTE:
Resaw, then sand.
eASE
ANO UO
the blank 10 a final STAWTOUT
AS
thickness, of ~".
~lONG
BlANk
Now rut the blank into two pieces, each 6
long.t<> fonn abase (E) and a lid (F).
F1~C;ERsurr, A "finswr .101" in Ih. base
0,

allows aCClOSSto the electrical fixlure. To

make this. bore two 1"hok-stmhe ba......,.then
4JUt the wa..;tc between them witlta sabre
saw.see ~1S!.Sa.
(0110r.ROOI'.:Next.forma V,".o.epwoove
for th, ('ll'Clrl"al,'OO'd in tlw bouorn oi Ih~
base using tht rourertabl. see Fig. 9,
R()l!NI)()''}R Er'(iF.S. After cutting this

cut

(lfl,'n all LIt,- cdg~s 01 the 101'and

bouom with a> ...round-over bit, To do this.
mise the bit 1;," above' the table. ><'eFig. 10.

gf<)QV,

ASSEMBLING

','

8ASE- .,

a,

10
..our ACitOSS
(NO GRAIN fllsr

110"
TWO
,DfA..
(no HOLES
fOR 'INGtW $1.0J

1"

2" _.J

THE BOX

When the base and lid arc complete, finish

' ..~ X 1 ..'" aAOOVf

fOR (lfC'1':llC CORD

of the box b)' means of a lid block that's

a..,,-embling 1I1~nighllighl box. Du tlli< by gl""d tu lilt uodtl'>id(' of w(lid. see rll!. 12.
firsldriJling countersunk shank holes on the
bcuom side "f the base. see Fig. lIa.
\exl. center the base on the side as-

To make 1I1~lid block (C). start by cutling a :y~'piece of 81O<'kto fit the opening of
the Ughlchamber (-..i!ha fronlpanclio placej.
~clnlJly. and temporarily clamp them toWith the lid block cut to size. ruura narrow
chamfer
alonJ! all four edges of one side 01
geth"r. The sides should be inset an equal
distance all around ihe base, st" Fill. II. (In the block. (The <,hamfcrededge$lfl you reIn>t:a~.lhi~wa... l~".)
move and n'plae,' til(' lid more easily.)
Now drill pil!)1hoi, -s Ihrough the shank
'10\\,. lay out the position of the lid block
holes inlo the bottom ends of each side on theundersideofthe lid (see Fig.12a). and
1>;.
.....e. see Fill. II a, 111enIIluc and screw the glue the block in place.
..rcrrr HOARt). The light fixture has a
00.,,' in l'Ia'....with Iffi" I" AI woodscrews.
IJL>BUICK. The lid fils'nugly onto th, top "-pring retainer lhals.dl"SiJ:llCtl to scat into a

.,,.......

SIDE

I-'."-Ihickboard wilh a I" ItOI<.

","'C Fig. 13.
To make tbv lighl board (H). first
measure tlw olwning at the bottom of the
lighl chamber. Then cut a piece o( WO're-

sawn stock to fit this opening. 5(.'<1 rig. 13a,

Bore a J" hole through U1C center of this
piece. then gluc the light board in place in
the bouom ollhe base.
I~NISII.I applied a lung oil finish to tl1l'
box. Note: 11w OO~will r~O~1
more lir:hl
through the panels if you paint the three inside surfaces 01the Iighl chamber while.
Finally. gluea 11il'(:"of ("It (In Ihe bottom
ofth(' box to hold the electrical cord in place.

13

_,

I ',"
,"

,'....
/

WOOOSCREWS

"

-@

un

NOTE!
t.._"INW

ON AU. SIDES

BLOCK

a.

a.

t." INSET

PILOT

2"

HOISS

,,"

SACK

'RONt

....
t~

/
LIGHT
("'AMIot

.
.6x ''h
a,

cD
un

COIJNTruUNK
SHANK HOLE,S

"'t
,,"

..

