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NO.

62

NOTESFROMTHE SHOP

$3.50

NO.62

APRIL1989

E D I T O R ' S C O L U M N

Wodsmitkr
a ,(

Y I n the ldqtissue"f lvodd\pil, we inlrG Now we're putting them in Shop Noles 10 lduced our newaraphicstyl the new highlighttherna little more. EdirorDonaldB. P.schke TIp Bo)(Es. Anolher approach we're exway the an and text are laid out on a page. I TedKralice* Design Dirclor wasbothexcitedandnervousaboutmaking perjmentingwithis the useofwhatw cala tipforbuildins these changes. For ten years we ve always Tip Box.lfwe havea spccia] Managing EditorDouglasL Hicks projecl, a bulil alsohassereral applications, received very n;ce compliments about the AsislantEdiknsDouglasM. Lidster Iook of l{/oods,titr. So, my feclins wasi we will try 10hichlicht it in a Tlp Box in the Kent A- Buckton don t chansea sood tirins. P@iect Designer Ken itunkel For exaorple, when we were assenblins Butthechanseswevenadeaintended Tednical lllustratols OavidKeyling 1obe t p,tfr?rls nr the way lhe arficles the wall Unit shown on pase 4, we had lo Cary Chrislensen Now thal we havetwo issues ahe ed clamp larse plyvood sides to the are presented. Rod Sloakes I'vebeenveryhappywith all pl)1vood shelves.To get even pressure underour bel1s, Ch.is Glowacki alo.s the lengtlt of the joint, I uscd tapered thechanges.Theyletuspresenttheprojects read. clampins blocks. These blocks ae a nice gaum, in a slepby-stepformatthat'seasierto lrgr. SM@Sandy Cusromer And I lhink;t's easierto seethe processoi idea, so we pul th;s tip in a tinted box to Jackie Stsoud highlght i1alinle, seepage7. howeahprojeclis built. Pat Koob TEcHNreuE ARncLEs. While I'n on the Most of the chansesI lalkedaboulin the Lisa Thompson last issuehad to do with the sraphicsof lhe subject, the one request we've had conPoject Supplies LeslieAnn Gearhart show more tech olherchanses sistendy over the yearsis 1() articles. But thereareseveral TrryJ. Slrohman we ve made parliculely in the way we n i q u e s o n w o o d w o r k i n s .I n a d d i t i o nt o compuleropera$ons Ken Mine. p r e s e n t w o o d w o r k i n g t e c h n i q e s a s - addinsShopNolesas a regularfeatureand wearealsosoinstoput includingTipBoxes, wi& the projects. sociated Adminisrrarive Assrs.Cheryl Scotl Everyprojecthas: few interestingtech- nore emphasison fulHendh anicles on Jeen Carey niquesor somelips thal applyto manyolher woodworkngtechniques. Archie Krause Building Maintonance we ve included pmjectsaswell.Ir the past,we'vepfesenied In this issuefor example, usedio these lechniquesrisht alons with atl the three articleson fie techniqueswe associaled with other delaitsaboutbuildins eachpadicular solvesomeof the problems you needout pltqood. How to cu1lhe pieces OperarionsSleveKrohmer That approach is okay the information of a larse sheet.How 10 apply solid'wood is in the issue.But it's usuallybunedin fie edging stripstohide the plieson the edges Malkering ManagerSteve Doter jis to And a special article.And, to be honeslaboul it, ifyou re ofthe pllvood pieces. particularlyinlerested in that project, help trim the edging strips flusb with the not MO Jon Behile Sr.Louis, there'snotmuch poinl inreadinglhroughit Berkerey,cAltlch*l DeHaven jusl to seeil lhere sa sood tip or two buried we will continueto presentthese tech' OesMoines, lA Kentwblsh nique articles in tuhrre issues.In fact, we just for the techniques projects Anleay, we fell that there were a lot of ofrenchoose (ISSN0164-4114) WOODSMmI is pub- sood iips being $issed. So,we decidedto that are involved in buildins them. lishedbimonlhly Apdl,June, hishlight ihesetips so they re easiertofind. supr,uEs. Thal lakes care of most of the {February A u g u s l , O c t o b e r ,D e c e m b e r )b y Actually, we re doing that in two ways. madeto Woodsr?iilin majorchanseswe've woodsmilh PublishingCo., 2200 Grand sHop NnrEs. F'irst, we've added a regrlar the pasl two issues. However, there s one Ave., DesMoines, 1A50312. fealure called Shop Notes. Allhoush ihis moresmalladditionwodh mentioningWoodsmithis a regisleredtradomarkol page has appearedin a few previorls issues, Alo.g with the exploded view of the prc Woodsmilh Publishing Co. itwasneverthe re!'rldrleaturewe intended ject, the cuttins diasram,and the malerials Ocopyright 19&9by woodsmithPublish' it to be. lis1,we will alwaystry to include an inJorma' ingCo.All Righlsneserved. buildthe The ideabehindShopNotesisto sene as lionboxonthe suppliesweusedlo Subsc.ipllons: One year (6 issues) a collection of tips from the lvoodd,iitl project.Specifically, we want to provideinTwo Years(12 issues)$22-95. shop.As we're building the projectslor an fonnationon the lunber, the hardware, $12.95, and Canada andForeagn: add$2 peryea( tJ.S. issue,therealmys seemsto be a lew sood thefinishinssupplies. fundsonly.Singlecopyprice,$3.50. glrneral We receivea lot ofrequestsaskinghow tipswe wantto show. Second Class Postage Paid at Des in thisissueweve included much it costsio build a project panicuFor instance, Since lumfour tips that could be usedon a variely oi larly howmuchthe lumbercosts. Postmaster Sendchangeol address10 projects.How to inslall reccsscdwooden ber prices vary dramatically around the Woodsmith, Box491. Nlt.Monis,lL 61054. drawcrpulls.How to nake a s;mplcjis that count y, wecouldntcome up with one easy SUBSCRImON OUESnONS? Call8oG we decidd to list t]'e helps alisn a rolrtcr to cut a dado.How 10 dollarftslre. Instead, 435-0715 {lL residents: 800-892-0753). moun( false drawer fronts and get then numberof boardfeel ol lumberwe usedto 7:30AMlo 8:30PM,CSI weekdays. alisned. And howto rip thin stripsolwood to bu;ld the project.Aquick call to your local BACK ISSIJES:For a bookletdescribing be usedfor edsins plwood. supplier will tel you the p.ice per board foot. backissues, sendio address above. lyooL Lith In thc past,these n*nolssuE.TheJuneissueof That'squitea collection. SAMPLE COPYWewillsend a freesam- tips misht havebeen buried in the project (No. 63) will be maiiedduring the wcek of ple @W d WbodsniAllo anyone.Jusl anicle, bul could havebeeneasilynissed. J u n e 2 6 . 1 9 i l 9 .

Sawdust

WOODSMITHSTORES

sendushis/her name andaddress.

Voodsrnitlt

No.6Z

F R O M F E L L O W W O O D W O R K E R S

Tips & Techniques


R.OPE GLATP
f youve everslued up a frame, andfoundthatyourweb clampis lost somewhere, do whatI domakea ropeclamp.This clamp is madefrom two readilyavailable items a handscrewanda length ofrope. Applyglueto themitersofthe frameand assemble the frame, Thefl place the loop of rope around the fram. Noq wNIe holdingthe endsof the rope, slidethe handscrewup closeto the hame. To keepthe endsof the rope from slippins through the clanp, tighten down the back handteso the backjaws pinch the rope.Now, to get the right tersion aroundthe frame, slowlyclosebotzhandles onthe handscrewsimultaneously. MortA Robbins PleasantGmrq Utah Ed,itor'sNote: Wetrietl, thi"s rope clamp methodusing Larious tApes of rope. We worksthe found.l/,'nyLonhrpe best.And,, it's faiLy cheapat about30 cen$ perJoot.Also, V!" uide nslon flat webbing

GUIDE FOR Hll|GE tORflSE


Cutting hinse mortises with a chiselcanbe dif6cull The prob' lem is tryins to keep the shouldersof the mortises straisht and the bottomflaL To help simplifythis task, I built a chiselguide. The sdde is nade out of four piecsof Tarltlick stock.One shoulders ofthe dado. Finally,cutapiece for theback andglueit to thebackedge ofthe twowidth stopsto create a "window"for thechisel. To usethe chiselsride, mark the locationof the hinge. Now

'{HN ;fii'

'IN'H

RO'E

To use this clamp,open the front jaws while closins the backjawsso the clampforms a 'qr'",reier to the drawing.Form a loopwith the endsof the rope andlayit on aflat surface.Now, lay fte "V'of t]leclamp overthe endsoftherope.

stopagainstthe face of the door or stile. The other three piecesare slued to the top of the edge -o;;;;';o; stop and guide the H|IGI r4t EDaiioe chisel when cutting themortise's width andlenstl look throush the '\rindow in To mal(ethechiselslide, frst the guideandalisn the suideto rip apiece ofstock|-r,videfor the thelayoutlines.Then,clampthe edgestop.Cut it to lengthabout guideto theworkpiece. longer To cut the mortise, start by 6rr thanthehinge. Ther,I cutadado in thispiece oudiningthe three sidesof the equalto the depthof the hinge I mortise. First, set the chisel against the two width stops,andtap mortise ends. Then, hotd the chisl agairst the length along the lenet} of wast, chopaseries ofreliefcuts alongthe lengthof the window, aboutevery Yl6rr, refer to abaw ing at left.Thenlaythechiselflat in the dadoin the edgestopand pare straight in to removethe waste to the backof the guide. RogerSt-DeniA Rbon, Quehec

ourcKilPs

.Cut Pbwood Easier

Cuttingiarse sheets of pblvood onsawhorses orjust by yourse[ canbearealhassle. Wlen I don't havehelp, and I needto make longcutson a sheetof pl'-vrood, wantfor the mortise.(Ahingeis I put the plywood on top of a4x8 usuallyset into a mortisethe sheetof Sttrofoambead board. thickness of one teaf.) The Set the depth of cut on the lensth of this dadomust natch cirular sa]vso it cuts through the lenglhofthe hinge. the pbryood,but barelyinto the After theedgestopis fnished, bead board.You dont have to nextcut the threepieces to form worry aboutthe bladebeins the U'shaped chiselguide.First, damaged in thebead board. And, tv,/o width stopsareaddedto the idseasy to crawlalongthe top of . Dowel Centers topofthe edgestop. Thewidthof thepl'.rood to makelongcuts. Dowel centersare usetulfor thesepiecesis caiticalbecause Dahiel Mo,Lin markins matchinsdowelholes thisis]vhatdetermines thewidth - if they of the hingemortise. pieces Shaknee,Kansda in adjoining don'tfalloutbeforemakinstheir To determinethe width of . Clean Shoulders rnarL To prevntthis, placea these two pieces,measurethe Whenever I'm handcutting pieceofmaskingtapeacross the width of one leaj on lie hinse, tenons, I'vehadproblems keetr dowel centers-The points will andadd |r (for the width ofthe ins the shoulders clean. The still so throush the tapeand edge stop).Then rip the two bladealways wants to wanderotr maketheir mark. width stopsto size. Now, slue the scribelineright at thebeginRichnrd,Dorn them to the top ofthe edsestop ning of thefirst cut. Oelwein,Ioua so the ends alisn with the

To makeit easierto start the sawandto helpkeepthebladein linewhilecutting,I uta starting trowh,r7ithasharpchiselon ihe &ostesidr of the scribeline. To do this, jllst parestraightdown on the scribe line lirst. Then, male a secondcut,holding the chiselata45' ansleon thewaste side of the score line. This creates a channelfor the saw bladesoit ridesin the score line. Randnll Prestridqe Stuttgai.t,Genna.W

sEl|D |la tOUt ftP3


IJ]'ou'd [k to sharca tip with others,sndin yoff idea to Woodrr?it4 Tips & Techniques,220{GrandAve., Des Moines,Iowa50312. We p6y $15 for accepted tip. Plealesendan explanation and a sketch if neded (we'drawarcwone).

