NO.

46

NOTES FROM THE SHOP

$2.50

Sawdust
AugU$1. 1986

Number 46

EdItor
Donald 8, Pelldlke

OGtogn 00r1lCUJ<
Te<!Kra" ....
Ao.< .. tant EdJIonI
S_Krohmer
1lou918. L Hlcke
OougluM.L_
Tech Iica! IU5tra.tots
David K.-yIng

MlkeIWwV
Jlm PrlII
Sa,*I!pDOi1

MaNIgDt

SondyJ._

SlQc'''*'"_

dOL,

ntl:-. 1""1 r. Yt'he-nevt.'l' We gt"t a

r~ .. tool for the ~h0i>. Ihere 0<-eJTl5 to be a

~athenng ,If Int ,.. 1 f,\ t'l') uJ\(' wants to
have a chaneeto exanune t antJ w c.rk \\ ith
it aliltl~ to gtL (cO(
I (, r It.
Hut n IItH'II~ till 11~" 1(1:0'
{LfI('lln~
\"'l ur nfr, th('1'" rt tIl ,II \ Ilnlslt eom
mem It atl(Iut '1\11,111\ \ ~'ClU'''IKhl irma..:
in' tIlt eomrnr lit lot" nltt,mt
n<!gfI
U\Co.1Kt~1I1tl}ren~ronI t"(Jhl~l 1
d to rrents to qWlIhim,
nnd Ill< 11<
It"
Id be a mu I ""tt~r tool (thM
had '" t taUn the t m to \\'11> d dn\
~
'" nd. t Il101\' to

1)(
t.h< ... the oth<or tel to th
Ir
manubdUJ'< ... did ., <,,'lh
lh< coWd to ensuro top qua)jty. the rom
menta would be,
It' nice tool, but
It costs

'eah.
too much.

Somewhere an bet" ee n there's a hapI')

ChtIolaI_
mediwn. for til< mC-I pan, I'm hapI'> If
00"0 quality is built int" the tool. and the
vtc:i<y _"""
Jack .. Sl10Ud
only real problems eon.. -rn the "fit and
PeIKoob
finish." That i.. I'm happy if I can do
somethlll!! my"el( to mak(, improvemems.
Compute< OperalJOrlS
Thu\'~ the approach I t.ake \11th most
Ken MIM'
hand
tool . And it'. thp basI. for (he article
Admont$lt8bVe ASsIS\a<lf$
in this I,"U~
(on pair" 16)aoom lUnin~ up a
ChttyI Scott
block
plan~
KaIO_
A brand n,'" plane ril!hl out of the box,
IluIlQng ManenancIe
shOUldbe ronsiderc,la tool kit rather than
Atd'J1e KtaoM
tonI that's noady to use. Almo;! all planes
....ed a little luning up 10make them ",O)rk
properly
. andjw.1 a... import.an1, to make
WOOOSMmI (ISSN Ql_114)
IS """'""""
Iht'm r......
1good m ),OU1'hand.
brluClJIy (FGbruoty. Ajri. June, Aolgltsl. 0taXM;
AI liNt II may ..,. m (ru.trating thaI
o.c.ntJorllly _
~.'11 Co. 2200 you haH' to go IhrollJ(h thl' ell'ort at aU,
G'8rld A.. Des Monos. """.50312
e-~'
..,Ih a ne" plane. BUI it'. reWOOOSMITli 10 ~
trademar. 01 the
warding ",(.rk. You go' to know the I'lane
I'IIbIIIIq Co
from a n. w 1..... I>I><'t'lt Ho.. all the parts
CoPYfi9ht 1888 by WoodsmIth Nlksh<ng Co.
"ork Ilnd h"" th,y IItl"I:"lho.,
AI AqlIS Rosoroed
As )'ou \1'1.... fonll th., 1001lui tnto a 1001.
S,,*"piion.:
On. year (6 O$SUG$) $IQ, Two you add ahUI,' o()UUl'JI('tflo,1. Th.n I tikI'
yea,.. (12 _)
$18 S"IIIo copy pnce, S2.50 the old pme\l('C nf "d(hn~ my initial .. to lhe
(Cenedaend Fat. addS2peryear.)
1001.It kind of 88\'81\', .. ark .. l un th" toul

_11ft

~.
01 Add...... : Please be sure
ro_
both yoIjr old end now address
Seoondc .... ~poldatDes_.1owa.
I'oetm.. ,.. : Send Change 01 address noCJce.
Form 3579 flO _
Co, 2200

-..rg

G'8rld Ave Des MOin

.. , Iowa 50312.

BACK ISSUES

AI b.::k IIou<los 01 _,."

......
__
Soncffor a ~eet>ool<!eI de$abirg II1eCUUlllS and
_
01
isooJes

81_

SAMPLE COPIES

_the

KyoIj have a lnenG _WOUld !ok. 10see a COfT'/ 01

Wood,mllh,JUS'
nameendaddress, end
wel00nd e IIllITlple (II no cos,)

.trlp away Ih~ myths about btork plane,

Th.y~ otl.'ll dt'I!.:nl..,,1 as small planes
,1"'lgnL't I" I''''"'' .'n" I!1'8in.Thl. has ic
"'lh th,' blade all~It'andllw \\'ay the blade

"0

Is mounte..t J11 the plane.

