NO.

41

NOTES FROM THE SHOP

$2.50

Sawdust
Number 41

Sept.. Oct., 1985

EdllOf
Dcmald B. Peochke

DeSign llIreclOr
Ted Kran .. ~
AssIstant Ed1tars
Ste'le Krohtner
Doug las l. Hleks
Douglas M. Lidster

If d()iJI~!'Om!lhin~two )tear:o.
in a row e.Eablbhes " tradition, then I'm
happy to .ay that this i. our trndhional

Too many businesses make deelsions

based on how much money is going to be
made. The "bottom line" a11l'3)'sseems to
dictate deeisicns and new ventures,
I think I' beuer approach is to make

that \\ uulll makr- "Ire ..,nIts, 1\(1n nt the same

tim!' he int,r.,tinJ( to huild \\,,, &1,.
\,"antt.'tl tu lnclude one bl~P"")J4."Cl especially fur kids, The tin. we came ul' with
this year 1h an easel desk.
,

decisions based 011 the service you can

provide, I try to put myself in the CU$iorner's shoes and make mv decisions from

TH\I)ITI()S.

h(lliday!!ift iUl.
we've (ned to rome up with projects

that perspective.
.
This is the approach we used from the
\Vh"" IV,' l1""t ,u.rtcd th.. "roJ""t, I b<iginningwith lVOIld.",ilh (which b one of
lhouj..rht it ,-,oulel Jrutk. a Jrt't.lt art center the reasons why we don't carr)' adverfor budding art i.t8. But th" "I!:> one pro} tising).:\ ow we're trying this approach
TilCIlnlcallJlUslm!()f$
eet where my OP'111011 dldn't .",unt much. with the store.
David Kreyl1ng
\Ve docld,,,1 II) call UI ~.m.' expert, - We
For the pm;Lyear; Steve Krohmer lui,
Mike Henry
invited some (,flh ... l''HxIAlll;fJ( kids to te~t been heading up the work on the store.
SubscJ1ption Manager
it nut. They were mort' than eager to Part of his job is to order e"c1'IIl/rillg a
Sandy J. Baum
answer Our (}'It lioM.
woodworker would want - imported hand
SubSenphon Assistants
y~"the de.k top f"Jd~down okay Iwith- tool", power equipment, 3Ii species IIf\\'ooo
Christel Miner
out ban~nK ~'our head). The drawers ean (including exotic woods), finishing supVicky Robinson
be reaehed c;u;U) II dllt'~1l'Ltil)over when plies, speciality hardware. In short.
Jackie Stroud
ernwlinl: "'.1' th,' dr',k to get to the cork everything,
Computer OpemUons
board. E''''YthinjC cheeked out.
That job sounds like a woodworker'.
Ken Mfnef
But th~rc wns one thing we didn't an dream, But according to Steve, it has
ticipate. The longer we watched the kids turned into a nightmare of paperwork.
CirculatIOn Managet
1uI\;nK" ",,,,denul Lime, the more we He'. had to order over 4,000 different
Jell Farris
be~.n 10 see other possibilities for this item", from all over the world.
Adml,,;Stra1lveAss;S\8nt
projc'<'t.\~'Ith longer legs (adult size), it
But that's the approach we wanted to
Cheryl Scott
could bt m.",""ge center in the kitchen, take, and the store is well on the way to
Bu.ldongMaintenance
Or by mllkinp:it witheut 11'Jl>'. it could be. being the kind of store for woedworkers
ArchIe Krause
wall-hung'de.<k(for the shop, maybe),
we've alway" "anted to open.
Tin: ~-roRf:This past summer we did
Ifyou:.-.,illlheSt. Louis area and would
something I'\'~been dreaming about for like to vbit the store, tbe address is: The
WOODSMITH (ISSN 01$44114) ts pubhshed many years. \Vt' opened the first
WC)odHmilhsrere, 1063 S. Brentwood
bomonthly (January, March May,July,SePtem- s",,')' )110"'. lit's in ~l.I.ouis, ~li_wi.)
Blvd.. St. Louis, ~fO &3117.Telephone:
ber, November) by Woodsmolh PublIShing Co ..
11:11- the idea that 11'"odsmitil maga- (:11117273077, If you need a map or di2200 GrandAve Des Mo.,es, Iowa S0312.
zine hil.... I)ptl1ed a 1i-OrJ(i.~"litJ;Storr raises A rections. call or write Bruce \1in('"Clll. our
WOODSMITH .s a regl$lereotrademarkof the ((>\\, qu('!'>tinn!'. \\'h)' dicl )'OU J!U)'~at l'tJ(H'i
store m"nugcr.
Woodsml1h Pub,sIllng Co.
$,).il" decide to open a store'! An> th.n,
I!",itf lhe St. l.ouii'loeation. \\;11 there
Copyrlghl 1985 by Woodsm"!> Pubhslling Co. go}n$: to be muTe ~to,.et-~ Are )"OUgoing to be Iluu-e ::-tOf'f::;'In the future?
A,I AlQhts Reserved
offer mail'(lrrli'rI)urchru<c.,from the ,to",'!
IhOI.'"" \v..want to give thin firM.to ....
S1.Ibscriptlon.: One year (6 ,ssues) 510, Two
Th" fin>1 question (why did We docid. to ~"1'" II)",h:lk~ out.' theil we'll see what
years (12 iSoSues) S18, Single copy pnce, $2,SO open S $10....1) g..1s ot the heart ofh"w \\e h.,'pens.
(Canada and Foreign: odd 52 pa' year.)
apl)ruaclt thin).,.""htrt> at "rood~l,/ill '\~h(.>n ()nco la..'1!lque:;tion eonc~rning the store:
Change Of Address: Please be sure'" InclUde W(HKi.'l't"itl, st.arted !-'t','el) ~eJtn;.aj!(I, Ctnt'Clf J)fj ~'()Upl,'n lo Lake phone Ul'tlOrs or ha"e 3:
both yourold and new address,
the ded.i(ons that had to bt.' marl. "':L' \\ hat mil-urder cautlog?
Second class postage paid ilt Des MoInes, the purpo:;eof the comf"ll'Y\\l.. ,
Ko. Thl'l'Care already several excellent
Iowa.
Il', popular 1I0waday. (or th('
"f. <at"J~.. that offer mOst of lhe tooL; and
PostmaS1er: Send change 01 address notice,
companyto proclaim that lh...I'rimary j(oa) ,u"pli, .. we're earrying in the ;:t(Jre,
Form 3579. to Woodsrrulh Publlshtn9 Co , 2200 ofhis company i. to make mun~J"Without
In f:tct,ifyou"re U'YingLofino maiIorder
Grano Ave, Des Moines, Iowa 503t2
that goal, the rCII$OninK
goes, nothinlt ej,. "')(,....,..,one way is to .heck in the Wood
can be $chie\'ed, And I Lhmk mo.t (If u, ""IIi<Snll~ehook. It lisls ""talogs and
have becomecomfnrtabll' \\;th that "hil", iniol'lll;lLionsourte$ (ur 43 compani(!J;that
B.rlCK ISSUES
ophy, aceepting the fact that. roml'~ni.,. 1uI"ea wide range of woodworking tool~
All_ issuesof Woodsmith ate sb """liable. rnu", make money.
and supplies. (If you didn'Ltl1"eive your
Sand 10< a freeboOl<let descnbing the contents
But Lhat'. IIul the primary g031 of Mpy of the Fall '85 SUII~tliook, just drop
and prICeSOf a'l _ Issues
W""dslllilk Th. purpose of Wood.mill, Us a note and we"1Ibe happy to !;endone to
can be staled in th_ word.: To ,;erve you. This offer ends December 31. 1!l85.)
woodworkers.
IltiXT MAII.I!'G.
The Noyember
SAMPLE COPIES
This i:; not intended to be jU.'L an ideal Oet-cmber issue of lIWd,<milidNQ. 42)will
" you havea friendwho wOUld
!ok.to ..... oopy istic sentiment that makes me:;ound like a be mailed the week of December 16. 1985.
ot Woodlmllh, JUS! send the name end address. mce I:IIY.I think it makes good busine..s (Beoause of holiday mail. allow three
and we', ~
a sample (at no cost)
.cnw.
weeks for delivery,)

,,(lod.

"""r]

WOOOSMITH

 __

T_~ & Technigu_e_s__

CHECKING A 22'/,'

In order to make an octagonal (eight sided I

frame. ,)'OU have to cut 22:'/:: miters on lh(,
frame piece", (This type of mitered frame
\\'3< used on the clock. see pg. 10.1
The only problem is how Lacut aJl tlr(./Irat. 22Y,o mitez Note: T...,hnicall~'you'",
culling a 67~/ al/{/I~. But to do this, >'OU
have to tip the blade to the 22u mark on
the gauge (91) -22Y,'~6",).

However, most

58"' 1!3\Igt'S

(Jusl)' inaccurate, One

\\'8:'

to

arc
:set

110lOli

the saw

accurately is to use an ;'rti~l'::-ftlljustable

prorraeter; Or. "OU can make a {rial CUt (Inti

eASE UHf

..--'---I,!-Jl---.,-

tho face ofthe arm and the seecnd hole (#21

glc. put the compass at Point C UJuldraw " I_ted on the edge,
an arc on each line, Point. U and E, ,...,
Tt. "lake a wheel, start b)' cutling a
Step 2,
round wherl blank .lightly oversize with.
~Iovc the compass to these points 3nd hole saw; bandsaw or sabre .a\~ (:o\ote: If
draw two more arcs in.~j(lethe anglo, ("I,n- euu ing witha bands....
nw or-sabre sa", dlilJ 3
neet. t.he pt)lnl where th..-se Ul'\.~inlt~(.'(.t
axi" hole III the l"i!IIU'r.'
tPl)int ~..) to Point C nn(1 )oIOU'\>(> bisected
STEP 1 iIOIJJ<DING
the 00" angle into two ~5 :mgl.. ,
8IS"~(i' 90 A.'I'CLf.:.Tu bisect this 91) ~"J

MITER

-t-I

6ISI-:(I 15 .\.~GLf..Repeal this process to

b;,;,'Ct onc of the 45 angle:- to get a 22'.

angle, ."" Step 3,

rH~('K)IIT~NTo check

the mlter; urn...a

another line (Lin,.1) perpendicular (90' Ito
th" base line, (1'(ote: A, mentioned above.
you QI"e technically checking a 67'h' angle,
1b get the S7Yi anl[l", you have t" draw
this perpendicular line. )
Now make It trial cut on a 2.x4 scrap.
(Thick stork gives more surfaee to check
the miter, refer to rig. 7 on 1'1(. 11,) Slide
the trial piece along Line ,I until th. cut
lodge aligns with the angled lin."
TOY WHEEL flXlURE

'2
/

4S' ANGLE

lIST &LOa
IN THtS

COmt.

For years I've U$,'<I a hole saw tu make

weodcn wheels 01\ toys fOJ- my In'and
children, But the hole saw leave. a rough
cut and clunky, squared ...ff ed~ 011 th"
wheels, So I designed thi> fixture to clean
and dress them up with 8 disc sander,
The base of the fixture '" a piece of ,
pl>'wood that's clamped down to disc
<ander table. A pivot arm hold; lind support. the wheels and pivot., over a', holt
(pivot pin).
To limit the distance the arm will pivo;
(this determines the ";7~of the wheel or
chamfer). make an adjustable SLOpfrom

three ""3!Oht!X"S and a \\ing n\lt over a ~...

carriage bolt. The ~It run, in a 1/'- slot in
the plywood bas e,

j~JUSta

matter of u!rinJ(

th. blgh $chool l!'eomClry you thought

you'ri lIever need. A 2"11>'angle ii; half (a
bi<eclionl of a ,15 anj(le. which in turn .. a
bisel-iion or n 90 angle.
I)RA\\,\ 9<i A~GLF_Tudraw. 90' angle 1\11
you net'(l is eompru;,., a 'lr:light edge, ..
pie.:e of paper. and a pencil. SIan. by draw
ing a straighl base line, """ Step 1.
Now, draw a line that inten>ect$ this line
al 90'" by placing th~ "harp point of the
~ompa.sson any two poinbon the bas'" line
(Points A and B) and draw two IltCl\ that
intersect ahove ""d below th. line. Then
conne<:tlhe inten;l!<:tion I>oil'!.> to farm the
perp;;ndicular line.
\\'OOOSMITH

STep 2 CHAMRRING

..,-

HOlf/

Onee all the whee. tin! uruform, turn the

pivot ann en edge .0 Hole #2 fit,; un th~
pivot pin. see Slep 2, Nu" adju"t tlw .10]1
w'_"""", until a thamfe.. \\~IIbe lake" off
th. <-dge oj the wheel and pivot the "rm
into the spinni,,!!:diS(",

then cheek the cut enel again>! n 22,,,'

16i\l') anJ(le drawn on a piece of paper, I
like t hb seeond way because you're checkinll' the aCIIL..J cut on the workpioce.
Now the problem i" How do you dt:", "

22V:c angle? Thi$

Then "lace a washer over the ,,'hl'l'!

"axle" on tbe Pl\'ol arm, and place a whe...!

blank over the washer.
Xext, fit Hole #1 011the pivot pin so the
pivot .tIII IS flat on the plywood base and
arljlL...t tht.<.ttll) washers and \\'in~ nut until
the "lank j, just touching the ""nding disc,
sec Step I, Th1"11
on the sander ami ,..,tal~
lh. bh..ik by hand until if. round,

tl'jll;(1111E, 7Ilrk
G""t"n BtlY. '\';$(()UN"ltl
SEND IN YOUR IDEAS

If you'd hke10_.

To make the pil'Qt arm, cut a piece or

stock to 211,' by IS" and trim a l~'c1eanmce
,'tit "IT one end, Then add a wheel -axle"
made Ii'om a machine bolt. CUl oIT the
thread,andepoxJ itin. holcneat the end.
Nexl, dnl) t wo "--din. hO)"$in the pivot
arm, The rlt$t hole (IFI) is drilled lhrllUgit

a woodwork'ng up WIthotho,

readers of Woodsmilh. send your Idea to:

Wooosmlth, Tips & Techniques. 2200 Grand

Ave.. Des Mcjnos,Iowa50312

We pay a """,mum of $10 fot I 1>$. end :;150'
more for speclallechniQUos (Illat are aCC<ll>led

forpUblicatIOn).Plaase gIVe a compiele exlllana

Ifon of your Ide. If a skatcilis needed. sand ,t
along: we"il draw 8 new one.

Kid's
Easel/Desk
---------------A KNOCK-DOWN ART CENTER

I rI...,rled 10 try I!Oml1hinll:n~\\ on Ih

proJ""t I.,.l..ad of u nil:1".,11110.,,1JOIll'
ery methods. 111~ ","",k.I
..wn litlln~'"
The eonneetor 1 usc 1to make the J ml>1
<O&.l>l-of a boh thalJ ,,"'lhrou!;tl('Il<' (f
the p,eces the Ullli~hl In lb. ,,,amp"
,oho,,"n In fill. I
be t IOlICn we I Utto.
metal do,,~l th3t'. mounted Into tb, 8CCond P'(" (the .helr t, ~ t'll :!
The jenu t.....
ted hJ thi... ",n,'dor .'
,urpn-m~"~'
strong y, t, ~Oll can take It

nw.

apart ",th an Allen "f\'!I(h

KNOCKDOWN flnlNGS

Silk"e thl- ('f.nu("(:tol' is u~('lllll)',Innil t be

major pieces of tht PI'(' eet, 1 ~lartt"tt b~'
experimeniinz with mounung tht'I-c.' con
nt.'C\.(J~to the i'n,i 1)[a tt~t
I'it...,f.lln'la,' to
one of the ,heh"'~ ",,,Ion thi. "n'J"ct

The

[if'!-it

fol('P j" to U:o-t'a square

If' mark
IlI'lt(1 to

the centerlines of thv htllt>8. I \,

in!-llstl l \\'0 i'OI\rll'lllr" 1)('1 "')'lllr, ..c, 1

marked l \\ f) lines Ulr(.t:'i" lhi' l'11CI ;11\(1(Ul'{' of

the workpi ecv, "',' Xt<')1 I in Fill. :1.
Then I marked the eento ...lOint. uf II
total of four hfJlcl'i. '1\,,(, h(JI(.:o<
nl',' l'('ltlt"'"."cl

on the \hirkllt:o,!--at the "nd of the \)(1:\1"(1 tel

accept tho bolt. Th.. r,nh.,."nt"

other

of th,

LV.'Qholt!8 at" on the fUt'l' ("I' thc'

metal cro .....dO\'lI~, "('''' ~ll'J'

I)KII.LI't;

Til ... flc)r.f:-.