No. 62

\foodsmirh

F E A T U R E P R O ] E C T

Displaywall Unit
With justtwoanda hnlf sheets youcanbuildthis of pLywood waIL unit.
The shelues are deepenoughto displnystereo equipment. And the doors at thebottommakea nicecabinet to heID conceal ant clutter .
7 V a l a r s ep r o j p c l l i k F l}li. rusualyduFlo rJre 5nalsandinc Display Wall Unit, plla,voodis an each sheet sers)_So,rather than ide3l natenal to work with. It's taLe a chance on a sloppy fit, or flat, dimensionatlystable,and on a joint line that looks wa!y, I comesinsheetslarseenoushso cuta y{i,widedado, andrhencut you don t haveto go throughthe a tongueto tt. tediousprocessofedge-gluinga EDcrNG. In addiliontousi.q lol or boanl. I ocedrer. tonsre u d sroovcjo;nerya. lh; However, there &e two main primary joint to assenble rhe disadvantases to pl)'rvood. The case,l also used it to a$ach edsF d g e " h a r e r o b . c o v e r e dr n i n g s l r i p s r o h i d F r h e e d g A o | l h i sone way to hide the plies. And, casesides and shelves. the project has to be desisned Althoushtbe edginscouldbe around the fact that p])vood slued on with just a plain butt joinl, usins a ton$e and sroove comes in 4 x 8 sheets. Togetthemostefficienluseof joint helps alisn the edsins. each sheet, you have to jusgle wlen you re working with lons the size ofallthe piecesto fit a pieces (as on ihe front of the cedain cutting diasram. I also case),you needall the helpyou had 1(} watch the grain direclion can get to get those long strips especially with the doors. slud on - without sliding all Hereltriedtoarrangethepieces overlheplace. on the sheet to get the nicest FrNrsH. When the case was grainpattemon the two doors. done, I decided to apply two ToINERY. After working out coats of Minwax golden oak the cufting diasram, I had to de- staio. Then I finished the Wall terminethejoinery.I decidedto Unit with two coats of use tong'le and groove Mccloskey Heirloom semitoss joints throughoutthis project, !"mish. besinninqwith the orithree fixed shekes to

rrt lA/

yousc'oulrobuild rhickn"*firoushour hcn fie .heel

joint marv tojo;n Ge SUPPLIES

TUNBER To join fiese pieces, SrebTarr{'ickoakdn!,ood I cul a Y4,'widedado . 112 . 5Board ftYa".*icksotid across the inside o6k Yarr-thick oakpbryood face ofthesides.Then . 1Sheet tonguesare cul on the HAIDWATI (Se page 24for kit) . 2 Recessed red oakdoorpulls .2Pairpivothinss .l2Brasssheusupports . 2Adiustablelewlers We usedYairoakply . 1Doubleplatema8neticcatch wood, which is rarely H||t3H exactlyTarrthick it's . Stain: MinwaxSolden oat usuallyjust slishtly . Vamish:MccloskeyHeirloomclear less. It can also have smidoss vamish slight variations in

tsutwhy cut a Yr'-

wide dado? Why not m a k e j t T a ' rw i d e t o match the thickness of

Woodsmith

No.62

EXPTODED VIEW

CROSSSEGIION

CUTTING DIAGRAM

It,tAIERIALS TIST
3/4 py 155/s\7911 A C*esids(2) 8 FixedSheres13) |'t py 151a\29rA P n ( 2 ) % ^ p y2 8 1 h x 3 r 2 c lopBrm D CaseBacklll fa"pty291h\1(P4 E IopAdt Sheves12) 1!'ply 14hx2831 F BoiomSheill) %"ply.28lb x 1312 %"py.13,1 63 ! 4 G D o o ri s x2 2) EDGING SOLIOTFIM H TopBonom(4) ,tx1 15:A (2) I Front Sdes !r'lxl 80 J Fredshereq3) -1'1t 1 28 { AdjShalves (3) Yi r 1. 28h L PanelSp&ere121 ]/i x 1.28 M T o p P aT nr em 1 l ) ; / a x1.28 N Fre.Srdp(1) A\ 1\t 2811

ri

x 2 .30

l . a B d .F L I

N,,.6,1

W,r smith

THECASESIDES
clnm srzri--lbnrakcthe sides, fFtcrt a larse blank to a rorgh width oI34'. and a fnished l--nsth pasc olT9lrr , seeFis. 1.(See l0 forclltling plywood.) ToNctrEs, AJter Llreblank is cut 10 size, plywood, thev pre tongusare cut on allfourcdgcs. Ton$es areusedtoanachhardwood edgiig, rcfcrto Irig.ii. (llcgimingon page20,t|crc s an articlcaboutaddingedsing to plywood with shelves(B) and thcscrladoeshave 10be t o n L u e a n d s r o o v e j o i n t s . ) periectlyalisnedso thc shclvs lay nat.The Procedural Notc:Wl]en I had the router 1nckis tocutdre d a d o c s a c r o s s o n e b l u k o lsetup to rout thc longues,Iwenrahead and ply{ood, thenctrtlheblankinhalftoget two routedthe sametonaucsor the si\ shelves (B, EandF). (Seethe scctionbelow.) idcnticalpieces, seeFiL. 1. \VallUnili)y naking D]1r)(JIis r.oRsHELvEs. AfterclltlinLallthe ton!au--s. I cLrtthree dadocsfor the fixed shelves (B) acrossthe larsc blank. rirst. nrark the locationof the three dadocs, see Fig. L Then claDrp a slrai,rhtedge fcncero thc plywoodblank and rout eachdado.(In Shop Notcs on pase 12,we show a snnpl. sausc tohelp alignthc frnce.) cL"rcAsEsrDr.is. No{ togetthe two case sides (A). I ripped rhe pllnvood bluk inlo two pieccs. cach 15.rS'\ridc. BAcrips-EL RrBBrr.'thc last thing is to rollt a rabbetonthc backedgeon cachcrse sideto attachthc casback (D), secFis.2c.

FIRST:

5ECOND:

THE SHEI.VES
the shelvesfor thc cdginla sldps,see t'ig 3. Next.lout ton$rcso bolh.rdsoft|cfixcd shelves(ll) only.Thesc, tonexesnt into thc dadocsinthecasesides, scc Fis. r. TRIMmNc{i},is BACK. Thc (B). two top ad- slep on the tongues.Thc loneueson dr-ront edsc ol the ilxed shelveshavc to be (E), andoneboftom trimmcd backto all{)w spaccfor the edging whcn it's applied to thc cascsidr,s.Trimthe (F). I starled bl' cuttins all six of thcse tonsuesback lr' onboth ends,s--e l,'iS.4. shelves to size.se--l.'ig.3. Hor-Ds r.oRprvmHrNc. hter. \rhen thc ToNcriEs. AJter dres|elvesarccut 1osize, doo$ are mounlcd,I used pivot hingcs to tonguesare rout.d on tre./'rnt e.lg.solall mouot them,kief ro I.ig.1.Thc only prob lemwithlheseIingcsisthalrouhavelodrill theholesin t|c botlomli\ed shelf(ll) D./br. thecaseis assenrblcd. If youdon t drill these hoics ro{. you cant get thc drill close crough to the comeraftcrasscmbly. Also, these hol--smlst bc drilled ;n the dght locationfor the doors to s\ring prop' erlr'.scc Fig.1. Mark LheceDterpoint ollhe Iolcs i/i" lrom the.,.1slo|/dr1 oflhe bo1tom shelfaDd l,/r'from lhe front shoulder. Alter ma*insthc localiorr. dlillthe holesat bothendsofthc shclftoacceplthe bushings forthchi ge.seeFiL..1.

rf
t

I nxrDsHEr.vEs Glar .\=

aDJUSTAT|I SHETFI

i "oi%" l\
' l''!' I

o.
ADJUSTABIESHILVES
2 flEcFcur B^cK __:JZi .\_-[Z D.[L HrNcE

\foo.lsrnittr

ASSEIIIBIE TIIE GASE


Oncethc shrlvrs weremrde.l be,aan to as sembiethc casc.I slarled by laettingthree position clanrpsin on thefloor.spacingt|em so they rvouldbe in line with thc dadoes. Then standthe sidesonedgcwith lhetr\ed (B) lmselvinplacc sheives TAPDRD \Vhent ou re clamping BLocKs. rridepicccslike thesecasesides, the clanrps

l h e m i d d l e .T o s e t

gluc in th dado.llren clamp the shelf in placc,chcckinglorsqtrare a,rainst Lhesidcs To get evenprcssure on the entire length with a lramingsquare. Clmp tbe otherfwo of the tonsue and dado joint, I lrade li\ed shelves usnrsthc samcprocedure. tapered clamping blocks. The tapered As the clampsarc tightcnrd, nake sure blocksare nothing more thanlcnsths ol the front shouldersof thc tong1les on the 2 x2 scrap. Usually you can lnd some shelvesare lush with the shouklcrsof thc lhat ae alreadyslishtlywarped andlorm tooereson the casesides. If no1.use a plane or belt sandcr to crealea bowedshapefrom the middleof thc 2 x 2 outlo the ends.You don t haveto work too hard - about h6' per foot is enoush.Il just has io bowenoughso fie middlelouchesbeforeihe ends.