It makt-s a nuv e;tOry. And It's a :;,wry
th ..t'. I.... n al't1l1ndalm"'1 II1I1g enough to
1)(ll'lU"'''-ug. IIIf)n~l
ctt'atPs ('redibilit~.
'lll\ the l't\or)' if' not very accurate.
Wh,ch i8 \I hat led to the nrtiele (on Pag{!l~)
about block I'L~n,~, ml,unting angl,,--, and
110.. block Iun,'" actually cut wood.
Oka
, "hat are you g.tting at! Arc
",ying blodi: I'lanes aren't ItOO<I ("r
cndgram'
Wt part of It. The thinl: is that
a I:"n Mil eonsen-us

IUnes
gTSI

(all

I'

()n!)

that

block

be u-t fl1r planing end

<I

(lut that
ung, Tho,'rereaUy nice
~rn
rt o( tnmm nl: JO!.,., Even "ben
,,!nnlllg \\'Ith the ,",tin lao on the edge of a
""0"11, And "Ih" ..... 1). If you have a 1argo

~urf*'l'(,j t n,I grailll(.},l.ant,

m.i~hl bt a tM.'tt,'r lt1UU:..

8;

bench plane

So lIS I \\',.. ~illlll~ d"",, in the ~hOI'

tuninl! 111' my nl'" blo",k plane -kit: 1
lhn"!IIlt thai all th., (olkl"re and storie.
I've he.. ''! are b'l, n .. tll1~, but I don't have
101><,
haml"'l'l'll b~ th(m )Iy block plane j"
ni<~ hllle tool and I'm happy "'orkinI!'
"ilh It - .\.n "11h the gr.nn
Jt:"~:UI\ c.,s~ MOliI \\oodworlUng
pruJcct.oItnt! to be a oen""o(.ter ,-each
>1t'1' ..-ith ,18 o"n chaltenl!t'-, But th_
JM\elr) QM! \\C buill for t~ L~ue "'as
almo 18 O<'nes o(lndhiolual projc'CI..<.
.'01"a Io,IXtimt".

"'I' \\anl..d

to lr)' a

rl"\\'

lechruqU111thai nil k' mt-d to cornt' 1<>lIelher in Ihls on,' l'roj,'CI, Cunin!! the
par_hohc CO\.un Ihl' -ide. of the ca.e \\ith
table :<8\\ \\',.. one o( Ih. It!<'hniqu", I've
been "ailing 10try
I al....\\'3nl,t! to \I ork with. marquetry
\','nt.'t"r ~1Quntin~thil" Jl"lrticular inlay w~
and miuie It m)" ll\\ n
no UIIlI>J'o\11,'m, BUI I wanled to sec how to
STORI~s Th, r~'1 une other bo;ndit 10all "PI'ly Ih...tini,h
tlWl ...ork. A. I "&6 tUlllllg up. ne ... block
Youh2\ to oal the inlay. "ork in P""t<'
plane, I ~tllrt<'" thmk1ng About ho" it \\ood IIller larouI.llt but Di.t on itl, then
IlIjllI n and Ii h thi whole .urfa~.I
funct,o"", and "b~ bulll th" .. a~II..
I()outak~a"
y 111( flhem)wand
..
,..,.. at lim if aU that "''"' j!l>in~to
folklore auooated ,. th old tools, ) ou be- ",ork but ilCllll('outJ
t tine.
RUI to thlDleo( them L' re:tI toot- that are
And tb
I' tMt _med like the
builttodo8Job, Rlock plane- are rue< ,tt~ """,I run
mou UIlI:the Ik. A jewelry
planes lhat (all be held in 000 hand (.. hiI~ Cl.",lk, t
d(.'!l('J"\. abrass!ock\\;lhll<
you hold the .. rkp'('C<' m the olber hand),
0" n ke\ MoonUnll this lock tllJ'l>ed OUIto
Th,,:.-re 111'"fur all >OI'U of little trun1><'
an aftemoon"I'FO <>rt lilli-ell,
m111~johs
Hutonrl It \\~ mCJrtl:Wfi In. and actua1l~
It .Iruck me Ihat Ihat \I 11$ ki'lld of an
""rkell, I WIl!lI:Iad I had th haneetoadd
Important thoughl. (Thinll" t"nd to take (m ,t to Ihe Cll.<e.
mo", lmpon".,.., when I'm working alone
~~XT~IAIl.lN()TI... (Jdoberj""u. of
in Ihe ,hop.)
\\'(j(l(bmith INo, 17) wiu be mailed the
But in thl.e e il ",ally ",3!' important to week follo\\'illl(OClober 31. 19l16.

