,

(tal,
" \. '-'
! ,''''':-'
.'. PURVEYORS OF FINE MACHINERY"

W/CAST IRON WINGS & TABLE
Motor: 2 HP, 11CNI22fN, OOgIe-ph_
' PrKlsiongroul'ld iron
2r 1 )9110"
10" LEFT TILTING SUPER
HEAVY,DUTY TABLE SAW
, Motor: 3 HP. 22OV. single-phase
grOl.lrJd (ast table
w/2 (<1st iron elrtenslOn Wlrq..
Tabk> wI wings (lttOKhed: 27"
Arbor. 'I," (Kc/!plidado
10" LEFT TILTING SAW
WI 7' RAILS & EXTENSION TABLE
, Motor: 3 HI'; 22011, singk!-pmS/!. 3450 RPM
- Pre(uion ground cast iJon
Ext/!nslon ubi/! !>Ill!! lrx 44'
Arbor: 'It" (<lccepl!. diido blades up to 11/ .. 1
' ... "'" -- Obssic"Fe!n ..;
Ntr: '11'
biadesuplD 'J/ .. ,
- Cutting capacity.
Cuning capacity: 8" k!ft, 54" right
' Mal!. depth eX cut: 3" 9rJ", 2'It"@I<lS
;:;:::;;;;. ..... "'PP'''''';';'''!..'"",, "'" ''''
RlpUp.KIty. 30"
Cutting
l 'I,'.9ft, l't.". 4S'
o "'pptOl:.
weight: 2981bs..
G0444Z ONLY $575
00

GO
n
S76 ONLY $615
00
D
M.D:. depth ofcvt: 3"

,A",ro" '"pp., S
weight ...
--
INCUN" SHOP FOr a...".I(, mitE
Gl023SL ONLY ' 975
00
6" JOINTER B" X 75" JOINTERS
Motor: I HP, llfN, Motor:2 liP. 11fNl22fN.
Table size; 6" 46" 1QtT-III TEFC, 3450RPM .lJIKJ
Ma.l. depth of (ut 'I, "'lICI m.. II . Pl'Nision ground (1>lllI)n table FUI ...... OJ
. Max.rllbbeMgupacity;'/t' MOeIUfAKl "" IAmYMM
, CutteTheild kni\leS: 3 5500 RPM IIlOeD
Cu\whl!ad di!.: (utterhead diameter: 3'
Cutterheild speed: otcut: I
4800 RPM
Max. rabbeting
(uts per minute: depth: ''''
14,400 per mirM.l1t:
Iron 22.000 (G0586)
ApprO)(. shipping Approx.
weight: 270 II. weight: SS81bs..
IlICIJMS A rm MIl OF INTRODUCTORY PRICE!
WlnMltuca G058EtoNLY
INTifOOUCTORY PRICE! If'k:t:" ....
G0452 ONLY 5325
00
G0593
VT
ONLV $995
00

15" PLANER
, MOlor. 3 HP, 22CN, '>Ingle-phil:>!:
, Prt(\slon ground (Mt iroo Llbk!
size: IS" x 2ft
Ma., cutting height: S-
Min, '/0 ..
'UM-1N

MOIllE lAIC
OSCILLATING SPINDLE I
12" DISC SANDER
, Motor: 1 HI'; 110"1, rEF(
iron till to 45
,
14'h" square
, Disc !iiloder table:
IK UIPU
SHOI' FOX
n ... ,,,'" !lltel
G1023SLX ONLY
B" X 76" JOINTER
- Motor. 3 HP, 22W. phase, JEFe. 3450 RPM
- r.bl/! 8' x UN .. ' - lnfNd table _ 43
1
/,'
Cutlerheild knive-s: <I HSS, 8' l 'I.' l '/I"
4900 RPM -Cuts fminUlI!: 19,600
, Culterhead dlam/!tl!\': 3'/,'-
, Mal(. depth 01 cut: '1,"
- Max.labbeting depth: ,;,'
- Appro .. shipping weight: 5971bs..
,
-
IfI'TRODUCTO,.r , ...... .
P/tKEt
G0490 ONLY $750
00
_
12" BABY DRUM SANDER
' Sanding motor: I '" HP, 110122011, 'i,ngle-pha:s.e
, Convey motor: 'I.. Hp, 11OV. slngle-phase,
""liable speed 0-15 FPM
Drum sJ)Hd: 2300 FPM
Max. stod; SIZe: 12" W x 3)/ ,"
Min. $lock length: 8'
Min. stock k!ngth: 1'
Max. cUlling drpth 't,"
, Ftl rate: 16 FPM &]0 FPM
' SpirJdl/! sizl!s: 'N,
'1.".I'I/SoT
, : loop
Cutttrheid 3"
Numberof knll'es: 3
Cutterhl!ad speed:
5000 RPM
"PProx. shipping weight
661Ibs..
/ NT/fOOUCTORY PRICE!
G0453 ONLY 5775
00
Spiodle speed:
1725 RPM
- length: I'
- APPfQl. shipping
weight: 1801bs.
FAKfAUlt
.. ""
' .
G0529 ONLY '450
00
' Approl, shippi"9
weight. 1991bs.
INIlUURrAL.DUlY
CONYEYOl'ELT ,
SIPi' MANPLU
POnA,IIUTV
14" BANDSAW
MAO'LW
lSotOl1
"""."
Motor: 'I. HP, 1 HWI22fJ11,
me
groulld IfQfl table
Table size: 14".14"
Table ti lt 4S' right IS'Ieft
Cutting capacity/throat: 1 l'h"
MiU. cl.lltJrlq h.eight: 6'
o StU: 92'Hto 93'1>"
('la' to
J
!." wide)
BI<lde speed: 3000 FPM
. 4' dust POrt
sll!PPing Wl!ight.
165 Ibs.
INCUIIiIU Qt.llt,;
'!.APE IIUAIl SnnM. '/.-
.u.0l. FiltCl MI1II1: tALJti
G05BO ONLY $325
00
20" PLANER
Motor: 5 HP, nov,
Max. (utling width: 20"
cuttill9 ht!ight: 8"
o Min !tock thiclmess; 'I,,'
Min. slock Imgth: 75'
Mal-CUlling dl'pth: 'I."
Feed r.1I\e: 16 FPM & 20 FPM
. Cunerhead
3'11'
Number of kniveo;;"
CU!1emud speed'
5000 RPM
o Table 2()'" 2S't.'
(20' x 55'1,' wi extension)
Approx. shipping
wt'Ighl 9351bs.
INTROOUCTORYPRKEI
G04S4 ONLY ' 1175
00
24" VARIABLE SPEED
DRUM SANDER
Drum motor: 5 HP. 22fN, s1ngle-phioSE'
(Olllleyor motor. 't. HP
Conveyor speed:vanable,O 20FPM
thicknlm. 4'.
Sandp.lper: r hook & loop
Control with load m('ter
0...5t (1) 4' , Appro .. shipping
weight: 4891b$
INeWOUA
IIEAVV-fUTY
,,.OU
OOfiIVEYOIt 81111
THE ULTIMATE 14" BANDSAW
Motoc 1 HP. lllJViUOV.
slogle-phil)l!, TEFC
PrKiSion 9'ound cast irOfltable
extruded aluminum rence
Cutting cap;lcilyll hroat: 11' ;,"
,
Blade 92'/,' - 93';," long
I'll' - '/,' WIde)
, 2 blide speeds: 1 SOO & 3200 FPM
, shipping weight: 198 1bs.

" MAK IJ
, - . 1101001
fAl!TOIY1
IIICLUOES FEMer. MinI!
IALII[. QVleK
'LAD' UUA5 SmlM
G0555 ONLY $425
00
a
11fz HP SHAPER
MOlor: l'hHP; l1OV/22O\1, 5ir"lgle phase
Pre<isior"l ust Iron table
siu: IS-
Spindlttravel: 3'
1mterchangNbie spirdes:'1i &'1.'
, Spindle opoeningi on UbIe:
l 'I.: 3'h'& S'
, Spindle speeds: 7000
& 10,000 RPM
Mu..cutterdiameler:5'
, mippinQ
weight: 2211bs.
INtLIIDU MlnllAOlE
'mtllm'll
UmvtUAlH
, 1IOUI-tOWlf SmNH
G1035 ONLY ' 515
00

DmOIIA'
111"
nt
2 HP CYCLONE DUST COLLECTOR
Motor:TEfC 'F: 2 HP,
220\1, Slng\e--phaJ.e
125
CyclefRPM: 60 Herut
,,,,RPM
r.oIe size:;
Impeller: 13';,' steel. riW!tl1d
Suctior"l(apacity: 1154 CFM
2.S SP
Static preswre: 10.4"
FIII/ation: 0.2-2 miclOn.

. Fll tH surface alN. 86 sq. fI
CoIectioo Drum: Steel,
35 g"ll<)ns
' Awox. shipping weight:
315 100,
17" HEAVYDUTY BANDSAW
, Motoc 2 HP, 11OV(22fN,
slil91ephi!se. TEK, 1 m RPM
gl"Ound WI iron table
, Table sire: I r x 1 r x I'h'
(utting height: 12'
Slide length: BI' /,'
' B0de sires; 'I.' "
., .. 1600& 3300 fPM
f' . ()JSI porI: (2) of'
' ApPfflX UlIPpong
wetght: 342 Ibs.
-
"",ID'INISO UOI fACfOltYl
uttLIlDU '/,'IUP'. flMU'
"""''HUTY MinK tAUtl
G0513 ONLY $795
00
g
3 HPSHAPER
, Motor:) HP, 220'1, 5ingJe-phaw
wi rewrslng sWitch
IfCWPU MITt.
.... un
'fENeiWITH , Pre<isloo ground usllron
Table size wfmndal'd wing
attached: 30' "'J{ 28'i,'
--,
......
) interdlangeable SPindles:
'1>:'1<' &1'
Spiodle travel: 3'
, Spindl!! 011
table: 1'1,',2'10', 4
80S'/;'
Spindle speeds: 7000
& 10,000 RPM
mipping
weight: )571bs
MAl fUTle
M Ir eK
G1026 ONLY $950
00
g
3 HP CYCLONE DUST COLLECTOR
MotocTEFC HP;
22OV,
, Amps: 19.5
Cycll!lf1PM: 60 Hertz!
34SORPM
hole Sill!: 8'
Impeller: 1 S' IIveted
capiKity 1654 (FM
P 2.0' SP
Stlti( pressure: 142'
Filwtion: ().2. 2 micron,

Fillef 108 sq. ft
(olledioo Drum: Sleet.
Clfd. No 583
INNOVATIVE
THINKING.
IT'S WHAT SETS
US APART.
Sincr 1958. Varalh .. hal bun
!W!lIing the ,lart<ioJrd in the wood
Ufl! industry. The flnt potyure.
thane. Tke fiBI gd . tain. The
fn! polyurethane.
The rlfsl walerbaled floor finish.
And now. loya oil bal ed premium
wood staim.
And lhen, in 1003, Vllrathane
was the first 10 intnxluce Trial
Site Stain Packets.
Ayailable in each
of Varatnaoe', 24
beautiful suin COIOfS,
these convenient pack
els help lake lhe iU"'-
work oul of wood work
by en"';"1 you It' l lhe
right coloi' lhe first time.
1m:. Since Itw
of trial
fini5hing
experts
(heck. even
some com
petito,,)
hm
embraced
the idea. Chalk up another
groundlnaking innovation
to VaralhMw.
NOTHING RUINS
YOUR WOODWORK
LIKE THE WRONG
STAIN COLOR.
. \laralhallot spent yea"
the p"fecl palelle of H colon,
working ck>sely with lop furniturr
makers, analyting industry color
WE HAVE A
REPUTATION FOR
BIG INNOVATIONS.
I
Now, HERE'S
A BUNCH OF
LITTLE ONES.
5 F I RST CHO i Ce"
trends. cOfllix:lilg extensive consumer
research. We ended up with 14 sIlt.
ing colors that COOSl.lmer5 pn!'fer JTlllIr'e
than 2 10
I o\w tke
coloR of
Minw ....
""""
Firtih .
Youw
w""""
hard 10 pt'rim your ..... oodworking craft.
We've worked hard 10 perft'1:1 your
of prenum wood Slain colors.
And now with w packets.
it 'li cai-iel" than ever to select the one
THE
VARATHANE
ADVANTAGE.
Here, what makn Varathane
a wood stain: the
perfect formulation of soya oil
and MJperior piGment'. VaroiltNne
uses oothinGleu than ultra-dear
soya oil in all
of itt stains.
It ' Ii clearer and
liehter. so it
prOVide. a ..... ider
range of color
than stains made
with linseed oil. And our premium.
Iranslucent piements are much
smaller in poilrticle siu. oiIllowinG for
superior color penetratioo. Of course
lhet-e are other ways to mak $Iains.
But none: bElta.
10 learn more about products and
projects. and for professional tips on
woodworkine and wood fmishine. visit
woodarnwen.com today .
_ ............... ,...-.. ... ___ c ......... .
-._h' ..... _ _ _ ... _
_ .. __
= RUST-OLEUM"
cO.PO .... TIO.. CJ0C'6
PROJECTS
28 rouler-bit holder
32 kerfing jig for bending plywood
38 ready-to-serve wine cabinet
46 amazing-space tool cabinet
This tour-dOor cabinet occupies jost 7 square teet
of wall pt delivers 2ti SQuare feet 01 1001 storage.
58 tones-of-fun tongue drum
62 graceful bowfront table
82 end-grain cutting board
98 more cutting-board designs
TECHNIQUES
34 put an end to measuring mistakes
52 make any bandsaw a peak perfonner
Master woodworker Michael Fortune shows how
10 tlmeLCJ and use thiS key shOp tool.
68 making curved and tapered legs
76 cut straight edges on anything
Know your madllfltrlQ 09bonS tor takilg
the crook out Of lessthan-perfBct sltldl.
90 pack more workshop into less space
DIscover 21 storage-savvy ways to address the
mess In yom faVtlnle hall9out.
1[1; try gauge blocks for fasl set-ups
Cut profiles of your router bits and use them for
quick adjustment when making these cuts agar!.
TOOLS & MATERIALS
70 shop tested: air-fiHration systems
Purlf)' Shop's air with one of these 10 moDeb,
100 five shop-proven products
o EPA R T MEN T S
6
8 sounding boartl
12 ask WOOD
20 shop tips
112 what's ahead
58
nus seal is )I0Il' asstnlCt! .. , we bIikI
every vOOfy every lad, anti test mwy
f'eYIeWed i0oi in oor to gunrtee
roor soccess aoo complete salislaction,
WE DESIGN 0lR TO 11 MOST S1RINGfM' STANDARDS,
1RIPlE 0iE0< EAOt ONE R>R QUAI.l1Y ASSlJRANCE AND
BAD< t.VfRV MAOINE \I.mt A RJU. TWO-\'fAR WARRAN1Y!
MINI PLANER/MOULDERS
O pen sided Mini PlanerfMoulder allows
plenty of flexibility for profile moulding and ,I"n', ...
FEATURES:
1"\0(01",2 HP, singleptl:lli. 220V
Varlabl. IpHd motor,O,S HP
7.000 fl.PM
Feed I'llte: wln3 15 FPM.
WI7)9.1.IBFPM
Mn. profll. '/0' '*IIiII"
H.t . profile ..... ,dth' 6\1,- PI"" rrl
Pianln, width; 7" M .. ulde,
MII\. stock 18I1ath; 9'
Min. stock thlckness:!t." ,.,..,.
i"bl(.ltock thK;;kl1eu; 7'/1"
Appro. sh'pp''''

v..rillble
Speed
PI<,."erl
Mould.r
10" LEFTTILT TABLE SAW
WITH EXTENSION KIT
T he ever dependable W1677 l eftTilt table saw is even
better with this extension kit to increase ripping capacity!
FEATURES:
3 HP.l1O.
motor
PrecI\.lOO ground UII
or..., obM WI1b TlIon
Ml. bbde Moghe 1"
1UpP-l, upKlt)', sr
.. ',4. arbor !Cuptl !bcIo IllS
up U> " ""
HU\'f.ckn), Cllt lren
T his mortising workstation nlndles
everything from standard Clbinet dOQr
stiles to posts and beams up to 9"
FEATURES:
I'kxor: !'.i HP J I rNmov.
'*'Ii""1't.a.e,TEfC.J12S RPM
.. ze:I9"", 12Y:."
VortiaI >pin'" tn1Il 9"
Hue! verdQl tnYtt 3"
T1blelon&-travcl: I .. Yo"
"",,,,",,1"
Col ..... ' till: :t30'
Feoce M>gIe".O )0'
Spondle <peed I.m P.PH
Approuh'pPnl 'fI'e!lIIt: 315 Ills.
20"PLANER
with SPIRAL CUTTERHEAD
FEATURES:
Motor: 5 HP. 220"', ilngI.pN.se
PrKislOl"llf"OU'ld inf ..:!
and ubles
$'1t;25>;' x W"
(SS';'" x 20" with extension,)
+ Cutting t)tithe S';."
MllC depth of Yo'
CUltemud ",BOO RPM
Cuttemud diameter: 3Y,"
Feed rates. 16 & 20 FPM
Approx.lhlpplng wtlthe B75 Ib,.
Spiral
CutttrMad
8 " JOINTER with
PARALLELOGRAM ADJUSTABLE BEDS
T hiS Jointer, with its large 8" x 4)l;'i" infeed table and
built-in locking mobile base is loaded with features.
FEATURES: "",notic rwitd>.ith tt.. ... 11
-">ad f'RIKt_
Motor:) HP, 11OV, wntItphase, 3,.50 RPM
prtCision ground cut Iron.
parallelogram design
Deluxe cut Iron lente size:)S" x 5"
Cutterhud d,ameter " ]0/ .. -
eunerhud knivu.
.. (HSS) 8" II: y,- x '/," ./
Cuts per mlroute. 19.600
Cutterhud 'PHd: <1.900 RPH
Mil)(. dept/! of tilt 't."
Appro)!, shipplnl
_ ,gI'lt: 600 Ibs.
2
W e designed this 2 HP Shaper
to give maximum performance.
FEATURES:
2 HP. 110"'1110"'.
"'1&t..pnue motor
Ur&e preclllon around
c;.ut oron uble. 2-4" .2'"
HtIIII)'-ch,1Q' Pure
'II" Jr>d W spondIes ndudo!d
3" splndle u'ave!
Ha--y as!. Iron tonI.truetion
with 02057
Adjug",bI ..
Hobile Bue
(not Induded)
C.bir>e1. ,1<U>d "'Ill> pc>wder c .... lftI paont
Appl'Olt.lhoppi", _,ght: 270 IbI.

SHOP FOX" is a registered (rademar k
of Woodstock Intematlonal, lnc.

TO OUR INNOVAT I VE MACHINES
AT A N A UTHO RIZED DEALER, PLEA SE
CALL FORTHE LOCATION NEARI;S'TYOUI
SHOPFOX,BIZ 1-800-840-8420
CIrcle No,
Octnber 2006
_ 170 lor PIQI1/s'
50CtI nWerary.
Better Home8 and
Vol. 23, No,!5

BUJ(JIIEII
&:eclJM EdiIrK
JIM HARllOUl IIIAIILN KEMME'/
Ellillrill Ma/IagI!r", Tools _Ill Ted1,..ues SenIor
DAVE CAMPBEll KEVIN IW1'LE
Tt:d1I1{JJtS Editor
BOB WLSON BOt! IIUNTBI
i'fojects EIhlf Projects EdIor
OWEN DUVALL JAIl me
0Wgn Masltl CraItma1
.&F YEIITZ CIlllClt HEDlllfD
Jt\ [)Qo;u Jt\ IkrecIcJ As:sis\a'I\ Nt Diredoo'
IWIl EtI..ERS GIIEG Sl:tlfRS ctIER1'L A. CI8lU
l'fI:Id\J(;t<orVl.lfflcet.lanallt'f
IUJlGARET ClOSNEJI SHHI'f1. Ml/IffON
Ph:llc9'a+lhm MARTY BAlDWlH. sam LITT1.!, BLAJItE MDAT5, JAY Wl.OE
11M CAIIILl, LORNA JOHNSON, ROXANNE leMOINE
Jeff KAll. DEAN FIENE, PAT LOWRY
c;.:.,l nbIJIrig CrlIItsman JIM HEAVEY
f'n:Iotreaders &ARBARA XWN, IIA L.lCIR, JIM SAJlDB'IS
CUSTOMER SERVICE: 800131496&3
mann, Me 10 .
... ;;;.;;CS;;; ,
I'Iu'e:J1ZM}.1Wi
/MIglI' AMANDA SAUtOOT
JACK Cl\RlSTlANSl:II, ClROLYN WlS
RY.QIIlTHlLAMl
.l.ssislanls GAVLf CIJN, JENNlfI! ROOGlEJII
ATLANTk
1815 Old Alabama Rd, 1320, GI.J76
Fl'nIe: t>7&W7 .0110 fu: S18iS07-0118
DE1lIOIT: IIP'M Associatss
29.l5O So:.tIJIieId fId . Suite 31, Souldleld. lot 48076
Phone: 24&'551-7490 Fn 243mJ.7(99
8USINBS IlEVElDPt.IEIIT
NEW YORK: Media
52 Ilf, Crolon 011 Hu:iI<rl, N'1' 10520
Ptae: 9Uf2J!l3483 Fu; 91-'1ZJ93-4\13
lDS AHGEUS: SOu1hccist Projects
12fi82 F'Io:a'J Citdt fb1I, Sln O.eoo. CA r.!128
f'!\ona: 858167H1921 Fa:J:. 36OI2<165661
JOEL [TIENNE
Comumer Ond(lf ROBIN IlUTCIIINSOti
AssiSlanl CIlrr:s>JIJlef frrIilrIo:etioglolw.,ef BIll WOOD
Associate Director of TOM OEEflJljC
WanaQeo' TIM ST1ltfFER
0perui)nI; Ul8Y EHUK!
s-o-v.ee DntU DOUG 1IlSON
GlI)(4I TOM 0A'm
MEflBlIlll PUBUSliNC GROtI'
JACI( GRiFf'll
Friance & AIlrmi:sh!Xol KARLA .lB'fRIES
IoInrtidurlog BlllICf HESTON
CootJrner DAVID BAll.
CreatM! SeNic.es ELllN III UTHOtJDEA
Wporalll Sllu JACII BAMBERGER
IIltmir::IM Media lAlIIEJi WlEHER
CrpoJrate IIb1<etiog 1IA1tC' WEBElI
I\esea'd1 IIRfTTA WARE

Issue No. 1n
.11'.\
5
-
_ .......

11 __ 001
1-800-966-3458
1-800-966_3458 (1m
irde N !IO
Coming to your newsstand!
Outstanding
Project Plans
for your Home,
Yard, and Holidays!
Build any design in a
weekend or less
Save money with
off-the-sheH lumber
Use only basic power
and hand tools
Availabl e on newsstands Septembef 12 or
order online at woodmag81ine.com/putlllcations
editor' angle
High school:
wood shop:
alive and well
(in places)
It's no secret: Wood shop is disappearing
from schools everywhere. But there are
innovative teachers who manage to buck
the trend. Here are two of them.
I caught up with Jeff Hall (right)
during a bandsaw-blade test.
I
f you read the tool reviews in every
issue of this mugazine, you already
know of Jeff Hall. He's been doing
independent Irxl1 for us-and doing
a first-rate job of it-for the past several
years. What you may not know is that when
Jeffs not torturing tools, he's teaching
cabinetmaking at East Hi gh School here in
Moines. RL"CCntly, honored
with the 2OJ6 Teacher of the Year Award
roc Des Moines schools.
Like a lot of great teachers, Jeff cares
deeply about his students and is someone
they confide in. Plus. he expects quality
work fmm tht!m. He actively keeps
his students, and his program visible at the
school and in the community. For example,
when East High recently underwent
renovations. his students built donor plaques
and constructed new display cases. He
exposes his pupils to expert woOOworkers
and :;,et up a pmgmITI for his student" [0
become mentor.; in instructing children and
in pen turning.
Another "teacher of the year," for
Yavapai County. Ariwna, is Tom Bockman
or Prescott. His program is explooing in
popularity with 91 students in 2003--()4, 172
students in 2(X)4.......()5, and 201 students in
2005--06. For the first: time, he had to tum
advanced students away this school year,
while adding another beginning class.
How does he do it? Tom chalks up
his success to several things. First, he
developed an interactive CD for 8th-grade
students. It gets the kids (and their parents)
excited aix)Ul high school shop class by
showcasing in-class and job-site activities,
Second, the Prescott students conduct
attention-getting community such
6
Tom Bockman (left) Invited Internat ionally
acclaimed woodturner Richard Raffan to
demonstrate for his woodshop class.
as a wishing well for the Make-A-Wish
Foundation. For these Tom is
tireless in pursuing publicity-another key
to the popularity of his program. Finall y,
his students have the opportunity to make a
little money by selling projects to libraries,
furniture stores. private citizens, and the
school board. 1beir most ambitious project:
a school board conference table fully wired
for electrical outlets, interfaces for laptop
computers, and lighting.
Of coun;e 1 don't have enough space here
to mention all of the outstanding teachers
helping to pass along wmdwurking skills to
a geneml ion less exposed to them than ever
before. But for scveml more examples of
young woodworkers doing great work, see
page 8.
To all of you who are mcntoring
tomorrow's woodworkers, in a classroom or
your home shop. keep up the good work!
WOOD ",a gazlr... O",,,ber aOO6
Sears has the
parts I need to
get the job done
6.6 million parts
all major brands
750,000 online
schematics
- - __ .i-----
sounding board
Our bulletin board for letters, comments, and timely updates
Woodworking lives on with today's youth
Although many high schools are cutting
back on vocational classes, there are sti ll
some out there instructi ng students in
hands-on skills---such as woodworking-
thaI could lead 10 either a career or hobby.
At WOODti magazine we applaud those
adult.!. "' ho teach the neJt t generation. as
well as those young people are eager
to learn the craft.
Students work together to build
and expand WOOD's table
Juniata VoJley students, from \eft, seniors Tyler Hall, Matt
Boone, and Corey Ughtner, sophomore Corey Boone, and
junior Nate Paterson, reeoglneered and built thi!! game lable.
Five afmy high !;Chaol woodshop recentl y built a
modified version of the game table you featured in issue 167
(Dcccmhcr/Januliry 20(5/2006). They wanted to make it
bigger to seat more so they doubled its length. added
two leg'! to support the middle, ami expanili.."fi the size of the
cup holders. Usi ng cherry, they linished the table with a
natural cherry stai n and four of polyufClhllne.
The group usuall y follows a magazine project's plans as
closely as possible, bul after game
{abies on the Imernct. they elected to change the playing
surface, They rece,<;!Ied the top W' to kct:p cards from slidi ng
off; added a layer of 'iii" closed-cell foam under the surface
for paddmg; and used velveteen fabric., rathcr than felt ,
because it's less li kely to "pill" (develop ti ny balls of fabric
that result from wear),
It took the.: group three to make the table, working
two hours a day in class. (Incidentally. in another
class made the game table shown in your
magazine.) Thanks for the project and plans.
8
-Tony Payrlfl, Incustrllli Arts and Technology
JUI1/lI1a 'lallsy High ScIloaJ, Alevmtlria, Pa
High schoolers fulfill their
mission to craft chairs
Two students in our .,.--...,.--
cabinetmaking class
recently built 12
dining
chain. from the design
you published in issue
(March 2(04).
Dovi 18, and
Ian Marsan. 17. worked
together to build the chairs
from cherry for their senior
project. (La'\t year [hey
built a cherry dining table.)
The only difference In
thei r chai .... is the. seal: Ian
wanted red fabrIC
buill a ."nWg'dChairn lor their
senior project..
upholstery on his six, while
Dovi preferred black \'inyI IOr hi s. Because Lan's dad works as an
upholsterer, he helped out wi th thaI Working about four
hours each day, the guys completed the chain; in about seven weeks.
Dovi. who graduated as valedictorian in his class., also operates
his own Web sile bu!oines!o, dhpens.com. There he sell s custOIn-
turned pens as well as other office and ki tchen accessories.
---Jo8 Marla and RoJand Bessette, cabinBtmaking InstflJCfoo,
Southeastern Regional Voclltional fecfJrncaJ HlgIJ Schoof. South Easton, Mllss.
Father tutors daughter
with Tudor birdhouse
My daughter. Anna. li kes
to look through WOOD- magazi ne
and has been aski ng me to buil d
something with her for solTle time.
The Tudor birdhouse plans in issue
169 (April/May 2006) seemed like
the nght project. so I decided to set
aside some ti me with her and bui ld it.
We mMe some changes because
she didnt v.'ant 10 wait for deli very
of the copper foil for the roof. I had
cedar shake. ... lying around, so we
Anna and Paul Timmerbefg
show off their version of the
Tudor birdhouse.
used them for the roof. She did all the painting, nailing. and design
changes, with help from me on the power tools. She so pn:)l)() of
the birdhouse and look.<; out the wi ndow every morning in hopes of
seeing its fif"!'; t tetlant:'>.
-Paul Tlmmeroerg, St. LOUis
cnntirllled on paf1t' 10
WOOD m.g.zI... Octobar 2006
Do MORE, MORE ACCURATELY
A drill press is no longer just a drill press thanks t o the
robust features incorporated into the PQWERMATIC
PM2BOO Variable Speed 18- Drill Press. Do more with a
digital readout for accurate speed setting. two lasers in an
X-V axi s to pinpoint the drill i ng center point, an extra large
cast iron table with sliding extension wings, variable speeds
from 300 to 3000, as well as a 5/S" keyless drill chuck for
quick bit changes. Find more about the PM2800 at a local
POWERMATIC dealer or at www.powermatic.com/wood
CArcIe NG. 1662
sIr KEYLSS
DRl..LCHUCK
EXTENSION
-,
AVAILABLE
FALL 2006
i
i
,
I
r
f
,
board
Pegboard sides add
extra tool storage to cart
1 loved yoor tbign for the rolling
workshop storage unit in issue 167
(December/January 200512006). I made
it even more u!t(: ful by adding perfOT1lled
hardboard to the two "ides from which I
hung tools. I simply cut v.t grooves in the
top and bottom 2)(2 cleats. and added extT'll
2)(2 cleats with grooves yertkally to hold
the 1/." perforated Illlrdbourd.
-5t8V8 votta/, Edell PrairM. Minn.
1/ .. " grooves Y.! ' deep,
,"' trom fronl
'I. x 29," x 651,.,.' perloraled hardboard
HOW TO REACH US
For woodwol1dng advice:
Post your woodWorking qU6StionS ijoinery,
finishing, tools, wming, geflefal woodwor1<.-
jng, etc.) on one 01 20+ online forums at
woodmagaline.comlforums.
To contact our editors:
'0
Send yoor comments via E-mail to
woodmailOwoodmagazlne.com; or call
8001374-9663 and press option 2; or write
to WOOD magazine, 171B Locust St. ,
l S221 , Des Moines. lA 50309.
Putting reclaimed wood
i back to work-In a bench
After many years of intending to build a
workbench fo.-my shop, I recemly built
your workbench from issue 166
(November 2005). I panlcularly liked the
use of top strelchers, which makes for a
stiffer frame.
I built mine all1lOSl enlirely ofrecJnimed
wood. I made the top from salvaged maple
flooring boards set on edge, with the
tongues and grooves cut off, using the
equivalent of 60 square feet of flooring.
"Log" on to this Web site
After reading your article on master
w()(xiworkcr Jerfry Lohr in issue 167
(Deccmber/January 200512006), I
wanted to share a Web slle devoted to
those who enjoy wood in it s rougher
stages. Jeffry suggests finding a local
sawyer to obtain rough lumber or to have
your logs custom sawn, and folks can do
Article updates
Issue 169 (April/May 2006)
The artide UFasteners for a lasting,
firm hold- on pages 64-65 descri bed our
finishing trim screw as a decking screw;
however, irs designed for finish carpen-
try applications. We recommend our R4
multi-purpose screw and RT trim-head
screw for fastening deck boards. Sec
and, a photo referred to a competitor's
screw as a uWCut: which is a trade-
mark. of GRK Fasteners and refers \0
, one of many patents owned by GRK.
For more information on our product line
please visit grkfasteners.com.
--{Jr. Mirco wallhlJf.presidsnt & co-owner,
GRK flisttJfI6lS, T/lund Bay, 0I1f.
Subscription assistance:
To notify us of an address change, or to
get help with your subscription, go to
woodmagazine.com/sen'ice; call
800/374-9663 and press optioo I OUtside
the U.S., call 5151247-2981 . Or write to
WOOD magazine, P.O. Box 37439, Boone, IA
50037-Q439. Pl6aS1! enclose your address
label from a recent magazine issue.
To find past articles:
See our index at woodmagazine.com/indel.
The re.<;;t of
the bench
I made
from pine
reclai med
from old
buildings. I turned the
vise handle from a salvaged piCl.."t": of
maple. The maple for the vise jaws turned
out to be the only new wood in the project.
--Ouer Mar1h8ller. Mandan, N.O.
(hat by going to forcstryforum.com and
using the locator li nk to find what they
need. There are more than 3,000
members on this Web site discussing
foreMry, sawmilling, drying, construction,
safety, and many other woodworking-
related areas.
-Dave Klish, Oneida. N. r.
Issue 169 (April/May 2006)
If you're building the planier box on
pages 56- 59, you've probably noticed a
few missing dimensions from the
stretcher (part 0). The correct
dimensions are shown, below.
, . ,.
....:rl,,- I -,,Irr
'r-ILL i !
y t Trim 10 til
v.' roun<i-overs during installation.
To ordet" past issues and articles:
Order past issues of WOOD magazi ne, our
special issues, Q"" downloadable artides from
issue 100 to present Visit CU'" ooline store at
woodmagazine.com/stDn!, or call 8881636-
4478. Some Issues are sold out.
Updates to previousty published projects:
For an up-todate listi ng of changes In
dimensions and bUYing-guide sources
tram Issue 1 Ihrough today, go 10
woodmagazine.comJeditOfial .
..,.
AWARDED MOST I NNOVATIVE
History has 8 tendency of repeating itself and it has with the
revolut ionizing POWERMATIC PM2000 10 Tablesaw. Following its
t ime-honored Model 66, the PM2000 has it all and then some.
Equipped wit h the industry's first arbor lock., an integrated castor
system, a true quick release riving knife and blade guard system,
this machine is e powerhouse. Backed with the industry's most
durable 5-year warranty, this li ne comes in 12 variations. Find the
model most suitabl e to your needs at a local POWERMATIC dealer
or at www.powermatic.com/ wood
WTEGRATED
RETRACTAlIU
CASTOR SYSTEM
QUICK RElEASE
RIVING KNIFE
GUARD SYSTEM
A,.,80RU)CK
ask wood
Answers to your questions from letters, e-mails, and WOOD Online
Sorting out a maple mix-up
Q
. I was given some maple
boards, but how can I tell if
they are hard or soft maple? Also,
what's the best finish for each?
-Rebert IOOg. High Ridge, Mo.
project and personal
preferences. To
preserve maple's
light color. apply a
non-yellowing,
water-based finish .
To bring out the
paUL'!"n in bird's-eye
or curly maple whi le
giving it a light
amber color, apply
boiled linseed oil
and allow it to dry
tOr a week before
applying a dear film
finish.
If you want
Soft maple
Got a question?
If you're k.>okinglor an answer to a woodworking
Quesli on, write to ASK WOOD, 1716 Locust St.,
LS-221, Des Moines, IA 50309-3023, (If sefld us
an a-mai l at askwoodOwoodmaga2inll.com. For
immediate feootlack from your fellow woodwOOl.ers,
po:st yoor quest ioml on erie of our woodworking
forums at woodmagulmt,com/forums.
Hard maple
A
. Color and grain similarities make
. hard maples-sometimes called
sugar, rock, sweet, or black maple-lough
to distinguish from soft maples, which
include red, silvc'f. or swamp maple. For a
simple test to tell the difference, Robert,
mix two tablespoons of ferrous sulfate
(iron sulfate) in one cup of water and shake
until di%olved. (You can find ferrous
sulfate at many lawn and garden stores.)
Wipe the :>elution onto a piece of the
unknown lumber and wait a minute for the
woOO to change cotor. Soft maple will turn
a translucent blue-black color. On hard
maple, the surface turns greenish gray.
darker colors,
though. use a dye
instead of a
Ferrous sulfat e 5Ollrtion applied to these sample boards turns the 50ft
maple (left ) a blue-black, and t he hard maple greenish gray.
Whether you have hard or soft maple. the
"best finish" is just the one that suits your
Patching a nuisance nail
Q
. I didn' t angle my alr-pow-
ered brad nailer right,
and the fastener blew out the
side of my project. Can I pull the
brad through, or do you have a
better Idea?
-Shawn Smith. Bridgeport. OhiD
A
You can pull t.he brad through,
Shawn, if the wood is soft
enough. the brad head i ~ small enough,
and you have enough room to attach a
pair of locking pliers to pull or pry it out.
Anolheroption, shown at upper rtXh/,
is to break otf the brad beneath the
surface and patch thc hole. In this
instance. bending the loose end of the
brad back and forth broke it off just
below the wood surface. Should the nail
break off slightly above the surface, use
a hammer and nail sel to drive the
exposed portion beneath the surface.
After li ghtly ~ n d i n g the damaged area,
fill the hole with putty. as shown at
lower righl. to match the finished color
of the wood.
12
pigmented stain. MapJe's small pores don't
trap enough pigment to produce an even
color without blotching. Unlike stain
Break the nail
off beneath
the surface. J
pigments, dye will fade with age, however,
so apply a darker surface than you want for
the long term.
Kid-size table heights
Q
. I want to build a 3x5' table
. for kids to use, but I' m not
sure what height to make it. Any
advice?
A
. Here's a good way to measure table
. height tor kids, regardless of their
llge, Shannon. Seat the child on a chair or
stool they'll use at the table. Measure from
a poi nt just below their ribs to the floor,
and use that dimension as the table-top
height. Adding a couple of inches will help
the table adapt to kids as they grow.
This play center from issue 167 (December/
January 2005/2006), page 76, stands 9 ~ high
at the sides and 1" high at the table top.
COn/iII/led 011 page 14
DEWALT
GUARANIUD
. .
ask wood
Wipe out stain streaks
Q
. I built an oak sideboard from
WOOD magazine plans In
Issue 155. page 66. When
applying the stain, I accidentally left
a streak of stain across the grain.
Now, I can see that wipe mark.
What can I do about it ?
---lJ.]ve PanisIl, ltlurlg5viJfe. N.C.
A
You have three opportunities to
. refTlO\Je soch l1aws. Dave. An
acddenlaJ slain drupkt or wiping mark on
a freshly stained :ouTface can be masked by
applying enough to thai area to
penetrate the wood as deeply the droplet
or wiping mark. Then remove the
stain. making your final passes with the
grain using a clean cloth. If the resulting
color is 100 dart, lightly wipe the whuk:
surface ..... iih a rag saturated in minernl
spirits.
As the bmder in the Slain dries. you can
still remove unwanted slain using mineral
spirils and <!. soft mg. as !>hown bel()w. Wipe
the streaked area fi only.
Once the hinder in the stain has dried
and locked the pigment in place, however,
you'll need to remove the mark with
sandpaper of the highest grit used for the
rest of the project. Then restain until you
match the color of the surrounding wood.
To lessen the impact of accidental stain
streaks and spots. apply stain working from
the haltom to the top of each IiUrfacc. That
way, any accidental drips faJl on prcvK>usly
stained surfaces. where they're less likely to
show up if you wipe them away while still
" .. et. Wipe away excess stain before it
hegins to dry, and work on one face al a
time to avoid leaving accidental streaks 00
adjoining surfaces.
14
Holding together memories
Q
. I have a question about the
scrapbook project in WOOD
magazine Issue 166, page 72. Do
you have a recommendation for
gluing leather to wood?
--Duc1Iey WillJams, WIChita, Kan.
A
. Any white or yellow wood glue
. will bond most raw leather to
wood, Dudley. According to technical
specialist Dale Zimmerman at Franldin
International, that company's original
Titebond glue once was used to cormect the
Shrinking a saw blade
arbor hole opens up options
Q
After recently buying a 12"
mltersaw, I discovered the
blade that came with the saw has a
\Ie" arbor hole. I am trying to find a
replacement blade, but they're all
made for a 1" arbor. Where can I
get a 12- blade with a ;i," hole, or a
bushing?
--8ill RsJJer. V8ooJuver. Wash
A
. A bushing will expand the blade
. options for your saw, Bill. These
bushings, which look like carefully
machined washers, slip into the ' " arbor
hole on a 12" blade, as shown below. That
reduces the hole size to fn your saw's
arbor. Freud makes a bushing (no.
BL7JMCE9) for downsizing ,- blade holes
to fit your saw. Make cenain the saw's
blade mounting washers and arbor nut
place pn:ssurc against the blade bOOy, not
the bushing. to keep the blade from
spinning loosely on the arbor. Before you
buy a bushing, though, make certain the
saw didn't come with a bushing that's
jammed onto the original blade or arhar.
woodmagaa.h' .. . ., .....
ends of leather drive belts for heavy
machinery in fdCtories.
A scrapbook binding, such as the one
shown al righI, won', face the smne stresses.
but you'll need to take a few precautions.
Some leather treatments or colorings reduce
any glue's bonding ability, so lest the bond
by glui ng a leather scrap to a wood scrap
and giving it a light tug. Abo, yellow glue
won't discolor most leathers, but check for
color transfer when gluing thin or Iight-
coloced leather. If there's a problem, switch
to a clear-drying white glue.
on {KJf(f! 16
ask wood
Upping the amps
a
_ When my 14.4-volt cordless
drill batteries gave out, I
found I could buy a new
cordless drill with two
batteries and a charger
for about the same price
as two replacement
batteries, so that's what
I did. The new batter-
ies were marked 2.6
Ah, whUe myoid drill's
batteries were marked 2
Ah. The salesman said I
could use the 2.6-Ah bat-
teries In myoid drill. Is
this correct?
-Juhll Watkins, Ulilrk, Ark.
A
. So long as the new
batteries fit into the old
dri ll and are the same voltage,
they'll work just fine, John.
Batteries with higher ampere-
hour (Ah) rdtings store more
energy than batteries with
lower Ah ratings. Your old
dri ll will run roughly 3D

