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GUILD EDITION Vol. 37 / No. 217

MACHINE Projects,Tips
& Techniques
Mortises Made Easy!

Tips & Tricks on
Installing Drawer Slides
Tuning Up Your Drill Press
Using Bar Gauges
Editors Top Picks
Table Saw Blades
WS217_001.indd 1 12/8/2014 10:08:31 AM

PUBLISHER Donald B. Peschke

EDITOR Bryan Nelson

MANAGING EDITOR Vincent Ancona from the editor
Phil Huber, Randy Maxey


Dirk Ver Steeg, Peter J. Larson The start of a new year is always something to look forward to.
SENIOR GRAPHIC DESIGNER Bob Zimmerman Spring is just around the corner. And its easy to imagine the shop door being
open to the fresh air as you begin a new project. Well, around here weve been
CREATIVE DIRECTOR Ted Kralicek working on a new project of sorts a bigger, better, improved Woodsmith.
For starters, youll be getting a bigger issue. Weve added 16 pages thats
CAD SPECIALIST Steve Johnson more than a 30% increase. As to being better, all you need to do is take a look at
SHOP CRAFTSMAN Dana Myers the table of contents at right and youll see an incredible mix of projects in this
issue a small, easy-to-build weekend project, an heirloom piece of furniture,
Dennis Kennedy and a couple of handy projects any shop could use. Thats the variety of projects
you can expect to see in every issue.
PRODUCTION ASSISTANT Minniette Johnson But we didnt stop there. Youll find that the table of contents continues on
page 4 and covers the wide range of topics in this issue. We have some new
departments like Mastering the Table Saw, where the focus will be on taking the
Woodsmith (ISSN 0164-4114) is published bimonthly by
August Home Publishing Company, 2200 Grand Ave, Des Moines, IA 50312.
work you do at your table saw to the next level. And we have that other shop
Woodsmith is a registered trademark of August Home Publishing.
Copyright 2014 August Home Publishing Company. All rights reserved.
workhorse, the router, covered as well. In Router Workshop, youll find the tips,
Subscriptions: Single copy: $6.95.
Canadian Subscriptions: Canada Post Agreement No. 40038201. Send change of
tricks, and techniques for getting the most out of your router, whether you use
address information to PO Box 881, Station Main, Markham, ON L3P 8M6.
it hand-held or in a router table. Finally, Great Gear and In the Shop will provide
Canada BN 84597 5473 RT
Periodicals Postage Paid at Des Moines, IA, and at additional offices. even more information to create a top-notch workshop, no matter where you
Postmaster: Send change of address to Woodsmith, Box 37106,
Boone, IA 50037-0106. do your woodworking. As always, well continue to feature the great tips, tech-
niques, and tools you need to know for building any project.
Since were adding pages, its also the perfect opportunity to make a few other improvements. Our goal is to make Woodsmith easier to read, handier to use,
ONLINE SUBSCRIBER SERVICES and simpler to find all the great woodworking information youre accustomed
VIEW your account information to seeing. So weve updated a few things throughout the magazine, like the look
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Printed in U.S.A.

2 Woodsmith / No. 217

WS217_002.indd 2 12/5/2014 2:54:25 PM

contentsNo. 217 February/March 2015




shop project
Scissor-Lift Workbench . . . . . . . . . . . . . . . . . . 20
Built around a foot-operated lift cart, this workbench is easy to
set to any height. Plus, great clamping options and a dust
collection system make it the perfect solution for any shop.

weekend project
Spice Carousel. . . . . . . . . . . . . . . . . . . . . . . . . 26
Keep your most-used spices close at hand with this rotating
carousel. Youll find a lot of woodworking packed into this
project along with finishing options for creating a unique look.

shop-built machines
Router Mortising Machine . . . . . . . . . . . . . . . 30
Youll be creating precision mortises with ease using your
routers motor and this shop-built machine. The secret to
its smooth operation is ordinary metal drawer slides.

heirloom project
Stylish Cherry Hutch . . . . . . . . . . . . . . . . . . . . 40
With its elegant look, this tall hutch will add style and some
40 much-needed storage to any dining room. And youll learn a
lot of great techniques and tips as you build it. 3

WS217_002.indd 3 2/13/2015 7:43:02 AM


from our readers
Tips & Techniques . . . . . . . . . . . . . 5
all about
Working with Bamboo. . . . . . . . . 10
router workshop
Milling Bits for Mortising . . . . . . 12
great gear
Creating a Custom Plane . . . . . . 14

woodworking technique
Installing Drawer Slides . . . . . . . . 18

working with tools

Tuning Up a Drill Press . . . . . . . . 54

in the shop
LED Lighting Retrofit . . . . . . . . . 58
woodworking essentials
Choosing & Using Bar Gauges . . 60
mastering the table saw
Saw Blade Preferences . . . . . . . . 62
tips from our shop 60
Shop Notes . . . . . . . . . . . . . . . . . . 64
4 Woodsmith / No. 217

WS217_004.indd 4 12/5/2014 2:55:27 PM

o m o u r

Tips &
Cleaner Circle Cutting
Faced with the challenge of creating mul-
tiple wood discs for coasters, I needed a
way to cut them out without making a
center hole in the workpiece. I came up
with a simple solution using a circle cut-
ter and a scrap block.
To do it, adjust the drill bit on the circle
cutter so its higher than the depth of the
cutting blade by the thickness of the work-
piece, plus 18", as shown in Figure 1.
Use a scrap block of wood thats at least
the same thickness as the workpiece from
which the circle is being cut and shorter
diagonally than the diameter of the circle.
Locate the block in the center of the circle
and use double-sided tape to hold it in place. 1 2 Circle
To keep the parts from moving as the Circle cutter
blade makes the cut, clamp the work-
piece to the drill press table. The block
stabilizes the circle cutter without drill-
ing into the workpiece blank. The disc is Drill
completely cut out when it starts to spin. bit
After removing the scrap block, youll Drill bit Blade

have a blank disc with no center hole. The

same block can be used again to cut out block
multiple discs. Workpiece
Min-Hao Kuo !/8
East Lansing, MI

Win This Kreg K5 Jig

Simply send us your favorite shop
tips. If your tip or technique is selected The Winner!
as the featured readers tip, youll win Congratulations to Dan
a Kreg K5 Jig just like the one shown Breyfogle, the winner of
here. To submit your tip or technique, this Kreg K5 Jig. To find out
just go online to and how you can win this jig,
click on the link, SUBMIT A TIP. There
check out the
information at left.
you can submit your tip and upload
your photos for consideration. 5

WS217_004.indd 5 12/3/2014 12:16:16 PM

Small Parts Organizer
I often use several types and sizes of fas-
teners in the course of building a project.
But often their containers end up scat-
tered all over the workbench.
This nifty little organizer holds all the
fasteners Ill need for the job at hand,
keeps them in one place, and provides
easy access. In addition, it has a deep
tray on top for keeping larger parts and
small tools handy.
The organizer has two hardboard and
plywood trays with recesses for shallow
containers. The recesses are sized for
six-ounce tuna cans, but any other type
of shallow container would be suitable.
Spacer blocks keep the containers con-
tents visible and easy to grab.
CONTAINER TRAYS. Begin by cutting two
pieces of hardboard to the dimensions
shown for the container trays. Using a
circle cutter at the drill press works great
to make the four holes in each of the
pieces. The base pieces are cut from ply-
wood and are attached to the container
HANDLE !/4" roundover
trays with glue. I eased the top edge of
the hardboard trays with a roundover bit.
SPACER BLOCKS. The two spacer blocks are %/16"-18 NOTE: Tray bottom and base pieces
threaded insert made from !/2" plywood. Container
now cut to size and glued to the con- trays made from !/4" hardboard. Tray
tainer trays, as shown in detail a. The sides made from !/8"-thick hardwood.
Handle made from 1!/4"-thick hardwood
middle tray has a through
hole drilled in the center of the
spacer, while the bottom tray 1!/4 8 a. TOP SECTION VIEW
has a threaded insert installed TRAY SIDE
%/16"-18 x 5!/2" 8
in the top of the spacer block. threaded rod
7#/4 3%/16"-
TOOL TRAY & HANDLE. The tool dia.
tray at the top of the organizer is a piece SPACER BLOCK
of plywood with 18"-thick strips of hard- %/16" fender 2 2
wood for the sides. I simply glued them 2
Container 8
in place. The handle is also made from CONTAINER
hardwood. Use the dimensions shown in TRAY !/2"-dia.
detail b to cut it to size and ease the top !/8" BLOCK
edges with a 14" roundover bit. Glue the 2
handle to the inside of the tool tray and
drill a hole through the tray bottom into !/2 NOTE: Size holes
2 for containers
the handle for another threaded insert.
ASSEMBLY. With the parts built, screw the
threaded rod into the bottom tray. Next, %/16"-18 BASE
threaded insert b. SIDE VIEW
add the spacer block, fender washer, %/16" fender
and middle tray. The fender washers washer 1&/8 4
keep the parts spinning freely. The tool !/2"-rad. !/2
tray is simply screwed in place. Now !/4 2!/4
you can load up the containers with the 1 HANDLE #/4
fasteners you need for your next project.
Dan Breyfogle 7#/4
Mason City, IA

6 Woodsmith / No. 217

WS217_006.indd 6 12/3/2014 12:17:01 PM

Saw Blade Caddy
I dont like to lay saw blades on the saw
table when Im swapping them out. Im
afraid the teeth will get damaged. So
changing a saw blade had turned into
a juggling act until I came up with this
handy blade caddy. It provides a place
to hang the blades so they they dont
get damaged during the setup process.
EASY JOINERY. The saw blade caddy con-
sists of four parts joined together with
angled butt joints and screws. A short
dowel in the face of each upright pro-
vides a way to hang the saw blades.
The center handle connects the uprights
and makes the caddy easy to transport
around the shop.
To use the saw blade caddy, place the
new blade on one side #/8"-rad. !/4" roundover
of the stand while
removing the old %/8
blade from the saw. HANDLE
The old blade goes on 75 1
!/2" x 1!/2"
the empty side of the dowel !/2"-dia.
stand while installing 4 #/8"-rad.
the new blade. If Im 10
only going to make 3
a couple cuts, I just
set the stand aside
while I make the cuts 75 BASE
and then reverse the
whole process. BASE NOTE: Base,
Serge Duclos #/4 handle, and
10 uprights are made NOTE: Tilt saw
Delson, Quebec from #/4" plywood blade 15 to
#8 x 1!/4" Fh make joinery cuts


Multi-Tool Sander. Bill Wells of Olympia, Washington, Band Saw Table Pin. Bill Huber of Haslet, Texas, got tired
found the sanding accessory that came with his multi-tool of looking for a wrench to remove the table pin every time
too large to get into tight areas. So instead, he wraps strips he changed his band saw blade. Instead he drilled a hole
of adhesive-backed sandpaper onto an old flush-cut blade. in the head of the table pin and installed a solid steel pin
This allows him to sand the tight spots. that provides enough leverage to remove it by hand. 7

WS217_006.indd 7 12/3/2014 12:17:18 PM

Rolling Center Finder
Over the years, Ive seen (and used) many different kinds of
center-finding tools. Whether they were shop-made or manu-
factured, they all had a tendency to use dowels, steel pins, or
some other type of material that would drag along the out-
side edges of a workpiece. Recently, while shopping for some
shower door replacement parts, I was struck with the perfect
idea for an improved center-finding tool.
NYLON WHEELS. At the heart of this design is a pair of inexpen-
sive sliding shower door replacement rollers. The rollers glide
smoothly along the edge of a workpiece. After cutting a piece
to size for the base, take your time in laying out the hole loca-
tions for the screws that secure the rollers, as well as the hole
for the handle. The rollers need to be the exact same distance
from the center hole in the base. With the parts completed, sim-
ply glue the handle in place and attach the rollers with screws,
and this tool is ready to put to use.
Gerald Welf
Ease end Fridley, MN
with sandpaper

a. b.
Ph machine 2!/2 NOTE: Drill
screw center hole
5!/4 NOTE: Base is made in handle
from !/2" plywood. at drill press
Dowel is #/4" -dia.
HANDLE !/8" -dia.
#/4" -dia. !/2 BASE #/8

#/8"-rad. Shower door


Drill Press Table Gauge

After building a new auxiliary table for STRAIGHTFORWARD OPERATION. The jig is Check the reading on the dial at two
my drill press, I wanted to ensure that nothing more than a piece of stock with positions that are 180 from each other.
the table was exactly perpendicular to the dial indicator attached to one end The table can then be adjusted until the
the drill press spindle. Since I already and a steel rod inserted in the other end. readings are the same. Be sure to check
owned a dial indicator, I came up with To use the jig, insert the steel rod into the several locations front-to-back and side-
the simple jig you see below. This jig drill chuck and tighten it in place. Adjust to-side to ensure accurate adjustments.
allows me to adjust my drill press table the table height so that the indicator nee- Doug Fleming
to a very precise tolerance. dle touches the table surface. Medicine Hat, Alberta

NOTE: Use epoxy to

secure steel rod
to body
!/4" steel
4#/4 rod
NOTE: Drill 1!/2"-deep
hole for steel rod

!/4"-20 x 2"
hex bolt #/4
Dial 1#/4

threaded knob

8 Woodsmith / No. 217

WS217_008.indd 8 12/3/2014 12:18:03 PM

{ The support brace conveniently
folds up alongside the roller stand,
allowing the entire unit to be
stored together.