.t"

WOODSMITH

T_ips & Technigu_e_s __

___

TENONS ON LONG BOARDS

I've a "'ay" had a problem maklllg accurate

I"')OM on the ends of ",.",1.
an' 100

_w

I long to.lu!lO"era

",.. ob"loo.

u."

tabl, ...,. orTOUI~rtable,

er

L-

to

dicular\\;th th"l<IIC" .(th~ workpiece, Next

ride the router agnin<t lh~ rollar on both
t<idcsofth,. worklll,'("(' to form Ihe ,houlden;
Then continu(' r'tKltlnJ,t tifJ ((,lrm the tenon,
IIlld finaUy <\11(.tHhI' I>IIplrt surface,

use hand-htold

Rnaa Spitrak
Jlordt." P~'?tn8Y'ra W

nJUt:rr. Bill"""""," or bter you haH to CUI

""Id.

IIW;os the 0UISide

.upport l!IIriac<' that

up hall the TOUt:rr.:'0 hoi< do you hold the
nJUt~Tba<e lIat!

-.

"I,mnl(. lfif~
an overlay or lill (nmt, it ean
",. lined up with the other dn,wc!'>' and door
frollla or tho outside or the ""bill'(. Once
alignt"", "Pl~Y pressure so Ih(' f".nl ..nd
<Ira"...r....., temporarily attached.
I;'in:ill)~ puIJ the draw .... out, elnll, IIIMI
,,,-nnancntl,) >'CreW the f:!lst front to IhI'
dra\\cr III the correct location.
1'l<"p~n Shirley

fASTENING GlASS STOPS

I recently rGl1Il'l. t1 3 ."mndfathl'r cluck m
""Iiel rherry t'a,wninJ(
hanlwood gla."
stops into lh, mbl"'I, in the door has alway"
presented ;0 pnlhl ...n, If lhl'y'", glued in
1l'.'l'nI:UlOnll)', till'
,"'nl be easily nplaced And ""iling th.I1I,,.k> craekinc Ih<'
Jdas,< and I""", .. nail""Ie$.
I ")I,,",, thr' probltl" h) u.ing 1 .101ll:
brown P"l'er otnpo bet \\ een the g1a" stop
and lhe rabbel In thl' door.
one
method US<d to bokl bo\\ 10 f3<'l'PI;.~,~
m
lW1llnJ(.) Th. J<1V<'T .1 nps are 'p"""'I a
roupl. inches apart and held in place with
Jl:lueon both >.1... o( Ih, paper; 4B.. .,.ar dul
nol to gr-t I(lu(' \\ h""'lh"n' "n'l an} IJIlI",r)

D.,

tm

IOta

It~,,,,,

'fT. (")/'1'''100

A 81TPOCKn

'1\

S,11f"8

nJUter bit set ;nclu(I(.~It ~t.antlanl

....
i..
r tlull
IIlld "tIota.

~pts diffeTlmt culling h'~lIb

Ont problem

I'\"e "'ul i.holdin~ Ii

rnu., ;,.

CUT WOI:t(.
I'IICI lONG

IHlNII1M
IINOHIO

" ...,SHtO
IlNOIM

"NON

My ..,IIILion is to begin with

The paper i> thin 1,I(,11ll'1(1111"''''1notice. hIp

I"nj(orthan the finished length. Rout OUIthe

rl><'('k>oClh<,tenon. bul 1t"8\". band
cod
,II tbe "ery .nd of lh<' bc.anllo S"I'port 1M
rout.r h:Ioe, see drawinl' l&ho,. Alter mut.
IIlI: both dlk.,. cut (>ITthe band and I""",

or"

HOIf

cuttlns: bead .. Ink- ...."""1 III.'

bit. If.
R\\!rA1In1 to hold.1Illd I'm 81"")5 afraid lhe

lhe fulisbc.-d .....,.,.,.

But there', another prohl. m - huw
YOII rout .trnight shouldl'1'lI und k,cl' th~
.1Ioul,l.r on one face even with tho' _lIt,ukl.t
011th,' other face'! Th solve this pmbh'm I
built" .top ('Ollar that a,'(., a., n r"I),,' fOI' th,

w,

eu un.:

head \\ ill be dulk"" or rh pp<d if I

hoL1'1 wllh pIi,'''' or in a lise.

1b n:"plaCL' brukt'n J!l.\,'......~imJ)I)' in.*rt ~t

thin knife blude 1"'1w,...n th. >top and iramt
and gL'lltly 1\\;,1, Th paper \\iD b(. 'plit
right do..", th, "",1.11. and the \\ ood ""'"
can be puIJ,"" <>1It. Tht:1l <I.."", "ff the oIcI
_,..
n:1.ra.~,Ill< gr;", lind .tart o'...r.

Ju .. '" IJ Job, son

I.,k~ CitY.F oridn

ou..
SMell

S_IO
IW(

01_.
IMal,TlU,

rs THtCl(tI1lSS

'"", ... lIar I> marle from a couple of po"'"

of senJ> thaI swd"ich a >p8<t'r I<lrip The

thk~"flhe'pacer.tnpshould",jU3lthe

or

thirkncl!s
the \\0I"kpie<e ",.. \\bole a."
18helelt~th"r
.. ith <:toe ancl""""" ~
and then lhe "(>TIrpi..-ce '" pinrh,'\l uuuue bJ:
U!'bt:rnmg n \\1nR nllt on n caniagc bolt.
\\1wn ... ing the stop collar to cut n "'null,
<h"ck Ihllt tho' ..dge of thl' ctlllnr i" 1>I"l"n.
I!< mbly

I a,ld e""

Io .01\1 Lh" problem,

mUII'rI."", to ride again.<t.