Dealer Inqutrles welcome
e c op y rl llht 2008
,
percenlionger with your new 2.6-Ah
batteries than with the old ones.
eire .. No. 9210
, One good turn ...
! a . I' m satisfied with my
1 bandsaw, except for the
blade tensioning knob. The 2W'
diameter knob is too small for my
hands and it's too close to the
housing. Has anyone found a larger
knob, handle, or crank that makes
tension adjustment easier?
--Bob Rufener, Hartf()(O, Wis.
A
You'll need only five minutes to
replace that knob w](h an easy-to-
turn crank, Bob. That's how long it took us
to install the Quik-Crank bandsaw
tcnsioner (Rockier no. 20410. $35,
8001279-4441 or rockler.com), which
works on most 14" band!..1ws. lust unscrew
the original threaded tensioning rod and
knob, add the replacement rod and nut, and
attach the crank using the set screw and
allen wrench provided, as shown below.
If YO\I need a more heavy-duty option,
install a Spinner 3 tensioning crank
(Highland Hardware no. 189102. $60,
8001241-6748 or tools-for-woodworking.
com). This retrofit uses a 5" chromed cast-
iron crank wheel attached to a .s" acme-
threaded rod and hronu: nut dc"igned to
keep the tension setting from slipping. Both
types fit most brands of 14" handsaws .
'"
WOOD InilII"':rin " October ZOO6
, MOtOI
, SwIng' I"
'I,'
"
, SPOnCIIe Llper MT'2
, Numbetol 16\195, lOO, 360,
440, 510. Ssn,620, 7)0, m, 820. 1<100.
1 '00. 2200, 2600, 3500
Mol . Q,II1n(f 10 lillie, 1 r
, Mu. dlltin(1 Ipindle 10 b&!.f: 24' ....

. T.blt 11It; 11'1,'
, TJbIr IWHlg: 36(1'
Tlbletllts: 9O'1tt! .. !'ioghl
, AppIodm.lte Wpping
weight m !bs.
AYAILA.U
FU. 2001
GOOS1 ONLY ' 239
0
'
12 SPEED 20 FLOOR
DRILL PRESS
, Motot 1 HP. IIIN(22O'1.

, SwWI!J 20"
, DIll d'II.d:: 'I,'
, Onlh"9 upiO!Y l' .' sift!
, SpirId\t Ulptr MT ..
Spindle 1IM;4',,'
, 12(m.JIO,
0J.440.630.670,126O, 14)0,
16S0. 205Q, 13SO,llOO RPMl
(01" __ l,6U'
, Prt<:iIO:In ground C$' Iron IibIt
11'/.' 16'i,"
Swftcl\a, 110Y only
, 0-111 hfIght: XI'
JHppIng WI- Jll Ibs.
G790S ONLY '495
00
8 SPEED FLOOR
GEARHEAD
DRILL PRESS
, Matof-,' "" HP,
UIN. l-phni!
, SwI'9 'lI1
e
,
S"incHuaper- MT '3
-.bwof'!>Hdl:'
, 125.1so. ,no. 5)5,
840,1070. 1740ind J.QOJ\PM
, U' I,' , 19"'-
. --
WfI9I>r 4ll Ib$.
tfI' QUAUfY tMlIS
CMUClIIiCUIPUI
, Motor'" HP. IIOY,singif-p/IaW
AVilY
, Mchod:'Io' ',,' POPUW
, 0riI'''9 UPKilT ,," MAeHIM"
, Sj:JIno:IIeUll""I"lIITll

12 (140. 260,
1lO. ]I!(l, 48(), 540.!i8tI. 1160.
1510. 16s.o. 2H10.105O RPM)
, (<>RoT \I;/e: 2595'
i'floion 9<QI,Jrod UI1Iron t.l>ble
11'/,'sq.
swlng:)6(I'

, ...... m: 64"

lnd .. .dH W.,!n 100ht (bot> "'" ""Iudtd)
G7944 ONLY '250"
".
, o-allheoght;{o'1","
, Appnl . WI" 322m
G0482 ONLY $595
00
DRILL PRESS WITH
TABLE
, Colo, 'IiIE 1 78fT
, longitudInII trwfIc ,.
,
, en... tAlMslm:2l"'J 7"'"
,
G0520 ONLY ' 1850
00
Doililng upKiIy: I" wee!
SpondltUl!*Mr'l
Spondletrl"Jel:.'I,"
Nl.II!'Ibt'rgf!PMCh, 12(210.110.400.
4<10,610. 67(), 1160. 1.30. 1650. 2050,
mo. 3:500 APMJ
, (011< sill!: 3,623'
i'f111on IJI'OII"d col&liron 1",*
T"'*l<zt: ll'I,'!oCl
IWOIlg: 360'
Tabift!'": go'left" ri9hl
, 0-" htoght 7ft'
, J.wo>.i""lf Ihippk>g weoght 283 Ibs.
G7947 ONLY ' 425
00
, M-=\'"Hp.llovn2OV.
songIe-phHt. p.ewoted nov

, SpindIf Ulpe<c MIl!
' SpondItIrMi:6
, Sp,1Id\e Virliblt.
J." .. """
c ....
CoiurM diwnIttt: 4'.','
19'/:'.21"'-
111_ dlsuncupndlllO ubi<!:
IoIu. d/$Ur 10 blw: !I:r

7761bs.
THE KING
OF DRILL PRESSES!
HEAVYDUTY
GEARHEAD
DRILL PRESS

, s..Ing: lO'N
, 1',,'lnMildSfHI
, SpondIfQptr-MTM
, Sp!rodltb'-"S' "" .. l:"'''''''
,
, c .... WI!: l.rnr
, loIbJto .....
,
.-
WIlIJin\J Wl:
901 11>0.
INNOVATION
shop tips
Helping you work faster, smarter, and safer
No-brainer setups
for feather boards
top shop tip
Feather boards add both
y Feather board setup stick
safely and consistency to
many cuts on the router
table and tablesaw. But
there's a fine line
between too much and
too little pressure, and
finding that line used to
drive me hall nuts. That
was before I made a few
featherboard setup
sticks from scraps of
hardwood.
After perfecting the
feather-board lenSKln for
a -thick workpiece, I made a setup
stick by planing down a scrap of stock a
little at a time until it just slid easily under
that feather board. Then, I labeled the
slick so I'd know which thickness of
material it works for.
Now, when I need to sel the feather
board, I simply slide the appropriate
setup stick against the fence, stand the
! feather board on top of it, as shown
I above, and clamp the feather board to
I the fence, The setup stick also ensures
: that the feather board stays parallel to
i the table top, applying uniform pressure
j along its length.
-John Ducey. LawrlffiCfl, Kan.
Microadjust your fence with a turnbuckle
Making superfine adjustments to my
router table fence was hit-Dr-miss until I
came up with my own microadjustment
system, shown be/ow. With this system, I
simply clamp one end of the fence and
make fine adjustments to the other end,
fore or aft, with the turnbuckle,
To add a turnbuckle to your
fence, use the hardware shown
to add a pivot bolt to both the
fence and the starting block.
Use a turnbuckle with eyes
large enough to fit snugly over
the bolts. If the eyes are too
large, fill them with epoxy, let it
cure, and then drill out the
epoxy to fit the bolts. Use a
washer on either side of the eye,
and lighten the assembly
together.
The turnbuckle works best on
the push" stroke, so always
make final adjustments by
driving the fence away from the
slarting block to take out any
slack in the threads. To ensure
20
that the fence doesn't move once you've
got it perfect, clamp the turnbuckle end
of the fence down. When not in use, you
can leave the pivot boH and eyes in place
and remove the turnbuck!e. Then store
the fence and the starting block.
-Wayne OOOOvan, KBlIS<IS City, Mo.
,
The Top Tipster
A recent newcomer to woodworking,
John Ducey is just starting to set up
shop. Other than his tablesaw, he
owns a router that he received for
Christmas a year ago. He then built
the router table, shown above, that
inspired this issue's Top Shop Tip.
For sending the Top Shop Tip of this issue,
we're doubling the number of routers in
John Ducey's shop by shipping to him
a Porter-Cable 895PK 2-hp router kit.
Attaboy, John!
Top tips earn tools!
Describe how you've solved a work<.hop
stumper, and you'll get $75 if we pri nt it.
AIXl, if your tip garners Top Shop Tip
honors, we'll also reward you with tool
worth at least $250.
Send your best tips, along with photos
or illustrations and your daytime phone
number, to: Shop Tips, WOOD
Magazine, 1716 Locust St., LS-221,
Des Moines, lA 50309-3023. Or e-mail
tips to: shoptips @woodmagazine.com.
Remember to include your contact info
in the e-mail as well.
Because we publish only original tips,
please send your tips only to WOOD
magazine. Sorry, submitted materials
can't be returned.
("amilll/N/ ,m fIuge 22
i
!
!
You see your tools as an extension of who you are. You see a piece of
wood and you see opportunity At Steel City Tool Works. we know who
you SRI. And you're not like everyone else. Which is why our tools are nol
like everyone elses. Bottom line? We make toots that make a difference
in yoor work We back them up with the best warranty in the business.
We offer features that come from the minds of woodvvorkers, not sales
guys ., need of a good gimmick. And ...-.e're doing business in a way that
Is flat-out reshaping the industry. Welcome to the new City.
Visit steeicityt()()/v.Jorks.com to find your nearest distributor.
C..-de NQ. 1769
BY TOOL GUYS. FOR TOOL GUYS.
shop tips
Laid-back sander sharpens knives and chisels
As a wood carver, I spend a little more
time sharpening my knives and chisels
than most woodworkers. And while I
could justify spending up to $500 on a
dedicated sharpening system. a few
dollars and a little ingenuity allowed me
to tum my strip sander into one of the
best sharpening systems I've ever used.
Begin by bUilding the dual sander
base, as shown in the drawing. Be sure
to add hardwood feet to the sharpening
base 10 create a space for the tool rest
hardware. Next, mount the sander to the
X mHEAIITDUTY
Prvfeuional
X aPrHJNAl CDllFOIlT
CwllionH Grip
PEIFORllANa
DriV'fS 6 Diffef'l'nt Sizl'
StllpleHNaiis
X mORDINAIlf POWER
14 Amps of SU'fI' Pow"
X OTING DESIGN
New Ergonomic StyliR9
base. Finally, build the tool rest , as shown,
from i!' threaded rod and a piece of 1x1'
aluminum angle.
The base allows you to tip the sander onto
its back so the bell will travel horizontally
and away from you. This positkm is ideal
for sharpening lools. Fine sanding beM of
400 to 600 grit will work l or many sharp-
ening chores. For more versatility, a
leather belt is also available that, when
Ireated with an abrasive, will do an excel
lent job of stropping gouges and chisels.
-{;ene ClinIY. Ck:erQ. N. Y.
ETFX50'
e
"' ........ "
... It's what
YDU're come to
XPECT from ArrDW!
'ftp/rtg Amtrlcil itrvltg
45brace
0/ is" hardwood loot
22
TOOL REST ASSEMBLY
If-
''- ";n. nul
lock washer
%" nut.- :
-1x1 " aluminum
, angle 1001 reat
%" nuts
Washers

Yo" plywood
WOOD magazine O<::lobfr aooe
TIle .IDS Co.",.ao
(IJ,. t;lill'fflJlJ1lti}MJj illJl/; t;ql(I#J;JifllJ,
JDS Air-Tedl 750-ER
4;' .. ..,.
..
,.


JOSCyclone
2HP1 4SO al.I
)HP 1100CFM
www Jdstools com
For more information or a dealer near you call 800.480.7269
The first blade
good enoug h to
honor the Corter brond .
Pr .. cision mill.d t th
Indudion hardened
Flexback con$Wvdion
Match tooth welded
Alio from Carter Products:
guides I stobiliu.rs
tension d.vicu
tires I much mora
UL11f comes in qUOIt and gallon
II;S available in glo55, Gnd satin sheens.
ULTRA Max is an environmentally safe,
revolutionary dual drying polyurethane.
It dries by coalescing & oxygen cross-linking
for a harder"through cure."

l ow voe -does not e)(ceed 250 giL

Extremely Durable

Dries i n 2hours

Exotic Hardwood Approved
DualDr

Made in the USA
TECHNOLOGY
D "
H D

Latest TORMEK innovation
Turning Tool Setter [TTS-100 [
fingernail gouges and skews
Fingernail bowl or spindle gouges using SVO-185
Gouge Jig. Oval or flat skews even with curved edge
using SVS-50 Multi Jig.
Creates the ideal edge geometries recommended
by skilled and professional turners.
Exactly replicates the edge geometry in seconds
- you just touch up the edge.
Patented design - works irrespective of stone
diameter or honing wheel.
A perfect and polished edge in 60 seconds.
Remember - a TORMEK edge makes a finer cut
and stays sharp longer!
( www.torrnek.com. Click N; ws for full information. )
PRECISION MEASURING
SYSTEMS KIT
As vou know your project s t urn out only as accurate as the
wood that goes into it. Our Precision Measuring products
help ensure that your mat erial s t urn out fl at. st raight and
square allowing vou to build your best
i
See these Pllducts in action on our website' 800 447.8638 www.kregtool.com
A slick solution for
portable-tool bases
When culling soft woods with my jigsaw, the steel
shoe (base) always left: unsightly marks on Ine
workpiece. So I bought some self-adhesive polyester
film (such as Mylar) at a crafts and hobby shop, and
fit a piece to my saw's shoe. After thoroughly
cleaning the shoe with alcohol to remove any oil or
grease, I applied the sheet to the shoe, being careful
not to trap any air bubbles.
Now my jigsaw glides on the workpiece without
marring it. You could use the same material on your
circular saw's shoe to protect the wood underneath.
-Rusty /l1fJram, Cedar Grove, N.J.
Suspended storage
saves steps
Workbenches work best ...men they're in
the middle of the shop so you can move
around the project. The problem: Your
tools are usually stored around the
perimeter of the shop. The solution: the
tooJ storage shelf, shown below. It not
only makes use of vacant overhead
space-it saves time and labor, Shaped
like a stirrup and mounted to the ceiling
joists, you can configure it to your needs
to hold small hand tools, clamps,
screwdrivers, and whatever else you
want to keep handy.
-&1d 8*, Jr. , Land O'lAkes, Ra.
cnnlillued on 26
Mount
YOU'RE PROBABlX JUST As AMBITIOUS_
Shelf mounted
over workbench
25
Whether you are a d()-it-
yourseller. a prolessional
woodworker or somewhere
in between, you have a world
lull 01 prOjects in the home
or in tile sllop tllat will be
easier and more enjoyable to
complete when yOll use Qual-
ity clamps. bench vises and
miter boxes/saws Irom the
Adjustable Company.
Look lor them under the
Jorgensen, Adjustable and
Parry brand names wherever
line tools are saki .
Made in the USA by the Adjustable Clamp Co.,
433 North Ashland Ave., Chicago, IL 60622,
_coni
shop
Supports for dust-
collection ductwork
I needed a good way to install the
main duct runs of my dust-
collection system, and I wasn't
looking forward to the prospect of
trying to raise a network. of pipes to
the ceiling by myself. The system
shown at right, using 50 cable
ties and furring strips,
provided the solution.
I started by screwing furring
strips to the joists along the path 1
wanted the dLICls to lake. I then
laid the zip lies across the notches
in the furnng strips and zipped the
lies into large loops. Next. I fed the
duct paris through the loops and
joined them. With the ductwork still
hanging low, I had no problem
sealing all the way around the
jOints. Once the duct was joined
and sealed, I raised the entire
labyrinth up to the ceiling by slowly
ralcheting up the zip ties .
Alma. MiCh.
26
Hes --II
DUllt-colieclion ductwork
WOOD ..... gu:iBe Oclober 2006
New 'Beiich Dog Available in Foil 2006_
-
P MAX
.. ...
ro
... 1.""'fItaff1t/ fO<Jrto. bit II<xag. ..t1It poA.OU/ !JhtJIvH.
.. D"_II9/1Oil wi!/! fIiII .. t.tn...", NIl Nllli"l1 ,-...
... ."dc_mad.iIl USA,
Comploto Ro"lO. hbl.
.. U""1 .... fQt '1r:>rlo9 yotJ. """'"'"
oMAl( c-,.Iet. _ .... _
>'"M _ --...:.'AI "'"' _1M>It ... BOIl' .nd CfOn ,*,_1 COfI.lruclion
Pr<>I.U.X ft>;f Ce '!HI fonlte IItrlmaie In .m.ngll>
.
. -c.
..
... Curved _ pa" .. ,. for Nofl...-
... So/fd BaltIC pllMJl conofn.oction_
.. r.,DM lin 27- x 2Q' h.-gM. 3.'1-""
.-.u:c-_ ......... T._
___ CIO-o< __ . No
__ c.w....- __
'RO_X 'ROFESSIONAL
CABINET
".-.MAX 11._ T
-_ .... .-.,."""""
CaII-->x __

---


.. HI-Jo sro_.
Preml .. m Wod'benches
.. RfNjf s/ort>g9 .,..a lex f<xlIs e'ld
... C.binet-:t/y/!>
... MoM. t .... reedy
... Fronr row dey 1">01"
.. Pmmi<lfl'l ";s
50' MODEL
SlOC": NO ' 0015
1
....... _H --
........ !D ....
_
___ I""",*,,

_ .. _-"'--
72- MODEL
STOCK NO. ' 11-08&
...-.-Nn-_
.."..... 1q> /IHI'l412). , c-
{II-O(I-.(W3J. a..:o _ " .. (MOo(IIIn

1
1720 RPM spindle speed.
2
' 0,,111,1""'" . board spindle storage.
f ' ndles With on e
5 sizes 0 apl bTty and easy storag .
Compac;t design for mo II
Digital spindle speed display.
3 variable speed ranges ; 4001000, 790.2000. 1500,3800.
Pivoting headstock for outboard turning.
Mcxi.tl ZS-ZOO fYl J
great ideas for your shop
router-bit holder
and profile display
The best edge
treatment is but a
glance away.
S
ee instantly what profile
each of your router bib
create by building
handy bit displtly with lnalChing
You can sit the bit
support on your workbench or
build the optional wall mount and
secure if to a surface. The
bit suppon shown at right
measure>: long. but can be
lengthened to hold more bits and
profiles. Add 1 lAM for each additional bit
you wish to add. For large-diamclcr bit".
such Il!> a panel raiser, you' ll need to
lengthen il e .... en more. For 5n'k1Uer-diameter
bits. an extm inch per bit should suffICe.
We built our wall mount extra long for
adding more bit .'>Upportll in the future.
To form the angled bi t support, start with
a piece of stock. U'Itng a
push.stick for safety, bevel-rip it a l 18, and
1t8 x 2" F. H wood screw
centereo over stud
Routed \
profile 1'r'

.",.....
,,-.
V. hole '1" "'!,db<''':Cx:
v." dowet
'12" long
, deep.
centered
shank hole, countersunk 00 back side
' " ..... x 1" F.H. wood screw
OPTIONAL
WALL MOUNT
2W BIT
SUPPORT
EXPLODED VJEW
use cloth-backed, double-faced tape to stid
the two pieces together in the configuration
sh()\\lll in the phol.o at left. Then drill VJ;"
holes Vl" deep into the support, and
separate the support from the liCl'1Ip.
To create a profile lOr each bit yuu'll
house in the bit !>upport, CUt blanks 8" long,
Stick the waste stock to the bit support, and and drill a .. hole centered side (0 side and
drililhe If.t" holes. ih" from one end. Now, rool each 8"-long
2B
blank with a different bit. Crosscul a
I" -long section from each blank, and glue
in a pic of \4" dowel W long in the
previously drilled hole. The profiles can be
removed from Ihe base so you can hold
them up 10 an edge needing routing. It also
gives you (he flexi bility to rephlce bits and
m(wc them as future needs dictate .
Project Kavi" BowIe
WOOD ""'9u1na October 2006
And r h t ~ .. !Oomething worth passing
CONTEST
Use your talent
to win amazing
prizes, .. and
help find cures
for childhood
illnesses.
Y
OU could win $5',000 worth of woodworking tools and accessories from Peachtree Woodworking
Supply Inc. or one of many incredible prizes and help to raise money for St . Jude Children's Research
by entering WOOD Magazine's Build-A-Gift Contest.
All woodworkers are encouraged to enter. There are 25 different GRAN D PR I Z E!
ways, to win. Winners will be featured in the $5,000 of Woodworking Tools and Accessories
2007 Issue of WOOD M?gazlne and on WOOD Online. from Peachtree WOGdwolldng Supply Inc.
After judging, the handcrafted gifts you
enter in WOOD Magazine's Build-A-Gift
Contest will be sold at both a live and
online auction to benefit St. Jude Children's
Master Routing
Package
Saw Blade Package
Shop Safety Package
Power Tool Package
Dust Collection Package
Research Hospital. Its mission is to find
St. Jude Children's cures for chi ldren with catastrophic
Research Hospital illnesses through research and treatment.
HW . P ........... , ... 4" No family ever pays St. Jude for treatment.
Sanding Package
Drill Press Package
Clamping Package
T-Track JIg & Rxture
Package
And Much Morel
So, when you enter your gift, not only do you have a chance to
win a great prize. you are giving the gift of hope to the next
generation.
Visit www.woodmagazlne.comJcontest
lor complete Grand Prize list.
WOOD Magazine's Build-A-Gift Contest Entry Form-
There is a limit of 3 total entries per person. Please send your
project in a box no larger than 2x2x3' . Please submit a copy of this
form with project submitted.
OiIadline: November " 2006
I want to enror my entry in the foliowino caleoorv. olease check one:
o Best Use of a Router
o Best Joinery
o Best RniSl1
o BestTurned Gift
o Best Home Accessory Gift
o Best Clock
o Best Holiday Themed Gift
o Best Mi niature Repl ica
CONTEST
o Best Wooden Toy or Chil d's Gift
o Best Jewelry or Keepsake 80x
- -
Please check one:
o My entry is an original design. I certify that I have designed and t>uilt
this project myself.
Signature: ____________ Date __ _
'::::J My entry is ooi lt from an existing p1an.
Signature: ____________ Date __ _
Name ________________________________ __
Address _________________
City
,-------------------------
State/Province' ______ Zip/Postal CQde _____ _
fItlone _______ EMaiJ (apli onaQ __________ __
Send Projects 10:
WOOD Magazine's Build-A-Gitt Contest
clo Sheryl Munyon
1716 locust Street (LS 221)
Des Moines, IA 50309-3023
----------" A Contest Entry Form is also available on our website: www.woodmagazine.comlcontest
Prizes and Sponsors
GRAND PRIZE!
chtree Woodworking Supply Inc.
.. ro.. s.. 1r,,"_CaM
$5,000 of Woodwortdng Tools and Accessories from Peachtree Woodwortdng Supply Inc.
THE ST .JUDE AWARD
Preserlied to the entry that raises the most money through the auctioo.
PowermaUc Deluxe 14" Closed Stand Bandsaw.
Aetail value $1,000.
BEST CRAFTSMANSHIP IN A PRO.JECT
BUILT FROM AN EXISTING PLAN
BosclllO" Dual-Bevel Slide Miler Saw with Rne Rmshing and Solid
SUrface PTolessional Series Circular Saw Blades. Retail value $900.
BEST ORIGINAL DESIGN
General lnternatlonaJ 50-090K Job Site Table Saw. Retail value $680.
BEST USE OF WOOD
Hitachi Cl0FSH 10 Sliding Dual Compoond Miter Saw with
laser Marter. Retail value 5500.
@ BOSCH
HITACHI
POWER TOO LS
Each 01 the categories below havelwo Winners: One for "Original Design" and one for "Built from an Existing Plan."
BEST USE OF A ROUTER
Freud FT1700vCEK 2-1/4 HP Variable Speed Fixed Based Router.
Retail value $18(1,
Frewl RTP1000 Ultimate Portable Router Table. Retail value $200.
BEST .JOINERY
Porter Cable 5116 Omnij\g. Retail value S3OO.
BEST FINISH
I PDRTER+tABIE I

Varathane Prize PaCkage includes an assortment of Wood Stains,
Polyurethane and Gare & Repair Products. Retail value $250.
CELTA
T ... !kM- .(,J!:O=- .. ... __
_ moot too __ lit" 5:<10 p.on., on N_ I,:IDOI!.
....... I ! ... __ "';oI_<lClnldl
__
......" ""_""""' ... _ ..... ..
___ (rilt...w:wt. __ ...
BEST TURNED GIFT
Delta lA200 Midi Lathe. Retail value $300.
.......
BEST HOME ACCESSORY GIFT
TItebond III Ultimate Wood Glue, ntebond Original Wood Glue,
ntebond Glue and more! Retail value $300.
BEST CLOCK
Klockit Patriot Kit with unfinished clock case wood parts,
hardware, dial , glass and quartz dualchime movement.
Retail value $520.
BEST HOLIDAY THEMED GIFT
Gorilla Glue 4 oz. (16 piete), Gorilla Tape (12 piece) and
Grolla Vest. Retail Value $285.
BEST MINIATURE REPLICA
Makita 18V LXT Lithium-Ion Cordless Impact Driver Kit,
lBV power. , 2V weight. Retai l value $320.
BEST WOODEN TOY OR CHILD'S GIFT
$250 Woodcraft Gift Certificate.
BEST .JEWELRY OR KEEPSAKE BOX
Adjustabla Clamp prIZe package inCludes a variety of
Jorgenson and PoflY damps. Retail value $250.
__ ."'"",,"",-' __ "'"
_<JW _'"' _ Nt .... til fm\"1IId,/<o_
_11 "" to:. [_..,._"''' ...
_rW_Cttro ..... IOtrt'<m_ .. ,. .... ... _
... onIrr1crm 11 _. __ ._ If<! _lfIIytro. *rig"""", '"
__

PrClOd""'" b1_._ ... ....:1 rd_ln:JoidrllNdp_A

.... 11ng ,,-,
......... .... r.,_' ...
01 ... -=-. .. 01 ...... _ ... ___ .. _
Z21,lla_1/Io __ "' ____ IoiIolt.
"_"b1lO1llla.Qr:ll"'II'II __ .