Roller Stand Brace

Some shop roller stands tend to fold By using a 90 street elbow above the DIGITAL WOODSMITH
up easily when using them. This can snap tee, the brace can easily be disen-
be especially dangerous if the stand is gaged by slipping your foot underneath SUBMIT TIPS ONLINE
being used for outfeed support while the pipe and popping the snap tee off If you have an original shop
cutting material at the table saw. the leg of the roller stand. tip, we would like to hear
I solved this problem by making a Greg Nowlan from you and consider
brace out of PVC pipe. The brace slips Scarborough, Ontario publishing your tip in one
over one leg of the support stand and or more of our publications.
snaps down over the other when the Jump online and go to:
stand is open to lock the legs apart. When
you want to fold up the stand, the brace
Click on the link,
folds up, as well (inset photo, above).
SIMPLE DESIGN. Start by measuring the
diameter of the legs on the support Youll be able to tell us all about
stand. When you shop for the PVC pipe your tip and upload your photos
hotos and
and fittings, youll need an inside diam- drawings. You can also mail your tips
eter that fits over the legs. One tee stays to Woodsmith Tips at the editorial
intact and slips on one leg. On the other address shown on page 2. We will pay
end, I used a snap tee that slips over up to $200 if we publish your tip.
the leg. Snap tees are commonly used
in sprinkler irrigation applications and { The support brace is easy to disengage RECEIVE FREE ETIPS
are easy to find in the plumbing section from the stand by popping the snap tee off by EMAIL
at home improvement stores. the leg of the roller stand with your foot. Now you can have the best time-saving
secrets, solutions, and techniques sent
90 street directly to your email inbox. Just go to:

and click on
NOTE: Size PVC pipe Youll receive one of our favorite tips
Snap to accommodate your each and every week.
tee support stand 9

WS217_008.indd 9 12/3/2014 1:41:39 PM


working with
Over the centuries, bamboo has been used for every-
thing from walls and roofs to cooking and eating uten-
sils. However, until recently, availability was limited to
the regions where it grows. Using modern processing
methods, bamboo has become more widely available
throughout North America in products such as floor-
ing, countertops, and cutting boards. But bamboo is
also a great material for woodworking.

BAMBOO CHARACTERISTICS to those of red oak. (See the box on the extremely fast. Plus, it regrows from the
Bamboo is actually classified as a mem- opposite page.) Compared to red oak, root stock, meaning the plant doesnt die
ber of the grass family. Most commer- bamboo is harder but lighter, and has when the bamboo is harvested.
cially grown bamboo is a species called a finer texture. However, a large part Even though raw bamboo has to be
Moso and is primarily imported from of what makes bamboo so desirable transported from overseas locations, its
Asia. It has several characteristics similar as a building material is that it grows often touted as a green, sustainable
material. But to be made into lumber
Horizontal grain Vertical grain products suitable for furnituremaking
(natural) (natural)
and other uses, it requires extensive pro-
cessing. Bamboo stalks are segmented,
hollow tubes with thin walls. They have
to be cut into strips and laminated into
boards, panels, and veneer using adhe-
sives under high pressure.
VARIETIES. The strips can be glued
together edge-to-edge (horizontal grain)
or face-to-face (vertical grain) as shown
Horizontal grain Vertical grain in the upper photos at left. As you can
(carbonized) (carbonized)
see, horizontal grain exhibits the unique,
interesting grain patterns by which bam-
boo is typically identified.
Carbonized bamboo (lower photos at
left) is darkened by the application of heat
during processing. This process actually
caramelizes the sugars in the fiber.
Bamboo is extremely easy to machine
{ Whether sold in its natural state (upper left photo), or with a darker, carbonized look (lower with common woodworking tools,
left photo), horizontal-grain bamboo has the characteristic nodes most associated with although it tends to splinter some when
traditional bamboo. Vertical-grain bamboo (right photos) has a more uniform look. cutting across the grain. In addition,

10 Woodsmith / No. 217

WS217_010.indd 10 11/22/2014 9:39:05 AM

bamboo is naturally moisture resistant. DESIGNING WITH BAMBOO
This feature makes it well suited for items Few woods are as readily identified
ntified with h
like cutting boards and countertops, Asian furniture styles as bamboo. oo. Almost
although a finish is still recommended. any project that uses bamboo takes on an
COST. As you might imagine, the extra Asian flair. The wide variety of bamboo
processing and import expense can drive products available (photos at right) gives
up the price of bamboo. Large panels can you the option to use bamboo for almost
be pricey, and the cost of dimensional any project part. { Bamboo is sold
bamboo lumber is almost one and a half SELECTIVE USE IN DESIGN. The good
od news is in a wide variety of
times the cost of red oak. One supplier I that not every part of the project
rooject has to sizes making it easy to
contacted listed a 34" x 8" - 97" board for be made from bamboo to take ke advantage customize for specific
$34.50, or $6.40 a board foot. of the look. For example, you ouu can save project applications.
Additionally, most lumber dealers money with the use of a secondary
nddary wood,
dont carry bamboo products apart from as shown in the photo at left.. Here,
H a less
flooring. So you may have to order it expensive wood (maple) is used sed for the
from one of the sources listed on page 67. drawer sides. Similar savings gs would be
gained by using bamboo forr the visible
parts of a project but constructing
tructing the
case from a secondary wood..
Another option is to use readily
eadily avail-
able hardwoods throughout ut a project
and apply bamboo veneer to o a few select
parts. Bamboo veneer is available
lable in 4' x 8'
sheets in thicknesses from 0.6mm
6mm and up.
Often a small but prominent nent detail is
enough to convey the stylee you want. { Bold end grain is a
Drawer knobs, door handles, s, legs, trim, prominent feature of bamboo. It can be
and even inlays can be madee from bam- showcased or covered with veneer edge-
boo to create unique features. s. tape depending on the application.
The end grain of bamboo can be quite
noticeable, especially on big panels (pho-
(pho Bamboo may not be right for every
tos at right). This look may be desirable on project. But if youre in the market to try
{ Using a secondary wood for less visible some projects, but its also easy to hide in something new, it offers a unique
areas of a project is a good way to use areas where it looks too busy. Bamboo appearance that can look great on the
bamboo without spending too much. veneer edging is available for this purpose. right piece of furniture. W

Working Characteristics: BAMBOO VS. RED OAK

Red oak has long been the go-to hardwood for furniture Bamboo Compared to Red Oak:
building, flooring, and a myriad of other uses in the United Easy Difficult
States. But the recent surge in popularity of bamboo has General Bamboo
allowed it to gain a foothold in the marketplace. As the chart Workability Red Oak
at right shows, many of the attributes that have long made Fine Coarse
oak a favorite among craftsmen and consumers is equaled Wood Bamboo
(and in some cases, surpassed) by bamboo. Texture Red Oak
Taking into consideration the fact that bamboo can be Easy Difficult
harvested in as little as seven years without harming the Ease of Bamboo
plant, bamboo almost seems too good to be true. But, like Finishing Red Oak
any product, bamboo has its downsides.
Bamboo by the Numbers:
BAMBOO DRAWBACKS. Lower grades of bamboo may be sus-
ceptible to dents and scratches. Also, potentially toxic 18.44% Lighter 27.91% Harder 3.13% Less Dense
chemicals can be added during the processing phase of Bamboo Bamboo Bamboo 0.62
2.92 lbs./board foot 1650 lbs-force
bamboo imported from some countries. So the reliabil- Red Oak 0.64
Red Oak Red Oak
ity of the manufacturer should be a consideration when 3.58 lbs./board foot 1290 lbs-force (Specific Gravity)
selecting a product. And with its contemporary look, bam-
boo may be difficult to fit into a vintage dcor scheme. Source: 11

WS217_010.indd 11 12/10/2014 12:05:26 PM


best bits for

Routing Mortises
If cutting smooth profiles is the main rea- End mills are typically longer than
son many woodworkers own a router, spiral bits. So this means you can create
cutting accurate joints should be a close deeper (and stronger) mortises. They
second. More specifically, one joinery also add stability to keep the bit from
SPIRAL END technique where a router really shines is wobbling in the cut. In the lower photo,
cutting mortises. A router leaves smooth you can see how an end mill has a much
walls that create a solid glue joint. thicker root than a two-flute spiral bit,
A simple approach for routing mortises which makes for a stronger bit.
End mills have
a thick "root" is to use a plunge router, an edge guide, CHOOSING END MILLS. The terminology for
and are less and a spiral upcut bit. The cutting flutes end mills can be somewhat confusing.
likely to break
of spiral bits work like a drill bit to pull But there are key features to look for.
chips up and out of a mortise. They do a You want a standard end mill with four
good job, but these solid carbide bits can flutes. It should be listed as a center-
be pretty expensive. Plus, youre limited cutting, single end mill with a plain
to a few diameters and cutting lengths. shank and a 30 helix. To make finding
Recently, Ive been working with a dif- the bits easier, Ive listed the bits shown
ferent type of bit that works just as well here in sources on page 67.
and costs much less than a typical spiral Theres one exception to this rule, and
bit a high speed steel spiral end mill thats for creating larger mortises. To
(left). The reason you may not be familiar make a 12"-wide mortise, an end mill like
with this bit is that theyre usually used I just described can be a little aggressive.
in milling machines for cutting and shap- The solution is to use a roughing/fin-
ing metal. However, some of the features ishing bit, as shown in the upper right
Four-flute end
Spiral upcut bits mills leave a that make them ideal for creating smooth photo on the facing page. Instead of
pull chips out of smooth edge metal surfaces make them good candi- smooth cutting edges, the flutes are ser-
mortises easily
dates for routing mortises in wood. rated to break up wood fibers. As a result,
END MILL BENEFITS. End mills come in a the cutting action is a lot less grabby.
range of configurations. For woodwork- Some end mills have a flat spot on the
ing, Ive found that an end mill with shank thats used with milling machines.
four flutes gives the best results. The In a router be sure the collet has a firm
extra flutes leave a smooth surface. grip all around the shank.

12 Woodsmith / No. 217

WS217_012.indd 12 11/21/2014 8:30:35 AM

bit has serrated
cutting edges

{ Rout the mortise in a series of shallow passes.