TAPERED BLOGKS

ins blocks. (For S h o pf i p . W l c t

cRossSEcTtoN

GUTEDGING
in eacbstrip Lofit ovcr thc longxeson lhe can trim lhis slight lip lush wilh the plydrying, I cut l2 edla cases es and shclvcs. scc Fis. 6. Sincethe wood.(l useda flushtrinrjis. sccDast22.) pRoFILE cdgins is 1' wide and th-- plt$ood is only EDGEs.AJter tbegf ooves arc c11t, .L 'lhick, lhe stuovesafecul slishtlyotr{cn ro!nd ovrr th lronl edlaes olallrhe edging tcr.This producesa lip on Lhe insidecdgcof s t r i p s $ i t h a ! 1 r o u n d { v e rb i l o n L h e r c u L c r ( H ) , t w o r o r l h e L\ecasesidcsand ontbcbotlomolfi e shetves. tabl,-. seefiC.ll 'lbcut front edges (I), and thc oltsctsroove,Iuseda yr dado ShopNoic Snrcct}.s. l]dgiilastripsare sixfortheshelfedg bladcon drc lablr saNsc,t li,i deep. seelri!.. fanly narrow,luscd agroul trorveltopush rine(J,l0. \f 7 . ( T h e J r f o o v ei s 1 6 ' d c c p c r t h a n t h c then firousb lhe rcund ovcrbit. scc Fig.3. crrrDI)(;rNG. Start b!'ripping I {ideedg Longue to allow a gluc rclicl) Positiontbe AlLhourrh Lheround ovcrbitlras alall-btaringslripsfronr.tr' thickstock.-l.lrcncutthc groove so lhe edginJa will stick just a |air ing pilot.I usedthe lenceto guide the long tvelve pieces needed to roughlcngtl. abovethe iace oI the pl\qood (abouttir ) strirrs. Aligr the lencewirh the edgc ol thc oFF.CE\"IER GROO! I.. N--xt.I cut gfoovcs \!he iLsialued in place, se--liia. ti.Intcr.you pilot.thcn pushthe sLrips alonJa Lhefcncc

No.6l

\\',^,,1].r'r,rh

EDGING - ,, ,.0
dgingslips, I cut them all 10lenllh. bottom strips (H) roltl9lloM riocrrc

sides. seel'is.9a.
Next. cut the front strips (I) thar go on the frontcdg.s of the sides, ud round over lhecnds.Also,sincethe laroove in lhisstrip exlendsthroughthe topcnd,cutafillerplura to fit this hole,seeF'ig.9a. Noiv. cut th-- shelfedging (J and D 10 lengtlr roundoverl]]le ends,dd alue it onto thc shclves.Whensluins the fixed slclf 'I strips on. the lip on lhe top shelf facesup. hc lipsonrhemiddleabottom shelves hce doM. DRn-uNG TEMPLTTE, Aller attachingthe edsirs strips,I drilledholesfor the pin sup ports usedto mouni thc top adjuslabie shelves(l.l). Ib positionthe holes, I crt a drillinA templatcto ilt letween the rop and middleshelves-Then drill tr' holcs.spa(d pagc5 assbownin the CrossSection, Afterusingthistemplate to drill the holes in the uppcrscctior ofthe $Iall Llnit,trin it d o w nt o d r i l l t h ch o l c s i n t h el o w e r s e c t i o n .

b.

a-__-'

rOP AND BASE


ft)p .\NDB()TroM pn-\El.s.AJter attaching panels(C).The roppaneliscurto litbehind thc lips ol Lheed,rins slrips abovc th top shell see l.ig. 10.Be sureto notc the grain directioD this panelis oolr'.lt/,.\larobe (D) out ot ll ply causethegraio directionmns verlicall!'.It's cutwidc cnoughro fit behindthe lips of thc panel rronledsinsstrips(l) on the sides.The on back oflhe casesides,and bcnvccnthe on the boLldn is cut lo flithe same way. top and bottom fix.d shelves, see lig. 10. Aflercutiing the panelstosizc,gluethem Then screwit into lhe rabbets. in pl:ce behindth--lips of ihc cdsing strips.

complctcdbyaddinla the caseback,I addedthetop md bottom added edsinspieces madctolooklike alllhe


otheredging.'ro do this. firstadd a spacer (L) 10the lop edgcof the 1oppdel, seet'ig. 11.Cut anotherspacer106t on the bottonr cdgc of the bollom panel, secFig. 13. Now, on the top panel only, cut a top panel tlim strip (M) I' wide (to duplicate the look ofthe edsins) and round over the front edscsand endswith a 14'round,over bit. Then glue this trim strip to the front of the spacer(L), sceFis.12.

spAcERs. To complele thcsc panels,I

Vorxlsnith

No.62

rHE DOORS
The cabine!is rcally

However,I added doors(G) to the bo1deleminefiebcisht of thc doors,measurebetweenthc rdgti!' li|ips on the two lowcr shelves.Thensub lract yr forthe f3'rslace aboveand belo.x the doors,and subtractanotheryd' for the 116'thickedginsslripsthattrim thc doors. 'lb gcr the widrh of the d belween the edgin,a stripson drc casesides, subtract 7sr (for thc t'3"sp:rces on eachsirle oI the doorsandthe onebtween the doors). dd subtracttl'for the eddntastrips.'lhen divideby two andcut the doors1owidth. EDcrNGsTRn,s. Aitcr cuting the doorsto size, I cut yr6r-thickedgingstrjpsto coverall four edses of the doors. (Refer to Shop Notesonpalae 1:tonhowtocuithesestrips.) Afterthestripsarecut,glueandclanrp thc shps on the sklc edgesof the doors first. Then add the stripson the top and botrom cdges. Finally,trim the edgesfl sh with the puus- Befde mountingthe doors,I cut recesses for the pulls ad mountcd them. (SeeShopNoteson pase12). HINGES. The doorsaremountcdbenreen -nrc the two Iowershelves wilh pivothinges. holesfor thcsehinses are alreadydrillcdin As for the top holes,vou need to add a fi r stlip (N) behindthc lip oI the ed,.ins slrip on themiddleshclt seFig.16.Cutthis srrip to fit, then drill the holes in the sanre position ason the botlomshell seeF-is.l5a. Then mount the hinses and screw them to thebacksollhedoors, seet'is. 16. I alsomo!nted adoublenasneticdoorcatch u n d e r n c a t ht h e n 1 i d d l ef i x e d s h c l f , s e eF i g . 1 7 .

I.EVELERS
Althoughthis wall Unit maybe perfecdy square andlevel,thefloorit restsonmaynot be-especialyiltheunitisoncarpetinsand againsta wall. There'susuallya iack stip underthe carpetnearthe wall.This cantilt the topof theWallUnit out from tie wall. To levelit , I added lwo adjustable levelers bebindt}le bottompanel,seeFig. 18.The trickio adjustjnseach leveler is to drill ahole throush the bottomshef for access to the s{rew in the leveler.lrcate this hole so it with thetopofthe screw. aligns Thenmount the leveter bracketto the bottomprnel,and levelthe Wall Unit. Coverthe accesss hole with theplugthatcomes with the leveler.

No.62

Wooclsmrth

H N I Q U E S

Cutting Plywood
guidcthe cirtu 1o /r,". "- buitd a Droicct with Dly edgelenceto lhe plywood lar saw of sabk saw.The fcncc I usc aulo i rchallensrisrolayort V V w o o d . r h erfs the bladeotny circrlar saw ailtlcpicccs sotheyfilon alxssheet (oron nraticallyalilans parlialsheets) \'ithamininrulllof waste.l he 'l) make lhe le c, rip a picccof .r1' pll' sc.ondchallenleiscutlirglhoscpiccesoul iroodaboullr w e,ardglucthcpllnioodon oftheshe--L \tiLhclea , straightcdgcs. top ot a picrc of !1' Masonite,see Fig. l ROUGH CUTS Thcn run the.ifcular saw acai sl lhc ply is to sood icncc to tirn ofl the rilahtedgcoflbc The inilialstcpin cuttingout the pieces Thisgetstbc right cdgep--rfectly cut them to rcush size I usuall!'cut thcnr ['lasonite. in line with the pathot thc bladc about !1' to tjr l ger lha rctdcd.'lhis $'hen the fe cc is clampcd to the plr'e\ra so you car makcas"-c allowsenough ond passc,r cachcdgc to get a \l To illusrale some0ft hc prol} we ve madeupa luns involvcd. a cultiig diagranr that presenls nunler of ly!jcal fLi ts. 'lhe first sLep on this panicu laf curtingdiagranris to cut off the slrtend olthe shecl,scpa lr a t i r go f f p a n sG a n dH . T h i si s alsolhc ll rst probhN afea. $IDE ct"Iri,Its oft.n the case t|ar ,vouhav--to cut a pieceoII 4 I t h c c n d o l a m u c hl u j a e rs h . c l . ilyou hlve so e In mostcases, h,-lp,I'oucan nrakr tbis $pc of you a i/,r i4l,t.ul, buL .uLon atable saNB . u ti n t l i s c a s ct h e p i e . e s wood.you rt cnsuring (at too wide for the rip lcncc alsolraveLomakcsurc il s perpendicular arc 26' wklc (whichisusually a ,ahtansic)10lhc lof andbotldn edgesof srtlingsonnrosttablesarvs nhal do you do? thc shcct. lf not, you ll run inLo problcms hnitcd ' l h e rto e :1') So. a r es e v c r a l \ ! a y t so g o a b o u ti t . l whcn cuttingolfadjacenlpanslaliY.Clanrp olDlysood.and usc a usualll make a rough cut with a ponable thc fcnc. to the sbeeL circularsai!ofa srbrc sa\r to gct the pieces iraminlasquarc lo chccl il againstthe lop size. dorvn to a nranageablslrproKr. To lalt. ilr rough culs. you FEricE. In ordcr to Dake this t! peoi cut o I clampa straighL- have to raisc tlc pllslxtrl oll the lloor to a lafgesheelol pltnvood. prcvideroom lor the blade10clcar.I placc t h es h e e t o i p l ] $ o o d onsome 2x1s-$ith a! leastlwo boeds on bolh sidesot the c t. see Fig. 2. Arothrr nicc way ro supportthe plywoodis to lay lhe shctdown on a piece oI Styroloan bead board. (Tris tir is ex plaincdon page:1.)
It \nu u<p J LirrulJr .J$ u. -'brc ,N".

placethe pllau)d with the goodtacedorf, Both tools cut o lhc upstrokc,so most of saws the splintering is on thc lop sidc.'l'able is cuton Lhedo$n strokc.so thc sphrteriDg Okay,backto the cuttins diagram. Cut off the end section with pd ts G and H ilrst. cuttirg at leasl l!'wider than the final r/.r wider). \ridth (prefefably c r r T r r N cP A r R s . 0 n t h e r e are tbree mainingsc.tion,Urere grollps ofpjcccsio cut:A.ll and C,DandE.F. \!hen youie dealingwilhluo pieceslikeE,l'rhaL nrethe samc sidlb. I rip lhcnr oft on a table s a $ a s a F i , n r s t .s e e l . i g . : ] . -lhen I final cut them into two p1-aces. scparale -Ibc kc,v hcrc is to nuke tbe rough cul \ride enoush lo accoLrni for lhc flts made l . / k ? . , t h el r v op i e c c s n s s ' c l l a os nt h eo u t sideedlaes olloth pi(cs.]'lat js, allow 11' Iort|c ortside cuts.and anolherr/1' Ior th pieces. cutsbclseen tbe Lwo Rorj(:rrun;I..s.OIthe renaining section. you couldcul olfpans C.l) tlc sanre way as 1,1.1: on a tablesas . Bul lirc rdgc thatgoes againstthe ience (the edge to thc right of

ROUGHCUT

wlHuYoui-;

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Pos[roN
ON BOTH

Irl

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sIrrith

N,,.6l

GUTIII{G AT AN ANGIE There'sa diflerentsetofprobimswith cut Ityouneed !o nrakean dgled col on a ldge tjng apnrt pairs likc C,H, or wheDdcaling prece, asonpansCandD. thereareacouDle with a very larsepiccclike pad A. flNAt tuts In bolh cases yo! havea lactory edgc to This lypc olrngle cut isdilficultona table Alter rough'culling the picces down to a work offof. brt the piecesarcmore rhan2.1' saiv.So that lio ts you ro using a circular muaaeablc size,you can trim the edgesto lons morethancanbecrltwithastandard saw.ora sabresai! - both ofwhich mishi gel them to thefinalsize.This usuallycalls np ienceon mosttablesaws. producea fairly rough edgc thal has to bc ror a senesofcuts,noljusLone. You could use a portablecircular sarvro cleancdup in someway.

pans C,D) is not a iactoryedsc"- one of the original edges It s the rough,curedlae leit overfron cuttingoffpans c,lL As mentionedearlier,whn you make a 'touAh cut, as when cutting oll parls (;,H, makesurethe fencis perlendicularrothe top edge (the factory edse). 'mis just{ul rolrgh edge is the edge that will now be asainstthe fenceto cutoflpafls C,D. 'lhcpointhere is that "roush 'cuts arc Dor supposed to le roush-'lhcyare i,irel cuts that get thc piecesdown to a nanageablc size.'lheyshould bemadcwithcee soothcr cuts that followwon t be messed up.

curm LrNclrr. Pices E and I,'are now cutto fin:l width,butnot tofnal lenglh.The problemherc is that they arc very long. If you place thcm againsta stardard miler gaugeto cut ofl1heend to lcngth,lhe piece maylcnd to twisl (bccarsethefafenddrass) a n dy o r d o nt g e t a g o o d cut. To solvetbis prouem, I add a fcncc10rhe miler gargc to suppod thc lons piece for mostof its lenglh,seeFig.4.

