Documenti di Didattica
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TEST LESS.
Save time with 4200 series jigs from PORTER-CABLE. Each comes with a single-piece steel base that attaches
directly to your workbench. Other timesaving features include clear onboard instructions, board alignment lines,
template adjustment knobs and router bit depth gauges. Choose from three models, each offering a different level
of versatility. It all adds up to quick setups, easy
adjustments and fewer test cuts. One more
example of how we dont just pay attention to
the details. We obsess over them.
Board alignment lines Router bit depth gauge Single-hand clamping
WSP.SIP_003 2/15/08 2:57 PM Page 3
MAKE MORE.
Now you can cut hundreds of joints with just one jig. The new OMNIJIG comes preassembled and calibrated
right out of the box. Color-coded onboard instructions ensure its also easy to use. Router bit depth gauges and
template-positioning stops combine to offer repeatability across applications. Add innovative details like a
router stabilizer bar and variable-spaced
fingers and no other jig even comes close. To
check out our instructional video featuring
Norm Abram, visit deltapor tercable.com /jigs.
Variable-spaced fingers Router bit depth gauges Router stabilizer bar
Model 77240
WSP.SIP_004 2/22/08 1:59 PM Page 4
18 Four Methods of
Casework Joinery
28 Resawing:
Basic Hows and Whys
36 Using a Shaper
62 Sliding, Circle-cutting
Band Saw Jig
64 Straightedge Jig
4 table of contents
WSP.SIP_005 2/22/08 1:58 PM Page 5
74 Seven Steps to
Veneering Success
82 Machine Cutting
Mortises and Tenons
98 Workshop Tricks
A
s our presidential election approaches and Ann Rockler Jackson Founder and CEO
party lines are being drawn in the sand, I Mary Tzimokas Circulation Director
cant help but notice some parallels with Meg Clark Direct Mail Manager
Kelly Rosaaen Circulation Manager
woodworking. We woodworkers are a collegial Dana Severson Advertising Director
bunch, but even we seem to fall into a couple of Alyssa Tauer Advertising Operations
general camps. Some of us focus on furniture while others make their shops the
ongoing project. If youre of the second persuasion, your jigs have all the bells
Advertising Sales
and whistles, theres always a new shop fixture in the works and you can never
J.F. Van Gilder Company
learn enough new techniques. Sound familiar? Then youre going to love this 12740 Hillcrest Plaza Dr., Suite 120,
Woodworkers Journal Special Interest Publication. Special Projects Editor, Chris Dallas, Texas 75230
Marshall, has selected some dandy workshop projects and techniques from our David Beckler david@jvgco.com
Terri Mathis terri@jvgco.com
archives and compiled them here. Jim Van Gilder jim@jvgco.com
In this issue, you can build Ian Kirbys custom workbench, sharpen your resawing Phone: (972) 392-1892
Fax: (972) 392-1893
skills and scrapers, add six snazzy jigs to your collection and get the low-down
on why Sandor Nagyszalanczy thinks a shaper can beat a router tableplus
Subscription Inquiries
lots more. Be sure to check out Chris guide to 50 great tools and supplies.
(800) 765-4119 or
Hey, who among us can resist some new shop stuff when its this good! Go www.woodworkersjournal.com
ahead, embrace your inner shop rat. Thatll get my vote any day. Write Woodworkers Journal,
P.O. Box 56585, Boulder, CO 80322-6585.
E-mail: woodworkersjournal@neodata.com
Include mailing label for renewals
and address changes.
For gift subscriptions, please include
your name and address in addition to
your gift recipients name and address.
6 introduction
WSP.SIP_007 2/15/08 3:00 PM Page 7
2X PERFORMANCE
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Ryobis new One+ Lithium-ion battery produces maximum performance for a much
lower price than the competition. It powers every Ryobi 18V tool, making Ryobi One+ the
most affordable and versatile 18V lithium-ion tool system in the world.
By Chris Marshall
E
very die-hard woodworker knows that woodworking takes
stuff. A well-equipped shop includes a workbench, power
and hand tools, gaggles of bits and blades, fasteners, clamps,
adhesives and finishing supplies, personal safety items, a shop vac
and a dust collector. Then there are those incidental items youll
eventually need knobs and doodads for jig-making, lubricants
and cleaners, storage bins and organizers, a moisture meter, tune
up and calibration tools, accessories to enhance current tools,
books, DVDs and other reference materials ... you get the picture.
Sure, new tools and supplies can put a dent in the bank state-
ment now and then, but their benefits can outweigh the cost.
They really can help improve the accuracy and quality of your
work, speed certain techniques along and ensure that you are
protecting your health so you can enjoy this craft for a lifetime.
The trick is knowing what to buy so you can shop wisely.
At Woodworkers Journal we scour the trade shows and meet
with suppliers to find the best new innovations for your hard-
earned shop dollars. And, were happy to report that there are
lots of great new products worthy of your attention. Theres no
way we could compile them all in one article, but here are 50 of
the best that caught our eye or made their way into our shops
over the past year or so. If you didnt catch them on the pages of
your print issues, heres a second look at the really good stuff!
Stainless
Sanding Disks
1 Microplanes 5"
Sanding Disks ($9.95 to $13.95) are
made from hardened stainless steel.
4
7 8
9 10
11
Woodworking Supplies
13 15
14
14 Varathanes patent-pending
Waterbased One-Step Stain and
Polyurethane ($15.99 per quart) stains,
home page to find everything from
Craftsman Furniture Projects to Jigs
and Fixtures for the Table Saw and
by a single AA battery for up to 65
hours of use. Pro Tech: 800-468-8371.
seals and protects in one step, an indus- Router. ($17.95 to $19.95 each.) Reusing Old Timber
try first for interior wood. Its available in
eight colors. Varathane: 800-553-8444. Pro Tech NoiseBuster Electronic
Noise Canceling Earmuff
18 By reclaiming old beams, rafters
and flooring, East Teak Fine
Hardwoods now offers Forest
Biscuits Connect and Clamp
17
16
Smart Design
Heavy duty aluminum extrusion
& hardened steel drill bushings
Drill into pre-aligned holes
Built to be portable or bench
mounted, and designed with a
built-in clamping system
Three Types of
Pocket Hole Joints
Flush, Corner & Angle
Assemble flush & corner joints
Pre-aligned drill stops for Edge-to-surface joint Edge-to-edge joint Right angle joint
5/8", 3/4", & 1" stock
NO. 846
Workshop accessories
19
20
21
Dremel Multi-Vise 26
25
24
28
27
JessEm Rout-R-Lift FX
33
32
Workshop accessories
36
40
41 With lithium-ion technology, Makitas 7.2-volt
TD020DSEW Impact Screw Driver Kit ($109) pro-
vides a 1.1-pound, 10" tool with 177 inch-pounds of torque.
Thats impressive for such a tiny tool! Makita: 800-462-5482.
44
43
42
Hand Tools
Veritas Sliding Square
45
47 Veritas replaces the usual
narrow rule with a square
plate on its Sliding Square ($31.50).
Grex P635 23-Gauge Graduations on both the end and
Headless Pinner edges allow for two-axis measuring.
49 48
50
By Lonnie Bird
I always construct
large furniture case-
H
ave you ever wanted to build a chest of drawers or
work with dovetails. dressing table but just werent sure how to begin?
Perhaps you saw a photo of a china cabinet in a mag-
Even though the joint azine and you wanted to reproduce it but felt it was beyond
your reach. Although large-scale casework projects can
is often hidden by seem somewhat intimidating, building them is really noth-
molding, the strength ing more than constructing boxes. Once you gain an under-
standing of the methods involved, construction becomes
is unmatched and much easier.
Drawers, which are also boxes, are fit within the case-
ensures the longevity work and slide on wooden rails or runners. Doors are often
of the piece. added as well to keep the contents of the chest hidden from
view, although sometimes doors have glass panes, or
lights specifically for displaying the contents of the case.
The challenge when constructing any casework is to keep
it square. As Im sure you can imagine, its much easier to
fit doors, drawers and molding to a box with 90 corners
than to a trapezoid or a parallelogram. But that becomes
easy, too, once you realize that parallel sides of the box
must be exactly the same length.
Over the centuries, cabinetmakers have developed
a number of ways to construct casework, and each method
has its own advantages. By understanding the various
methods of construction, you can design your own case-
work to suit your needs. Once youve constructed the case
or box, you can add feet, moldings, doors and other details
to give your design distinction.
For the purpose of discussion, Ive divided casework into
four separate categories: frame-and-panel, post-and-rail,
box construction and face frame. Although these categories
work well for getting a grasp of case construction, cabinet-
making is too diverse to always fit neatly into categories.
Sometimes youll find it necessary to combine construction
techniques from two or more types.
Frame-and-panel case sides, even complicated ones with tombstone panels (as
shown here), are still just wood panels surrounded by stiles and rails.
Frame-and-panel
Frame-and-panel casework is simply a series of wood panels
surrounded by a stile and rail framework. The paneled Frame-
framework is joined at the corners to create a box. Probably and-
the most familiar example of this timeless design is the roll-
top desk. Mass-produced in large numbers around 100 panel
years ago, the rolltop desk was once a common sight in
Americas offices. These massive oak desks featured a
large, spacious writing surface supported by a pair of chest
of drawers. The space between the chests provided a knee-
hole. A frame-and-panel assembly covered the knee hole at
the back of the desk to provide a finished appearance.
Positioned on top of the writing surface was another Stile
paneled framework, which housed a series of small
drawers, pigeonholes and other storage areas. The
inside edges of the framework were grooved to
Panel
Stiles and rails joined at their corners form a frame, which is filled with a Rail
flat or raised panel.
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20 four methods of casework joinery
WSP.SIP_021 2/14/08 2:36 PM Page 21
Right Sized
ly assembled with mortise and tenon Rectangles choice when the case is positioned
joints. The inside edges of the frame high off the floor. Dressing tables, tall
members can be left square or stuck The Fibonacci Series chests and sideboards are just a few
with a simple molding profile that is examples of furniture that use this type
mitered or coped at the corners. The is figured by adding of construction. The posts are used as
panels can be raised or beveled along the successive number legs to elevate the case and are usually
the edges or simply left flat. embellished to eliminate the plain,
Once assembled, four sub-assemblies to the number that square look; a tapered leg is a simple,
of framework are joined at the corners to yet elegant option. Other versions
create a box. Although a simple butt joint precedes it. The rate include turning or compound curves
has sufficient strength, adding a tongue of successive terms such as cabriole legs.
and groove joint at the corners helps Construction: Typically with
with alignment during assembly and goes 1, 1, 2, 3, 5, 8, post-and-rail, a set of matching posts
glue up. The assembled box is usually are joined with wide boards to create
supported by bracket feet or some other 13, 21 and so on. a box. This construction method is
type of short base to lift the box off of the very similar to the methods used to
floor. After assembly of the casework, 3 join tables and beds. The posts are
doors, drawers and lids are added. 5 mortised to accept tenons, which are
1
2 1 cut on the ends of the case sides.