2"

-'
-CUT

10m

~ -t
UGHTf . l80ARD

~--4"-

H
_/

eUT

--t-Tom

__

29

S_C__R_O~L__L__S__A_W

P_A__T_T
__E__R_N~S

~tt

Night Light Panels

The magic ofthe n;!!ht ligbt ls in the

scroll-sawn panels. Here are some

suggestions (or making four interchangeable panels.
SCaOWNG

TIPS

The patterns mown here arc half-size,

50 have them l'1lI"'IWd 2OCIl\ 81 a copy

shop. or send lor the fullsizepatterns

from Wood",,;lh f't'fTj"~tSIIPJlfic;J.
see Source" llo1ge31
-';ole:The fig/tt,.r areas of tlw drawings are thosethat should be cut away.
(I used a :-10. 5 skip toolh blade in the
scroll saw for each olthe pauerns.)
A'lTACH PAl'lb-a.". First finish sand
each of the J).'IIlcl blanks. Then gluc a
pattern to the blank using 3M's Sprow
MuuOlora Ughl coat otrubbercemcm,
DRflJ, HOI.F.~.Before you begin 10
saw. drill starting holes for the pierce
(inside) cuts, and for the other hili."
ANI!>II. Finish the panels by dipping
them in 3shallow pan of lung oil.Then
poke out the excess finiSh from the
drill holes with a wire brad. (A ~hOIof

compressed alr works e...'en beuer.)

FAUING STARS
Drill the hole, for the background

stars firsl (using

V16" and

11l"drillbus).
The points on Ih" moon and the fai-

ling stars will be sharpest if you form

themwhh two inter$('Ctingl1IlS. rather
than by hying 10pivct around them.
JACK O'LANTERN
Drill oul tho '13J1I (with 1116"and 'VJi'
bits) and til<' moon (with a ~." bit)
flrSLThen cut out the details of the
pumpkin, Pivol the blade onl)' when
culting out th~ eyes and the mouth.

CUIaround the renee pans next. and

finallycui around the cal
CAT'ISHIN'
Tbispaucmrequiresthemoststarting

holes for the pierce cuts, Drill these

first.then CUi out the smaller areas.

CUIaround the cat last. mus gives

you more sUpJ>OI'\when you're scrolling between lite leaves).

SNOWTPINI
l)rill holes forthe snowilakes (!I!s"bil)
and the tree ornaments G'rl").11I1m
drin !<larting holes for the snow Oil the
branches. Next cut the tree ouulne,
and finally the snow on the l!1'Ound.