1 111 t

i),:,

Aflt'l' lht,

,I.

111,le

Iocanons we rv mark .. l. [ ,,*111 dO'H'hng

jij! (".,. SoUR"'"
~,IIto tlnll ~Iu.
hol(~ on the l'("I... sec ~t"-'I)2 in Flg :1,
Then I switched to the,ln11 press to tlnll
intt;~~tjn~ ,a--(Ila.h(,tt"$ In th~ fat"'" for
tbe ere ........
dowels, H't" ~lc'I' :~
Shop :\nl<'. The ,,tru<(lono th3t came
with tb~filtin~ ('31...i for lh .. Ie) tl(t a
"1....-dia, ho!~.but I (olund that to I", a liul.
til!ht. A .. .,113..hul, ali"" 8 mol'< pla) for
.....,('r lIIlju,tment.

"Il'.

ClOSS SECTtON
" HOU

I.

..

...,..

... IOUGH

An.r dnUin" the Iwle., ,t', ..ml'ly a

matter or mounung the metal .10".13 and

OO:t- 1>1.'"fig. I). and ul!htemnjl them

"nug
an AI),.n w.........h

,,"h

fUT

aoss

.....

, I+OlI

00wtt "-.01,/

Once I lI"l th~ hanll' "r how

I" mount th,

1 ht~rall work OJI thl' t'aMI
desk, ~tan b.\'glum~ tl}joC(thlrt\\{1 fJi{'<'f11
()(-14 ( fll'ltlal, ~tex:kto rrulkll {'ach (tKlt
(A1. "", Fig. 4. Th do thb. cut four l'i,......
'5
3", wide by III lonl( and IIlu(' thelll
tOji{t'lher in t\\'O paiNo. ,-\fttlr th,y'ri' (I~',
trim them lO:{ - "'ide b)' 1,." lilng.
llIULL JOt~T l'U".:( TUNIIUI r.S. Th,
feet 3rt! held to th~ upright .. Ill) ,"th th.
knock-<lown fittinl."" To [1... 1".... Co,, lh.
fillin!:". llrill two 'Y.".<lia. I' "(I~('Jlcoun
lerOOr on th., holtom of"lIth ('MJt. ('~ntcr

COkNIClOI

DQUQCnIrfl

connectors.

DRIllING
PROCEDURE

ORIU If. HOlES

". Oft,

\VOODSMI fH

these eounterbores (In the thickness of the

foot and located 2V" and 7" from the back
end. see ~'ig. 1. ~ow drill a
hole for the
eonneeicr bolt the rest of the way through.

RG"'

UPRIGHTS

v.-

fl ~-

lAMINATE1wo PlEaS

II

..

,.L..

"I

...

... '4~.

...

_.

:'\

...

'"

..

....

\1-

""0

.~ 'r

+
"

,,

..I

SHELVESAND STRETCHER
Now lh~ shelves (C, D.El and stretcher (FI
can be cut to size from ~'4 stock. Rip the
three shelve. to 3 width of
and the
stretcher 10 " \\;dlh of 3W'. Then trim aU
four pieces 32" long. see ~'ig. 6.
IlRILL UOI,':~ FOR BOLTS. Afte r the
shelve, and stretcher are cut to size, drill
two holes in th, ,'ncb fc,l' the connector
bolts, (Note: Set ""id~ the middle shelf
since it won't have any holes in it.) Center
the holes on the thiekn~"" of both ends of
the top $helf. bottom shelf. and the
stretcher, refer to Fig. (;.
DRILL>JOI.1iS
'-ORfRO,iSI)()II'ELSFinalIy. drill the holes for the cross dowels on the
bottom ,.jde of the tep and bot lam shelf and
on the IJack side of the stretcher; (These
holes are posiuoned so they intersect with
the I.'. holes in the end, see Fig. 6.)

r.

Next, cut four uprights (Bl from 4'4 stock

-fF;" co~N.cro~~i
'. IADlVJ ON
4
fOOT ~
HOlE
"
All COR e:IS
to finished dimensions of
wide by 41~~'
..
I' ,
J'. ~
.
/. (ASstMStl tWOl
long. see Fil(. O.
.- (OUJ'"lIUO.(
BOLESTO \TT-'CU.. ~:t
..
'T. To attach the
i,_.'t'!i T
I
upright. to the feet. start by drilling 8 v..
", 140,. ~
~
hole, 11'" deep in the bottom end of each
FRONTVIEW
4
~
-7
upright for the connecter boll. Center tbe
hole all the width and thickness of the
.""' > OAC'
RONT
upright, s.. Detail in Fig. D.
TOPCORNERDETAIL
UPRIGHt
UptiGHt
Then drill a I~dia .. IV,.-r1ee" h()l~fOI'
r
r
l~,.
,...
the cross dowel on the inside face centered
r
y. up from the bottom edge.
r' J
c:
SUELf,\;';DSTRf;'1'('Ut:R
III)Ls' A1\er the
UPRlllHTSi'
holes are drilled on the bottom end. of aU
I. ~'. IOUND-OVt
<t
i
4
Ctll TWO
0" All EDGES
four uprights, another series of holes is
OF lEACH
(xc"'" aOllOM
drilled to connect the shelve e, Center
, IADtUSON
these V"-dia. holes on the width of each
.'",' CONNECtOR
All fOf> C-ORNfRS
upright. lotating them 17" and :38'1" up
HOllS FORTO' SHElf
from the bottom edge, see "'ig. 5.
PIVOTHOLEDETAIL
To connect the stretcher (F), I wo mOI'C
1'" holes are drilled on the back uprights,
21'1.
'(VOl HO\! ON
Center them on the wielth. 5'1, antl7~:
up
FROm Ul"lttGHTS
ONLY'
from the bottom. see Fig. 5.
"",
pn'OT HOI.~:S.There's still one more hole
'-'
to drill in each/roll' uprighl (the uprights
4"" ..
'IVOI HOll
fSEE DETAIL}
.cith",.t the stretcher holes). This hole
~
serves as the drop-front pivot hole.
MArkthe 1II8id~faces of lhe uprights so
',. HOlf. ~~. ott,
\
FOR mOT"N
-r
you have a mirrored set. Then drill a
I
~,..-dia., ~-deep hole on the inside face of
fOOl CONNECTORPffAIL
CONNECtOR HOLES
each upright, refer to the Pivot Hole Detail
FORBono,-\ SHIt'
orlU.
HOlt OH
in Fig. 5.
INSJDff~Cf Of
vnrGHT
..... ._
c
RDt::<msf, TilE COR:-<RS.
When all the
hole. are drilled, round the tOP comers of
_'.
CONNECTOI
Ir
HOttS
fOlt
J
the uprights and all four corners of the feet
StROCHft
coos, OOWll /{
'>
2'.
10a~, radius. see Detail in Fig. 6.
I
Shop l\ ote: J used a quarter (2S~ piece;
SfE DETAil
,~
t
as n template. Then I eased over aU the

sv.
CONNECTOR
~
HOLE. 1'.. DEE-fl'
edge, on the reet and uprights (except the
+!
bQlt",,, end. of the uprights) with 8 V,'
3"
round-over bit.
J'~

aI',

OF4'4 Sloat TOGtlHtlit

ENDVIEW

ON All l-OGfS

..

., ItOUNOOYEa

lOP VIEW

WOOOSMITH

NOTe,

<4

f~'.tHlc~1

(cur !WO .,as

~.

",
~
~L
II.,. OEfP _

'\'''1

_to.

NOTE!

:. HOlf

it

~,.--.
_t_

"

~.

-J1
5b

",..0..=
lotllH'Cr,m

MIDDLE_SHelF
!..

_.

iI

32

NO HOUS OIJW:O
IN MIOOlt SHELf

,II:

...t. __

;0;1

I ~

&ACtl: EDGE

"I-

(9@;,

&AQC.lDG

TO!UJl_OnOM
SHElf

T
1

AU STOCk.

-~

(-.

-. .. !.,

I"Gu".

,-

..:::WHE.!!
32

~
j

01
"

;;; .\:.,. Ht;>Lf.

'ft

OE[I"

<0::

t
I

..
M'DDU !HElf

--"I '

SI(fIG fOI G~

~S

110""'" SHIll

;=J

,
, .. .. .

rHKIC;~(U
Of

.tAAk)~Tt

""'':* ,~

'-

.OU...

Now the drs"..-r umt conn

be built l'hL'"unu
I..;,made h)' j()lJlin~ ttlt' .nill<lll .,,,1 OOllll,n
shelve- \\ ith ff)1Jt dl'1,jen;, :8<'1.'
R \IJOf:T .UR 0 \1 k "\.\1:1 l'h., Ii...t ~lel'
~ to C'IlIa .. rabbet on 10' balk MI!"" of
Ih\ WI' ,hel( 1(') and bottom .h,l( (I, (nr
the .. back pane] IQ "",' t tg. i.
ACter these rabbets an cut. np th.
middle sheif E I to final .. idt h to equal t h"
d"lance Irorn Lhc rabbet 10the (1't>1l1l'11l'
or the tOj)'botlom Aheh '''' ... ,e t Ii: 7
.JUN)&'" ."CtR ['1\ Iltt.N'" ~l'\t.rot the
four .. lde by .-d.'Cp d.d,~ for Ih,
d"id~",(.Il tlw , ~od (ar< of thl bottom
anti middle .""Iv~" ~'" f II': s.
To cut th(':-.\ dsdoe -, !"It t th~ (11"t"I'~
bft ....t.:1,.'O the ..\\lcl( ,laclfl blad, arwt thl"
rip fence to 1 , 311rt mal a II,,1.AAon 1~llh
shelves, Then flip the board .-nd (on,,,1 tu
make dA(I<K>:-.lh\ NU11\' l)uolan("I'(t .) I rom
lh(;t other enci. :\(,\1. r,~t Lhi (\'h\'l' (or
12V;" anll cut \\'(1 nl(Ifa) rlallu("s oll "ach
board.

,,

DIVIDER

01""'01
NOTt lOCAJION
Of aoss OOWll
ttOUS ,.. tli.ArlON
'" I'OSI'_
Of ......

(CUT FQIJ. "(CIS

..
......,

aaca

-~. . .....

n.

UNIT

DRAWIR

"

...

1". -

NOTE
4U GIOOV(\ ...
wlDl a, . 0(1'

Ant>r lhll (littltltS ,II't' I,.....'m

I,Jclc, cut four drawt-r Cll\'lfltrl'l (4;J (I'Clll1 1 1
1\ I I)""Its

stock

lQ U

finil'>l,c() width le, Inal('11 lht

width of the middlo' shelf. and til" h'n~"h uf

31r;!'" see }-'iK ti.
'" IOUNI).OVIR ON
TOP ,.ON' EOGEAND

aonC*

ll"

fRONJ fDOE

~C:RO::S:S:;S:E:CT~'O~N:,_...,...

otAWl.

DIVIDE.
G

.onQA4 SHIt'
o
~

OIVlOlIS ftUSM

WI'"

,.lOm IOGl Of'SHnvtS

..,. -~.

MASONIJI
SPAUI

TOP SHIV:

tK;l-;~_

""to

Tht.r'(".t_&

';"'(.'Uor. 111FiJ= \I.

n h.<R<~I

n '"

krep lhe .1",,, en; (rom II<rdp,njt' on Ihi.>

<h:ll< Ira.! "hen Ihe:r"re pulled nUl.

r'g

SlOW

:w. 1'.' ' ;

C)\ ..

shelfand only 0111' (n.1l1 "I~,' o(lh., mid.II.-

... ... ''''''''

..._,

~I
DfYIDf_1

R()I"I'

and bottom shelf with U V,,- r-OUlu-"()\'t\f bit,

rt>(er to the C ' ",-octiollin Fijt' !l.
1", 11,._ft~
\lltl.\ SU\' ~IUl'th" (Ii, ut
eno III the .1.dOl rlt('('kinl[ In make sure
I~'",
Oll.h .. ith th. (ronl and th., ,nd
art' -quare, see f Ig 9
1'1( \~ .. H. ",'\(
. k ... \\'hell the 01\ lfil'r 11111
'" ,II'): C'Illlwo \''''<Olllte ",,,,,,,;( II) 10
fit tn Ihe bottom o( lhe dra.er .' ....'mnl.... I

uu to

An",- <ullin!: lh,

more :-olel}beI()n- a:'~lnblinJ: the ctl~.\\tJ

unit. ER.."'l'over both Iront ,..lg\~~of thl' t~)f)

UVfl RONT fOG( -,

1St;Tilt: "i't.sl;( 1:.'.

dividers to size, cut lon,I(Ut."b c('lll(r('~1 UI\

bolh end, 1(. iii Ih. d(lfloe' in Ill(' ,h<'ln' ..,
...x- Fi.:. !I.

21) (k("..,

tie.'

gluing the ~ll.I"" In

Ih(' fToJlt edge- 1(1 make> It f-a.,'llf'r (II

kid.lo iii th~draw.", Into Ih., "I...
nm~.
be\it

JOINT DETAILS

'-,.... 't8Ll. """1na11~u..( :r ronnf'C'tor ...tt)

.."" mble Ihe f.ocl 10 the UI'rij:h15 .nol ~

COnnl",lol"> 10 fa-It'n Ihe helf Ulilt Mild
tnteller tn th( UI,rij!'hl'. "of' ~"j!'. IU

caoss

DOwn

DROP fRONT

the ba...ic: cfc...k unit j~as! jmt.l(ocl.

\\"Ol"k can bt'gin c)n thl' oro}, [runt 'l"h,
;\'0\\' that

100'

,A'

t ht tfl)' 'l"<lrnltJdl(.'

sht.'lf

to allo,," acte!'.." to IhI:'(IrA\\'t~ t'\'('n \\h(n

il'.clo,,,d, see pholll on 1'1:' I, In Ih,' hOlO
il hI\> a ~'onni"a"'O\"'I'('d lJ3'I('I. bUI ulhl'r

SIIITCHt. f
(IOUNOOyrl AU
FOUllOGISl
<001

fram'" fit!' hc-l "'('P"

, JOINT CONNfClOI
(fOOl TO UHIGIfT ONlY,

option.. are di""u>",~1 ill

HcIUI'\'(''',

"K. 21.

('l'T t'RAJlIEl'tt:('~S. Th "llIk~ lh~ (1,.111('.

start by clIlling lWO .Wes (0 lInd IlOO1'1111.