Post-and-rail 13 Often, four posts are used, but if the
Another time-tested method of case 8 case is very wide, as with a sideboard,
construction is known as post-and-rail additional pairs of legs may be added
sometimes referred to as leg-and- for more support. At the case front, a
rail. Post-and-rail construction is a good framework of rectangular openings is
created to allow the fitting and installation of doors and draw- den compartments. The entire assembly rests on bracket
ers. The top rail of the framework is usually turned on edge feet that lift it a few inches off the floor and raise the writing
to create a broad surface for dovetail joinery. A single, wide surface to a comfortable height for working.
dovetail is sawn on the end of the top rail. This fits into a cor- Construction: Construction of the box method can be as
responding dovetailed socket on the top of the leg post. simple as butt joints and nails or as complex as half-blind
Lower rails are joined to the legs with double tenons. dovetails. When deciding which joint to use at the corners,
Doubling the tenons creates twice the surface area for glue I consider the material, the overall size of the box and how
and significantly adds to the strength and rigidity of the case. it will be used. Ill often fasten the corners of diminutive
Vertical frame members stiles are either dovetailed or boxes with glue and nails. Afterward, Ill cover the entire
tenoned into the horizontal rails. The back of a typical case is box with a figured veneer to decorate the box and hide the
also a thick, wide board or several boards glued together simple construction.
with several tenons cut on the ends that fit within mortises in I always construct large furniture casework with dove-
the legs. Dividing the wide joint into a series of smaller ones tails. Even though the joint is often hidden by molding, the
strengthens the leg mortises and helps avoid splitting of the strength is unmatched and ensures the longevity of the
case sides during seasonal changes in humidity. piece. Splined miters are also a good choice for small, deco-
rative boxes that wont be subjected to a great deal of stress.
Box Method An added advantage with miters is they allow the wood
The box method is the technique that you probably used the grain to flow in a continuous pattern around all four sides.
first time you built a small cabinet, tool chest or jewelry box. If the case is to have drawers, the dividers and partitions can
As the name implies, four planks are simply joined at easily be joined with a sliding dovetail that fits snugly within a
the corners to create a box. Its undoubtedly the least com- mating socket in the case side. Drawer runners are typically
plicated method and one of the most widely used. joined with mortises and tenons to the front and back dividers,
Because of its flexibility, the box method can be used for a creating a strong, rigid framework for drawer support.
variety of designs and furniture styles. The completed case Backs on these cases are let in to a rabbet that is cut
could rest low to the floor on bracket feet or be positioned along the back, inside edges of the box. The back is usually
at eye level on a post-and-rail base. made up of a series of random width boards nailed to the
Although the basic design of this construction method rabbet in the case. The edges of the backboards are also
is quite simple, it functions well within complex furniture rabbeted to allow each board to overlap the next. A quirk
designs. The slant front desk, for example, has an upper bead may also be shaped along the edges to dress up the
corner cut at an angle that supports a hinged lid. The lid backboards and hide the seasonal wood movement that
folds down to form a writing surface and expose an elabo- occurs between them. The finest casework of this type
rate arrangement of pigeonholes, drawers, doors and hid- sometimes has a frame-and-panel back. Although consider-
Stile or Apron
Post
Post-and-rail
When you start thinking of furniture in terms of its most basic
forms, even complex pieces become easier to understand.
Face Frame
ably more work, the rigid framework adds both strength
and stiffness to the case, and the frame-and-panel design
provides a more finished appearance, especially if the case- Stile
work will be viewed from all sides.
and the stiles provide a place to mount hinges. The top rail of
the face frame often is sized wider than the stiles and bottom
rail to provide an area for application of a crown molding.
A quality set of drawer slides will last the life of a drawer, and theyre
easy to install with a few basic shop tools.
Installation Basics
M
ost of the furniture we build
will still be in daily service
when our grandchildren
retire. Viewed in that light, the cost of If theres more than one drawer
upgrading from standard to heavy- in an opening, space them so
duty drawer slides isnt such a big the bottom drawer has enough
deal. But the benefits sure are. A slide clearance to slide properly, then
rated for 300 to 500 pounds will oper- divide the remaining area
ate beautifully for a drawer full of equally among the drawers.
heavy books or documents, but it also
will endure many more decades of use
than a slide rated for light use (say,
50 pounds).
Installing them is a snap. Begin by
building your drawers so theyre The slide receivers
exactly 1" narrower than the opening. must be mounted truly
perpendicular to their
(Check the specifications that come
openings. Lining
with your drawer slides: there are a
up the screw holes
few versions that use metric measure- is best done with a
ments.) This allows 1/2" on either side template (inset), or by aligning
of the drawer, which is exactly the the slide with pencil marks
right clearance for the slide to operate drawn along a square. If the
properly. More than 1/2" means the slides arent absolutely parallel,
slide operation will be sloppy: it may your drawer will never glide
even derail. With less than 1/2", the properly.
slide will quickly bind.
Most slides are screwed in place
along the bottom edge of the drawer
side. To locate the matching receivers
inside the cabinet, use a paper With the receivers installed
template (usually included with the in the cabinet, use the slides
slides) or an aftermarket plastic as templates to locate screw
template (available for most brands of holes in the wooden drawer
slides), as shown in the photo sides. Screw the slides to the
sequence at right. In either case, fol- drawers and slip the drawers
into the cabinet. Thats all
low the individual manufacturers
there is to it!
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WSP.SIP_028 2/14/08 2:28 PM Page 28
By Linda Haus
Point
fence
S
o you can use a band saw to slice
thin pieces of wood from bigger
pieces of wood whats the ben-
efit? Why not buy your wood sliced
thin to begin with, or just plane or
sand it to thickness? Here are five
good reasons: First, youll get the best
use out of expensive or beautifully fig-
ured wood. Second, youll be able to
create book-matched, slip-matched or
swing-matched panels. Third, youll
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Using a Shaper
Router tables are miraculous, but sometimes
p r o j e c t s r e q u i r e h e a v i e r - d u t y m a c h i n e r y. A
shaper is like a router table on steriods. It is
made for handling large cutters and big stock.
By Sandor
Nagyszalanczy
T
here arent many red-blooded
woodworkers around who dont
value the benefits of using a
router table. Its versatility is legendary.
But as miraculous as a router table is,
there are times when a project
requires heavier-duty machiner y.
Thats when a shaper really shines: its
basically a router table on steroids,
made for handling big stock. Shaper
cutters come in a wide range of shapes
and sizes and allow you to make mold-
ings, create interlocking joinery for
door and window frames and form a
variety of other millwork profiles.
But if you already own a good router
table, why would you want to add a
shaper to your home shop? For
starters, anything a router table can
do, a shaper can do bigger and, often,
better. A shapers beefy induction
motor and stout spindle can handle
heavy cuts in thick stock that would be
difficult or impossible on a router
table. Better yet, a shapers large-diam-
36 using a shaper
WSP.SIP_037 2/15/08 10:51 AM Page 37
eter cutters are less apt to burn stock or spindles with a heavy-duty induction
leave chatter marks than comparable motor housed inside the base of the
router bits are. Its larger cutting arc The hand wheel changes a shapers spindle machine. Pulleys on the motor and
also makes a shaper cutter less apt to height, while controls inside the base change spindle are connected with one or more
tear out woods with figured or inter- motor speed. drive belts, and most models offer at
locking grain. Factor in a shapers least two spindle speeds slower for
reversible motor and versatile fence Shaper Anatomy larger cutters and leisurely feed rates;
and you have a machine that is worthy The heart of any shaper is a faster for smaller cutters and rapid
of consideration for any size woodshop. motor-driven shaft, called a spindle, feeds which require the belt be
If youre new to the shaper, this arti- that protrudes vertically up through a moved between pairs of pulleys. Also
cle will help you understand its basic flat tabletop. The height of the spindle found on most models, a rotation
setup and use, for both straight and is accurately adjustable via a conven- reversing switch allows cutters to be
curved cutting, as well as the use of ient hand wheel on the tools base. used to cut in either direction.
important accessories such as hold- One or more shaper cutters may be A shapers cast-iron (or molded
downs and power feeds. Besides learn- mounted on the spindle at one time, aluminum) tabletop has threaded
ing to do accurate and effective work held securely with a locknut. Some holes for mounting an adjustable,
on a shaper, following the methods pre- shapers have a built-in spindle lock, removable fence unit to guide
sented here, as well as using appropri- allowing you to change cutters with straight-edged workpieces past the
ate guards, will help you work safely as only one wrench. cutter. Most fences include a centered
well. Once youve become comfortable While some light-duty shapers have port for attaching a 4" (or larger) dust
with using a shaper, you may wonder universal motors that drive a 1/2" collection hose a good thing since
how you ever got along without one. spindle directly, most shapers power shapers can produce bushels of chips
Fence/guard
Unit Lock-down
Handles
Cutters
I N N O VA T I V E S H O P S O L U T I O N S
Metal spacers help set up cutters correctly on the spindle, while a variety
of throat plates accommodate the different diameter cutters.
38 using a shaper
WSP.SIP_039 2/15/08 10:52 AM Page 39
You can work with a cutter either With the proper fence adjustment
above or below the workpiece. Hold- and a straight cutter, you can use
downs keep the stock in place. your shaper for a horizontal jointer.
R
nut is installed and tightened.
When multiple cutters are used at one time, spacers or
shims may be inserted between cutters to set and fine-tune
the distance between them. This is a crucial part of setting
up cutters that create interlocking joints as well as cope-and-
stick type cuts for cabinet door rails and stiles, as the exact Love At First
spacing of bits affects the tightness of the resulting joint.
Most shaper tables have a number of concentric, throat THE NEW ...Slide!
insert plates that are added or removed to accommodate JessEms New Mast-R-Slide Precision
cutters of various diameters. When mounting a new cutter, Mast R Slide Sliding Cross-Cut Table is the ultimate add-on
always choose the insert with the smallest hole with enough for your tablesaw. Thirty double-sealed
precision bearings in an innovative linear
clearance for the cutter to spin. guide mechanism provides an exceptionally
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Cutting Direction and Spindle Rotation Fits most tablesaws and offers a maximum
Most cuts on a shaper are made with the cutter spinning count- cross-cut of 36 inches. Upgrade your saw
with a Mast-R-Slide from JessEm Tool today.
er-clockwise (as viewed from the top), with the workpiece fed
by hand from right to left over the cutter. However, unlike a
router that spins bits in only one direction, most shapers have
an electric switch that reverses the rotation of the spindle, thus
turning the cutter clockwise (since a cutters knives cut in only
one direction, it must be flipped over for clockwise rotation).
With most cutters, this allows you to work with the cutter
either above or below the workpiece, lending flexibility when
tackling a variety of different shaping situations.