Fr-L:srr TRm lllr. Anolher method is to Lrin the rough edgeoffrlith a llush trin bir. 'l}is is a very similarlechniquc ro sins the straighlbit, exccptfor the lencc. A fiushLrin bit hasa ballbearinspilol that rideson thc bottom ofthc bil. So,thc fcnce has to be clanped to thc boltom sidc oIlhe pltNood while the rouler rides on the rop side,see].'ig.5.Also, theedscollhe fenceis alsned riaht wheret ou wantthe cutlnrc.

lRllttltNc

wttH a RoutER

with a slraightbi! to cut throughthe ply

the middle ol the rorgh piecc.I would

c a r b i d e - l i p p eb di t .

FrRsTP]rss.

-Ihc LOIIG PIEGES

roulahru! cdge (lhe cleani1 up, scc Fig. able to gr a good cut here becausethe factory edge is againstthe fencc.All you needis 10makea ver) slight trim air to producea new,cleaneledge. pAss. Aiter trintming off tltc SECOND rough{ut cdge,I make bro tnal cuLs to riD the Dicces to fina] widlh. But instcad ol makingthecutwithrhcficrorr-'edgc agai sr the fcnceason thc firs1pass,Iflip the piece aroundandrun thejustrut edgeagainstthe lenceto cut oll pieceE firs1, seeFig.3b. -fhc F-\cToRy EDGlr. reason hasto do with the iactorycdge. Aithoughth;s edsecanbc lrustedto makeinilialroughcurs,I don'tIike il as a finai edge.Its usuallybansedup in somc vay - with splinteredand denred edgesthal oughtto be Lrimmed off p.,Lss. THrRD So_ cot ollpiece E using the tresh{ut edge asajnstt|c rip ience.lhcn you haveto makeathird passtocurparl l'to tnalwidth,see lris. 3c. m a k c t h e l i n a l t r i n r c u 1 . ( S i n c ey o r l ' r e ,nakinga fine cul on the ed,a--, usc a good plys--.ood bladeand rakeir slowandcasy.) Ilowevcr, ifyourcncular sawprodu.esa roulah, splintered edjre, or ilyou useasabrc sawonthe roughcut,Lherc'sarrothef wayro gctagood edAe.lwould1dmthc cdgewirh a roulcr.And therc arc t{o waystogo here sith a straightbit,ora nushtrinr lir. s'fli,crcl{r Bn.]b trim with a saaightbit.l likc to use a largeslraightbit (usually a31l bit).Then clampa straightedge tcncclo the plrlvood to guide the router. Adjusr the fencesothe bit t msaboLrlfrd to r's'otrthe edseoftheplrlvood.prod cinsafresl cdge. The lenceforlhis tdmming opcralion can be the samerypcasusedror thc circularsaw (seeFi,a. 2), exccplsetup lor thc router.Tlre onelhingvou haveto watdr is ihal the fencc 's per?endicL ar to the cdgc olthe pieccso youlc not cutlingat an angle. asis nlreded to separale the rhfeeparrsB.To make this type ofcut, I usc a panel{utiing jig. Thisjis is a poor-man s versionola slk! ingplaltomrloundo somelargcsaws. pieceofplylvood Il sbasicallyjusta wirh a nmner screwedto the boLlom. The runner ides in thc milerslot toguide the plryoori plafornr.'nrere s also a fcnceon the back edgeto glIidefie pieccsquare|o thc blade, seeFis. 7. (llisjisisdiscussed i n d e t a iilr tinodsr,ti, No. 18.) I use it to cut piecesoIJa long, nanow piece (like pafts B). JusL lay rhe long piecc o thepanekutiingjisr{rsuppodiltocutthc pieces ' I olf to rough lenlath. ocuttbem tonnallcngth c, lampastopro the renccon thejis. Place the leftend ol rhe rough c!tpiece agains!rhe sropandlrim olf thc right end. lhc stopallows!'ou to cut off thc olier tlvo pieces at --xactl)'rhe samc lcnglh,wilhout mcasuring.

,lt,

N,,.62

Woodsmith

1l

S O M E T I P S F R O M O U R

S H O P

ShopNotes
DRAWERPUILg
lMy frst thought about routi.s recesses for drawerpulls(on the wall Unit and Desk) was io makea template and use a router a n d a s u i d e b u s h i n s .T h a t ' s probably th best approachif you'redoinga wholekitchen. Since I only had a few recessesto rout,I did them free' hand. The pullshavea .*2'-wide lip aroundthe outside- thal s enoush room to allow some LAYoL-r.I began by locating on the positionof the recesses the workpiece. (lhe measurements are on t}le plan drawings.) Use a square to draw layout lines formins a rectargie, see Fis. 3. Now, se1a drawerpull inside to the layoullines as a template drawthe round ends.seeFig. 1. To FREEHAND our WASTE, roul out most ol the recess, mount a Ya' straight bi1and set it to depth to alisn with the.lpst padofthepull, seeFlg.2. (Note: On ihe pulls I used,the back is sandedat an ansle. So the di$ tance f.on the lip to the back of the pull is inconsistent.)Tbe recess has to be routed deep enoughorthelipwonl sealtighi againstthe front of the the door or drawer tront. ($lth a slllal router, mal(e lwo cuts, increasing the depth belween cuts.) Now, tum on the router and plunse the bit into &e center of the layout lines. Slowly clean out waste moving in a clockwise direction holn the center to the layout lines, see Fig. 3. Stop about h6" ftom the lines. cHrsEl-'ro uNE. After most ol the waste is cleared out with a rouier, switch to a chisel to clean oul to the layoutline,seeFig.4. The lip is wider on the ends of the pull, so you dont have to chisel out a perfect radius.

Whe]lftut i)tg ont the rccessfot a ptlL, ralt deeperc lth sothe 1seatu tilt ht elta u 6t I ip of th eN L thedn et or doarflnltt.

us o n*ro',. aatstt4

ALIGNMENT FENGE ROUTER


a I when routins a dadoacross widepanel(suhas on the wall lnarkthelocation Unit), I usually of lhe dado6rst.Then I clampa pa?llel to th e laystraightedAe oul lines to guide the router. The problem is trying to fisure out the ri?ct location of You haveto measure the tence. the distancehontheedseof tle routerbase to thecutlingedgeof the bit, then transfer this to the workpiece. measurement S o m e w h e r ei n t h i s p r o c e s s , there'slikely to be someerors. caucE. To be a little more aL' curate, I made a simple dado gauge. It'sjust: piece alignment with a dadocul acrossit ol scrap that you can use to al;gn the straightedgelence parallel to !'our layoutlines,seeFis. 2. To make the sauge, clamp a pieceof scrap downto thebench and clamp a bigher fenc at one end,see Fig. 1. Now mount the bit in thc router and run the router base asainst the hish fence to rout a shallow dado the pieceofscrap. across usrNcrHEG{ucE,'lb use the gauge,tum il over on the workpiecesothe dadoalisrs wi& the layout lines. Then butt the straightedge fence againsl the end of the gauge and clamp the straishtedsedown, see Fis. 2. Now rout alons fie edse ofthe dado should straishtedge.The natch the layoul linespedectly. S i n c e r o u t e r b a s e sc a n b e mountedotrcenlerin relationto the bit, alwayskeep the router facing the same direction fiat it waswhenyouroutedthe dadoin

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novrsxnuow-oroo "iicliEi-riixi

Voodsmith

No

S H O P N O T E S

DRAWERAIIGNTENT
I W h e n n l o u n t i n s r h e f a i s e ttedrawerandsqueeze thefalse lronts 1o the front of rhe Desk iront and the drawer loqether. drawers, I used a four-screw see Fis. L The screw points t e c h n i q u e . T h e r w o b o t t o m tcmporarilyhold fie fatsefronr screws get the false front close in position.(O.the niddte Desk to the conecr posirion, whitethe draweryouwiii have10puli the two top screws fir in oversize drawer out slightly so your fin shankholessoyou canfine rune eerswili clearthe divider.) the fnal Dositionoftle fatsenonr scRL-woN ttoN"r. Now, care SrrAN'KHolls. Begin by locat- tully pull lhe drawer our of rhe ins and driline four :,,li,!dia. caseand clamp the false fronl ro counterbored shankhotes in the Lhedrawer,seeFis. 2. Norer'Io drawer front. Drill the bottorn prolect the false front, use pads b{o holes a little .s,rQll?ftha! under the clamps. Wlren the standard shank holes (dritl r^,l clamps are tight, remove rhe Ior No. 8 screws) so the screw bottomscrews.'nren driilp;tot tnreadswill siishdy "srab th holes for the two 1op screws wood Thcn, drill rhe toD rwo a n d d r i v e t w o r o u n d h c a d holes k6'r ior"f than usual screwsjnlo placein drehotes. (drill ta" Ior No. I screws). AJter the top screws are in AIter the holesare drilled,in, place, remove the clamps ad sert rou.dhead screws into rtc push the drawer back inlo th. botromt*o holessu thc purnts opening. if the front js our of JUststjckourfro th m e l r o n r o l r h e position, pull out the drawerand dmwer, see Fis. L Then, slide gently tap the fJse front wirh a lhe drawerinto the desk. malletuntil it sinpositon. (The ALIGNINGTHE FRoivT_ Nex1, top oversizeholes allow some holdthefalsefionrin positionon minor adjustnents to be made.) the front of the drawer so ir's Once the front is squareand square and there are unilorm the gaps even, drill the pilot eapson allsides.Oncethe fatse holesfor thc boftomscrewsand fiont is in pos;tion, reachutrder

2 onu nLor

r{ ltrotr RtrovtNc

IHIN EDGINOSTRIPS
lTo coler the edaesof rtreply$ood doorsontheWall Unirand the pLvood lalsedrawerfronts on the Desk,I sluedon thin eds, ins strips.The only problen is howto serup the lablesawtocut a e'irs of h6'r-thick strips. ll you set up to cut the strips ,el&zfl the fenceand the blade on lhe talle saw,the thin pieces can easilyget caueht and kick back.Instead, thebestmethodis to cut the strips off the x,aste But this canalsopresent prot> tems How do you move the Ience the exact same distzncc eachtimc 10cut multiple strips ro a It n itinl) t hi. kn es s? smP. The solurionis to use a simpie stop.The stop is jusr a blocknounted toarunnerthats in the mitergaugeslo1, seeFis. 1. And, on the edse oflhe stop theresaDanhead screwfor"fine tunins thewidthofcur. usrNc THEsrop. To use the stop,moveitalongside thebtade and adjusl the screw until rhe distance befween the bladeand the screwhead equdsthe rhick, nessof the edgingsrrip. When i1's ser, pull rhe stop about3r in frontof thebiade, and screw a llathead scrcw into rhe end of the runner ro kcep the stoptrum movingtorwtrd agarn. Now, \lide rhe workpieLe against the screw head. And then slide the rip fenceagainst the workpiece. After lockins downthe fence, cut ofl a strjD.T; cut strips exactly the same width,slide tbe workpieceand lence against the screw head againandresetrhefence.