\VOOJ)SMI'lIi

(.II (",m 1~ .t6<'k 10 1 _ .. ide, "Then trim

I~ ,II, 10finl:'h,'CIk>nJllhto equal the
d'-'ant(' (rom the top oilh~ top -Iklfto tbt
bottom ,,( the bottom .helf. see F, . 11.
'ron th< rails to len:gtil ~ Ib,
iram, fib between tb~ uprilCbl~. Tbt-,
makes th, mil. 2' .".,,, lhan 1M wi<lthof

sruaT(~

...

:S.",

tht' desk
width

f1IWi'nlng.

tThu; 2

"r hc,lh .1I1~" the

fl-

allows

(llr

--

......
,..

......
I

RAIl

,....

thf>

l.nl.'lh o( stub

STILE

DRO~ FltONT PANEl

tt"nllnlt, ;tu(1 ~ :-.pa(irl~t

I. ,\1 I x vn: rue l-l)I(\11(.'" Before as~('Inl)ling thr- r''i''lll', laminate a piece of

t.AMJNATI 10rM 'S'DiS Of

CROSS SECTION

coo

I'flrlnil;'~ltn ,'uri, ..jt)", (,( a 17 x :11" pi(-,\t> fir

~... ~1"H"lIIh.(It "ill be trimmed to filial
(Iimf'n~iclI\~
later )

MASONIlt WI'" '<)tMJCA

,.,

AU G'fOOYIS(I~Tla(O
ON SToc.lC

DI('

(-t T (;nIK)\ t:!' .soy. cut ,b.'TOO\'e-!'"

on thto
in j.)t l"ft~~ of thl' frame I)i("('tl... ",. nt>t'fl
ancl JU~l ,\j,lt.' l'll0U~h to accept lht'

l-()nnK"a"("O\ ered l13n..-1, see Cross &"C'lit n

In f II! II
sn .i TJ. \:()'~ Aft. r the gnwJ\.\.-....an: cut
rut stub II nons on thce",I",,(the rails to tit
th. grooves, oc<' t '1::. I~.
SI'\I t.N ,TRII' \\'h('n the frame I'
"'mb ,,1. Ihe bottom rail ha. to ",. ",,-1uoned FI the rlr3v.ll~ can be fl:."m(,vt1i
when th,- (ramt. Ii' til tht! ~:lf.:-t'rl posirien, Til
elnthis t()(1 n flat't'Y :-.lnp in the gtVu\(.. on
tlu- l eunm ,,( paoh stile, ~'(. FiJZ.la.
This ,I nl' b cut to Icnlrlll to equal tll('
dislllllc('
w",IIII1. bottom of the bottom
,1101(1"th. bottom 111'111,
middle shelf. 1'111,
Itt f(lr eh-arnnce, sec "ig. 12.
(l T THEP\'.:I .. :\c.,\\: dry' as......
semble the
(ntml. to ):'l'{ the ln~ldt.dimensions (If) tllt_'
bottoms of the ~'I"OOq...) an<icui th~ ""n.1

'--1

u.t

to

RAlt

.All

oaT A"IIUU
MAIl( I"'SIOt
COthtl

STill
I

3'.

el\ f:l, . IM.":''''': Bt'i re 1inal4L..~( mbl-: round 0'" the In- de edJr'" of tbe
fram, "lll.a .... und-over bit. The reund-

111'HI'(;

TIlE ("OR~t.KS. On~" th~

0'

_.CIKI
101lOM
.... 11

SlU, I

CUT SJ'AGU m#
TOAt GtoOVf
.. .. POSmON

TOP COINER DUAlt

OH'r rout",1 alon!! 1he cntirv Iength uflh.

rails, but I'" Z'tulJpetJ on the stues, 1m'
a.-.,,mbl, tIK- frame and mark the inside
eorners. Then ch,,,,".mblp ancJ rout th,
,<file ~toppml:short or th. mark. Fjnall~.
coml'l.t. round;n): hv hand. see fil!. 11.
\..,~
.'tit I ..; ~\ \t t. \' I) 1'\~.:I...A ncr' l he
corners art' rflllnf.icd. glut" the frame
tO~"('lh('rwith th~ IlIlllCI;n place. check;n!!
to llt, ~un' Il'" ~qunre.
(ram(' .,,,II'.n~1 ar, .",",bled. round lh~
top t"u out ..id<- cr)nw~ to a: ~radius, ~I?e
hI!". II. Th("lleat-(
cr all the out~,,,,,
.. tg{og "Ith at
rouOfto()"ttr hit.
PI' (rr 1"\ The (froJI fJ"t)nt ph'ot:; on a pill
m:uiE" (rom H N,"h'\\. f.("c f'i\!'. Is.. To O"t>atu
.karol)('< (QrP 'oUDg. fln-t file the oollom
,n<L! of the ~11el< ro"nd. Then driJJ a pil,,1
hole and liC"'W In :-'0. ' ,1 _. wood""""
until onl~' Ih,' &hank sucks out. Finall): u"",,
a hack;a\\" to cut off the head l.amg. ,.
Itlng pin.
To i""WU the dr"I' (ront.I...en IIK- ... nn(.'(!lo~ unci InOUl1t the ~)jn;o.in the pi,{,t
holes ill Ih. IIpri):IIL'. H'C Fig. 16. finaUy.

MIDOlt

SHIll-

fit
RC)l 'I'

PlYOT PIN
DETAil
I

".

"'

.. '"
SIIU

aOUNOOVU
EHOSWITM
flL[

N08.1',
WOODscllfW

"' OIUS ON TOfl

OUTSID(COIN(IS

CUT HEAD OfF AfTR

SCR(W1NG INTO mlf

01 Slilts

!GUlf It

000.(l'

mOllnt mll~"lC'tic."teho, to hold Ih" drop

(rllnt 10 thc' 1o," .h,'lf. "eo ~il!".17.
\VtX)J)~MI, 11

,. .

GUill.

THE CHALK 'RAY

)'

C"A~l.AY

'CUlllOM"

.) STOCJc

lOUT OUt GROOVE ,_

Dl1P IY 1 .. W'OI

..... trwo

_.A'"
....., .-_;_

.......
......
:::.::=r::,'U;._I:=.::. .:..:.:.=--...:"'=''!=;;;

N.S~ISto

.....
,--'-1.j--'--- -----

C~

lOX lIT

AGU.I 19
SClEW Af'oIOGWt

"'CU'
10f"IAY'
OOnOM::::::"iO::f'
SIDE OF
I'OSITlON TaAY ' '

flo.... IOlTOM Stfftf

1t. '.

NOlxt.fh.
WOOOSCREW

NOTE.

..

SCREW CHAUt flAY

10 IOtTOM SHIl,
(DO NOT ClUJ,

,5'.

11

fIG
WIDrH Of OlAWl1

OII'(N,,..O llSS

"~.

SJAmWl1H

AStOt

GIOOYf

I.

..
I ''''

fRONT 8ACK

,..

(CUtfOOl "'CIS)

.le'lj(I1\,1 '" Ihp <i'llilk Ira)

I.'

and rruLke a "'<'roM pa.....

Then mo' e tbe f,nee oJ,ghtl~ 1IlllJ/i from
tbe bit and "'I ...at the pro<e<lure unul the
groove i,1 .. wide 1:\01. 'Ib ke.... th, bit
from zrabbine tb e workpiece, 1I1"3~'S
mo'Yt>the fence bark: 80the bit is l1.~ttll'~on
the fmnl of lh,' j!TOO\'l' )
TI) comptr-te th(' l-'I'c.I(~'t-, rout a cove on
both ~j{Jt,_>g(,f th v grfJ(t\

~ \\

hh 8

l'tII't.,lwlx

bit. Locate tfu Ienee ..o that lhll ""'Itl'r (,r

the bit i, 'Lli~"ll'd with th,' shoukh-r "f Ih,'
gJ'OO'e.:-('(>!-'ig. 1~,
Si'l('t'1nC)~t~ ..eerv
bil. rout only to "d"l'th "f about " . make
lhe cut in two tm!-'~c~to I(l'l It (Il'lllh "f ,,".
flOl \"1>1)1(; Til>; ('()It\"I;It~.Aftol' IIu-

.I'('X

groove is routed. round nil four ".nll"'''' to

1':" radius. Then c:,~t' UVl1r all thf' tOfI):(,.
\,-ilh a 1.' fr'lln(}U\'\'I'tlit

CHALK TIAY

SUPPORT 8RAC~Er

ea-el

(and <Ira"",,,1 ran be u-a-d "h..:hrr the

drop front IS ~IJIor 11o"n
THi: TJt.\\_ To make Ih, ('hulk trd~ 1.1,cut
a pieee of I I stock 3 ." de and to 1,,.,,'1h
~Jit':"
- le:o-... than the (1".Utncl' lM.'tV."'f-l\
the drop from til"",K'" ~ 'I! I~
ROIT {;Ron' t;, Then n.ut a -d'~I' b~
I :wide \!TOO' e eenter..-d on I~ I~ 11.
rOLlIthi ~,
.... on the roult'r table_ I
.lartNI with a 1'0- t!tr,lI~hl hIt rou~h!y
....ntered on tbe "orkl.( ... 8(.., ~',g l'
~Iake a J1'L". tum the ~l.O<'kend fur 011<1.

SIDE 0

NOTE AU OIAWf. sroa:

OffP

ISU ,-.oss SKttOH

l'

down the- t~ ~.th, dIalk lr ..~loal.IN.'un

sc:n-v.:t.",J .nd removed.I

US .... N TO .. THlC.aHHS

$lot

or

StAllS Wll" A PtH

,CUT fOUl P1.fUS

S'-f~."i)Jtr HR.\( " ..:n;. '1'0 m41U11\'

tht, truv
to the bottom ~hl)(. make t \\'1 ~Ur}pc,,;
brackets (~rl jnll (If ,,_,'raJl.t 1..tIH,'k. J'l(tt' tu :
fig, H' Th." ,,'re" und IIlu,' th,' hrlllk.\<
10 th,' bouom
lhe chalk tnt.>
~ 0\\ center thl' chalk tnt\ on the bottom
6h~1(and t!C1'f'" tbe bn"'kel& W Ih... ,h.lf.
...,f~r to .'11':
1:\011' [xm'l gil,.. the
brackets to the helf If you \I ant 1.. 1,,,',,k

THE DRAWERS

'TIw two dra....""" ..... made OUI of '-th,,k

stork Itnd Joined ,.,lh 1><" JUlhl$.
t ITn'1; nn; 1ll;lt;.
... To mak, the four
dra""r fronUback I"~'C'(:\1. ('ut I""
pll~ of 1 .a ...tock to a ""rlt h flf 2 .- and a
rollgh ["\gIh of 10 ., Th(n ~I 1,.0 mo....
pst_'('(".. 2 .b~'i
,{orlheCourclrA\\tr
ties
II

R..... w th ..,... f'OJrbL,nk.. 10

.1

hick

ncs.~to prudu('(' the ('I.:ht ,Ira" tor Illt"('I'"

To dett'nnin,' Ih.. fin"h.~1 h'nlZ1hof th,
(ronllback pi""" Oleasun> lh, dra\l
"""nln" and .ublnt,1 ... lin my ...... lhlS

"r

carne out to 91

~.
l
::
.-

fl'Vu. ONflONT

S'O

80' JU",.",
flU VOIDS lEfT

IY eonOM GlOOVl

CROSS SECTION

((Ntl'

WI'" rum

I.

MASONI"

CORNER DETAIL80nOM

1.-, f.1~1';"" 2(,.)

A& ('JI"lhc

"de pie'>. th .. l.. n~'1h .huul,1 ',<)11011

Ih ..
rl.plh of the ol"'"ing.

An., the drn\l "r p:u18 art'

cuI to length. th,' box jlllnh <0" tit ,ut.

(I-~or a fitep ..b~'-st(I)arlitll" (In ho\\ t(, l'tal
box J0inl8, t\('t> l~!(~r~/~"liIJt.
Nt), SZ,,)
Cut y... !II; Y.- IJil\~ Mill :,lfll~ rnr tht1 tXtX
joint> on the end of ell~h Iliec". Tho front
back piece. (Nl hove five pin. und sl:.,.1
\VOOOSMITIl

with a 1Il0! on III<' top colge while the 41.,

cO; ha\ t ~\ 11In." and Fotart with a pin uri tlk,

top

nu"

TI. tiT

.......

:\v" test the width or a

dno".r piece n III<'0l"'run~ lOU may M, e

10 trrm JU t 0 '"ud~,'()11 off the 101' anti
bottom .. I~.. until II Iit s,
UUTT.,,, (.MIHH t.. When Ihe drawer
plt.'Ct'!o\fit th~ cll"lning. cut 11 ~ (.-wide b)'
y,.dtI1'
alo'\I: th~ bot~om inside
,,11(' IIf ('lI<h I>I('C(' 10 hold a~, ~t.""nrte
d.lI\\,r bottom IP). Ltll:"t~th.. groove in
li",' with tht .. cond pinlSlol up from th~
bottom tcI~l........ Detail in rig. 20.

r---;l

IOtJNO

...

OVII

BACK
STOP

1,
MOUNTllltG

PACKI'

~COUSllC4LCDUNG 'IU

Kl""''''

(liT' .'(Jm)\,

--

BACK PIN UP BOAR!! OETAIt

see t la;. :!i'

l'1li'{t I

MASON,rfI.C.

IACIt STOf'

SHIETCotl(

"'Of
000

~E!lKL..To

determine th,.ilW ofth e dr.\\ or bottom (1'), d,,

a....~mt'1lt:.at'h draw er. measure th4?> in~ifl(>
clinltlL"IOIl'and alt" ,. (or the combined
(i"llth (If t t ,I "''''_)fl\ (". The n cut the bottom
leI fit al I J: LJ\ rbe dra\\('r l(l~thcr.
"I)

ACOUS'1CAL
CEIUNG

nu

.,.
'.

MAS<IN11t

...c<

III'tII t" Final". in-tall Ihe handle,

c\,' o1'n-t1
on thl' rro;,l. of each drawer
lACK PINUP BOARD

SUPPOl;l AlM

\llI.n tht' drawer- " cre eornple te, ( eut

th, back to fil and m"d~ 3 pin-up boartl to
fil
een Ih~ 101' :",d middle shelves.
II KJo. Cut th back \(1) from v.. ~Ia."'nilt
10 fil ,",i", the ul)liJ(h~and betweenthe
rnbl"'l. in Ihl' 101>and bottom shelves.
I'~II II()AIIlJ.Then 1 made the pin-up
board fl~.m H l>it'Ceof V. -thick cork glUM 10
the -mooth (back) .ide of an acoustical

m'l"

('t~iliJlj{(ilp

I. (()',

()th(,I'

pg. 21, Onc,' it',

inK. -<e fig. 21.

rl". cui it 10 fillh.

open-

To h"ld Ih~ 1'''''UJl ho...nl in place, cut I we

.tolh(RI from I I ,'.)('k and serewthem to

Ih. ul,ri~h". """ Detall in Filt. zt.
"inal": lIl.'l'rt Ih"I,in'up board Ifrom the
back "I(I~)und Krt.'\\ tht" )1~.rule ~'l'"k to
t~

fO!'

...

..

options, see Sources,

...

SCkEW'AC~
INtO .AllaS
WITH HO

MOUNTING

S .. I Fh

aU'KT

Q'

WOOOSCREW

,
~

"fOs.,,,

12. ~
MlOOtI SMIU

woooscwfw

.. -..