01 ... __ ... _ ..... __ .-.
.. __ .... ...

_dol. .....,, __ ,-.p:agoU ... ___ u"'_
&ra_rd __ .,.JI"IIII"'_ Sl ..... ......

--._
aQI .
Log on to www.woodmtJgazine.com/contesttormorelnformationtJndfull contest rules on the Buifd-A-Gift Contest.

and
kerfing jig
7"---- Rib
t
To bend plywood or solid stock
you need to saw many uniformly
spaced kerfs. You'll quickly plow
through them with tms simple jig.
C
utting closely spaced kerfs into
the hack of a piece of stock and
leaving a thin web of wood on
the front allows the workpiece to bcnd-
ideal for forming a curved part. (For i.I kcrf-
bending anatomy. see the photo at riglir,)
WhClhL'f bending solid stock or plywood,
uniform kerf spacing guarantees the best
results. Here's how to make ajig for your
table&aw miter gauge that'll accomplish the
job wilh speed and accuracy.
First, from plywood, particleboard, or
MDE cut a -Ytx2V4x I6" miter-gauge
extension. Then cuI a Ih" saw kerf \1.1" deep
centered in the extension, where shown at
righl. Now rip a \Ig"-wide strip from the
edge of a -thick piece of stock. cut a
1 \I2"-long piece, glue it into the extension
kerf, and chamfers, where shown at
right. (Centering the pin in the extension
provides ample support on both the
"infeed" and "outfeed" sides of the pin
when kerfing II long strip of .... 'OOd.)
Put the jig to work
To prevent chip-out at the back cdge of the
wurkpiCt.-"C. fit your tablesaw with a zero-
ten Ihe extension 10 the miter gauge.
32
clearance insert. Then adjust the cutting
height of the blade. For solid stock, adjust
the blade ;.(jlhe cui leaves a lilt-thick web.
For plywood, adjust the blade so it slightly
cuts into the crossband direcIly under the
face veneer, leaving a L/lb-Vx"-thick web.
Glue pin into kerf,
flush at the back.
Now sel the kerf spacing and cut the kerfs,
as shown in the photos below. [The photos
show setting up and cutting Y .... -spaced
kerfs for the aprons (F) of the bow-front
table on page 62.1 .
KERFING JIG


6" Sand slight chamfers
--------= "'"7l along l op edges.

".." saw kerf V4" deep
WOOD magaziJle aooo
avoidi
put the kibosh on

n\eaSurlng
n1istakes
A
ccurdC
Y
in woo:iworking often boil s down to
measuring correct ly before machining anything.
The following five tips should help you avoid common measuring
goofs. First, though, we offer a few that apply to all work in
your shop:
Double-check before cutt ing.
Use the same tape throughout your project, when
possible, because minor inconsistencies from tape to tape can add up
to major headaches. Sometimes, however, you might need specialty
tapes, such as for cent er-fi nding or left-ri ght readi ng. We'll show you
these tapes and tell you where to fi nd t hem.
Before you do any cutti ng, check and adj ust machines and
accessories to male sure they are square.
Dry-fit your project before glue-up. That way you' ll get a chance to
fi nd and wrn:cl assembly problems without being pressured by
drying glue.
FIND TRUE CENTER WITHOUT STRAINING YOUR BRAIN
Mistake: You've miscalculated while trying to find a workpi&C(l 's center.
SollltiOI'l: Eliminate the chance for 8rr0r'3 in math by using a measuring
tape with a half-scale on the lower level. This board i n
length, fop. TIle bottom row on tha tapa Indicates that the halfway point
is 14''/,s", To maJ1l. the midpoint, go back to the top row, find 14''/,8" and
make your mark, bottom.
MeasurePro 16' centering tape. $15, PriceCutter. com; 8881288-2487
34
DON'T GET BURNED BY TAPE' S FIRST INCH
Mistake: You measured from the I " mark r ooming" the first
inch), then forgot to add an inch when maJ1l.ing.
Solution: First, use a steel rule Of folding rule that doesn't have
the play of a retractable tape's hOOk. Second, il you must burn
that Inch, make your mario;, top, then double-check It by mea-
suring 3gain using the hook, bottom. This example shows how
buminglhat inch resulted in greater accuracy, as the bottom
measurement is '164" shorter than the tape indicates.
USE LEFT/RIGHT TAPE FOR INVERTED MARKING
Mlsblke: When you hold the tape In your left hand so you can
mark with your right hand, the numbers on most tapes read up-
side down. That can lead to confusion, especially for unmarked
fractions.
Solution: Rather than try to figure out which mark is t and
which is, for example, get a lett-reading measuri ng tape Of one
that reads from both sides, as shown below.
Fastcap 16' LeftylRighty, $6, Amazon.com
li"'l'iiii
How Do You Create Beautiful, Strong Entry Doors With A Router?
Thanks to Freud's latest patent-pending Innovation, you can create
unique wooden doors with the security of durable mortise-and-
tenon construction with extended tenons of virtually any length!
A beautiful, custom crafted wooden door can enhance any home, adding curb appeal and value
to ltIe exterior and a warm decorative touch within. Traditional custom doors have been too
expenslve for most homes, but this new router bit set from Freud has changed the equation. Now
anyone with a suitable 1/2" collet router' can bui ld beautiful,
durable, affordable 1-318" and 13/4" thick Interior Extended
or exterior doors - as well as sidelights and
transoms in any size or style!
This system leIs you build doors with true
mortise-and-tenon construction, including
extended tenons, for rock-solid joints that last a
lifetime. No other router-based tooling has ever
offered this capability with such ease of use. 111e DVD
video and poster included with the set take you through all
the steps, including routing, mortising, raised panels, glass
installation and much more.
These bits feature Freud's exclusive TiCo" Hi -Oenslty
Patent-Pending rail bit
comes apart 10 rout
extended tenons lor
extm.-strong mortise
and tenon jointsl
Carbide designed and manufactured by Freud for a f!awtess finish in mH1worXing applications.
They also feature Freud's Perma-5HIELoe permanent coating to reduce heat and corrosion
for long cutting life. Visit your Freud dealer and see the latest in router bit design and
innovation today!
-A"*'Irn(m 3HP II)tn.t' ~ o d Some 2-114HP rtJUtIorI _1ICClIIp!aIlII;. ODf"oI\A)'OlJ" _ ~ ~ beIoIe using.-.y rouWior biI:
To sign up for Freud's e-mail newsletter or to f ind a dealer near you VIsit: www.treudtools_com
Red router bit. are 0 registered trademark of Freud America. 'nc. (US) 1-800-472-7307 (Canada) 1-800-263-1018
avoiding \Norkshop goofs
DON'T DOUBLE THE CORRECTION; HALVE IT
Mistake: You remavad double the intended amount when l ine-
tuning a tenon to lit a mortise, instead of half from each side.
Solution: To avoid cutting too much off a tenon when maKing
microadjustments, leave reminders where they will be seen. Write
the word 00 the tenon cheeks and also on a piece of tape
near the line adjustment knob of yom tenoning jig, as shown.
Then split the difference between both sides when you need to
remove more. Similar errors can happen when machining half-
laps, and the solution works the same.
36
3 Year Factory
Warranty on ALL
Festool Tools
McFeely's
Honors All
FESTOOL
Specials
Top rated
Tools that
Work as a
SYSTEM
USE STOPBLOCKS TO MAKE REPETITIVE CUTS
Mistake: Individually measuring and cutting each one of multiple,
matching workpieces (picture frame sides, for example), leaving slight
discrepancies in actual dimensions.
Solution: Eliminate culling each piece to a pencil mar1(.lnstead, use
a stopblock clamped to a fooce Of miter gauge, as shown, to ensure
each workpiece will be exactly the same length,
WOOD magWnfl October ZOO6
LOOK A TYPICAL TABLE SAW CAN DO.
COII\'crt your lable saw into a molder \lith the Magic Molder .
MAGIC
MOlDER.
9250 AYe thals rli CA 11311 '11 712 0221i Ir FAJ( 118 ,n 7102
Email ul .... I'hul elm 'Nlh,le .ww elm
...
Every Product, Every Day"
--------
66 PIECE
MLCS
ROUTH! BIT SET -
I & - . ,
With LiREE. . . ,
BEARING LUBE! .. ,.,',
. , '
JUST $2.88 PER BIT!
A huge ooIlectim ri excdlcnl
quality Carbide TIpped. anti-
kickback (larger size;) rouler
bits with i high Imtper-dlure
ccii.ling 10 fight residue build
1IjI. WwI box can be
waJllI\()unlt'\l,
- .
- - - - .
: . '.
I WOOO STORAGE INClUDED I
8 Sl:l'1igtlt 6 OYer 6 Ct:M.> . 5 [lmrtail 4 Chamfer 3
3 Core Box 3 ROllI.:! Nu;e 2 Roman 3 Mortising I
2 Slot Cutler 2 Flush 'Ilim 1 &m Trim I Ptlint Cutting Round (J,:er
1 Fbi Bottom Rouoo 1 Rahbt1irtg . 1 \luhl BeadIRa'd Bit I Keyhole
"
1 Double Cow & Bead I FI3t Iloaom Sign i2ttering
W1tII FREE LUBE!
I dassical Bil 1 Dish CuUer . 2 Edge Beading
1 G!1:X:M t'onning Cl<l\'iical I Sign Lettering
1 Iklub/e Fillet & Cow . I Ogee flkt 1 Panel Pilot
I ROlIn! OYer 3 bearings & allen 9.'Tt'I1Ch
j:' 4 " ' S 4: 1 I.w
Ho "zontal
Ro:':terTable
Rout wi de stock FLATON
THE TABLE with tall bits
in the horizontal posi ti on.
Dont stlIld stock on edge! Our
r1l'\l. rerldncll make; tall
auxiliary fenres, multiple feaIher-
boards or jig!
Make mortise & tmon joinery,
ral.'Hi "'ith \mlcal raised
panel hils, moIdinp am picture
frama This x))" x 25" tabif!
features Micro Nilustable bit
height adjustments. Sl.uniy V4" thick MDF core, durahle melamine ard
poJ)'ethy\E:roe edges. Extension fences on 00th silb ti
the rolltel' plate give maximum r.tock support. The 3/8"
thick roulPr plate is rdd hy ru,m;;"", ",",",.
arK! tv.u locking knohi
I mAL OFFIIR
TABLE
& BITS
SPECIAL!
Gel THE flATIlI'l)
IbtrotaI R(X1Ief
Tabit plus a looT r-o::e
lI2" shank
Raisel P:Ind bit n

INSTRlGi\CU
I'OJJDID!
NEW! MLCS
Drill Press Table
Ml veMility am pndsion 10
)l1driJl presn,ith the MIfl)
12" x 24" drill pns;
Includes 1'.1\':ick; for
hokI-dcNtns and
aijuslllble
fence fox
maximum
hokling jXI'M't
In' ,h.,k
bits for makln!\ panel
00xs, table and dmlwr

locie Raised Pallel
with Matr.MI
1/2" shank with carbide Oltte3. I.ockOO in
loint easy aligrunent MJ an attractr.'l'
edge tocaOinet (hlfli am. >t.er.oe>. U;e
with pJyv.oo:l MDf sI-.:I1'ffi frum
1/2" 10 I" thick. glue SI.Irface.
Maled7J1!" thidt
MI1'lMelamine. Rl'lnoyJbIe
insert can be drilled for any
sanding drum. Worlis with drill
pres; taIlk5 that parallel
slots III the center hole thal
SPECIAL
Rail & Stile, GluejoinL Dr.J.\\\!f
lId, and f);):,r Up bits
18005339298
$44
95
1$j9
9S
MLCSWOODWORKING.COM
can aa:t1JI t'.>.u 9-1Il" on
center bolls or thal are
9-114" or smallet REG. S99.95II' 477
Order Online 2417
P,O. DOX fM.W. ...... , 10046 Il2OOII
eready-to-seibinet
Keep your favorite wines, stemware,
and serving accessories handy
in this stylish unit.
D
on't leI the sophisticated look of pmject fool
you. With straightforward case and drawer con-
structioo, a full-size pattern for forming the feet,
and wineglass holders, you'll complete it in a
jiffy and have plenty of rea<;(lnS to toast your success.
Start with the case
1
Fmm W' cherry plywood. CUI the sides (A), sub-lop
and shelf (B). and bottom (C) to the sizes listed in the
Materials List.
2
Cu1 a .' dado II. nd rabbet Jh" deep across the inside face
oeeach side (A). where dimensioned on Drawing 1, to fit
I!ll RAIL-TENON DETAIL
'4" grOOll'es
\tIio" deep
\II. from
edges

'I. chamfers stoJ.l)ed :::::,J
2" from ends 1---....
16

...
the sub-top and shelf (8). TIlen, on the same face of each
side. cut a v." rabbet %" deep along the back edge to house
the plywood back (I).
3
From W'-thick cherry, cut the st iles (0 ) to size. Then
rout W' chamfers, stopped 2" from the ends, along
both edges on the front faces of the stiles. where shown.
For an easy way to do thi s without tear-out, see the Shop
Tip. page 40, top.
4
G1ue and clamp the stiles (0 ) to the sides (A). where
shown on Drawing 1, flush with the ends and outside
faces of the sides. After the glue dries. sand the assemblies
to 220 grit.
n EXPLODED VIEW
wood screw
<D
pilot hole 1 y.." deep
shank hole. countersunk on botlom face
eo rc x 2' F.H. wood screw
11." grooves 11." deep-<:::"
V,. from edges
4"
K

-
1
,,..0 raund-overs
39
Don't get burned routing
stopped chamfers
Ever experienced tear-out or burning when
routing a stopped chamfer? Tear-out can
happen if you rout the entire chamfer in one
pass. Burning occurs if the spinning bit
lingers in one spot, so you need to quickly
pull the part away from the bit at the end of
the chamfer. Here's an easy way to avoid
these problems. With the part on edge and
against a stopolock, rotate the part into the
bit, as shown at right. Without hesitating,
rout about two-thirds the length of Ihe
chamfer. Then flip the part end-far-and and
reposition it against the stopblock with the
face down and partially chamfered edge
toward the lence, as shown at far right.
Rout again, slopping when you pass the
previously chamfered area.
YC
'14' rabbet '118" deep
'"
, r -
Q

7
' " 0
Rotate part into
bit and rout about
two-thirds of
chamfer length.
. /
'"
,,,,' shank hole, countersunk
on bottom lace
T 15'1'. "
SHELF
v.
cnamfers
'/8" chamfers on Iront
end file<! and sanded
L .
H
'''"
%;," shank hole, countersunk
40
on bottom lace
Bll OUTER HOLDER
SECTION VI EW DETAIL
'4" chamfer
-1 ,or---
I ' 1
I
,,;"
( (s) I
e", ,,"c""'haLo"<""hoIe=',-____ 7\-;.>--'
countersunk '
pilot hole
'fl' deep
" snank hate,
oountersunk
on bottom lace at S"
1,1," chamfers
5
1n the sub-top (B), drill a pair of counter-
sunk mounting holes in the bottom face
and a pair of V12" expansion slots W' long for
attaching tbe top (0) later, where dimen-
sioned on Drawing 2. Drill overlapping holes
to form the
6
From Y4"-thick cherry planed to match
the thickness of the plywood txJttom (C),
miter-cut the bottom front trim (E) and side
trim (F) to the listed. Glue and damp
the trim to the bottom, noting that the non-
mitered back ends of the side trim overhang
the bottom W. After the glue dries, rout a %"
round-over along the top and bottom edges
of the trim. Sand the assembly smooth.
7
From %"-thick edge-joined cherry, cut
the top (0) to si7.e. Then mut %" mund-
overs along the top and bottom edges on the
ends and front to create a bullnose profile.
Sand the top smooth.
Now glue the case together
I
Dry-assemble the sides/stiles (Ai D) and
suh-top and and verify that the
parts fit together correctly. Make any needed
adjustments. Then glue and clamp the parts
together, as shown in Photo A.
2
Mcasure between the tiles (D) for the
exad length of the sub-top and shelf trim
(H). where shown on Drawings 1 and 2.
Then, from W'-thick eherry rcsawn or planed
to 1/4" and ripped to match the thickness of
the Y4" plywoOO sub-top and shelf (B), cross-
cut the trim to the measured length. Cut an
extrd piece from 4" scrap to the same length
for use as a spacer to complete the case
assembly. Glue and clamp the trim in place,
flush with the top and bottom faces of the
sub-top and shelf. Sand smooth.
thai the sub-top and , are
the rabbeted back edges of the sides (A).
Drill overlapping holes to form 1
II" deep in the face and edge of the foot
blank, where shown on the pattern.
3
PosifiOO the case with the back down.
Using the spacer to maintain the correct
distance between the st iles (D) at the bottom,
clamp (do not glue) the bottom/trim assem-
bly (C/E/F) and spacer to the case, as shown
in Photo B. Then drill mounting holes
through the bottom (e) and centered into the
side:> (A), where shown on Drawing 1. Drive
the #8x2" flathead wood screws.
4
TO mount the top (0), position it with the
bol/om faceup on your workbench. Then
place the case. with the sub-top (B) down,
00 the top, centered side-to-side and flush at
the hack. Mark the centers of the mounting
holes and slots in the sub-top on the top, as
shown in Photo C. Remove the ca<>e, and
drill pilo!: holes into the top at the marked
centerpoints. Reposition the ca.<>e. Now, using
a shon screwdriver. fasten the top with
#8xlW' Ilathcad wo(xi screws and #8xl Vl
panhead screws with #10 flat washers, where
shown on Drawing 1.
S
From W' cherry plywood, cut the back
(l) to size to fit the rabbeted opening in
the case. Position the b.'lCk in the case, tight
against the top (G). Drill mounting holes
fhrough the back and into the case,
centered slde-Io-side, to the case, 0;1' It,.
spacer tight between the stiles (0).
;1
toget her, keeping the top surfaces flush.
Measure the diagonals to verity square.
shown. Then remove the back, sand it
smooth, and sct it aside.
Move down to the base
1
From laminated W-thick cherry (or Ivt-
thick stock), cut two 2x90." blanks to
form the feet (J). You'll get two feet from
each blank.
2
Make two copies of the full-sire foot pat-
tern from the WOOD Patterns. insert.
Spray-adhere a pattern to each blank, folding
the pallcrn wtX..'TC shown. Using a brad-
poin! bil in your drill press,driIIIW' mortises
9/16" deep in lhe face and edge of each blank,
where shown on the pattern and as shown in
Photo D. Then, using sharp chisels, square
the ends and sides of the mortises.
3
Bandsaw and drum-sand each blank to
the pattern lines. but do not separate the
feet. Using a round-over bit in your table-
mounted rouler, round over the edges and
ends of the blanks on both where
shown on the pattern and Drawing 1. Sand
the routed edges smooth.
4
uSing an extension on )'Our tablesaw
miter gauge for support, and a stopb1ock:
to ensure identical lengths, crosscut two
Using a brad-poim bit, mark the centers
of the mounting holes and slots in the sub-
top (B) on the bottom face of the top (G).
40."-1008 feet from each blank, where shown
on the pattern.
S
Cut the rails (K) to size. Using a dado
blade in your tablesaw, form a 1/." tenon
V:J:" long at each end ofthc rails, where shown
on Drawings 1 and 1a, to fit snugly into the
foot (We made test-cut.<; in cutoffs
to verify our setup before cutting the rail
tenons.) After cutting the tenon cheeks. set
the rails on the tx)lIom edge ... and cut the ends
again to trim the Pl.t-wide tenOrL<; to t w.
6
Refit your tablesaw with a standard W-
kerf blade. Then cut a pair of W'-deep
grooves VI"" fmm each face of the rails along
the top edges. where dimensioned on Draw-
ing 1a. The gmoves capture glue squeeze-(nlt
when mounting the base to the case. Sand
the rails smooth.
7
Dry-as.<.;emble the feet (1) and rails (K),
and verify that the parts fit together cor-
rectly. Then glue Ilnddamp the base together,
as shown in Photo E.
8
Place the case on the floor with the bot-
tom up. Apply glue to the area on the
rails (K) between the W grooves. Now posi-
tion and clamp the base (J/K) to the bottom
of the ca...c, a.<; shown in Photo F.
41
Yo" grooves V .. deep
y." trom bottom edge
ID MACHINING THE DRAWER _ _ __
STEP 1 STEP 2

wood lance
,
Tablesaw
Inside
lace
Outside
"00
Auxil iary w_
fence
i-'-:::::- dJ
w
%" dado blade
fence
dado b,=:-1
Now head up to the drawer
I
From 4"-thick chelTY. cut the dmwer
front (L) to size. Then, from stock
planed to W', cut the back (M) and sides (N)
to size.
2
Fit your tablesaw with a 1/4" dado blade,
Then, referring to Drawings 3 and 3a and
the four-step Drawing 4. machine the
grooves. rabbets, and dadoes in the dra .... 'er
parts. When cutti ng the W'-deep grooves
from the bottom edges in the fmnt (L) and
sides (N) to receive thc W' plywood bottom
(0), switch to a standard W'-kerf hlade and
cUl the: grooves to width in two passes to
snugly ti t your plywood,
42
3
USing a 45 chamfe r bit in your table-
mounted router. rout a W' chamfer across
the ends and along the edges of the drawer
front (L) on the front face, where shown on
Drawing 3. Then drill an 1Ih.4" hole, centered,
through the from for screw-mounting a 11/4"
knob later.
4
From 1/4" cherry plywood, cut the bottom
(0) to size. Sand all of the drawer
smooth. Then glue and clamp the front (L).
back (M), and sides (N) together, keeping
the top edges of the back and sides flush.
Check for square. Now slide the bottom (do
not glue) in place, and secure it to the back
with #18xV.t brads.
Ill! DRAWER JOINT DETAIL -
""


@
'I.
l=t)-

I-{C
v.' :..:i
w-
IJ W":J --
'/eO chamfer
Il'I CASE SIDE SECTION VIEW
liD
11
()
CD

w

liD
IQl

5
From i'-thick cherry, cut the drawer
cl eats (P) and stop (Q) to the sizes listed.
Position the cleats (withom glue) in the eR,<;e.
tight against the sides (A) and stiles (D).
Slide t he drawer into place, and veri fy that it
moves smoothly. Iflight. remove the drawer,
and plane or sand the cleat." as needed to
achieve the desired fit. Then glue and clamp
the cleats into posi ti on.
6
0ry-Clamp the stop (Q) to the shelf (B),
centered side-to-side and flush at the
back. Sl ide the drawer into the case until it
contacts the stop. Verify thaI the front (L)
overhangs the shel f trim (H) W', where
shown on Drawing 5. If the overhang is
greater than W', trim the stop width. as
needed. If the overhang less than W', posi-
tion the drawer with a W' overhang, and glue
and clamp the block to the shelf tight against
the drawer back (M). Remove thc drawer.
WOOD m aqa2ine OctOb<oT 2006
Shape the wineglass holders in 4 quick steps
It's easy to cullhe rabbets in the wineglass holders and chamfer the edges using a standard blade in your tablesaw. Here's how.
STEP 1 Raise your blade 111.r" above a zero-clearance insert, and
position the fence V'- ' rom the inside 01 the blade. Using a pushblock.,
pustlstick, and feather board for safety, rip the outer holders (5) along
one edge and in(\(!( holders (A) along botfl edges, keeping the same
face against the fence.
STEP 2 lower the blade to ""' ", and reposition the fence 2V." from the
Inside of the blade. With the top face of an inner holder (R) down, cut
the piece, turn it end-for-end, and cut it again to complete the rabbets.
FOf stability, keep the push block centered on the holder. Repeat for
the other inner holder.
STEP 3 With the I i
the inside of the blade. an oul er holder (S) tight against the
holders, switCh your ,1O.od""
blade insert. Ti lt the , and raise it :V.-. Position Ihe fence,
fence with the top face down, cut the piece to complet e the rabbet.
Hold the pushbiock snug to the fence to keep the part stable. Repeat
tOf the other holdS(.
as shown, and cut a chamfer along both edg&S of the inner hold-
ers (R). Then reposition the fence, and chamfer the inside edge of the
outer holders (S).
Add the wineglass holders
1
From cherry, cut the wineglass
inner and outer holders ( R, S) to the sizes
li sted. Using a standard hlade in your
tabl esaw, cut Ith" Lf.{' deep in the
holders, where shown on Drawing 2. making
two cuts to form each rabbet. Then bevel-rip
a t;f' chamfer along tile edgn (not ends) of
the holders, where shown. For help with cut-
t i ng the rabbets and chamfers, see the side-
bar, "Shape the wineglass holders in 4 qui ck
steps," above.
2
Using a wood or cabi net file, funn a V8"
chamfer on the front ends of the inner
and outcr holders (R S), where shO'Wn on
Drawing 2.
3
Dri ll counlersunk mounting holes in the
bottom faces of the holders (R, S), angling
the holes in the ouler hol ders (8) at 8, where
sh(Wl[} on Drawing 2a. Sand the hoklers.
4
TO mount the holders (R, S) in the case,
position the case with the top (G) down
and supported on 4x4 spacer s for clamp
clearance. as shown in Photo G. From W'
With the inner and outer holders (R, S)
clampetf in position with 1 V.."-wide spacers
between them, drill pilol hole$ Inlo the shelf
(6) and drive the screws.
43
scrap, cut a lY16x12" piece. Then crosscut six
l." -long pieces for Position the
holders (without glue) on the shelf (B), flush
at the back edge, with the lVl<s"-wide spacers
between them, as shown. Clamp the holders
into place. Using the mounting holes in the
holders as guides, drill pilot holes into the
shelf. Drive the screws. For easy
later, remove the screws and holders, mark
the holder locations. and set them aside.
Time for the shelves
1
From h " cherry plywood, cut the shelves
(T) and dividers (U) to the sires listed.
Then, from -.!"-thick cherry planed to match
the plywood thickness, cut the shelf trim (V)
and divider trim (W) to the given sizes,
2
As you did for the base rails (K), eut a
pair of Vs" glue relief grooves along the
top edges of the dividers (U), where shown
on Drawing 1.
3
GlUe and clamp the shelf trim (V) to the
shelves (Tl, and the divider trim (Wl to
the dividers (0), keeping the ends and edges
flush. Sand smooth. Then glue and clamp the
dividers (U/W) to the bottom of the shelves
(TN) where dimensioned, keeping the parts
Cutting Diagran>
:Y. x 7V. x 00' Cnerry (5.3 bd. ft.)
flush at the back. (The shelf trim overhangs
the divider trim W' at the front.)
Finish up
l
As needed, sand any areas of the case,
back, drawer, wineglass holders, and
shelves to 220 grit and remove the dust.
2
Apply a slain, if you wish, and clear fin-
ish. (We applied Varathane Premium
W[)(xl Stain No. 245 Traditional Cherry, fol-
lowed by two coats of satin AquaZar Water-
Based Polyurethane, sanding to 320 grit
between coats.)
3
Whell the finish dries, remount the wine-
holders (R, S). Then fasten the back
to the with #4x%" nathead wood
screws. Attach a lV4" knob to the drawer
using the screw supplied with the knob. Fora
smoothgliding drawer, apply paraffin wax
to the dcats (P) and bottom edges of the sides
(N). Install the drawer and shelves in the
case. Now fill the cahinet with your favorite
wines, wineglasses, and accessories, pop a
cork., and celebrate your fine work!
Written by Owen Duvall with Chuck Hedlund
Project design: Kevin Boyle
Illustrations: Roxanne LeMoine; Lorna Johnson

I
@
(0

@
'Plane or rasaw to lt1e thicknesses listed in the Materials List.
.' . - '"
=:
.. .
.@
. x 7'/. x 96" Cherry (5.3 bd. ft .)
II
:v. x 5';2 x 4a' Ct1erry (2 bd. ft. )