Although even a medium size shaper (112 HP to 2 HP) has
enough power to tackle most cuts in a single pass, its usual-
ly better (and safer) to take two or more passes. This is espe-
cially important when using large cutters for raised panel or
stile and rail joinery cuts. A rough cut on the first pass
removes the bulk of the stock, and then a light finish cut on Visit us at www.jessem.com
the second pass leaves a smooth final surface. Before shap- Call: 866-272-7492 Greeneville, Tennessee
ing good stock, its important to take at very handy for putting a straight edge
least one trial cut on a piece of scrap on boards and planks too big and cum-
wood to confirm that all cutter and fence bersome to feed over the jointer.
settings are accurate. Offsetting the shapers fences is also
useful when shaping operations
Hold-downs and Featherboards require an entire edge to be removed
To get accurate shaper cuts with say when putting a full bullnose
smooth, chatter-free surfaces and roundover on the edge of stair treads.
for safetys sake its important to Narrow pieces, like stick cuts on the end of rail As useful as the standard fence
use hold-downs or featherboards to stock, require a miter gauge, a commercial is, there are many straight-edge shap-
keep workpieces pressed firmly crosscutting gauge with built-in fence or a ing operations that will require the use
against both the fence and the work- shop-made sliding jig. of shop-made fences or jigs. A custom
table. Spring steel hold-downs come as fence can, say, tilt the angle of the
standard accessories with most stock relative to the cutter to create
shapers, and they easily lock into spe- machines standard fence in place. unusual moldings or raised panels. In
cial holes in the shapers fence. These The split-style fence has two separate addition to straight cuts, custom
are best positioned so that theyll wood-covered faces that straddle the fences and jigs can allow you to shape
exert down force on the stock adjacent spindle and cutter. After a cutter is curved parts, such as stair railings.
to the cutter (see top left photo, page mounted, the halves are adjusted side
39). Hold-downs placed this way not to side to create an opening just big Cross-grain Work
only keep the stock from lifting, but enough to clear the cutter. Fence faces A shaper can cut across the grain as
also provide protection from the cut- are also adjustable front-to-back and well as with it, although care must be
ter. A pair of horizontally positioned are usually set parallel to one another taken to support the stock firmly during
hold-downs, mounted to the shapers for typical straight cuts. But they can cutting. Wider workpieces, such as the
table, will press the stock against the also be set to different levels, like the ends of rectangular cabinet door panels,
fence on either side of the cutter. infeed and outfeed tables of a jointer. can be fed by hand using the shapers
With the infeed fence set farther back fence as a guide. However, narrower
Shaping Straight Edges and the outfeed fence set to be flush workpieces must by aligned and guided
Like a router, a shaper can cut either with the outside cutting arc of a with a miter gauge, crosscutting gauge
straight- or curved-edged parts. Most straight cutter, you can actually use or sliding jig. Such a gauge or jig is a
straight work is done with the the shaper as a horizontal jointer must for making the stick cuts on
A Rainbow of Cutters
T
ters
he
he versatility
the
versatility of
the incredibly
of aa shaper
incredibly wide
ters itit will
shaper is
wide range
is due
range of
due to
of cut-
will run. Cutters typically have
to
cut-
shaper
shaper itself,
er
er all
itself, its
all your
Straight
its important
your choices.
choices.
important to
cutters: Used
Straight cutters: Used for
to consid-
consid-
for shaping
shaping
two,
two, three
three or
or four
four knives
knives made
made from
from rabbets,
rabbets, grooves
grooves and and dadoes.
dadoes. Use
Use
high-speed
high-speed steelsteel or
or carbide.
carbide. Typically,
Typically, aa single,
single, wide
wide straight
straight cutter
cutter or
or
you
you buy
buy cutters
cutters to
to match
match your
your aa stack
stack ofof two
two oror more
more narrower
narrower cut-
cut-
shaper's
shaper's spindle,
spindle, but
but you
you can
can employ
employ ters
ters to
to joint
joint or
or trim
trim stock.
stock. Insert-knife cutters accept interchangeable
aa larger-bore
larger-bore cutter
cutter onon aa smaller
smaller spin-
spin- Single-profile cutters: Available
Single-profile cutters: Available in
in knife sets into one cutterhead.
dle
dle with
with bushings
bushings designed
designed forfor the
the ogees,
ogees, roundovers,
roundovers, coves,coves, beads,
beads,
purpose.
purpose. SinceSince you
you can
can easily
easily spend
spend flutes,
flutes, etc.
etc. You
You cancan use
use them
them individu-
individu- Glue
Glue joint cutters: Single
joint cutters: Single cutters
cutters
more
more onon cutters
cutters ally,
ally, or
or in
in combination.
combination. and
and matched
matched pairs
pairs used
used to
to create
create
than on the strong
strong 90
90 or
or 45
45 wood-to-wood
wood-to-wood joints,
joints,
including
including drawer
drawer lock,
lock, miter
miter lock,
lock,
tongue-and-groove,
tongue and groove, andand
finger joints.
40 using a shaper
WSP.SIP_041 2/26/08 11:02 AM Page 41
cope-and-stick style window parts or dont like the idea of getting your fin-
frame and panel door rails. gers too close to those big, meat-eat-
ing cutters (a healthy concern), you
Curved Shaping should definitely consider buying and
You can shape both concave and con- using a power feeder. With its variable
vex curved edges on the shaper using a speed motor and grippy skateboard
rub collar to guide the cut. Equivalent A rub collar and starter pin can shape curves. type urethane feed wheels, a power
to using a pilot bearing on a router bit, (Guard removed here for clarity.) feeder smoothly guides stock past a
a ball-bearing rub collar fits onto the cutter, while your hands remain out of
shapers spindle, either above or below harms way.
the cutter, and it bears against the edge Besides providing safety, there are
of the work as the cut is made. To help other significant advantages to using a
you start and stop a cut safely, install a power feeder: First, the device feeds
starter pin in the tabletop. This small stock past the cutter at a steady rate of
metal dowel provides support for the speed, assuring a smoother, clean cut.
stock so you can start a cut without the You can adjust the feed speed to suit
cutter grabbing the work and chewing the heaviness or lightness of the cut,
it up. A ring guard or spindle-mounted the hardness or softness of the wood,
cutter guard should be mounted above etc. Second, a power feeder allows you
the cutter to surround it and prevent to climb cut stock feed it in the
accidental contact. A power feeder lets you climb cut stock same direction as the cutter is rotating
The rub collar method is ideal for which you cant do by hand feeding. something you cannot do with hand
rounding over the edge of a curved feeding. Climb cutting generally pro-
tabletop or raising the edge of an arch- duces cleaner cuts, especially on high-
topped panel for a stylish cabinet door. slightly larger than its final size. The ly figured woods, than feeding stock
You can also use a rub collar for trim- rub collar rides against the template as against cutter rotation. Since a power
ming multiple parts to an identical the work is trimmed to final shape. feeder will run in either direction, you
shape, using a straight cutter and a tem- can work with clockwise or counter-
plate. The template, cut from MDF or Using a Power Feeder clockwise rotating cutters.
Masonite, is temporarily attached to If youve always been squeamish
the surface of the work, which is precut about using a shaper because you
Rail
Rail and
and stile cutters: For
stile cutters: For making
making and
and inin both
both vertical
vertical and
and horizontal
horizontal of
of the
the knife
knife you
you want
want to
to use.
use.
cope-and-stick
cope-and-stick joints
joints for
for door
door and
and win-
win- styles.
styles. The
The latter
latter can
can shape
shape both
both Insert-knife
Insert-knife cutterheads:
cutterheads:
dow
dow frame
frame construction.
construction. Available
Available inin straight
straight and
and curved
curved edges.
edges. Another
Another style
style of
of multiple-profile
multiple-profile cut-
cut-
single
single and
and two-cutter
two-cutter styles,
styles, these
these Multiple-profile cutters: These
Multiple-profile cutters: These ter
ter with
with aa single
single cutterhead
cutterhead that
that
require
require careful
careful setup
setup and
and adjustment
adjustment versatile
versatile cutters
cutters save
save the
the expense
expense of of accepts
accepts interchangeable
interchangeable knife
knife sets.
sets.
for
for tight,
tight, accurate
accurate joints.
joints. buying
buying dozens
dozens ofof different
different individual
individual You
You can buy sets designed for general
Panel-raising cutters: Used
Panel-raising cutters: Used for
for cutters.
cutters. shaping
shaping or specifically made for cope
shaping
shaping thethe raised
raised edges
edges ofof panels,
panels, A
A single
single multi-profile
multi-profile cutter
cutter shapes
shapes cutting
cutting or shaping raised panels.
these
these single-profile
single-profile cutters
cutters come
come in in aa several
several different
different profiles.
profiles. You
You simply
simply
variety
variety ofof shapes
shapes (ogee,
(ogee, tapered,
tapered, etc.)
etc.) set
set the
the height
height of
of the
the cutter
cutter to
to the
the area
area
By Ian Kirby
T
he workbench top is to the tect it from clamp heads and glue drips
woodworker what a face plate is with a sheet of Masonite.
to the machinist a surface
used as a reference. In wood terms, its Benchtop Characteristics
a dead flat, hard surface. Its edges and Well: Many contemporary benches
ends are square. It wont sag under offer a well as a place to put your
load. About every two or three years, tools. My experience is that the tool
any distortion due to movement, you want ends up in the well under the
wear, or dings can be skimmed back board that you just carefully clamped
to accuracy by planing. It neednt be into place to do the work that requires
babied like a piece of furniture, but the tool! So, my bench has no well.
you dont cut into it by chiseling, Structure: In the past, benchtops
sawing or drilling. Apply oil to keep were made of two or three thick
it clean and protected from spills. If slabs of readily available quarter-
you must use it for glue-ups, pro- sawn hardwood maple in the U.S.,
Exploded View
10
3
3
5
2
4
6 8
2 5
4
6
Wedge
(Side View)
7 7
The wedges are custom fit
to each tenon. See the sidebar
on page 50 for details. material list
T xW x L
1 Benchtop Laminations (16) 13 4" x 2 3 4" x 60"
2 Legs (4) 31 8" x 31 8" x 321 4"
3 End Top Rails* (2) 17 8" x 33 4" x 231 2"
Bench Stop 4 End Bottom Rails* (2) 17 8" x 3 3 4" x 231 2"
(Front View) 8 5 Long Rails** (2) 17 8" x 3 3 4" x 50"
1
/2"D. 6 Long Rail Blocks (4) 17 8" x 2 1 2" x 113 8"
Mount the
stop to the leg 7 Wedges (16) Cut to fit
so the end is 8 Bench Stop (1) 13 8" x 31 8" x 12"
flush with the
top of the
9 Vise Cheeks (2) 1" x 41 4" x 14"
6"
workbench 10 Vise Spacer Block (1) 11 2" x 51 2" x 10"
when the stop
*Distance between shoulders is 17".
is at its lowest
point. **Distance between shoulders is 4312".
1
/2" Note: Cut the rails slightly long and trim flush with legs
after glue-up.
31/4"
Washer width
3
31/8"
End Top Rail 1
/4"
(Side View)
21/4"
31/2" 13/8" 1
/2" The mortise for the vise is 1/2" deep.
The spacer block is mounted right
Workbench Top behind the mortise.
(Top View)
Workbench Top
(Side View)
4 31/4"
1 17/8" 103/8"
1
/4"
91/4" 10
Leg 3
(Side View)
1
Note that the end
1
/4" /4" top rails are held
1
3 /4" 31/4"
1/4" above the top
plane of the legs.