Lower the bit between each pass. The result is a
1 5 3 1
mortise with smooth walls (inset photo). 4" 16" 8" 2"

WORKING WITH END MILLS. If youve ever cut should go smoothly without burning, the upper right photo. It all comes down
mortises with a router, then using an end although some burning at the ends of to the type of work you do or would
mill will be a pretty familiar experience. the mortise is normal. If all goes well, like to do. I suggest starting with a 14"-
Even so, it pays to run through a few you can set up to take a deeper cut (14") dia. bit. This is a common size for many
pointers. And if youve never routed for subsequent passes. furniture-making tasks. The second bit
mortises, this is a good place to start. The bits do a pretty good job of pull- to get is a 12" roughing/finishing bit.
Since mortises are deep cuts, you cant ing chips out of the cut. But on a deep This bit creates a heavy-duty joint in
rout one in a single pass. Its just too mortise, you may need to vacuum out the larger workpieces.
much material to remove. Instead, you debris to limit heat buildup and bit strain. From there, you can pick out some in-
want to nibble away at the mortise in a For larger diameter bits (38" and 12"), between sizes like 516" and 38" bits. These
series of progressively deeper cuts, as Ive found that slowing down the router give you flexibility to match the mortise to
you can see in the photo above. (if your router is equipped with vari- the size of the workpiece. A good rule of
How deep of a cut you can take depends able speed) helps it cut more evenly. On thumb is that the mortise should be about
on the material. Dense wood requires a my router, that meant slowing down to one third the thickness of the workpiece.
shallower cut than softer wood species. 16,000 RPM (the halfway setting on the Be aware that these two bits require some
With this in mind, I like to set the router to dial). Remember, end mills were origi- additional hardware for your router. Take
take a 18"-deep cut on the first pass. nally designed for cutting metal at slower a look at the box below for details.
USE YOUR SENSES. Listen to the router and speeds. So a slower router setting will You can depend on your router to cre-
notice the condition of the cut to help help it clear wood chips more easily. ate accurate, smooth mortises. End mill
you gauge your progress. The router WHICH BITS TO GET. Speaking of bit sizes, bits offer you a way to get those results
shouldnt sound strained. And the cut you have several options, as shown in without spending a lot of money. W


Replacement 5
Most routers come with either a 14" collet, a 12" collet, or both. collet 16"
Collet sleeve
Since the shank of an end mill bit matches its cutting diameter, fits inside 12"-
youll need some help to accommodate 516" and 38" bits. Thank- dia. collet
fully, you have a couple of solutions.
SLEEVES. If your router has a 12" collet, you can get adapter
sleeves that fit inside the collet and accept bits with smaller
shanks. You can find sleeves for both 38" and 516" bits. The
5 " sleeves are often referred to as 8mm sleeves since the two
sizes are interchangeable. 3
COLLET. The other option is to get a different collet. Porter
Cable, Bosch, and other router manufacterers offer accessory
collets for 38" router bits or 8mm (516") bits. In general, a col- 5
let offers a more secure hold and less vibration than a sleeve. 13

WS217_012.indd 13 11/21/2014 8:31:05 AM


creating a
Custom Bench Plane
In the fall of 2014, Lee Valley introduced
Veritas #4 Smoothing Plane
a line of Veritas custom bench planes
with the claim that they could be made
Lever cap Cap Blade carrier Tote nut in over 9,000 different combinations.
As you can see in the photo above, the
Norris-style styling is sort of a blend of modern
and retro looks. But I was more curious
about how these planes can be custom-
ized and, more important, how they
Tote perform on the workbench.
TRADITIONAL SIZES. You can order a plane
in the following sizes based on the con-
Blade ventional Stanley/Bailey bench plane
numbering system: 4, 412, 5, 512, and 7.
Prices range from around $270 to $380.
Once you choose the size of plane you
Knob want, you have a number of choices to
make to design your custom plane.
FROG ANGLES. The cutting angle of the
Mouth plane blade is one of the most impor-
adjustment tant considerations to make. And the
Tapped frog of the plane dictates this angle. A
hole frog is simply the bed where the blade
Blade set
Toe screw rests. Its shown in the illustration at
plate Tapped
hole left. Lower frog angles are great for
trimming end grain. Higher angles can

14 Woodsmith / No. 217

WS217_014.indd 14 12/10/2014 12:05:57 PM

help you get a smooth finish without
tearout on figured woods, as shown in
the photo on the opposite page. I had A traditional tote is
similar to the style found
no tearout issues while smoothing the on older Stanley/Bailey-
style bench planes
face of a curly maple workpiece. I used
a 55 frog and adjusted the mouth of the
plane for a thin shaving. (Ill talk more
about the mouth adjustment later.)
Lee Valley supplies three standard frog
angles of 40, 45, and 55, as shown Veritas totes are
more upright to
below. A 45 angle is what youll find on allow your arm to
most bench planes and makes it more of be more parallel
with the stroke of
an all-purpose tool. the plane
One unique aspect of the planes is you
can order a custom frog in 12 increments Traditional tote Standard Veritas tote
from 40 to 65 for only a $10 surcharge.
Theyre also available separately. The
frogs are interchangeable, so I can see
having a few different ones on hand for
various planing tasks. As youll notice in
the drawing on the opposite page, the
frog is held in place with just a pair of cap
screws, so its easy to remove and replace.
TOTE OPTIONS. The next choice to make
is the size and style of tote you prefer
(upper right photos). The totes are avail-
able in two styles and three sizes. The
Tall knob Standard knob Wide knob
traditional-style tote is for those who
are comfortable with the style found on { You can customize the feel of a hand plane by choosing a traditional-style tote or a Veritas
older hand planes. The Veritas style is a tote. Totes are available in small, medium, and large sizes for a custom fit. Your choice of
little more upright to allow your forearm knob boils down to personal preference and how you grip your plane during use.
to be more parallel with the direction of
the planing stroke. Ive used both, and Canada and had customers measure their KNOB CHOICES. The knobs are available in
the Veritas style does take a little getting hands. Then the customer was asked to the three styles shown above. The choice
used to if youve been using traditional try different sizes and styles of totes. comes down to whats comfortable for
planes for a while. Their feedback was recorded and ana- you and what type of grip you typically
The designers at Veritas did their home- lyzed to come up with the final design. use when planing. Lee Valley recom-
work to come up with the three sizes of When you order a tote for your plane, mends the wide knob for larger, heavier
totes. They designed a device that mea- youll need to measure your hand. The planes to make it easier to lift the front of
sures a hand across the knuckles. They distance across the palm at the knuckles the plane on the return stroke. For a No.
placed this device in their retail stores in determines the size of tote that fits best. 4 plane, I prefer the standard knob.

NOTE: The sloped bed

of the plane body
plus the angle of the
frog determines the 40 o Frog
combined blade angle

55o Frog
45o Frog

Plane bed Plane bed Plane bed

{ A high-angle frog positions the blade { On most traditional and antique hand { A low-angle frog places the blade at an
to provide more of a scraping action for planes, youll find a 45 bed angle thats angle that slices through end grain more
smoothing figured grains. suitable for general planing tasks. easily for a smooth surface. 15

WS217_014.indd 15 12/1/2014 2:01:49 PM

Completing the Final Details
After youve chosen the size of plane,
tote, and knob, the next decision to make
for your plane is the type of steel used
for the blade. Your choices of blade mate-
rial are O1 oil-hardened carbon steel or
PM-V11, a powdered metal alloy that Ver-
itas uses in a lot of its cutting tools. I like
O1 steel because its easy to sharpen to a
fine edge and it costs a little less. But Ive
recently become a fan of PM-V11. It holds
an edge much longer, in my experience.
Plus, sharpening and honing PM-V11 is { The frog is held in place with a pair of cap { The bottom pin on the adjuster mechanism
relatively easy with diamond stones. screws. The toe plate is used to align the snaps into the frog and is held secure by
frog during installation. an internal retaining spring.
As I mentioned earlier, the blade ulti-
mately rests on the frog of the plane. The
upper left photo shows how the frog is
installed with two screws. Veritas rec-
ommends loosely installing one of the
screws then sliding the toe plate back
to help align the frog parallel with the Blade carrier
(bottom side)
mouth before tightening the screws.
ADJUSTER. Once the frog is installed, the
adjuster mechanism snaps into the frog,
as shown in the upper right photo. This
two-in-one (or Norris-style) adjuster
allows you to adjust the depth of the
blade by turning the knob at the top.
Simply nudging the knob side-to-side
pivots the blade to adjust the cutting
edge parallel to the sole of the plane.
A minor complaint Ive had with older
Veritas planes is that the adjustment { The blade carrier nestles in the blade slot (top inset) and is secured to the blade with a single
mechanism for the blade depth was too screw. The cap iron is attached to the blade carrier with a pan head screw. Adjusting the
coarse. In other words, barely turning position of the carrier on the blade can be done with the cap iron installed (bottom inset).
the knob would extend the blade further
than I wanted. For this new line of planes, This makes precise depth adjustments when its reinstalled back onto the frog.
Veritas researched several different thread easier when turning the knob. This makes getting back to work a
pitches to arrive at a good compromise BLADE ATTACHMENT. Next comes the blade quicker task without having to fuss with
between a fast or slow blade depth and cap iron assembly. Veritas uses major blade adjustments.
adjustment. A slow adjuster mechanism an unusual method of connecting the CAP IRON. Veritas uses A2 tool steel for
with finer threads is available separately. cap iron to the blade and then register- the cap iron because it doesnt warp or
ing the blade on the adjustment twist during heat treatment. Like the
mechanism. This blade carrier is blade, its lapped flat. This guarantees a
illustrated in the drawing on page seamless fit with the blade.
14 and shown in the inset photos To install the blade, the center hole in
above. Its a ring-shaped piece that the blade carrier fits over a pin on the
locks into the slot in the blade with adjuster. Then center the blade side-to-
a small cap screw. The cap iron is side by adjusting a set screw on either
then held tight to the blade carrier side of the plane body, as in the lower left
with a single panhead screw. photo. Once you do this, theres no need
One nice benefit about this to fuss with the screws after that.
arrangement is that when you The final steps in assembly are install-
{ A set screw on each side of the plane allows you remove the blade for honing, the ing the screw for the lever cap into the
to center the blade in the mouth opening. You blade carrier automatically regis- frog and adding the lever cap. The lever
typically only make this adjustment once. ters the blade in the same position caps keyhole-shaped opening drops

16 Woodsmith / No. 217

WS217_016.indd 16 12/1/2014 2:02:16 PM

over the head of the screw and slides into
place. Then you lightly tighten the lever
cap over the blade and cap iron assembly.
Youll want just enough pressure to hold
the blades position and still allow easy
adjustment. It doesnt take much pres- Toe plate
sure to hold the assembly secure.
ADJUSTABLE MOUTH. If you take a look at
the photos on the right, youll see how
the toe plate on the bottom of the plane opening
slides to create a wide or narrow mouth
opening. When removing a heavy shav-
ing, it helps to open up the mouth. But
when it comes time for smoothing a
surface and producing thin shavings, I { The planes feature an adjustable mouth. { An adjustment screw serves as a stop to
like to set the mouth pretty tight. This Loosening the knob allows the toe plate to prevent the toe plate from damaging the
helps prevent tearout as the blade slices slide, closing or opening the mouth. blade when adjusting the mouth opening.
through the wood.
To adjust the mouth opening, simply tighten the screws used to secure it. Slide The 55 high-angle frog made quick
loosen the knob and slide it forward or the toe plate all the way forward to install work of smoothing curly maple. With a
backward. The knob is attached to the toe the blade assembly and lever cap. Then sharp blade and tight mouth opening, it
plate with a stud through a slotted hole adjust the stop screw to set the desired removed the tearout that occurred while
in the plane body. A knurled adjustment mouth opening. running it through a thickness planer.
screw right behind the knob allows you IMPRESSIONS. Veritas hand planes have The 45 frog performed well in a vari-
to set the width of the mouth opening. had some of these features for a lot of ety of general planing tasks. I had no
You can see this screw being adjusted in years. But combining them with the new complaints about its performance.
the far right photo. This screw also serves features that you can customize to your If youre happy with your current
as a stop to prevent you from acciden- liking is pretty significant. plane, there may not be a compelling rea-
tally damaging the blade by sliding the But what matters more to me is how son to upgrade to a Veritas custom plane.
toe plate back too far. the plane performs. After a light honing, But if youre looking for an heirloom-
Youll back this screw out when install- I gave the No. 4 plane a thorough work- quality investment that you can use right
ing a frog to allow the back edge of the out on a variety of hardwoods. The 40 out of the box and for decades to come
toe plate to contact the front edge of low-angle frog sliced through end grain you wont be disappointed. These new
the frog. This aligns the frog before you easily without requiring a lot of muscle. planes are solid performers. W

Accessories: PLANE FENCE

Each side of a new Veritas custom plane is
drilled and tapped with a pair of holes that
can be used for attaching accessories.
Currently, the only accessory available is a
fence. It comes with two steel rods that thread
into the side of the plane. The fence is posi-
tioned and locks onto the rods with knobs that
act much like the collet on your router.
Here, Im using the fence to bevel the
edges of a panel. To set the desired angle, Ive
attached a beveled auxiliary fence. It guides
the plane along the edge of the workpiece.
Veritas has hinted that there may be more
accessories to come. One possibility is a knob
for using the plane with a shooting board.