No.62

Wu smith

1l

F E A T U R E P R O J E C T

Study Desk
'Whether youbuild thisdesk for a home , ffice or a kid's room it's designed . The topis extradeep for fficient useof space for morewable surface area draweris specifically siTed to holdfiIefolders . , andthebottom

r.", ourrouuitdrhisdesk. \l/r,"n rhe6rsroues whatsizeshould V Y tion I hadwas: ir be? inaL question, it tumedout,hada numberofanswers. Starting with the top, there are two "standard" depths:24rr deepand30r'deep.Strndardlenslhstend to bean evennunber of feer 4 feet.5 feet,etc. To getthemostamount of]vorksurface whiletrking up the leastwall space, I madethe desk30'rdeepbut only 4 feetlong.This msls the top seemdeepfor its length,but it provides amar.jmum ofusetulworkarea. Next, I had to sizetbe drawers. This depnded on twocompletely difierentcriteria. Firsl h?nted atleast onedrawerto holdfile folders.So,I sized the bofiom drawerto acceda standard office 6leholdcr ftamF. The othercriteriafor the sizeof the drawers hasto do with the joinery. SinceI wantedto assemble me drawers with routercut dovetaits, I sized themaround got standard increments forthedovetail template.This to be sort ofa headache. until I decidedto usefalse fronts for the drawers. Then it rras easyto sizeeach ''ral" drawerto fit the dovetait template.

DItq|ERsuDEs.Sincetlle bottom drawris a file drawerandsubject to alot ofweisht, I mounted it with a setof metal,full extension drawerslides.For the top twodrawers, I madewooden runners. plywooD. This desk is madeout of oak plwood, andaI of the pieces are sizedto lay out on sheets of plrryoodwith a minimum of waste.Because I used pbryood,it actuallydictatedsorneof the otherdesicn features. Forexample, I addedl-wide solid-wood edc, ing to thedesktopto makeit lookthicker (whih helps get away ptywood fom thatstandard ?arr look). The samewas doneon the tluee "legs. Sinceboth sidesof theleft "leg" arevisible,I hadto adda pieceof yai plywood pbYoodto fil the void bhind to the Va!' theedging. However, ontheothertwolegs the |'-wide edgingandthe drawerftontsconceal thevoid. nNIsH.To finishthe desk,I started by staining ]vith two coatsof Minwax'sgoldenoak.Then,to providea durable surface, I applied two coats of satin polyplastic urefiane. Another would option bcroglue larninateto the topandaddoaLedsinsaroundit.

Woodsmith

No.62

marERtats ust
OESK
B TopFdi Bk Edq n9i2l 1! r I 49 C TopS d e E dn q g( 2 ) 4x1 31 3ltdy 27ir \2sia D D,awscases(2) E CaseBekll) ilpry-tstt x 281,! F DEre.Dridds{2r %py 16!x2591t G DrawerFunieG(41 !1r ltt 25-rl H C a s e E d g1 rq llr1 28r! 6i I Drawe Srl d e S p a c e 6 1 2r ), : r l 3 t 2 5 ! 1 1.r J ( ckboard spaceG 121 | 1 - ,11.2 K (ickboa'd (1) l'trpy 151ix4r-: L Aprons(2t 1,1 4 la r2g M AprcnConneclorsl2i l,i al/] x 23r.: - 271t! N LeiLeglll 1t pty x 2Bi\ O L e l l L eF g,e r P a i e i l t i 1 1 p y . 2 6 1 : r 2 8 l l OFAWEFS P T o p D r a w e r F n . r1 B t,x3r! 11 2a 1c k 1rt31 24 0 ropDfawe,Sd (a 2) R Md DrawerFd.iBack{ , '2 :i1 51:- l4 1.,2x5/:24 S M d .D r a \ Y ed re Ss ( 2 r T B l mD r a { e r F d i s a c k l 2 f lr x i 1 4 U Bh1m.D6"erSd6(2) 1.N7 21 V DnwsBonomsl3l /ipy.r31ar23r,! N W T o p D c w s F r o n t l r ) 3 \ p y. 1 4 1 14 X Middoraw r nllll ?:ply l43tx7 Fe ro Y Bhlm Dr .arerFronl{rl 1/pty 141ir12. 'MeasuremenrWrlhoutLl6 Edq ngStrp

EXPLODED VIEW

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as

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@

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suPPr.tEs
. . . . IUIYtBER rr./r', I !'r Sheets oak tlryood r,'2SbeeL 14 c,ak pl!1lood ' tlrick solkloak r0 Board1i..l.iL l0Boardfi. h" thickpoplar(drawers)

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HARDWARE AIID FINISH . Hardrvarc: seeprojccrkit. pase24 . Stain; Ilinw:LXgoklcn oak . \rarnish:Salinpolvu rer|nne

CUTTING DIAGRAM
rd r o 36" Ls.r.d, Ft,)

3 4 ' x 7 " s r " { 3 . eB d .E . )

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r : " r 6 " 7 3 t 3 . 3 B d ,h . )

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1i

TOP
'lhcn tonguc nratcles the \ridLh of a li lcsl slocli10a unild n iridth of I ' cuLtilo groovc lhal you\'e cul in a pi.c. olcfr:rD. lronl arrdbrckedgine srrips(ll) andlhe r$o (For nrorlrnriormaLnm on { dging ply$ood. sid. slrips (C) ro fouJlh lcnglh (2' lonser Pn)cedu ral Nolc:Orcc the rurLeris setto tbe conect dcpth lo cul the Longues on thc t o p , Id i d n l w a n t l o s ( o p . I k c po t ng o i n g and cut the othef fi!-- picccsthathavolonguesto size:Lhedraver case sides (D) and th,size.r'oucancutlonguesceno te eld nra lf o u r drasr dividers (F) (secpasc l7). assell edgeslor lhc cdgirrg slrips. To nuke t|c as thc lefi lcg(N) (seepasc l3). llrc I cut Lonsues. I uscd a slr:tlahL bit witb an edgc lhclonguesontheseIi{csbcforc procecdguideon thercutef tocu! Li,riforr rnbbets on both l:icesol the pharood. Sncakup or the rIn; IN(;. r\ficr cuttiIrgall thetonsu--s, I .!1 InaldcpLh olcut uniilthcthlckncss o I l h e the edgingstrips(B,C)torlhe toDirun :l/r'

29lr'rvkl.by lTfr' lonjr. see l.ig. 1

Next..11t a roorc onall lour edsingstrips Lollt thc tongucso! lhe phavoodI crl thc groole sith a dadobladr on lhe labie saw, and used a feathcrboard 10 hold the snip againslthe fcncc.scc Fis.2. Thisgroolc is cul l./r widetofittheionguc.but Li deepef ihanthe lenlatb ofth. tonglrclo allowaglue friiel.,ql$, Lhesroovc is rrosilioned so the (l:rr' ) abovcthc frcc edgnrssticlisjusrahair oflhc pllnvood *hen il s ltlued nr placc.scc ( lhlslip islrinnned flushlatcr.) l;iJt.2a.

JJ I

APPTY EDGING
AllefcutLingrhe groovcs. the next stepis to shon poiils oI Lhe mirers aliJtn\rith t|c n erfieedgingstrips(B,C) rolengthto fiI shouklcrsoftirr to gues.se,-I.ig.:1. (;r-rrrioN s'TRrps. Altel a snip is.ut to i|tIT'I RTo lItr'cTH-The procedurcI uscd Ienslh,Jllueil lo thc tolguc o lhe edgeof iras to mibr one pieceofedging to lcnglh, LheplFvood.luscd aclamp;rgloard (with and lhrn glue il in placebfforc nrcasuring rcundededgcs)agrinsl the edgins to belp -lb pro andcuttinsthcadjac c i d e( a n d ts o na r c u n d appl!'u iform pressufe, see lig :]. lhe top).Ilcginb! miterinsrheedging strips tct the lonsue oD lhr oppositcsklc lro I longcr thal each side ol th"- rop pancl. gellinladamal]edbv thc clanlrs. I also cut \ow. sneakup on lhc final le lalh untilthe somcscrap blockswitb r,,i'Jarlnves i. thcm. \!lcn:rlliour sLripsareLhed in flacc, t|c toD cdgc of Lhe strips should bc slightly hjghcr t}an the laceolthe pl\sood.'lb trjnr i t n u s h . lu s e da f l l ' s ht r i mj i g .s e ep a s e : 2 . Ror r!D r)\'riR rDcris,To complete the top, I found.d olcr lhc toD ard bottom edges sith a l.r' r oundovef bit. secfig ,1.'lbkcep ther outerliom tippiDg$'hllc rorlinglhelot. tom edJte, 1 placcda piccc oI t/:1'\lasonile ncar lhc liDof the edsins,seel.jg..1a

A't

16

V (r\lsmith

No.6l

DRAWERCASE

cas sides (D) and a ose back (E) to frnished sir, secFis. S. dEwer dividere (F') to widLh so they re .]/J,, wider the the back (I). (This allows for thc l3'LlonC tonCues to Jlr inlo the case qids.lThen cutthr rluders ro.uushl.ng1h tu cqualhe widtlrntlhe slLle-ljFtore.ourinA the lonsucs on lhesedividers.add a trr '-rhick edsing strip 10the fronr edgeofeach djvidef. }lqrc ro\criEs. The ncxt step is to cul tongxeson thc lrolt and back --dses ofrhe casesides{D) and the sidcsolrhe dividers (F). (Thetongueon the ba(l of the dividers is cut later.)tjsc the sameprocedure as on the top to roul Lheton$es, seel'ig.5. NOTE: DADoEs.The dividersde nrounled to thc s i d e s b y r o u t i n l ad a d o e st o a c c e p r t h c 'l'hese tonexes. dadoesare positioncdtl, and23r,/.jl fromlhe1opedge,seeFig.5 Next. I cut anothersct ot dadoesin rhe To delcnnine the lcnSlh otthe runners, placinsthe caseback (E) betwcenlhe run sidesforthewoodcnrunners(c) thar,.uidc Irst placca scrapof.j/rrplywoodin lront of nersand lhe backcdsins. (Besurelheside the top fwo drawers. (The botton drawer thebackcdsingsLrip,sccFig. ('lhisaltows with the y3rkerf is on the ri./r t side.) 8_ uses melal slides.) cut thesc two dadoes forthelhicknessotthecaseback.) Then cut Now appl)'sluein dre boltom hvodadoes across thc insidefaceofthe casesides2a' thc runnef to lcngth so thc back end burls ineachcascsideand in thecaseback,and li1 and9'/i' from the top, seFig. 5. a g a i n s tl h e s c r a p ,a n d t h e f r o n r e n d i s the dividcrs(l) intothc dadoes. Makesure There sone morc dado(rcally,a ts,-wide recesscd lti' ff om thc lionr edgirg srrip. thc front endof rhedividersareallned wirh kerf) to cut for the metaltoptasreners. No$youcansluctherunners(c) into Lhe the liont end of the woodennlnners_ It son the insideof the narl caseside,seeF_ig. 6. top lwo ylrrdadocs oI eachcascside,leavins Once evefihing is in place,cldp the EDGr\c.Nex1, rip l, wide edging sbips roon tor tbc caseback (D), seeFis.8. casetogcther. To makc sureclanrpingpres(H) iorthceaqe s i d e s\.e E I i s 8 T h c nq l u e crfrl DrvrDERs TrJ l}iNGTr, AIlef thc run- sufe is alplied in thc niddle ofthc joinr, I the srnL's L,'rlrFfront ud ba.k eJqE\ of rh. nersaresiuedin,culrhcdividers (0 tonnal usedtapcredclampinsblocks, secp:se 7. cscsides(ll). and roundthciredsesusins lensth.Trim offthe backendofrhe d;viders sp.rcERs..qfter the glue sas dr,v.I added the santeprocedure as on the top (A). so thc lront end alisnswiLhthe tronlend of sp:cersto both casesides.sclrFis. 10.'two RIJNNERS, The top t$o drawersare sutr thc sooden runners (C). Ilc sure ro allow drawer slide spacers (I) are addedabove portedby lourwoodcnrunners (G). These enougl lergth for a 78'r-lon,a Longuc on rhe thcbottom dividcrto mounrthc melalslide. -Ihen.,rlue runnersarccul 13,!r wideandjusr a hair less backcdse.Then routlhe ton!'ues on theback h{o snall kickboard space.s t h a n . t r ' t h i c k ( t o s l i d c a s i l y i n a 3 , 1 ' edse to nt fie dadocsin lhe casback ). (J) beloirthebottondividerto iillin frontof groove),see Fig. 7. Rolrta longue on each ,!ssr,rMBlr'. Aller thc divide.sarecot, the the kickboard(ti. Finally, cura kickboard runnerto fit in thedadoesin thecasesidcs. casecarr b assemblcd, seeFi!a.9. Beginby (I0, ardslue it behindthesespacers. cA'EBACK 2<\r ,iDEo;aaa;