Bench 1"
Underframe
Top Leg
Joint Detail
(Front View)
2 Long Rail and Long
2 Rail Block Assembly
(Side View)
31/4"
1" 5
3
5 /4"
6
53/4"
1
/4"
31/4"
91/4" 1"
51/2"
1
/4"
1
/4"
In the past,
benchtops were
made of two or
three thick slabs of
readily available
beech in Europe. Both are light- quartersawn in a plastic bag, folded over to make an
colored woods, which reflect light very airtight seal. How many strips you glue
well, and thus greatly help when setting
hardwood maple in one clamp-up depends on whether
a plane or using a try square. Making in the U.S., beech you work alone or with a helper. The
fine visual adjustments over a dark real dividend of a helper is having some-
bench is like working in a badly lit in Europe. one at the other end of the board to lift
room. The days of big slabs are gone, and shift and at the other end of a clamp
so an excellent alternative is to lami- to attend to its positioning and other
nate strips of flat-sawn material. Their tasks. Working as two, you could begin
combined edges then create a quarter- with as many as six center strips.
sawn surface. I used 8/4 flat-sawn soft Working alone, begin with three center
maple that was 6" wide, sawn down the solid surface on which to work, such as strips. Position five clamps equally
center, then planed and thicknessed to an existing bench or sheet stock sup- spaced on the work surface. The
yield as big a section as possible. I man- ported by battens and sawhorses. I remaining six clamps sit on top of the
aged 134" x 234". used 11 bar clamps, augmented by work, spaced between the bottom five.
upwards of a dozen fast-acting clamps to Using fast-acting clamps, align the sur-
Making the Top align the edges. I applied Titebond II face of the laminates by keeping both
Lay the strips out to choose the glue with a 3" paint roller. Pressing firm- heads of the clamp centered on the glue
best color and grain pattern, then num- ly to wet the surface, roll a light coat on line. Also align the ends. After the first
ber them for an orderly glue-up. I used each face. The squeeze-out should glue-up dries, add one strip to each side
16 strips to make a top 28" wide. Gluing show as small beads, not drips. to allow ample time for precise align-
this many strips together requires a flat, Between jobs, store the roller and tray ments before the glue cures. By careful-
ly managing the assembly this way, I keep the blade sharp. As the surface
needed to remove only 1/16" to flatten becomes more refined and the depth of
the top. Its possible to make three glue- cut is reduced, the shavings become
ups a day: morning, noon and evening. like duck down and the planed surface
is left very smooth. Dont sand the
Flattening the Top benchtop because the residual abrasive
Make the top flat by planing across the grit will dull your blade after only a few
grain. This may seem counterintuitive, plane strokes when the occasional re-
but its the best way to remove the The rail numbers match the leg numbers. flattening is required.
slight but inevitable unevenness in the Top rails are marked on the top edge, bottom The top must be flat in length, flat in
laminations. All woods plane well rails on the bottom edge. width and out of winding. Use a two-
across the grain with minimal tearout. foot straightedge to check your flatten-
Its important to follow a planing pat-
tern. Begin at one end and concentrate
on a band 6" to 9" wide. Move to the
next band as flattening occurs. After
flattening the final band at the other
end of the top, set the blade finer and
start again. Use your straightedge from
the very beginning and check every
direction. Use a bench brush repeated-
ly to avoid planing over shavings. And
Clamp a rail square and upright in your Slower is surer: knife the shoulder lines and
tenoning jig. The jig guides the cut and keeps clean up with a wide and sharp chisel.
your hands safe during the operation.
ing progress at close intervals across benchtop surface. The center lags
the top. I also used a six-foot extruded A block clamped in place on the front of the jig have a 3/8" clearance hole and
aluminum level to assess the flatness of positions the rail to cut the cosmetic shoulder the four outer ones have a 5/8" clear-
the overall length. Use winding strips and avoids sawing into the jig. ance hole to allow the top to move
end to end, middle to end, and across unhindered through its shrink and
the top to make sure there is no twist. expand cycles.
The maple bench stop is a sliding fit
through a hole in the top and is around it. The deliberate absence of a Mortise and Tenon Underframe
anchored to a leg of the underframe long top rail allows long clamps to pass This underframe uses through mor-
by a coach bolt. A wingnut on the bolt unimpeded under the top to hold tise and tenon joinery a typical fur-
allows for easy locking of the stop at assembled furniture parts firmly to niture makers joint but on a big
the desired height. You will need to the edge of the bench to be further enough scale to qualify as post-and-
chop the hole in the top to accommo- worked on. The top itself provides the beam construction. Because of its
date this feature. anti-racking benefits of a top rail when large size, the joint is cut with a mix-
it is attached to the underframe. ture of hand and machine tools rather
Goals for the Underframe than hand tools alone. There are many
The bench underframe must be Attaching the Top ways to achieve the end result and
sturdy enough to support the mass to the Underframe each depends on the machines you
of the top and any of the work that goes For many years I insisted that the top have available. For example, provided
on the top, and it must resist racking and the vise be attached by machine you get the geometry of the joint cor-
when its moved or during bench oper- bolt and nut. It meant lots of work bor- rect, you may cut the tenons on a band
ations such as planing. Almost any soft- ing accurate holes and fitting 10 neat saw, whereas I used a table saw.
wood or hardwood will fit the bill. The plugs to cover the bolt heads. Then,
one shown here is made of mahogany many benches ago, I began using lag Making the Underframe
and put together using through- screws, and my confidence in their Start off by marking out each joint as
wedged mortise and tenon joints and lifelong holding power remains firm. though it were to be made by hand. I
bridle joints. It calls for legs over 3" The top has six lag screws, one in the had to dodge some growth defects in
square with rails almost 2" thick. center of the end top rail and one as the mahogany stock, so the first thing
The end frames are sized sufficient- far to each edge of the end top rail as to do once the parts are milled is to
ly inboard from the edges of the top so is practical. I used 3/8"-diameter lags decide on the layout (which parts go
that fast-acting clamps can be used all that extend to within 1/2" of the where) and mark each part clearly. I
Use a 7/8" spade bit Clean up the Put the leg in the vise on a support block and
on center to leave mortise with jig- chop out the bulk of the waste using a mortise
1/16" of waste on guided router bits. chisel (above left). Then complete the cut (above
each mortise wall. The insert (left) lets right) by pressing a sharp bench chisel tight
you cut two sizes against the face of the angled guide block.
with the same jig.
used numbers and arrows made large Cutting the Leg and Rail Joints unchanged. Turn the workpiece
with a felt pen. The numbers and I cut the leg mortises first using a around to make the second cut. The
arrows tell you the inside faces, which shop-made tenoning jig. In each case, tenon should fit tight. Offer the uncut
is important to know when you cut the the rectangular peg and the rectangu- rail to the completed leg part of the
slopes on the ends of the mortises to lar hole are centered, so after you cut joint and assess how close you need to
accommodate the wedges. None of one side, turn the part around and cut be to the mortise gauge line. Set the
the marks are planed or sanded off the other side. This procedure can blade only 1/2" high. Set the work in
after assembly, but they will be hid- only produce cuts that are correct and the tenoning jig so the cut will err on
den. They were also recorded on alike if the parts have exactly the same the rich side. Saw both faces. Clamp
paper as a backup. thickness. Thats why careful prepara- the work in the miter gauge and set the
Mark out the joints with a marking tion of your stock is so important. blade to the correct height to remove
knife, try square and mortise gauge. Clean up the bottom of the joint with a the newly cut face. Now test the 1/2"
The top joint doesnt have a unique chisel. Cut from each side shoulder stub tenon against the mortise. If the
name. Its a variation on a bridle joint line to leave a mound in the middle. tenon is too rich, release the fence lock
that is often called an open mortise Once you have established both shoul- handle halfway, adjust the fence with
and tenon here in the States. The top der lines, remove the mound by hori- hammer taps, and re-test.
edge of the rail sits proud of the top zontal paring. My jig is guided by the Because the rail is too wide to fit
end of the leg by 1/4" to avoid the fol- fence and advanced by hand, safely dis- inside the tenoning jig, its mounted
lowing problem: If the leg and rail are tant from the saw blade. The rip fence instead on the outside at the front.
made flush and shrinkage in the rail controls the setting. To affect a slight Although you can cut shoulder lines
occurs after the top rail is attached, the adjustment when setting up the cut, I directly from the saw, getting consis-
ends of the legs would be proud of the slacken the fence locking handle, then tent results on every piece is risky busi-
rail. The shrunken rail would then pull lightly tap the fence with a hammer. ness. I take the slower but surer route:
the top into a cupped or curved state. Because the saw is set at full height, it knife shoulder lines, saw within a 1/16"
The bottom edge of the joint has a 1/4" would cut deeply into the jig, so I glued and clean up with a wide chisel.
cosmetic shoulder. I coined the word on the thick bridge pieces front and
cosmetic because its main purpose is back to stiffen its structure. Because Making the Mortise and
to hide shrinkage and to cover any the rail thickness differs from the leg Tenon Joints
less-than-perfect edge you may have thickness, you must change the set- The normal order of cutting a mortise
made on the bridle opening. Both parts tings. However, the tenon is centered and tenon by hand or machine is to cut
of the joint can be cut on the table saw. on the rail, so this setting stays the mortise first, because its easier to
Machine
screws
Installing the Vise Hang the vise 9" to 10" from the working
Value for price, the Record 53ED is the best woodworking end of the top and so it is clear of the under-
tool investment I know of. The jaws of Model 53ED are 1012" frame. You can mark out and cut the jaw mor-
wide and open to 13". Remove the metal dog that is intend- tise by hand or you can use a router, 1/2"-diameter pattern
ed for use when the vise is mounted at the end of a bench- bit and a pattern jig. Clamp the jig into position, locating the
top with a series of lengthwise dog holes. English hand tool opening with a batten screwed to the back of the jig that
woodworkers did not clamp work this way. Using the vise puts it 5/8" from the top edge of the bench. Stand the top on
dog on a side-mounted vise against an opposing dog could edge. Prepare eight spacer strips 1/4" x 1/4" x 20" and
split the benchtop in two. The metal jaws each have two stand them all on edge against the fence at the top of the jig.
1/4" holes so that wood cheeks can be bolted in place. Later Set the router bit to full depth and ride the router base
models no longer come with threaded holes, so you will against the strips to make a cut 1/4" wide. Remove a strip
need to thread your own with a 5/16" x 20 tap. The cheeks each time you make a cut. On the final pass the pattern bit
are then drilled and countersunk to accept 5/16" x 114" flat- bearing rides against the jig.
Begin the vise installation by clamping the Hang the vise with the top turned upside- Make the fixed cheek square with the benchtop (left). A
pattern jig for routing the vise mortise in down. (The mounting bolts are on an older clamped workpiece should be square (center) with the top
place to the benchtop. bench, before I began using lag screws.) and vise cheeks parallel (right).
head machine screws. A quick-release trigger disengages Hold the vise in place with clamps and blocks. The jaws
the screw so that work can be held in one hand while the are thinner at the top edge than the bottom. You want the
vise is quickly adjusted. The trigger turns a bar that lifts a metal face flush with the bench or a whisker below. To com-
half nut in the fixed jaw casting. The half nut is held in place pensate for the casting variance, plane the spacer block at
by a metal plate fixed to the casting with two 1/4" bolts. an angle so the vise tilts toward the back lag screws. Once
Lock them down tight when you get the vise, and that is the vise is hung, make and attach the wood cheeks, prefer-
about all that you will ever have to do other than keeping the ably of quartersawn maple or cherry. The lower edges sit
bars and buttress thread clean and lightly oiled. 1/2" above the guide bars. Note that the jaws toe in at the
Because the jaw is deeper than the bench is thick, you top to compensate for the flex in the casting when the vise
must fill the gap with a spacer block. The block must be is under load. As the jaws are tightened, the clamping force
thick enough to leave a gap of up to 1/8" between the top is evenly distributed from top to bottom rather than being
edge of the fixed jaw and the mortise it sits in. If you make concentrated where the screw is located. The jaws should
the top edge tight, the spacer block could compress enough also come together parallel so that the clamping force is
when you tighten the lag screws to break out the strip of evenly distributed side to side. Again, you may have to plane
benchtop above the fixed jaw. The side edges of the jaw the cheeks to adjust for any distortion in the casting. The
should fit tightly in the mortise. toe-in need only be a maximum of 1/8".