> An accessory like a fence turns your plane into a

multipurpose tool. Use the fence to square the
edge of a workpiece or create a beveled edge. 17

WS217_016.indd 17 12/1/2014 2:02:41 PM

w orking
wood ique

tips & tricks

for installing
Building drawers that slide smoothly install accurately. The key to simpli- THE RIGHT LOCATION. One of the ben-
while holding a lot of weight is a tall order fying the process lies in the fact that the efits of using full-extension slides is
for traditional wood drawer guides. Over slide separates into two components. you have a lot of freedom in locating the
time, wood components wear down, and The smaller part gets attached to the hardware on the drawer sides. The truth
seasonal humidity changes can cause drawer box, and the larger piece mounts is, unless theyre special-purpose slides,
drawers to stick. In addition, wood to the case (more on this part later). you can attach them almost anywhere
drawer guides dont give you complete BETTER SCREWS. Before going any further, I you like on the drawer box.
access to the contents of the drawer. want to take a moment to talk about the That being said, I have two primary
The solution to these challenges is to screws. Many slides come with screws. locations for the slides. These are shown
use side-mount, full-extension drawer But if theyre ordinary roundhead screws, in the drawings below.
slides. While they arent appropriate for I toss them and order screws that are Probably the most common location
a period furniture reproduction, I do use designed for installing slides, as shown is to center the slides on the width of the
them on many shop and furniture proj- in the lower left photo (for sources, turn drawer sides, as shown in the left draw-
ects where reliable operation is a must. to page 67). The washerhead screws have ing. The other location is flush with the
TWO PARTS. On the surface, metal drawer a low profile. A large bearing surface and bottom of the drawer box, as in the photo
slides seem as if theyd be a hassle to deep threads ensure a strong grip. above and the lower right drawing.

Drawer slide centered

< These
T special screws on the width
h a wide, low- of the drawer side
p le head, and the Drawer slide attached
to the lower edge
d threads can be Side-mount slides of the drawer side
s without a require !/2" clearance
at each side of opening
p hole.

18 Woodsmith / No. 217

WS217_018.indd 18 11/21/2014 10:03:19 AM

{ Cut a spacer to support the drawer slide in { Measure and mark the location of the next { Clamp the spacer in place and continue
the correct position. Rest the drawer slide pair of slides on the case. Then cut the the installation process. Repeat the steps
on the spacer and install the screws. spacer to match. until all the slides have been installed.

When attaching the slides to the slides wont get in your way. And you seem like overkill, but without these
drawer box, its a good idea to drive can just cut the spacer down to line up screws, the slide mechanism will likely
screws through the vertically slotted the next pair. Here again, use the slotted creep out of alignment over time.
holes first (far right drawing). This gives holes (running side to side). This will If you pay attention to these few
you room to adjust the position up and allow you to fine-tune the front-to-back details, youre guaranteed to get the best
down for the best performance and look. position of the drawer in its opening. performance from full-extension slides.
CABINET COMPONENT. Attaching the slides Completing the installation process The result is drawers that you can rely on
to the drawer boxes is pretty straight- means youre ready to put the drawer to carry a heavy load and operate
forward. Installing the other half of the into place and fit the two components smoothly year after year. W
hardware is a little more involved. Thats back together. Carefully line up each part
because youre working inside a cabinet and slide the drawer box in. Youll feel a
where things may be a little cramped little resistance here. Dont be surprised.
and dark. In addition, you need to make Thats just the way the parts reengage.
sure each pair of slides are installed con- Once the drawer is installed, it should
sistently side to side. operate easily. If it doesnt, take a look at
Drive screws
The method I turn to for this task is the box below for two remedies. into fixed holes
to secure slide
highlighted in the three photos above. DONT STOP NOW. Once both parts of the in place
The secret is an MDF spacer. This sup- slide are installed and youre satisfied
ports the slide and guarantees that each with the fit and movement, theres one
part is aligned. Then its just a matter last step thats easy to overlook. Thats { Complete the installation process by
of starting at the top and working your to add screws to the round, fixed holes driving screws into the fixed holes in both
way down. This way, previously installed in both components of the slides. It may the drawer (shown) and case components.


After taking the steps shown here, you card stock, brass shims, or even washers.
may find that a drawer isnt opening Dont feel you need to shim both sides Place a shim
between the
and closing as smoothly and effortlessly evenly. The small amount of shimming cabinet and slide
to fit a drawer
as possible. The problem may just be the isnt noticeable. that is slightly
size of the drawers. Carefully measure the TOO WIDE. The solution for a wide drawer narrow
drawer opening, the drawer box, and the is to trim the drawer to tweak the fit. You
thickness of the drawer slides. Drawer can do that simply by jointing the side.
slides have enough play to tolerate a Or you could cut a shallow groove or Cut a shallow
groove in the
slight variation in the size of the drawer. rabbet sized to fit the drawer slide. The drawer side
But if the drawer is too large or too small, setup is the same as cutting a rabbet by if it's slightly
too wide
that can stress the mechanism. burying a dado blade in an auxiliary fence
TOO SMALL. If you find the drawer box is (or cutting a wide groove if the slides are Make sure screws
too narrow, shim one or both sides of the centered.) Trim one or both sides of the won't extend into
drawer opening
cabinet portion of the slides. You can use drawer until you get a smooth-sliding fit. 19

WS217_018.indd 19 11/21/2014 10:03:44 AM


With this multi-use, compact workbench, you can raise any project to a
comfortable working height easily and safely.
For years Ive had a scissor-lift cart in The mechanical advantage provided design and dust port allow it to also
my workshop. Ive primarily used it for by the hydraulic cylinder is incredibly function as a downdraft sanding table.
loading and unloading heavy items from convenient. But by adding the additional Best of all, building this workbench
my truck. It wasnt until recently that I workbench (complete with vise, tool tray, wont take you more than a couple of
decided to take my cart to the next level and magnetic tool holder) its easy to turn pleasant days in the shop. Turn the page
and make it even more useful by adding a one dimensional cart into a must-have, to get started on this Swiss Army knife
the auxiliary top you see above. multi-use workhorse. The hollow-body of shop accessories.

20 Woodsmith / No. 217

WS217_020.indd 20 12/5/2014 1:28:12 PM

Construction Overview / OVERALL DIMENSIONS: 42 "W x 14 "H (35" Max.) x 21 "D 1

Sturdy MDF worksurface Holes and slots

stays flat and withstands in the top provide
heavy use a wide range of
clamping options
(middle photo below)
Solid hardwood
edging covers the
MDF edges of
the benchtop

NOTE: Source information

for bench vise and other
accessories can be found
on page 67

Dust port allows

benchtop to function
as a downdraft
Metal dog in sanding table
vise aligns with
dog holes in

Heavy-duty bench Skirting is sized

vise increases the to fit over cart's
versatility of the tabletop
Bumpers hold
workbench bottom
edge level with Handle removed to
handle brackets when avoid interfering
scissor lift is lowered with workbench
(brackets remain)

Locking swivel
casters keep cart
from moving
during use

{ A dust port on the side of the casters Hydraulic lift makes
benchtop allows it to function raising and lowering
the workbench a breeze
as a downdraft sanding table.

{ A magnetic tool holder along the { Holes and slots in the benchtop { A wire mesh auxiliary tray keeps
edge of the workbench provides allow you to conveniently clamp often-used items close at hand
easy access to tools. a workpiece in place. without collecting sawdust. 21

WS217_020.indd 21 12/5/2014 1:28:47 PM

NOTE: Benchtop
cut to size after
!/8" chamfer on top edge gluing up
Building the of each hole and slot


The heart of the scissor-lift workbench 8&/16

is the heavy-duty benchtop. I wanted
it to be strong enough to withstand
the repeated use of raising and lower-
ing heavy loads the hydraulic scis-
sor lifts intended purpose. But I also A
wanted to give it some added function- BENCHTOP
ality. So I drilled dog holes and long NOTE: Benchtop NOTE: To see how to
made from three make the slots, turn to
slots in the surface to provide multiple, layers of #/4" MDF Shop Notes on page 64
convenient clamping options.
To ensure I had a rock-solid top, I a. 2!/4 5!/8
glued three layers of MDF together.
The fragile edges of the MDF are pro-
tected by some thick, hardwood strips.
The skirting underneath the table forms
the hollow base of the workbench. It
provides a place to mount a vise to the
underside of the top, as well as allowing #/4
for a dust port in one end.
FIRST THINGS FIRST. Before you can start accordingly if you choose a different I then cut the entire assembly to final
making sawdust, you need to have a model than the one shown on page 20. size after the glue dried.
hydraulic-lift table at the ready. The If youll be adding a vise to the project, BENCH DOG HOLES. Any workbench sur-
information for where I purchased my youll want to have that on hand, also. face that may be used for woodwork-
lift can be found in Sources on page 67. BENCHTOP BASICS. As I mentioned before, ing isnt complete without the addi-
But really, there are several good options the benchtop is constructed from tion of bench dog holes. They increase
available. Just be sure to buy a model three layers of MDF as shown above. the functionality of the workbench
that has an easily removable handle. Start by cutting these pieces a little by providing a place to insert bench
Youll also need to adjust dimensions oversize and gluing them together. dogs and add clamps.

Transfer centerline of
holes to edges of
dog hole template
Dog hole
2!/4 7!/4 2!/4 template

Dog hole
template #/4" Forstner
4!/2 bit
2!/4 Align centerline of
template holes with
#/4"-dia. through layout lines
hole on benchtop sides

19 5!/8

Forstner 5!/8
B 7#/8
Drill into Benchtop p
prevents 7#/8
board ttearout on First holes drilled
tthe lower with template flush
fface at end and sides

22 Woodsmith / No. 217

WS217_022.indd 22 12/10/2014 12:07:00 PM

NOTE: Edging is glued B
to benchtop flush with
top and bottom C

Edging is mitered and

applied to top before
rounding over corners



37#/4 a.
C 1"-rad.
roundover B

NOTE: Edging is made
from 1!/4"-thick hardwood.
Dimensions shown are TOP VIEW
before rounding over corners

DOWNDRAFT BONUS. The bench dog holes weight) of the top, I found it much easier edges with the benchtop edges and
also serve another purpose. They allow to drill the holes with a hand drill rather clamp it in place. Be sure to have a
the top to double as a downdraft sand- than taking the top to the drill press. backer board in place under the assem-
ing table when a hose is attached to the To keep the bench dog holes evenly bly to prevent tearout. After drilling
dust port in the skirting. spaced during drilling, I made the sim- the holes, add a chamfer to the top
Drilling the holes in the benchtop isnt ple template shown at the bottom of edge of each hole to reduce chipping.
difficult. But because of the size (and the opposite page. Align the template CLAMPING SLOTS. To make the four slots
in the benchtop, I used another tem-
plate and a three-step process. Shop
NOTE: Size opening in Notes on page 64 explains how to make
vacuum end skirt to fit 18 VACUUM
dust collection hose END SKIRT this template and walks you through
F the process of creating the slots.
#/4 BENCHTOP EDGING. With the holes and
5 slots completed, I added the hardwood
D 1!/2 edging to the top, as shown above. Cut
Dust hose these pieces a little long, miter the cor-
hook up
%/16"-dia. ners, and attach them to the top using
5 through holes glue and clamps. I also rounded the
corners of the edging (detail a) using
END SKIRT a coarse file and sandpaper.
SKIRT #8 x 1!/2" Fh
woodscrew SKIRTS. The boards that make up the
skirting create an opening that is
4!/2 sized to fit over the tabletop of the
cart. Cut the side skirts to size first,
and then form the rabbets on each
end using a dado stack at the table
NOTE: Benchtop
and skirts are shown saw. The end skirts can then be cut to
bottom face up length to fit between the sides.
The vacuum end skirt has a hole
a. b. #/8 drilled near the center to accept a hose.
D The vise end skirt is notched to provide
!/4 D
#/4 clearance for the vise rods. I made this
notch at the band saw. With the parts
NOTE: All parts
E #/4 are made from made, use a little glue and screws to
#/4"-thick hardwood Drill and assemble the four pieces. But hold off
TOP VIEW for a #8 Fh SIDE VIEW on attaching them to the underside of
the benchtop. Youll do that later. 23

WS217_022.indd 23 12/5/2014 10:01:01 AM

NOTE: Size opening to
NOTE: Blocking is made 15!/2 H fit dust collection hose
from 1"-thick hardwood
BLOCKING !/4" x 3!/2" lag
a. Benchtop
screw with washer

Side Vacuum end 10

skirt skirt SIDE

#8 x 1!/2" Fh Vacuum
woodscrews end G


Side skirt
!#/16 Side
#/8 skirt

!/4" shank Drill a

Vise hole #/16"-dia. x Vise
end #/4"- deep end
skirt pilot hole in skirt
NOTE: Benchtop,
skirts, and blocking
Benchtop are shown bottom
face up
NOTE: Skirt and blocking
assembly are centered
on bottom of benchtop