r'\lrzlr' f.oNT \ar6d:r,.


N,,.6l
\(rrrLlsmirh

.liiTl"%

Ii

APRON }RAI'IE AND I.EG


to the leLs, Lhccnds ol the aPrors will be pulledup tighl aganrst lhe legs. are a ie* more steps sTEPs,'llrcre ntoRl.i the lram-'. f iNt, found belore asscmblinla o v e r l h c D o l i . r r e d g e o f t h - ' a p r o n s( L ) . Then, cut 1{r kerls lor the 'nettrltop in eachconncctof(M). Also,drill fastcncrs thernto t|e holcsin eachcon ctorto iasten 'Ihc framecar now bc slued togcthcr' legs. by lamir-rIr l}rc. Thc,lftleg(N) is rnadc together. natinglf'asd lr' pllNood panels size Bcginby cutli g t|c leg (N) to thc same (D 1.2 . ' h l enmakc asthecascside s ),sec'Fis and addedeing(H). tonsueson the --dges Nex1.cul a h'fillcr panel (O) to 1ilbc olthcleg,see nvccntbeedgingoDlheinsiile Fis. 12.I slishlly lcveled (l]') thc cdses of tlr Fnel ro ge1a tig|t fit Aiter gluirg the panclin place, tdm bothedgesofthccdgins nushrvilhbolh pllNood faccs. theleft complete RorrND ovriREDGI\G.To seelig. 13. strips, les.rou d ovcrlhe edlaing Ilowcvcr, there s a little prcblen slrcn edge. roundingov--rthe second !4'hdd\ood pllsood is usurlyless Since lcs andfrllerpmelcoInbined thar l/ 'thicL Lhe arc lcss thm 1 'lhick. \\l]ren foLnding ovcr the onl hebitnlns bclow ed,ae. thebcaring second a ridgc.lb prevenl thecenLeeoifiandcreales this.l stuckt1mlaters oftapcjustbelot ll)e cenleroltbc cdginJainthelcaringtond on. secFig.lila.

Iiegin cr:r PrEcrisbuildins th apron


aprons (L) aDdtso apron connecto6 ( ) ro *idlh andlengtb.seefi g. ll. arcjoinedwiLh rolriERt. l h--tramepieccs s--eDetailin Fis I 1 dadoand rabbetjoiJrts. Nole thal the dado is locatedso thc picces won t be quite JlushoD lhe oulsidc.This is whenl'ou scrcwtic connectots intentional.

-....-.. ll I Apx@oN coNNEcroR, 2

+
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f,l
HotEs --=..=.-:

ASSEflTBtY
are colr\tctc Nowlhat alloI tbe nrainDarts ! h ed e s kc a nb e a s s e m u c d . the left lcg b.{la.ving hRl,\IETo I Ir;- SLart dow flatand centerthc apn)nlralnc on lhe les. Chcfk ihal the Lopcdgesare Jlushand seeFig. I4a togcther. thenscrc$'thepieces

'l'o scrcw thc cAsli. FR,\LDTo Drd\\!ER iLhL sidr of Lheiranrc to ihe dr2$er casc, position. up i thcir finished standlhc picces see Fig. 1{. Ce lcr lhc aPronlralnc oD lhe dla{cr casewirh thc top edgesnush, and the clampthe partstogctherto hokl th.m

while driviig lhe screws. ,rDDToP.lo atlachthelop, !un ilupside doiln ard ccnier the bascon it. s-'efig. 15. into \ow. sliptbreemtaltabletopfasteners eachkcrf in the apronlramc andr ighLlegof the cav. and scrc* them to drelop.

WLr smnh

No.6l

DRAWERS
('ltis alloivslor the ta'rdccp sroovesrhat srain flossliom toptoboftorn,seefig.17. the runrcrs $ill nt into,seel.'is 17.) All threelronts are cut io &,idil to allowa rorn_rtRy. Next,Icut Lhell]]"dovelailjoinrs h6' spaceand a 146'tlick edging strip on at.ach comef. I alsocut a laroove for a lt' e a c hs ; d - -( w h i c hn e a n s t h e y r e y r r n a r plywoodbottonr in cachpiece(seeFis.18), rowerthan rc draweropeni,rg). a d cut the dmwer bouoms O) to fit. Theheisht oteach falserrontislesscriri Bcforeassemblins thc drawers, drill four cal sincethev float in theverticalspace.I holcsineachdfawerliontto attachthe falsc cut the drawer fronts 10heightsof 4' (rop, fronts.(Referto ShopNotes,pase13.) rD,7' (niddle, x), and 12' (bonon, r). RTiNNER cRoovE. Ilcforc attaching Lhe EDGD{G,N D pl,Lls, Next,all four sidsoI fdse fronls.rout a l/alwidc mnner groove cacb talse frcnt arc dsed with Z6',thick on thc sidesolthe topand middle drawers, cdgins (see pase13).Then Iroutedrecesses seeFig.19. andmountcdthe drawerpulls (seepage 12) . Nowplacethc top tivodrawersin thc case MoI;NI rAlsE FRoiitS.l o rtount the falsc to check Lhefit. Yor nray have to slightly lronls,inscrlthe drawers intorhecase.Then plancth runne.sto gei thc drawersto slide I r s e d t h e l e c h n i q u ed e s c r i b e d in Shop smoothiy. Alsonmuntihclotlom nledrawer Notesonpagel3 tomount Lhefronts. according lo the instructioos thal comewith FI\ISH AND FILElil,.txntlaRri. Once the the full extcnsion metalslide. froDtswcrenounted, I stained and finishcd r,srirrio\'Is- Its besl if thc talselronrs thc dcsk.Finalll',laddcda melalrackin the are cut iron one piece of plywood so the botlorndrawerfor hansinsnlefoklcrs.

wood,scc Fis. 16. joinls r{) a routerandtcmplate 10cut doverail join the four drawerpieces. I sized theheisht of the drawcrstoproduceanevcnhalfpin at thc top andbottomof cachdrawerside.(Fbr nrorcon dovetailjoints. seell'oods,,ii, No. s8.) This neant the top dratler pa s are all ' rvide, 3!1rwide.thcm dle drawer5 -L/{ and the bottonrdrawer7'wide, scc l_ig.16. Next,cut all of the drawer sides (Q,S,U) 'lons. Thenio 2.1 dctcmrinethe Iensthof the ftonts dd backs(P,R,T), measur hc dislance befwecn lhe rxnners and add h'.

1!.1 I35^?#Xil
@ \
MIDDIE DRAWER fRONT/BACK

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DRAWIR

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srDEs

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islt ;-t0",.
TOP DRAWER
FRONT

DRAWER

BOTIAM DRAWER 5IDE5

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4.O
AOTTOM

iMIDDIE ORAWER FRONT AOTIOM DRAWER FRONT/BACK

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I8

DRAWER A55EMALY NOIr

..- cRoovE aof, 60EoM !r' D;EP

No.62

\flr'.,clsnith

I9

] O I N E R Y T E C H N I Q U E

EdgingPlywood
the beautyof plywood I I nJonunately, t\-,, is only skin deep.It's nice to work with pllvood whena projectcals for larse pieces, but somewayyouhaveto coverthe edssto hidethe plies. Coveringthe edgesis usuallythoughtof asjust a cosmetic coverup. But besides hidins the ply layers,there'sanothersoodreasonfor addinsedsinsto pb.i/ood. APPEARANCEOn the Wall Unit and the StudyDesk shownin this issue,all offte main pieces are cut ftom pllvood. This makesconstruction easier,but it createsa problem trom adesignstandpoint. The problemis that the mainpieces look too thin if edcins isnl added.For example, on the Wa[ Unit the sidesare over 6 feet hish, yet only yatr thick - a little out of proponion. On the StudyDesk,the top really oughtto look a little thicker than74rr. The solutionis to addsolid'wood edgins stripsto the plywood.By addins 3 l"-wide strip to the plwood, the piecelooksthicker (It alsoallows youto andmorein proportion. roundoverthe edses) IO EUE AIID GIOOVE When I want to apply solid'woodedsins stripsto plyvood,I usatonsueandsroove joint.Butwhynotjustgluetheskipsright on the edse? you cansimplygtueon edging Granted, stripswith just a simplebutt joinL But that maynotactuay bethe easiest method. The problemhasto do with alignmenl OntheWaltUnit for example, I wanted to add lLwide edcinc strips to the pbvood sides.I could havejust c1ltthe skips and gluedthemonwith a simplebuttjoint. AucNMENr. It sounds easy, but whenyou actually standealingwith stripsthatare over 6fetlons,andtry to set theedseoftne srip alisned$,ith the faceof th plwood, it can lead to headaches. As the clampsare tightened, the edgingwill tendto slip on the glue.The pressure with eachclamp applied
Y '

can actua y push the edsins out of alisnment- in differentdirections. Ifthe edgingslipsdownbelowthe faceof theplNood, you'I seetheexposed edse. To preventthis, I try to alisn the efuins just slighdy(L32r!) aborthefaceofthe plywood,