The next step is to remove the fluted offering the tenon piece to the newly cut the top end rail for the heads. The two
walls. Use a 1"-wide chisel, being care- mortise and decide how close you center clearance holes are 3/8" and the
ful not to cut beyond the outer edges should cut to the mortise gauge line. four outside clearance holes are 5/8" to
of the holes. Make a 1/2" or so depth of cut, saw allow the top to shrink and expand.
The remaining waste is removed by some temporary shoulders, and test this
two router bits: a pattern bit (guide stub tenon in the mortise. Adjust the cut Assembling the End Frames
bearing on the shank) and a trim bit as necessary and cut the finish tenons: Once the end frame parts are made
(guide bearing on the tip). The jig is faces, shoulders and cosmetic shoul- and ready to assemble, finish the rails
an exact rectangle cut into 1/4" MDF. ders. Next, saw the kerfs for the wedges. and the inside faces of the legs. I used
Clamp the jig in place and clean up the Use a 3/32" blade set 1/4" from the edge an oil finish. Finishing at this early
sides of the mortise with the 1"-long and ending 1/4" short of the shoulder stage allows glue squeeze-out to dry
pattern bit. Turn the leg over, clamp line. (The wedge kerfs are made using on the shoulder line. Clear it away
the jig from the same face and rout the same jig setup that was used for the with a sharp chisel and the result is a
again. Remove the jig, set the trim bit cosmetic shoulders.) The long rail tenon clean, clear surface and joint line.
to depth and clean out the waste is too heavy and too tall to stand upright Begin by clamping the end frame dry.
remaining in the center. in the tenoning jig. Use a 3/4" dado head This obliges you to get all the neces-
Knife the lines for the wedge open- and make multiple passes across each sary clamps and protection blocks in
ings on the outer faces of the legs. I face. Clamp the work to your miter fence place. No matter how long-winded the
decided to wedge out the longer rail and make a trial cut from both sides dry clamp-up seems, its a vital step
joint 5/16" and the end rail joint 1/4". about 5/8" from the end. Check this stub toward a successful glue-up. Put the
By drawing both joints full-size you can tenon in a mortise, adjust the blade parts together dr y and check for
determine the gradient and make height as necessary and complete the square, twist and alignment. Then
guide blocks (see photos, page 49) to cut. The cosmetic shoulders and the glue, clamp and drive in the wedges.
direct the chisels in cutting the slopes. wedge kerfs are made by sawing down Now that the end frames are complete,
Whenever paring or chopping a work- the tenon as in ripping, then cleaning up use the same steps to complete the
piece held in a vise, rest it on support the curved-out bottom with a back saw underframe.
blocks that sit on the vise guide bars. or narrow chisel. Youll need to mount the vise to the
This frees you from tightening the vise top, as described on page 51, before
to resist downward pressure from par- Final Details your work is done. Attach the bench
ing cuts and mallet blows, and the Sawing the Leg Ends: Form a stand- stop to its leg and engage it as you
work is easily returned to level and ing pad so that the the leg ends wont mount the top to the underframe.
height after checking. break out at the edges when the bench Clean up and oil all the unfinished
is dragged. areas, and you are ready to put this
Making the Tenons Holes for the Lag Screws: I used 412" new and essential tool to work in your
The bottom rail tenons are made in the lag screws to hold the top to the under- shop. If youve built it carefully, it will
same way as the open tenons. Begin by frame. Drill 118" counterbore holes in serve you well.
By Chris Marshall
W
oodworking doesnt involve and lower it partially into a hole in a ment cabinet with an oversized top
much drudgery, but I can board clamped to your drill press and a base that clamps to your drill
think of three tedious chores: table. That option didnt work for me. I press. The top compartment serves as
Scraping dried glue, cleaning pitch off needed a place to store all the differ- a dust extraction chamber with an
saw blades and, of course, sanding. ent drum sizes and sanding sleeves adapter port that attaches to a 21 2" -
Concerning that last one, sanding that come with a drum sanding kit. I diameter shop vacuum hose. The
curves is the worst type especially also needed to stash my Forstner bits, lower compartment houses a storage
when you have to do it by hand. If hole cutters and other drilling doo- drawer just big enough to hold a
youre still wrapping sandpaper around dads, so a drawer seemed in order. healthy collection of sanding sundries.
dowels and sanding till your arm goes Equally important, the sanding-drum- Although I could have cut an oversize
numb, its time to convert your drill and-board approach doesnt keep dust hole in the worktop to make room for
press into a drum sander. at bay and thats a real issue if you the sanding drum, I installed a router
Theres a low-tech approach to drum have lots of curves to clean up. table plate instead. Because it lifts off,
sanding that I didnt adopt here. You My sanding station satisfies all these it gives you plenty of access to the dust
could just chuck the sanding drum needs. Essentially, its a two-compart- collection chamber whenever a sand-
ing drum or drill bit accidentally slips
down inside. Plus, most plates, includ-
ing the Rockler aluminum router plate
I use for my setup, come with inter-
changeable inserts. Just bore one out
to fit around each size of sanding
drum you own.
One other benefit to this project is
that you can use it for either sanding
or routine drilling. I never take mine
off the drill press. The worktop over-
hangs provide plenty of room for
clamping a fence or drilling jigs in
101/4" 7
/8" Magnet
2 1 2
3
14" 3
13
9
7 11
10
8
11
Exploded
View
1
2 12
6
material list
(cabinet) T xW x L
T xW x L 7 Work Surface (1) 3/4" x 161 2" x 161 2"
1 Back (1) 3/4" x 8" x 121 2" 8 Subtop (1) 3/4" x 161 2" x 161 2"
2 Sides (2) 3/4" x 8" x 13" 9 Plastic Laminate (1) Larger than work surface
3 Base (1) 3/4" x 14" x 19" 10 Side Edging (2) 3/4" x 11 2" x 161 2"
4 Divider (1) 3/4" x 121 4" x 121 2" 11 Front/back Edging (2) 3/4" x 11 2" x 18"
5 Drawer Stop (1) 3/4" x 1" x 2" 12 Vacuum Port (1) 21 2" Dia. opening
6 Front Panel (1) 3/4" x 37 8" x 14" 13 Router Table Insert Plate 1/4" x 8" x 11"
place. You should know that Ive sized to back. Turning the stop sideways els, confining the glue to about a 4"
this project to suit my drill presss locks the drawer in the cabinet. Make area. Sandwich the panels and fasten
large table. If its too big, as is, for your the stop and install it on the divider them together with four screws, one at
drill press table, just bolt a piece of ply- with a single flathead wood screw. each corner. Apply an oversized piece
wood to your machines table and Drill the countersunk screw hole in of plastic laminate (piece 9) to the
clamp the station to that. Or, adjust the the stop slightly oversized so the stop worktop with contact cement, and trim
dimensions in the Material List on the swivels easily on the screw. With the it to size with a router (see photo,
facing page to make a smaller station. stop in place, fasten the divider to the below). Once thats done, wrap up by
carcass assembly. I used 4116"-wide marking the worktop to locate the
Basic Building With Baltic Birch spacers to hold the divider in place router insert plate.
Get construction underway by cutting during installation (see photo, page
the back, sides, base and divider 54). It needs to be positioned carefully
(pieces 1 through 4) to size. I used so it will clear the top edges of the
Baltic birch plywood for these and drawer. Wrap up the carcass assembly
most of the cabinet parts (the drawer by cutting and nailing the front panel
front and front panel are solid birch). (piece 6) to the carcass.
Round the corners of the base to keep
it from scraping your thighs, and Preparing the Worktop
chamfer the back outside edges of the The worktop consists
sides and the sharp edges of the base of a build-up of plas-
to minimize splintering. Bore a 212"- tic laminate and
diameter hole in one side piece to two layers of ply-
serve as the dust port access (see the wood. Cut the
Drawings to locate this hole position). work surface and
Fasten the sides to the back with subtop to size
screws and glue, and tack the base to (pieces 7 and 8),
the carcass with a couple screws. Youll making sure the
remove it later on, so no glue here. proportions The author trims the
To limit the travel of the drawer, match. Apply a laminate flush with
I fashioned a swiveling stop (piece 5) few dabs of hot a piloted flush trim
that functions like a turnbuckle. melt or ordi- bit, holding the
workpiece in place on
As you can see in the Drawings on nar y wood
an anti-slip mat.
page 59, a notch in the drawer back glue to the
allows the drawer to slide past the stop center of
for removal when the stop faces front these pan-
17
15
material list
(Drawer) 17
T xW x L 14 18 15
14 Drawer Front (1) 3/4" x 4" x 14"
15 Drawer Sides (2) 3/4" x 4" x 123 8" 18
3
/8"
16 Drawer Back (1) 3/4" x 31 2" x 113 4" Drawer Exploded View 14
17 Drawer Bottom (1) 1/4" x 111 2" x 121 4"
18 Magnets (4) 3/8" Dia. rare earth 13/16"
19
19 Drawer Pull (1) 112 Dia. knob
sides, then dry-assemble the drawer where they meet the drawer. Drill Complete the drawer by installing the
box and check its fit in the cabinet. shallow holes with a Forstner bit, add pull (piece 19).
Once it slides in and out satisfactorily, a drop of epoxy in each and press the
disassemble the parts and rout slots for magnets into place (make sure to Finishing Up
the drawer bottom (piece 17). Chamfer check for correct polarity between All that stands between you and
the front outer ends of the drawer front. each pair first). Now glue up and a proper drum roll is to apply a coat of
I used four 3/8"-diameter rare earth clamp the drawer box joints, and finish and add the vacuum port and
magnets (pieces 18) to hold the draw- check the drawer for square by meas- insert plate (pieces 12 and
er closed. Install one pair in the back uring the diagonals. When the glue 13) to the cabinet.
face of the drawer front at the overlaps cures, slide the drawer bottom in dry
and a second pair in the cabinet sides and tack it to the drawer back.
Rout 3/8" dovetail slots in the back of Complete the sliding dovetail
the drawer front on the router table. joints for the drawer by
The author used a backup board forming pins on the
instead of a miter gauge to steady sides. The author used a
the workpiece for these two cuts. backup board here to
prevent rocking.
By Chris Inman
A
woodworkers mallet is a very to make one is well worth the effort.
personal tool. We learn their Among domestic wood species, maple
subtleties of weight and bal- is the best choice for a mallet. Its both
ance so that the slightest tap can hard and dense, so it withstands repeat-
accomplish just what we need from a ed blows against chisel handles. Many
chisel or carving gouge. After many exotic species are even harder than A comfortable handle is the key to a successful
years of service, with a handle dark- maple, so they also work well for this mallet. To reduce tearout while spokeshaving,
ened by sweat and glue and the scars application. Padauk, for example, is hard work from the high points to the low.
of time, your mallet will begin to feel and stable and, because of its beauty,
like an extension of your hand. makes an excellent accent wood.
Mallets purchased from a store The mallets head (pieces 3 and 4) is of maple (pieces 1) to each side of the
do everything you expect of them in a built around the end of the handle padauk strip (piece 2). If you have a lit-
practical way, but they lack an undefin- (pieces 1 and 2). Laminating the mal- tle birds eye maple around, use it to
able quality thats so evident in a hand- let in this way is much easier than try- really make this a special piece.
made tool. Given the years of service ing to mortise a hole completely Padauk, as with many exotics, is an
that a mallet provides, the time it takes through the head, and it still results in oily wood and sometimes doesnt bond
a strong assembly. well with yellow glue or hide glue.