,h<'!"...
HARDWARr FINISHING

The 1 1 .ttl' i,to in-tall the hardware to

,t,. NYlON GUDI
....0
SUJlIKlrt Ih, dn111front. (S(.", Sources. pg.
:!-I. fctr in(~)I-mnlitln about lhi~ hardware.)
L----MA...:.::..:'r.::R.::IA::.l:.:S=U:.S-T
------Ididn't follo\\ the lnstructicn Ihat came
with Ih,' drop-Iront support. Instead, \()
Ov.,oll Ofmtn,lon.! 3. w Jt 30" d 48" h
mount Ih~ t\V1Isupports. fi''lll lower the
A FHI (4)
,.",. x 3~ 18
drop Iront into. horizontal position. Then
Upnsht. (4)
''II. x 3',4 44',
>ere" Ihe lOp mounting brackets to the
C Top SM" (1)
It.-,. Ji 132
fronl ul'n~ht". refer lu Detail in Fig. 21.
o Bo"o", She" ttl
Il". a 732
No" If)\\ l'r thl' :-.Ji(Jjn~head tn the lo\\t:....t
E M.clcfl. SMlf (1)
''"', 6' 32
l~),illf'n anft attach th(" IO"'{_T mounting
F S'mchoH (1)
"
a J'~- 32
hrack~I'10Ihe uprights. \\llh th" .Iiding
G Orow.r Dn...den (4)
l.).ll X 6"-. - 3' ..
Iw.d MiIIsJ.:llul! I th. (0" ~r hracket. in.-tall
H Otowe, $poe.,. (2)
1."- 6"' 9 I.
lhe '"I>port ann b.,..,"eILo the drop front.
I Drop hen. S".... (2'
'-'I,. l' J - 22
1I."III.r. ...,,, (;Ln.:i. To romplcte lhe
J Or.p ","" lo.b (2:)
''';' xl', -~
__',I...k.mount I~ handle on Ihe OUI

CROSS

1'f'C~..ing

the sete\\"'S

",1"" th, .urface on the ""jde. Also. al

Ulth nl'lon 1>.. ", IIhd.s 10 each foot I~,
frum Iht ~n,I,. see F,g. :.!O.
t'I'ISIl I found II ea.,jc.t 10 take the
whol( lhin~ allart for finishing. Then I
appli~d 1"'11ooat. of .atin polyurelhane. lel
.t t1r)\ nnd ""RAAembl ..d it.

K OropFrom'onoe'(I,
L (hotk T.rvr(1)

' ... lS.-.29.).

, :a 3';'. 2a~.

M Svpport iko(k., .. (2) t, 'I :a 1... 5'"

N Ota~, F,ont'lolIaGJ (4) I. :a 2",,1 9J.J ',.
o Drow., S'd... (4)
1/..' .. 2"A, _6){..
, Orawe, Bottom. (2)
"
6~ x 9/,.

o toek

(1)
R aoc.k $t0l (2)

,~

':V"

21 I/, It 32
)( tIJ 16..

DIAGRAM

A'llOA,IOS '.'1\0

I.

:-i(lt" of the frame.

SECTION
CUnlNG

It

7'.- 72'

--"'.

L
J

A150 lEOU'11S
MASONITE" .,.
\19< H.K.P'Q)
ONE 'tECE Of fORMICA36 36

-'ort. N ond 0 produe. two 1.....thickpiK"

when Nwrwn from .'4 ('" I. octuol) "'ock.
"Port, M ond R can be (ul from % terap.

------------------

Woons~IIIH

Desk Clock

A MITERED TIME FRAME

Sometimes It's hard to imagine
how little wood it lakes to build n
clock, Th,>ca..... for this desk cluck
ran be mad e from a few small
.CTlIpS of hardwood,
and the
movement j~ an inexpensive
battery-powered quart,l( model.

(~

Sourees, pg. 2<l.1

THE CASE

The case for this clock is based on

making part of an octagonal
(eig!lt-sicled) Il-ame. It starts out
as one piece oi 44 stock ripped to
a width uf2VtaJld about 22" long,
see Fig, I. (This is loneer than
needed to provide a "handle" for
cutting the mite,." on th~ small
case pieces.)
The inside surface of the clock
case has two grooves lhal hold
lhe fronl and back panels. However, before these grooves can be
cut, Idid the preliminary work of
laminating the stock for tho panels so I could determine th~ final ------'
width needed for thc panel grooves.
TlI& r~\-"&LS.The easiest way to make
the panel, is 10 use Yo hardwood plywood.
But I wanted to add a lillie color to the
clock. so I made the panels by laminating a
5 by 10' piece of ~'o.-micato a piece (If '"
~la.'Qnite using ""ntact cement.
PA.
...ELGROO\ES.Now the YI"-dceppanel
~OO\'e$ can be cut so they're .et in Y? from
the front and back edges of th~ C1iS('.
Th do this, a(liust the fence se it's '"
from Ihe blade, see Fig. 2. Then pia" a
groove down one side of the workpiece.
Swap ends and plow a second groove on the
opposite edge, Since must blades CUl a kerr
about y." wide, \'cry tilli. acljU$cment is

passes to widen the inla)' ,l!l'OO\'.

to its final width of '1'w ,
CUTTING THE INLAY

Mer this eenier groove is CUL, an

inlay strip is ripped (from eontrasting wood) to fit thv groove.
RIP 1-"1..\): Start b)' ripping n
piece of ~'4 stock the same length
as the case workpiece 8JKl just a
hair ever Y,' thick (so when it's in
the groove it will stick above the
surface of the workpiece).
Shop Note: \Vhen ripping
pieces thi. thin. I use push jil!
that rides on the fenee of the table
saw, see Fig. -1. (For more on
building thisjig, seeThlking Shop
in II'oo<islllilh No, 39.)
RII' I~LA1'TO"IDTII. The next
step is to rip this .lri,> to the
width of the !!''OOve,see Fig. o. To
maintain a unifonn width, I us~d
a small push stick to press the
strip again'L the fence just ahead
of the blade.
neee.. :uy to widen the groove to fit the
INLAYTHE STRIP. After the inlay 511;1>is
Formica, Masonite lamination. tlf using
cut to lit the groove, glue it in place. \Vhcn
plywood, tho groo\'. would be widen)
the glue is dl1: plane the inla)' flush with
THf: t~l.A) C:ROO\"E.After the grllO\'CS the surface of the workpieee. Next, round
for the panels are cut, a "'-\\'idc by V,"_ over all four edges with a ,." round-over
d""I' groove is cut centered on the outside bit. see Fig. 6. Then cut the ends square,
surfaee of the case for an inlay strip. To cut
CUTTING THE MITERS
this centered groove. adjUSt lhe fcnw ,;0
the blade is almost centered on the work- Now the five small section....for the clock
piece, see fig. 3.
ease run be cut orr lhi. workpiece. Each of
Then plow a groove the length oi the thc:--t ,)if>C('$ 1"t"qUlrt"!' 22l,tj miters,
workpiece, Swap ends and make a second
SF.TTII~;.\~(:LE. Adjust the blade to
pass. This will produce a gt'OO\'C exoeLly :l2', angle and make a teSl rut on a scrap
centered on the width of the workpiece,
2.1. (S!n,'c all of t he case pieces will be cut
Then it's just a matter of mo\ing the fell''<' on thl' "\\'IISle side," check the angle on rhe
lowal'd the blade anel making two Iharl' pi"," Iltul i.
off)

Y'

or

ROUtE 2

CUmNG 'ANEl GJOOY(S

so alADf ' H1Gtt

flNCt

,,,I

eurnNG INLAY G.OOV(

Of" aLADE I~."HIGH

_"'r-I
" ..

SECON,'AS' /

cur

GIOOV(
TO MATCH:

W:.oJlj~f

CROSS SECTION

.. '-.t--

,~r[J":"-;

-'ur-~--'

l:{ ',"...
10

,N,OTE:.UN 0""'"

EDG

AOAlNSr flHCt fO:

2nd ANO 4,1-1PASS

-FIRSt 'ASS

NotE: RUN OPI'OSlTt EOOE

AGAIHST ffNCE roa
2nd AND -Cth PASS

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

~.

rn
fOURTH PASS

AWAY

~'HttDPASS

,"ItO PASS

\),'OOOSMITIi

To help eheck the blade anb~e. I drew n

22~' angle on a piece of paper ami cheeked
the miter on the 2x~cul-off, see Fig. 7.
(For infonnation on how to draw lh._ angie. ee Tip> & Techniques on PI!".:1.)
~ET U' TifF.~\\\. Once the blade angle is
sei.] used the following set-up tc mner the
pieces to length. First. I clamped a s 10p
block 10 the Ienee to gaul(\' the lenj!(h ufthe
segment. see fig. 8.
Shop Kote: To prevent any chance of
kickback, IK- sure lhe step block b in front
of lh,' blade far enough that the workpiece
can't eontact the block and the bladeal the
same time.
Abo. 10 help hold the workpiece ,"ead;'
when cutting the"" small pieces, I added
an auxiliary fence to the miter gauge. CUI
this fence 1(1length .0 it extend s about I
beyond th saw blade tso it .u1'I'0rt, both
the workpiece and th" "ej!"menl being CUI
off on the far ,ide of the blade),
One other tip: To prevent the workpiece
from "Uding tluring the CIlIJl. glue a ;LJ;II of
,andpaper to the fat... of the renee,
SJ::T('\'T-(W>' t.t:SGTH Now the two uprights for the cluck ease can be cut to a
length of 3". (mea.<wing frnm the squatv
end to the point of the mite!'), To set thi,
lenJrth. first cuI a kerf in the fence to serve
a.' a reference point. see fig. ,..
Now place the workpiece against the
miter fence (making SU''e the inlay slde is
UP) and push the end of the workpiece
again.t th~ .top block. To determine the
length of the upright segment. lay a nile 011
the workpiece (see Fig. ~). and adjtlSt the
position of the .top block until the :l'''"
mark on the rule a1ign,- with tbe inside
(fence skle) of the referen ee kerf.
crr ri..: 1"RJGHTS. When the step block
is 8Ct for the right length, CUI an uprighl oIT
one end of the workpiec.... see Fig. 10. Then

flip the workpiece around and CIII off the

second upnght from the other end. (Be

RQUIf 4-

FlGUU S

..

t!m.
RiP A
-WIDE

STilt.'
~

. WOOOSCIAP
PRESSURE snCK

,(}

,. 1
STOCK

AGUR 6
GLUt INLAY

'NTO GROOVE -

'.

ROUHD.oVER

sn

IOU'ER
TAalf

Uf"'-E

'Y'

IS( nit JIG

SAW SlADE

FIGURE: JO

ROUtE l'

lE ..rllM tNO 01 WORKPIECE

sure to keep lhe inlay side up.)

ro COItRCTTHE ANGlf

TRI\' Til!; ESDS. Ane. both upright.

have been cut. the mitered end. of the

workpiece have to be recut to get the
miters l(oillg in the right direction to cut
the three top segments. 'fum the workpiece over (1;0 the inlay side faces down)
and trim both ends. see Fig. 11.
(XT THESHORTSEG:IlS~'TS. No\\ follo\\
the same procedure .... on the upright., tc
CUt the three top segments to a length of
211.. ' (from long point to long point of tho
mitered ends). sec Fig. 12. Adjust the
fence .0 the 2,. mark is aligned with the
reference kerf in the auxiliarv miter fence.
Then cut a segment off eaeh end of the
workpiece.
Before cutting the third piece. flip the
workpiece inlay-side down and trim one
end to gel the miter I(oillg in the right
direction. see Fig. 13. Then position the
workpiece inlay-side up and cut the third
segment from the just-trimmed end.
WOODSMlTH

'WORKm-CE

SAWDUSt

.ruiF

',NLAY

S'DE

SA.W II,.AD

AGUJt! 1

ooWN
flGUIf

",.

SfGMENT

R[.SET STOP BLOCK

TOWAID BlADE TO
CUT SM.A.lU1it ",eelS

INLAY
SIDE

"''',

13

__

r---.

2',.-

Itl-TllM

(NO TO
CORRtel

THE ANGlE

'NLAY SlOI!

00_

11

ASSlMIll

Aft~r the Ih,'case "'b'l'l1 -nt-,have been rut

to knl!lh. t h<Y .. III he ~"'u...J together to
fonn the .....se Since the- at'(' ~nd-~"nIin
mit er jomto, Ih" k,'y to glumg :h~m
tugether to fonn a .Irun~ bond is careful
appliC'JIli..n of J:luc
J ap pIlM the Klu, in two steps, In th,
Ii"'t ,t~p J rubbed Ihe glue into the end11"''" and "'r"~I.\\'.yIhe excess. Then I
usetl my linl["r up tn 'PI~.rl
a "",'On(llight
coat un thl' ,nil,t',~1('n(l!lju~lbefore pressinl! them l{'J.!lthtlr.

..... 101'

SfGoYotHl
TOONf

S<Cl1OH

THl eASl

,
t

(;It ~ l ,'tl(;"T ro St:(;\It:,'T The ~e

quence us v(1

CASE ASSEMBIVSEQUENCE

r-

.,._

ll'

'Cmbl(. the (rame- In-

.~lijlTlm~nt Ig

HOl.O 00_
RAJ AGAiiNSl

- "\(\

til

\ elves Joirun~ tach upright to on. angll'd

top M:J111l<'1l1
1in;1. ".(. ~t('p I in Fig. II.
here
difficult since you're
...-oriong witb round",1 l-d~C'.[ did it b)
carefully align>ng the ,.. ""I grOU\'(>; on the
JJ..f( d~surtaees, IW\' ,,"jg. 15.
\\'hen th.. I",,, 1'1('('(" are ali),'llt.'d, p"""
them lil[hll)' 10g.lh.,. (ur about a minute
while !K,!dlllj[th" ""'mb!y flalaj!3in.<t the
work ourf.",. (I pUI \\"'M paper on Ihe
work surfuce ttl k,t>Jlthe case i;4.~nL~
from ,Iickinjl.)
Gil E TII~:ro,' SM;M~;~'T.
When the glue
i. dry 01\ th,
uprighl :111{1
angled
:l('~>'JT\~III.
{lWIIIII (Ilur hours), the lop piece
can b<' glu,t! to om- th,' pairs, S(>~ :;tep 2
in Fig. 11.
JO'~ TILET\\(j~lJ)~;,
Then the Ja_<I,Wp Is
te, Jilin tht t \\ 4' JZIU~I'U~I
r-tdl';:. to form the

',,"fAa

'.....

WAJ[[O

jmn('<1
or

SAN-Qf'APE:R

;I

Cram e-,

~lt'I':!
In FIll 11.
S<l1IM"(, TUt. IInn ...\, After the glue

.nd.
nat

''''",In.'CI oH'm'ghl on Ibe as-emhled ease,

the
oCtile UI)r.~hto can be squared 10
....,.1 on I.... do..-k ba.se, Todo this. tape a
.Jxo"t, f """,I,,"pe r I". fl31 -urfate and rub
the C'JIN' bac:-k"",I forth
no 1:3P>' an>
I, n, .... ~ 11( '10. Ii(, elIl'\Jul not 10 Sire!',
IlK

~"'.",IJOIIIIS

MAKl THE PANELS

PANel

.st,"

IfWO '*f(.ISI

AUG'" lOP Of'

ClOCK'ANII WI'"

r..;

fRACtO

OUTUHI
Of CASl

cut til ElZ,,, l~(")!in b~' cutting 1\\'0 5"

"'I"un'" Then measure the distance be
I"t','n Ih"
Ih~ I(I't>Ilve,;in the
"I'n~ht., and CUIIh,' I';III('lsto fit.
It T nu, (OR'~;Il.~:-;CXI.the corners of
th, panel, art cut 10 match the angles in
tIK'<"-'" . Slid~ thv panel inln the ca:<e
th~ top 111<' i> .li~'l1,~1with th.. an(rl<o<l
JQ!llt. M'( Fi~.
Ii,
:-':0" measure th, distan .... from the bet10mof I....
grOO\ C in the top piece to
u,., 101' <-d~of t h, pallt'!. Then" ithdraw
Ihto I"",el from th. ell," and mark wi.
m~a>ur~m~nl
n Crom each upper
rorner on Ih~ .. de to( th~ pan~l.

until

--

4'

I<OU

ttu Furmiea-covered panels can be

boltom.o(

_.