Completing the WORKBENCH

With the benchtop and skirting assem- drive long lag screws through to attach thin panel is screwed to the blocking to
blies complete, there are just a few more the skirting to the benchtop. And sec- completely seal off the dust cavity.
details to wrap up on this project. Some ond, some short pieces of blocking are STRUCTURAL BLOCKING. Start by cutting the
hardwood blocking is attached inside used to seal off the bench vise from the three pieces to size for the side block-
the skirting. This blocking performs two dust chamber. This provides better air- ing and the vacuum end blocking.
functions. First, it provides a place to flow through the dust port. After that, a Use the hole in the vacuum end skirt
to mark the location of the hole on the
vacuum end block and drill this hole.
6 6
The two side blocks need three coun-
terbored through holes drilled on the
#/8" x 2" lag screws
1!/2 2 with washers edge. These holes allow for the use of
lag screws and washers to attach the
I blocking and skirting to the benchtop.
With these holes drilled, I attached
the three blocking pieces to the skirting



I assembly J #/4

NOTE: Vise blocking made #/4

from #/4"-thick hardwood.
Vise end blocking made
from 1"-thick hardwood Table I

edging NOTE: Benchtop Vise installed tight
assembly, vise blocking, against benchtop and end
and vise assembly are edging with lag screws
shown bottom face up

24 Woodsmith / No. 217

WS217_024.indd 24 12/5/2014 10:01:22 AM

with screws, as shown at the top of the
previous page. Then, its just a matter of
marking the locations for the lag screws
on the underside of the benchtop using
the blocking as a guide. Drill the holes
and attach the blocking and skirt assem- #14 x 1!/4" Fh sheet Vacuum
bly to the benchtop. metal screws hose
earlier, the vise is sealed off from the
hollow dust chamber using some short Sealing
pieces of blocking butted together. K is !/4"
28 17!/2
Since these parts are not structural, SEALING PANEL plywood
they are simply held together with glue
at the joints. With the assembly com- Drill #/16"-dia.
pilot holes
plete, attach the vise end blocking to for attaching
the skirting with screws, as shown at #8 x #/4" Fh workbench and
woodscrews bumpers
the bottom of the previous page.
NOW THE VISE. No workbench is com-
plete without a good vise. And this
a. #14 x 2" Fh b.
multi-use bench is no exception. Set NOTE: One bumper Sheet metal Vacuum
the vise in position and mark the loca- required on each screw centered #/4 Benchtop end skirt
side of lift assembly on bumper
tions for the mounting holes. Drill the
holes and use lag screws to secure the Side Vacuum
#/4 1!/2 blocking hose
vise to the underside of the benchtop
(detail a, bottom of previous page). L
3 Vacuum end
SEALING PANEL. To complete the bench- BUMPER
1 blocking
top, youll need to cut a thin plywood 1 Base K
panel to fit between the skirting on the rail SECTION
underside. This panel makes the dust
chamber completely airtight. How-
ever, since you may want to access the to the lift table. Its pretty heavy, so it overview, page 21) interfered with the
interior of the workbench in the future, might be a good idea to have a helper workbench skirting in the collapsed
be sure to attach the sealing panel to assist in setting it in place. To keep the position. This skewed the table
the blocking with screws only. (You benchtop in position, I used sheet metal slightly. To compensate for this, I made
should also avoid pushing bench dogs screws through the lower part of the a couple of hardwood bumpers (detail
below the surface of the benchtop). skirting into the lift table edge (above). a, above). Theyre simply attached to
FINAL DETAILS. With the sealing panel in BUMPERS. On my lift cart, the handle the framework of the lift table with
place, the workbench is ready to attach brackets (visible in the construction sheet metal screws. W

Materials, Supplies & Cutting Diagram

A Benchtop (1) 214 MDF - 19 x 3514 H Vacuum End Blocking (1) 1 x 3 - 1512 (6) 14" x 312" Lag Screws w/Washers
B Side Edging (2) 114 x 214 - 3734 I Vise End Blocking (2) 1 x 3 - 512 (4) 38" x 2" Lag Screws w/Washers
C End Edging (2) 114 x 214 - 2112 J Vise Blocking (3) 3 x 3 - 6
4 (6) #14 x 114" Fh Sheet Metal Screws
D Side Skirts (2) 3 x 5 - 291 K Sealing Panel (1) 1 ply. - 171 x 28 (2) #14 x 2" Fh Sheet Metal Screws
4 2 4 2
E Vise End Skirt (1) 3 x 5 - 18 L Bumpers (2) 1 x 112 - 3 (1) 7" Woodworkers Bench Vise
F Vacuum End Skirt (1) 3 x 5 - 18 (36) #8 x 112 Fh Woodscrews (1) Hydraulic Scissor-Lift Table
G Side Blocking (2) 1 x 3 - 28 (12) #8 x 34 Fh Woodscrews

1!/4"x 5" - 60" Hard Maple (3.1 Bd. Ft.) #/4"x 6" - 60" Hard Maple (2.5 Bd. Ft.)

#/4"x 6" - 60" Hard Maple (2.5 Bd. Ft.)

ALSO NEEDED: One 48"x 48" Sheet of !/4" Birch Plywood
D D One 49"x 97" Sheet of #/4" MDF

1"x 4" - 96" Hard Maple (3.3 Bd. Ft.)

G G H I I L L 25

WS217_024.indd 25 12/10/2014 12:07:22 PM


Spice Carousel
Solid-wood construction and interesting drill press techniques put an
attractive new spin on your spice collection.
While woodworking is my primary containers dont stack easily and end up the seasoning you need. Best of all, the
hobby, I also enjoy spending time in the lost in the back of the cabinet. woodworking is simple, but interesting.
kitchen. Im not a chef by any means, but The spinning rack you see above is a I made two versions of the carousel.
my family enjoys some traditional dishes welcome solution to any kitchen coun- One was stained (above) and the other
I manage to cook up. tertop. Angled slots display eight jars to was painted (refer to back cover). If
One frustration with working in the keep your most often-used spices read- youre painting yours, you can use an
kitchen, however, is digging through ily available. And a lazy Susan bearing inexpensive wood like poplar. For the
the cupboard to find spices. The various allows you to spin the carousel to select stained version, I used soft maple.


Drill !/16"-dia. pilot Cut to just
hole through after outside of 1"Forstner bit
locating centerpoint layout line

Scribe a
10"-dia. circle Drill #/8"-dia.
shank hole
after drilling
Base counterbore

NOTE: Diagonal and NOTE: Flip base

centered layout lines over for drilling
locate center of circle

Layout. Strike lines across the diagonals Rough Shaping. Use a band saw to Centered Hole. A counterbored hole is
and centered on the edges. Scribe a cut the rough shape. Staying close to used to mount a bolt for smoothing the
circle before drilling a pilot hole. the line means less cleanup work. edges and later to assemble the body.

26 Woodsmith / No. 217

WS217_026.indd 26 12/1/2014 12:58:17 PM

10"-dia. finished base
cut from blank
The carousel is made of two main parts: A 10!/4
wide base and a thick body. Theyre both 10!/4
round, so youll want to have a compass
and straightedge on hand for laying out Centered
layout lines
the centerlines and circle.
GLUE-UP & LAYOUT. Start constructing the
base by gluing up some narrow stock
to create a blank at least 1014" wide.
Once the glue dries, trim the blank to
form a square and then plane both faces
smooth. This makes the layout go a little Locate base centerpoint
easier. The drawings at the bottom of NOTE: Base is made from with diagonal
#/4"-thick hardwood layout lines
the opposite page step you through the
layout process. In a nutshell, youll draw a. #/8 SECTION VIEW !/8
two diagonal lines and two centerlines
that locate the slots for the jars. !/16
!/8" #/4
After scribing a circle on the base blank roundovers
and cutting it out, I used the drill press
to true up and smooth the edges. To do
this, youll use a carriage bolt mounted 1

through the center of the base. So the

next operation is to drill a counterbored A file removes the high spots then fol- I installed a 18" roundover bit in the
hole. The counterbore will be used later low up with progressively finer grits of router table. You can see in detail a
to assemble the carousel with a lag screw adhesive-backed sandpaper attached to a above and the right drawing below how
and glue holding everything together in wood block. You dont want to apply too the bit height is set to create a 116" fillet
the final assembly. much pressure let the abrasive do the around the edges of the blank.
TRUING UP THE EDGE. The drawings at the work. I started with 100-grit and sanded For this task, I removed the router
bottom of the page show you how I used through 220-grit for a smooth edge. fence and used the bearing on the roun-
a sanding block to smooth the edge of INDEX MARKS. Theres one more layout dover bit to guide the workpiece. After
the base. Install a carriage bolt through task that will help later on and thats to routing one edge, flip the blank over and
the center and secure it with a washer extend the lines to the edge of the base, repeat the process on the opposite edge.
and nut. This assembly can then be as in the center drawing below. These I took the time here to carefully sand the
chucked in your drill press. Position the lines come in handy when you make the roundovers smooth, especially the end
table to within 1" under the base. Youll body of the carousel. grain. If youre applying a stain, you
use the table as a platform for a sanding ROUT ROUNDOVERS. The next step involves can sand up through 400-grit to provide
block (left drawing below). some quick work at the router table. a more even stain color on the end grain.


applied to !/8"
block roundover
bit A
Align square with
Hold sanding block layout line and
A mark edge NOTE: Rotate base
perpendicular counterclockwise
to base edge against bit a. END
a. bearing

#/8" x 3!/2" SECT.

carriage bolt VIEW

Gap between !/16

base and table

Smoothing the Edge. Use a file and Transferring Lines. To help with Routing Roundovers. Use the bearing
a sanding block to true up the edge of aligning the body of the carousel on the roundover bit to guide the work-
the base and make it smooth. later, extend the lines to the edges. piece to profile the top and bottom. 27

WS217_026.indd 27 12/1/2014 12:58:42 PM

NOTE: Carousel body is Fasten 2"-dia.
glued up from three hardwood knob
layers of #/4"-thick hardwood with epoxy
a. b. !/16
!/8" Knob hole
NOTE: Final body C KNOB SPACER enlarged#/8"-dia.
size is 6#/4"-dia. roundover
%/16" self-adhesiv
dia. !/16
7 bumper !/8" roundover
7 1!/4 B
B 2"-dia. rubber
BODY disc in bottom
of each hole

Bumper #/16

Alternate 1
grain direction
of layers A

Base 1!/2 #/8" -dia.

through B
6" lazy Susan
centered under Next, lay out the diagonals and center-
base and attached lines as you did on the base. After scrib-
with four
#6 x !/2" Rh ing the circle, drill the center hole and
woodscrews A
then cut the blank to shape (Figure 1,
opposite page). Using the same carriage
bolt, washer, and nut as before, chuck the
assembly into your drill press to sand the
#/8"-dia. #8 x 1!/4" Fh
self-adhesive woodscrew outside smooth. Then rout a roundover
bumper on the top edge only (Figure 2).
#/8" x 4!/2" lag DRILLING HOLES FOR THE JARS. The most inter-
screw with washer
esting part of the project comes next.
Youll attach the body to the base and
Completing the CAROUSEL then drill the holes that hold the spice
jars. If you take a look at detail b above,
Setting the base aside for now, you can GLUING A THICK BLANK. The body starts youll see that the holes are angled.
start to work on the body of the carousel with a blank at least 7" wide by 24" long. This tilts the jars back for display when
that holds the spice jars. Later on, youll After planing this smooth, cut three 7" stored and keeps them from falling out
bring the two parts together to drill x 7" squares from the blank and then when you spin the carousel.
the holes for the jars. Then youll add a glue them together, alternating the grain Those layout lines you drew earlier
spacer, knob, and the lazy Susan bearing. direction. This minimizes warping. come in handy now. Center the body on


NOTE: Jig top
and base
NOTE: Jig parts are
made from #/4" MDF
1 Clamp carousel
to jig top
Align edge
are the same size layout line
Carousel with centerline
#/8"-dia. base of jig base
#/8"-dia. x 5" a.
hole through steel pivot pin and bit
jig top 2"
Centered Forstner
index line bit