To make the handle, glue the pieces Therefore, just to be on the safe side,
use epoxy to prevent any possibility of
delamination due to oil in the padauk.
Another advantage of epoxy is that it
remains somewhat flexible after it
dries, giving the mallet more resilien-
cy when delivering a heavy blow
(glues that are brittle
will crack with this
kind of shock).
Once the
glue dries, rip the
handle to a width of 134 ",
then lay out the handle
pattern shown on the
next page. Next, cut
a shoulder 234 " from
the top end of the
handle to positively
position the two
3
6
1
Head
(Side View)
Handle
(Side View)
6"
11/2" 21/4" 11/2" 1
/8"
4 13/4"
23/4" 23/8" 23/4"
33/4"
2
3
4
5
material list
T xW x L
1 Maple Handle (2) 3/4" x 2" x 1318" 131/8"
core pieces (pieces 3) of the head during enter the kerf easily.
the final glue up. To do this, raise your Assembling the mallet is a sloppy
table saw blade to 1/8", clamp a setup task given all the glue thats involved,
block to the rip fence and position it 234 " especially when the pieces begin slid-
from the far side of the blade. Pass the ing around. But you can prevent the
handle over the blade a number of times sliding by driving three small brads just
to cut the shoulder and complete the slightly into each padauk face and then,
tenon. Clean up the saw marks on the using a wire cutter, cutting off the brad 13/4"
tenon with a sharp 1" chisel, then use a 1/8" above the surface. Press the core
band saw to cut the wedge kerf and pieces and the handle into position on for cleaning up the excess glue.
shape the handle. Take a few strokes top of one padauk face, then press the The next day, belt-sand the pieces in
with a spokeshave to chamfer the grip second face on the other side of the the head lamination flush and scrape
until it fits comfortably in your hand. head. The nails will indent the wood, off any glue residue. Band-saw the
Now, from maple stock thats the preventing the pieces from slipping curved top on the head and sand this
same thickness as the handle, cut two around when the glue is added. cut smooth. Now use a block plane to
234"-wide by 214"-long pieces for the Now disassemble the mallet, spread chamfer all the long grain edges of the
mallet heads core (pieces 3). Cut the epoxy on all the joining surfaces, and head and a chisel to chamfer the cross-
outside edge of each piece (the strik- clamp the pieces back together. Be grain edges. Chamfer the end of the
ing faces of the mallet) at a 3 angle. sure to adjust one clamp to lightly hold handle, too. Use a palm sander with
The padauk faces (pieces 4) meas- the maple core sections against the 100-grit paper to remove belt sander
ure 234" wide by 6" long and have ends handle, but be careful not to clamp too marks and ease all the corners. Once
cut at a 3 angle to match the core. tightly or you wont be able to insert the youre satisfied with the feel of the tool,
From padauk scrap, also cut a 2"-long wedge. Put a little epoxy on the pointed apply two coats of a penetrating oil fin-
by 158"-wide by 1/8"-thick piece for the end of the wedge and drive it into the ish and youre ready to go to work.
wedge (piece 5). Belt-sand one end of top of the handle. Youll have plenty of Pounding never felt so good.
the wedge to a blunt point so it will squeeze-out, so have a few rags ready
By John G. Premo
Exploded 3
6
View 3
9" 5
1
12 /2" 12"
2
Jig Supplies material list
The following supplies are available
19" 1
from Woodworkers Journal to T xW x L
5 complete this project (Note: prices 1 Upper and Lower
subject to change): Tables (2) 3/4" x 19" x 19"
Adjust your Full-extension Drawer 2 Sides (2) 3/4" x 11 2" x 12"
miter bar before Slides (1 Pair) #32490 . . . .$16.99 3 Full-extension
attaching to the Star Knob* #23838 . . . .$1.09 ea.
lower table.
Drawer Slides (2) 18"
*Two required. 4 T-shaped Mending
Adjustable Miter Bar Plates (2) 1/16" x 31 2" x 4"
19" #21982 . . . . . . . . . . . . . . . .$15.99
5 Adjustable
5 2 Please call 800-610-0883
Miter Bar (1) 18"
mention code WB035
6 Star Knobs (2) 1" Stud x 1/4"
(End View) 1 3 21/2"
A
s you can see in the photos at
right, theres nothing too tricky
about the construction of this
jig. I used quality 3/4" material for the
fixed and sliding tables (pieces 1) and
clear stock for the sides (pieces 2).
Using the dimensions in the Material
List will keep you in pretty good shape The upper sliding table gets half of the slide, the T plates and the star knobs. The author
with most of the band saws out there, drilled and tapped holes in the mending plates to accommodate the star knob threads.
but I suggest you measure yours care-
fully to determine if any minor adjust- Lower Fixed Table (Bottom View)
ments are necessary. After cutting the
tables to overall size, use your dado
blade to make the band saw blade slot
down the middle of each one, and
clean up these cuts with a chisel.
Now, screw the sides in place
on the bottom table, testing the fit on
your band saw table to make sure its
snug. Install the slides (pieces 3) and
the mending plates (pieces 4), as
shown in the Elevation Drawings at
left. With those pieces put together,
place the jig on your band saw and
slide it into position to find the exact
location for the adjustable miter bar
(piece 5) on the bottom of the base. The lower fixed table gets the sides and the adjustable miter bar. Both of these pieces must be
custom fit to ensure that the fixed table fits over your band saw table perfectly.
I drilled and tapped threaded holes
in each of my mending plates to accept
the star knobs (pieces 6). Before
assembling your jig, drive a 1" brad up
through the bottom of the upper table
to serve as your pivot point, as shown
in the Exploded View at left. The brad
needs to be aligned to the front of the
saw blade. When youre ready to make
your first circle, the radius will be the
distance from the blade to the pivot
point. This jig can produce circles of
surprisingly large diameters. When
fully extended, it is sometimes neces-
sary to use clamps to fasten the back
of the fixed table to the band saw table
to prevent it from tipping. In practice, a small nail is driven up through the bottom of the sliding table. That pivot point
and the sliding nature of this jig will allow you to create a full range of circle sizes.
Straightedge Jig
This versatile straightedge jig trims plywood,
but it also breezes through rabbets, dadoes
and grooves. Its a must-build for your shop.
By rick white
H
eres a slick jig to have handy
whenever you need to straight-
en a rough edge or plow a
groove. Its actually a multi-use
straightedge, designed to custom-fit to
your portable router. The router runs
along its fence, and that guides
a straight bit along a hardboard
template attached to the bottom of
the fence. Whenever you need to
make a cut, just line up the edge of the
template with your trim line on the
workpiece. Youll never have to go
through the old measure-and-clamp
routine again. The jig also performs a
bonus task on the table saw more
on that later.
The heart of the jig is a
straight, jointed plywood fence
(piece 1). Seal this along its two
64 Straightedge jig
WSP.SIP_065 2/15/08 9:29 AM Page 65
10
9
7
material list 5
T xW x L 8 2 3
1
1 Fence (1) 3/4" x 2 4" x 60"
1
10
9 T-bolts (4) 18 5 16" x 11 2" Hold-down
Back Detail
10 T-knobs (4) 18 16" Plastic
5
ripped edges with strips of solid hard- The adjustable stops are simply short
wood banding (pieces 2). Then plow a lengths of stock (pieces 7), each of which
grove in the top to house an aluminum is attached to a base (piece 8) with glue
T-slot track (piece 2). and clamps. These bases need to be a lit-
Cut one 1/4" hardboard template tle wider than the stops, so they wont
blank for each straight bit you own. interfere with the routers travel (other-
Each of these templates (pieces 4) wise, the machines handles might hit
should be 7" wide to begin with. Attach the stops). The wide bases also keep the
the first template to the bottom of the stops aligned at 90 to the fence.
jig with bolts and nuts (pieces 5 and 6), The stops are secured to the jig with
then install your largest-diameter T-bolts and knobs (pieces 9 and 10),
straight bit in your portable router. Run which make them adjustable along the
the router along the fence so it trims entire fence length.
the template to size. Use a permanent Earlier, we mentioned a bonus func-
marker to note the bit size on the tem- tion of this jig, and here it is: By attach-
plate, then chuck the next largest bit in ing a couple of toggle clamps (pieces
the router. Bolt on a new template 11) to a spare set of hold-down bases
piece, and repeat the process until you (pieces 12), you can use the jig to
have individual, marked templates for straighten the edges of rough boards.
each of your commonly used bits. Clamp the stock to the jig and run the
If you stop building this jig right now, jig along your table saw fence to slice
you can make any straight trim cut, off the bad edge. Simple.
through groove, rabbet or dado you The hold-down option on this jig allows you to
need. To tackle stopped cuts, just add a slice straight edges on rough stock without
pair of adjustable stops to limit the fear of binding or kickback.
routers travel.
17 14
Clamping Jig
Exploded View
14
Rail 2
(Side View)
1 9
/16" 10 13
3
13/8" 5
/16" 3
/8" 1
9
/32" 7
17 3
3 1 17
/4"
3
11/2" 1 /8"
/4" Clamp Pad
3 5 5
3 3
/8" Dia.
1
/16" 3
/8" (Side View)
/8"
5
/8"
material list
T xW x L
1 Rails (2) 3/4" x 13 8" x 14"
2 Fixed Stiles (2) 3/4" x 13 8" x 2 3 4"
3 Sliding Stiles (2) 3/4" x 11 2" x 211 16" Heres the miter clamp jig in action. It eliminates creep and adds another
4 T-nuts (2) 5/16" - 18 level of safety, especially on cuts like the one shown above.
5 Clamp Pads (2) 3/4" x 13 4" Dia.
6 Upper Pad Nuts (2) 5/16" - #18
7 Clamp Bolts (2) 5/16" - #18 x 5"
8 Pad Fender Washers (2) 5/16" I.D. x 11 4" O.D.
9 Lower Pad Locknuts (2) 5/16" - 18 the sliding stiles. This will allow them to move in the
10 Head Spacer (1) 3/4" x 7/16" x 35 8" rail grooves. If they still bind, trim their shoulders
11 Toe Spacer (1) 3/8" x 25 8" slightly with a block plane or sanding block. Be sure to label
12 Head Bolt (1) 1/4" - 20 x 11 2" all four parts to avoid confusion.
13 Toe Bolt (1) 1/4" - 20 x 31 2" Using diagonal lines, find the center of each sliding stile
14 Knob Stop Nuts (2) 5/16" - 18 and bore a 3/8" through hole, using your drill press. Slip
15 Knobs (2) 5/16" - 18 x 2" Dia. 5/16", #18 T-nuts (pieces 4) into the bottom of each hole and
16 Pad Liners (2) 13 4" Dia.
hammer them flush.
Assemble the jig body by gluing one fixed stile between
17 Washers (4) 1/4" I.D.
the rails and clamping it, then add the sliding stiles and
glue. Clamp the second fixed stile in place at the other end.
Set the assembly aside to cure while you make the clamp
pads (pieces 5).