~ 1
~

va.,..1

XU,\ cut ocr lh l"':tn)corners at a 15"

or'
O.,U

'M MOttS

tHROUGH lACK
SIOf OF tA,fVR

=============:::::~===::;;;;::;;;;========~~!x>=I:lo:m::..or
12

d""

,
TAACf INSfOi
Of CAS'
ON lACK OJ
ClOCK'ANlt

until

5111111:.' AkGUS

,IOM IIOfM MAIk"S

nlST JOINT llN(

"'l'

3111(1,
,lartinl{ at th, mark,_ After the cornerg ha\'~bt,,'n rut . lid( the ~lIels back
into th,' c,...... Th~n lIIark where the upnghts end, and Irion the exee~s off the
t he panel, .e(' Fig. 17.

\VOODSMITH

MAKE THE FACE

When the panels fit the frame. I mad" the

clock face by drillinJ! holes for the movement and hour markers,
I'OSITI():< Til.: '('F.. I wanted to make
certain the face was centered even thou~h
the panel might be cocked in the case. So I
slid the face panel into the ease and tra ced
the inside of the case on the back ,ide of'the
panel, see Fi!l:. 18.
The cluck hands are attached to a
threaded stud that projects from the clock
movement through the face panel. I
marked the location for this stud 2\~" up
from the bottom and centered between th~
tmced lines, see Fig. 19.
After marking th. location for the stud,
the posiuons of the hour marker!' are 10-

cated b)' using a compass to draw H l!.-

radius around the center hole. Then use a
square to mark the location. of the hour
markers on Ihe circle.
DR11.1.rue 1I01.f!S. Aner the IlOllitionK of
the hole. are marked, drill a hole for the
movement's threaded stud. (I drilled from
the back to avoid marring the face.)
HOLR ~1ARKR$. I wanted to have bra ss
hour markers. SOI made them out of No. 14
bra" s roundhead screws inserted from the
back, see Sum" es , pr;. 24. Drill '%, holes

(for a tight friction fit) and epoxy the

screW$ in place .
After these screws are inserted, cut
them to uniform length by USU11ta .pacer
jig made out of V,.- ~1a:.
sonue. see f~ig.20.
Drill four hoIes in the jig to match Ih~
positions of the screw s, Place the jij'( over
the screws and cut them off flush with a

RGUIitE 20
SJ'ACflt JIG

VActl

JIG

CLOCK PANEL
ftGURE '2

SAW OFf
SCltCW

2
SAND SClfWS
flUSH wnH
SPACE. J1G

HOUIf

,.

ACC-EN.l
stltlf' ...

ROUlt 25

- ",ll.Fh
WOOOSCRW

lRACi lOCAnON

Of

POSIOONING BLOC:
ONTO lASE

hacksaw, see Fi!.'S. 21 and 22. Then "lind

the end. smooth. (Brass "ill sand e.,ily.l
MAKE THE BASE

f'inally, the bas" is made. It's a sandwich

of the same wood used to make the ease
and the inlay strip. sec Fig. 23. FOJth. IWO
outside pieces, rip two pieces or.J,'4 stock to
a width of lV,., and about 7" long.
Laminate these two pieces to a "' rip
that's the width of the inlay sUip on the
ca.-e frame. When the glue isdry, plane the
surface and trim the base to a length of6".
Then round over the top edges,
POSITIO:< OLOCK. The case is mounted to
the base with a small block. Thi. block is as
"ide as the space between the front and
back panels and as long as the distance
between the uprights, sec fig. 24.
'Iraee the outline of the block on the
base. Then glue it in place, When the glue
Is dry. hold t he dock frame to the base and
dnll two holes (for No.8 X IY,' screws)
through the base into the bottom of the
upng. hts, see F'''19. _v_
GI\'E IT TilE WORKS. :-low mount the
movement to the face panel and CUL the

hand" 00l'ize, see Fig. 26. Finally. I applied

two coats of tung 011to the CMe.
WOODSMITH

C(NTEa

SCltW$

ON

L.__
-~
AUGN INLJ.Y ml'
WITH ACtE-Nf STRI'
qNr(RfO ONaASE-

INLAY
STRIP
/'

CROSS SECTION

NOTE:

CUt HANDS TO leNGTH

WITH SCtS.SOI:S

b.>l

t...

t--

Je

1'~"

l::-

o
POUitONING .

1-......

.IOCK

.-

MlNlItE

HAND

HOOR
HANO

DIMENSION OF HANOS

I;.. -

~/ ~l'1
3'

13

Round Trivet

A CRISS-CROSS SURFACE SAVER

)lakmg n round trivet like the one beneath
the teapot ~ an interesting challenge. This
lli"cl ha.' grooves routed til lighl angle> on
(11>po.srite side....ofthe workpiece to create a
unique lattice pattern,
\\'ben J IiIOI :;8,. une of tbese trivets, I
couldn't helpwonrlerlnj! how ttl hold a round
workpiece in place to rout parallel jlTOO"e.,
Then il dawned on me - rout the ~'TOO"es
while the workpiece is squnrc.theu cUIII to
the round shape.
A" J began experirnenung with making
tnvets. r found lhnl the thickness of Ih.
stock plnyt'd. bigpart in the overall appear
ance of the lattice pauern. Ueing stock
that's ,to ',. thick seems to look best.

:SO. to start. Iresawed (ripped on edg~)

""me stock 10 a thickness of '",., Then tu
make an l:f'dia. round trivet, I glued up
enough ~. stock to form a g' square. see
Detail in Vig, 1.
ROUTER TABLE SETUP

The Iattiee pattern i~

formed by l'Oulinjt
double-stopped grocves all both {ace. of
this square, To t up the router table tocut
lhe gro,)\'es, mount a ~. carbide-tipped
core box bit,
Shop :':ole: r experimented with bulh
straight bit' and core box bits, A <u'aijthl
bit tend. to bUI'T1
at the end of thp grooves.
That mc:ms sanding. So. I settled 011 a
carbide-tipped core box bu that burned Ie..'
and produced an lnteresting round bottom
in the grooves.
POSITION~'EN(.:.Om'. the bit is in place.
""'t up the router table to CUt a groove
centered on the workpiece, Since I was
working with a 9" square. J positioned the
fence 4Y. from the center of the core box
bit. see ~'ig. L
..\uD STOPBJ..()lKS.This center groove is
routed on both faces sothe ends SLOp I- from
both edges of the workpiece, To do this.
clamp plywood stop blocks to the tnbJp $0
the inside edges are i1''- (rom the eemer of
the bit. see Fij!, I.

stnp of 'Y' wood,

When the"" spacers art" mounted. the
~l~nit(' strips are placed again:':t Utestop
block., ~ the grooves stop ~."shorter than
the eemer p''Oo"e. see Fig. S.
The ]"\\"d. 'pacer is placed against the
fence to ,hilt the groove~ I" to each $ide of
the center zroeve. (Cut this spacer long
enough 10iiI .nlljtly between tbe V'-space,'>'
"" it holds them up a~'l!inst the stops and
keeps them from tipping, see Fig. 8.)
Shop Note: J found thal labeling the

14

S.. ..\C.:KS"'OM GK()()\...:s t

t'--'U

",j.

TIle

spacers used for grooves #,1 and 15 consist

of \~'U strips 7J. wide lhal go agailltit the
stop, and a ,trip 2" ";de that goe,. aj.rainst
the flnte. see Fig, 9. I labeled these with an
x .ymbol,
~j.\('y'tt.~
"'OR CHOO\ I;~S_6 \4'i1) .;_

>'JliI<l'I'>I used for grooves

The

#6 and #7 consist

of two strips 1%" wide lhal go against the

~0l's.and n strip 3"wide that ~s against
the fence, see Fig, 10. I labeled this set with
~pace~'\ithP'8phic~~rmbolsma(lejtea:-it'I
10keel) the sets togelberduringthe routmg .. [' .ymbol,
~

9'

..

MAKE POSITION SPACERS

At this point, the router table is .ct up to

rout. the center grooves, But, before you
begin routing. YOIIhave to make three se~
of spacer blocks for the additional grooves.
The ide. is to use the spacers to rout progressively shcrter grooves that "iU fit 'he
final round shape of the trivet, refer to
Detail in f'ig, L
SPACERSFOR GROOVES .2 AND '3, The
spacers used to cut gJ'OOYCS
In and #3 on
either side of the center groove consi~1of
two strips of ~. Masonite and a j"\\;de

steps. J marked the set for grooves #2 and

"':1 with th~ symbnl

r----.. NC!

'<~
stO'

810CK

4',,- ~
~.

.,..

;;-*

Po':.-

MEASURE10

ClNl'fJ Of

arr
USE A
\? CORl'
lOX lin

WOODSM1TH

I""U" 2

THE ROUTING SEQUENCE

IVhen aU the spacer; have been cut 10 size.

the grocvescan be routed. The depth of CUI
must bealittlemore than haJfthethiclrness
of the stock to produce the lattice pattern.
On I',".lhickstock I found the bestdepth for
the grooves was o/Ili
For a smooth cut. it's. best to make two
passes. On the first pass aU groove, are

$TOP

routed to half depth (about to'). Then the

entire sequence is repeated to deepen the
graO\'''S to the full depth of '"
Tll~ ,'IRS!'I' \55. Now the routing ean begin. Thel'outinll'sequence:rtartswilhapa...<,;
on each side of the workpiece to create the
center grooves. Position lhe \\o.kpiltCC in
the upper right-hand corner created by the

fence and the right stop block, see Fig. 2.

Theil lip the workpiece down 01110 the bit.
To roUt the stopped groove.jusIslide Ih~
workpiece from right to len keellingthe top
edge tight ~gajnst the fence.
Next. flip the workpiece over 10 rout H
center groove on the other 'ide. However,
be sure to position the workpiece so the

1"00.' s ,.,. .J..

just-cut groo\'e i~
11e'7J('1,dir"laT to (point-

ing toward) the fence, see f'ig. 2.

Shop Note: I found that the grooves arc
such a strong image all the tap of the workpiece that I kept wanting to tum the workI>i.."c$o the gJ'Oo\'('ontheIOp$idl!(lhe$id~ I
was looking at) ran parallel tu th,' fcnt'e-

10 the fence.
TilE SK(.O'iI) J'ASS. The second :>t't o( cuts

F;WOHIIJlfCE

OVU TOtOUl
GROOVE 1

ON $IDE ..

*~

'~U'E

....Un,

creates the two groovescn both .idl.,. "ith.

center groove (grocves #2 and #3). This
sequence is shown in Figures :l thru Ii.
The pcsition of these gl'OO\'C'iS
i~
eontrelledby the Ospacer set. see Fig. 8. \\1th
the threespacers in position.place thestoek
in the upper li),(hlhalld corner and rout
1,"1'00\'(' #2, see Fig. 3. Then keep the same
Iaee up but 1'O18ll' the square 180" and cut
groove -#3 on the other "ide of the center
groove. see Fig. ~.
Anel' these two grooves are routed. nip
the square OVCI'and repeat the process Oil
the opposite side, see Fi~. 5 and 6.
THE TOIRJ) PASS. The thil't! set of cuts
requires the x s-pacers to rout groove;,
and fiG, see tig. 9. It's repemlve, but just
make sure the visible grooves (on the top
side of the werkpleee) art' pointing toward
the fence when the cuts are made.
TH.: FOliRTIl P.\SS. Finaltv, the fourtb set
of CUl$ u_theLsPHcersct, and followsthe

"Gun .~,

\:::

the same way 1was mf.';0fr the workpiece.

The trick is to concentrate finkeeping the
visible greoves always pointing' toward the
fence even though the workpiece L, moved

parallel

fIR~T PASS

SjCONO PASS

NO S'AGtRS

GtOOVES_2 AND If3

,. WlO( SPACI.

'11"

1/ .. ~

..

*
f1
,

..... WID!- Sl'ACf.S

,1""

fQURTH PASS
GlOOVES:

,..
II

11-6 AND .7

3'WII>'"ACU

AAlIIeprocedure as before,
REPEAT\T .VLL 1>':P1'8. After all seven

jm)O.e~ have been routed on each side to

approxim~lelyhalf depth, adjust the height

of the bit so it cuts to full depth ('Y,.'). Then

repeat the entire sequence ofpasseson both
sides of the workpiece.
\VOOO$MITH

" .. WIDE SPACflS

IS

flOu.r 11
WORJ(PIECt

MAKING 'T ROUND

.
~

I
DlU,l HOtE fOt
flAMMEl POtNt
CNTUlO
C< _.GOWU

(
..

SPACE'., DOWfLS
TOCa..ESf()ND
WITH HOlE'S rN
WOa1C"KE

a ~,' slnlighl bit anda trammelauachment,

rTM
~

!-

11 rr;;~

maua)

(1 I ! I

'lI"c-tl'
TOP VIEW

SCRAP 2_4

t OWIEItR

x:t:LL15

at I I I I I
D

"." ,.LOf HOU: fOlt

LOWEIING

an

lOP IEW
cROSS seCTION

POINT

looft.--

WORXPlEa

Bho!, Xote; When u~ing routers with a

rigid trammel base, it may be necessary to
drill.
starting how to get the bit in
,,,,,,ition before turning on the router, Make
t,(!l'lUinthe edge of the holejust toucbes the
c)ut~id(>edge of the trivet circumference.

y,

rout the circumference in three

,,<'tting the bit deeper :uteI' each

oomplN< I"'SS,
WORKe(,..CH

FIGURE 14

'.

.OOND-.OVER

art

,,

MAKE !'ARtIAl CUT WITH

' .....ROUNo.ovt ... r
ro PIOOOCl -auu NOS'"

flGUlf 14

RGUlt 17

~..oowa .......

L..........SAHDPA".

ROUND THE EDGES

\\1,,'n the trivet i;. routed free, remove it

frqmth,'ji~;,"d round ever the edges, I did
thi> on th" router table using a -11." roundover bit 1"ise'<1 to Ie..'" than full height to
pruduCl: a bullnose edge, see Fig, IL
Although the round-over bill used has a
ball-bearing pilot, I didn't reel this gave
optimum CODlJ'Ol when rounding' the edj(e,
S<., 1added a sUlbilizinl"brace, sec Fig, Ir"
To position this brace. place the trivet so
the edge is firmly against the fence and
of ""Jill Uluching the bearing on the router
bit, Then clamp the braeeso it', perpendieulartotherencewithoncedgcincontnct
with
the edge of the trivet.
\\'hen the brace is in place, roundover the
edge of the trivet by rotating it eounterclockwise ,
t'I"ISHI"G, Ati.el' the edges are rounded,
I sanded the triv.l smooth and finished it
with Deftoil
ShoPNote:f!astraightbitisuscdtorout.
tbe grooves, the ends will probably bum.
Sand of( th. bum marks with sandpaper
mounted in a slotted dowel on a drill press,
see Figs. 16 anel 17,
\VOODSMITH

12,

1""'"''
VISE

,,!.