,
,.

IIbc~lnll't()2'"

lOCATING DltAwtR fRONTS

Sometim4!'O. \\'httl I rUl~hIlll'lallin.g a (ir'.l\\"('l"

I di>'<O"er11', nn' .(I,ullhL ilut if the raJ>,;;
drawer frunt i. n.Ii~'1I,,1 on relati<m to t~
restofthl'.,.h
nd,lh,'drawer
look line
One
to aJ4:n Ih .., dra,...,r front is ""th
douhle-,oo ..od <mJll1. upc
Start bJ maJdng lhe dra....er .. ithwl the
faL-e fronl altnrhed 'lllen 1l"..'t.alJ the ,.lid""
IIlld draw.r on the <nnlll<1. Onl." tht' draw~r
'" in P'-. appl) (rilM of c;,.rp<'t tape to the
fronl and ~l off the "n.leethe facing.

"""y

FOT 8 O""h frollt

can then

Ix> "'i~.<1
in "'I~li~n
to the drdWO"

~",all

V.

110"" '"

fl"".,,"t'l1Iblinl!' the biL

!'labt'rl!J''f,fllt'rc''I'

1.\,"1l~'I./UI''tJ

1----------------4

",U

"""'cr. Ihe fat"" front

Il

",kllln my ~IOOdsm;thl'O\tt"r Ulhh'ln hold

Ihe bit while it'. belng assembk]. Fi....t, tlrill
.l ,,dlll. bol. near 3Il ""1:(' o( th. I.,hl, (0
tM.'t't'llllhe
arbor. Then chiJ.;t1a t" \\itt,,-,
b) I k.n~pocketW'd ....pil1t(llh.t.'hk tOl'
around the hole.
'"'" l"",kl'1 ~
a.' a hold"r to IOn,pnt Ib<cutter head from rotating "hil~ addmg th ..
arbor (b~turning the roth..,. head UI>Slde
'" .. n In the pock"I), or jn.lallilll: the pilol
" th t~ ILt'borrl~\\'n in Ihe bol, a,
the o.rt. '0", pocket i< u,..,(ul KtIlun \\ h,'n

SEND IN YOU. IDIAS

~ you d .. to _e a"""""""'''''II lip wIth_

,.ad.,. o' Woodsmlth send YOU' K2e. to
WDOdsmllh Tops & TecI1niques 2200 GtancI
A..

0.. ~_a

5031Z

.r.

w. pay a ",,,...mum 01 S1010< (jpS. and $ISor

mot.
10<
tor

spedalleC!lniques

(1tl8!

IICCeOle<!

pull4ic:allOll) PteaS<I glve a complete plana

1lOn of your Idea a SketChIS_.
Hod ,(
alor>g: '110'11 draw a new one

Collet Problems

SOLUTIONS FOR ROUTER HEADACHES

I goe,., it'" not a secret that we like u:\Ing
roeters here at ll'ootlxmilh I of\en~t a.;ked
whal power tools to buy 51'l!\ when ""tting
up 3 shop. A router would have to be one of
my tin;t cimices.
But routers have their share of problem,.
1(', not 'U1)lI,sing. Any 1001 that wurk., ill
excess of 20,000 RP~I (by far the high.t
RPM tool in the shop) L< likely to have
problems. M""t of the problem ann qUI:>-

"CQU( NUl

tions ['\~~encountered eemer around a VP1,)'

small part of the router- the ooll~l.
THECOI.Lt:r.So, what'. a collet? A eoll.t
is a split, cone-sheped sleeve that hulll> tbe
bit in the router.
All collet", work on the same basic principie: a taper on one part. of the ..ssembly
works against a 18p"r on another part, By
ti!(htening a nut "round the collet (0" in
some routers tightenin!! duwn the collet
itself) the two tapers belli' on one another
and cause the collet to squeeze around the
shank of the bit.
A router collet is different from a drill
chuck in lhat a collet wraps around and
beai.. on the entire shank uf the router bit,
A drill chuck bears on a limited number of
points (usually three),

the poin. wh.... th,' collin!! head meets the

"hank), it ,houJ"n\ I,, in-erted all the \\'3V
,Illwn into th~ .. ,l1et. If it'" 100 d~~p. th(.
",lIel "illlJllly grip th"lrtlll>lt"," radius and
'lOttb. ~ntire 6hllnk"flb. hll, 114-,' ~ 'K. 2

lliRliallED cougr

SIhIPIf JAl'fR

MAJCI'IA

MIlWAUKIE

DOUBLETAPER. Black & Decker and

Porter-Cable routers both have a double

tapered collet. A taper on the eQlleLnut fits
over 3 taper on the collet. And then a