II- ----'---,L- --'.----,L--.L..l..,..L-.J....L.-,

@ @
I
:v. x 48 x 96' Cherry plywood
44
Materials List

Case T W l oty
A .."
,' W
""W
CP
,
,
..,'" Yo" 15'1',' 16' CP
,
.....
C
""""
Yo" 16W 16* ' CP
D
"'"
W tv.." JaW C
,
E oottom front trim Yo" Yo"
".
C
F bottom skle trim W Yo" 1f.W C
,
G ..
Yo" 171io"
".
EC
H
Sl.btoJl <n.I
w , ' 13'1'. C 2
lhltftrim
I>d< w W 31>!.' CP
J'
"'"
'W
,.
4'h" LC
,
K
oj,
."
'W
14, ' C
,
Drawer
L
"""
o"
"'I, .'
'''''.
C
M ... W
,.
13W C
N
-
W 4'1 .. ' 14'1',' C
,
D
""""
,,' 1314' t41/o" CP
P
"".
... ''1'',. I5\'. C
,
a
""
:Y,' Iv.-
,.
C
WIneglass hoklers
R imer hoIcIars 15,' C 2
S ooter hdders '1". 2v.' t5' C 2
Shelves
T ...,.. :y .. 14''1',0' 15Y,.' CP 3
U ""'"
'4-'. t40/,.' 4' CP 6
V shEff trim :Y,' -Yo 15..' C 3
Materials key: CP-d1erTY plywood, C-<herry,
EG-OOge-)oiled cherry, lC-lamir.atM cneuy.
Supplies: flathead wood screws (6), ftathead
wood panhead screws (2) , Ux.jol'
1lalhead wood screws It2), .to Hat washers (21. spray act.&-
sive, "8xf. tIrads, 1 Yl satirHlictel knob (avaitable at )'OUI
local home CfIIlt8l' or tlardware store), paratlin"!'l'l!X.
BlIICIe and bits: Dado-bladl! set, ",,' and .joI' rolloo-ovar and
45' chamfer router bits, ,;/ tIrad-polllt tJits.
@
CD
.
'I, x 48 x 48 Cherry plywood
Now. tum a $5_00 rough board info
$75.00 worth of high-dollor moldi ng in
just minutes. Make over 500 standard
patterns. curved molding, longue &
groove, picture frame stock, any custom
design. QUICKLY CONVERTS from
Molder/Planer to Drum Sander or power-
feed Multi-Blade Ripsaw. Made in U.S.A.
5Yeor Warranty. Choose from 12" , 18"
or models.
Va,/a"'. F d Malr
"'. DIH.,." ,
Just a twist 01 the cJioI the 'vVoodmasler
from 70 10 over 1 ,(xx) cuI! per inch. ProdllC:&
a fi nish on trdy groin patterns no
other planer con handle. Plenty of American-
made "muscle'" 10 handle mooey-soving,
"straigh...&om.lhMOWmiU'" lumber. Ideal for
high-Yolue OJrved molding.
S"a,. ... U,,,,,, /d pe, ,. .... ,
cr. .... 'rom 500+ ,._,,,,1
RISK FRff 30
o
D .. ,
fri .. , ONe,! ... _ .....
'1OU CAN MAKE A
GOOD lMNG MAKlNG
MOlDING WITH A WOODMASTER_
o
"My partner and 1 make custom mokllngs.
flooring, walnscotll'lg. mantles and more. In
1-1/2 days, we surfaced 2,500 boaI'd feet of
hickory. Ourt'MJ famiNes ale malong a IJlOd
liYirtg.1f hao.e a Wlodmastef lIod II table saw,
)OtJ (3'l male II (POd IMng making molding."
- James Tulley. Black Hawk SD
ADD OUR IOUIII Ill.) 21
HURRY - GETYOUR FREE DVD & BUSINESS STARTER KIT!
CAll TODAY and we'll RUSH you our new WOocimaster OVD & BUSiness Plan! You' !! leam elactly how to start &
operate a profitable molding buslnessllncludes business plan. tnSU\.lctr.oe DYD. full spees. prices, UMITEO-TlME
SAVINGS OffER, and Info on easy finanCing.
CALL TOLL FREE 1800-8216651
WoodnIaster Tools, Inc. Dept. P325, 1431 N. Topping Ave .. Kansas City. MO 64120 W'W'W.WoodmasterTools.com
CRill No. 1 820
shop'-in-a-box
tool cabinet
L
ooking for an easy-to-build project
that makes a really big impact on
reducing shop dutter and improving
work efficicm:y'! Here it is. With identical
case and door construction using simple
rabbet-and-gnxlVc joinery, you can make this
cabinet in a few c\'cnings or a weekend. For
materials, you need only a 4x8 sheet each of
W' perforated hardboard and h" plywood.
plus a guaner-sheet of \14" hardboard.
Start with the case
1
From .'/4" plywood. cullhe sides (A) and
top and bottom (B) 10 the sizes listed in
the Materials List. (We used Baltic birch
plywood. which we found at a local home
center, and applied a dear finish.lfyoo plan
to paint the unit. you can use Jess-expensive
type AC or Be plywood.) Because the
thickness of plywood varies, you Inay need
46
Keep tools, hardware, and supplies organized in this
saving, 4-door cabinet. Though it occupies little more than
7 square feet of wall area, it offers a full 26 square feet
of storage on the perforated-hardboard panels alone!
to slightly adjust the sires of some parts and
the mating dadoes and rabbets.
2
Mark centerpoillts for 114" holes W' deep
for shelf supports on the inside faces of
the sides (A), where dimensioned on Draw-
ing 1. Drill the holes using a hrad-point bit
in your drill press. Adjust the depth stop for
consistent drilling depth.
3
Fi' your tabJesaw with an auxiliary fence
and dado bladc that malches the thick-
ness of your %" plywood. Then cut a Ys"-deep
rabbet across the inside faces or the sides
(A) al each end, as shown in Photo A.
4
TO cut a 1/4" groove It deep in {he sides
(A) and top and bottum (B) to fit your
W' perforated hardboard for the hack (C),
where dimensioned on Drawings 1 tmd 2,
switch to a standard 1,i"-kcrf blade in your
tablesaw. Position the fence 4" from the
inside of the blade. Then cut a groove along
Though the case measures just 12"." deep,
it houses all f our doors when closed.
WOOD mag""I.... ZOO
light against an auxil iary
lence and miter-gauge extension, cut a
rabbet across each end on the inSide lace.
the back edges of the silks, top, and
bottmll on the inside faces. Now repo-
sition the fence, as needed, and cut the
grooves to final width to snugly fit
the hardboard. Sand Ihe parts smooth
to 180 grit.
5
From y." perforated hardroard.
cut a 3P14"-square piece for the
back (C). Then dry-assemble the sides
(A), top and bouom (B), and back,
and check that the part" fit together
correctly. Make any needed adjusl-
menls. Now glue and damp the case
together, measuring for equal diago-
nals to verify square. Drill mounting
holes through the sides and into the
top and bottom, where shO\vn on
Drawing :2, and drive the screws.
6
Frnm W' birch pl ywood, cul the
shelf (0) 10 size. Then, from your
V4
H
perforated-hardboard cutoffs., cut
two 4x51/.t spacers. Position the shelf
in the case on the 5Vt-tall spacers, as
shown in Photo B. Drill the mounting
holes, where dimensioned on Draw-
ing 1. and drive the screws,
7
From plywood, cut the mount-
ing deals (E) and spacer (F) to
1!hx31". Bevel-rip one edge of each
cleat at 45, leaving a \4" flat, where
shown 011 Drawing :2a.
8
Posi ti oll the case on your work-
bench with the back (C) up. Then
glue and clamp a mounting cleat (E)
in place on the back, lighl against lhe
top ( 8), in the orientation shown 00
Drawing :2a. From inside lhe case,
drill mounting holes, centered in the
holes in the perforaled-hardhoard
back, into the mounling deat, where
shown on Drawing :2. and drive the
#8X:Y"4" flathead wood screws to f ur-
ther sirengthen The attachmenl. In the
wooclzna, .alac.oom.
i the shelf (0) on 5'h
R
_tali spacers and
tight against the back (e). drill mounting
holas through t he sides (A) Into the shetf.
FlI CLEAT MOUNTING DETAIL
'&

0
:y, ' rabbet
t' deep
....
0
:V," I--
:::

118 x 2w" F.H.
' ..
, '111\ wood screw

,j\
' w

=..!:I ..-l-
Walt mounting cleat
MagnetiC catches
Ita J( 3' F.H. wood screw driven into watl
D CASE SIDE
(Inside face of left side shown)
.vol' rabbel "" deep I''''
2Yo1' , r-

n
.. ..
32W
location 01
outerdoor .... ,.
cont inuous
hinge

Vol' l"IoIe
Location of

W deep
inner-door

I
continuous
. [
"

hinge
'1
V,' groove
W deep
i I

'Y,' from
4W
;
back edge
v,' i !

Location


ofparl
"..". shank : "I
I
@
holes. il. i
-.
countersunk !. :
VI'
"I..
on outside i i
face 5 Y,'
'"
:l1
i ,..
,
:V. rabbet
deep
I . . 1
Note: Right side@is a mirror image.
iii CASE
Vol ' groove t' deep
:V. from back edge
Ita x 2" F.H.
wood screw
\

,/. groove :" deep .' from back edge

47
AUgn tile inner-door hi nge with the marked
li nea, and press the taped hll'lge in place.
Then drill the mounting holes.
same way. glue and screw the spacer (F) to
the back, ti ght against the bottom (8).
9
From V," hardboard, cut a stri p
for the bin stop (G). Glue and damp the
stop to the bottom ( B), 4W' from the front
edge. where dimensioned on Dr8wing 2.
1 O
FfOm plywood. CUI the shelves
(H) to size, and set them aside.
Now build the doors
I
To ensure that the outer and inner
fil into the case with W' clearance at the
top and bouom. where shown on Drawi ng 1.
the ojX--nings between lhe lOp and
bottom ( 8) for the outer doors and the top
Ilnd shelf (D) for the inner door... Then,
from plywood. cut the ooler-door sides
(I) and inner-door sides (J) to the sizes listed
and lengths equal to your measured open-
ings minus W'. (Our sides measured
for the outer doors and 24lh" for the mner
dfXlrs.) Also, cut lhe tops and bottoms (K)
for the Cluter and inner doors to size.
2
From W' perfordtcd hardboanl. cut the
outer- and inller-d<XJr panels (L, M) to
the sizes listed.
3
USing a dado blade in your lablesaw. cut
a ,." rdbbct a" deep across the ends of
each outer- and inner-door side (I. J) on the
face, where shown on DrawIng 3.
4
TO cut grooves deep in the door
sides (T, J) and tops and tx>\Ioms (K),
where dimensioned on Drawing 3a, switch
tn a W -kerf blade. Position the
fence 111l" from the inside of the blade. Then
cut a pairofgroO\'Cs along the iluide face of
each part, rotating the part end to end
between Now the fence away
from the blade as needed, and cut the pans
again 10 widen the grooves and achieve a
snug fit with your perfcnted-hardbo..1rd
panels (L. M).
5
Sand the door sides (I, J), tops and bot-
toms (K), and panels (L. M) to 180 grit.
48
Position a hinge on an 1'00"'.00".'.' (.1)
with a 'II" overhang. Measure from the
to the hinge to find the spacer width.
Clamp tne spacer to the door, flush with the
back edge. WIth the hinge tight agafnst the
spacer. drill the mounting holes.
IBDOOR
(Left door shown, viewed from back)
1 W cootlflUOUS hinge
, I hoi " 30.' IotIg for outer door
plot e''" ..........
.'
....
counlersunk \ ............ .....

#8 x 2" F.H.
wood screw
\
\
3<''' for partC!)
24Yl' for partQ)
\
\

I
Location 01
strike plale
on pan()
1
\ r-
.
.... ' .'
" ...... .
.. : ..
. " ..
, . : ...
. . .
.. ..
. . : ....
..
.....
.'
\4'4'
...
..


..
.'
.
..
.
..
.: .'
.

\ 1\ Localion of strike plale on panQ)
grooves
de,p
.y .. rabbet
'hi" deep
Then glue and clamp each door together,
checking for !.Quare. Drill mounting holes
Ihrough the side. .. and into the lOp:> and bot-
toms, where shown on Drawing 3, and drive
the screws. For ease in mounting the hinges
and installing the doors Imer, ident ify the
lop (K) of each door and the side (I, J) that
you'll hinge-muunt Wlhe case.
m DOOR GROOVE DETAIL
the screws.
Add the easy-to-make bins
I
From 4" plywood, cut the fronts (N)
and backs (0) tor the eight bins to the
sizes listed. Then, from \14" hardboard, {;ut
the sides (P) and bottoms (Q) to size.
2
Lay out the angled edge on a side (P),
where dimen:,ioned on Drawing 4.
Bandsaw or scrollsaw to the marked line,
and sand smooth. Using this piece as a tem-
plate, mart the angle on the remaining side
picn:.", and cut and sand them to shape.
3
Sand the fronts (N), backs (0), sides (P),
and bottoms (Q) to 180 grit. Then glue
and damp the parts together in the configu-
ration shown.
Sand, then apply the finish
l
lfnccded, fill any voids in the plywood
edge, with a paintable wood putty, and
sand smOO(h when dry. Then sand any areas
of the case, doors, shelves, and bins that
need it to 180 grit. and ease any sharp edges.
Remove the dust.
2
Apply two coats of a clear finish, sand-
ing hetween coats. (We applied
Varathane Diamond Water-Based Polyure-
thane, satin finish, sanding to 320 grit
between coats.)
Complete the assembly
I
Measure the of the outer- and
inner-door ."iides (I, J). Then. from t W(J
1V2x4R" cont inuous hinges for the outer
and two l\l'lx30" hinges for the inner
dOOl"S, hacksaw the pieces to the measured
lengths. To m<lintain the correct orientatioo
of the hinges during assembly, mark the
manufactured (uncut) "top."
2
TO position the hinges on the case sides
(A), where dimensioned on Drawing 1,
ptace the case on the left side. Draw align-
ment line." on maSking tape \Iir;" from the top
and bottom (B) for the outer-dooI' hinge and
00
shelf (0). Man.:. tile centers of the slots.
ViI" from the top and shelf (D) for tile inner-
door hi nge to center the hi nges top-to-bottom.
Then, to position the barrel ofthe inner-door
hinge W' from the front of the shelf so the
door do:.es nush with the shelf. adjust a
combination square to the distance from the
front edge of the side to the shelf less YIt.
(We set our square to 4Vi'.) Now mark inter-
secting lines the squan:.
3
TO mount the inner-door hinge, apply a
few small pieces of clOlh-backed double-
faced tape to the casc-f,iJc hin!:,'C leaf. With
the hinge leaves positioned at 90" and the
markt.'(] top cnd of the hinge correctly ori-
ented., align the hinge with the marh, as
shown in Photo C, and press it in place. Using
a self-ccntcring bit, drill the mounting holes.
Drive the screws, supplied with the hinge, in
the two top and bottom holes to prethre<td
them for easier
mounting of the II CABINET
DBIN
4
TO mount thehingcs on thcdoors, where
shown on Drawing 5, place a hinge for
an inner door along the front edge of the
side (1) identified for hinge-mounting to
the case. With the hinge leaves positioned at
90, the top of the hinge at the top of the
door, and the end" flush, align the hinge so
that the barrel overhangs the edge Ih,".
Next, to ea.<'ily keep the hinge aligned,
measure from the back of the door to the
hinge for a spacer, as shown in Photo D.
(We measured llIcn, from 1/4" hard
board, cut a 20" -long piece to your measured
width. Now clamp the spacer \0 the door
and mount the hinge. as shown in Photo E,
driving all of the screws. Repeat for the
other dDon;.
5
pOSition the case on the right side (A),
arxl screw-mount the right inner door, as
shov.n in Photo F. Raise the door to the
closed position. Then mount the right outer
door. Using a helper. reposition the case 00
the left side. MOUn! the remaining dOOf'i.
door later. Then
remove the screws,
hinge, and tape.
In the same way,
mount the outer-
door hinge, eltcep!:
position it so that
the barrel over-
the front
edge of the case
W'. Usc a combi-
nation square or a
W -wide strip of
W' hardboard as
an alignment aid
to set the hinge
overhang. Now
reposition the case
on the right side
(A). and repeat the
hinge marking and
mounting process.
Note: Right outer door removed lor clarity.
49
G
TO mount magnetic catches to hold the
doors closed, where shown on Drawing 2,
position the strike plates on the hack edges
of the inside door sides (I, 1), where dimen-
sioned on Drawing 3. noting the different
locations for the outer and inner doors. Dri ll
the pilot holes, and drive the screws supplied
wit h the catches.
Next, matt the center of the shel f (D) on
a piece of masking tape positioned behind
the inner doors, as shown ill Photo G. Mate
a catch to the strike plate on the left inner
door. Holding the front of the door and shelf
flush, align the catch with the centerline, as
shown. Mark the centers of the mounting
slots. Drill the holes, remove the tape, and
screw-mount the catch. In the same way.
mount the catch for the right inner door,
tight again&( the left-door catch. Then mark
the center of the shelf (0) on the bottom face
at the front edge. Now mount the catches for
the Quter doors, aligning the catches with
the centerline.
7
TO mount the unit, ttold the remaining
mounting cleat (E) btl on your wall
wi th the beveled edge positioned where
shown on Drawings 2 and 2a. Dril l counter-
Cutting Diagraxn
'0 0
,-
'1,1' I :
,
J K K
J K K
.. .,
J K K
"
, K K



,
o J( 48 J( 96 Baltic birch plywood
50
Lock hooks to perforated
hardboard in a snap
Here's a simple and inexpensive way to secure
standard, nonlocking hooks to perforated
hardboard so they won't come out. Strap them in
place with M-style hook holders. Just center a
holder over the hook shank, and press the barbed
ends into an adj acent pai r of holes, as shown.
You easily can rel ease the hol ders 10 reposition
the hooks. The holders fit standard 9-gauge and
heavy-duty 5-gauge hooks used in Va" and VO
hardboard with ''H" or %;>" holes spaced 1" apart.
A bag of 50 cli ps, no. 1169A85, costs $1 1.89Irom
McMaster-Carr, 404/346-7000, mcmaster.com.
mounli ng holes through the cleat i nto
the wall and fasten with #8x2W' nat-
head wood screws. Using a helper, hang the
unit. Then, from inside the cabinet, drill
mounting holes, centered in holes in the
back (C), through the case mounting cleat
(E) and spacer (F) into the studs to anchor
the assembly to the wall.
8
FinallY, install the shelves (H), where
you wish, using W' shel f supports. Pl ace
the bins in the cabinet behind the bin SlOp
Wi
."--/J ; ,
. ,.
,
I
I
I
I
H
F
E
@
See more FREE
simple shop
project plans at
(G), where shown on Drawing 5. Nuw tidy
up your shop by tilling the cabinet with
tools, and supplies, hanging items
on the perforated-hardboard panels using
sui table W' metal hooks, avaiJahle at your
local home center or hardware store. For a
simpl e way to keep hooks securely in pl ace.
see the sidebar, ahove .
Wrrtten by Owen Duvall
Project <lesign: Jeff Mertt
Illustrations: Roxanne LeMOine, Lorna Johnson
Materials List
HNISil EDSIlE
Case T W l Mall \.IIY .
A
-
.,'
32'h" 8P
,
B
.. ..,-.,
.,'
12m" 31." BP
,
C ...
, .. 31." 31.' PH
0 ...
," 7W 31 ' BP
E JTQIrti'lg deals ... 1'),," 31 ' BP
,
F
,..,.. ... 1')"" 31' BP
G
,.,"""
v.' ,,' 31' H
H
""""
:v.' 3',." 30
7
,.' BP
,
Doors (2 outer and 2 Inner needed)
ouIfJ-OOocsiles Yo'
"'10'
-,'
BP

J inner -ooor skies w <W 24W BP

,
"" ...
v."
4'''"
14V." BP
,
""""'"
l
..,.,-
'10" 14'!0'
""
PH

- M
-- ""
141/0" 23.\1,'
'"

,.",
BinS f8 needed)
, "',',
0"'"
o' 1' 31(.0" BP 6
:v." 3Yo" "Y' BP 8
p """
v.' "V. 6V.. H 16
a """'"'
'I,' 3,' 6V.' H 6
Materials key: BP-8altic tirch plywood.
harclloard, H-Ilardooard.
Supplies: wood screws (6); ;8:<2' Rathead
wood screws (48): ,8x2 y,'llath6ad wood SCleW3 (2): t8x3'
ftathead IIIOOd screws (4); cIotl'K:tacked. dOtt>Je.lacoo tape;
l'hx48' contiluous (2) and 1 'hl<30" contiooo:lS
Minges (2); paintable \\Iood flIJ!ty, magnet;ccatdles (4):
W slle/1 (8): V .. pertoratecHlardboard hooks.
Blade and bit1 Oado-hlade S61, brad-p:llnt bit
WOOD Oclch<>< 2008
O
kllY, Ml ~ y c you couldn', afford
that $\,000 handsaw. Perhaps you
had to settle for an el dle3pO that
)00 hide in a dart comer of your shop when
YOUf w(xllJworldng buddies come calling. No
need to feel shame-with the right TLC and a
few ck..-VCT add-ons. you am tunc up and trick
52
out a Iow-oost tool and make it detiver clean,
precise s with every flu of the switch.
How's that fK)SSible? We let one of North
America's premier master craftsmen. Michael
Fortune, tackle that question. (See more on
Michael, aboW! right.) During a recent visit
to his v.rorkshop in Lakefield, Ontario.
M!chael Fortune
resaws with pr8Gision
on his pet1ectly tuned
and modestly priced
Rldgld band saw.
Michael introducal us to one of the stars of
his loollincup. a modest 14" Ridgid bantls:Jw,
model B514OOO, with a V.-hp. 110-volt motor.
purchased foc aroorxl $350. ''lllaCs plcnty of
saw fur a Of1C-man shop," he says, ''provided
you set it up properly." Now, you can do thc
same with your low-dough bandsaw.
More on the expert
Artist, award-winni ng furni ture designer, teacher,
accomplished woodworker- Michael Fortune fits all
of these descriptions. His designs have appeared in
museums and exhibitions worldwide end can be
seen on his Web Site at michaelfortune.com. In
addition, Michael teaches design workshops at
universiti es and woodworking schools throughout
North America. You can catch him teaching bandsaw
and other woodworking-related workshops at The
Woodworki ng Shows and the Marc Adams School of
Woodworking. For more on the Marc Adams School,
call 3171535-4013; or go to marcadams,com.
Made from
Macassar ebony
wi1h silver and
mother-of- pearl
i nlay, Michael's
signature
chairs consist of
steam-bent and
laminated parts,
held together
by mortise-and-
tenon
They command a
price that only the
affl uent can fork up.
Begin with a good basic tool
M
ichad has five handsaws ill his shop.
all rigged simi larly to the two shown
here-his Ridgid and a more expensive 14"
Gencral Internati onal (GI) (about $8( 0). He
isolates five key ingredients that a top-per-
forming cutting machine should include:
Rock-liolid base. A vihmtion-free
handsaw, Michael says, "starts with a solid
base that finnly on the floor." He does
not rest his bandsaws on wheeled mobi le
ba.'ies. Instead. he installed a piece of pl y-
wood with munded-over edges beneath the
GI . Beneath it , he attached four Teflon slid-
ers (oometimes call furniture
movers) that he purchased at a
kx:al hanlware store. These
give the tool full contact with
the floor and let him slide it
around wi th relative ease. The
legs on his Ridgid and several
other statiooary tools also
have sliders beneath them for
quick and acca..'iional reIoca-
lion. End re.. .. uit: TIle solution
is dirt cheap, and it meets the
woodworker's
Dust disposal. An effi-
cicnt machi ne provides one
or more dust-collection ports
attached to a vacuum to keep
the wheel housing from fill-
ing up with sawdust and
interfering wi lh the saw's
DpCmtion. Michael especially
li kes the built-in dust collec-
tKlIl of t he GI hecause it
eliminates having to work
around a shop vacuum or
large dust-collector hose.
big assignments faster, as when 4"
or wider hardw(xxi hoards, for example.
Top-quality blade. According to
Mi chacl, " New saws t ypicall y come wit h
bad blades that need to be replaced." That's
the fi rst th ing he does. And while he's tried
al l kinds of blades, he always comes back to
his favorite-a liz" Skip-tooth, carbon steel,
coarse blade having three teelh per inch and
a large gullet. "I found a fine-toot h bl ade
isn't really heUer than a coarse blade for
clean, stmight cuts," he says. Equally impor-
tant is the quality of the weld. "For trueness
Adlustlibte
wood ....
and durabili ty of thcir welds, I rely on Be
Saw & Tool, Inc. [call 888nSJ-2236, or
visit for all the bandsaw blades
in my shop."
Stock s upport. Finally, due to the
small size of b.'tndsaw tables, Michael engi-
neered a simple adjustable work. support
system that includes an inexpensive ball-
bearing roller stand (minus one leg), a wood
support mil attached 10 the saw's base, and
a lockable, adjustable wood arm that
neels the stand to the With this add-on
he can saw boards 10' long.
Adequate power. "A
Ih.-hp bandsaw motor works
fine for most workshop joh.'i,"
Michael says. But he agrees Trickedoutand 1 Intemational bandsaws are
Ihal a bigger motor handles when it comes to cutting, t hough IntemaUoal costs hundreds of doltars more .
.. oo<lm. .. ,. ..... l n"."' .. n
Set up your saw for success
A
ccumte handsaw adjustments make all the difference between
a so-so cut and one that requires little cleanup. Here arc
Michael's secrets for achieving great results.
Center the blade ror centered cuts. First, with the saw's
power off, spin the upper wheel by hand to ensure the blade stays on
the tire, turning the top-wheel adjustment koob as shown. Then,
with the cover slightly
ajar-enough to see the
wheel and blade-turn
on the saw and fine-tune
the wheel angle to center
the blade perfectly on the
crown of the tire. h i ~
will cause the blade to
center on the lower tire
as well, prO\'idcd the
bearing and guide blocks
are correctly adjusted.
(Michael never adjusts
the lower wheel.) Make a
tesl cut in scrap, and then
compare it to the draw-
ing at right to determine
if your blade is centered.
Apply the right blade teDllioning. Michael
applies just enough tension to allow him to deflect
the blade 1/.' with finger pressure as shown. "When
tensioning the blade, I get better results by adjusting
it lower than the settings marked on the saw;' he
says. "For a 1ft blade, for instance. I adjust the ten-
sion 10 the W' setting." After sawing, Michael
releases the blade tensioo to avoid creating a tire-
damaging track and forming a bend in the blade that
could stress the weld over time.
Use a wheel brush fol' a clean sweep. Too much sawdust
buildup on the wheel could move the blade off the crown, affecting
cut quality. A simple brush located on the lower wheel keeps saw-
dust from compacting on the tire. On one bandsaw in Michael's
54
HOW TO TELL IF YOUR BLADE IS CENTERED
straight:
,,,,,i,',,, oOCfown of wheel .
Cut drillS as shown
when blade is too
forward on wheel.
Front of saw
I
shop, he fastened a small piece of wooden push broom inside the
lower housing, letting the stitf bristles do the dirty work. Another
option: Purchase a whee! brush from RockIer, no. 28299, $5.99 plus
shipping. (Call 8001279-4441, or visit rockler.com.)
WOOD magazh.. OcIOb.r 2006
Set low-tolerance
guide blocks, The
ideal sctting for guide
hlocks., according to
Michael, removes any
side-IO-Side play in the
blade without rubbing
constantly on it. "I fold a
thin piece of trdCing
paper thai measures
thick around the
back edge oflhe blade to
l.'litablish the needed
cleanmce;' he advises.
"'Too much play could
let the blade twist and
score the blocks when
cUlli ng tighl curvL'S."
Trick the table and true the fe nce .
Michael offers a neal trick that
leveling the table. FirM, he reverses the 0"
table stop bolt underneath the table, thread-
ing it from the bottom up instead of the
typical top down. He then bores a 16"-
diameter hole I" deep in a Wt length of If.!"
brass or alummum rot.!, and sands the solid
end flat. Next, he slips this "cap" aver the
bolts threaded end, as shown at right, and
adjusts the now easily acce. .. sible locking nut
aOO bolt head. for right. until the square
l>how.> the hlade at 90" to the table. This lets
him tilt the table to the lefl by removing the
cap, and return it to 90
g
by adding the cap.
A good fence = good cut. , Michael
always !<ups all auxili3ry wood fence
att ached to his handsaw's metal fenct:. Why?
So the blade doesn't abrade the metal fence,
to support wider stock when resawi ng, and
because it is so much faster to an
au:c.iliary fence 10 the table. To adjust the
wood fenc:c. Michael removes it and
adheres one or more lengths of masking
tape along either the bottom or top edge of
the saw's metal fence, as shown
Adjust the thruat
bearing. Michael slips a
6" metal ru le that mea
sures v'd' thick between
the back edge of the hl ade
and the thrust bearing, a. ..
shown at right, to establ ish
proper clearance. He then
locks the seuing in place
wi th a few turns on the
hexhead boll using a
wrench. Make: the S<lmc
adjustment below the saw
table. Spin the wheel hy
hand and do a visual check
to ensure the correct clear-
ance is established al both
locations.
Tightenyourbelt. Hero's another idea
for some bandsaw models. To ensure a well
tensioned belt between the motor and saw.
Michacl loosens the bolts holding the motor
down, and then drives opposing wedges
between the motor and saw base, as shown
beww. With the slack removed. he retight-
ens the motor's bolls. This results in a belt
that delivers maximum power and doesn't
slip. Note also thc 1" -thick plywood. added
to the steel base to reduce vibration.
Keep tools within easy reach.
Michael likes his tools dose at hand. For
quick adjustments, he employs a pair of
rareearth to hold a wrench to the
upper wheel metal (From Rockier:
VR"-thick magnets, Vi" diam., no. 30810.
$6.69 for 10, plus shipping; call 8001279-
4441, or visit rockler.com,)
A hole in his pushstick keeps it hanging at
arm's Teach on the upper housing koob,
where shown below.
55
4 common handsaw cuts made easy
W
ith your handsaw tuned up and ready
for action, follow Michael's lead and
try thc.'>C basic cuts. They tunc up YOUT saw-
ing skills as well.
1 Right-on rip cub
Michael prepares a length of rough-cut lum-
ber by ripping it \0 size on his bandsaw. "I
haven't used a tablesaw to rip boards to
width for at least 30 years. I do it all on the
handsaw," he says. "It's flXlre efficient
because it creates waste while using
less energy." He first freehand cuts one
rough-sawn edge working ck)scly along a
marked cutline. He then joints that edge.
Next, he places the jointed edge against
the fence and trims off the remaining rough
edge, as shown near right. The cuI remains
true for the entire length, barting any blade
drift problem. He finishes by jointing this
edge to clean it up. Note how he the
guide blocks just Y4" above the workpiece to
eliminate blade movement from side to side,
and to maximize control.
HI haven't used a
tablesaw to rip boards
to width for at least
30 years. "
2 Straight-up resawing
With his saw set up as described earlier,
Michael can resaw with perfection. using
the most inexpensive band saw in his shop.
as shown below and on page 52. Here. he
switches to a taller auxiliary fence to pro-
vide full sllpjXlrt as he moves the blade
through the workpiece. He keeps his push-
stick handy to safely complete the cut.
3 Cut curves with confidence
CHOOSING THE RIGHT BLADE FOR CUTIING CURVES
For clln'es or freeh.'l.nd cutting. Michael starts the saw blade just 1112"
to 1/,..." outside the cutiine, maintaining that distance throughout. (If
your cut requires turning a sharp mdius, be sure you use the correct
blade width, al> shown in the drawing at rjght.) For best control, the
trick lies in applying side pressure on the workpiece and blade from
the concave side of the cutline, where indicated by the in the
photo below. Later, Michael staples a strip of sandpaper La the
curved cutoff and uses it to sand the curved edge on the workpiece,
as shown below
56
Blade width
__________________
:: <\
Yie" -------------'''''''--,
R=',i"
WOOD rnligazh. 1I Oc!ob.r 200Ei
4 Jig up to cut in the round
Michael's circle-cutting jig consists of a piece of Yz" plywood
with a dovetailed key glued into a centered dado. Into the
dovetailed slot slides a matching dovetailed key with a dowel
pivot pin at one end as shown in the drawing below.
To use the jig, determine the radius of the circle you want.
Then, with the jig clamped to the bandsaw table, move the
dovetail key until the distance bet'Neen the right-hand tooth
of the blade and the center of the pivot pin equals that radius.
Clamp a stophlock on the key at the end of the dovetai l slot,
as shown at right. Drill a '14" hole centered on the underside
of the workpiece. Slide the key back, and fit the workpiece
onto the pivot pin. Turn on the saw, and slide Ihe dovetail key
and wOrkpiece toward the blade. Rotate the workpiece clock-
wise into the blade, applying slight side and forward pressure
until the stopblock. abuts the end ofllle dovetail slot. At this
point you will begin cutting a perfectly round circle, with the
side and for\',:ard pressure keeping the dovetail key in place
for the duration of the cut.
Front 01 teeth
on centerline of pivot
Bandsaw table

. /
/ ....
\
,,-
Wnlloo by Jim Harrold
IUustratiorrs: ROkanne LeMQintt; Lorn, Johnson
CIRCLE-CUTTING JIG
' wide dovetail slot
,.--1/, dowel 'h0 long
C -
-
.... tered

o x2x 16' , 1/.'
W hole, _______
0/4)( 1 18' clamPed
to bandsaw table
. #8)(t'h'F.H.
\ __ wood screw
Simple but effective
shop-made T-fence
Many times the new (or used) bandsaw you buy
does not come with a fence. That was the case
with this small benchtop modef in Michael's shop.
The solution: Make a simple T-fence using two
pieces of straight plywood scrap. (Here, Michael
used Baltic birch plywood.) He saws '/16' kerfs
into the ends of the edge guide to quickly clamp
Ihe T-fence to the table using a pair of spring
clamps. Then he glues and screws the two
pieces together at a right angle to form the T.
To use the Tfence, just locate it the needed
distance from the blade. Remove one jaw cover
from each clamp, and slip the uncovered jaws
into the kerfs when securing the fence to the front
edge of the saw table, as shown at right .
centered :">-
4)( 1'/11 4" slopblock
or double-faced laped 10 key
V
/1W
57
tones-of-fun
___
slilted top of this six-note, e asy-to-build instrument.
58
I
n a few hours and
using jusl a tabl c!.aw,
jigsaw. and drill press,
you can build fhis modern
version of an ancient
instrument. The project-
tJCMgncd by cra(l<;man and
musician Steve Rober ts of
Chico. Cali fomia-uses
.'>imple butt joinery and
a. ... ..embles with glue only.
The tone quality of each
drum is unique. See the
sidebar. "About longue
drums:' page 61, to learn
more about them, and go
to tongue<irum.com to heaT
what one sounds like and
see video cl ips.
/'