30

Woodsm'th

Nll.71

PROJECT

SUPPLIES

Sources
Music Box \Vood IGt
CARVING KNIVES
We also put togelh,1' a wood
All the hardware needed to kit containing 0,,1,/ the wucd. \\r e experimented with B variety
build the To), Box is available veneer, and inla)' ttl make th( u( knives while chip-carving the
from \Voodsmith Project Sup- Music Box, (Order tIll" music top of the Musk Box shown on
plies. The package includes
movement and hardware '113' page 21. I even called Wayne
hinges. lid supports. ,Iwlf 'UIl- rately. 5('(' column ~tlel1.) 11u, Barton who is one of tile finest
ports.casters, plus a sheet oHull p3C'k-ilgC includes aUtill! walmu. ehisx:atV<TSaround 10ask him
';7 pauerns of letters A B. and inla!'. and burl veneer Note: about carving knives, And he
C and num~rals I. ~. and 3. Not,,: This 15 "'I! a r\..ad)'-I1)..,1~..mble sent usa No.1 Swiss made Klctkit All pit.'t'e> lUu,t be cut iluri zli cutting knife to try out.
W'Kld and paint ""' iu<Judi'll.
veneer mii}' contain pat(hi."- or
'Wbatadifiereoce-the5e arc
To) 13<" Hardware
771100"1"0}'
Box Hardware
&'2n1$,so wc re ~lpplyiRS!mort' the same knives used in Swiss
carvlOg schools and Swiss wood
Pa('kagc , "
"" $~4.95 than )"ouneed
(2) 1V2" x 24" HinKC"';'.5(_T~
MUNicBox \Yood Kit
-hop-, The blade is short (only
(2) Adju<table !ld $"1'1.,11,
771350 Muslc Box \\".",,1
lit. Iong) so you can control the
(4) 2" Plau-Ca ..<.;tt-1"!"
and Inlay Kit.
_ .....SI7 !I:. CUL1)",,~'ly. The handle is also
(I) \O~.'X 2l.,.!' x 24 '1 \\ablut
(4) Shelf Pin Support
-horter and thinner than the
(I) ~.!"
X 31,.02" x ~l~" \\ ,11111J1
others we tried. ILfeel. ., if it
(1) Pattern A R. C and I.2.:1
-(I) ~"x 2~'",'"X 3i,.,111 \\'atllu'
""'IS custom molded to fit IUY
HAND MIItROR
PlywlKld rk>"~m.Good 1Sick Jl'III1I.Mer practicing. it made
j\ Sitround ~vclt."C1.ttlass mirror (l) 4" x 12 I \\'alllUI 1',11'4'( sharp, clean precision cuts
for tlw Hand Mirror is available
BackedBurl\'tn"'r
".(ply and veryaceuratety. (This
from \Voodsmith ProjeClSUP' .(1) ~'6"~ 21" Mapl, 1\\ al is the knife I'd recommend. It's
plies. blcludcd are a full-size
lluVMapic Inlay :-lOp
shown inthe photos on paJW21.)
Musk Box Chip-Carving Kit
If you don'L want to make the
mirror and Icttcrpatt('m.I'lt"~'
~/JIrif!1 It'll, ..,'. (\Vc' I't:'t:Olll1Jlr:nrl
\Vl' aJS41 lJullvgt tlu-r a kit r'1'r invvstmcnt of a KlOLZli knife,
Dow's Silicone Sealant to attach chipcarvers.h's idcnticalt thl' W,,'", offering a less expensive
the mirror.)
veneer kit. bUI instead (If V-('II('('( "puon This knife has a larger
H~nd Mirr."
and th~ inlay. We ",.pply a 10lll( (2 \-!'Iong) she<>p(<)ot
bladewith
771200 5" Round Ik"V('I<~1
block "I' ba';'''WI"KI for I~"nl)'
01 a thkk oval handle. W'hil~itcall
Mirror (Sil<."ci[y letter) ...._SII.9S practicing. ,",'e're al!.:tlincluding be used for chip carving. the
(I) 1'1I1~~ ~hrror I'att<nl
a (ullsized chiJk,"'aning pattt"m.
lonR.r blade makes it more of a
(I) Capitall.cllt'r Pattem
Musil' Box Chip-Ca,,';nll Kit mulLipurposeknite.
765305 (3-0. tube) Dow Sili 771375Music Ilox ChipChip-Carving Kni\'e~
cone Sc.>aJant
$3.:..19 Ca.rY1I1JtKIl.....
~J
771385 KlotZliSwiss Made
-(I) ~jtlx2lj" x In" lJ,a .."~"""lJOd CuUmg Knite
MUSIC BOX
(1) t'2" x 2v-!" x 2 J" \\'aln111
IOverall Lt.>ngth 5=11.") ..... $13.50
All the hardware for the Musk
(1) \-2" x 311-l' x P..'i"'alnut
759120 Sheep(oot J31ad"
Box i" available
from
(I) J.1I" X 2118" X 37,.,.'\I'alnut
Knife
\Voodsmitb Project Sup.
PI)'WlKldBottom. C,ocKI1 Sid, )V('raU l,(OngthIW.")
S6.50
pliC's. This package cuulains
an IS note Inu~il'al nlbvc:ml'nl.
ORDER INFORMATION
Not~: \\1(\()d i~
"fl' inC'lllded.
(S('<' wood kits in ",'xt ~olumn.)
BY MAIL
BY PHONE
Music 11<1)(
liard",,,,.,,
771300 Ed.twei,;,o. .... $11.95 To ord~r by mall us.! the furlll ~'or fttst~r st'rvice use OllrTnll
....
nclosed ....ith n l"UlTl'nt is....u( 1'". order line. Ph(1n~ttrde-rs
771302 Its A ~11l,,11
or
WLit~yc)ur omer on a pi(."t.~'- ..'lin be placed MoodaylhrQugh
World.................... ... SlllIS
ofpa)X'r.and ",'nd with achl't k Iridily. 8:00 A.\I to $:00 PM
771304 Silt'nl jl;il1hL. SI1.95
or mon\~ order. (lnciud ...$.~50 Central St.-tndan!Tim".
771306 SOllwwh{...,O"'r
handling alld shfrlPing <,hargt
B. for" calling. have your
11l<'Rainb"" ... ..... _~I'I95
\1M
IIr ~ia.ter C.,rd rend).
with
~ach
order.)
1,-\
r
e>id"nt'
(lp.'.) \2" x 7 If," IIr:,,' Platt:<!
add 1" sales tax: CA resid 'Ilts 1800 444 7002
I linJ;!t's. Sen""..
(1) ~'x 27~" x :i' .....
11. XJ~1a~ ~dd 6.25'&""k'" tax. SI-.nd h>.
TOY BOX

!'.

(You('uttil fit rour I~".I

(l)~tusil""dl tnUYI,.'nltll1 wilh
onloff pin. CSur~lli,.,. Ihw!"l.
call for nl<,'1'",(111 .w.ulolbilil')

N'l.71

Woodsrnith J?rojcd:Suppli("S

P.O. Box 10300

Des~foines,lA5()306

"l'I, If 't,,;",,",,1+4;0,.drlil'il''lJ.
.\."

'-rt(:$ l'ul,jr

(I) ('haHflr!

ott , lkCt;'llbe"~1JfBfJ.