second taper on the collet fits into a

13.,..1'\'(1hole in the end of the router arbor,
~2
~'lhe nut i< lightened the collet squeezes
I'd likt to k'lOIC u'/,at calt~e.sa n)J(f('I'bll to
."'."'" the bit, The only problem with this
8(urllo cr,,'CP IIp out oJ'tJu c'IJIltf ./II(I/)(I'f.
~Y"LA'm1.< lh,' length of the coUet - the
trat i'f/o the Ktood. I'ec ,'l' i'tttl ~f'f't..'m/proj.
Hlaek & l)t'('k(,. ""II.t IS only II." long,
ecls II'M" Ihis happmed. Ouc it "uflPClll'f/
Thnt's nol much surface jtT3bbing the
rigllloft~ I <htekNllo be 0/1,... tlu: bil """
shank (Or lh., ruultr bit.
l;g/l("I1/ ill pluce,
1HIU';Ant:J)('Ou.t:T. The Japan ese routThis problem i<n't unique, \Ve regularly
, -t" t'lllklUl, Hitachi. an<! Ryobil usc a
receive letters ,'Onl3ining horror stories or
lllro'sdc,l eollet without a collet nut.
bits coming loose in oollel<; and gamg too
Thr.",!, on the mllsiok of the collet fit into
deep into somebedy's prize walnut project.
Ihn.'",I. "',,", the !<I'bor. Th tighten iI, a
\Ve've had il happen in our own shop, and it's
Is ()"~ l11l(tt"Y ffll/t t (1(08i!IJI/)f-'fI('r ,h,lll '" (
"""K'h is put on the eQUet itself. As it\;
,d
oil,,?.. !
frustrating.
screw L,I into the arbor a lapel' on the inside
I
think
'0
(,;ce
the
box
at
the
end
nf
thi;
TOO DEEP A CUT. It usually happens
"r lh,' arbor bears against a taper on the
when taking a deep OUI - deeper than it lutiolp), but part of the problem L' that ~OIl 001<',,11, uftbe collet, This 5qUI!e'J.(>S the cellet
should be. I can tell that I'm in trouble by a have to live \\~lb the collet d.. i~,"",1fur th.
,,,",,,lIId the shank of the bit.
cbange in pitch (whine) oflhe motor. If you router )'QU M"e - {'oltel~aren't mtorSlMPLETAPEI!.The system used on the
hear a change in the pitch (or even ,U'I.ecl
.-h."'j!~ablc frum one brand If>IUl(>thorHew- ~1il" aukee router is a very straight for,
it) tum oerth. router and check to see if the t\"~r. when bU)ing a n('\\ routtr. the (ll~lh'l1
approach to 3 collet and it seems to be
bit is slipping.
~fthe collet would be one lhinl( I'd ,'()n.wl,r. nne of the best around (pun intended). A
l\lool c:olle~ fit mt4l Qrlt! (I' r'flJr tl3....ic tapered collet tits down into a lapered hole
Part of the problom here is th"t a dccl'
cut oau,e. con"ide.'able "ihralion and d""ign>, """ Fig. I:
in the rout(!t" arbor. As a collet nUL is
bending of tb. bit which puIs ",,,,,ure
SPLIT ARBOR. The r\t'" St:tr=t roUlt-f'!'
tightened il pr"".e. the <-ellet straighl
ag-dinst the side of the cullet. Irs likely to }lavea very i'imple ('olJ(.'l~Y:~ll'm- in fal1.. down into the arbor and squeezes around
loosen. So on.. solut.on .s to take Iightrr it'. not really a 8eparn(t' ""II .. t .t all. In, the shank of the bit.
cutS and increase the depth .Iowly.
!ltead. n la~-d nut fit .. ("'{ora taptron t.he Do roll/-rr COIl-rtH I'V<'r
Ollt lind /Iced
BIT INS&RTION. Anuther reawn a bil
>plil end uf tho thre.d.d I'<>uh'rarbn., A. rrpillri II!!?
might come loose is that it's inserted Itlafar the nULb tightenL'(! it "'luoeZ-e$the arbor
One ."Outer bil dj.uibutor cl3ims that
into the collet, There'" a lemptation to push ,.round lb" router bit .hank, One of the
allproximalciy lilY} of bit breaka~ comes
the bil IIll the
down inlo the COllel, probl~,"" with this "y.tem i, that if ,ume"'Om worn 01' dirt)' collets. I fyou're working
thinking lhat if if. out even a tittle. il \~111 thing goes wrong. you can~ .imply I"place
with. 'harp bit ,,;th a clean shank and the
n collet, You h.,o to repbce the ent;"e bit is in."ertcd to the conwl depth in the
lose SOmegripping power.
But some biL,can be inserted Iwd,,p. tf a ...-bor - and tbat can be 3lmo.t "-< expen1'OIlter,but the bit $tiII slips. tho problem
bit has a slighl lransition lillet (3 radiu. at ;'1\'("a,.... buyin$!'a "'hole ne\\" router,
may be in the collet it..<elf,

0,,

".rd

II"""