-
II

__ , T_'
1, Jigsaw along
Start with the
With the t op (AI on a ,
drill two I" start holes for your ji gsaw through the top,
drum parts where shown on the pattern.
outside of tongue 1. Then, from the round end, cut
along the inside of the tongue.
1
Frum a hard-
wood free of knots. cracks, and checking,
cut the lOp (A) to the size liqed in the Materi -
als List. (We used padnuk and red oak for the
project. Other suitable woods are purple heart ,
mahogany, rosewood. birch. and maple. If
you wish. you can make all of the drum paris
from one type of wc)()d.)
D EXPLODED VIEW

2
Pholocopy the full-size top pattern rmm
the WOOD Patterns. insert Spray-
adhere the patcern 10 the tup. Using a twist b1t
in your dri ll press or portable drill. drill two
-Vi' .. tart holes for your j igsaw through the
lop. where shown on the pauem and 1:I1I
shown in Photo A.
Local iOrl 01 part

. '
trMilered ends
'h" t:::::.... ......---
........ I
Self-adhesive rubber bumper J
, . -diam. rubber ball
_ V." hole
,..de
in
'f. dowel
12'h'long
3
TO form the tongues in the top. fi t your
j igsaw with a blade that has 20 teeth per
inch for a smooth curve cut. Beginning at
start hole # 1 and fol lowi ng the patlcm lines,
cut around tongue 1. as shown in Photo B.
Then CUi around tongues 2 and 3, as shown
I!I FEET LOCATI ON DETAIL
(Viewed from bottom)
....
59
-'
til Photo C. Now switch to start hole #2, and
cut tongues 6, 5, and 4 in the same way.
4
Fmm -Yl-thid., defect-free cut the
(B). bottom (e), (D), large
glue blocks (E). and small glue block (F) to
the listed.
Now assemble the drum
1
Glue and damp the ends (B) to the bot-
tom (C), where shown on Drawing 1.
keeping the edges flush. To prevent loss of
resonance, make sure yo clamp all of the
drum tightly together. After the glue
dries, glue and clamp a side (D) in place
against the ends and bOllorn.
2
eU! a Y16" groove -Y16" deep, centered,
along an edge of each handle (G), where
shown on Drawing 1, to receive the mallei
handles (I) for storage.
3
Miter-cm a 1/2H chamfer on each end of
the handles (0) and the four blanks for
the feet (H), where shown. Then miter-cut a
2l;1!,,-long foot from each end of the blanb,
flipping the blanks end to end between cuts
to ensure correct orientation of the mitered
ends for each pair of feet. Sand the handles to
220 grit.
4
TO attach the handles (0) to the drum,
cut a JI/:x12" spacer from 1/4" hardboard.
Draw the spacer 1%" from hoth
on one face. Position the drum on a flat
2
TO complete the assembly, glue and
clamp the large glue ...... ...... .. :O!::::- ..... Iii
blockB (E) and small
glue block: (F) to the
ends (B), bottom (C),
and side (D), where
Next glue and
clamp the top (Al in
place. Then glue and
clamp the remaining
side (D) in position, as
shown in Photo D.
Add handles
and feet
surface with the bottom (Cl up. Using the
spacer, glue and clamp a handle to a side (D),
as shown in Photo E, RL-pcal to glue the
remaining handle 10 the other
S
GIUe together four pairs of feet (H) in the
configuration shown on Drawing 1. (We
wrapped masking tape around each pair of
feet to keep the milered corner tight unti l the
glue dried.)
6
TO mount the feet to the drum wi th a R"
overhang, where dimensioned on Draw-
ing 1a, cut four W'-square spacers from V4"
h<lrdboard, Rub the edges of the spacers
with paraffin wax to prevent glue squeeze-
out from sticking. Using douhle-faced tape,
adhere a spacer at each (;orner of the drum
1
From %"-thick stock,
cut a 714xS-!N blank
to fonn the handles (G)
and feet (H). Rip two 1"-
wide pieces for the han-
dles and four :%"-wide
pittcs for Ihe feet from
lhe blank. (You'll get 1",'0
feet from each piece.)
Using the spacer to position a handle {G). glue and
clamp the handla to a side (0) with the handle ends
al igned with the spacer lines.
With the chamfered ends
(H) to the bottom of the drum.
at the corners.
60
WOOD m.aqa.ziJ .. ., October 2{){)8
With each rubber ball positiooea in a If," hole in scrap and held with
a clamp, drill a Vo" hole YJ" deep in the ball.
Using sandpaper f oldea into thirds, sand the kerts and openings
betwe8l1 the t ongues, progressing from 120 to 150 and 180 grit.
un the bottom. flush with the edges. Sand
the feet smooth. Then, with the drum placed
011 2"-tall spacers 10 provide clamp clear-
ance. glue the feel to the drum. as shown in
Photo F.
Time for the mallets
1
from a 1/4"-diameter oak dowel 36" long.
cut two l21h" -long pieces for the mallet
handles (I).
2
To drill centered holes in l"-diameter
rubber balls for mounting on the ends
of fhe mall et handles (I). where shown on
Drawing 1, chuck a ." Forstner bit in your
drill press. Clamp a piece of -l4" scrap to
thc table, and bore a hole through the
scrap to position each ball for drilling.
Rechuck: with a V." brad-point bit. Then,
holding each ball in the h
M
hole, drill a
\h" -deep hole in the ball. as shown in
Photo G. Use medium-hard rubber balls,
such as availabl e at your
Cutting Diagrazn
4 X 7'/.0 x 60" Oak (3.3 bd. ft .)
local toy. hobby, or crafts supply store.
Now glue the balls to the mallet handles
with rubber cement.
Finish up
1
Scrape off any glue squeeze-out. Then
finish-sand Ihe drum to 220 grit, remov-
ing any sharp edges.
2
'lb remove spl inters that can inhibit free
movement of the tongue:; and to create
clean edges for the hest appearance. sand the
saw kerfs and openings between the tongues,
as shown in Photo H.
3
Finally, remove the dus!. Then apply
three (:oats of a clear finish. (We applied
satin {XIlyurethane, sanding to 220 grit
between coats.) To prevent slippage of the
drum and adjacent surfaces from vibrating.
install self-adne:-ive rubber bumpers on the
fe et (H). where shown on Drawing 1. Now
grab your mallets, and chct:k out the drum's
amazing sounds, .
Written by Owen Duvall
Projuct design: Steve Roberts
Illustrations: Rourooe LeMoine; Lorna JohnSOl1
@

Vo"-diam. Oak dowel 36" long
....
About tongue drums
Tongue drums- also known as sl it . log,
a nd xylo drums-have been used in
African, Asian. and North and South
American cultures for hundreds of years
for communication, ceremonial, and
other purposes. Though originally made
from a hollowed-out log with a narrow
opening (slit) in the top or side, modern
tongue drums consist of a wood e nclo-
sure with a slitted top. typically having
from 4 to 14 tongues. When struck. a
tongue vibrates, and the tone that's
produced resonates in the enclosure.
The tone quality and frequency depend
on the length, width, and th ickness 01
the tongue, the density 01 the wood, and
the size of the enclosure.
Materials List
FlN1SIIfC SUE
Part T W L Mati. aty
A ... W
"
'"
p
B .... '410'
"
5'1, 0
,
C
""'"
w
"
10 ..... 0
0
"""
.,'
"
'"
0 2
E
"", ... -.,'
6' .W 0 2
F
-..,-
.,'
5'
"
0
'G
""'"
...
"
8l1,' P 2
'H 1001 ... . ,' 2'- P

--
v.'-dlam. 12W 00 2
'Parts initially CtJI oversize. See 1he i""IStructions.
Mlterill. key. O-red oak, Ol)....()ak oowel.
Supplies: Spray adIlesNe; double-laced:ape; parallin wax;
l ' .oomeler medil,m-hard rutlbef :'Il s (21. a1 tC',l ,
tIobb)' . 8fId CflIItll supply s1ores: !Ibbef cemefI;
sehdhesMi rubber tx.mpers (" ).
alld bits: Jigsaw tJIade wi th 20 Iee1h per m,
set, < ' Forstner and v,' bf3d.point Oils
61
AT A GLANCE
Overall dimensions are 35." wide x
12
7
.<\.' deep x 32:V.' high.
For the board feet of lumber and
other Items needed to build this project,
see page 66.
T
he delicately curved legs and elli pti-
cal shape of this table make it a real
attention-grabber. And the wall-
hugging design fils easily into any entry or
hallwdy. Build it and you'll \cam txJW easy it
is to make the curved and tapered legs and
kerf-bent plywood aprons. You' ll also dis-
cover how to Jay out an ell ipse of any size.
Start with the legs
D LEG SPACERS
....-F:=::I
shank hole,
countersunk
:to hole


Rear edge
@
Left spacer
" .

IV .. '
-,-"tJ-. !---t< ....::::.......Jl
I V. -I
Center spacer
@
o
@
Right spacer
From tW' slock, cui three 3)(32" blanks for
the legs (A), and pl ane them to l ilt thick.
(We used maple.) You also can laminate the
leg blanks from i' stock. To t{)fm {he legs,
see page 68.
Build the table body
For the body panels (B), cut a . x24x32"
plywood blank. Then cuI the shurt ribs (C),
long ribs (0 ). and leg spaccl'N (E) to the sitts
listed on the Materials Ust on page 66. Drill
3t countersunk shank holes and holes
in the l eg spacers, where dimensioned on
Drawing 1. Make sure the right and left
spacers are mirror images wi th the W' holes
offset from center, as shown. Mark the rear
edges of these two spacers. Now lay uut.
cut, sand, and drill the body panels, and
the body, as shown in Steps 1- 8
of Drawing 2. To Jay out an ell i pse of any
size, see the Shop Tip below.
SHOP TIP
Draw ellipses the easy way, one-quarter at a tim.e
Here's how to draw an ellipse of any size, using a scrap of
wood, a pencil, two nails. and a framing square (or a piece of
plywood with a square comer).
lay out the major SKis snd minor axis of the eUipse on the
workpiece, where shown below. Then to make an ellipse
trammel , cui a 'hxV/ scrapwood strip to Ihe length indicated
at boftom. Mark a hole center for a pencil and points A and 8
for two nails, where shown. Drill a snug hole for the pencil, and
drive the nails through the strip. File or grind away the points
ELLIPSE LAYOUT
One-hall major axiS
Onehal!
ELLIPSE TRAMMEL


mUlor !lXIS
B
,.
\
."
Mi nor !lXis
4d nails with points
fil ed or ground away
A
L
,,"
cr _
matof !lXIS
Snugflt hole One-hall major axis plus 3"
of the nails. Next align tne outside edges of a framing square
with the major and minor axes drawn on the workpiece, and
secure it with double-laced tape. Place nail A al the corner of
the square and nail 8 against the edge of the square aligned
with the major axis. Now rotate the trammel, moving nai l A
along the edge of the square aligned with the minor axis and
nail 8 along the edge al igned with the major axis, and draw
the ell ipse in quarters, as shown be/ow. To see a video Clip of
how to draw an ellipse, go to woodmagazine.com/ellipse.
63
II!! BUILD THE TABLE BODY
STEP 1 Draw guidelines.
e Draw parallel lines.

-
Major axiS
"
Major axis
axis :>-
BODY8LANK ._ '_
. 32"-
..
.-------

STEP 2 Make an ellipse trammel.
Pencil
,
15V.
--- 4d nail
4d nail
,
Grind or file away nail points.
Hole sized
for a snug fit
STEP 3 Lay aula hall ellipse.
O Adhere a framing square
(or piece of plywood
with a square corner)
10 the body blank with
double-faced tape.
BODY BLANK
Flip the square, and draw the
second quarter ellipse.
o Saw the body
__ \_-----""\ blank in half
::::
Push Ihe nails against ._ ..-
square. __
",. . -' -
_.-=--
Draw Ihe first Quarter ellipse.
STEP 5 Layout and drill clamp head holes.
Mark 1M first hole center.
Compass
Mar1<: a guideline
I" from the edge .
the hole layout on the
oUlcr side at the centerline.
e Step olf four additional hole centers.
Drill the holes with a t o Forstner bit.
Square
"
'h x . X 18'!," trammel beam
STEP 4 Bandsaw the body panels.
Mark straight lines.
\
\
Bandsal'l; then
sand to the line.
o Adhere the blank halves with double-laced tape.
STEP 6 Drill shank holes.
Location of 0
Mark the hole
centers. and drill
V3:! ' holes through

both panels.
",
Shank hole
at intersection
of lines
Mar1<. the panel orientation.
64
STEP 7 Countersink the s hank holes,
and drill screw-acces s holes.
GREEN: Countersink on top lace.
REO: Countersink on bottom face.
STEP 8 Assemble the bo<:Iy.
'8 1 'fl" F.H.
1.-/ wood
6 ..
lIo'h

__
=
, _ , '" @ the
, a panels@
BLUE: Enlarge hole to '1.1' fo r screw access.

<0 .... 0 Glue and screw

, J thenOs@and
) E 'A.<" Pllot hole 0/. deep - ......
Add the kerf-bent aprons
1
For the aprons (F), cut a 4X4
'
/4X40"
plywoOO blank. Then. for a tight fit
against the right and left leg spacers (E), cut
10 bevels on each end, where shown on
Drawing 3. Now, measuring from the bev-
eled ends, cut the two aprons to finished
length. To maintain continuous grain orien-
tation when attaching the aprons to the table
body. marKlhe top edge of each apron.
Nole: Although a !rerfed maple board con-
forms 10 Ihe broad front curve of the tahle,
it is too stiff to bend around the tight curves
at the ends. Because birch plywood becomes
very flexihle when kerfed, and closely
matche.f the color arul wain of the maple
legs. wt' chose it/or the table aprons.
2
'1"0 mak.e a simple jig for k.erfing the
aprons (F) on your tablesaw, page
32. Then adjust the cutting depth so the s.aw
blade just begins to cut into crossband
directly under the face veneer. (Depending
Ii)
With the
(E), drill a pilot hole
screw the cleat in place.
'8)( '''''''" F.H. wood screw G Glue arld screw the
spacers to the panels@.
lEI APRONS (Top vi ew)
on the numlx:r of plies in your plywood,
you'll cut within I/lb-Vs" of the oulside face
of the plywood aprons.) Now, starting at the
square-cut end of each apron, cut W'-spaced
saw kerfs. Be sure 10 leave a full-thickness
plywood rib at each beveled eoo.
J
eut three 4x4V4X2" scrap plywood
cleats, and drill a centered counter-
sunk hole in each one. Screw the cleats to
the leg spacen; (E), as shown in Photo A.
apron
(F) as tuck the ends under the
ollerhangi ng edges of the cleat s.
Then test-fit the aprom (F), as shown III
Photo B. Leave 00 more than a V,6" gap at
each end between the aprons aoo leg spac
en;. To ensure uniform clamp pressure, rip
four hardwood strips aod dry-
clamp the aprons to the body, as shown in
Photo C. When you are satisfied with the fit,
apply glue to the edges of the boJy panels
(B), and clamp the aprons in place. With the
glue dry, remove the damps and cleats.

;
j from the center to
aprons (F) in place.
65
Make the top
l
Edge-join 3/4" -thick stock to make an oversize
blank for the top (G). (We used loopard wood.
See Source.) Sand the blank smooth. Then lay oul a
with the dimensions shown on Drawing
4, and handsaw aoo sand it 10 shape. Now rout a W'
round-over along the bottom edge.
2
Plaee the top upside down on your workbem.;h
and position the table body on it, flush at lhe
back and centered side-to-side. Using the shank
holes in the top body panel (B) as guides, mark
screw-hole centers on the lOp. Remove the table
body, and drill pi lot holes into the top.
Now finish and assemble
1
Drill 3/16" pilot holes into the legs (A), where
dimensioned on Drawing 4a, and screw in the
hanger bolts. Then fini sh-sand the legs, aprons (F),
and top (G). Apply a clear finish. (We applied two
coats of satin polyurethane to the legs and aprom
and tu the top, lightly sanding with 220-
grit sandpaper between coats.)
2
Place the tahle hody upside down on your work-
bench. Insert the leg hanger bolts into the holes
in the leg spacers (E) and fasten the legs with wash-
ers and lock nuts, where shown on Drawi ng 4a.
(You'll need a rocket wrench with an extension to
fasten the center leg. ) Then place the top (0) upside
down on your workbench. Position the table body
and legs assemhly on it. and ,-.crew the top to the
body. Now, place your table inside the front door,
and add a welcoming vase of flowers .
Written by Jan Svec with Kevin Boyle
Project 0031gf1: Jeff Mertz
Illustration!: Roxanna l aMolna; lorna Johrl,orl
Cutting Diagrazn
m LEG AND TABLETOP
MOUNTING DETAIL
(Viewed from back)
'--'-" I,'
x 2"
hanger bolt 1
';." washer "'\

B
1 V," lock nut
1t8 x 1W F.H.
wood screw

1/," iQ'_
12""" '1,-20 x 2"
hanger bolt
E
E
@
A
#8 x t v,- F.H. ......1
wood screw --

A
32"
II EXPLODED VIEW
I
Oc:cc;:dAi ;c:;;;;-"J;-" . '{Al:"''''":.:'.; J
1'". x 3'h x 72' Maple (4 bel. ft.)
O .. f{At .. ,,"'"o:::c:cc;:;-jJ J W@ =" , = ']=
w. x 3'h x 48" Maple (2.7 bd. ft .) x 5'h x 48" leopHrd wood (2 bd. ft.)
-
on' lw:"
" "'
4 X x 96" Leopan:J wood (4 bd. ft.)
E
(f)
I
c
c ,[ (61 I 0
.-.-'
. . _ ..
" --- "
.. ' .

..
"
,
(- ---_.J
;
/
'.
.
.C':'"..
" -Y. x 48 x 48 Birch plywood
B6
Materials List
SI1E
Part T IV L Mati Qly
'"
""
H""
"'"
""
B"
body-
<" 1(W." 30'h"
C
""'''''
, .. 2.' 4"
D
... ""
." 2W B"
E
".,..,.,
v." 4'4' 1'4'
F"
.,.,..
W 4'1.' 190/."
G" ..
.,"
t2'",,-
35""'-
'Parts cui Q\'efSlze. See the Wl\.lCti,:ms .
Materials key: M-maple, BP--hirch plywood,
EL-edge.pr.ed wood.
"
3
BP 2
BP 2
BP 2
BP 3
BP 2
EL
SupplleJ: 1 II,' al"(\ '8xt 'h' tlathead wood screws,
1I.2I)x2" hanger bolts (6), '/. washers (6). Yo' IodI r'lJts (6).
Bil: W 1000000over router M.
Source
Leopard wood. To check ttle prce and avaiatilily 01
leopard wood. go to woodwOikerssource.rlet.
WOOD ""'1a:o:l .. " OctDber 2006
68
" .
nIce
Learn how to
make curved and
tapered table legs;
then prepare to be
complimented.
hen so much about
woodworkin g
involves Slraigbl and
<;(ju.ue cuts, the sinuous shape
of curved and tapered legs
always grabs people's attenlK>n.
Nonwoodworkcrs admire them
for their grace, while wQ(xj
workers wonder, Huw'dYV14 do
Ihat? It's easy.
Design guidelines
When designing a curved and
tapered table leg, use )lOOT
personal and the
project's overall "lyle tl) guide
the shape and dimension of
the legs. Traditional furniture
such as Queen Anne,
have design rules of thumb
for cabriole legs that you can
adapt to curved and tapered
legs. For example. Queen
Anne-style form a con-
tinuous $-curve wit h linleor
no straight section in the
middle of the leg. Example."
of these and other design
rules can be found in hooks
such American Furnilure
o/the 18th Century.
The curved and tapered
leg shown here and on Ihe
bowfront table on p(lge 62
Uf>eS a gradual taper from ll/:t"
square just below Ihe block 10
at the fOOl . There's al$Oa
straIght section althe center.
There's no formula for sizing
a bhmk when creating your own
designs, as long as the compleled [!I
Cut on
, , Block

Notch
leg complements your proj-
ect dimensions. For example,
the block on the leg we' ll
make here ahout
41h" long, or Ihree limes its
v.idth The block width equals
twice the thickne .. s of a
table top. If you have a project
that calls for a specific look,
researchalld measure examples
of furniture before dmw-
ing a pattern.
Let's make a leg
We' ll U-'iC the legs from the
bow(ronl table to show how to
creale a curved and tapered
leg. sO stan by machining a
l'hx3x3r blank. If you can",
find IW'thick make
your own by first ripping
%x6V." stock down its center.
Find the !l ttrar.: li ve gmin
match and glue the , .... '0
halves together, shown in
Photo A. Then plane the
glue-up to size.
Mark the length of the
hlock atop the leg blank.
and extend the line around
bot:h il s faces and sides.
(Find dimensions and a pat-
tern for this leg on page 85.
Layout the taper on bot:h
faces of the blank at the
foot cnd by marking in
from each edge. In this
case, we placed I wo marks
in from each edge.
Repeat this on the opposite
face, and then d .... J.w line. ..
on both faces from your
end marks to the marks
defining the block, as
shown in Photo B, as guides
for both bll mlsawing and
beltsanding the tapers.
Side
Bandsaw on the waste
Sides of the taper lines.
shown in Piloto C. and avoid
cutting into the li nes defining
the block. To sand the taper,
first secure Ihe blank between
t wo dogs made from W' or
Knee
Face
Ankle
Foot
WOOD m&guu.. Oc.oh .... 2006
thinner scrap clamped to your workbench,
as in Photo D. Thcn mark wavy pen-
cil lines on (he side to be sanded (0 visually
gauge your progress. Belt-sand until the
taper reaches the pencil lines on both faces,
as shown in Photo E. Flip the blank over
and repeat this process on the other edge.
Bandsaw the curves
Whether you lL'iC our pattern or one of your
own design, tmnsferring it to a hardboard
template helps ensure all your legs will look
the same. To copy the pattern on 85,
create a 1" grid on the hardboard and repro-
duce the leg design in the same proportions
as the smaller paper pattern's grid. Then cut
and sand the paUern to your pencil
Using your template, tnmsfer the leg shape
to roe side of your tapered blank, shown
in Photo F.
Then make the straight cuts that define
the block. To countemct the effects of the
taper and create a vertical kerf, press the
block against the bandsaw table as you make
the straight cut, as shown in Photo G. Stop
at the start of the curve. Now cut the notch
on tbe opposite face of the block.
From the foot end, begin bandsawing the
curves with the taper pressed nat against
the saw table. The slight angle of the cut will
not affect the until you reach the
straight cut made earlier. As you approach
the end of the curved cut. press the block
firmly against the table, and then complete
the cut. Repeat for the opposite curved cut,
as shown in Photos H atxll.
Next, remove saw marks by hand-satxling
with 80-. 100-. and 120-grit abrasives. If
you use a random-orbit sander. as shown in
Photo J, center the pad over the curve and
sand with light pressure un the edges of the
disc. Keep the :.ander moving to avoid
or nat As with the tapers, a
"',avy pel'lcilline helps you gauge your sand-
ing progress.
Hand-sand the curved surtaces with the
grain for your final grit. Foc' the block, hand-
sand with a nat pad to hold a crisp edge
where the blnck meets the curve, as shown
in Photo K .
Writt9l1 by Bob Wil&an with K", .. in Boyle
69
70
I
II the war against workshop dust. gathering debris dirCCtl.y from the 100:1
with a dusI: collector or shop vua::uum should be your first line of defense.
You can win that battle but lose the "'."ar if those tiny but dangerous
aubome particles e;cape.!IO al-.o need air support. ThaI's where a ceiling-
hung filtrdtion unit comes in.
Here's how these "Imrie machmes won... Eacb has a steel box with a bIo\\er
inside (hat sucks dust-laden air into the filters and exhausts clean air out
the other end. 1be (which l()()ks like a common furnace filter) catches
the hulk uf the 1&1,1Cr particles. Smaller particles get trapped in the
high-effICiency filler behind the preliller.
With most of these machines costing more than $200, we wondered if they
were much more effective than a simple box fan with a filter taped to the front.
So we nm that option through our tests, too.
WOOD rn.I.!Jazlll.. Octob4r 2D06
Airflow: Does bigger
mean better?
At a minimum, the air-filtration system you
choose should be able to the air
in your shop every 10 minutes. To firxl oul
how much airflow you need. first figure the
cubic footage of your shop (length x width x
ceiling height. in feet). and then divide that
number by 10. The result ing number shows
the minimum air flow you need in cuhic
feet per minute (cfrn). For example, a 14)(18'
shop with an 811.!' ceiling holds 2,142 cubic
teet of air. Divide that by 10, and that shop's
filtration system shoold poll at leasl2lS drn
of air.
Because manufacturers use different tesI-
ing methods to arrive al their airflow specs.
v.'e evened the playing field by testing all of
the units using a single method. (OUf num-
bers may not agree with thei rs, hut they
provide a fair head-ta-head assessment.) We
measured the airflow of each system in our
test using a hot-wire anemometer at 25 spe-
cific the face of the prefilter,
and then averaged those airflow readings.
The results of our test are shown in the
chart, at rjght. As you can see, seven sys-
tems charted airflows between 547 and 650
cfm. with the Grizzly 00572, lOS 750-ER.
Shop Fox WI690, and Jet AFS-IOOOB all
bunched up from 630 to 650 dOl. Penn State
Industries AC620 and Jet's AFS-500 pulled
only a little more air than the box fan and
filter setup.
How well do these
machines gather dust?
Although a good second line of defense, an
air-filtration system may still let through
small dust part ides that can lodge in your
lungs. (See "Particle size and your health,"
at right). For complete prote{;tion from air-
COLLECTION TRAY LOCATIONS
r 0
2
1
3' high
3
3' high
3' high
6 .'

!
0
under shelf
0
2' high
on 110 4
AIRFLOW THROUGH THE TESTED SYSTEMS
We foone three clistlJ1d tiers 01 airflow p8r1ormance trom the systems: SlMn units tletween 547 and
650 elm: three llrn:luding a simpte 00x fan) meaured 232-2&4 elm; and Lee valley tell sQuari!ly In tile at 414 cfm.
700
'00
'00
"
_ '00
a




200
'00
."
."
'"
'"
."
Airllow' musured with hot-wire lnemometer at 25 distinct points I .' 110m the l!J'e!iltellace. To test
realworld ilrttOW. filtefS undm identical ilrld then lappe{! clean tlelore airflow
ITI&iIsuremenls were shown are an oIlhltll! tests.
borne dust, you should wear a snug-fitting
mask. or respirator. We focused our tests of
these units on the nuisance dust that seems
to settle on everything in the shop.
After sealing off our 14xl8'test shop in a
shroud of heavy-duty plastic sheeting, we
hung an ai r-filtration system from the
ceiling and placed eight collection trays in
various locations around the shop, as shown
below left. Next, we plugged the system into
a timer that would turn it off after exactly 65
minutc. ... and then turned it on at its highest
speed. Our respirator-equippcd tester then
cut 160' of MDF and exited the shop. Six
;
scale accurate to 0.01 of a gram.
hours later (five hours after the air filtration
system turned off), we returned and weighed
the amount of dust in each tray. The results
of this test are shown on the next page.
Surprisingly, almost all of the high-cfm
allowed !TX)re dust to settLe around the
Particle size and
your health
OustcoIlection and
filtration-equipment
manufacturers often
explain the effective
ness of their filters by stating the smallest
part ide size (in microns) that their filter
will catch. But how big. exactly, is a
micron?
Well, there are 24,500 microns in 1",
or about 380 microns per lAo'. A
10micron particle can be seen with the
naked eye; a 1micron particle requires
a microscope.
Dust particles larger than 10 microns
settle to the floor quickly, so they don' t
pose a Significant breathing hazard. Our
body's natural filtering systems (nose
hairs, etc.) do a pretty good job of filtering
out dusl in the 4-Smicron range. and
particles smaller than 0.3 micron beha\le
like a gas, so we tend to inhale and
exhale those withoul harm. Particles
between 0.3 and 5 microns pose the
biggest health riskS because they slip
past our natural defenses and can lodge
in the tung passages. (TobaccO smoke
particles range from about .01 to t
micron in size.)
71
HIGH-AIRFLOW SYSTEMS KEEP HEAVIER DUST AIRBORNE
We placed eight wllection trays arouoo our test shop, arid Itlen tl\e d",t that settled in10 each 1r<1'j atter cutting
150 lineal feet 01 W MDF ,t.,if-littratioo s)'Stems were run al the,r hignest speeds during the cutting arid tor one hour
attern'ards. We lllowecllhe dust to settle lor Ii\'! more hours, then weiQhed collection tray.
These numhers silo'll tl'1e ivtfaQe wti{lht of tile dust in al l eiI,1ttt trays for each system.
,." - r----------------- - ----,
O.BO
0.10
'"
0.50
0.'"
0.35
0.30
0.20
0.10
0.00
Tests collducted in a 1itS! shop No dust collection was used during this test. Avtrage. 01 three tests.
DUST COLLECTION AND AIR FILTRATION WORK BETTER IN TANDEM
To see how using ontool dust CIlllt'ction would allect tile performance of UJese air tillers. we took one highCFM
air-liltmion unit and reran the dust'settl ing test, this time Vlith a typical two-baQ dust collector connected to the
tablesaw. llle was dramatic. JltSt down tile spw:J 01 the air-l iltration molor to a rate more
IOlthe size of the soop lesseoed the settl ing dust by aboot onethird
'.00
... ,
0,70
,."
'.5<l
0.40
0.30
0,20
0.10
'.00
0.a1
SHOP FOX W1690
(high speed, "11th
dust collector on)
0.07
Tests conducte<l in sealed 14x18x8'h test soop. Average of lests.
shop than the lower-cfm models. After
sharing our result s with several airflow and
fillralion we concluded that the
high airflow (about three times what's
needed for a shop this size) likely carried
heavier particles out to the perimeter of the
shop heron: they enough to fal l. A
low-crm modeJ--or no air-filtration system
at all-allowed those heavier particles to
fall harmlessly to the floor.
So why didn't the JDS suffer the same
heavier fallout as the other powerful units?
Its diffused exhaust, spread out over the
entire rear of the box, reduces the velocjty of
72
MeetMERV
When you replace a high-efficiency
filter, how do you know you're getting
a good one? According to AI Vaeek,
executive director of the National
Air Filtration Association (NAFA,
nafahq.org), all replacement
particulate fitters should have a
Minimum EHiciency RejXlrting Value
(MERVI marked on them.
He suggests that woodworkers get
a filter rated at no less than MERV13,
which fillers out more than 7S percent
of the particles sized 0.3 micron. And
for woods li ke cedar and waln ut that
can trigger respiratory reactions, go
no lower than MERViS and wear a
respirator. A MERVIS filter catches
95 percent of all particles sized
0.3 micron and larger, but AI says
such superfine filtration has its price:
Every step up the MERV ladder costs
a 10- 12 percent drop in cfm.
the ai rtl ow without affecting the volume of
ai r, keeping airoorne dust to the filter
inlet. All other air-fi ltratioo systems in our
test have a smaller exhaust outlet that
increases air velocity.
We repeated this test with the multi-speed
Shop Fox set at its lowest speed, and again
at high speed with thc cunnected
to a dust eollectoc. Slowing the blower
resulted in one-thi rd dust fallout; add-
ing dust cullection to the mix cut the amount
of settling around the shop by a whop-
ping 87 percent, as shown at left.
Fine points on filters
The prefi lter protects the high-efficiency
fi lter from larger particles that woul d
quickly render it inefficient. The
prefilters 00 the JDS and Lee Valley may
seem more economical than disposable
prefilters, but in our tests, washable filters
allowed morc dust through to the high-
efficiency filter, as shown opposite page,
lOp, A disjXlsabJe prefilter can be tapped out
several times before you have to replace il.
We also found two different kinds of
high-eft1ciency tl lters on the tested uni ts.
Most use a super-fine mesh bag filler, bUI
the Jet AFS-500 uses a disposable pleated
paper fi lter instead. This Slyle of a
much surface area than a bag filter,
so it wi ll load faster and need to be cleaned
and replaced more often. Among the bag
fil ters, Penn State and Shop Fox have the
largest surface area-about 30 percent more
than typical. That should give you more
time between cleanings.
As for how wen those fi lters actually
work. at snatching dust, filter efficiency rat-
filter shown after
dlspoub .. prefilter
With the prefilters removed, we see how welt they do their job. The bag fitter behind a washable prefilter (left) is caked whh dust that
sl'lould nave been caught by the prefilter. The bag fitter behind a disposable prefilter (right) shows that far tess dust that slipped through.
ings should indicate boilr the minimum
particle size and the percentage of those
particles it captures. (Particle size alone isn't
enough because even a burlap bag will trap
some O.5-micron dust.) Higher percentages
are belter, obviously,
The manufacturers' specs for filtration
effKiency are shown in the chart on the next
page, but we were unable co verify these
numbers in our testing, in fact, two manu-
facturers, Grizzly and Shop Fox, couldn't
provide us with their filters' efficiencies,
Thinking outside the box: Other meaningful features worth having
Off-timer, Just because you're done
working in The shop for the day doesn't
mean your air-filtration system should be.
An off-timer allows you to set the system to
run from 30 minutes to eight hours and then
shut itself off.
Remote control. Uecause these units
typically hang high overhead, it's nice to be
able to tum them on and off, select the
blower speed, and set the off-timer without
having to get out a ladder. Except for the
Delta AP-200, Jet AFS-500. and Lee Valley
LOOKING FOR A SELFSTOPPER

-------


,.