!'O\\'

PLYWOOD

16

Tilt: ROt,.,,,!: J 1<:.To hold the workpiece

in place while routing, it's mounted 10 ajig.
The jig consists of a piece of ".. plywood
wnh a2x4 scrap fastened to the bottomso it
can be held in a vise. see fig, I L
Next, three Yi'-dia, holes are drilled in
the plywood for the
dowel pins that hold
tne werkplece steady during the routing
operation. First drill a I'ihole at the center
of the plywood and Itlue. length of dowel in
the hole so it project. just less than the
thickness of the workpiece,
Then place the workpiece on the plywood
.... 1he dowel goes through the hole created
by the intel'l!e(:ling center groove., No"
mark th,' location of the two end holes,
Remove the workpiece and drill these
t\VII bole.. to accept "-dia, dowels. Finally,
drill 8 small h"I,' in th. end of the center
dowel t~accept th,' trammel point.
~T U' TRUIMI;:( .. The pattern of the
routed gTOO\'t':'; ts designed for tin 8'" diameter trivet, Til rout 10 this diameter, set the
distanee bet ween the trammel point and
the inm r t'(lge of the router bit 10 ,J". see
L"
r IJ!,

'RAMMEl

,.....

After the groeves are routed, the trivet can

be CUt to the round shnpeusing areueerwlth

Sguare
Trivet
------------------

The round trivets (in the previous article)

Arter this groove i< cut. carefully tip the

workpiece up and Il.waytrcm thl' bit, Then
rotate the square 18(t' anti repeat the cut t
make the second gJ'Wve.
To rout the groove.; on the OPIJO.itl'~id",
nl11lhe ~U1lJ"e ever And position it against
th e ,top and the fence, Make certain the
f..""JC)\'("~on the top surface are p' rp 1I~/i'II
iarto(ptlinting toward) the fence, The" cut
th... jIrOtI\'CS on this side,
P\s.'''~~T\lOAl'II)THR,Tos('\ up [a"the
second set ofcuts. place the I'-wide spacer
tlbtaill.."!t the fenceand repeal the~(Ioquen(.'i!o(
four ,,"-s"'. see Fig. :1, Finally. "lace the
2"-Willt'spacer against the fence and ,'Out
Ih, four outer grooves. see F'ijl', ~,
II 'h,,".Il.ixgl'uovei- have bee" routed Oil
t!-<:'('h ..ide, r\"f.;,t the router bit to a Yi(;" depth
and ,'ejJ<'.,tthe routing sequence to take the
grl'l"\,~' \0 full depth,

present somewhat or a challenge far la)jog

out the groove, and cutting the cireumference, but a square trivet ilt even easier to
make and just as attractive, The square
trivet shown here starts OUl as a 7- square

made of :,-thick stock,

ROUTER TABLE SET-UP

Unlike the round trivet, the square one

doesn't have a center groove. Instead, the

router table ls set up to rout a pair of " ',

wide grooves that straddle theeenterline or

the trivet. Todo thison the 7"Slluare trivet.
position the fence 2''4'' f"'Omthe ttJ~lrof the
bil. see Fig, I.
ShQ,' Note: I switched loa I'.r' ,<'roil/III bit
(which produces flar-boucmed grooves as
shown in the photo). and resolved to deal
with the inevitable burn mark>; IUler.
All slx grooves step 11.. from the edge of
the trivet, To control these cuts. damp
plywood stops to the router table", the
inside edges arc ;;. .' from the edge of the
bit. ~'(' Fig, 1.
>'OSITtO\ $1' '(,~:RS, This set-up on thE(
router table is used to rout the inner pail" of
groove.Qneith.!,.~ideofthecent.rline,
Th.
posuion of Iht ne~t pair of gro<J"(>:, i> enntrolled by a spseer th8~ i,placed between
the fence and the workpiece.
Cut thisspaeer '" widealidlon!!~II(>ul1hI"
fit betw n the stops, see Fig, :I. Theil fo,'
the third pair of grooves. cut D spacer 2"'
wide. sec Fig, 4,

ROUND THE CORNE~S AND EDGES

ROUTING SEQUENCE

Aflerthe spacers have been cut to size. the

routing sequence can start, This is a series
of cuts 00 each side of the trivet to produce
Ilro",~.',,deep,
However. I found the cut
was smoother if the bit starts al half depth

(about v,.;,
TDE FlIIST1',\55, Beg," by pl'lcing the
\\ "rkpi""e so it fits tightly;" the upper
right-hand corner between the fence and
the stop block, Fig, 2, Then. tip the workP'~ down. and slide it to Ihe lert,

After all the groove< were cut to full depth.

I uscda 'luartcr(251' piece) 10 mark an arcon
tht .. >nler". nnrl sanded them to the line.
Then I rounded tbe edges with a 'I. roundover b,t 011 Ih,' router table,
R~;ll(l\ I, illftS 'IARKl>.Te remove the
bun, mllrJ<t.at the end, of the groove",
mount a stri" of sandpaper in a slit dowel,
see rill, If. (on previous page), Then chuck
the dowel in a drill press and ",Iply ju"t
enough pressure 10 remove Ih~ marks,
f'inally. , sanded the trivet smooth and
",>ph.d I WII coals of Deftoil,

r.,~tG",u.... nrr--------~~--R-R-ST--PA-S-S------------~r-r-,
HNCf

not'

StOO

MtASUIlE FROh\

OUTSIDE fOG! Of 8ff

lout

liGHT TO un

RGU E-.

SECOND PASS
2~SPAClR

BtOO('

C=
\VOODSM1TH

17

___

'E_oy Bank Truck

MONEY ON THE MOVE

The bil!Kcst problem with toy bank. is bow
t(~J,.'l'l your

money out when

)'("U \\'~llll

it.

Th. usual seluuon on most banks i. tu drill

a h'JI~on the bottom and use a cork stop.
Pull out the stop and out comes your
tllOnC)', But that's lOOeasy,
I thought the chullcnl1l' of building a lOY
bank would be to figur~ out n "".''CI. hidden release to gel the money out. That was
the idea behind this bank truck.

-----

THE CHASSIS

To build the truck. I started by oultU)Kthe

chassis (A) frern " piece of 11 .I"ck (' v,,
thick> !I'. long and til n rough width o(
2;,".
A\I.t: II\1K)~. Then I cut two dadoes on
the bottom to hold the axle s. Both of the'.
dadoes are V, wide by V:deep. The front
dado is positioned Vz" from the front of the
chassis, and the back dado L"2' (,.om the
back end of the chassis, .e<' Side View in
"ig. I.
('All IIAIJO. There's another dado 10 cut
on the lop side of the cbassis where the cnh
\\ilI be mounted. Thi. dado i> Yo deep. and
the width is equal 10 the thickness of two
pieces of YI stock. (The cab that fits in this
dadu is made by laminating I WI) pk'C(>; of
~'4 stock togethcJ:)
Shop Note: Although these three dadoes
(and the groove lhal follows) can be cut
with a dado ""I (I wo bl.ri~. and chippers),
it leave; a ~tightly Irregular bonum. Instead, I cut these dadoes on the "outer
table using' a Vi' slnlight bit to get a smooth
bottnm.
To cut the dadoes on the MITt'" workpiece needed for the chassis. first clamp an
auxiliary fence over the router table's
renee to cover the sawdust hole, see rig. :1.
Then use a push board (a piece of
ply
wood works well) to guide the workpiece
through the bit, see Fig. 2.
TRIM TO WIDTH. After the three dad"""
(for the two axles and the cab) are routed.
the chassis can be trimmed 1(1 a final width
uf 2". m;m off both edges to clean up any
ehipout caused when cutting the dadoes.)
C''';STt:R GR()O"E. Finally.. a groove is
routed down the center of the ehassis 10
hold the engine compartment and also the
secret sliding mechanism, This !D'OIJ\'e is
deep by 1',,. wide. see Fig. I.
To rout thls groove .0 if. centered, I
used a two-pass procedure, refer 10 Fig.
Start b)l setting the fence on the router
table so the bit is near the cent ..r of the
workpiece, Now make one pass with one
edge of the workpiece against the fence,
and then flil' the piece around to make

0/,

v,

another pass with the other edge again::;t

I~ the fence were positioned so the bu
the fence.
wen' routing the shoulder nearest Ihe
1'0 widen the gl~,o\'e. move the fence fence, the rotation of the bit would be the
away from the bit and continu .. with thl~ same '" the ,Ii.-.c'<'tiunof f.'<.od. This can
Iwe-pass cutting procedure
until the ,>1"1"" th .. bit to grab the workpi eee and
~\'e is Ih' wide, see Fi!t. 3.
"run with it." rl1w effect is like kick-back
Note: When routing a "...joe gr<lO,'&.o likt' - except the piece ls.thrown forward.)
this, ft-..>d the workpiece from ril!'hl !(lIen
01 \lln.R sxn. Aner the center
is routed, cut a v," -deep 450 chamfer on the
and adjust the fence SO the biti.cullinglhe
shoulder of the groove that's [arthes: from 1'C"rend "flh. chassis. see Chamfer Detail
the fence. This way the shoulder being cut in }-lg. 1.
('m" RE310IAI.Il()Lf:. 'Ihen the last step
is fed 119(1;.'1 the roiauon of the bit.

gM'!)".

AGUU 1

....

2~

...

...

Li' --.__~.L=rr
"..Lr-<:
,
I
SIDE VIEW
.- ~.~--~-----.. 1"'..... -.

- AXlIOA~S

DElr

OADO JOt AXlf

..

,.

CHAMfER DETAil

a.

18

~
DADO fOR CAB

lfAlOf

CHASSIS

OAOO fOR AXLE

WOODSMlTH

on the ehassis is to cut the coin removal

hole. Drill IWo }"-<lia.holes positioned as
shown in Fig. 4. Then usc a coping saw or
.,;abr~sa" to cut out the "lot betw ee n the
holes, To sand the edge,; cflhe slot smooth,
I used a drum sander on a drill press.

mUlt :J

RGUli2

_our

if

l' ,-.WIDE (
GROOVI CENTEIiD

ON CHASSJS

IrT CUTS ON

SHOIJI.IlEI
FAtl'HSr
FROM FfNCI

-'--I
I

1lIE ENGINE COMPARTMENT

..I\t this point, tht.chassis is complete. Xow

it's just a matter of adding piece. 10 n, 1
started ,1\ the front. adding the engine

compartment

(8) eee

1I0U'U

CHASSfS

Fig .. j.

ROUtU

The engin() ooml)";'lrtm~l\tstarts out as a

block of two pieces of 4 4 stock laminate-d

together, Cut two piece. 2<, wide by
about 6' long. (This is oversize to make it
easier to work with.) Glue the-se (\\'0 pieces
tOj(.tb~r and then trim them to width to
equal the widlh oj the th assis.
RABBE'I$.Next, cui rabbets on the bot,
tom edges of this block to produce a lOllgue
that tits .nuj(ly in (he center groove in the
chassis. I cut the se rabbets on the router

table using a v." straight bit. see Rabbeting Detail in Fig. ii.
CIi.U'EK TOI' To complete the engine
compartment. I used n ~5chamfer bit on
the route" table to shape the top edlle;<.

These chamfers are

Detail in Fig. 5.

y.

ftOUU<4

''''Ill
T9P VIEW

,.. t'...,.
, rtr--~lr----;-l

I .OIA. kOlE

I"I

JJ.~t__

FIGURE 5

'"...

$tRAJGHT

..

==--====ll,-

0-

.'.

_L_~

COIN REMOVAl HOl

T'.