""y

\VOODSMITH

The pressures on a oollet sometim es turn it

into an oblong shape. Then it', time to
replace it. Don't put it off to the side throw it away IUId got a new aile. Rel~acing
a oollet can be an expense (SS to $'251, but it's
small compared to dCl'troyin,l(a project.
COli gOIl se lI,e wrc,U'/Jes to light~" the
collet too mu.ri, f}I' 100tittte!
Ye., Youshouldn't have to be Superman to
tighten 0" loosen aeollet areund a router bit.
In fart, you shouldn't oven need to use two
hands to tighwn the eolItt,
The wrench." u..;uallyhave enough offset
so that they can be positioned ,;lightly apart,
from each other. Then grip both wrenches in
(II.. hand and squeese them !Ogl!ther to
tilthten, Any more than that il; tOOmuch, 'fu
loosen, reverse the positicn oCthe wrenches
in relation to each other and once again
squeeze them togethi!r.
Wily d"". the bit C07ll~ t<J08t11101'( ofte"
l/'h_~r'_Fm 1(uri'ing 'flith thr rollttT U,t)l("ttd
nnder th rol(/cr table!
Part of the problem might be that s..wdust
and chips can fall into Ute ~'OUetopening
when th(' router;" upside down. If dust or
chips are packed down in the OOtWmof the
Qpening, the buildup \lin pre\'ent the ~'Ollet

\\'hen bu~~ngbits, be sure to buy from a

reputable manufacturer; "One major problem is that some route.' shanks a~n\ mao
chined to tight tolerances." aecording 10
\Villiam Whiteside of \\'hite.ide

Machine
Comprul)',
Whiteside turns the shank. on his bits so
,hey're no more than .001 undersize, But
he's seen bits that arc tL.'<l much as .00--''''
undersize. If 8 bit is undersize, the collet
ha. to be squeezed more and it's likely to
eventually tUI1. the collet into an n\'.1

squeezes on the steeve and then the sleeve

squeezes on the ". shank bit, 'transferring
the pressure tbroull'h a sleeve is more
likely to cause problems than oqueezing on
the bit itself, For this reason, I've started
slowly replacing all my ~." shank bits with
~," shank bits so I don't have to use the
reduction sleeve when working with the
)Iakitll router,