.. '

-
. .:.


.,
.-
Units with a built-in olf-timer automatically
power down after one of severat preset
times. so you can set it to clear the air when
you're not around.

#650, all of the tested units come with
remote controls. Kudos to JDS and Penn
State Industries here: Their remotes display
the fan speed and off-timer settings, as
sho.",.'fi below. (With the other five, you still
have to be able to see the display on the fil-
tration unit itself.)
Like your TV remote control, most of
tht::sc systems use infrared (IR) remotes that
require line-of-sight to the filtratKm unit.
That sometimes means walking around
behind the unit to start and stop it. Penn
Jet 's compact remote tucks nicely into
an apron pocket. Although larger, JDS',
control comes with a walt-mounting
bracket, and shows timer and Ian settings.
Siale industries' mdio frequency (RF)
remote can be used anywhere within about
40' of the unit-about twice the maximum
range of I R remotes .
Alrflowgauge. Over time, dust buildup
in the filters SHIrts to imJX=de airflow, rerx1er-
iug the system Jess effective. The process is
so gradual, you may not even realize it until
you're looking through a dusty haze. Only
the Delta 50-875 has a built-in airflow gauge
to give you an at-a-glance indication of when
ifs time to clean or replace the filters.
ALMOST TIME TO CLEAN THE FILTER


-

A vane In the exhaust of the Delta 50-875
shows that airflow is still sufficient lor
effective tittering. When the needte hits the
red area, fillers need cleaning.
73
Filter seals. You gotta love thc blower's
work ethic: It keeps trying to pull the same
volume of air regardless of whether thc filter
is packed or not. And jf it can't suck dust-
laden air Ihrough the filter, il might jusl pull
it around the filter. Fortunately, almost all
of the units we tested (except Lee Valley)
have seals at the high-efficiency filter to
prevent dust blow-by. We prefer box-
mounted seals to tilter-mounted seals, as
shown at right, bccauM: thcy make filter
replacement easier, although both proved
effective.
HOTES: sua is first two dimellSions.
2. Speed caf1 be charog.ed ()11 box and by
remote controi UIlIess Othel'/ll"iS8 !lote<!.
('j COOtrollro only by remote
( .. ) Cootrotfro only on box
3 (N/A) No ofllimM 011 ttlis mOO@L

(IR) Infrared
iRC) RadiQ conlrol
1'1 No remota control for this modal.
Let's clear the air and
choose a favorite filter
The lOS 7S0-ER ranked near the top in our
airllow tests, yet left the least amount of
dust settling around the shop. And we like
the display on its remote control. \Ve would
replace washable prcfiltt-'I", though, with a
disposable one to extend the life of the high-
efficiency bag filter.
On a shoestring budget? Our $20 box fun
with a furnace filter duct-taped over it tested
as well in airflow and dust settling as sys-
tems priced 10 times more. It's not as easy
to tap out or replace the filters, and you
74
Seals mounted on the flange behind the filters (left) work as well as a spongy foam seal
(right) that wraps around the perimeter of the bag filter. The foam seals pinch and bulge
during Installation, though, which can affect the fit of the prefilter.
5. (01
--
IWI Wasftatli!
6. Rating Iff mlirlUfacturer. Percentage of
particles of this sire by the fiUer, occording
to Ame<icaol SOCil!tv 0/ Heating. Refrigerating aod
Air-Cooditiooing Erljllo!'JMS stalldard 52.2.
1-1
Unable to oNain rating 'mm manutacturer.
7
I

GOO<
, ..
won't get a fancy on-timer or remote con-
trol, but it did the job pretty well. This simple
setup might hold you over until you can save
enough money for a larger unit.
6
1'1
Airflow
IE) Eyebolts
IHI for tilrr,ing
'"
Remote CIlnllo/
lUI filt8(8

I') years for $15
10. OJ TaiW"dO
(CH) China
ICAI Canada
11 . Prices current at time 01 article proouctiorl and
rio "", include !<hipping. whefe applicable.
Written by Dave campbell
with Jeff Hfltt
(fl ....... ....
I
Whether you're a custom
cabinetmaker, a trim carpenter or
own a high-production shop, you
recognize Bosch for the precision
engineermg that produces the world's
finest jigsaws, tools and accessories_
What you may not know is that
you can bring that same level of
performance and precisIon to your
table with our expanded line of over
550 router bits_ In fact, we engineer
every Bosch bit to outperform - and
outlast - any other bit on the maf1(et.
From our patented Oyanite Carbide'"
to our fully-hardened alloy steel and
diamond-honed cutlinB edBes, e'oIery
Bosch bit combines exclusive features
that help you make hlgherquallty
cuts with optimal relief and ultimate
durability. All day, every day.
A better bit. A better cut Bosch bits -
Engineered for tradesmen.
PATENTED DYANrTE CARBIDE
OUTPERFORMS AND OUTlASTS
TRADITIONALCARIUDEGRADES
patented formula allows Bosch Carbide to
hold an edielonpr lor precise and consistent
performance throuthoot the bit's life.
FUUY+lARDENEDANDTEMPEREO
AU.OVSTEEL DEUVERS UPTO 55%

Bosch brts made from our '-Hn,lIIted
alloy steel "-up to 48'" endurance
Itrefll!h . rod up to hiJher tllflSlle 1Ir.n,th
than competitofs' bil. made trom
r.orH'lflat1ref.ted sle-el.
FROM SHANKTO HEAO SCREW,
EVERY BOSCH BIT IS ENGINEERED
TO EXACTING STANDARDS
lonpr wnlo.s work well witl'll&mplales. lemplilte
auides, routJrlfI tables and doYetaJl )ias.la...,
bnrirIJ:I ...... sup.nor IUidance. And t.OIlII'OI cut
desI&n Pm"s cut depth and redUl:e$ klckbadL
BOSCH
I nvented for life
how to cut a straight
Before you can turn rough lumber into a
project you're proud of, you need to
start with one straight edge.
I
na pertect world, the hardwoods you buy for your projects
would come with laser-straight edges. Unfortunately, that
perfect "factory" edge is the exception rather than the rule.
In this anicle, we'll show you how you can create that ideal edge
on less-than-ideallumber.
Suaight edges start at the lumber store
When shopping for lumber, choose the best boards available.
paying special attention to the gmin and how it will appear on
your finished project. You can buy lumber in rough condition
with no sides surfaced. or with only the faces planed ($25). or
surfaced on both faces and both edges (545). Choosing the latter,
while more costly, often eliminates the headaches of cutting a
straight edge. However, even S4S lumber can warp.
Warped boards, although more difficult to work with, can still
be put to good use. A board with flat faces but crooked edges, like
the one shown at left, can be machined to crcate straight
as shown in the dccision map on page 78.
Don' t work with more than you need
After you've selected your bomds and allowed them a tewdays to
acclimate to your shop's temperature and humidity levels, cut
them to rough length before doing anything else. The longer the
board, the more stock you'll waste trying to straighten it. Leave a
few inches to allow for waste.
To plane or not depends on your tools
Once the stock has acclimated to your shop, you can go one of
two directions. Either joint and plane the faces of your board flat,
and then work on straightening an edge, or straighten an edge
with the stock faces in their rough condition. We recommend the
first course of action because some of the prep methods work best
with clean workpiece faces.
But the option you choose may be determined by the limita-
tions of your tools. For example, you can', tace-joint an !:r'-wide
board on a 6" jointer. And. cleaning both faces on your planer
does not guarantee they will be flat. only parallel. In this case.
straighten one edge, rip it to width on the tablesaw, joint OJle face,
and then plane to thickness. If you need the final workpiece wider
than the knives on your jointer, simply rip it into two or three
pieces, joint and plane the taces. joint the edges. and then edge-
gluc them back together once they're square and true.
Read what your board's edges tell you
Now eyeball along the length of your board's edges to determine
your next move. If it has one reasonably str.l.ight edge, you'll have
no trouble making it perfectly straight. A small amount of crook
takes a little more work, but can be stmightcncd quickly. Even if
your board has a crook, you'll be able to put a strdight
edge onto it in a couple of steps. Here's how to get a straight edge,
from best- to worst-case scenarios.
WOOD ....... g .. zi .. c Octo",",,< zooe
edge on anything
Jointer: The essential straightening machine
II you work with rough lumber, you realty should own a good jointer.
II's the best toollar cutting a square, clean, straight edge, as shown
at right. as well as for cleaning and flattening a board's face.
Although a 6' joi nter performs well , consider stepping up to an 8'
jointer, which not only machines wider stock, but also has longer
infeed and outfeed tables to better support long workplaces.
We don't recommend using auxiliary stands to add infeed and
outleed support to jointers because boards with rough or crooked
edges can sometimes knock stands over and poSSibly cause the
jointer'S knives to gouge the board.
Rely on your jointer to machine a straight, square edge on
a rel atively straight board in just a pass or two.
Best case: No crook
C
onsider yourself ahead of the game if
your workpiece falls into this category.
Regardless of length. you should be able to
machine a straight edge quickly with a
jointer, ubove. If you don't own a jointer. use
your tablesaw to cut away the rough edges,
as shown below.
Rest your rout er subbase on top of the
guide board and run the bearing against its
edge. Trim no more than v.." per pass.
wOO<hn.aq .... l .. c."' ......
A router will also help you machine a
straight edge onto this type of board. If it
h a . ~ a rough-sawn face, use a guide board
with a smooth face and a straight edge on
top of your wockpiece, as shown !xmom,
left. Use a top-bearing pattern bit in the
router. Set Ihe guide slight ly back from the
For this method, use either an upcut or
Oowncut spi ral bit or a straight bit that 15
longer than the board's thickness.
workpiece edge and equal to the amount
you want to remove. Make two passes if
necessary.
With boards that have smooth faces,
clamp a straightedge (this can be a board,
shop-made guide, or commercial accessory)
onto your workpiece so the router-as it
runs along the guide-removes no more
than \/16" with each pass, as shown bottom,
center. Make as many passes as needed to
straighten the edge.
You also can cut a straight edge at your
router table, but it takes a little more setup.
First, chuck a stmight or spiral bit in your
table-mounted router and set the height for
just a little more than the thickness of the
workpiece. Set the in feed fence so it will
remove no more than I I I ~ . Align the outfeed
fence flush with the front edge of the cutter.
If you don't have a split fence, simply clamp
or double-face-tape a piece of plastic lami-
nate, equal 10 the amount of material you
want to remove, to the outfeed side of the
fence, as shown below.
Sand a slight chamf er on the end of the
laminate nearest the bit so t he workpiece
won't catch as you foed It t hrough.
77
For a straight edge, go straight to the best tool
The tools and methods you use to straighten a board's crooked edges vary depending on the severity of the crook and the length of the board.
Use this decision map to determine the best tools and methods to use for each situation. For more options, read on.
76
START HERE: Cut your board to rough length; then assess the edges of the board.
No crook
(basically straight but rough)
Jointer Tablesaw
Slight crook
"or less of crook over 8-12' I
jli fence on your tablesaw
bandsaw?
tablesaw sled?
(pageBUj
Bandsaw
Router
Table
Severe crook
(More than 1" of crook over 8-12' length)
Do you have a 7'
tablesaw sled?
(page8U)
CIrcular Saw
Typical case: Slight crook
(t" or .... otcnaalt __ ...
M
any boards fall inlu this category
when they warp as they swell or
acclimating to the environment
around them. Plan your straight edge to give
the board the grain direction in the
project. Boards in this category will be
machined in different ways, depending
uJX>n their length.
MAKE NIBBLING CUTS
TO REMOVE CROOK
Make I!!Ilck work of
boards l ' long or less
For short boards try the simplest options
fin.t: jointer, tablesaw, or bandsaw. The
jointer proves quickest, even if it takes a lew
passes to straighten an edge. You'll the
same technique for the tablesaw and band-
saw: ripping wilh the concave edge against
the rip fence. Edges cut on the bandsaw or
tablesaw, although straight. will have saw
marks thaI dean up with one quick pass at
the jointer. The router table option leaves a
jointer-smooth edge, but lakes more time
setting up than ajointer.
Take several light cuts off each
EI
An 8U)dliary fence allows
follow a straight path, and the
cut a straight edge. for the I
end first; then joint the full
length 01 board.
Choose from many options
for boards 1-3' long
Boards of these lengths offer you the most
of any size stock. At the jointer
you've gO\ two ways to handle these
First, joint the edge as usual, concave edge
down, taking off a little more with each
subsequent pass until flat. Or, "nibble" sev-
eml passes on one end before spinning the
board to do the same for the other end, as
shown at left. Repeat umit the crook is
nearly gone, then joint the entire length.
The tablesaw and bands.1w again provide
good options, but with one imJXlrtam
change. For boards longer than I', add a long
auxiliary fence to maintain contoct between
the end points of the board's concave edge
and the fence, as shown belaw, left. Make
your aux.iliary fence twice as long as the
workpiece, plus an extra al each end, and
center it with the blade. Clamp it to the rip
fence, or adhere it with cloth-backed, dou-
ble-faced Iflpe.
To use your router table for this length of
boon!, combine the extra-long auxiliary
fenLoe of the tablesaw method with the nib-
bHng actioo of the jointer, as shown below,
center. Use a sharp straight or spir.!l bit
(upcut or downcut), Using a handheld router
and straightedge will take several passes.
but requires little space, an attractive solu-
tion for shof.k" tight on elbow room.
Cutting a stroolight edge proves easy when
using a carrier or sled, such as the one shown
beloW, on the tablesaw. To use this sled,
place your boan! so either edge hangs over
the edge of the sk:d, aligning the boan! to
cut the most attractive grain pattern. Secure
it with the hold-downs, or use screws al the
ends. Rai se the blade so it cUls through the
piggyback.ed workpiece. Build this sled
from the plans on page 80.
ends 01 a workplece.
the table when ripping.
79
CARRIAGE BOLT
HEAD DETAIL
'1. 20 carriage bolt
31// long
TABLESAW RIPPING SLED
Rle head 01 carr.l age '/.' wing nut
bolt flat on two SideS. /
""
Yo' fender washer
'/:I" groove 'I. ' deep

'1. -20 carriage bOlt'
3>h' loog ---...j
3 . ..... \
.Ao... 'l
Vo' holes
48" lor short ripping jig
84" lor long ripping jig
See WOOD insert
for holddown pattem, page BZ
Don't sweat straightening boards longer than 3'
You have four options with these boards:
jointer. rouler with a straightedge, circular
&<tw, or a tablesaw sled. If you have a 6"
jointer. use the "nibbling" method; if you
have an 8" jointer, you'll be okay to use
either method because of the support from
the longer
Your circular saw provides yet another
way to cut a straight edge. You can do this
by using a straightedge. or by snapping a
chalk line to map out the cut, and then rip-
ping aloog that line, a;; shown below. Laser
guides. available on some saws, make it
easy to track a chalked or drawn line.
Rigid l oam insulation makes a great
sacrificial culling surface. Set the blade
depth so the saw cuts slightly into the l oam.
80
To use a straightedge. first determine the
widest poinl oflhe l-look by laying the board
next to a straightedge. as shown below. At
one end of the boartl make a mark equaling
the widest point from the crooked edge.
Measure the distance from the blade to the
edge of the saw base below the motor. Clamp
a straightedge to the workpiece that exact
distance from the mark you made. With the
saw bafie following the guide. rip away the
crook. You can make a reliable strJ.ightedge
guide-which also eliminates chip-out and
aligns quickly along your cut line-from the
plans on TIu! neXT ".age .

I
Wit h your crooked edge lying against a
straigMedge, measure the widest gap to
detennine the path you want the saw to cut.
Worst case:
Severe crook
B
efore machining a board like this, first
determine how it can best be used.
Removing the crook from a 10'-long board
means wasting a great deal of wood. as
shown beluw. If you really need a long
board, try to find one with a stmighter pro'
file. If you must get long 'NOrkpieces from
these boards, you ha .... e three options: First,
rip with a circular saw; second, use a sled
on the tablesaw; and third, use the bandsaw
with an auxiliary fence--but only for work-
pieces 3' or less. Longer boards just create
more difficulties on the bandsaw.
the crook along the entire length wastes
wood and leaves a narrow workpiece.
Instead, cut it into t wo pieces. right, to
maximize its width.
Make your own zero-clearance cut-off guide
You can construct two cuI-off guides, a
4- and 8-looler. for use on different
workpiece lengths. Made to custom-fit
your circular saw and rouler, both
guides can be constructed from one
sheet of W plywood, (We recommend a
sheet with sanded faces.) Here's how:
Una up saw against fence and cui 10 remove waste.
1,--,-2"--- - 6' " . J w
I ' F? ! -"?!R -:J
'==4V,' ,"'.-.< J 1
_ __ _ _ _
Begin by snapping a chalk. line along
the entire length of the sheet 1" from
the edge. Using your circular saw, rip
along that line.
END VIEW
Use the factory edge of the cuI-off piece
as a guide for your circular saw to
make the fest of the cuts. From the
remaining plywood piece, rip two
strips 2" wide. two strips 8" wide,
#8 x;y." F.H.
wood screw
and one strip 11 wide.
Cut the strips to the lengths
shown in the illustration at right, and
assemble the sleds, removing any
glue squeeze-out.
Once dry. secure each sled to
your workbench, allowing clearance
for the saw blade. Using your circular
saw with the blade you would
commonly use, ri p the edge on the
wider side opposite the fence, as
shown below. Do the same for the
other side with your router.
Whichever diameter router bit you
use will be the size you should use
in the future for making cut-ofls .
,/
'no" shank hole, :
countersunk
'h,.o" pilot hole
';." deep
lor
your waste off each guide (left).
To use the guide, clamp a wit" the cut-off edge aligned on your mar k. Set
the saw blade to the appropriate and make the cut (right).
4' GUIDE
32" shank hole, countersunk
CIRCULAR
SAW
Written by Bob HunlIK \lIn J<'Iff Mertz
Illustrations by Tim Cahill and Roxanne LeMoine
81
I
n just a couple of evenings and using
only a few narrow strips of maple,
cherry, and walnut from your scrap
bin, you can make this striking project. So
rustle up some damps and water-resistant
glue, and let's get going.
For two more cuuing-board
see page 98.
Start by making a blank
1
From ffiilple, cherry, and walnut stock
between Vi' and 1" thick, cut strips to
the widths and length shown OIl Drawing 1.
You can use stock with different thick-
nesses (as we did) because you'll plane the
blank to a uniform thickness after glue-up.
To ensure tightjoinls, prepare the strips by
jointing one face and an edge and then rip-
ping them to the needed widths.
2
Edge-glue the strips with the jointed
faces down in the arrangement shown
on Drawi ng 1 and in Photo A. To keep the
82
glue-up flat, center the clamping pressure
on the blank by positioning riser blocks
under the blank, as shown.
3
With the glue dry, scrape off the
squeeze-out from the faces of the blank.
Then plane the top face of the blank until it
is flat and the blank has a uniform thick-
ness. Now turn the blank over and plane it
to 5h" thick.
4
Trim the blank ends square and to a
final length of 35".
Now craft the cutting board
1
Crosscut twenty-tour lY4"-wide strips
from the blank, as shown in Photo B.
2
Align the strips on edge with the wood
patterns matched. Then tum every othl.'r
strip end for end to create the pattern shown
on Drawing 2. (This also staggers the joints
for a super-strong board.) To simplify the
glue-up, separate the strips into three
groups of eight pieces. Now glue and clamp
the pieces in each group together, as shown
in Photo C. (To prevent the cauls fmm
sticking to the strips. either place wax.ed
paper behind the cauls or remove them after
the glue set);.) After the glue dries, glue and
damp the three groups into one lamination,
making sure you align (hem correctly to
continue the pattern.
3
Scrapc off all of the glue squeeze-oU!
from the cutting board. Then, using a
belt sander or a random-orbit scillder with
80-grit sandpaper, sand the cutting board
faces just enough to flatten them. Now
finish-sand the faces with a random-orbit
sander, using progressively finer sandpaper
up to 180 grit.
4
RiP the long edges of the cutting board,
leaving a finished width of 11". Rout
Vs" round-overs along all of the top and
bottom edges and corners of the board.
Now sand the edges, ends, and round-overs
to 180 grit.
5
APPlY a food-safe finish of your choice.
(We applied three coats of mineral oil,
let each coat penetrate tor five minutes, and
then wiped off the excess.) FOf" otht."I" finish
Glue and clamp the contrasting wood strips
together in order, keeping tile bottom faces
and ends flush.
Using a stopblock attached to an auxiliary
extension on your taolesaw miter gauge.
crosscut 1 V. "-wide strips from the blank.
Face-glue and clamp together eight strips
at a time. Keep the top and bottom edges
flush and the ends aligned with cauls.
options, see the article "Is your finish food-
safe?" at woodmagazine.comffoodsafc. 3 tips for taking care of your cutting board
6
TO prevent the board from slipping
during usc and to allow llir underneath
it for drying, drill pilot holes and screw six
%"-diameterrubber bumpers to its hattom,
where shown on Drawing 2. Now gaTher
up M)me fresh vegetables, and start slicing
and dicing!
1
After use, hand-wash the cutting
board in warm soapy water, rinse it
clean, and wipe it dry. Never let it soak
in waler.
2
At least every three months or
whenever the wood looks dry,
reapply a protective oil finish, such as
mineral oil, to prevent water from
penetrating and damaging the wood.
3
When the cutting surface becomes
heavily scored. sand it with a
random-orbit sander, starting with 80-
grit and progressing 10 180-gril
sandpaper. Then reapply the finish.
Wlitlen boy Owen Duvall
Project desJgn: Jeff Mertz
Illustrations: Mike Mittemleier
Supplies: Waxed paper, minerai Oil, .y,' rubber bumpers with screws (e). We loull(l In" Oil and b\mpers at a
hardware store.
rolWJd.over router bit.
D CUTTING BOARD BLANK
Walnut
Cherry
Cut 1 y." -wide stripS from
blank. and POSition on
edge to form cutting boar\ r:-
Jj ....
,' to 1"--1.:] ".
I---.. t1 W


35W initially,
35' alter trimming
blank ends
2 ... I [
2 , '" /J )
21<>" "
o CUTIING BOARD ASSEMBLY
See more
shop-made
kitchen projects at
1',,"
#6 x 'h" R.H
wood screw
'}i," round-overs
along all edges
and comers
Every other strip
fumed end for end
""',"-diameter
ober oumpar
I r _ from each edge
83
GMT has been manufacturing supreme quality router bits for the world industrial
woodworking market since 1964. Woodcraft is proud to offer CMT industrial quality
to the United States woodworking market. When you make your next move in router bits, think
Woodcraft and GMT' Woodcraft- helping you .. .
,
Better Homes and Gardens
PATTERNS
October 2006 Issue 172
Wine Cabinet, Page 38
Tongue Drum, Page 58
Bow Front Table, Page 62
How to cut a straight edge, Page 76
Dear Reader: As a service to
you, we've included full-size
patterns on this insert for irreg-
ular shaped and intricate proj-
ect parts. You can machine all
other project parts using the
Materials List and the draw-
ings accompanying the project
you're building.
oCopyright Meredith Corporation, 2006.
All rights reserved. Printed in the U.S.A.
Meredith Corp., the publisher of WOOD
Pattems. allows the purchaser of this
pattern insert to photocopy these pat-
terns solely for hislher own personal use.
Any other reproduction of these patterns
is strictly prohibited.
Bow Front Table, Page 62
Wine Cabinet, Page 38

CJz3:
wow

u.>

CD
Q)
::s
Cl
c:
0

to
Q)
::s
Cl
c:
0

"<t
Q)
::s
Cl
c:
0

C')
Q)
::s
Cl
c:
0

C\I
Q)
::s
Cl
c:
0

Q)
::s
Cl
c:
0


0/16" slot 1%" long, centered
HOLD-DOWN
FULL-SIZE PATTERN
(2 needed)
SV2" ----t---------;

How to cut a straight edge (Hold-down),
Page 76
Tongue Drum, Page 58
Z

w


Q.Q.
@ OW

(i)
I
..J
..J
;:)
U.
@) @) @)
1:: 1:: 1::
co co co
a. a. a.
- -
'0 0 0
c: c: c:
.Q .Q
0
Cti Cti
(.) (.) (.)
0 0 0
...J ...J ...J
4 V4" rabbet 1/4" deep
1 V2" t--
i:D
OJ
U
go;
0
:e
4V4"
4V2"
"TI
.,
0
V4"
\J
~
...
-4
Q)
tT
I .. 6 - - - - - - - - - - - - - - - - - - T - - - ~
" I ..'iii
Location of part ."
Q)
CQ
- - - - - - - - - - ~ - - ~
CD
en

32"

N
Waste
Cutlines
12"
N
:..
t
Wine Cabinet, Page 38
---------- - - - - - ,...----------,
\-f\

\ 1 \,
: "
\ \ ....
\
\ Q) \,
\ \.
\ Q) ';
\ ';
\ \
Q)
c: ;
Q)
c:
'0
o
LL
en
Q)
en
' a.
OQ)
EQ)
'0
.U)
;.;,;::
)(
8 I -
__ \
Q)
c:
'0
o
LL
en
Q)
en
to'
OQ)
EQ)
'0
.(0
;.;,;::
)(

. '--_____ ./. _______ L...-__ ---:: ____ --'
__
MabIle SawIng & RoutIng
Center Plan
OP-()()271 $7,95
Download any of these woocIwortdng plans at the prices
listed above, or have them mailed directly to you for an
addltonll $1 each. To download a plan or to view a larger Image,
go to .ld I"'" 11 ..,.....
Call"" free 1 ...... 31 4471 for paper-plan credit card orders
The next energy crisis could strike
lit any time! Will you be
Price breakthrough! Power DR iI,mand for:
This tOOOW
priced undtr $15()O' -
lhat's $650 1ess lhan
Comp." AI, sm.99 """'" $

, " WAS:..$2OO;tm
Hem No. l fA94-SOS39
.... m n; 1m nitride coated Act today & get
tol tner bits last longer than choo for I ...
ny bit you'.,e e"er olNned. 1:'
201'<.
offers performance '
stand.rd suel bits
can't match! "
They feature --=--
318"
titanium nilri(k coating &

for smOOlh, burn-free
cutting. mclude: 1/4",
In". 9/16",
5/1(". 1111(>", 71g'., 15Jl(''', I",
11/8",1-1/4", I-JIll", I-In", 1-518",
11,04", 1-718" '" r. AIL bils tr.t':I" }" have
WI .... lOOIb Ik!;ip. Come, wllb OOx.
Compare At; $79.00 $ 'I" Compare .
WAS:.8:lD:99 2 ,.
Hem Nv UA94-56443 Item No. UA9 .... 56319

and America blows away the You'd pay hundreds more Get this 12V blower for under $40! It you purcha.ed these
You' d expect 10 pay up w!hl timcs!he router bit. separately!
price roc a oordkss rechargeable blower A ((ream bu)' for wood
of this quality! For qrnct cleanups uftrr "orken ... JS high-quality
l)'I()\\<ing (II" trimming cleaning up routef bits rOf
0)1' the Hoor. nothmF. beats this 51.14 each!
blower. lib 14.000 RPM motOf gale im;redible
force llimdl; ot 120 MPH to send debm flying huge of
without cumbcrsome cords or expensive that Jet you
AI.o 1\ built-in heavy-\lut)' rechargeable V-grOllVe, trim,
battery ..... Hh up to II 35 minutr run time per chamfer. and much
ch'''ie, bli:htwei"ht, etl/onolllic design more with pmfe>osional re.'-Uh. every
easy to maneuver and II detachable noule. rlmc. BilS hi\'C 1/4" lind solid
COIDp<lrc At $149.99 $39
99
* carbjde or carhide lipped tor year.; of dependable
11 HaT ' '-JD \lie and ckan cut, with a wt'W'kinC em;,r of IcS$ than
" RIC '. l' R1('/-" r* 0,2 mm. B,l scol1lc in a ..... oodc:n !iIIor.gCCIISCllillh
,
Item Nt! UA945734f1 Ship I,bels 10 l etp llIcm clcln and OIJllnlzW..