This litde lip ensuresthe edging strip covrs the edgeof the pllvood completely, evenif therearevariations in the thickness ofthpLryrood. Also,by creatinsthislip.you cUlT @rHr to euE dont haveto try to set the edginsto fit exwith theface acdyflush ofthe pbryood. After Although the tonguecanbe cut on a table the edgingis slued on,you cancomeback saw,I think you get tlle bestresultswith a andtsimotrfte lip soifs perfectly flush. ro ter. Router bits don't splinter the ply, Trimming off this lip is easier than it woodassawblades sometirnes do. sounds. On smal pieces, I usea handplane ff I'n workins with smal pieces,I usea or s.raprto trim otr the tip. r I'n working router table,sliding the workpieceaainst with larsepieces(widlalot ofedgins),I us fte fence.With large piecs(ason the two arouterwidlaflushtrim biL (we'reshowins projects in this issue), I use a hand-held a flush trim jis to help with this trimmins router. It's a whole lot easer to handlea process 22) on page router on a large pieceof pL'rvood rather than having to man-handle the sheet on a ror|cu: oR eroovE !!ttt? routertableor on a tablesaw The easiest way to align the edgingto get Rorn P"cBBEIS. To make a tongue.just this !d2rr lip is to usea tongueand groove rout a rabbeton eachfaceof the plwood. joint.Thatis,cut atongueonthe edgeofthe Sinceyou're working hom both faceswith plywood, andcut asroovedownthe edsins anidendcal sftingon therouter,thresult stripto fit overthetonsue. But whichdoyou ing tongre wil be perfecdy centered on the flrt frst, the tongueor theg?oove? thickness of the pb'wood.That's exactly pRoBrxMs. Most of the fitting problms you stemfrom cutting the groove,because Ro('IER BII. Okay.let sbackup aminute.

haveto be concemed aboutboth $e oridt, ofthegrooveandtheposiliotl ofthegroove. Thegroovehasto bethe right ?r?di,to fit the tonsne.Ar?d,it hasto be pxitiolwd,on theedgingstripsothestrip sdcks upto form the ip above thesurface ofthe plywood. go ahead So, andcuttheerooves in aI lhe edgingstsips firsl risht?We[, youcoulddo that, but onc the groovesare cuL you're committedto the po&tion of the groove. That is, you wont know if it's in the right position to create thatlittle 162rrlip until after the tongueis cuL So,ut the tonsuesfrst? Well ifyou cut the tonguesfirst, andthen cut the grooves later with a dadoblade,you haveto make sur the tonsre fits the exactwidth of the dadocut - but the srooveisnt c1ltyet, so youcant checkit. Ifs a pmblemeitherway.Sowhat I do is cutbothofthemfrst. Thatis,I cuttheactual tonsueon the pl''woodfirsl Brrl, I alsoset up the dadobladeandcut a sroovein a test pieceto testthe fit ofthe ton$.

LOolllsuNlKrr \rz'rHtata tA|lEts oit to||{ slDts -roNGUE

'T:3 / TDGEOUIDE

..-%"THrc(

Voodsmith

No.62

Sinceyou're going to be routing rabbets, tongue fits the groove in the test piecetherearetwowaysto go aboutil usa rab Wlen the tonsuefits the sroove,rout mb pilo! or, use a betson bothfaces bet bit $'ith a ball-bearing of a[ the 'lea]" pieces. strajghtbit with ,n edgegride attachnent As eachtongle is completed, usethe test pieceto checkthe fit in the Sroove. Runthe RABBET Bn The mbbetbit (seeFig. 1)is testpiecedownthe lengthof the tongre to the quickestto set up,but maynot givethe seeif there'sa tight area.If you hit a thick bestresults.Oftenthe pilot hits a litde void spot,run the routerback overthat area,or in the corepliesor runsovera little splinter cleanit up with a chisel. on the edse.Ifthat happens, the shoulder of CUTflr|G THE GROOYE the rabbetgetsalittle bumpin it. EDGE GUTDE. Althoughit takeslongerto After the tongre is formedon the edgesof set up, I like to use an edgesuide on the thepL1l'ood, I cutthe edsingstripsto width router widr a straightbit, seFis. 2. (For a ,nd to roush leneth (about2r'longer than %"'widerabbet, I usea 14r' straishtbit soI'm needed). Then I setup the tablesawto cut sureto cleara*?y all thewaste in onepass.) the groovein the edging.There are tlree The edse guide smoothesover any thinssto consider here. bumpsor dips in the plyaoodedgeand tends toAiv better res'rltsfor $e shouldr. Most routershavesomesortofdgeguide 3 accessory that attaches to the baseof the router so you cancut rabbetsor ma&e profileson the edgeof a board.) Also, sincestandardrabbetinsbits only cut you can usean edge ide rabbets, mbbet. stide if youonlywanta yarlwide sE-tuP RorrIER, To makethe tongueon First, thewidth of thegroovemustmakh the edse of the pl,v,/ood,set up the edse the thickness of the tonsueyouvejust cut. rabbet.Then the Thafs takencareofwith thetestsroove. slid to rout a 9ir-r,vide depthhasto be set.This is whenyou need Scond. thedepthofthe srooveshouldbe the testpiecewith thegroovein it. a litde (k6") deperthan the lensth of the Usea dadobladeon the tablesawto cut a ton$e. This allows the shouldersof the groovein apiece ofscrap.Then setihedepth tongueto "bottom out" agajnstthe edging ofcut onthe routerandrout rabbets onboth strip beforethe end of the tongle hits the facesof a piece of scrappbvood. (Make bottomof theSroove. surethe scrapis ftom the samesheer asthe Finally,thegroove hasto belocated sothe "real pieces.) faceofthe edgingsticksupabout142'r above Gradualyadjustthe depthof cut, always the fuceof theplywood. makinscutson bol, faces until theresultins PostfioN GRoo\,T. To get the goove in

y a matter thatposition,ifsbasica of sneak, ing up on the cut.To get close, measure the sizeof the shoulder above the tongr.le. Then set the lencethat distance nom the blade, plus16zi'. Nowmakea testcul cuttingagroovein a pieceof scrap frst. Thenholdthegrooveon the tongueon the edgeof the plr.wood. You shouldbeablto feeltheslishtlip onthetop edse.Slideit alongall the tonsuesto make sureyoufeelthelip everyvhere. I1youdon't, movethe fenceoads' ftom the bladejust a hair moreandcnt anothertestsroove. The ideais to feelalip. (Ihe tt2,,isjusran approyimate measurement, but it shouldn't be muchmorethank6',.) W}lenthegroove in thetestpiecechecks out,youcanworkon therealedgingstdps. prEcEs. wARpED Asyoustan, lookfor any warpin the edgingstrips.It nahesthingsa little morediffiultif a strip is warped, but it will still work because the tonsueand sroovejoint will forcethe strip intoposition. X a strip is waryed,facethe bowededge towardthe rip fnce,seeFrg.3. Thenusea featherboard to force the strip againstthe fenceasthegrooveis cut. TEsr FIr. As eachgrooveis cut in each edgingstrip,testits fit on thepwood edse. If it s too tight, don'tchange the fenceuntil grooves arecut in all the pieces. For any strips with groovesthat are too tisht, movethe fenceo?rayfroln the blade slightly, and make anotherpass.This widensthegroove, but keepsthe same r,, lip on the top edseof the strip. AJterthe groovesare cut, the edging stripscanbe gtuedandclampd to theedse of the plwood, seeBoxbelow.

HOtr' tO CrArnP EDOll{O tO PTYWOOD


The problem with most pipe Mst so the bottom edgepills clamps(andbar clamps)is that away trom the pllrood. theyapplypressue too high up. RotNDEDcEs. Onesolutionis The pressureis appliedin line to rnahea clampingboardwith with the screwon the lamp round,ed ed,ges. The round head, whichonmostpipe clamps edsesredistributethe force of is centeredabout 'tr' to ?arl above the surface of the pipe. This canbe a problemwhen you'regluing l-wide edgingto plt'wood, Tarlthick orevenin the usualpracticeof edge-gluins 7a"-thick stocktogether. ff I'In sluins anedgingstsipto pl'.wood,I lay the cia.rnps on a ilat surfaceandpush the workpiecesdoM againstthe pipes. However,as the clampsare tightened, pres the clamping sure will be appliedat the top edseofthe edsinsstrip,seeFig. l. Thiscauses theedgingstripto the clampsoifs centered on the all four edseswith a %'r roundthickness of theclampingboard, over bit. The round edse ,,vill seeFig.2. transferthe pressure to the cenTo clamp edging to Tarr ply, terpointof the radius%,, above wood,I rip aclamping boardout the pipe- exactlythe centerof ofVarr-thick stockard roundover the 7al plywood. TlirNsrRrPs, Wlen gluingon thin strips (such as the Yt6r'thick stripson the doorsofthe Wall Unit), I makea slisht alteration. Thesestripsare so thin thatiI all the pressure is at the cnter,the top andbotton edges mayactually curloutand wont get enough pressure. So, I nake the clampins board with only one round edgewhich is placed asainst the clamphead.It still dis tributestheclamping pressure evenlyto the other (flat) edge that s against the thin strip.

No.62

\Toodsmith

zl

l r G S A N D

F I X T U R E S

Flush Tiimming
Y V wooden edsing strips o n p l y i l o o d f u f p l a s t i cl a m i natc),vou bavc thc problen of how tolrin the edginsdownso it s nusb silh the suriaceofthe plwood. lJsnrga routcr with a nushtrinr bitis probably thecas iest method.llul, therecanbea problc r.11sdiificult to balance t h c b a s c o t l h e r o u l e r o ne ft naF ro\rcdgina srripwilhout having it lipand creatinaan anglcdcui. 'ii prevent!his, wc dcsigncd a flush lrinr jig. I1s actuallya ''outrigger" thal s arhched to the botton ofthe router. NErvB^\E. lb nuke the jig. begii by nraki0ga base plate (A) f.om -v{'Masooile. First,cut thc bascplatc 7'x 7r, seeFi!a.1.Then use your router'splasticbaseplaieasa tcmplatc to lay ort the bit holedd dre screwholcs No\r drill the holes, counterborinsthc scrcw hol.s to keep the screwsbel.^v the surfaccolthe plate,seeFis.2. srrpporr RArr,s. Aftcr nraking th base plate, I cut fwo suppon rails (B) 10 size flying nr my fac.,I nddeda plastic chip shield,seeFic. L ENDsuPPoRrThe lasl piece to makeisthe end support(C). This coDtrols the ansleof the bit andacta s sahandle C .u l l h e e n d supDod10 nt betweenlhe sutts port rails,seeFi!a.5.Then gluea I YJ'widegrip on the top edge. sErrrPrrc.'lb set plhe jiglor routinA.mountaflushtrimbit in 'lhen the fouter. hold a squar alo g the cuttin,aedge of the bit a d alignthe botlomedgeofthc end support (C), sec Fis.5. W h c n t h e e n d s u p p o r Li s aligred,dghlenpuhead screws tisr\cTIrr.Jrc.Tu o s el h e j i g , adjustthe bn dcpth so the cutting edlae is only on !hccdgirg. Then place the jis on thc workliece so it ides on thc bit'spilot and the end suppon. Nowtum oDthe rotrlerand pull it toward you. concentratino g n k e e p i n gp r e s s u r e downon the/,ar.llr. not on therouler.Ilthe bit is cutlingat u angle,raiseorlo$crthe end suppod,seeFigs.6aand6b.

trom 71'sLock, sccFig.3.Also. there:re lwo lhrr kerfs nrr from thc cnd of these rails. Thesekerlsareusedto mouotthcend sup olthe bit. lon (C) and pemit aliltnment Now, screwthe suppoltrails to thc basc plate,seefig.3. Then screwdre baseplatc to !hc routcr Lrsingthe orisinal router scrcws.s.e Fis. 4. To keep the chips rrom