(Note: Some people bay - and it makes

~rJmesense to me -that
if YOU'rE!usin~ a
router \lith a reduction steeve, you should
shape.
alw ay" cheek to see that the UII">ltgll expan ,1/r!(! store a nd C(l.tol~Js(!{fi'" '/," ~"allJ. sion .tit in the sleeve is lined up with the
bit. t ttiere ''''y ad.v,lIItny, 10 IIll1'illll til"''' IIJ""'Oil expansion ~it in the tOlI.t. This
bit I/fill, 1(1raer .'i"a,,~ftl
.hould help prevent ~lippajre.)
Bits "ith '3 ~,dia
. hank have twice Ih. \'"''(It procedJI1x slWltld YIIII,l(J/lcjl(' ,(!het' a
surface area in contact with the collet, Even' router bi, isstuci,' i), 0. NHle' and 1f'O'/Y cortt:
time I've wonu,li with " ~~"shank bit rv~ IlItl'
immediately felt :l diff(.renc(!, There's ll":O"
..
This seems to happen a lot on our Porter ..
vibration. And \\'here there's less vibration
Cahl" router, If the collet nut is completely
the bit isJl\ as likely to CC1meloose,
loose and the bit still sticks. I give the rllil,'
\\'hen 1first started using' W' shank bits, I "lit tnot the bit) a sharp rap with the wrench
\I'!I.' surprised to find thut Ihe," arcn\ much
'"'hK:h i.... most convenient since it'~in my
more expensive IhM ". shank bus (about 52
The sharp tlIp light on the nut is
to $.> IIlO,." pel' bitl, III the manWacturllll(
usually ennu~ to break it free, Or J tap the
pmcet'....~t.rail!hlbits that CUt Lw'l-!er than l.. end orth. bit with a block of wood. (Don't tap
grooves notuall)' start out with a '1." shank.
the bit with a metal wrench; carbide chips
Then
some
are
machined
down
to
be
sold
l""&'iJ~:)
ROU 3
Oil the few rare occasions where I have
with a ". shank. The v." ,hank bit. are ,010
had
til use a t>,liI'oiplie", to carefully pull the
to indu!'try while the " hunk hits Iii'" ..,Icf
to hom~woodworkers,
bIt out, I've dis<'O\',rcd that the bit or eellet
Many t'Ommercial-duty .'Outel>' ,md large "'asn't clean.
plunlt\' route"", are actually de.igne<1(I)r ' .A fINAL THOUGHT
.hank bir,.. 1b u.<.e ~hank bits in
routers (such ;1.< the ~1akita ;3601BI, yr_. AIIIl<'~an)' I'outel' (like any tool) will cause
have to in.<crt a h reduction sleeve ill;id. some kind of a problem at one time or
the eollel, ~ .. Fig, l. On the other> you u>c' another. BUI ifyou takt'the exll'R time to be
.maller oollet,
sure )'ou're working "ith a )(OUd L'Olletand
REDI,:CTJON SLEEVE. While we're on the
bit, wKIthc~'re kept clean and fit logethera.>
from going down far enough to tilt.n the subject or ,'ed.retion sleeves, I think thi:; the)' .houM, many of the problems ean be
bit, see Fig, 3, It feels like it's tiltened, but $Iwve m.1y be th~ source of problem. lI;th kept under oontrol (or at least on the right
the tOIlet ln8y not be squee~l ti!,.<ht aJ'OWld the ~!akitu rout~." The collct itself
''''''t,)
the shank of the router bit,
To pre\'cnt this I alwaY'! b,1l.h off the
router
table top bej'mT
also
blowallthedust
out removing
of the colletthe
opebil.
rungI I
onoo the bit is removed, Sometimt .. it takes One imporuuu difference in ('()Uetdesign is
3l8UR-<:AaUi
loosening and removing the nul and takinl! the number of lllits cut in lhe collet. ~I""t
the collet all Ihe 1t"11oul to clean it, And ooIl~1.6ha", oD<!expa,\j;ion ,lit fill Ih. OI"il
while if. OUt, clean OUI any little wood through the $id. Some <'Ollets(such ;1.< Ihe
slh'= or chip, in the roUet slits.
Porter-Cable) also have two more slits I alf
Art
bils l'fW ti,e primary OOIl$t of )("'11through the collet to "give" when tiltht
slippagt!
ening the collet around I he bit.
Sure, Th. >hank of a router bit shoukl b<!
Probably th~ best de.igned <'Ol1et,in my
Ol<HH~.OUGH5UT
' ' HT surs~
clean of ru.'t, dirt, oil, and burrs. I make 8 opinion, is found on Milwaukee IWlers, The
lOt
habit of checking and cleaning the hank Mi!waukeceolletbaseightslitsin.l. None or
WW
berore putting itin lhe rout<,r, If there's a the eight ,;lila i~
cut all the way through the
HAlf
burr on the bit, it'$ probably an indication
from theouLOideto tbeshank bole,
CONtAC1SAJ
sur
_POOITS
that it'" slipping in the oollet. The burr will But alllh(> slits run a1mo.<;t
the entire length
ruin the collet <'0 I try to carefully file the ofthe collet. Youcan ,;queeze the ~lilw.uKee
burr off or throwaway the bit,
oolIetin your Jinll"l" and {reI the gh'e.
l)ULL BITS.Probably the bigg ....t prob
"1th other coIlNS, if the shank hole in the
lem ofall i.the most rundamenm!. Irthe bit coUetorshAnk on the router bit is,,\ pencetgets dull, it's working too hard - caUSIng ly round, the bit may be held at only thr<-e
vibration and evelllually coming loo,~. points, But with the Milwaukee tODet,JlW"
Don't take chances with 8 dull bit. GeL it sure isgoing to be applied unil'o''Il1ly around
sharpened Or buy a new bit,
the bit,

htu"'"

V,

"'lit'"

COLI F. DESIGN

r;~~~~_~_~~~~~~~~~~~=::::~::::::::::::===

"'

000""""

WOODSMITH

@r

___

lewekY

C_as_e

A JEWEL OF A PROJECT

Filk' JIwelry deserves a fine home. The

challenl!l' is. to build a ease thai has a dehcste, yet rich appearance - In keeping with
1t6 conten~.That'swhat we tried to dowith
thi!>esse. And we also wanted toadrl a fancy

touch with the inlaid top.

I n one respeet this ca.se is only afour-sided
box that's joined with miter and spline
joints. But what make!' it a Uttle unique "'
that the sides. are cut to the shape ofagenUe
parabolic eove (sort of an onSet swoop).
CUT SIDES

I started work by cutting the stock (I used

walnut) for the sides to rough size. This
means cutting two pieces of 414 stock ('1',.
actual thickness) to a rough width orall, by
28" long. ('This ~"elds one long and one short
side OUIof each piece wlth a little le1\ oven)
TIll: TEMPLATE. Ne.<t, set up the saw to
CUI the parabolic cove in these two pieces,
To do this. you need 8 template to set the
position of the guide fence that's used to
guide the stock. (Note: In place of the
template. you can also use the cove jig
shown in IVood8mith No. 36.)
The template is made by cutting. reeta.n
gular oole in a piece of posterbonrd. see Fig.
I. The critical measurements ofthl, hole are
the "idth of the center opening (2Y."l. and
the distance between the opening and the
outside edge of the template (%i.
SET SAWBI..AI)' After making the ternplate. lilt the saw blade to a 45 angle and
raise it to a height of",,.",see Fig. 2. (1~lting
the blade at 45' i. the trick to making a
parabolic cove.)
PQSITIOl<FEl<CE.Now use the template
to position the fence. h, helps here to place
masking tape over the table insert and
mark where the blade enters and exits, see
Fig. 3. Then twist the template until the
edges touch the mark .. on the masking tape
and tape it down. see Fig. 4.
"""at ,
ANGLEnMPIATE
~

high I"~I male. _1""'< with the stock for the

.,.Il' IItn .,f till' on a pre......of scrap fmit to
~N Ih. (..1of Ihl. "peration). Slide the
\\ "rlcl'lI"'(, .1,,,, Iy over the blade and it will
cut n ('1.\".".