Prh:e ",nO;li $to.OO Ptia: COOlpare Af: S399.99

before n:1Nte.1S otrer Ili'JMIb. rOUR PRICE
No. UA9456M2
You'" Find
Of PfOducts

overstockS
Uquida';ons n.. 8Mt v.I.", O,;.."t C'r hK tk /I..,.t&",11
priced 1
0
1-800-229-2901

24 hours a day,
7 days a week
save money Somc IImltl\!1oru may "pply.Ask YOUT for dttl\lt,.
()YenI'eight have dramatically reduced !Ihipping.
pack more workshop
If clutter and cramped
floor space best
describe your
workshop, fight back
and win with these
space-saving ideas.
N
obody plans to up the shop; it
gets messy for lack of a plan. If
you're close to owning an unwork-
able workshop, devise an organization
stm\egy and take acl100.
Every woodwol'ker'scluttercure is unique.
so pick and choose the ideas shown here that
suit your situation. Whichever solutions you
go with, yoo' lJ first need 10 do three things:
Define the boundarlel5 of your shop to
determi ne how 1T1 U1..:h space you actuall y
have, Remember to think verticall y. too, not
just wit hi n your shop's width and lengt h.
Decide what needs to be kept within
the shop and what could be moved else-
where. Then list the you need to
accommodate immediately and envision
locations for tools you' ll own eventually.
Make the same space hold more or
serve multiple purposes. Search out areas
with untapped storage potential.
Bust up the clutter
You can't organize your shop until you gel
Tid of needless stuff, so play "moving day."
What would you keep or toss if you had to
pack everything and move next week? Send
everything that's oot a keeper to the or
to the secondhand store. Tum unused tools
and loose hardware into :.omcone else's
clutter hy boxing them up for the next garage
sale. Then take nearly empty cans of pai nt
in forgotten colors to your local hazardous
waste disposal site.
As you sort, distinguish between tools
and supplies for home repairs and those for
woodworking. Box up plumbing and elec-
trical specialty tools and fixtures you'll sel-
dom use. Then store them on high shelves or
the shop.
90
Layout space for flexibility
When reorganizi ng your workshop, plan for
changing equipment or different V>'QOI.\work-
ing interesl<;, such as woodt urn ing. A si ngle
area wi thin your can serve both exist-
ing and future uses, oot only if you design it
with that flexibility. Here are 10 ways to
make smarter use of the you have:
O
Adjustahle shelring adapts to change
better than fLXed shelving, especially
for storing lumber. The wire rne!!h shelves
used here provide venti lation for lumber and
are readil y avail able at most home centers.
Run shelves allthc way to the ceiling to use
every cubic foot of space,
PlilD far the equipment you expect to
add along with what you already awn.
Tllat eould mean leaving a corm::r empty
until you can afford that handsaw you've
been eyeing, for example. If you're creating
WOOD ....agazh O<:1obu 2006
into less space
a shop from scratch, add 22O-vlllt outlets to
power step-up machinery without the hassle
of cords or rewiring.
A Mobility = flexibility. Even if you
don't have to accommodate pari::ing in
a gardgc shop, put equipment and storage
cabinets 00 casters and mobile bases. That
leis you use the same floor space for more
than one task, speed<; cleanup, and makes it
wvod.Jnagaaia . c:om
easier to accommodate new equipillent as
your shop expands.
". Look ror neglected spaces to add
W storage. A cabinet on wheels can he
stored beneath a tahlesaw extension and
rolled out to double as an assembly wb1c.
Also, store loose parts in stacki ng bins
beneath. jointer tables, between the legs of a
lathe. or below a drill press table.
A,Add wall cleats for a mOle flexible
W l.youl. Wall cleats give you the free
dom 10 add or rearrange wall cabinet .. as
your needs change. They also make it easier
to build or buy additional cabinell> gmdually
instead of all al once. In addition to cabinets,
can hold specializcd stOl"dgc, such as
clamp racks and tool boards.
A Create space where YOIl can lit and
W' work, Between cabinets under a
countertllp, leave a knee space wide and
deep enough to store a mobile storage cabi-
net or scrap bin. If your countcrtop stands
higher than your tablesaw top, build a roll-
ing storage cabinet short enough to fit into
the knee space but lall enough to double as
an outfeed support for the saw or other
major tools amund the shop.
&:I. Double-duty design uses half the
V space. Instead of a separate router
tahle that takes up more floor space, drop a
router table insert plate into the tablesaw
extension. This arrangement lets you use
the same fence for two tuoh.
A.Make a place for wood scrap!. For
W' pil.'Ces too large for the IrJl>h bill too
small to store with your lumber, build a
mobi le scrap bin. That way, you create a
source for small project parts, scraps for
testing blade or bit or just material
for buildingjigs.
r.'\. Fit tall tools iDto cornen. Use gaps
W between benches or cabinets and walls
to store tall, narrow tools, such as a drill
press. Mobile bases make it easy to move
tools into these tight spaces.
steel leg stands with mobile
cabinets. This keeps accessories close
to the tools that use them, creates a hefticr
tool base for greater stability, and relieves
of the storage burden on your other
cabinets and drawers.
91
o
Custom cabinets: Think inside the box
O
Bump up wall cabinet capacity by fil-
ti ng them with clamshell doors. Use
the inside cavity to hang tools., or fit it with
shelves to organize fasteners and loose
hardware. Then customize the outside of the
door for hanging storage.
6\. Add dimension to storage. Perforated
hardlxmrd ca. .. y-to-i nstall
storage. bllt alternative methods use space
more efficiently. Instead, buy or build cabi-
nets that hold more tools in less wall space.
A Add cabinets that create storage within
W atorage to hang tools and organize
accessories. The accordion cabinet (page
46) UJ..eS two intf.!rior ooon; with perforated
hardlx>ard for layen; uf hanging storage.
o Replace space.ealing drill and routel'
,., bit packages with a storage cabi net
that hold .. everythi ng you need. including
wrenches. and
A Use slide-out trays ill base cabinets to
provide access to the contents with
less bending or kneeling. For a simpler
alternative. fit cabinets with adjustable
shelves to keep tools and supplies from
hcing heaped un each ulher.
92
A Customize drawer storage speci fica! ly
W' for such items as planes. chi<;els, and
saw blades. Allow space at the top of the
drawer to hold a removable tray.
a Make 1001 or task. 5pecific trays, such
V as this portable chisel lray.
simi lar trays for turning ur measuri ng tools.
Rock or roll?
A Use cabinets instead of open shelves to
W keep dust off tools and d uller out of
sight. If a cabinet and coontertop arrange-
ment such as this one doesn't fit your work-
shop plans. add storage beneath
your workbench for increased weight and
stability and to keep lools dose to where
you'll use them.
Mobil ity onl y goes so far in the shop; some items are best left with a solid foundati on.
Use these guidelines to decide what needs to be rock solid or ready to roll.
I{eep these rock solid Make these mobile
Workbenches. Put benches on Saws. On a mobile base, a l ablesaw
wheel s only as a last resort . can be swiveled or moved to rip
Workbenches are best planted in large panels and tucked out of the
one spot for greater stabil ity. way when not in use.
Lathes. The vibration of a lathe Drill press. A mobile base allows
makes it a poor candidate for mobile you to wheel this tool into a corner of
bases and casters. If you need the shop when not in use.
mobility, use wheels that retract
Router tables. Shaping long stock
completely ar law, removable rolling
dollies.
is as easy as wheeli ng your roul er
table into a wide open work area.
Jointers/ planers. Joi nters can be
mounted On bases with retractable
wheels. Planers can be attached to
cabinets with locking casters.
WOOD ..... g-.slne OctDber 2008
Space-stretching
tips just for
garage shops
O
NO space goes to waste. Put that area
above your garage door to 'NOrX by
suspending a platform beneath the ceiling.
It's a h<lndy spot for lumber. tool cases, and
household items you muved aside to make
room for your shop_ Just make certain you've
firmly connected the framework 10 the ceil-
ingjoiM. ...
Need temporary storage for a couple of
long pieces of lumber? Rest them 011 the
garage floorcentcrcd between the wheels of
your car. Raise the boards off the floor using
scrapwood support", and cover them to
guard against vehicle leaks.
Up aqainstthe wall . Sheet goods Jean-
ing against a wall space and
tend to w.up. Solve both problems with a
simple bungee cord. Mount eye hooks into
the wall studs more than 8' apart, cenler the
panels between the hooks, and pull them
tightly against the wall with a pair of bun-
gee cords hooked at the middle. Most panels
are 4' wide or less, leaving plenty of room
for shelves above your sheet goods.
.:. Put high walls to work. Not all storJ.ge
.::I needs to he within easy reach. the.
high in your garage (0 add one addi-
tional layer of storage for items you'l! use
infrequently. Mount Gfhinct" in the space
above your car hood. You'll add storJ.ge with-
out sacrifICing parking space .
Written by Robert Wilson
Illustrations: Bri lln Jensen
Use every cubic
foot of your shop
Even litlle changes can add up to big
space savings. Here are five more ways
to stretch your shop:
In basement shops, drive nails or pegs
into the overhead joists to hang clamps
conveniently close to your workbench .
If you can't foresee when you'll have
time to build shop cabinets, don't wait.
Get started with inexpensive, ready-to-
assemble cabinets from a local home
center. Then cllstomize basic boxes
with add-ons, such as router-bit holders,
tool racks. and additional shelvcs.
Handle every incoming item ooly
once, For example, don't leave that new
box of screws yoo just bought resting on
your workbench because you're in a
hurry. Take the extra 15 seconds to store
it now and you'll save youn;elf 15 minutes
of clearing accumulated dutter later.
Don't stop with your shop. Add or
improve storage throughout your house
to create places for items that don't
belong in the workshop.
Create a limbo box for all those doo-
dads you toss into your shop when you're
in a hurry thinking they're too handy to
pitch but not ready to When the
hox fills up, it's judgment day: time to
sort the trash from the treasures.
93
*10661 4 pb
4170626-7 U+:'99 pb
. 70627 5 Qot:?9 pb
. 706564 pb
;1 70704-2 U4:99 pb .70725 7 hc
with lay.flat spiral binding
1f707224 he
with layflal spiral tlIodln9
D.vid l1\i.I'. - -
power tool
maintenance

i!:.-. , ...,
-;'0;

.... _-_ ..
;170708 3 pb
in WoodWorker's Book Club and
. 70691 ' pb . 70569 9 1J.+:'19'" pb "0653- 1 pb
.705848 pb "0585 5 s..l+:9'1 pb U06?2-9 pb 1t705228 pb
" 0547 5 pb .705798 ph ;180869. 1 pb H0S52 5 U4:'I9 ph
" rices ar!! publishers' li st prices.
1170713-3 1,2.4.B9" pb 11 70693-7 pb 11 70705-9 U4a9 pb ' 70697 8 124:99 pb 1/: 70649-9 Uok9'1 pb 1170710-9 hc
with lay..flat spiral
' 706630 U+:'99 pb 1170690-3 pb
How the Club Works
FREE CLUB BULLETIN About
-'u (1-4 tlmes per year), you'll receive
a bulletin, fe<lturing a Main Selec:tion
and 100 ,y mor-t of tt'le o\r'Id bf!st
woodworlOng books.
EASY ORDERI NC To place an
,yder or the Main SelKtiOr'l,
simply at
www.NoodWo!kefS!IookClub.com
or return your Selection Card by the
malted date. If we doo', hear from
you, we'll send Main sel.tion
01'1 future prepaid
&; handling il. FREEl
RETURN PRIVILEGE If the b1..IlIetln 13
delil)'ffi and you eYe!" re{:eive the Main
without having 15 to
notify us, you mil)' return the
at Club expense.
NO-OBLIGATION MEMBERSHIP You
hi ve no obligation to buy any merf'
books; just agrtting to try the
Club for 9 months. After lhItt, you may
cancel at /Illy time. Each you buy I
book. your wil be
tor 6 months from the puKhase date.
P.O. 8oJ< 921-4
Cffitt.Jllllip, NY
KOOt.;. 1: 1 lll ll122_9274
1-800-4411-0912
Call TOLL FRU Mood"y-Saturday,
9a.m .. lp.m. 9;t.m.-6p.m. Sat EST
www.WoodWortten8ookCiub,(om
Uncover the secrets to getting
t he perfect finish - every time!
Finishi ng guru Bob Fl exner
shows you how.
A S3.95 value; yours FREE
with membership!
Joi n online @
www.WoodWorkersBookClub.com
for an even larger
1170698-6 1l4<-'W pb " 70491-6 U4:-99'" pb
book
WoodWorker's Book Club Is a Division of F+W Publications, In(.
MEMBERSHIP SAViNGS CERTIFICATE
YES! I want to loin WoodWorker' s Book Clubl Please send me:
My Book
FREE
My 2nd Book
, ...
and My 3rd Book with My 4th Book Mr.
fREE for !9.99 FREE Gift
''LI_' _' L-'-JID 'LI _ILIL-JID.I' , I !
VISNMasterCard/AmEx Orders Call TOLL FREE 1800-4480912
9a.m.-7p.m. M-F 9a.m.-6p.m. Sat EST
I'm S9.99 plus Sl.99 shipping &. hal'ldling, for a total of just S17.98.
o Check enclosed (or) Charge my D VISA 0 MasterCard D AmEx
"'<t_ _______________ Exp _____ _
Signature-,======= ___________________ _
(REQUIRED Of MR'I'ONE)
100vi! rrod How the Gub Works and undef3/and I hove NO OBLIGATION 10 buy ony more boob.

(>\00f...r)
Address _______________________ _
City' __________ State/Proy. ____ ____ _
0I'f .. good f<l<.- ,,-. in U.5.""O Conod.I aNy. CA. (0. <:A M.o\ NY and OIl, pIN .. ocId 1.0 (.....0.
odd, .... .ond....,;1 in U.!. furok;....u.:... and C'iT for tOUIcl121.81 . Onr
_ H _10< Tho Ub.......-1IIr nght ."._.
Mail today to: WOODWORKER' S BOOK CLUB ' P.O. Box 9274 NY 11722-9274
ORm.R rom" KAK06wn
FR INFORMAnoN WORI H
INRJRMATDI WOR11t WRITIIG fOR
- take. moment to till out the
card .... MCtion Dr wtsH

IastIr IIISponSe. Order aI .. ttems
thai kItInst you. EadI adN Its wII
mallhe dlrecIty to yuu.
Adhesives & Anishes
IlUEDEnJl SPRAY-ON SU.DI '.5IiM
Lroeoox," In w;Q<'Qs. No .... 'I!qlirod. 0-
k"lcl<lr\j r ..... _ n 32.,..,.", """" """",",,100 '1'""'_
DClNJER PR:l)l.(;TS 01'- I'fo. 17.
TTTlUIOftD"''' ULTlMAft WOOD GLUI
notxro" *' tICr'>:I-...... \;r1g!r apm ...........tlIv

__ """ .. I_--.ru
Ttebliltd"iDi:::llU_...:l-.:r.....x;oj-lo>.<lO(I

QOAIUA _0 PMMIUM GLU'II
8ordo wood. _ . ...-. a!I8I1>OII. ""' rnn. h:n:t:Ibti shu'll
<XR..l.AGLJ.. am. No. IHI.
... WU
BRM'AA '" I In.st\r'og _1rlII lhI.....;.od I'nsh
n-o..l.I"Iiqo.lobloncl oA ,"",,, ...
a t'lldtk>n '" the woc<:l
HENRY FlACK INfL. Cl"," No. li0ii.
VAMTHAIII_OOP'. IIUCHN .... _nlD

-*'\I b:n F<:<m.JQIed
.....
....... 11 .
TlMI ,...WMO TOUCH
F,,1'.lC>o-;
........, w:u:I 'ZN1 W:o:I swr..-.:I Yi1 0... Friot-.

.-.Is. lNfEDClI..SCHTlO CIrc:M ..... 128.
A GUlDli TO GftAIIHO A.MD .T ...... 'MQ DOORIi
n.m.-","", et-o.os ho:7ow 10 1M rrn boO; 01
'A'IY;<j 10_.
ZAA GtItiW'lQ TOOIard ZAA OW ""-_ l.NTED
C .......... ,.,.
ZAR" WOOD ST"'"" HARDWOOD
R.OOR FINISHING APPLICATION OUiOI
ThoInlcrn"et ... .. .,.irlQ
'" r1o;toI:
unddlooo<ql. ThilolA-<:cb

Ibn. <:nI4 11M. 1'"',
Bits, Blades, CotUng Tools
__ .oacH IOOWUI TOOL vce-. CATALOG
GtI .... ...... ii_ .....
.........
bU., -..-. (U U n.
0CJ&;t1 PCWER T(l()..$ AtfJ CIrdoo No. 113-
irl
hili t:IIIrUsaNs 00II .. b;
r3

l"",..-.::t..w.fWrnl/'if"loj "
... 8.
.-.m-....
onvc a..b..,. '-.,.., roily 10 !hJp:l poo:;Uo

N:. 0de ..... t7L

q:, _..-.::t _tor., '-'Ire..,.;cth fIr-.;h, No
splintomg ortea<o..ts. r", Ii'>I 01_.
'-"G. CO, tiC. CI"," ,..._.
RUWD $AW RAN.
-n-o. coI;q a..str_ ""'II ..... ...-.:J OOr'o!fiIs lor ...
f""'-<l saw _. FnEUO. elrell No. :ne.
'MUD ROUUR .. n
.... Fto:v:lIWlf!'r bh n ., U.
,....,ta, lXl,.."...bto..-.;l __ WID. C""''' No. 232-
INFINITY CUTTING TOOL& CATALDO
$Io:t< n:i..o:Io'il """',.. bI; . fUJ. .. bI
MU. _1JIIodN. m-..s..-.::t rT\'Of

on.., orQeo-Q.Il!r 1100. N'NTYTOClS Cirdoo No. 2111.

__ "'.<mi:Ior.U.)<U __ !obU

SlW. I slta<nt rrd:lIr'-:l to" ""'""
...,_hrrd:rQ
n.Mogi<:MXWr. ..
" .... anq.d8 led. LIUt re. _75-.
... o.J5Icrn-
mIIde ct..9J. LRH ENT6'A"CSES. ar.::t. ltD.. 2318.
"'CS WOODWOfU<;INO
"-'.CS QIIIn alJ..gt!llll!lC:u1 01 o:>..IQr t:Jls,...,_
_ID'II <Xu -. __ CIJIIn. I<XI rat:xi! ta,1'oII'"or
<D.IJQ hr1d1JrQ1, b:II. au:AIos. Ffw
M.C'>tID. No. 20IL
WOODLIff.UU
t",*",. n:uon.
_ !I'fSI8rn& Pro-Gr1p to. CI8f'r1l6, Qw1(f

Ftte C&\aIog. WCXlC(JllEus,o> CIR .. Ito. 310.
Books, Plans and Videos
AJlENCAM FUItJIlTWW D .,ON eo.


McnioIdvlir ... _.
-. 1'IaItlw.n. b:X:tI, Ifld DCd<t.
CMSog. J-MfFICN; Flf'NTURE CSIGN co
",,,,,':'=' CIrcle .....
". W PUMJeATlOfOI&, INC.
S!rO b' R::nn!Io"I O"1l>.f'I<tOOIId _ ......
I'ri$hng. kit. Tbo....,.
.:>"....,." F&. W I'\.IllCA.trlNS, re. arc ........
MlnUl HARDWARE &PECIALTlII CATALOQ
lOOi>'V1, U..:dJ
r.:r r.xo 1rd 0I.IIX:a ........... dod<!..
rtt!oio;Il'oses. CfUIlS, tI:!: .. ___ t'$<).

SffCWJES. am. No.. 401.
U-UI.D WOODWOAXING PLAItS
'*>c>o lQo4/!.l-VO'<Idsol U-
aI:I!&::oqIC1 pIir<S'" to... p-cee. (:U DI!nl .... tI\'III
...... Clod. No..a3a.
WOOD lIA4AZ:lNIl WOQDWONUMO IIi'l..toNS

fI<rTIh dD:tdwx:1' .... _ t..1..,.", WI,
on;! ptJoOr1l"1 "'W::X;O :Iq>., ........
.-IadItn w::xxJP\..ANS. a...... ___
General Woodworking Catalogs
"till WOOD CIUFT CATALOG I'ItOM
CHIiRAYTRUI
M U-o;h r:ug<o><J Is on;!

_1If'd......,.
.........
lOcOs, poR ......... ........,...-d rn..d>
, "'''''''';;:, ".,... _ CIUIicO- 010FRY
ffiEE TTh'S. No.. M1.
........ --
WOn..-d __ cu..t.J1li
a::J.IPI#( ... ST3..
QfnZZL'f INDUSTRIAL, INC.
(().!-poge ....

P"Ca' GAZlLY I'OJS'TR.O(.,N)_ caret. No. 583.
HARTVlLLI TOOL CATALOG:
0..1:, 1OOIs..-d .. hi to ... poaoo oro.n::I
"-'* f"OO.lO-ih:l..-d .IQJ!I r.nl b:*i. led
aQ:IIIII; tnd lru:tII_ h -. 0.:-"
&lItly. f'IIoo:. can Ha-: 10 rano 8 _ I<H3
oe.. H.ORM..Lf TIXL CIrde No.. -.
SQUA,. DRI'II
C8'>maI<a _. 0... so
P'Q<I'S '" thl t-' l!_1 ...., _
'"-'ppl"", MCfl:ELY'S. Cllde
...... 48.
M)CKLIIt WOODWORKING. HAADWARIl
dta"d-l<:>{nj sIqJ 1COIo .-.:1
MeI<e)(:V""""'n1ho$tql __

-"- Ft(X)<l..ER
CIrdot Nco. "I.
SCHLAaAUGH & SCNf$


SCN& CIme No. M:J.

..
..
r--.. I.srta" IInI ......... .". 00_ "*"""iOI1InI.,

FOR
_.s.m. ...
I'IO.:'O::1W'T" 9..F'P\.y CCFf' ara. __ Too.
WOOOWOAKaRS ItNtDWARa CATALOG
o....lI.OXI_"sb:t<.
I.a..,.r ..........
r..m.-a .... T'S.
Hand Toois, Jigs & Clamps

.

>nJ bem cia"r(:$. :mi!I' ciarrl:e. .,.... _>nJ_.
CIrdoo __ T'
" ... TOO&. JOURNAL
IIQJt lInI ...... flrd Io::a a..&ty ....... 1OC*ii km
<he past. lII:X>.IlOd..-. IOd IiII<:rt .-two OJ
IU teieP':n'>&Cion >nJ 10d _ ... fHI'r; .....,. W&<-"/
,., u .... 01 t..e-......, Io::a O"tlfro..r .... bIO<:tu1IlOCD,< fK
tCoO....o..H<AL .... :r:r2..
r_ INDUSTRIAL

gal9 tunlllolollnl PI""'" led a:x-""< U
, ......... ..rodll-.:l-..porD fMt".r
I'O...ISlRolI.. l'CO. CIJe .. __ T93..
WOODWOAkaA CATALOG
_ tro...:rot rI
baIUr (Jaty ,...",.. 2 tD III!
PI'09 ClllIiIoO .w>AN 'M){)CW(lf';1(E.
ClN; .. No. 7".
JUtEG TOOL CO
ntooll Wld
"'*' jonety i-"dt.dr'O .... '-' Ire d

rn:re.. llX\..

SYIR.
O.MS
Sll.lty WOODWOflKINC HAICJ t.lWI
rfUi-m ...
fliW"d_fl:t ...
....
poeo:ee. Uj CUI .... n.c tnio
w:::!Of.
1<8'0)& 1'0">:1_
_III C02\J(I. KIIT_ & I'I'o"UY\ l}f:m ....
_ TtSl..KY STCH:.. am. __ lin.
Toot.S I'OfI WONUNQ WOOD
.... ..... hnI!OOb ........
WI> ..... "'" mejor t.-mdI!.. bruiQ.>e br,..-o,., Mid tho
to""'" yw WI Iho ,.,.",. toot lot itIe j<:t>. T()(l.S
WOOO Cird. No. 830.
TRAPIT1CIMI. WOOOWO!'IKI;II CATALOQ
0..0"'" 98 pog!OI p(Oo!d Witt> "'''*'' tu-d ted; b

'MXD....::H<Bl CIrdIo No. 831.
Hardwood & Lumber

...... lrbeI.
b.<t; b_ few tt"o!!taa
BEfV\ HAfViI<OCOS. C_ No. MoO.
utT'IlIMn-.cOM
i-fI;1l!JJiili:) _rd..ate _UTtlef omll..-..g
__ on -.,. lind """ tuOI!d t:aoro_
t:<.rdo!o. WI1I cJ _ uni"lg !nl PM _. fI.O<Ctc
....'" bl.rio- t.lTERNE"TtlMEeACOM CI"'" ...........
ITHE M. WALl.. LUM15EII CG.
ald_lnOO-. WI>hp Lt'SOf
,,>OIe.. CaI<>;j. STBIE H. WPil U.M3ER
Q:J Ci ........... 8M.
WOODWOItKIId KlUt'lCI
0... 100 kmSW""d .... <Qtj. W'rI:>Ir_ ..........
$rlt CUrIIly dnJ.r"C!llFS (J t\rlo.
II'mwiflfd v.o::oMH<lR'l s::l..H;E. _ ..... -.
Income Opportunities &
Education
WOODMoUTIII ","UI
r.<;I"r>-poIeoI ...,.. <.-110 roM! )OS r.:tno. Q-YlOgIe.
_. dO'ne$t>:; WOlet. pod om -. DIeIe<
l.WU.ACTtAf.IG;. t.C. cr"" .. No. IIH.
t6 TO OROEI PUASE USE THE AnACMED CARD OR VISfT WWYr.WOODWOItIetSCent.com
Kits
IUlLD 'fOU1t 0WJ0I MMILT HIIRLOOM
Cdo:rio Tl",," Cb::k 00d< lolls. pIIN .....:l
'972 oo.ONIAl T1MES
CIrc. ....... _ .
"'..."
n.108dI .... <1 "-"Pie!J I;)r ""'"' ;>5)an:
a...tt &"d dod< __ 0ieI!I, -,.-10-
_ p\IIr'S III>:l """ let .II oI<JI ........ KLOCIOT CIrc .. Mil. '7;,i.
IUILD MUS:AL IN.TRUM .. nSl
KIt&. pIiIrw.. 8I"Ioj b I'f\III<ng hotpo. <U::irnIn.
nu:fI men. MUSICMAKEKS l<ITS.lNC.

WOOD.oAT KJf'S
$nee
l.ltn<o;t; woodbOolt I<;M. I(b ""'pier<I....-,., P'Y'(;M(
80AlS, NC. Circle No. 813.
Miscellaneous
....... ANI ..... IUCAIUTTLR GIANT
WIt .. 3M ..-A SeIiet:t P\ul>::fla i-dlri-Q ...
...,....,.-d J>85 r"IIIQIiIlIM NoIPtMOrs. -., ci 1<1<n
Throd ..........
P)<1mIoo:!;il<:aI em lillie GionI Uo:rln ... ....., ""
lV tON.
AMII'UCAN STEIL SPIUI IULD1NGS
....... rrhj. CUbJllc6vl .... rm1t".
t-,. __
Ift"d'IId .-dis tela A<J.'*>' b..bXI
...., .... n:I S8\.OnI '*O'tY pahll-..;t'OtOWlIIbd. 3
rnxII!II kldlCO'lO! t.:m RTEC S1m.c:cA'_ am. ..... to.&.
HOT OA.WO- GAMGI .... "....
eo-.l ..
r..t _ 0( hd; II;u ""'" to r.:w. klm 0'''' to) M-
l1li QIRQI'L 1-OT()ot,,\Y.'i GNW3E I"ATIHS. CMIIoo ..... 11M.
PLANNINQ TO IUILD'
__
It'Id tluIIto IrON . ...,
Xl_.......,
eire .. No. U'"
AAOIAMT "'001'1 COMH.NY
CN rUJ1: I'af. "M:6: C'l "'"..,...
row: '1'lOJ .... .....". kU'I:la "'-' lruui FrooJ
dBoI{J>"""'" fWlA'IT a.- ..... U01.
Power Tools

<:A POrtICIIt _1tI".,.
irdIstty 1OOay. Fnd 001 1'IQw)'<>J 100 CiIf\ pmtiIl'd1. 6eiIf.
BAKER PR:DlICTS CI ..... No. ,.28-
.... va Ma.v, .... 1(I: MONDY
""*" l wtII-og 'f'J'.I ""'" I.n"t>of ........ Ao T,ac
... at ...
CCO<:'S s.o..WMf'G. LL .. C, CIrde _ 14M!.

rd 1'.b.>(IW p-...,. IIotd'io'M on::I
ICOIUO<\III USA. rid car.::a, !Nt
TH:: CIVFrSMAN GAlLERY,
CI ... 1e JrkI. 14l1li.
DRILL ooeTOfI DfUU. lilT &KoUIPEHE ...
9wp <tl bO IInpIO.'e h <III"O'J profICtL $Iwpra
:l.I32" 10;11(' Dt.,., 1Ibco.J. _. F_ -,10 .... err!
"","CHI Oocb-._ -rfna
1'Ia.....-m ORlJ..OOCTOt eircle Mo. ,." .

_
,
_ on::I """" oct. fTU3'dI,. 0ebI0Ied
co..-n
r<lri:1 EFU:lG.
c:troMt Ma. 1115.
'lIN "<nInR fOOl.l
"'" mctQ 1lo:;:o;t; I<n I'V""....-dro i.TQ. .. _ , ordI;
Ib'QIdQII /nJ '" oc:mn. I\I'ri"\;l
h_" .. <iII'"Ct I'W'OJII' .-drg;wl. CCJTtre::1 hI;t1
Gtmm ..-8o:xtutI n:-8III"dIr" ICIO;n
!'B-IPO<MRTCO..S. a..... _ 111a.


PlQllalp;wo<uuom Ffe..V, <:Otae ..... 15ft.
oaHlIIW. AND G.:NlAAL Ilf1'DIHA,noN.u.
,..0.:.. ... o...- r<l
pori::rmro It.!
_....-.:l 'TOp b:t' ftUI <1 'M'XD
HfIR'oIO,TD-W.. a.dII _ 1MS.
__
..

U,S" cs.... _'ML



rri<f<>-"'*-"l4 1..-. un/<.A.....-n
CIf'cIe _ , ....
lilIW MI'ORCITM COWH..U$ gRILL ..
Th& DOl $In .. flQOI_1iIbIe .,...,
D.nbIIy, Puwe-lO"d
RslTm&.
().Jl 1l"J.ltC:r. __ .. ...-.g.r .., lcd<'" ()?,<o
on::I Sf>It loFclPoooe- on::I sro
ba.i:ro::h.nL MAAlT",USA. r,c, am. No. HI10.

- .

-
.
... c. __ L &0 M1I1lWR
Tl"o. PO'-"-l and ,...". ).1/2' HF V;J;\8tM
.. a<l)"


SWI.
I." err!1/Z" _. St"OIft loti< b'--,. r;.
ctwvoa, on::! rru:i"I """",,, WIth e r-.rdy

,
,
i"'d,.o;Ied, FtM MLCS LTD, CI ... 1e Ito. 'Its.
.... T1It IY
o::nJ8Ss led \PO" "'*

IloIIIeo'i lie, Pr:II!e"'--'rOool dllt twr'olrs, prj to;ot .....
.
.. WARO .... NMlNC OUST COLLliCflOH

....... /loods, ,emote
_""-. 81c, 40-P8OI' n. caIIlIo;I. PENN
ST,o,TE N:OSmIES. CI ... 1e Ito. 11n.
n. CAT.u..OII
..

p>:i..dion eq..iporent 85 _ ... tho An.sIil ..... F'CMIEJ'\MATK:,
<: .... 1. No. , .. .t.
ItIKON POWER TOOI.&


.......:e, I'ocl.o::Ia nct..Ot: D-I n-.b'1IIrI.. Sro:Ion..
. .s;TOO..S Clf'cle1to.1&71t.
TOOLS I'IC.
S. per! cI tt"ot 'cOolie tool v.tI1 MS\IIO UN
t:O'1IrtIIIO ro<.oton b" proIe-...oOcnaI o.nd I>i:.fM-bo.OOId pt<XlucU:n
BuI CiOft UIWIe. eign3, 3D car..-.g .......
SHCP8OTT<:O..S I\C Clrefoo _ Hi4.
IffT"AOOUCINO nUL CITY Too.. W()fQ(s. lilY yoo...
oun.. '011 foot. oun..
Ronwnbo< ""-' !hiro;;JI--.!luI; 10 _ a"lCI """""" r.--,o: LahIrJ
\0 ... ",""",1 Thell the bonn:! SIMI ary 100
We Iin.....-.g OU" 250"..... cI 10 tmv)W IOOIfIlMth
a Iai' pt\c8, on::! \tl8 k>o;jeIit __ 1Yltjo ., tII!l
t>.JIIi,... STEEl aT!" UXll V\Cfl;KS. elrc:le No. 1711 .
oUID HONINoQ IYSTEM
Top QUIOil"t md>., s....dM lor cobo-u
--.. """XdVTon Itld now
!I/1atpoIn on::I _ Idg& m..d1 """"' MOiI!'.-d ","" TCR-.E)(
VS .... ClI'CIe _ 1711.
-... ...... SA_LUi
Cor...ert b;I!IlliQ ....!>;>ther )W'rt. r.ovcot
SJ'N'f'tf, '-"""I a ... pa1atOe b<nIoow mil.
PootI<nli $3"MTik lila'! at $4,4\15. Send !or cu <:aI&lg, weco-
I.mA PACOJelS, Ci ... 1e No. 1800.

WOOOI1'OCK II'f1"aMATKNUoL. INC.
0... hi '" S:)P FOJ(" W<:o;lw<ritrg ""'"
.... .. Ilomo!!Ito;)ppt()l! n-fT8:t>t"g
_ mIo'l)I oddlOOlll a1cl __ naI .. _ fr"om
IrI'f _ mro1s. As!< ro- SI-O' FOX"' III 'pJ 0XiII
01 <:cr1Iac! "" _ b- 0l4lJlIer ., 'fCU
_, WXOSTCCKlNTEA'oIAT1CfoW... u:: Cite .. "",. 1824.
Proilect Parts & Materials
AIIAMS WOOO PRODUCTS
-""Wocd Produ::b
<;aIabg hiQIlIiQhti">;j tIW" ...... in Jtod; !d:j
o,o,QOd mIdII "\TIt """ ,., the
good oidUSA A""", .... <II klId>en--.::l

OIlaIOg.:illon. I'lJIWf!; Vo'fXX:! PR'XIUC!s.
Cird'II"'" fUI.
WOODWOAXINQ MRh AI)

St....-
pegs. 1</"QbI, tor _ docIo. ...,.,.........
!JOdI_1::tdoI!I. ... on:r rTOol.
0.... 3.(XXJ itm"8 n Qoct.. "'-ol!D-pogoab

w:x:t:S SU.y 00.. N.":, __ .. 831.
TO ORGER PUASE USE TXE lTTACtIEG CAIIG GIl VISIT _.WOOOWoft(..c:enter.com
OMORNI WOOD ,"",OOUCTI, INC.
are !he b:uf, d Cl!b:m> I'otOO 0::. Q.r
r. a ... '**'II aI ur-ir"QI. .....-rn i"rldoI_ .....
kNi", Nn:l ifQt. b.n11BS1 ___ o...cm
.... ....... ,.(:h.:ut.. """<OOetil
toe _. ClSIJ:R.E woc:o OOFOD...CTS. ....c, c:- _ , ....
MARl MRT"S " MNJR MRYlCI,
s..ro (l'IHio"Io rwts b ", rT"WIiO' t:.vdo. "" molt ... """'" J'OI,I
t:o...oghl thom, Do-t'(OUr1III 01 t'oIMl 00ne b 1"". SEARS
f'oO.ATS & POE""'" CIrcle No. , .
Shop Accessories
HNCH DOG INC.
IIItM. AootIioooI8ondI D:>g t>c.'lI
.,...... cll><Cel)llCnllllOOII- EIEi'Q1 0ClG foIC. Cln::1e
Mo. 1170.