Wedge Clamp jig

spacers base to table

Top a.
Pin rests spacer !/16
Base 12 on base
Spacer inset 1" from base edge

28 Woodsmith / No. 217

WS217_028.indd 28 12/1/2014 10:15:16 AM

the base, aligning the layout lines, and How-To: SHAPE THE CAROUSEL BODY
fasten it with glue and a couple of screws
from the bottom placed near the center. 1 SECOND: Cut just
outside of layout line
To ensure consistency in the location Rout B
of the holes and make for easier drilling, counter-clockwise
I made the drilling jig you see at the bot-
tom of the opposite page. It uses a pivot
pin to allow the body and base to rotate !/8"
FIRST: Drill a centered
for drilling the eight holes. #/8"-dia. through hole roundover
The box at the bottom of the opposite
page and Figure 3 at right provide all of a. END SECTION
the details you need for setting up the
assembly on the drill press. There are a NOTE: Rout
!/16 top edge
couple of points to keep in mind. First, THIRD: Insert carriage bolt only
center the drill bit 116" in from the edge and sand edge on
the drill press as before
of the fillet on the top edge (Figure 1a,
bottom of opposite page). Cutting a Circle. After laying out lines Roundover. Using the same setup
The other thing to figure out is how to and scribing the circle, cutting the at the router table you used on the
get a consistent depth for all of the holes. body to shape is an easy task. base, round over the top edge.
Figure 3a at right shows the goal. To set
Align 1!/2"-dia.
this depth, I drilled the first hole, care- 3 layout 4 sanding drum
fully checking the depth as I went. Then lines and
clamp to
I set the depth stop on my drill press to jig top
drill the remaining holes.
SANDING & ASSEMBLY. Sanding the inside
of all the holes was a bit of a challenge.
What I found works best is to use a hand
drill with a 112"-dia. sanding drum (Fig-
ure 4). Ease the sharp edges of the holes a.
with some sandpaper before adding the
knob and applying a finish. Body
In the main drawing on the opposite #/16
page, youll see how the knob is attached. Base Carousel clamped
To elevate it above the jars, I added a in vise while sanding
spacer made from a dowel. I eased the Jig top
NOTE: Sand inside surface
end of the dowel with sandpaper, then SECTION VIEW of holes top to bottom
I cut it to length and drilled a centered
through hole. Detail a on the facing page Drilling Large Holes. With a 2"-dia. Sanding Smooth. Use a sanding
shows how the assembly is held together Forstner bit and a jig, drilling the holes drum in a hand-held drill to sand
with a lag screw and washer. I used glue for the spice jars goes quickly. the inside of the holes smooth.
to secure all of the parts.
FINISHING TOUCHES. To finish the maple
carousel, I used Pecan water-based stain Materials, Supplies & Cutting Diagram
and painted the inside of the holes black. A Base (1) 3 x 10-dia.
4 (1) 38" Washer
For the painted carousel, I applied Som- B Body (1) 214 x 634-dia. (1) 6"-dia Lazy Susan Bearing
erset Gold milk paint followed by a coat C Knob Spacer (1) 114-dia. x 1 (4) #6 x 12" Rh Woodscrews
of Basil Green milk paint. I sanded some (2) #8 x 114" Fh Woodscrews (8) 2"-dia. Rubber Discs
areas through to bare wood to simulate (1) 2"-dia. Hardwood Knob (4) 38"-dia. Self-Adhesive Bumpers
wear and then applied a burnt umber (1) 38" x 412" Lag Screw (8) Spice Jars
glaze. The stain, paint, and glaze are
#/4" x 5"- 36" Poplar or Soft Maple (1.3 Bd. Ft.)
from General Finishes. The final coat was
spray lacquer (refer to Sources, page 67). A A A
The last items to add are the rubber
discs, a lazy Susan bearing, bumpers, and #/4" x 5!/2"- 48" Poplar or Soft Maple (1.9 Bd. Ft.)
the spice jars. Once the jars are filled with
your favorite spices, dont be surprised if
your dinner guests ask you to make a
spice carousel for their kitchen. W 29

WS217_028.indd 29 12/1/2014 10:15:30 AM

hop -built
s s

Mortising Machine
Most projects I build have at least a few machine plans. This design has a keep- a snap. Common T-nuts and studded
mortise and tenon joints in them. And of it-simple philosophy. Its mostly built knobs round out the hardware list.
the two parts, the mortise causes the big- from plywood parts that are glued and POWER SOURCE. This mortising machine
gest headache. If thats the case for you, screwed together. The moving compo- uses a medium-sized router motor as
then maybe its time to upgrade from the nents the router carriage and sliding the power source. I find that a variable-
drill press and chisel method. A dedicated table operate with heavy-duty, full- speed router gives you more versatility.
mortising machine may be just the ticket. extension drawer slides. A no-nonsense But even with a single-speed router, this
EASY TO BUILD. Complexity is the big stop system and a commercial toggle machine will make creating accurate
obstacle to most shop-built mortising clamp make cutting identical mortises mortises a quick and easy process.

30 Woodsmith / No. 217

WS217_030.indd 30 2/4/2015 12:42:16 PM

Construction Overview / OVERALL DIMENSIONS: 26"W x 23 "H x 21 "D 1

NOTE: Mortising machine

painted with "hammered" finish Router carriage
spray paint in verde green designed to accept
a mid-size
router motor
Large handle
can be used
Stout hardwood fence with either hand
won't flex under Router carriage
clamping pressure moves on
Stop block
makes repeatable heavy-duty,
mortises a breeze full-extension
drawer slides

Toggle clamp securely

holds workpiece
against fence

Upper table
adjusts in and out
to position workpiece
in relation to router bit

Threaded rod and

push-button nuts
create stops for cutting
repeatable mortises

Slots act as handles

for sliding table
back and forth NOTE:
to create mortise Mortising machine
is made primarily
from #/4" plywood

Sliding table
rests on
drawer slides for
smooth operation

Wide base provides

NOTE: room for clamping
For hardware sources, mortising machine
turn to page 67 to worksurface 31

WS217_030.indd 31 2/4/2015 12:43:07 PM

!/4 D rad.


B 6#/4 C

NOTE: All parts

are #/4" plywood
E 1!/4
8 18
6 5 B

2"-rad. D

!/2"-rad. BASE BOTTOM
(all corners)

#8 x 3" Fh woodscrew

is wider than the top. This creates

A solid FOUNDATION a flange for clamping the mortising

machine to a worksurface without
interfering with the sliding table.
A fixed, stable core is a must for mini- improves rigidity and provides more I cut the base top to its final size and
mizing vibration from the router and meat for attaching heavy-duty hardware. shape and used it as a pattern to trace the
for keeping the workpiece from shifting Theres no need for fancy joinery here. rear profile on the blank for the base bot-
during the cut. That job falls to the base Instead, parts are cut to size and fastened tom. After rough-cutting the shape of the
and post assemblies shown in the draw- with glue and screws. Once the founda- bottom layer, the two parts can be glued
ing above. Its also a good place to start tion is built, you can move on to the together. Use a router and flush-trim bit
because all the other parts are attached to moving parts of the machine. to remove the remaining waste and cre-
these two components. Theres nothing complicated about the ate a smooth, even edge.
The material of choice here is 34" ply- construction process. However, I want to POST. The second assembly is the post.
wood. (I used Baltic birch.) As you can see, highlight several key items. Its function is to provide a mounting
the assemblies are laminated from two BASE. You start by building the base. In point for the router carriage that youll
layers of plywood. The added thickness the drawing, you can see the base bottom build momentarily. From the top, the
post has a U shape (Top View above).
Dont rush things by starting to cut
%/16"-18 hex a. SIDE SECTION VIEW
nut & washer and glue parts together. Its a good idea
%/16"-18 x 2" #/8"-dia. hole
E eyebolt to knock out a few details on the post
&/8"-dia. face while its a separate part. The first
counterbore 1
of these is to cut a slot. The purpose of
the slot is to allow a pair of springs that
1 connect the router carriage to the post to
%/16"-18 1!/2 !/8 To open the eye,
T-nut C refer to Shop Notes retract the carriage between cuts.
C on page 65 I made the slot by drilling end holes and
then connecting the dots with a jig saw.

32 Woodsmith / No. 217

WS217_032.indd 32 2/4/2015 12:43:45 PM

10" full-extension
8!/2 drawer slide w/screws

#8 x 2" Fh woodscrew
1!/2 F
C 10
%/16"-18 x 5!/4" 1#/4 #/8
threaded rod 10
NOTE: Cutout in
router mount and
Threaded rod will cut clamp should
threads in router mount. match diameter of
Add epoxy to hole router motor
for a secure hold 4!/8
9!/2 E

Drill %/16" c. TOP VIEW

through hole 2!/16 D
6&/16 2!/4 C E
Drill (/32" H
pilot hole
MOUNT 1 G !/8 C
%/16"-18 through !/8"- I
knob & washer roundover
B !/4 H
b. E E

H %/8
C !/2"-dia.
4!/8 3!/4
!/4 !/2
2%/8 2%/8
2!/8 2!/8
B !/4 1#/4"-rad.
TOP 2!/16

The upper drawing and detail b on the ROUTER CARRIAGE. Your work on the fixed the depth of the mortise. Both pieces of
previous page have the dimensions you parts of the mortiser is over. Now its the router holder have a half-circle cut-
need for this. Then I reached for files time to tackle the moving parts. The first out on the inside edges. Like I mentioned
and some sandpaper to straighten and of the these is the router carriage assem- before, I sized this for a mid-size, Porter-
smooth the sides of the slot. bly thats shown above. Cable 892. You may need to alter the size
Creating a mounting point for the This assembly is made up of two sec- of the cutout to match your router motor.
springs is the other detail on the post tions. The U-shaped carriage and the Two short pieces of threaded rod, knobs,
face you need to address. The springs router holder. The carriage is the simplest and washers apply the clamping pressure.
are attached to a pair of eye bolts that are to make. You need to size the parts care- I drilled the through holes in the clamp
anchored to T-nuts. The lower drawings fully to wrap around the post and a pair first. To mark the holes in the mount, I
on the facing page show where to locate of drawer slides. The goal is a smooth used a brad point bit through the clamp.
the through hole and counterbore. sliding action on the slides. The back and These holes are sized so that the rod cuts
The sides of the post are glued up from sides are joined with a tongue and groove threads into the mount for a stronger con-
two layers of plywood. Take note that the joint to align for assembly (detail c). nection. I backed out the rod and applied a
front edges of each layer are offset to cre- The router holder takes a little more little epoxy to the rods as some insurance
ate a rabbet sized to accept the post face. explanation. The holder consists of a before driving them in for good.
When youve completed cutting the taper mount screwed to the carriage and a The router mount can be screwed to
along the back edge of the sides, you can clamp that secures the router motor to the carriage, as in details a and b. The
glue up the post assembly. the carriage assembly. These two parts carriage assembly is attached to the post
The post and base are joined with long are made from three layers of plywood. with full-extension drawer slides (detail
screws driven from the bottom, as shown Detail d above shows a through hole c). For the most stability, the slides are
in detail a and Top View drawing on the near the back edge of the mount that arranged to be in the closed position as
previous page. forms part of the stop system to control the carriage is lowered. 33

WS217_032.indd 33 2/4/2015 12:44:01 PM


HANDLE !/8"-rad.
a. b.
1!/4 D
%/16"-dia. CARRIAGE 7#/4 K &/8
!/2"-rad. K
#/8" hex POST BLOCK
nut K SIDE
#/8"-18 x 3" hex 4
head bolt #/8" flat J
washer G

#8 x 2" Fh
woodscrew #/4"O.D. x
2!/2 #/8" I.D.,
NOTE: 1!/4"O.D. x 1" nylon
All parts #/4" I.D., bushing
washer 1!/2
made from
hardwood H

Router carriage HANDLE BLOCKS. The four blocks shown

in the drawing above serve as anchor
The bushing rides in a slot in the handle
that draws the carriage up and down.

CONTROLS points for the handle shown on the next

page. Unlike the previous parts, these
are all made from hardwood for dura-
The carriage blocks are attached with
screws. The bolt and bushing are held by
a nut and a pair of washers.
The router carriage needs a little more bility and to accept screw threads better. DEPTH STOP. The job of controlling the
work before its ready to accept the router The first two blocks mount to the post depth of cut falls to the block and
motor. This isnt too difficult, though the and allow the handle assembly to pivot hardware assembly shown below. The
bits and pieces you make and add are clear of the wider carriage assembly. depth rod block holds a short piece of
important for the mortising machine to Glue the blocks to the post at the location threaded rod (detail a). I glued it in
operate smoothly and accurately. shown in detail a. Then drill a centered the same way as the threaded rod in
Lets make a quick rundown of whats pilot hole to accept a 516" lag screw that the router mount. You can use the rod
ahead, then Ill highlight key points along secures the end of the handle. to align the block with the hole you
the way. A large handle controls the up The other pair of blocks you need to drilled earlier in the router mount.
and down motion of the router. A few add are attached to the front of the car- The stop is provided by a fast-acting,
blocks and hardware additions to the car- riage assembly. Instead of a fixed point push-button nut located below the car-
riage and post are necessary to add this. of connection, the blocks house a bolt riage assembly, as shown in the lower
In order to create an accurate mortise, and nylon bushing, as you can see in left photo. For quick adjustments, press
you need a way to make cuts to a consis- the main drawing above and detail b. the button and slide the nut along the
tent depth. A basic stop system handles
this easily. A pair of springs in the back
lift the router clear of the cut and return %/16"-18 x 10!/2"
it to its ready position. threaded rod SECTION

nut, hex nut
& washer

L #/4
< Quick-Set Stops. Drill (/32"-dia. !/2
pilot hole 1!/2
Push the button in block 2
for fast adjustment.
Turn the nut to fine- 3
tune its location. !/2"-rad.
#8 x 2!/2" Fh

34 Woodsmith / No. 217

WS217_034.indd 34 2/4/2015 12:47:06 PM

SECOND: Fit handle shaft NOTE: Shaft made from two pieces of !/2"-thick
between arms and install rod hardwood. All other parts are #/4"-thick hardwood

ARM NOTE: Turn to
!/4"-rad. page 66 for
THIRD: Secure M instructions to 1
with washers make handle shaft P
and nuts
1 %/16

NOTE: Paint FIRST: Fit handle

handle shaft J over bushing and
black before N install lag screw
final assembly

b. SIDE VIEW !/8 "-rad.