-}-

___

~~~-!J..

.-

RABBETING DETAIL

,.eam
I.'

Oft'

. WrDoE

deep, see Chamfer

)IU(.'ST 1'(, CILI.'lSIS, After the M1bbct.

lind chamfers are CUl. the engine com,

.S
CHAMftIl

.11

partmem call be glued and clamped to th"

chassis, The only tlifficully here i>that the
block tend!' to slide on thl: glue 3. it',

..,
;

$l .... GHT

clamped in place,
Th make thi. alignment easier; I cut a

>Cntp piece to widt h to lit in the cab dado

(,pr Fig. 6'. $0 lhE' engine block could he
hutted "ltainS! this block lL' Ih. clamp is
tightened. (Note: Once lh~ engine bloek i.
clamped in place, remove the.crdp hl",,~ in
ease any excess glue has seeped out which
might glue it in the dado.)
When the glue is dl,),. slice orr the front
end of the engine eomparunem so it's Hush
with the front of the chassis. see Fig, 7,
ORII.I.HOLES.The last step on the engine
compartment is to mark the position of the
bole. needed for the headlights, the
radiator cap, and the front bumper,
The headlights are yo' screw hole buttens and need Yz-,dia. hole. "bout v,,
deep, see Fig. S. The radiator cap is a
dowel thaI fits in a !4-,dia. hole on the top
of the engine block.
And finally. the from bumper (e) is eut
to size "" it'~
v.thick. V,,,,ide by a" long.
It', mounted with two bumper support
pin>(which are
axle" pegs). Mark these
hole. on the front en,l of tl'" chassis and
while they'..., drilled, make sure you don'l
drill into the axle dad". see Cross Section
in Fig. II.
Shop ~ow:AAer marking th<positien
of these holes for the' piece I damped
the workpiece in a bench vise and used 3
Portalign to drill them . ..". Fig. 9.

RGUltf 6

CUT SCIA'

::; ro FIT
CA. 0

GlUE A,ND ClAMP

ENGINE IN
C(NftR GlOOVE

GU.~

fRONT VIEW

..

'

V.

WOODSMTTH

GUREq

S.DE VIEW
OIlU

KOLES
WlIH
PO.TAlION

Y'

lua

r
",
.
T- . '.,'
~@

" (
.- r~

:0. ......

ED
1

MOUNT FlU$.H
-Wtn4tOl
mGf O,"Vl$('

<.l

19

,-

...

RGU'110
10

TOP
VIEW

ftGU.E" 11

THE CA8

r,

o
j

I'

01\006 AilE ''J.

oa,
l

-<>1"

HOUS

FtGUJlE II

FlOURE 13
c.LAMPrifCfS AND
DItIU. HOltS fOR .PINS

CO!'ING

SAW-

Olttt.l. ~ HOllS
AND cur Out

..,~-i,I-.___

wrkoow WllH
C09tNG SA

fFGUlf '4

NOTE:COf 8EVELSto lU"" ''4~.

WIDE SHOVI.OEfI:ON EACH

FIGUU 15

SlOE OF WINDOW

m $A.W AT 22

~-4.,7'-,"
, ..~

"

'

,',

FIGUII 16

SIDE
VIEW

i
WID'>! Of
lANK BOX

EQUAL

to

HaGHT
OfCA8

r-

I..

CA. KAS
WID.
SHOULOl. ON lACH
SIDE Of ENGINE

r
~. oown

FOI GASCM

20

The challenge in building the cab is how to

make th~ windows. The solution turned
out to be kind of like the theory behind
carving - )'OU lout away everything that
doesn't look like a window.
The basic procedure is to CUt dadees in
two pieces (D) of 1'4 stock and laminate
these two pieces together, see fig. II.
Howevez , I found It WII> easierte start bv
.'
wO"king with one longer pleee rather than
t "'0 short pieces. I !>tatted "it hone piece
of J 1stock cut to a rough size of3Y' wide
b~' 10' long. see Fig. 10.
Cl'TI)AOOES.Then t eut : 11:"-wide darloc~
v". from hath ends of this workpiece. This
can be don" on the router table (refer to
I"ig. 21, or on a table saw with the use of an
auxiliary f.,K't' on the miter gauge. Clamp
R $t0l' block at one end of ibe auxiliary
fence nod use the rip fence at the other end
10 cernrul the width of CUt for each dado.
>'00 Detail in Fill. 10.
CIT'TUSIZE. Aftt'r lh" d:ld_ are cut,
trim the workpiece 10 a final width of3 .....
(Trim offbolh edges, removing any chipout
caused when the dadoes were cul.)
Then cut off the two blocks (D) fot the
cab, cUlting 2' below the dado to produce
blocks I" long, see rig. II .
..II(IxT wl~rl()\\.These dadoes produce
the ,id" windows when lhe blocks are
laminated.
Rut 10 produce the front
window, hoi.., have In be drilled in one oi
Ih" pieces, see rig. I!. Mark the centerpoints for fourY' -dia, holes at the corners
of the fronl window. Then drill out the
holes and CUI OUllhe window wiLha ('Oiling
saw, sec I"L'Ig 1'>
_.
1..\.I1IS.\1'E "It;('ES. When the f"ollt
window is complete. laminate the two
hili."" log,lh.r. To prevent the blocks
from ,Iiding on the glued surfaces, Idry.
clamped the two piece. together and
drilk-d hole~ for two alignment pins lY'
"owo)$l. "Ole Fig. 13. After the hole, are
drilled, apply glue, lap the pins in place.
"nd damp the pieces LOgether;
H.;' .:1. tDGES. \Vilen the glue is clry.
bevel rip tile edges at a 22' angle. Notp: If
all has gone aecording to plan. these bevel
euts will leave a v.. -wide pillar on hath
,itl"" of the front window. see Fig. 1<1.
AI,o, the front of the cab \\;11 have a
-,'"ide shoulders on each side of tile enWile compartment. refer 10 fig. 16.
"Qt:~,.
CAli. After the bevel. IIl'I! CUt,
sand the cab and glue it in the dado in the
chassis, see Fig. 16.
GAS1:\.'iI\S. Next, cut the gas tanks ( E) to
,Jzc (see f'ig. 16) and clamp them to the
chassis so they're flush with the top of the
chassis and y,.... from the back of the cab,
Then driU a 't,'-dia. hole (fol' lhe gas cap)
through the tank and into the chassis, Glue
and clamp the 8'3." tanks in place with the
dowels sticking out II,',

II"

WOOOSMITH

OUll1l

BANK COMPARTMENT

" ..I

NOTE:

11, ',l

The bank compartment i.a box made (mm

-thick "lock. ITo IlCl pieces lhi, thin.
resaw t -4 stoek (I(i\\n tc"!"'iz4!.'
Cl'T 1'0 SIZ. Then np the stock for Ihe
sides (F) and front. bark (Gl lO a width of
31'" . see Fig. 11. ITh;" width mu.t match
the dist.ance between the chnss..;:-, and the
top of the cab e, Sirl. View in Fig. 16.1

r,

. ..;fr

G.

--i

1 CORNER JOINT
TOP VIEW

.'.

PIN STRIPE

9PT10N:

cut rwo KERFS

, ~ DtP
ON $IO(S

3',

Next. CUl the 1Cide~to lenb-rth ::;0 they're

'." lunj!(!l' IhM Ih" distance bel ween the

cab and the end (If Ihe cM".L<.
JOINEk\.111l box ~itll':'are joined to the
front back with ~lml'l. rabbet joints by
cutting , ..-<I.,,)' by o"wlde rabbets on
bolh end,
Ib, ,ide I,i~, see Fig. 17.
nit: ~k"~TUA('KAflc, the sides are
cut. the Ircnt, back piece. are cut to length
"" when they' .....mounted to the side pieces
tht- uut",j(tt width of the box k. 1/4- wider
than thi' back of the cab, see Fig. ~O.
(aloo'r. fR0111lO'TTOl,.Next. the sides
and front. back pieces are joined to the
boltom (HJ wnh a rabbet and grC>O'ejoint.
1b make this joint. cut a y;, -widc gruove
d,,., the imide face of the sides and
fronLb,k JliPCtlS. sec Detail in Fig. 17.
ll()1"TtI'1 Nt)\\ to gel the final size of the
bottom. drya.,-"(:mble the box lind UJ~a~Ufi'lh,' lll,icJl' dimensions, adding ,~. for
the ton"'lIe~. '1'11<'11cut rabbets on ail (ollr
(.-d~>iO tu Il'.I\ t." l~)I.gu.$to fit $I\ugl~t
in the
groove-, xt't_ lJ.cl:\llll' ~iR.17.
('(II' H."I'"
II 11(l1..~.The la$t step bC4
fo", "",,mhl v ,. tu drill two I't-dia. helos

AU rtEelS ' ," rHICk

09

'IONr

$11'(

or

,
...

WIDi GROOVE
~"." DfEP

for the

hole.

eOlI11;n1Ilrltl

RJKl

CUT' i DiEP KERf

ON &At. PiKl TO
51.""Wt.A1E'OOOIS
t(

Ihnn th,' I"", ~",I to .1 ."ugh limgtb of 10 .

TMn th. ecru 1,,1can be CUt.
Set "I' t h. toblo saw to cut.
slot
centered on Ih, "1~lh and length of the
piece f'c.t'til! It'l' S,)t, oroI.rct the blade
approxlmnu-ly ''nl...." on the length.
place the .-Illt 0[(1... "orkvi~tlgllinst
the
hlade anti
I I h, h"11:111 of the blade
Ulllillill.' 1"'101 \\ h,,. the billde enters and
the WI'r"'. "r t h,' "ood are about
1 .. apart.'1t hj: II' Then mark this

"I)'"

Ie"'...,.

1.,:-ilic)11 em

'tl 1..1.1

l.ov.'.'r llll' hla.).

the

\\t1r.,lIl"('l

011

M~\

~tOftU~ a

I h..,

btock to clamp

tnarkA, ~

t(1

nl

2" long
1'<> It""11

:-;,'XI.tU! the top to

1~II~h .. , Ih.. com .101 I_ ....111<''''<1on th~

length, ~'1'I'it{.I!" ~\Ilkl. rhn,lnfc)'the fronl
edge RIle) nUl1111tlu (I'tilit ("()I"l'n- ttl a 1"
radius. ~'CFill 20
)llIt"TTUI\ Fill:lll~.til, <lump Ihe top in
place and drill v.. huJ,-, for th' four .lignment pins. Then apply Io:lu,.IllI' in the
alignment pin>. and clamp Ih. t"JIIll "lace.
VJOODSMITH

fAlSi !lA,0
TO CUT
COIN SlOT 1',~

..,

~I

'0 lll'GI'lI
Af'" SlOT
1$ Cut

"I

...

10'
04 1 "......

TO 2' LONG

AGURl20
<,'

TOP VI~W

._L

"1

t,,,.
0

-- ....

r( ,~
o

CHAMfER DEl All

r

. -'r
..

ItOUND

CO_Ntl'S TO

1 RAO.US

f
I',

tt-

fo~ig.18.

:\0Y. lUl'n un tlu' sa~ lllMlral!'4. th(* blade.

st"!IJJ}IIJ: \\ 111Il ll" )1..... 1 1$ ~tPltnlximateJ.\

, ~i"'"

...

I'

NOTE,
"iM,
fO"

saw to cut \,ul this hfj!..,see Fig. 17.

'S!W'IIH.I :-;.. w Ih., FI.I,,and fl'ontJbnck

am he 1(1u<~1alMI c amp ..,1 tu the bouom.

rue rru- To "uml,1l'1l tht 00>", the piece
for the toV (11'" cut to ..j7A; so it's V," wider

I. ~

GUlfl'

use a coping

Lf

~-!-

ON SIDES AND
FRONT &AC.

0"

BonOM
JQINT

SLOTCEHTEUD
ON lfHGTH

0.,0.

3'.' ,

NOTE:

'I ""EMIlUD

trw0

IlAN'
IS ... I'IfDll
JHAN lACK

'lllOX
~

~~

",

..

Of "'.

..B

21

u~:,
CUT

"((I' lOll

rc tOUGH

THE AXLES

JUIU' ItOCII$

L(NGfH

Refor<:mounting the bank box to the <hassis, the axle blocks (J) are CUI to size-ana
mounted. 1b make lh(' axle blocks. start
with a piece ~rstock \:. thick (to iiI th~
dadoes on the bottom "fthe chassis) by'Y,'
wide and about
IOIlIl.see Fig. 21.
uorxu OI"R Round over the bottom
edges of the axle block- uu a router t;{bl~
with a v. round-over bit, .,,~ f)"lail in ~ig.
21. Tben cut two blocks Vi' longer than the
width of the ehassis tso the blocks stick out
vo' on eaeh side),

MOON'

AX'"

""OCt( IN
NOJot

.....

s-

fQ DIIU

AXLE
BlOC.!Cj

Hot..

Eh

HOI.E~ FOR AXLE PEGS. In errler

AXlE

11<00<

WH(n

'. lOUNoova

en ON ItOUfEI tABU
flGUlE23

Sj,JPING TONGUE AND 8UMPE@

lONGUE tONGflt
TKAH .... NK aox

...-

DOWL\

~7,J

BUMPER

DETAIL

CUT .. OM
"feE Of SCit,Ap

GlUE AXlE

BlOCI(S

Amy WAJ(
TO GROOVe
so TONGUE

~JO DA.DOfS

SllOES EASilY

mUlE 14

DltU 11 HOtf
Off' ENOUGH TO

1
(I"

CROSS
SECTION

' .
OI'U

'.
DRIU
It,

on

HOlD SPRING AHD

ttlAO Of NAil

-----f---,

lfAR

AX",

1t0Cl<

,,; MOll:

rot act

f.rNI:SttHAJl--'
flGUlf 25

-0'" HOLl
~..- OlEP'

I'..

TONGUE

I'AI

AXU elQO(

.,.

,.
('

22

______

1ONGl/
IN
C(OSlO
~SlttON

au""",

til

mount the wheel. to the-se block S, ;, "-<lUi.

hal"" are drilled fo,' axle 1lCg5.(Note: Tn
hold them in place for drilling. I cut a notch
in 1he c'nd of a pi ece of ;;crap see rig. 22.1
A flo'r the hoi". are drilled, ~ue Ihe axle
blocks in th~ dan"", in Ihe chassis.
THE SLIDING TONGUE

ft ,

!'

TIle S("i.'r,,tto g..,tlin)t .,Ollr money out (If

thi> bank (n,ck iI' the ,Iidi"~ tongue IKI
that covers 'he coin "ot (In the bottom of
the chassis ThJ!O\flngue is housed in the
center groove ill th" chassis and is pulled
out by u,ing the ...,!IT bumper Il>' a handle
ITT 1'('"a t; m SI7.E. CUI the tongue to
width :illlllh iekness so it slides easily in the
woo,"e in the chassis, The lenJ!;thshould be
IUllllcr than the bank box.
Sl "PER. After the tongue is eut to .ize,
tho bum""r eL) can be added. Start with a
pit<" of 4 I SCTliI' S"long and wide enough
to work with comfortably. Then CUt a dado
al'rh:-;':-o.lht!
center of lhi~ piece to accept the
end IIr the tongue. see ~"i~.
ta.
Arter Ih~ dado cut lice oIT a "t -thick
I"'''''' tor th. hump"r and glue it to the enel
~)rt ht: lf~I)~e\\ ith the aid of two ",/' dowel
~lIll:;.t;""l" Fig. 2:i,
HU.t:.\.,t I"S The tongue " held in lh~
chl,.....'~ )rnJO\'l" with a spring-release pin
thaI II'''''' lhflllgh the rear axle. (Befnre
drilling' the bole...for thi.- pin. if. lwt<t til
11lI'" I hI' pin and 'prinl!' in hRnd 10~rot lh,'
n~hl dimensions for lite holes.)
Thepin is an Sd finish Mil, and the small
~flnnl! (compression coil) i~
from an old
ball point pen. see Sources, PI!. 24.
11. mount the pin, fir<1 drill a o/,."dia.
1....le Illug. enough for the diameter- of the
-pring) centered on the chassis lind the
rear axle block. "'" fig. :!-t. The depth of
this bole should be enough to hold the head
"f lhp nail and the spring (when fully compressed),
Fig. 26.
Follow lh" hole with a V,"-dia. hole (for
the Sd finish nail) tbat !toes all the way