........
. ..... _ ...., ITW>f "'* po::d.cts F<w
CAInEf'II'fO)",CTS N:;
1&111.
QU.l'lflEO INfM.IO TU .. MATIAI
<'8derI U:oe f"-."" "">$I.'9l
CTFOT RAaIINT f'RXJ..CTS. NC. ChIe No. 1t1:22.
MlW PATDfT_DlNO .... W...IAW
__ 1:iIaa
lCf _ Fooo tJtxf1..ooo I-Xl.. LlC _ ,_
n. COMPIIUtT
n N RIr1I:I:t> /II'"CI C\o$t Cok1:\::I1. The n
rn _ Wit18 oorJl)OIC' cIoooo!1\ rx-V rrcta, rd--..c
........" cIusI ... tJ OI'?! otq:>, The c;d:<"tes
l-mam
Tl.ff,


..-", .. """'" po<i.O; h.'ir Ao..HHJ'! Ir"a The M'II!III
AU al;ws 'PJ t>:C orir 10 .. "..., bM:w-)'CU" <OJ\I!I< tcm theq:,
cj .... IIbIttllA IIIOwI b .. yr.ubil I;:op ......
..u.;e ... TOCt. (X)I.,\O,NY, C_ No. 1979.
_TURI MnlIRS!'OR WOOO
....... """""""*'" b'","""",
pin rod piO.-. ""'" ..
6oIIs. _ b"cc:n:;tfC,
end Ffe!! ce.tabg LJGNCt.MT USA. LTD
C!rcl. Mo.
DI.ICTWORIt CAYALOO
F_ """"'U coo-.ao .. Olf"tlXr8l1S r-nrlng
eboooooo, ppe. .... F..e
$100 _ So'o'oI
(l'f'no., "'" S"YSTEMS. iN:. CIrc:M Mto.. 26M.
--
CfIn toeIlI, O$C&. r"OIII rd troMtI.
p!IcIito dn!cII)i to tt. .,.... CO"OtIJnI<. M <lngIiI
a IlooI< & Ioq> tu:I<o!d ..... _ --.on rd
"""" 100- """,,,..-don, otq>rolII b """"" ....... ,
li'I IAJlbarIiI a..::....-d
t'IIb. b' I'lUt'\' 100II a.d"> 85 CII'IJdI tu\'1.,
p::rrts & """'-'<tb. mn <tu"T1o & .,.. F_ 48-poge C8tat:g."...,
_ fti) HlLCXW _ 206IL
Woodtumlng Supplies
....... KARDwoooa
Q.JIity pen 1<119 """ _ ,."........ kits, Wft ....
""'"'11"""" 0IfId mao'Uf"",-, '" rq.
....., pen b t""""" ElEF,to
No. 11.17.
"",.-.en
I!llVo&. ""*>,<d_
HflPA:n..CTS ChIoo _1131
designer's notebook
mix-and-match
cuttingciboard
Simply alter the blank for fresh new looks. eSlgns
l
enjoYed coming up with the design for
the cutting board featured on fXJge 82
so much that I created lhese additional
designs (Of you to try. To pruducc the
patterns. combine concra"iting wood strip!'
of different widths to (onn the cutting boord
blanks shown below, making sure that the
blank wood patterns-when reversed-<Jff-
set all of the joint lines by alleasl
Although there's no rule for the strip wktths.
I kept them between M and 2 W 10 take
advantage of narrow scrap-bin rippings.
To make either of these cutting boards,
follow the instructions in the refereJ'K:ed
article, cutting the blank strips to the widths
shown below. Or if you feel adventurous.
try your hand al a new design. now that
you know the offset secret.
Design Option 1 ",c:::=. ,;1 round-overs along
... II edges and comers
Design Option 2
98
-

R.H. wood
-r---- screw
__ ."-diam. rubber bumper
T l' in from each edge

___
Cut 'v."wide Sirips from
blank. and posilioll 00 edge
10 fOl'TTl cut1ing board. '
,
:Y.'to" initially,
then planed to 'VI" ---1"""'1
w )

,):J !:IlItI. '"11111111'1,1
blank ends
rO\.lnd-overs along
all edges and comers
'(ham. robber bumper
, . In lrom each edge
Forrest Blades
Serioos woocfwor1(ers count
on Americanmade Forrest
saw blades for smooth, quiet
cuts, everytime ... without
splintering scratching or
tearouts. No matter what
your application, Forrest
blades are simply the best
money can boy. That's why
discriminating craftsmen
prefer theml
"[Your bfadfs} cut true. with 00
vibritiOlJ. I can say Wlffl confif1eoce
that Forrest blades are lJJe best '
Carl Stude - BuTbank, CA
Our Most Popular
Saw Blades:
WoodwOfkIJ H This award-win-
ning a11-purpose blade Is the
finest of itS type.
. Produces pertecI
milan; with smooth edges
... and no bottom splinters.
Ask for FOlTBSt blades at a fine
dealer or retailer. Ofder online,
()( cal the lactory directly. Your
satislaction is guaranteed ... or
money back!
www.slol.es.yaI.loo.corWIorrestman
1-800-733-7111
(In N.J, call 973-473-5236)
CadtWM
With other 'Wax, your world
appears b c: &
JessEm

INTRODUCING OUR
NEW W()()o'DYES
BIUll',u Mt ...., ..... .
III.'i1i'J.o.W ... .... w..t
D,oooXl. . ....... oI .... ...
....u ..... 0..0. Iot-..
...
.................. b. .
..... .... w.


Love At First
Slide!
JessEms New MastRSlkl e'" Precision
Sliding Cross-Cut Table is the ultimate add-oo
for your table saw. Thirty double-sealed
precisian bearings in an innov(ltive linear
guide mechanism provides an exceptionally
smooth and accurate Cfoss-cuttlng soluUon.
Fits most tablesaws and offers a maximum
cross-cut of 36 inchos. Upgrade your saw
with a Mast-R-Stidll n. from JessEm Too today.
VOOI
C.II,866-212-7492
shop-proven products
These woodworking wares passed our shop tri al s.
Planer-size drum sander leaves a smooth
surface and saves you money, too
Anythmg that eliminates the drudgery of
hand-sanding is okay in my book-that's
why I u<;e a drum sander. Li ke most home-
shop drum sanders, mine fealUres one open
end thaI penniu; sanding pieces up 10 twice
as wide as tlx: drum. It thicknesses as
reliably as a planer (but s]O\ .... er). and leaVe!!
a finer finish on my workpieces. From a
space slUndpoi nt. though, a drum sander is
just one more hig tool I have 10
walk around.
BUI Grizzly's G0459 Baby Drum Sander,
wi th ib 12x2r foolpri nL takes up only II
lillie more room than a typical benchlop
planer. (A Ithough, at ISO pounds. il weighs
aboul lwice as much.) And, like indust rial
scale drum sanders. txxh ends of the
G0459 are closed. That means t WO things:
1bere's no deflection of the drum, as you
sometimes can find on open-ended
Another feature that separates the
00459 from other drum sanders: its
conveyor belt that pulls wood through
the machi ne. Most use an
abrasive belt, but this sander's
rubbery belt (again. borrowcd fmm
industri al drum sanders) seems to
grip better. And it tracked true right
oot of the box.
You won't wa .. tc any time getting
to work. because the sander comes
completely as.<;embled. save for
installing the cr:mk handle and dust
port. I was surpri.'!Cd to M:C only a
2lh" dust port on the G0459. but when
1 hooked it up 10 my shop vacuum
and then sanded 10" -wKte walnut
boards, li ttle or no dust escoped.
Hook-and-Ioop sanding 3"
wide, make changing worn
a breeze. The ends of the abrasive
tape down with tape. which
isn' t as sexy a ... fancy cl ips, but equally
effective.
Baby Drum Sander G0459
Perlormance
Prioo
GriZzly Industrial
*****
$425
sanders; and you can't sand anything wider
Ihan 12", I'll bet that 90 percent oflhe
PieceS. I shove through my drum sander
measure less than wide. so that
capacity is plenty for me, -Tested Or Pat LOW/)' 8OOI523-47n; grizzly.com
Full-on clamping pressure with a flick of a lever
Remember the days when every clamping

operatlCln a chore becau:>e you had to
II handle or cnl nk LO tighten the jaws?
Pistol-grip style har made the job
easier, bot VersaClamp clamping
even more with a lever-activated cam to
apply prcs. ... urc. Llke.a c1amp-on 1001 guide,
you si mply sJide the movable jaw so l hal
bolhjaws touch the assembly you WJ.nt 10
clamp, and lhen push lhe lever down.
Instantly, 400 psi of pres.<;ure is applied to
the joint. (By comparison. pIstol-gri p bar
clamps deliver ahouI 200- 250 psi; II
threaded-jaw damp can go to 1,000 psi.)
Optional mounting ___ _
Mount a VersaClamp to the front edge of
your bench (or sawhorses. as shown at
n'ght) usi ng the optional brackets, lind it
acl<; li ke a tail vise and bench dog to secure
a work piece whi le you v.urk il. You can
still eosily remove the clamp for handheld
use. bur the [lfOt rudi ng hmckeL<; left behind
tended to eatch on my pockets. ] wound up
leaving a cltlmp in the brackets most of the
time 10 prevent that.
100
bracket s
The only othc:rduwn .... idc i"thc price. A
20"-capacity VersaCltlmp runs $35-about
the same price as a '24' 8es!iey K-Body
damp that boaSlS large. parallel jaw
and more clamping
-Testeo by Randy Zimmerman
VersaClamp
P8I'formance
Price
*"*""
$35; mounting brack&l S, SS/pair
T.S. Tool Co.
6 121933-542 1; Istoolco.ccm
WOOD m.agazin. OeloboN 2006
Stop bleeding:
Nip workshop nicks fast
When you told your wife you 'Were going
to the shop to stain a project. you probably
didn't mean with yuur own blood, But any-
time yuu work with cutting tools, there's
always a chance that you'll cut yourself.
QR powder-the same stuff used by spor1..<;
teams and physicians to stop bleeding- is
available for your shop and home.
Recent ly, a bench chisel "bit" me on the
finger when I instinctively reached for the
tool as it fell off the bench. The cut was
deep enough that 1 would have had to stop
what I was doing. and go in the house to
hunt for the antiseptic and a bandage. TOial
downtime: maybe [0 minutes.
Instead of a bandage, though, this time I
cracked open a plastic bubble of QR
powder. painlessly poured it over the open
cut, and tamped it down with my finger.
Within about 15 seconds, an artificial scab
had larmed. I shook off the excess powder
and went back to work.
QR doesn't contain so you
still have to cleanse the wound from dirt
and contaminants to prevent infection. I
forgot to, but the next day I notked that the
cui area wasn'l red, tender, or swollen, so
the "instant scab" works as advertised,
allowing the healing to begin quicker.
-Tested IJy J6" Mertz
QR Quick Relief
Performance
Price $5 (four single-use applications)
Biolite
80017227559: bioIite.com
cOIl/i,U/cd on r,ag( /02
Warm to the comfort of radiant heat
Floor Company '

IJ
LOIIVEST PRICES __
UNBEATABLE (,lUA,LI
112" Shank Router Bits
2-pc Rail & Stile
(Roman Ogee)
01'3'11'1:[ lock
3 114' 0 Panel Raiser
(Ogee) wt UrmrCutler
{)oo( l"
ReYefSlbIe Glue Joint
ONLY
Portable design for ease of
Quiet deluxe cabinet base
Laminated 12 ply birch
13116' ultra flat lop
Deluxe fence system
Fits all routers with
up to 3-1/2' diam. bits
Add thaI extrl Ilttl<! touch to
your handcrafted
table "dg(>s.
pinu.e frames, cabinet doors
and so much more!
shop-proven
products
Remove damaged screws
with GraBit
In 10 years of woodworking, I've damaged
more scfe\vhcads than I can remember.
Soft brass screws are the most suoceptib1c,
but even the heads of today's inexpensive
steel screws tcnd to shred under the
influence of a cordless drillIdriver. Once
damaged, you can't drive 'em in, and often
can't back 'em out. But GraBit screw
extractors give me a way to hack 'em out.
Eaeh end of the GraBit bit has a
different function: The burnishing tip
bores <lnd smooths a shallow dimple in the
messed-up screwhead. Flip the bit around
to expose the reverse-spim] extracting tip;
then use your drill/driver, slowly, in
reverse. The spim] bites into the dimple,
and oot comes the screw. Thc key, I found,
is to create a smooth dimple for that spiral
to seat in.
To GraBit, I intentiunally bunged up
a Phillips-head brass hinge screw so badly,
I couldn't even see where the drive slots
had been. To my surprise, the burnishing!
extracting process worked exactly as
advertised. In fact, no matter what kind of
screw I tried it on----steel screws, drywall
screws, screws, Phillips, slotted or
square drive-GraBit worked in them all.
The 2-piece sct works on screws from
size #6 to #14, and should be in every
woodworker's toolbox. The manufacturer
suggests not using GraBi! on screws longer
than 2". Such screws provide more
resistance than the extmcting tip can
overcome.
Extracti ng
tip
-Tested by Pat Lowry
Gra8it Damaged Screw Remover
Performance
*****
Price $18 tWOiliece set)
Aldan Corporation
600/8325336; aldn.com
continuHI VII p(jge 104
102
Don't let a cold garage take a
bite out of your woodworking or
home fix-it projects. Handle
all your handiwork in shirt-
sleeved comfort with a
Hot Oawgf' garage
heater from Modine.
Hush-puppy quiet warmth from natural
or propane gas.
Lightweight, easily installs only l ' from ceiling.
New separated-combustion units use outside
air for:
- Greater heating efficiency,
- Increased durability in dusty, dirty or humid
workspaces.
You don't have to go fur to find a Hot
Oawg. For a free brochure and the
location of your nearest Hot Oawg
source, fetch your phone and call :
888-288-4991
Energy EffICient Garage Heaters
www.modine.comlholdawg
..ffii'bD'NE
c ModIolI MatlulIICI..mg 200II.
Hell o.wgof _ IN Hell o.r..g logo ...
NgI5t_
!Mny!M>t","II ComP"!.
Love Wood?
" I really lo-ve the proceu of
thinking through how a
cabinet goes togeth"" ... "
Mike McGlynn's
fumlture appears
in houses on the
Nlouonal Register
of Histone Homes,
Woodworking IS
hiS passion
Whether selectlng
wood, hlordware Of"
the perfect finish,
he coon1$ on
Rockier to provide
quality tools
and supplies.
Check out how we can help feed
your passion for woodworking.
Get your FREE catalog today!
ROCKLER."
Code 70S
_.ro<:kler.com Stores mrtionwide
12 PoIition
Indexed Head
CildeNo.6111
12"x 1.
... ' ".
6SpHda
Speed Range: 430-3900 RPMS
SeIfEjecting Tailslodt::
211'2" Ram Travel
Carrying Handle
8" Tool Rest
ucts
Dust Deputy puts the cuffs on sanding dust
A conector gobbles up created
by machines such as a tablesaw. planer. or
jointer. But for portable power tools with
!;rnall dust 11 shop vacuum
more effectiveJy-that is, until the
fil ler becomes choked with fine If
only someone v.'OUld come up with a device
to kC(.'P my vac performing at its peak by
preventing that dust pack.
Oneida's Dust Deputy docs Jusl lhal.
Connected inline between the 1001 and the
vacuum. this heavy steel cyclone separator
octs like a full-size cyclone, allowing only
the smallest particles to get into the vac's
tub. I'll admit J was skeptical, but my tests
made me a believer.
After washing out my vacuum's tub. I
i connected its hose tn Dust Deput y's 2" lop
. outlet. Next, 1 hooked up another hose (an
optional hose kit from Oneida) between the
Deputy's lth" "ide inlet and my random-
omit sander. Finally, J hogged away a scrap
of bani maple with 8O-grit paper. After 10
minutes of sanding, I stopped and popped
off the vacuum's lid. Only when I wiped
the inside of the vac lub did I -.ee a truce of
dust. On thc other hand, a 4uick check or
Dust Deputy's lO-gallon steel drum
UIoW\:d lhe interior
completely
coated with
fine maple dust.
Thinking I
hadn't chal
lenged this
mini-cyclone
enough. I
thoroughly
cleaned the
we tub und Ihe
drum. hooked
up my hig drum

sandel' LO the in let, and again fired up '-.... ...

the vacuum. This
CO
2
Laser Engraving,
Cutting and Marking Systems
Starting at $9,995!
Unmatched Quality, Performance and Reliability.
Adding engraving
capabili ties to your
business has never
been mOfe affordable.
Engrave and cut photos,
ellpart. logos and more . and
it's as easy to operate as a printer.
Call us loday loll free at 666437
4564 to receive a free brochure,
sample kit and a CD demo of the
system In ael lon!
EPILOG
,., ee
EPILOG
..... .,.
16371 Table Mountain Pkwy . Golden, CO 80403
Toll Free: 1.888.437.4564 Phone: 303.277 .1188
sales@eplloglaser.com www.opiloglaser.comlbhg.htm
I continuously
fed IO"-wide
maple and
wa lnut boards,
litopping only
long enough 10
lower lIle
s<'\ntl ing drum
slightly between
After
abrading more
than 40 lineal
reel of wide
;.lock. I checked
the lub and
drum and found
the same result:
very little dust
In thc \'at.'l1um,
and a deep,
swirly dune of
dust in the
bottom of Dust Deputy's drum. it really
performed well. Bul then il l>oould for 5200
(not including thc optional $30 hose Ihat
runs between the lou] and the Deputy; ),OU
eQuid also use your own).
You can cut yourcm.t in half, though. if
you buy the DrY P..Ki.:agc that mounts on
your own 5-gallon bucket I assembled
model with a ,<;erup of plywood, gm.ket
material (I an old router pad), and u
ft:w bolts in less than 30 mi nutes. It worked
every hit well the Completc
- Testoo by Pat Lowry
Dust Deputy
Performance ..........
Price S2OO. Complete: $130, DIY Packajle
Visit our website
woodworkershardware.com
1-800-383-0130
Ca ll f or our
new FREE catalog
MEASURE
MASTER PRO
Feel-Incll-frQIion and Merric Coku!olo,
You wil l get prolessional woodworkill9 results
wilen solvinll measurement problems wilh this
easy-to--use tool. Wort in and convert between
dimensional tormats includlno Fflet-Inch-
Fractions, Docimal Feel-Inch-Fractions, Yards,
Meters, Centimeters and Millimeters as well as
Area and Volumes. the Measur. Muter Pro is
ideal tor last. accurate Board Feel estimales.
Sotye tor Weight per Volume. Circles.
Circumference and Arcs. Model 40'20
CONSTRUCTION
MASTER PRO
AdvOIIced FeeHncn-Frodioff
Conslroction-Moth Cakulolor
The Construct/on Master Pro sets me Industry
standard lor advanced construction-math calcu-
lators. It provides powerlul bUilt-in solutions lor
Framing, Stairs, Paneling. Circles. Arcs. Segments.
Compound Miters, Potyooos and much more.
Set prejerences for Fractions, Risers and On-<:en-
ter spacing. It's penect lor completmg plans.lay-
outs, bids ami estimates to save you time,
money, material and frustration, Model 4065
PROJECTCALCO PLUS
FIflI-lnch-FrQlion Proi' (11""1010(
Won: In Yards, Feet-Inch-Fractions and Merers
to calculate and conven linear. Area and
Volume measurements. Use built-in junctions
that quickly lind the amount 01 material reQuired
lor common lIome and buildinll projects-
Paintill9, Wall--covering, TIle. Concrete. Roof
Bundles. Block. Bricks and much more. Design.
build. Install and finish your projects with preci-
sion and confidence.
Mode18S'25
router
trygauge
blocks for
fast set-ups
Once you've fussed ove r setting the
perfect height for a table-mounted
router bit , make a gauge block so
next time you can skip the hassle .
Which bits need blocks?
Creating gauge blocks for the following
router hits good sense:
Matching pairs, such as cope-and-stick
bits, used to make rails and stiles on doors
and windows, or tongue-ancl-groove bits.
Bits requiring precise alignment. such as
those designed for cutting finger joinL" or
raised panels.
Any bits that you use to match existing
profiles, such on molding or trim.
Build blocks that will last
Machine yooT gauge blocks from hard,
tight-grained wood, such as maple, cherry,
or w<linut, or medium-density fiberboard
(MDF). lfyou think changing humidity
might cause wood blocks to swell or
shrink, make them out of ultra-high
molecular-weight polyethylene (UHMW),
as shown below.
Start wilh a blank at least 4" wide and
6-8" lung. Plane to the same
thickness as [he you would
ultimately use on a project. For example, if
your mils and stiles fur mised-panel doors
typically measure Vi' thick, make your
gauge blocks to match.
!lIiE!!lI!1mlIi
UHMW, at right, machines just as easily as
wood and won't change size or shape with
seasonal variations in humidity.
106
Now sct up the hit in the router table as
you would for a part. Make test cuts
on scrap to perfect the settings: then rout
the profile onto the blank, as shown bdvw.
Repeat the process for the mating bit (if
any), and then mal:hine the OPIXlsitc edge
of the blank. Finally, rip the gauge blocks
to about I Y.!" in width. Sand away any
splinters or rough areas, being careful not
to alter the profile.
How to use gauge blocks
To set up a bit, first raise it to the
approximate height. Make sure the router is
unplugged. Place your malching gauge
block---cenlereJ on the bit-with the
profile against the bit. Rruse or lower the
bit until it slides perfectly into the routed
profile on your block, as shown at right,
Cutting a gauge-block profi le on wider
st ock, bef ore ri pping to width, proves safer
than routing narrower pieces.
and lock in the height. Now set up your
tence or miter gauge as needed. Note:
While gauge blocks are helpful in set-up,
always roul a lest piece first to confirm the
accuracy.
Store your gauge blocks near your router
or router tablt:, either in a cabinet or
dmwer. Or, drill a hole near one end, to
hang them on a nail or hook, To avoid
confusion later, write on your gauge blocks
which muter biL-; they malch .
! Source
I UHMW: :r.x4x48" $20, plus shipping and
I handli ng, Amazon.com.
I
MATCH THE BIT TO THE BLOCK
the bit ti ght-
int o in it s height when
t he bit aligns with the gauge block.
WOOD maga zine Oct"ber &lOS
Creafe your
own woode.1
gear tlod(!
Bear Woods Supply
Wood Parts
Dowels
Knobs
Spindle.
Toy Wheels
Clock Parts
Scroll Saw Blades
Hardware
ooii __ ....... .. rn... Plens
fREE 80 page catalog ~
Call 18005655066 l!
www.bearwood.com ~
blade s
guides
tir es
t e n s io n de vices
___ .c.rterproducte.com
toll-free: 1I1!!I1I.1!!I22.71!!137
Resaw Will
Revolutionize
r Bu .
CHERRY TREE TOYS
1-800-848-4363
2104 BELOIT Ave.
JANESVIllE. 1M
Were not just America's
#1 ~ l i r for Wooden Toys
.. Kits
.. Furniture Plans
.. Toy Plans ..
.. Clock Plans
.. Outdoor Projects
.. Parts
.. Clocks
.. Finishing Supplies
.. Tools
WWWCHERRYTREETOVS.COM li
VISIT us TODAY OR CALL l!
FOR YOUR FREE CATALOG !
WOodworking Plans I
FMEE 100 lull color
catalog IeeturH plans
ttl make o'tGt 1.000 dlfleftnt
projects.
" _'_0"'" Mtlitl Spedl!ltlM _
1 P.O, Ikll 7ll Maund. Mil
1801H419870 ... ""' .... _ ....
www.melsBlwoodhobby.com
-..-:-.. __ MOl. 41 ..
-.... -- -....
... -'
-- ' ....... -
DOWELMAX
PRECISION ENQINEERED JOI NING SYSTEM
GOlD MEDAl WlMMEJI AT TilE
SCIENCE lOl'W(lN, ENGlAND
ttsplay cabinet was built with
Dowelmax kJ creats 60 pr&eise,
compressed dowel JoInts for
f"OCIo("solid COl1Struction.
For mOl'fl infrxrrI8tJOlt, Of to 0fl1er calf
1.877.986.9400
Of log on to www.dowelmax.com
Traditional Hand Tools
Rc:<tuetl yout fn.>e clllaLo&,. 96 filled
wilh quality hllnlllool. fot woodwork;:no,
wood catVCft and. ouldoonmen.
Traditional Woodworker
www.traditionalwoodworkt:t.com
- ............ "' . ....... -.,... 1 800 509 0081

MISSION BED & NIGHT STAND
l-.""'r .......... _oh<....ru<II'Idoy' ... _r
1Iiru_ .. l61or ... .. n.. ..... y
........... a hIDII<d __ <>fb .... "'"
fR: E
C"-T,,.OG

r.o lI(U: )OIIllllt:SCOtlDCDO,CAQ)Jt
BIDA..'tll t.HI ci
-
""
Z

-USYOOITYOURSElI
100'" USfABLE SPACE
Manr Illes. shipes & applieltlollsl Toug/I. rll\lUed
building -lasts' Heavy gatJlI8 Gal'talume Sleet Easy
to Irussless irnerior Totally malnttnlllCe trtel
U
SUEDE-TEX SPRAY-ON fIBERS
I ne In Nu luttlng
No pastinr; r,o skill required'
Av!lIable In 3D + colors
CMllrx FREE brocoore wi/!! of tmisll M<1oud
PROOUCTS
13142 Murphy wmoebaQo.IL 61088
8OO33S-SS37 81524; -8n5 r/It USI

For advertising in !fie
WOOD MarKetplace. please
call Ryan Inlel1and
at (866)-795-2587 or
ryan.lnIeI1and@meredlth.com
Do-n-vourself assembly-
no skilled labor or heavy
equipment required.
Variety of sizes IWldths
from 24' - 110'), styfes and
19 contemporary colors
Unique steel web-frame-
accommodates standard wood
siles & finishing matenels.
Building packages include steel
fremes & endwalis, sheeting,
hardware, trim and complete
assembly instructions
Surr'vl"S lIo/!hyiJ/J.rW d..,;i:bM!rs "'''' __ 1m
Ifl_; kit.

1-866-463-1229
www.miracletruss.com
Who Says
Good Help
Is Hard To
Find?
Ho_..,oo-
indwtrial plaoc,
o;:abiM\"II\WnB,
... cani,,! o. 3D
cnlu _ SbopBoc
CNCtools...,
--'"....,
wood....,rlu:r!
Stam I ,t
$6,995.00
wOOD METERS
For Ih. Woodwort;'r .
AAolltllr. probliKl',s well
as stUlI\kIng or warPIng
can f'l1In the bill pllee
t'l1I' buill Measure
tile molSlUf. With a
tnOllhlt meter to
be sur. the wood IS
dry. Carl for new
color broehure.
Lignoma! USA
Po Box 301'5
Ponl ' nd, OR
11729' .. iJSA
VIsit lor whal', rteW
& InllO'lalire i. wood ctlltinl (00111
:=:..i NFINITY-=-
._ . . -
TOLL FREE 877.872.2487
Specill llYlRP on JOOaf
Superl'AKs
flU oIuPJlIlliOll20BF
lIobb)PAKs
Ilard .. ood fJoorm&

'I

Proiects and Plans
Kit to build indude5 15" iron wheel /hoi
really works, o xle arK! stepby-step plans.
nni,hed pr0ect meawres
66t)( 2A"W)( 26 H, S3A.95 plus 5t H
ByeGone Workshop
888279-39.' 8-5 M-F EST
co ..
u-bildplay.com
"
(BOO) 82-U-BIW ;
PoweR POLe
,-
"10''''
N_ d a precise
tool for routing
furnit ure joints?
' f!"
Vis it us
we are the WoodRo'- '1'"""';""

Build An Heirloom Clock!
Our La!"' ca!alog
offers e wide variety
of plans. kits Bnd
components. You'lt
find movements.
dJat n.I"d.,n.rdw.re
and much more for
clock projects 0( an
s ktll leveJs,
call Today For Your FREE catalog!
1-800-556-2548
www.klockit.com
Deot: WD100fi I
lNhat's ahead
A sneak peek inside the November issue (on sale October 10)
Get a head $tart on holiday gift$
Accommodating
3-in-1 Bed
AI Jast! A tled that
stayS with a child
from infancy to the
teenage years and
I)eyood. It changes
from a baby crib II> a
toddler bed to a full
sizo tled. Simple fas-
teners maM it easy
to swap out the skies
and footboard.
Magic-wand kaleidoscope
H8Ie's a way 10 dazzle IOOs that do85n'\ req.ure batleriM,
compuler chips, CIr software. And it's simple to assemble.
Tile-lopped keepsake box
Build it In a WIleKeOO, add an tIIa, and you'll
Mve a present SUfe 10 please an)'Ollf on your lisl
Benchtop planers Planer tips and tricks Oil vs. fitm finishes Wood-joint torture test
Doll"! I>Uy your neK! thickl1essef This 1001 can do a lot more than plane Woodworkers tend to SW1!aJ" by one 01 these the strongest way to join two
until you Cheek QIJt this comparison boards to thickness. Here's hoW to finishes. Some 01 us swear at bolfl. learn to worxpie<:es? How strOfll,j is strong
of today's top 10 machines. expand Its}ob descriptioo. get tI'te best results trom each. erough? OUr scientific trials tell all.
11 2 WOOD "'_q_sln.. Oclohor Z006
You'll find over
. &00+
'lOOdWorfcing plans at
IQJdllllif'ziJII.CMJ/plans
From the I dKori ot
""p"
Download any of the 600+
woodworking plans, or have
them mailed directly to you
for an additonal $3 each.


"""""
m:11e &.


appealing
to"""
proj<ct5
THE
BEALL
TOOL
Co.
""'" "'" .
(800) 331-4718 www.beaHtool.com
>41 Swam; Ro.-d.. N.E. Newark. OH 43055 5
"'Clock supplies
,'_ "_: 1, 1. Clock Kits
"'WOOD. Magazine
Project Hardware
"' Woodworking plans
"'Jig Hardware
Schlabaugh & Sons
www.schsons.com
Ph.1-800346-9663
Kalona, Iowa 52247
Toll Free
1-800-683-8876
"\\ "_packard, .. ood" arks.com
Close ...
Thin-Karl sawing for ma.iroom board yield
. 24' di8.mO!\ef up to 11' long
(flxtaosions available)
1 HP recoi 0<13 e<Vir.tt
Harod puSh tood system Now
Cut up 10 100 Board Feet per Hour' $3,995'
Lie-Nielsen Standard or Low
Angle Block Plane.
\Special $135.00.
\i.1\e Hne Tool Journal
\\ 27 Fickett Rd.,
u.- e". Pownal, ME 04069
0\\ (HOG) 248-8114 j
www.FilleToolJ.comILN !
WDDd-Mizer
The World's largest Manufacturer 01
Portab!> Bano:l sawmiIs
"' __
Saw-Jaw
Order
From
Your
Favorite
Dealer
Online
Mail
"
Phone
Safely Remove, Instal l, Store & i
Protect costly 10-
PO BOX fA SO/;1 3 .f
____
The new MULTIMASTER RS Remodeling/Renovation System.
Everything you need to make your house like new in one great kit. The
MULTI MASTER does things other power tools can't. Sand into corners and along
edges. Undercut a door jamb. Plunge into baseboard ... right through the nails.
Remove grout. Scrape paint.
The RS Kit contains a MULTI MASTER 6362 variable speed toot plus:
Sanding Pad Universal E-Cut blade
HSS Segment Saw blade Carbide Grout blade
Scraper blade Tool wrench. screws and washers
Carbide Rasp Plastic carrying case
20pack assorted sandpaper, grits 60.80, 120. 180
For more information. a free brochure and to see the complete line of
MULTIMASTERS and accessories at a dealer near you call 1800-441-9878
or visit us on the web at www.feinus.com.
Visit us at Booth # 6413.
grout
Powered by innovation