%/16 "-dia. 3 c. FRONT
1!/8 M VIEW
1!/4 M
N N #/4 1!/2
1 !/2"-rad.
O #/4
5#/4 6 %/16"-18
17!/2 %/16"-18 x 12" hex nut
threaded rod &

threaded rod. To fine-tune the depth of detail b. Two spacers and a cap piece are
cut, simply turn the nut as needed. glued to the main handle piece. Whats FRONT
HARDWOOD HANDLE. With all the pre- important here is the width of the spac- SECTION
liminary items crossed off the list, you ers. They should be just a hair wider than J

can make the handle. The long, front- the bushing. This allows the bushing to
mounted handle is easy to use with move freely but without any slop.
%/16"x 3"
either hand and provides good leverage The arm has a hole drilled at each end. lag screw
for plunging the router bit into the work- One is used to attach it to the post. The w/ washers
piece. The handle is made up of three other is to join the arms to the handle
components two arm assemblies that shaft, as shown in detail b.
sandwich a shaft and threaded rod. SPLIT SHAFT. I was concerned about Creating the channel for the threaded
Each arm incorporates a slot that screw threads holding in the end grain rod is easier than it looks. Shop Notes on
houses the nylon bushing you installed of a solid dowel. To eliminate those page 66 covers the technique.
on the carriage. But rather than cutting worries, I made a two-piece shaft that You need to assemble the handle
a slot, I built it up from smaller parts, as captures a section of threaded rod. in a specific order. Fit the slot over the
you can see in the drawing above and This is illustrated in details a and c. bushing and drive lag screws to secure
each arm to the post. Then slip the shaft
a. between the arms and add the washers
C and nuts, as in detail c.
%/16"-18 x 2"
eyebolt RETURN SPRINGS. Two extension springs
w/washer #/4
%/16"-dia. are the final elements you need to add.
drill bit E D
As I said earlier, these springs lift the
F router carriage and hold it above the
workpiece. This gives you plenty of
room to move workpieces around and
set up the sliding table. One end of each
5.625" x .563"
b. spring is attached to one of the eyebolts
M OD extension on the back side of the post.
springs H
Springs The two springs meet at a single screw
eye threaded into the back of the carriage
J J (detail b). You can see in detail a how
%/16"x 2!/2" to locate and drill the pilot hole for the
screw eye VIEW
screw eye in the back of the carriage. 35

WS217_034.indd 35 2/4/2015 12:48:39 PM

1!/4 %/16" washer
%/16"-18 hex nut
NOTE: Remove the D
post to fit drawer 1!/2
slide components 3!/4 !/2"-dia.
together STOP BLOCK
2 S
NOTE: Use holes
in stop blocks
to locate hole B 3#/8 #/8"-dia. through hole
in post
%/16"-18 !/2"-rad.
S 6!/8
NOTE: Table parts 2#/4 TOP
are #/4" plywood. 1!/4"-dia. #/8"-dia. through hole,
Stop blocks are &/8"-dia. counterbore
glued up from 3 1%/8 (for all T-nuts)
#/4"-thick %/16"-18 x 22&/8" 15 1&/8
hardwood threaded rod
%/16"-18 BOTTOM
Attach upper portion of 2!/4 T-nut
slides flush with the end 12
of the table bottom

a. SIDE SECTION VIEW 5!/4 Even though theyre glued together,

1!/4 theres some work to do on each piece
18" full-extension
drawer slides w/screws before that happens. On the bottom
1!/4 layer, I cut the plywood piece to its final
shape with a large notch in the back
R 3!/8 and rounded corners at the front. These
D Q details are shown in the main drawing.
The top layer is deeper than the bot-
tom layer. Along the overhanging front
B 5!/4
!/4 edge, you cut a pair of hand-holds that
you use to slide the table side to side.
b. FRONT SECTION %/16"-dia This layer also has a narrow kerf cen-
VIEW through hole
tered on the top face, as shown in detail
b. It houses an aluminum strip in the
D E !/8 E D S next component of the table assembly
(the fence base). Its used to position the
!/4 R 3#/8
workpiece front to back in relation to the
Q !/8 router bit while keeping it square.
The top layer has the same notch at the
back, but I only roughly cut it out before
gluing the two layers together. I used a
router and flush-trim bit to clean up the
fixed so that the workpiece cant shift notch so it matched the layer below.
Two-way during the mortising process.
The other action moves the securely
Take a look at details a and b to
install a set of T-nuts in the bottom face

SLIDING TABLE held workpiece side to side as the bit

cuts along the length of the mortise. Fixed
and sliding may seem like oil and water.
of the sliding table. These lock the fence
base in position with knobs.
The notch along the back edge of the
The work up until now has been focused But as we go along, you can see how this sliding table wraps around the post. A
on making the mechanism for the router table makes it work. pair of blocks glued to the ears on
plunge smoothly into a workpiece. BUILT IN LAYERS. The table is a built-up either end of the notch house a threaded
From here on, you turn your attention to assembly where each new layer adds a rod. Its used to create the end stops for
the workpiece support and control func- different function. The drawing above the mortising machine. Use the holes in
tions of the machine. All that is handled gets the ball rolling with the two lower the blocks to locate matching holes you
by the table assembly. sliding table pieces. These mount to the need to drill in the post sides (detail a).
There are two separate actions going mortising machines base with drawer DRAWER SLIDES. I mentioned earlier that
on. The first is creating a way to line up slides. With this arrangement, you can the sliding table is attached with drawer
the workpiece in relation to the bit. While smoothly slide a workpiece side to side slides. But theres a little more to it. In
its adjustable, the setting needs to be to create a smooth mortise. order to allow the table to slide both left

36 Woodsmith / No. 217

WS217_036.indd 36 2/4/2015 12:50:39 PM

NOTE: Fence and stop block #/8"-dia.
are made from hardwood. a. TOP VIEW
Fence base is #/4" plywood FENCE
Attach strips of
adhesive-backed 1#/16
2#/8 sandpaper to 2%/8
FENCE BASE fence face
b. #/4 #/8 L
!/2"-rad. #/4 22 %/8
&/8 V
4 #/4


3#/8 VIEW
R 8
!/2" x 12#/4" - !/8"
aluminum bar
V #8 x 1!/2" Fh woodscrew
#/8"-dia. through hole, FENCE
&/8"-dia. counterbore STOP BLOCK 2!/4
2!/4 1!/4 1!/4 d. FRONT VIEW U
Sand dust relief on !/8
T lower corners of stop block

!/16 R !/4
Several details help accomplish those
SIDE SECTION Q tasks. An aluminum strip in the bottom R
c. VIEW Aluminum bar
face mates with the kerf in the sliding table
(detail d). And the slots shown in detail
and right, you need to attach the slide a line up with the T-nuts in the sliding
components to the machine base and table. Studded knobs and washers com- to keep a workpiece from creeping out of
sliding table so theyre offset. So when plete the task of securing the fence base. alignment while making a mortise.
the table is centered, the mechanism is Take a look at the extension tab in the TOGGLE CLAMP. The final piece of the puz-
half-open, as shown in the drawing and front of the fence base. It holds six more zle is the toggle clamp you see in the
details a and b on the previous page. T-nuts that are installed on the bottom drawing below. Its attached to a mount-
As you install the slides, its important face to anchor a toggle clamp that pins the ing base, so you can adjust its position
that the slides are installed parallel to each workpiece against the fence, as in detail depending on the thickness of the piece
other and square to the face of the router c and the drawing below. youre working with. The clamp sits in an
carriage. To install the table, you need to A STOUT FENCE. The next layer of the table angled dado to apply slight downward
remove the post and fit the drawer slides assembly is the fence. Its glued up from pressure in use. Turn to page 66 to see
together. Then reattach the post. hardwood and beveled on the back how the dado is cut. I glued a wide clamp
FENCE BASE. Moving up from the sliding edge. I installed a length of T-track in the block to the swivel head of the clamp to
table, you come to the fence base shown face to hold an adjustable stop, as you distribute the pressure more evenly.
above. The base does a few things: It can see in detail b. The fence is glued The mortising machine is now ready
supports the workpiece, serves as the and screwed to the fence base. to be put into action. The straightforward
mounting point for the fence, and deter- One more thing: I applied strips of design helps keep this a simple process.
mines the front to back position of the adhesive-backed sandpaper to the face You can read about it in the step-by-step
workpiece in relation to the bit. of the fence above and below the T-track instructions on the next page.
#10 x %/8" Ph
sheet metal screw a.
Clamp block is
glued up from CLAMP BLOCK
two layers of X
!/2"-hardwood. 4!/4
Clamp base is Toggle L
#/4" plywood clamp 1


W !/4 !/8

!/2"-rad. 37

WS217_036.indd 37 2/4/2015 12:52:31 PM

Set up & use the MORTISING MACHINE
The easy-to-use controls on the mortis- When its time to rout the next part, just more about these bits.) You rout the mor-
ing machine make setting up and using slip it into place on the table, and youre tise in a series of several shallow passes
it quick to master. The various stops take ready to get started. usually no more than 14" for each pass.
the hassle out of routing identical mor- In use, the mortising machine works You remove a lot of waste in making a
tises. In fact, you will need to lay out a best with either a spiral bit or an end mill. mortise, so you may want to stop and
mortise on only one of the workpieces. (Take a look at the article on page 12 for vacuum the chips from time to time. W


1 2

Lay Out Mortise. Draw a complete mortise on one of your Set the Depth Stop. I mark the depth of the mortise on the
workpieces. You use this to adjust the table and set the stops end of the workpiece. Lower the router bit to the line and
on the mortising machine. position the nut on the depth stop at the post.

3 4

Align Table & Fence. With the workpiece against the fence, Set Right End Stop. Slide the table so the bit is directly over
use the mortise layout to adjust the table so that the bit is cen- the right end of the mortise. Move the pushbutton nut on the
tered on the mortise. Dont forget to lock the table in place. right side of the machine so its against the side of the post.

5 6

Set Left End Stop. With the bit over the left end of the mor- Position the Stop Block. Chances are you need to rout the
tise, set the stop nut on the left side in the same way. Now you same size mortise in multiple parts. Set the stop block on the
dont have to worry about overshooting your lines as you rout. fence to simplify and speed up the process.

38 Woodsmith / No. 217

WS217_038.indd 38 2/4/2015 12:53:54 PM

1 2

Secure the Workpiece. After following the steps Routing Mortises. Starting at one end of the mortise, plunge the bit
to set the stops and adjust the table, you can slip 8" to 14" deep into the workpiece and slide the table to the other end
the workpiece into place against the fence and stop. of the mortise. Lower the bit slightly and make a second pass. Repeat
The toggle clamp presses the workpiece against the this process until the carriage contacts the depth stop. Remove the part
fence and prevents it from shifting during the cut. and install another to continue making mortises.