B
y itself, a miter gauge offers limited accuracy for cut-
ting angles. Youve probably discovered how difficult it Forming the Clamp Pads with a Hole Saw
can be to hold workpieces tightly against the gauges With a 134" hole saw chucked in the drill press, select
short fence without them creeping out of position as you the slowest speed and drill halfway into a piece of 1 x 3.
push the cut through. This clamping jig will help solve your Make sure the saws 3/8" guide bit slightly penetrates the
angle-cutting problems, because it applies pressure against bottom face. Replace the saw with a 5/8" Forstner bit,
the miter bar to hold workpieces securely. increase the speed and drill 3/8" deep to counterbore the
Start building this jig by ripping a 30" length of hardwood earlier hole. Now flip the 1 x 3 and re-chuck the hole saw.
for the rails (pieces 1) to the dimensions shown in the Free the clamp pad by drilling through, using the hole
Material List above. Plow a groove with slightly angled produced by your first cut as a guide. Follow the same
walls in one of the wider faces (it takes three passes on the sequence for the second pad.
table saw) and then crosscut the rails to length.
Make the fixed stiles (pieces 2) and sliding stiles Drilling a Hole in Your Miter Gauge
(pieces 3) from a single 1 x 8 board crosscut to Disassemble your miter gauge and turn the head over to
234" long. Mill a tongue on each end to the dimensions locate the pivot hole. Transfer the center of this hole to the top
shown in the Drawing: a tenoning jig on the table of the head and chuck a #7 drill in your press. Drill and tap the
saw works well for this. (Taper the tenon sides slightly hole with a 1/4 x #20 tap, and clean off the new threads.
so theyll slide even easier.) Rip the board to produce two Complete the clamping pad subassemblies next. Begin by
fixed and two sliding stiles, then trim a hair off each end of running upper pad nuts (pieces 6) up each of the clamp
bolts (pieces 7). Add fender washers the end. When the glue has set, drill lowed by the knobs (pieces 15).
(pieces 8), the clamp pad and the down through the fixed stile to pro- Tighten the knobs, then tighten the
lower pad Nyloc nuts (pieces 9). duce a through 1/4" hole. Next, chuck nuts back up against the knobs to lock
Tighten it until the rod is flush with a 3/8" drill in your press and counter- them in place.
the opening, then tighten the top nuts bore the bottom of the other fixed Apply epoxy to the bottom of each
until the washers are trapped. stile 1/4" deep. This will accommo- fender washer on your clamp pads and
date the toe spacer. screw the pads down. The jig acts as
Joining the Bar Reassemble your miter gauge, then a clamp here. When the epoxy has set,
Bore a 1/4" hole in the fixed stile cut the toe spacer (piece 11) to length apply Loctite to the three threads
nearest to the head of the miter (this will depend on your miter above the nuts. Use rubber cement to
gauge, at the location shown in the gauge). Fit the spacer into the attach pieces of router pad (pieces 16)
Drawings. Then, using the bar from counterbore on the fixed stile. Thread to the bottom of the pads.
the miter gauge as a pattern, mark the clamp bolts into the T-nuts in the Finish the wooden parts on your
and drill a 1/4" hole for the toe bolt sliding stiles, and youre ready to new clamping jig with a few coats of
in the other fixed stile. Notch the attach the bridge to the miter gauge wipe-on varnish and let it cure. Now
head spacer (piece 10) as shown in with the head and toe bolts (pieces 12 your miter gauge will function more
the Drawings, and glue and clamp it to and 13). Run the knob stop nuts accurately and safely than ever.
the bottom of the fixed stile, flush with (pieces 14) down each clamp bolt, fol-
T H E A L L N E W W O O D W O R K E R S R E S O U R C E D I G E S T . . .
Visit www.resourcedigest.com
to see the new 2008 version for yourself.
D
ovetail keys add strength and
Glue
beauty to an otherwise ordinary together
mitered corner. To make this
handy jig, simply follow the three-step
process shown at right. After the jig Form two identical rectangles from 1/2"
is constructed, determine where to plywood or MDF. The blanks must be
set the fence on your router table perfectly square. Glue and clamp the
blanks together.
in order to put the keyways
exactly where you want them.
But before you chuck your
dovetail bit in the router,
use a 1/4" straight bit to Flip over
plow a groove in the jig (to
remove waste material).
Switch to your dovetail
bit and remove the
remaining material.
Slide the jig along 45
your router table
fence to form
perfect dove-
tail keyways. Set the blade of your table saw to exactly
45 and cut the glued-up blanks in two.
Flip one piece over as shown above.
.
Side
By bruce kieffer
T
he best solution for flattening
cauls to the
veneer is to use a veneer press.
veneer.
Heres a simple one thats cheap
and easy to build. The heart of the
design is a set of curved, or cambered, Tighten the nuts
bearers. They distribute pressure with a box
evenly onto the veneer with the help of Position two 1/4"-thick sticks on the wrench until you
three cauls. Our design incorporates a 2 x 8s, and place the bearer on the see a consistent
bead of glue
method for curving the bearers so sticks. Slip a 12" piece of threaded rod
squeeze-out
they provide continuous contact along through the hole, and tighten nuts on
along the edges
their full length. All the measure- both ends of the threaded rod with a of the panel.
ments given here will create a press socket wrench. Stop tightening when
that accommodates panels up to 24" the bearer touches the 2 x 8s, and use
wide. If you change the dimensions, a straightedge to draw a line near the
add 4" for supporting the hardware. top of the bearer showing the low saw them close to the finished profile.
To begin, select a 2" x 8" x 8' piece point of the curve. Now screw the first bearer to the others
of knot-free Douglas fir. Crosscut the Release the bearer from the thread- and rout identical curves using a long
board into three 24"-long sections. ed rod and band-saw just outside the flush-cutting laminate bit. Cut 7/16"-
Select the best piece and rip it in half line, then return the bearer to the fix- wide by 3/4"-deep notches in both ends
for making your first bearer. Mill the ture, tighten the nut and hand-plane of each bearer, and nail support blocks
halves down to 114" x 212", then mark the edge right to the line. Since the to half of the bearers to raise the press
the edge on one piece at its center and camber is so subtle, draw a large off your workbench. Generally, youll
drill a 1"-diameter x 1/2"-deep coun- curved line on the side of the bearer to want a pair of bearers pressing on your
terbore and a 3/8" pilot hole. indicate the correct edge. veneer every four to six inches, so be
Now drill a 3/8"-diameter hole in Take the assembly apart, then rip and sure to make enough for your
the center of a 3/4"-thick scrapwood mill the other 2 x 8s like you did the first anticipated needs.
plate and set the other two sections of one. Trace the shape of the first bearer
the 2 x 8 on the plate, as shown above. onto each of the other pieces and band-
By Chris Marshall
H
and-cut dovetails, tusk tenons Thats when pocket screws or dowel still good options when you dont want
and other fancy joints are joints can really come to the rescue. to see oval holes with screws buried in
wonderful options to master them. Dowels can be ideal for situa-
for your projects, but lets face it: Skip the Glue with Pocket Screws tions where a joint must be both
there are only so many hours on a Pocket screw joints are as sturdy as strong and fastener-free. Theyre also
Saturday afternoon. In some cases, a they are easy to make. You use a helpful for keeping joint parts aligned
quick, efficient jig-made joint can drilling jig and stepped bit to bore during glue-up, especially when youre
bring satisfying conclusion to a proj- steeply pitched, counterbored holes in clamping odd-angle joints. Adding
ect, especially if youve still got some one joint member. Then, drive a cou- dowels to a cross-grain butt joint cre-
grass to mow or the bass are biting. ple self-tapping screws into these ates a mechanical connection where
Dowel drilling jigs have hardened steel bushings to keep your drill bit tracking properly. A
jig with repositionable bushings, like the once shown at left, expands your options for
drilling either end-grain or face grain so youre covered for most applications.
M
aking your own veneered panels adds a new dimension to your
Newspaper woodworking design capabilities, and its fun to do. The wood-
working techniques used for veneering are similar to those
Veneer
used with solid wood. Sawing, jointing, gluing, clamping, trimming and
MDF Core sanding are all familiar woodworking tasks. In this case, narrow sheets
of veneer are edge joined to make wider sheets that are then applied to
Veneer a substrate (the core the veneer is glued to). I prefer MDF for my sub-
strates since its smooth, flat and very stable. I find it easiest to use
Veneer Tape
wood glue, cauls (flat panels that spread the clamp pressure) and
Newspaper clamps. Or you can build and use the simple veneer press shown on
page 70. For small veneered panels like these, I use slow-setting yellow
Caul glue. Getting the glue on fast enough is always a challenge, so glue up
one panel at a time, and ask for some help if you can.
You must make balanced panels (a core with veneer on both faces
in this case), and you need to put both pieces of veneer on the core at
the same time. Oversize the veneer pieces so you can cut them to their
STEP 1: Use a veneer saw and straightedge to finished sizes after the veneers are glued to the substrates.
cut the proportions of the veneer sheets slightly
oversize (cut the substrates oversize, too). Cut to STEP 4: Flip the joined sheets over and apply a piece
their finished sizes after the veneers are of gummed backed veneer tape down the joint. Lay
glued to their substrates. a scrap flat panel over the taped sheet so it dries flat.
Remove the masking tape.
2 STEP 5: Lay the sheet with the tape side down over
the edge of your table. Open and glue the joint. Lay
STEP 2: I use my the sheet flat again to close the joint and
jointer and a jig to 5 place sticks aside the joint to hold it flat.
joint the edges of
the veneer sheets.
STEP 6: Assemble the glue-up sandwich as shown in the exploded
photo (above left). Using a narrow paint roller, apply a moderate coat
of slow-setting glue to both sides of the core and to each veneer.
Feather-Loc prevents chatter, Push-Loc is the ultimate push Power-Loc allows you to
gouging and dangerous kickback. stick for safety and convenience. locate your router switch
Durable polymer feather tips are Docking station keeps it right at anywhere you like. Put it on
rounded so they wont mar your your fingertips. Offset handle the cabinet, the table or even
workpiece. Available with Miter keeps your hand out of the way on the fence for easy access
Slot Adapter (shown). 10-005 for safety, visibility and and fast shut-downs. 40-028
horizontal use. 10-025
By Silas Kopf
W
hen I got my first job in the
woodworking world, I was
handed a flat rectangle of
steel and shown how to use it to shave
off very fine ribbons of wood. The
demonstration produced a clean sur-
face ready for finish. It was so simple
that it appeared almost magical. No
adjustments like a plane. Just grab
ahold and push the tool across the
board. My initial experience with the
scraper went well, until the edge got
dull enough that it was no longer cut-
ting neatly. I returned to the boss and
asked how to get the thing sharp
again. The accompanying lesson
looked like nothing was happening, the edge of the tool. And a lot of it is stones and burnishers out on the
but again the steel produced those fine the touch that is applied. I made many workbench. The key to getting the
shavings. At least until I tried to dupli- attempts to get a scraper sharp before scraper sharp is to get the edges filed
cate the sharpening. I was able to try it and have it work perpendicular to the face.
The problem with sharpening the like it did when the boss had done it. I demonstrate how to accomplish
scraper is similar to the problem with But finally, with success comes the this task in the photo sequence shown
sharpening so many woodworking revelation, So, thats how you do it. below. First, use the mill file and stone
tools. Things happen at the microscop- The scraper has four corners, and to get your scraper clean, with all
ic level, and you just cant see what is these can all be made sharp. edges perpendicular. Once youre sat-
going on. You need an understanding Therefore, it makes sense to do all isfied youve accomplished that, reach
of what is supposed to be happening to four edges while youve got your files, for a burnisher. Dont be afraid to use
Clamp the scraper in a vise with an inch and a half of steel sticking out. Use a fine mill file to file the edge smooth. Its crucial to hold the file very close to
perpendicular to get all the edges sharp. Place your fingers on the scraper blades sides to help keep the angle steady (left). Next, take a stone and polish
the face of the blade, as shown (center). This will remove any burr left from the filing. Now rub the stone on the filed edge of the blade (right), again
making sure its perpendicular to the face. This will clean up the file marks and leave the edge smooth.