U....dlUdly n ..... the blade 'in VI" incre'Rnd m.k, r.peated passes until ibe
lo1"d."at full height (%"J. (At this height,
t I,.. ...." ,. h...tld have the parabolic shape
1iI1I1I.:! ," \\id e, "'fer to Fig. 8.)
rn",11

)I; 0\\

slide

lhl'

'N,n (.

piece of straight
I,,, up al!1lu",t
the edge of the
Thl' \\1111'0.';1'0"
the fence... fmm th~ blll<l,ami lit lhl'
proper angle to make the CO\'" rut
CUT CO\T&.At'kr ciampinI" the f,n..., In
position. lower I.h~ blad. "" 11'. ,,"ly v,."

S\lOOU'

nit:

COVE. To gel

the smooth-

,.,;1 .ul. make the last pass very slowly.

t:\.n ...;th this, the cove will have tiny
",,11\'''. I found that a gooseneck semper
doc. ~ good job of cleaning the eove right
up. (St..., WoodslIlith No. 39 for more about

I!ImrJlclllngand using scrapers.)

AGUI'

WI'"

ONWS'

lAlll tNs.ERT

WOODSMITH

MmR AND SPUNE JOINTS

Aiter ~he cove is seraped ami sanded

smooth. cut the workpieces to get a I:r and
9' length out of each piece. The-e four pieces
are then mitered to get two front-back
pieces (A) 12V." long and two end pieces (8)
SV.long. see Fig. 5.
CUTTOLENGTH.To miter th ese pieces to
length, I added an auxiliary fence to the
miter gauge and used u stop block (:IS
shown in Fig. 6) to make sure I cut matching pieces to exactly the same length.
Start by CUlling a I;; miter on one end of
each workpiece. Thcnclamp a mitered stop
block to the auxiliary fence to eutone ofthe
fron~ back pieces (A Ho final length. 11 set
tbe stop so the pieee \\'1'" a little long and
made a cut. Then Inudged the stop over
and cut to the final length of 121' )
As soon a. this PIece is cut, cut the other
front-back pi,....., with the ,top block in the
same po>ition. Then repeat this PI'OCedUI'l!
to miter the two end pieces (8) to n final
length of8\,
GROOVE .OR SPLINE. The sides are
joined with the aid of splines. (Spline. add
strength to the miters and keep the piece.
aligned as they're clamped together.)
1b make this joint, ~'UUhave to cut a to,".
deep groove in each mitered end, see COl"
ner Detail in Fig. 5. Keep the saw blade at
a 45' angle and slide the rip fence over to
use as It .IOp. Position the f""ce 10 cut the
groove Vi. iI'om the iltsilb: corner of each

piece, see Fig. 7.

~ote; It helps here to use 8 lest piece to

_. -

The splines are

across the jomt
strength), ~l the
high (the combined

cut so the grain runs

line (for grearest

blade a little over ".
depth of the grooves in
the mitered ends). and set the fence "'.
from lhe blade tthe thickness of the saw
blade kerO...... Step l in ~ig.
9.
Now stand the workpiece on end and
make cuts on bolh ends, Then re-sdjust the
fence to cut off the 'plint'<' C_ Step 2) so
they're a tad Ie... than Vo' \lid~(to lI'lIvc
room for glue in the grooves).
Al\er the splines are cut. can:fully test fit
them In the grooves, Then band-clamp the
sides together to make !lure the C3&' '"
square. But don't glue the sides togethery.!
- the lock bas to be mortised in the front

.-

CORNfB, DETAIL
TOP VIEW

...,----===_ ...,----- I

121'.

t
W1DlM Of GROOVES
QUAIS W1l)tII
Of$AWMAQE
(00ItKUf)

""HE

."
.!I

S'/,"

-e

',.

..

,.

US(ffNCl AS
'S1QPWH(N

'

CUTTtHGSl'UN'
Gl!OOlll

"""If

FlGUItf 9

t1UM 'OPAHO

..--'...

aonOM EDGES

make sure the groove is not cut too deep so

you don't cut through into the cove.
TRIM TO II'IDTlI. After the grooves are
cut. the four sides can be trimmed t08 final
widlh ofZV'. Trim a little offbclh ed~ so
there's 8 ~'-wjdc border above the cove
and a \1. -wide border below the cove, see
Fig. 8.
SPLINES. The last step is to CUl the
splines. Since the spbnes will show on lhe
top edge of the ease. I decided 10 make
them out of walnut (using scrap left over
from makinJ( the sides).

_L

,,-J

2'."

....

1
t

v,
ANISHEO
RGOI! 10

wmnt

-CUI SPUJrrlE
10'"
=,-

""If

'.

..

_J

",
f

piece first.
WOODSMITH