NIGHTUGHT

The hardware (or the: Night

Light on page: 26 b available
from \Voodsmith Projt'Ct Sup-

plies. This package includes a

>ocket/lighl switch and plug
(with slx fOOl01cord). Iw04 WUtl

white nighLIlght bulb adhe

sive-backed gn'"1 (dt. and (our
full-size .....rollsawpatterrrs. (St."
previous pag e (or pauems.)
Night Ughtllardwure

771.jOO"ight Ught Hardwar.li!ckas:~ __

$9.95
(l I Sock e-t/Ught Switch, Six
Foot Cord and Plug
(2) 4 Watt \Vbll~ Ughl Bulb.
(I pe.) Adhc<ivt'-Backt'd F"II
(.I) FIII~Si7A'dPattern. and Instructional Sheet: Falling
Stnr s. Jack O'Lantern. Cal
Fishin', and ~n""~' PIne
Night Light Cherry \Vood IGt
\l'e also put together 3 cherry
wood kil centaining' only (11(;'
wood to make Ill. Night I.JghL

771450 Night JjghtCherry

wQ()(I K'J1 . _ .".......;fJ

c'''' ,c (fipcs.) 1,1,," x 1'VI" X S" l)ant'l~

(2pcs.)

v.z" x 51," X 6" B3s<>/lid

(lpc.) }'."x .I~I'x 16t".!"Sidt.,;

(I) .y," x 2" x l' tid Block
(I) ~"" x

2" x.," Lh"rry i'ly

wood J.iy,htAoa.rd. (;0.'" J Sio'.

VIX BnS
In Simp Now,- lin Ilag. 24. W(,
(liscusS(-"<I using 'fix bi15. \\:(.. :Ul'
offl!nllg lWt)SilA.'$:a

No.5 ,'ix bit

will drill pilot holl'S forNo. ~ and
Ij s<wWO'.l1>e No.9 \fL' bit can ),.,
used for No.8. 9. and 10St....ws.
VIXBits
771505 No.5 \"IX Hit
77 1509 No.9 \'jx Bit.

771500 Both 8it,;.

$8.95
S9.95
$17.95

ROUTER Bns
W,. alS<1used some routcr bits
Lhat we don'L normally

use

Iltese bits are carhid<Hippcd.

Rout~r HilS
271603 V"" Str.righl Ilit

(1/.," Shank)
_ _ $9.~f.j
771175 :It,' Roundov"r Bit
(\-2" Shank OnJy) ...._...._ S-I~.!':'
758-350 W'Dovelailllit
(!I." Shank Only)
$15.i5

31

LAST

L(.j()K

Final Details

.. TIlt ~trt'W' t t"I..'t I I'I fig lJ(IINtr,,, ,1.""fnrr' i~"

.(flt' "nliilflry 11'n....
1( lunrbl, .........
\ 11~liqlllRli.li,IIJ
(/fJ(" to Jt "':'("/f', "0/1/$ tlu G"'PJJer'tu tIlt: "VIII.

.A

Ptrtt
/JO."; ,,,,,

"'1 "'!fA ,ru'(IJ/ "I"III/tl fH: a.- "'(I~!Ile."

S4, "~

fid~('lit'" "HIII.;-,

... .11,,4'/ Jlf, I' ,',J', ,It). r Il(f

lirall

"f'

II(i

I/"'/rli ~!,cIII. l\',fh

,~Jtqlt'f'U11l!IIPJJOrlS

/. "11 r

1"""

tit

hold flIt

It(Ctl)/'J(i,IY ~Illt.

.11,,','tlr mil 't: (l$d{r:.

(III

"~IJ ,.(ierry ba.H~

(1" t I.*, "'JII tt r. ,",", ,,/"11 I rot If IY) 'f ~ld II {I""

Music Box

.l Opt'llt/I!I t/ri''''''fll'll,i

,1fll~u' 8'1J'i~tJpli'n.~n/

~:trIJ,.i~. Tilt' I,m!ls lllljJ'Vm/f ,,1 "tali." p!I1.!';U!1

It'hlfll 'Ireflil ,:~
I~t'ctl(l)Ili ~tnl~
If'J(., II it'~
(,'f~"'(1

" $,'11/'/ II

tv ,','''1'"''
,/;"

xJ"''tl'Jf

un Ill, I,d tdJ~th;1frlllrl"',\ ",It, 1"'Jlll

ll".f

t'.} 'I,r xcrutl :1trn 1~"1A Ilf \

rlllltlllH'rliollb

U""~f;tJ Il(rllf

lx,

11111