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WSP.SIP_080 2/20/08 2:46 PM Page 80
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By Ian Kirby
C
utting a mortise and tenon joint using hand tools is
straightforward. The required tools are few and the
method allows only minor variations. Using
machines to cut the joint opens the door to a wide
variety of inventive and personalized methods.
Inevitably the methods you choose will revolve
around the machines you have available and the
jigs you design and build. In industry you
would use a CNC router or a double-ended
tenoner and a mortising machine. Form
may follow function, but its joined at the
hip to economy. Since most small shops
are equipped with a table saw and a
plunge router, thats the economic base
I started from to make the joint
described here. I chose these particu-
lar jigs because they are safe to use,
easy to build and are constructed of
widely available and inexpensive
materials.
Form may
follow function
Similarities of Hand- and but its joined at the Essential Requirements for
Machine-made hip to economy. Machine-made Joints
Regardless of how simple or sophisti- Successful machine-made joints
cated the equipment you use, the Since most small require that similar parts be milled
design of the joint, its dimensions, and prepared to exactly the same
and the placement of its parts are
shops are equipped dimension and geometric accuracy.
the same for machine and hand meth- with a table saw and This is because the jig is made to
ods. Also the same are the need for accept only a workpiece with specific
geometric accuracy, the alignment of a plunge router, dimensions. Even if no jig is involved,
tenon to rail and the alignment of mor- all repetitive machine techniques
tise to stile. Since were not using ded-
thats the economic require this exactitude. Assume for
icated industrial machines, its best to base I started from the purposes of this article that you
make the mortise first and fit the are making a square table using four
tenon to it as you would using hand to make the joint top rails tenoned into four legs. To cut
tools. Most find that its easier to the shoulders of the tenons, you put
adjust the size of a too-large tenon in
described here. the end of the rail against a stop to
small increments than it is to make an position the rail ready for the shoulder
oversized mortise minutely smaller. cut. If the rails are not exactly the
End stop:
3/4" x 1 3 4" x 5"
plywood
same length, the distance between drilling operations, one operation for
shoulders will differ and the table each part.
frame will not be square. In other Using a combination bit, drill clear-
words, accuracy of machining begins ance holes and countersinks in the Raise the saw blade through the baseplate (securely
at the Preparation of Stock stage. baseplate. To ensure a flat mating sur- fastened by a hold-down clamped to the fence).
You need to know which side or face, make small countersinks on the The center line across the width of the aperture is
edge of each furniture part is the back side to remove the bulge or rag- aligned with the vertical line on the fence.
inside and the outside and the upside out typical of through holes. Clamp
and the downside. The simplest and the baseplate to the base blocks.
best way to maintain order is to mark Where necessary, tap the parts into
the face side and the face edge on exact position with a hammer. Tighten
each piece. Through this process you the clamps. Drill a pilot hole for the
will get the best-looking faces on the screw threads in the base blocks.
outside and you will get the joints in Drive the screws home and remove
the correct face. Machine-made join- the clamps.
ery requires that you make a spare
part for every run of necessary parts: Drilling Out the Waste
in this case, a total of five rails and five A table saw makes sawdust, a planer
legs, (or 41 rails and 41 legs, if you makes chips, but a router cutter turns
Remove the waste at each
were making 10 tables). You use the at such a high speed that it produces end of the aperture by
spare part as much or as little as extremely fine particles that remain vertical paring with a
required to make the four necessary suspended in the air for hours. Apart bench chisel. Now check
parts. Mark out the joint on the spare from adding to the general uncleanli- for square.
part and use it to check machine ness of your shop, such particles are
setups and cuts. No marks are unkind to eyes, nose and lungs. An
required on the necessary parts, save industrial CNC router is engineered to
for the face side and face edge marks vacuum up the huge volume of fine
that tell you how to place the work- dust it makes. Few small shops are
piece correctly in the jig. equipped, however, to effectively col-
lect the dust from a plunge router. My
Exactitude with Screws solution when mortising is to remove
Router jigs can be no more accurate the bulk of the waste with a drill press,
than their component parts. MDF and leaving the router to trim accurately to
plywood are stable and easy to cut and the line. Use a bit thats slightly nar-
join with screws, though only plywood rower than the finished width
Here are the finished baseplate and two guide
can be screwed on edge. Screw join- of the mortise. If you dont have
blocks, separated by the mortise workpiece.
er y is best done in two separate a drill press, a portable drill will work.
Rub Collar
Tenoning
Jig
Use the aperture and center line All jig parts are cut square and held
marks as guides. Clamp and screw the together with screws. MDF is unsuit-
parts together. able for this jig since its edges, unlike
plywood edges, wont hold screws well.
Drilling Out the Waste
Use a drill bit thats about 1/16" small- Set the blade to height and begin by cutting Sawing the Tenon Faces
er in diameter than the finished width the inside tenon face on the spare rail. Mark out the tenon on the spare rail.
of the tenon. Set up the drill press with Clamp the rail into the jig, making sure
a back fence that positions the bit in the the rail is firmly seated in the jig and
center of the tenon on the marked-out that the clamp head is firmly seated
spare leg. Next, position the leg as if to against the rail. Set the blade to height
drill a hole at the bottom edge of the for cutting the tenon length. Adjust the
tenon and clamp an end stop against the table saw fence to cut the inside face of
top end of the leg. Move the leg as if to the tenon. Make the cut, then repeat it
drill a hole at the top edge of the tenon. on the remaining four rails.
Now make a block that fits the gap The second cut is critical because it
between the stop block and legs bot- determines the thickness of the tenon.
tom edge. Set the drill bit depth and drill Position the jig, make a test cut on the
out the waste on one side of all five legs. spare rail, and check with a vernier
caliper. Make the full cut, then remove
Cutting the Mortises Position the jig for the second face cut, using the a part of the waste with a handsaw to
spare rail. Make a test cut and check with a vernier
First, clamp the spare leg to the jig, expose enough tenon to be offered up
caliper to confirm tenon thickness is correct.
then clamp the leg in the vise. to the mortise for a test fit. Repeat the
Everything is now solidly held the full cut on the remaining rails.
goal of every machine jig setup. With Using the same blade height, test
the bit set at the correct depth and the procedures and sequence of cuts, saw
router at full plunge, you can cut the the tenons to width.
mortise easily because there is so little
material to remove. Check the mortise Sawing the Shoulders
for accuracy, then repeat the cut on the The simplest way to saw the shoulders
four necessary legs. is with the miter fence. Use the saw
The stop block must be reversed to fence to position the spare rail. The
drill out the second mortise on the falling piece must not get trapped
adjacent side. Saw the tenon width and saw the cosmetic between the blade and the fence as it
shoulder using the same blade height. is cut off because it tends to take wing.
Making a Tenon To avoid this, slide the fence back out
A table saw, equipped with a properly of the way, as you can with a Delta
designed and made jig, provides a safe Unifence or Sawguide. If your fence
and effective way to cut tenons. The wont slide, set it about a foot from the
jig, guided by the fence, holds the blade and use a spacer block to set the
workpiece vertical while it is passed shoulder out the correct distance.
over the blade. Adjusting the fence With the shoulders cut the last step is
allows the cut to be made at any point to use your chop saw to miter the ends
while adjusting the blade height deter- of the tenons.
mines tenon length. Use the miter Mortise and tenon joints offer excel-
fence to cut the shoulders. Saw all four shoulders lent strength, and youll surely turn to
with the miter fence. them repeatedly for your projects.
Tenon Jig Components Note that the fence is well With a couple accurate jigs, you can be
The jig comprises seven pieces. behind the workpiece so assured of milling sound joints that
Six are 3/4" plywood, one is poplar, the falling piece cant get will stand up to the test of time.
although ply could be used here, as well. trapped between the blade and the fence.
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By Michael Dresdner
I
f youre like me, youll choose the Clear Coatings woods. Heres how I do it: Flood boiled
most stunning lumber you can find Clear coatings can add richness and linseed oil or Watco onto the wood lib-
(and afford) for your projects, as depth to wood, but some clear materi- erally. Make sure it stays wet for 10 or
much to display the wood as to show als intensify figure much more than 15 minutes. If any areas of the wood
off your skills with it. When the time others. The key difference has to do absorb all the oil during that time, add
comes, you want to be sure the finish with molecular weight. Low molecular more. After fifteen minutes, wipe off all
you apply helps showcase the woods weight liquids (made up of smaller the oil you can, then let it dry for two
character, making the figure and grain molecules) penetrate more deeply into days before continuing with the next
even more pronounced. the wood, whereas high molecular coats of finish. The process for shellac
Not all finishing techniques and weight molecules may sit on top of the is much faster. Flood the shellac on lib-
materials are best for all situations. wood. The better the penetration or erally, then wipe it off immediately.
Here are some recommendations for wetting, the more depth and shim- Wait only two hours before finishing.
your consideration. mer they add.
Oils, Danish oil, and dewaxed shel-
lac are low molecular weight liquids,
and all three do a nice job of bringing
out figure. I use boiled linseed oil or
Watco Natural, both of which not only
wet nicely, but also add just a touch of
amber color, which further delineates
figure in light-colored wood. In the
photo (above, right), quilted maple,
plain walnut and curly koa were all
treated with boiled linseed oil. As you Top: Quilted maple. Lower left: plain walnut.
can see, the oil made a significant dif- Lower right: curly koa. The left side of each wood
ference in the depth and intensity in sample was sealed with waterbased polyurethane;
the right side was treated with boiled linseed oil.
both flat grain and curly figured
Dyes brown dye to bring out the curl in fig- wood bleach. This process removes
Color can also enhance the grain, both ured maple. After flooding the dye on background color, but it leaves the
by adding bright highlights and by and wiping it off, I waited until the dark lines intact. After the bleach
intensifying grain patterns. For each wood dried, then sanded it well with dried, an amber dye brought out the
of the samples in the bottom right 180-grit paper. Sanding removed the bright highlights and deeper contrast.
photo, facing page, I used dye to add dye from all but the end grain that
character, but with a slightly different forms the curl figure, and it made the Dry Brushing
technique on each. woods pattern stand out without sub- Dry brushing, sometimes called dirty
On the left, I took a rather plain stantially altering the overall color. brushing, is one of those rarely used
piece of walnut, which sported an The third sample is a bit different coloring techniques that gives the finish-
unfortunate grayish cast, and livened and more complicated. Over time, sun- er tremendous control of stain. Unlike
it up by flooding on and wiping off a light changes Indian rosewood from a the conventional staining process,
fairly dilute yellow-orange dye. The dark purple to a much lighter blaze of which floods color all over the wood, dry
result is the mellow warmth that sun golds, reds and dark contrasting grain brushing allows you to place color only
aging eventually imparts to walnut. In lines. To mimic that effect, I first where you want it, even in impossibly
the center, I used a weak, reddish- bleached the wood using two-part small areas such as a single wood pore.
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Workshop T h e r e s n e v e r a s h o rt a g e o f c l e v e r
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WSP.SIP_100 2/15/08 4:33 PM Page 100
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