through the axle block, see fij!. 24.
HOLF. 'S CIWiSIS. Arter these holes ar.
drilled, mark the IlCsitionof tho catch hole
on the bottom of the ,liding tongue. (Thi
hole <alches lhe head of the n,ul whell the
~lidillg tongue i- closed, see Fig. 26.1
To locate this hole. pi"",' Ihe lon~ in

M'.

\VOODS~UTH

...,

the "('Jo~I' position on the. chassis, and

I)u.h an StJ nail thfQugh the hole in th~ axl.
block. "e<' Fill. 20. Tap th~ nail to mark the
position oi'the catch hole. Thenremove the
tongue and drill a ' .. -di a. hole ~. deep at
thLs point.
arrrox. After the catch hole is drilled.
CUt the 8d nall ro length so it extend" "
below the axle block. anti epoxy a button to
the end of th. nail, see Fig. 26.
Shop Note: In order (0 drill the hole in
the button, drill a ""-hole in a piece of scrap
to hold the but ton. Then it's rdath'ely easy
to drill a hole to fit snugly around the Sd
finish nail.

M f~NDER

.,
MAkt-F'''Sl
CUT AlOfliG
8OnOMEOG(

,1.-1t

Of ItUNNING

--------~.
,

\'.'"1

BOARDS

fUU SIZE PATTERN

'.

THE fRONT fENDERS

:-;ext, the front rend.!'>' I~II 81'(' cut to

shape (0 look just like real fenders. (J know
this shape 100"-, fragile. but they're Ii lot
stronger than they leck.)
The fenders are made b)' marking a
1\'. -radius arc and a I'Y,"rndiu. arc on A
piece of tq scrap, see Fig. 27. Then use a
quarter (2<ic piece) to CU"\,e the,. ares til
the ;(,'!Iight lines that extend back to form
the running board. (Thp pattern shown in
coo
')"' 1 J.., <.IU11'S17~.)
r-lg....
.titer the pattern j:-; marked UUl, rip
Along the bottom of the running boasds to
get a nil", smooth edge. Then cut out the
rest ~fthe proiile. cutting R little 10 the
uut~itle of the marked lines.
To smooth the cut edge s, I mounted
drum sander in the drill press and sanded
w th~ marked lin,,-s, 5ee Fig. 28.
Before mounting the fenders. ternporarily mount the wheels and then glue
and clump the fenders in place so they clear
the wheels. see }o~ig.29,
\10l'~1' Tlf"'; \\'II~":LS:, Now dll four
wheels can be mounted. 1'0 prevent the
wheel. rrum binding. I used piece or
posterboard to set the space bel WI.'<1nthe
inside of the wh<>eland the enn of the axle
block, see t',g. 31. (tut slit in the 1'0.1erboard to fit around the axle peg.)
~tOt::<T BA.'" BOX. The last step is to
mount the bank box to the chassis. Howe\'er, befol'e assembly. I clamped piece of
scrap ever the eha sssis to test the $Iiding
mechanism. :<ceFig. 30. (To .id the sliding
;tttion. wax the center g1'oove.)
After I tested the sliding mechanism, I
moumed the bank box tuthe chassis using
""",w<only (no glue ,- JUSt in ease I had to
the repair the sprinz-release pin sometime
In Iht futun
:\0': When mOllnlinl! th. hank box,
drill pil(.lllot".':11(or l\tl, H x I \18- f." brass
....
r'c..ws (hl'otl~h lht I{.,~tanks Cfontt'r
lht.~ huh.os
frrtrn th1' uutttldt\ ral''- teJ
avoid (irilllrlll nght Int ...lh( llnllt 11111'
of' he
box's fiidt:' rulci tlOt1~'ln. c(t Ig.. r.!,
.'I:\:IS.t. To C'tlmJ)I"le t}u' truck, I Mntt("'Ct
..II the surfaee . :<)ighl1r r<lundinjt the
edges and <orne ..,. Th,'n t fin.. h,,1 th,'
truek with tung oil
WOODSMITH

GoUtl 2q

DlUM

SANDEl

NOTE,
4nACHfEND'.
SO" CLU.I'$
WHEn

AGUltf 3-0

CROSS SECTION
c.lAMP saAP

to CKASS1S

'0 TlS' SUOING lONGU,

ANO Sf&JNG RELEASE!,IN

fhe-1

SUDING TONGUE

FtGUlf 31

use: POSIE.IO .... O

AS -S'Aal WHEN
GLUI-HGtN

GUI 31

!=ROSS SEq10N

"" sas

HO,."

1'.

""W$

~w

23

Sources
hardware store, In fact. we were surprised
al 1m, \""('I~ uf spnllj.'" a' iJabk>.

D[SK CLOCK

<an rdcr the J.Qrt.. (or the dock from

KI.(l{~IT, P.O. flo,~:!9 l.ak e Gene, a,
\\ I 5.1117; li()t)..',;~.~~1' c f
(."""I,'~)'
.111" (jllllrt: t'Lork, (.reJ\!I- :\1), I(MHlt,
t, .:,0. ('/",1.: lIa,,</ s. Ill''' s, Nu. 1lfi9I-l. f"N'
w th eloek crdee
J\\I ....rowv IIJ~Tftll"l1'4.H~
2). :"\ar
"'~tt A\P., P.O. H" .H'.
towr
III _, -: '{)O.4:!:!.(If~!o f ret Ca1Jilo~)

I,..,

KID'S [ASll

DESK

,,, I can order tnt, ha1"d'\lln: {or the kill's

" l,II. -k from:

lit.; \\tH)IJ\\OIlK":K~' Sl'C}I'.:, 21t'l..l1 In

,1\I..trial Boulevard, I(oj.:!t'rs. \1:\ ;,:,."71.
(61~1 .t:!;-.:21!t9 tt'atnlog
:-..! fI') J(lf rt
(umlorHoi'a,dC
I),
I l~i!C!I ,
.!', Ord er :"0. (~:;r~JO$
I.. r set, ,; 00
p<r It) sets, J(J I (,
I
fl' I "
Jam
wn [)lStnbut ... h"'D umque eata
( ,.,. [JQ ctf (4 SA?I :r Ord.r Xo. [)lJIlre
~ uf hanlwnn and 100" but specialize
per :"E't, 4.
f t (' /J
lJ F fOnt ~ I
I" ":tterJtroeJ( ~IIII'. Iini ..hes . ar'll ot
C'tlr""~H)ll~i~talll fWlli'hlt;;. Tht~
""t' JlIlt I",rt () ou will tl('t"lj :!. but thc~ 'n- universal,
It.l!l'lhcr a special kit (III' l\;;IHIl'fllr;tl, I"(;ul not ril(ht or IeI" h."d"u I. Order :" II.
vi"8 of f()ur .~(,II,I11(f' xff Ii"" ilii/i. (_ff/ ,\ ;.I(,t{(
I ).l '~', :!--t,95 r-ach. I(flll 1/,1 \/(IIJ,tt:tir (. "tt},
at'
, to u~: a .. hour fll.1trkt 1"" on lh,(}4Xk. .2" (Inl\-r ~ , 1)1J S4',(:-.;'It~
The ~lp ..;w'
rn1!;.J,rilltC-d Llii.
111tlit eat.alog It
\ou\l.dlnt."t,j~"
ltM~\\ "ithat't-at
actual"
IS
.
I.
$.9-.
nch
So/.d (Jak II U'I'
" f u' :h......d.. J.1 nk ~ r the 1TllII'kt-", A
2" t 3" IOIlIl roun,lh ad ~re\\ ,hou rl I
,"dUl
.. Order:\o. [)5I;19. $1.,;0
h.
~
0
Ba.
(,fd 8C(..,IOf41.
"
\I, rI< To ord"r (rom J""""'lown.
L,k ~
tht " .., H71UJ.s .'<,rt" "el "ll{1i' 111.. ('I ~tfl( Ord,r :\0. CI170. :S~.I~pE'.r ,et.
IN"\\ 1-:1.1\(:)lt., \\to fOllnl) th(' ('a...ie~t \\:,~
$1.2.; incluul'!" rO'11" hr,. S "t'rt'\\~, ru..nclhllg
nJ1ltcla$S J)():;ta~~:-',:111(1II l'Hla1c,~.
to t'f"nt"r an<1 drill t ht 1\1,1".. ill th~ CJll11J1
rCJ'<'II("\. "(Ill \\IIIIU't'tt n ~...r-dJ' l'lj'l't' eJ( tht, fltOt.'k for lhl'l jOint "cIJlnt'elo~ \"U" to
r onru"" furlh .. (....nl b,"1 h.rk "fthe " uck u.tW! it CI41\\'elingjiK' (lilt, j,f I'llr fa\'ol'ilt'''' ....
Il~ 1,1(>('l'onJ:.. Ol( as II" .. \ 10 and,
'h~
lIowl-It. Th~ .!londanl [1"",111and a
tit uxt: model "lttl
r...-:'In,,\n.llll~ ...ttt \\In
\\
-UJJnpc<l atlin<t "h, ....to fin<!,ucll
bush
~,
......
a\alwbl~
l(ICOlIy and (rom
p~
1'I",n .. < In.'<I looking In ,m,
most maiI..,rdcr eatal~
\el U\I J'a;r..' under
"'t('hen Cab'I<'t
and fOUlld nutllber o( lo.-al ,,,b,....t ~h' p
\, ,tth..B llU \RI, 'ro mk._th~ markt r
(hat ~lK."CUtli/..t10 t'(I\Jlllt_'111Il..
btrtt flJljj (le_::k tIll' \\1' II "cl J,la~tillaJlll
n.ltl \\(t purcha. ...l-d a :"x:~' Ilit,(x' of ~'urm
(lni. ~hOl) \''-t' ,itllll'cl tlurl lin intln.:.tlll~
~"IIItrnf>nt elf ",nl;.III1tI\IIJ" lI,n CJVPl'fl'uln
"'lI b''lInll. Xo. IIm \\hi', II1HII~ tinbh II
(tlfft'relJlj<,b:;, 'rh{,\' \\{'I"C'Ulllrt" than hal'IJ~ ('(, t :$1;.1(1(Sl.!HII~'r ~IU;U'l'roOt), r (II
to ~t11them _tt a f(:L"flft.ltlli(l ("(.:-l ($1 !"() per
mon' :n(Ornl.allUJl all11.Jt hU)lng oiff(rt'llt
"""p' oi Fomuca, ..-, the pardgl'al'"
"'Iuarc f" I).
1.8tl'1' "e d ,;ro\ .......llhal SOme lumber
under the I.)e,k I'I000k
abo,<
\1\Rt\l~, There are a '\\lilt. \-:u-it"t)j (
~anl< and bulldlnl! 'nto r, that earn
ronm<3 (or olh,r bl1l,d I r 1,1a."icI,nm
lI1ark~,.,.a\aitable I hat \\111 "'nl .... n pia.st
Il.3tt') ha\(' a i"j)('CUlI rtlt:k (1111{Ir a .....'lrtt'1l
lammal~. Eaoh has ,', rICh antag~, anti
.. hfJr\3" nnt} !oO('nll~ It'll U\'('r ft')m tar)!'I' 1h:-.:ltlv3ntage.. ....
fll ,ll'I~. The IlnCc.'" ~l,t'IIlI.'(1 rlur unci thl'
'J'ht brighte:-o.l rnlfll'H nr(_' Jl1UtIL' \\'Ith
{)ur l,tlCal
1.:anf:tt)c,fe"!{II"Sllllht, ,l'ks "\I'1'I;"'vtl u , hl"u;ul~J Itllni clt1-~tr:t.'!( 111;tI'K{'I"!".
supply ,ton' <'lIrrl.. 1Sanford', E"JIO
TOY aANK TRUCK
brnnd In ",nely o( col. r fo,., 1:,0
~
\ au """ erd, r th paru r the ruck from Th, '""rke ....\\ '1><orr ('Mliy \\ th a I
11M;BR~,l.\"-. 1\1(0 !'Ill Lak~ d Ih or (~It
<-"A.'er. but tend 10~mear \I
t resl Road. Carn<' em lIa.): C.-\ ('.,),11; louched \\;th lilt (. fin~ nnd a.... nd
\'.16) ;"1-1111 (~lltt ~:.!,t)llf'hir,pJnc: al~1 ,hie 011 c1olhinK. :;. .ll'f! .1 " h'L- a ... t
h.IIl<lluIK (ott t)O .111 onllI~. (.,t.ttlog: $1 .( ), r',ur l)r~~\\;T't.:\' rklr~ In thcir I)m .."
t'r,'Kf Thy \\'}'I ( Iff (1). ~ Ilia" 101'-t hick. I ,- ~;(ll1il}nllnt and ~tJfll)li('~l"Ht(llllg ()J'tll'I'
U\tt h(,It!, ()rltl-OI' ~I', '1'\\'11 .. $.:!fi l':tl'l"
:-;0 1\11(1(941111,
:l..". !r.II,,r ""11.
\ Ie rt"!1~ Ii. 1 ,It'll~ !'hafi. f(. r ,
AnfJlhf>r Chf,il't '\\'(lul11 t,t \\'atf:r-l,n n.,rk.",.
They aN' ....."hl) .\lllJabl ... It I ~
u,le hole> l 'rd, r :\0. '1"1'112.~.14 ":lch
/J'JI, H ,Ito 3. "~I.lo Ord, r an<!office >Ul'pl) ~Ion \\'e fOlln<!a ern)'
~o.TPR 12. ~ O-J ("'&rh
oho brand <el of ~ marl...... for :$"219. \\ ..
TIl< ,m;J1 rompre Ion CO" 'jJnnJ: .1>' also (IiUnd'd' nn<l md""iual :ian(ord'
\', a\'j .. \\'atl-rha to (not pt"rman{'nt
pmx Il"nllb:o IUl ldjd!:lmt.>tt.:r) (tlrtht
If1Il"k.ln~pin can tHo' "twa\ t,Jt~t'(1 (rum all f,lel ()\ t'rheDfl Proj"'clor
I',n'" al\;.tiJabJe to
l,.tll~l"'llntpen (tIll' "~lu'k,ulI" t~'PCJ.aUl \\c tJroa(t or fine Pf)iut arul It \ :ll'lt'l:-' of rolurs
rnulltl the stmt "))I'ltlJ,." 1.\ ,u.:kin~at d ltK1tl (or S!f\J e3ch,

J."....

f~,

"t~,,

.""ill

00"""'"

om"

r.

.'MY

24

The \\ ater-ba ..to nlArkf'f'S rvquire a

\\'t"t

~I..,nl!'or cloth to" 'I"' th. Of oil and thf'

colon t~ndto water 6"otl thou~h the 0\ er-

head proJectDr

pens an' much britter

or

than

the Crayola brand t. SUIIl"

the wau-r
haSi markers caution that lh(')' rna)' stain
clothmg; but most of thvm wnuld pl'ob"bl)
\\'a....h out ea_...ier than thv dl) t'I'L"l'marktJ":o',
.JI...-\('l\NOAKI), In ..tt'''41 "I Ulin)!, ."nrml(:t
tand marke~ on tht easel, another OJltl"11
"ould be t. 11.."," bla~kbo.'lnl \\e iuund a
.!~ablackboard at a to, .to re that could
1>< rul to fit the ''''''' 1111 to be ut least
16"' ,,/!t ,.). The eost \10 114$11 .)11. $inct'
blaekbeanl ...art" llolU:tlI)' In,t(ll from a .)14..-'(."('
I,f _'t,L"'lllit, I ) OU l'f''Jlfllamirulle 3 secfInd "11""(.' (,f t1Jrmil",te'I\"Yl"(l Y.... )1a. ..t)nitt"
to tho hack to mnkvthe J~\lllt.('fhi:-;. \"ll)'
.)OU \\oulet ha\t- t rmiea on the ciet.'K :-oJ,lt,
and hlac:kboarrl on thP elL"" .. de.)
~:a....U,t>" 2',,3 <h!llj(boam in iI' Of,
fir, Equipm ..nt and Sup!,l) catalol! (or
S17.!I'JIClrder XO 1'j.K\ ...~r,llo(')
)'1 \( h.BO.\.M" '\1"
tr ~'OU CJtn't fincl {I
Iolackboard th" I"jlh I ,ill'."aint ,"at<" avail
nl,l\'lo rnakt: )'OUI'CI\\'n bla(_'kl103I'cl011a l)iccl'
of \I.....lIIte. \\',. found GIII"'pi, Blackbo",,1
"!at I!a' a I,,<'alShe", In\ViII.am, d"3.I
rh, rmn,,~rer. "lnn"lnp. toldu,IMt
I.a\-ailab" at palnt. hard"'lIre. and bu,ldI K(,,(:'I1ter.-natJonv.iuc at the trul(e:'-"1:00n-.

"'I

I.

ta

pnn! of $t;.tJ.5. JKr'1II,art In l)iaeK ancl

$10.1 i I'"r qunn In J1I''('n
1'1"" t' 8(j,\RI)- \\t' fl)\4"I't."(J the back .Jf

1he (1.~k,{,'1."I('1\\ ith

l'.11L<ilnit, Mck. It

r If,

l'lllUV lMJanI and a

rl'qUlrt~

I"

a hulJelin bt)<lI't1

X 32"'.
To mak( our nJ;!lnal board .. e bou~t
"Ihick .-hoel rork alld!wl pwnned
Ul~It directly to th" M.,oml. back
lIut th n "" I"l'aliu>d lhal mo,t thumbtar'" are ... long thaI lin'), \10111<1Im,h
rli:ht Ihroul!b Ihe eork hut chulrlo"L I,,
),n'j! l,l Into the hnnl ~IU.l'iflllitl!, So ,\\',-"
Jdued I he cork to 8 ;t.xI' IJll'\'C of 1i(..'Otll'otical

Thi::- \\clrkl ..I ....,-.at. llUt tl)' thl'

"e bad pUrdlll.......! Ih,' ."rk. the ....'1

('("1Ins: tll~
Ill<

~. aDd the curkboard adhe''''e,

""
had 'pcJ1t more molK'\' than \\ e u'antell
\ belter ,dtv.. might "" 10 Ju.-t bu) a

at a t~,~.
di:--eoWll.
clr CJrjj~ F;uPJ.ll~'stor,", t.:lk, off thl' f11l01e.
"rut l'ut it to fit. S(~n~('url-n':l a l!'x:J' bullf'1 in
I... rd ror $IO.!I!I(0,,10" :-;, 1\"('-6& II .).
N-:t.r.- at.." cani. .. futt\lntl (lark brf,"'n
,~

trlJ.atlt.!uulletln

}III],tnl

thick ('f.rk :o"Otrip!i

~\'e

' ' }III 8QUKt\,~ WIth atl ..

bac.-king.A packa", of four ,tnp.'

nch ,trip mea,u ... ' 12"x ti") ;. $1!1.l!'1
~nnler :-;". I!i.K\.".,U A 1",C"kaKcof
(our !Cquare~(each t',1)uare m("a!-l.urc~
l:.t"xl2"'llS, S7,~1 t()I'flc'r S.,. l!f..K..'(Q>4-11
,~C)U\\ill

neccl l \lit') rNtl'kKJott'!oo hf lhe~c small

"'1un,.... 1'01' Ih. hlllh'lin holt"l,
\VOOn.,\IITH