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C O M M E N T S A N D

Q U E S T I O N S

Thlking Shop
FTUSH TilT B|rS
bits so the cutting edge is set BAIL BEARINC CONCERNS. stead, I let theflushtrim birclean backveryslighdytrom thebear- The other problemshaveto do up the glue as it's tdrnminsthe ins. (Amana sets the cutting wift thebal bearing andits loca- wood.Sincethe bearinghas to edseback .007rr.) They makeit tion. Theoretically,you sho0ld run on a smoothsurface, I setit this way so there isn't any way be ableto set the bearingso it beAonl, My squeezeout that the cuttingedgewill stsike runs right beyondthe joint line ANoTEER PRoBLEM. Wly the surfacethat the bearingis between the edginsandthe ply- doesthe areathat the bearing ridingon. woodor laminate. But I usually hasrun overhavealons scratch Note:Flush tsnn bits usmly set the depth of the bit so the line or look bumished? Before shouldn'tbe resharpened-bearing is about l,i6rrbeyond the you use a flush trim bit, check Sharpning only increasesthe jointline.Then,if therouterbasethattherearen'tanyburrsor dirt setbackbetween the sizof the shouldrock slishdy otr the sur, on the ball bearinc,andthatthe bearingandthe cuttingedge. facewhile roujing, I won't miss bearingspinstreely.Burrs can PRoBrxMs. For themostpart, trimminganyareas. leave a scratch in thework. flush trim bits are easyto us. There'sanotherreason for Also, don't pressthe berrins But therecanbeafe]vproblems. settins the bit beyondthe joint hard againstthe work surface The frst is whenyou'rerunning line. Sometimes a little glue (especiallyacross the srain). the router basealonga narrow squeezes out right aroundthe This can crush the fibers and edse.The bit cantip at an ansle joint line.I don'tliketo scrape - andyou ofr burnish the surface to theefue. I solved thiswith the theglue- ifs too easyto lift up maynot seethe bumishedarea jis shownon the opposite page. woodnbers while scraping.In- until afterthe finishis applied. I Flushtrim bits aremostcom, monlyusedto trim plasticlaminateor veneer. They canalsobe used to follow a pattem when you re trying to reproducean exactduplicate of a shape. And, for the projectsin this issue,we used flush trim bits to trim wooden edsingstripsflushwith the faceof the p\vood. nush trim bitshave eithertwo or threecuttingedges anda ball bearinsonthe endofthe bit that runs againstthe work surface. Theoretically, if ifs a flush trim bit, the cutting edgesshould alignpr'lectlywith theba]lbearing.But that'snot usuallytrue. We checkedwitl the Amana ToolCompany andfoundout it's a commonpracticeto mal{ethe

DOVEIilTJrc FOI]OW.UP
a I made the d&etuil jig thnt ?rastz WoodsmithNo. ,8 azd am rery pleased. with the result8'. An .tl.litional feature that u,ould benorthuhile i.s a Vr,"templatefot jewelr! bofts DougBreed PlAmouth,Michigen We'vereceived a numberof letters about the dovetailjig that wasin No.58.Manyofthe rad, ers wantedto know if you can make Yarr dovebns or throush dovetails with thistr.peofjis. uMnAToNs.The jig is de dra\aers. To makeY!" dovetails, samestopnut settingon tbe signed to make half-blind you wil reed a Ya"doverailbit front of thejis, the notches have joints, basicallyfor anda5,16" dovetails guidebushing, asrvel to be stbackt rrftom the toont drawers. It can not make asa differenttemplat. edgeofthe blanl. (Settins them through dovetails. Theseare I.EMPrATE. Youcanmakethe backrbogetsyouclose. Youmay usuallycut by hand. (However, template out of Masonite(aswe have to shim out slishdy with therearea fewrouterjiss, such described for the t2r'template in washersto get it exact.)To set as the high jig, or templates, Woodsnit, No. 58) or you can the notches backt2", cut a wide such as the Keller system,that buy a Yalplastictmplate.(See notch in the f:ont edg of the rnall<e through dovetailswith a Sources, page 24.) blank,seFig. 1. MATcNGTl{E TEMPI-ATE. To Then, to cut the individual %' DovEraIE. As for smallr make your o$,n Yar!templat, notches, I usedanindexingslshaff-blind dovtails, I did makea start $'ith the same Masonite temon the tablesaw,seFig.2. templatefor routing dovetails blank as the lrrr template, but First, mount a 516r'-wide dado with a Yarr dovetailbit. It works you have to cut dilJerent size bladein the sawandraiseit 74rl great for small boxes and notches. Ifyou want to use the Thenputa546rLthickindeing keyin theauxiliaryfenceandset the key 532" fiom the blade,see Fig. 2a. (This will cut s16" notcheswith ins between procedure Theactual for rout ing Ya[dovetailsis exactlythe sameas for ,r!r dovetails. Sinc the individualYarr dovetailpins arent very thick or strong,I've found then best to use only if both piecesto bejoined are ttrl thick or less. \0oodsmah

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cuT o;F wA5tt S0 rE lrafE

No.62

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P R O J E C T S U P P L I E S

Sources
Wa Unit Hardware OrdrNo. 762-300......$17.95 .2 PairofPivotHinces Desk Hardware OrderNo. 762-r 00.......S44.95 . 1 DoublePlate MasneticCalch .3 Recessed . 2 Adjuslable Levelers RedOak Pulls . 1 PairAccurideD rawerSlides .12 BrassShefSuppods .9TableTop Fasteners .2 Recessed RedOak Pulls .1 File !'older Packasc (Includes one file frame and 12 In the anicle on page22, we hangingfiles.) talked about using a fl sh trim Ifyou wish to order the desk rouler bit. Woodsmith Project hardwarepackageerilliori rhe Supplies is otrerinla these carnle frameand hansinsfiles,use bidebitsin ],, l and Y{" shanks. the lollowinsorder number: wcrecommendthe lr'r shank order No. 762-200....... $ 34.9s bits,illheywill fitin yourrouler. The Accuride drawer slides c a n a l s o b e p u . c h a s e ds e p a rately. These full extension slides are24"lorsand loadrated 'ihe qualily to 110lbs. of thesc SIUDY DESK 'Ihewooden pulls,the extension drawerslides, the top fasteners, ad the file lolder packase used on the deskareallavailablefrom Woodsmith PrcjectSupplies. This hardware or similar hardware may be found from somc of the supplierslisted at the right. t ok for code,,9 fol lowinethe suppliers' nanrc. DISPI.]AYWALI. UNIT All of the hardwae that we used on theWallUnitisavailable from Woodsmith ProjectSupplies. This hardwee or similar hard w a r e i s a l s o a v a i l a b l ef r o m severalof the sourceslisted at the right. Itr)oklor lhe codc t/U lolowin&the address.

GATA]OG SOURGES
Sinilar hard,bare and,supplies maa befolmd in thelollowing catalogs. HoueDer st|Ies and sizes maa uary. PIeaEe refei.to eachcatatasforo anns iltfomtion. AJbertCoNtartine Woodline 2050 Eastchester Rd. 173lClementAve. Bron-Y, NY 10461 Alameda, CA94501 DH,WU,FT FT AlleD Speciaity Hardware Woodcraft Suppv 3321v. Bruceton Rd. P.O.Box4000 Pittsbursh, PA 15236 Woburn,MA01888 DH,WU FT Bob Morganwoodworking The Woodworkers' Stor 1123 Bardstown Road 21801 lndustrialBoutevard Louisville, KY 40201 Rogers, MN 55374 F? DH,WLI,FT CraftsrnanWood Service Woodworkers Supply 1735 WcortlandCt. 5604 Alameda Place N.E. Addison,ll 60101 Albuquerque, NM 87113 F? DH,WU,F']'

Flush Trim Bits O r d e r N o2 . 71-aas..... . 1 6 . 9 5 To order, use& form or the Des Moines, IA 50306 S . Y1'Shanknush Trim Bit protective coverofthis issueor Please allow4 to 6r,veeks for prsewice Order N o .2 7 1 - 4 8 7 . . . . . . , $ 1 9 . 9 5 wrilFyourorderoo a sheFr ot delivery. Forfasl use . 1/r"Shank Flush Trim Bi1 paper,and send it alons with our Toll Freeorder line. Have your checkor moneyorder. your\4sAorMcreadymdcall: This type of routcr bi1 nray (Please also be purchased ircfude S1.50 shippins i o c a l l yo r taOO-444-7OO2 Accuride Drawr Slides lronr one olthe suppliers chargeperorder.) lAresidents Note:Pricessubjectto listed otder No. 762-r2o ..$27.95 pt. at the riaht. Codetr 71 add4% sales tax.Snd orderto: chanseallet 12/89

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PROJECT SUPPI.YUPDATE
Woodsmith Project Supplies Oak lcebox is now offerinslhehardwarcfor ordr No. 736-200......S39.95 thcl4'oods,,illi projects lisled .2 Bmssl-eft Handlatches .I BrassRichtHandbtch .6 BrassHinces (.'lJ'offset) .l "wlile Clad Nmreplate ot D oaK tcEBox . 8 Table Top Fasteners we rc offering the hardware for .8 BrassShelfSuppods the oak iceboxthal we leaturcd in llhods,rill No.36. 'nrehardware BUNK BEDS lhat we reoffer insdi{Ie$ slishtlt,in appearance We'veheardfrom nany readers lrom the sqvlethal se orisinally aboutthe problemstheyne had usedon the iccbox.However, it i n o b t a i n i n gt h e k n o c k d o w n is still solidbrass,and the price hardware we recommended tor is substantially l e s s t h a n t h c ihe bunk beds in lYoodsriiln lrardware orisinallyshown. No. 38.The sourcewc orisin:lly Note: You need to purchase listednolongercarries thehard wareshownin the issue. The hardwarc kir includes: Howevcr,we are now offering the orisinal hardwarethat was I,/4" DOVETAIL IEMPI.TATE listed in the issue throush Woodsmith ProjectSupplies. h l|'oadsntith No. 58 we fea lured a shoftmade dovetail lig. Bunk Bed Hardware Sbce then we've been -trorkOrder N o .7 3 a - 1 1 I ...S1.00 a. . K n o c k D o w n l ' i t t i n c s ( 4 ing on a Ylrlemplalethatwjllfit jig. (See pasc23.) .eededtomake b u n k b e d s . ) our dovetail We now have a Yi" dovetail OrdcrNo. 7s6 3o7 ......-.$3.95 templatc available. It's nudc .5'ftreaded Inseds (r,46'r I.D., from thc sameDelrin plasticas our !r'.rr templates. The lemplate o r d e r N o .7 5 6 3 o 4 . . . . . . .5 . 4.95 brackets, . l0lhrcaded Inseds (Vr6ril.D., comes with mounring bolts, and adjuslins *zshers. In for onebedVstorasc drawers.) OrdrNo. 756-309 ........$9.95 str ctionsde included. .25 Threaded Inserts(tu6'lD., Dovetail Hardwd forbunkhalsVslomsE drMF) OrderNo. 75ai41 .......S27.95 O r d e r N o7 . 3 8 - 1 1 2 . . . S 3 . 9p 5r . . Ya' Dovelail Template .l pair 2" PlateCasters(2 pair OrderNo. 762 5oo.........S6.95 . Yi I DovetailBit (H.S.Sleel) needed for eachdrawer.)

l7oodsmith

No.62