Materials, Supplies & Cutting Diagram

A Base Bottom (1) 3 ply. - 18 x 26 T Fence Base (1) 3 ply. - 1214 x 22 (2) 3 8" ID x 3 4" OD Nylon Spacers
4 4
B Base Top (1) 3 4 ply. - 18 x 22 U Fence (1) 218 x 23 8 - 22 (6) #8 x 212" Fh Woodscrews
C Post Face (1) 3 ply. - 51 x 22 V Fence Stop Block (1) 3 x 21 - 21 (3) 5 16"-18 Pushbutton Nuts
4 2 4 4 4
D Post Outsides (2) 3 ply. - 8 x 22 W Clamp Base (1) 3 ply. - 6 x 6 (2) 5 16" x 3" Lag Screws
4 4
E Post Insides (2) 3 ply. - 71 x 22 X Clamp Block (1) 1 x 112 - 412 (1) 5 16" x 212" Screw Eye
4 4
F Router Carriage Back (1) 34 ply. - 812 x 10 (2) 5.625" x .563" OD Extension Springs
G Router Carriage Sides (2) 34 ply. - 23 4 x 10 (8) #8 x 3" Fh Woodscrews (2) 18" Full-Extension Slides w/Screws
H Router Mount (1) 214 ply. - 418 x 912 (10) 5 16"-18 T-nuts (1) 12" x 123 4 x 18" Aluminum Bar
I Router Clamp (1) 2 4 ply. - 2116 x 6716
1 (2) 5 16"-18 x 2" Eye Bolts (1) 24" T-Track w/Screws
J Handle Post Blocks (2) 112 x 114 - 212 (16) 5 16" Flat Washers (8) #8 x 112" Fh Woodscrews
K Carriage Post Blocks (2) 3 x 11 - 4 (7) 5 16"-18 Hex Nuts (1) 14"-20 x 114" Hex Bolt
4 4
L Depth Rod Block (1) 3 (3) 5 16"-18 x 24" Threaded Rods (1) 14"-20 Through Knob
4 x 2 - 3
M Arms (2) 3 x 11 - 171 (2) 5 16"-18 Through Knobs (1) 14" Flat Washer
4 8 2
N Arm Spacers (2) 3 x 13 - 11 (2) #8 x 2" Fh Woodscrews (4) 5 16"-18 x 13 4" Studded Knobs
4 16 4
O Arm Caps (2) 4 x 13 16 - 6 (2) 10" Full-Extension Slides w/Screws (2) 5 16" Fender Washers
P Handle Shafts (2) 1 x 1 - 95 (2) 3 8"-16 x 3" Hex Bolts (1) Toggle Clamp
2 8
Q 3
Sliding Table Bottom (1) 4 ply. - 12 x 22 (2) 3 8"-16 Hex Nuts (4) #10 x 5 8 Ph Sheet Metal Screws
R Sliding Table Top (1) 3 (2) 3 8" Flat Washers
4 ply. - 15 x 22
S Stop Blocks (2) 112 x 2 - 23 4 (2) 114" OD x 3 4" ID Washers

#/4"x 6"- 72" Maple (3 Bd. Ft.)



ALSO NEEDED: One 60"x 60" Sheet of #/4" Baltic Birch Plywood 39

WS217_038.indd 39 2/4/2015 12:54:27 PM

Every set of dining
room furniture needs
a great place for
storing dinnerware.
This elegant cherry
hutch provides the
perfect solution.
While a good table (surrounded by
a set of chairs) is the centerpiece of
any dining room, the hutch is the fur-
niture component that does most of
the heavy lifting. It serves as both
a storage cabinet for a variety of din-
nerware, as well as a display area for
your fine china and other dishes.
STORAGE WITH STYLE. At over four feet
wide and nearly seven feet tall, this
hutch serves that role quite nicely.
And the cherry construction, paired
with the glass panels on the doors
and ends of the upper cabinet,
means that it looks great doing it.
incorporates a wide range of wood-
working techniques. Youll be able
to knock out some of the elements,
such as the cabinets and face frames,
with pocket hole joinery. Other
assemblies, like the doors and the
back panels, make use of a cope and
stick joint thats easy to create using
a pair of bits at your router table. The
drawers are built using half-blind
dovetails that can be made with a
dovetail jig (photo, far right).
All in all, the result is a cabinet that
not only looks nice, but also serves as
a worthy complement to the table and
chairs built in Woodsmith No. 216.
Simply turn the page to get started.

40 Woodsmith / No. 217

WS217_040.indd 40 12/8/2014 3:39:16 PM

Construction Overview / OVERALL DIMENSIONS: 54 "W x 80"H x 19 "D 3

Cornice built up from

three layers and
Built-in puck screwed to upper cabinet
lighting illuminates
contents of
upper cabinet Side assemblies
made with cope
and stick joints and
feature glass panels

Upper cabinet
doors built
similarly to
the side assemblies

Upper shelves
incorporate a plate
rail and thick
glass panels

Base cabinet Upper and lower

top covered with cherry cabinets connected
veneer and surrounded with stacking plates
by profiled edging strips
Cabinet backs
are frame and panel
assemblies with
cope and stick joints

NOTE: Refer
to page 67
for hardware
Drawers feature
half-blind dovetails
and full-extension Bullnose molding
drawer slides for adds a decorative
easy access detail to bottom
Base cabinet doors of hutch
have cherry
plywood panels
captured in grooves Edged plywood
in the rails and stiles shelves rest
on shelf pins

Cabinet face
frames assembled
with pocket screws

< The two drawers

in the base cabinet
have cherry fronts
with maple sides
and backs. The
parts are joined
using half-blind
{ Glass panel doors are partially dovetails, with the
inset in the face frame. Its easy to front rabbeted to
cut the rabbets to fit the frame. form a lip. 41

WS217_040.indd 41 12/9/2014 9:55:38 AM

UPPER A a. Bottom face of
upper and lower dividers
#8 x 1!/2"
2 Fh woodscrew
10#/4 VIEW
17!/2 5!/2 2 19!/2
!/8"-dia. hole,
C !/4"-dia. hole, countersunk
VERTICAL #/8" deep 8 for #8 Fh woodscrew
2 19!/4 16!/2
33 1!/2 8
SIDE !/4" through- 16!/2 8 B

NOTE: All parts are c. C

#/4" plywood
16!/8 47#/4
A #/4" ply.

b. A !/2 #8 x 1!/2" Fh
#/4 woodscrew
6#/4 B
5!/2 B
C VIEW chamfer VIEW

Build the DADOES & DRILL. The rest of the machining youll drive pocket screws through these

BASE CABINET steps before assembling the cabinet are

pretty simple. Youll set up a dado blade
to cut a series of dadoes in the sides: Two
to attach the back and face frame.
CABINET ASSEMBLY. Glue and clamps take
care of joining the cabinet sides to the
Construction of the hutch begins with on the inside face and one on the outside upper and lower dividers. Just make
the base cabinet. Its main framework is face of each. Then drill holes for shelf sure to maintain the 12" spacing at the
made up of sides along with upper, lower, pins in the sides as shown. front and back (detail b). Finally, cut
and vertical dividers cut from cherry ply- Youll also drill countersunk holes in the the vertical divider to size and drill
wood. The sides and upper and lower upper and lower divider that are used to shelf pin holes. (These holes go all the
dividers can be cut to size now. Note secure the vertical divider with screws way through the panel.) Position the
that the sides are 1" wider than the other (detail c). Finally, drill a series of pocket divider, drill pilot holes into the panel
parts. This allows them to accept the back holes on the bottom faces of the upper ends through the countersinks, and
assembly and face frame later on. and lower dividers (detail a). Later on, secure it with screws.
FACE FRAME. As you can see in the
1!/4" pocket UPPER RAIL a. drawings at left, the cabinet face
E frame components are joined
with pocket screws. This simpli-
D 1 1!/2
fies assembly, but there are a few
4!/2 considerations to make as you
#/4 G
start to put it all together.
I started by cutting the outer
stiles to size, and rabbeting the
H outside edges (detail b). That
3 !/2 way, I could clamp the stiles to
the cabinet and measure between
H 4!/2 them to size the three rails.
After cutting the rails and the
18!/2 1
upper and lower stiles to size, I
33 FACE cut the taper on the bottom of the
LOWER RAIL !/8" chamfers outer stiles at the band saw (detail
G after assembly
3 a). Then I cut the centered groove
in the lower rail, and the matching
b. dadoes in the outer stiles. Make
TOP SECTION sure these line up with the dadoes
NOTE: All #/4" VIEW
42#/4 ply
parts are in the cabinet sides.
hardwood !/2 The next steps involve drill-
ing pocket holes and assembling
!/8" chamfer
42 Woodsmith / No. 217

WS217_042.indd 42 12/9/2014 2:02:47 PM

1!/2 43#/4 BACK
BACK 4#/4
5!/4 M
3 J #/4
19#/4 BACK 1
4#/4 OUTER
a. STILE !/4

Upper 3
rail 5!/2
L 5!/4 4!/2
ply. 12#/8 Q
PANEL BACK PANEL !/8" chamfers
panel 33 5!/4
16 c. TOP VIEW
SIDE 27!/8 #/4" !/2
Panels J
are !/4" NOTE: !/2 #/8 Rail
Middle J
plywood. Bevel !/4" ply.
rail profile
All other parts BACK LOWER RAIL
are #/4"-thick M faces
inside 3

the face frame. This is pretty Its made of solid cherry rails and the upper and lower stiles (refer to
straightforward, although and stiles with 14" plywood panels. the left drawing below). After that, use a
I did use a few spacers sized to match Like the face frame, start by cutting the rail to set the sticking bit for cutting the
the openings in the frame as I screwed outer stiles to size and rabbeting the edges grooves and bevels in all the parts (right
it together. In addition, I cut two keys (detail c). Clamp them in place and mea- drawing). Note that the middle rail and
and put them in place in the groove in sure for the three rails, accounting for the upper and lower stiles receive grooves
the lower rail and the dadoes in the outer stub tenons added to the ends of the rails. along both edges.
stiles to ensure theyd line up with one Then cut the rails and other stiles to size. COMPLETE THE BACK. As with the face frame,
another (refer to Shop Notes on page 65). COPE & STICK. The back assembly is joined youll cut a taper on the outer stiles and
Once the assembly was complete, I routed with cope and stick joinery. This joinery rout a chamfer on the edges. Theres
a slight chamfer on the outside edges and is formed using a pair of bits at the router also a small notch to accept the bullnose
bottom ends of the outer stiles. Then I table. The box below gives you the basic molding (detail b). After cutting the ply-
glued and clamped it to the cabinet and overview of the process. Its valuable to wood panels to size, assemble the back
drove in pocket screws to secure it. make some test cuts first with both bits with glue and clamps. Then all thats
BACK ASSEMBLY. The cabinet back is a frame until you get the settings just right. left is to glue and clamp the assembly to
and panel assembly designed to look Youll want to set up the coping bit first the back of the cabinet, and drive in the
great when the cabinet doors are open. to cut the tenons on the ends of the rails pocket screws to lock it in place.



Sticking bit
a. a.

#/8 #/8
Coping bit
(Sources, page 67) Rout groove in
all rails and stiles
(outer stile shown)

Coping Bit. Use the coping bit to cut the ends Sticking Bit. After setting the height of the sticking bit
of the rails and upper and lower stiles. A backer bit to cut a mating groove, rout the groove and
holds the pieces square as you cut them. bevel on the edges of all the parts with the bit. 43

WS217_042.indd 43 12/9/2014 2:03:03 PM

a. 1!/4"
pocket W slide
screws 16!/2
SUPPORT support
16" full-extension 5!/2
drawer slide Face
frame stile
1!/4" pocket
Face frame W
W TOP VIEW screw
upper stile

19%/8 16#/4
U 4!/4

NOTE: Inside S 21!/8
face of drawer
supports are 1!/4" knob
flush with edge Center slides T
of stiles on drawer sides T
NOTE: Drawer fronts and SIDE
supports are #/4"-thick DRAWER
hardwood. Drawer sides 4 FRONT
and backs are !/2"-thick DRAWER
hardwood. Drawer bottoms BOTTOM V
are !/4" plywood (16!/2" x 19!/8") c. !/2
Drawer VIEW
side !/2

Add the DRAWERS & TOP Drawer

!/4" ply.
With the basic cabinet complete, you setup different, but its not an uncom- !/8 2!/8

can set about adding some of the details mon task for a dovetail jig. !/2
that finish it out. And that starts with The first step, of course, is cutting the !/4
two drawers that fill the openings at the drawer fronts from cherry and the backs
top of the cabinet. and sides from maple. Theyre sized to
DOVETAILED DRAWERS. As shown in the accommodate the sides and create a the drawer parts, cut a groove near the
drawings above, the drawers are small gap above and below the drawers. bottom edge of all the parts to hold the
assembled using half-blind dovetail Then youll want to rabbet the perimeter drawer bottoms (lower middle draw-
joints. These joints are an easy task of the drawer front to form the lip, as ing). The groove is located on a tail on
using a dovetail jig and a router. But indicated in the lower left drawing. the sides, so its hidden once the drawers
theres an added wrinkle to the process After that, its a matter of cutting the are assembled. While youre at it, set up a
with these drawers. As shown in the dovetail joints using your jig. The jigs roundover bit in the router table, as shown
drawing below, the drawer front has a manual should walk you through the in the lower right drawing and rout the
lip around it, and then the dovetail pins process of routing the dovetails. Once decorative half-bullnose around the
are cut behind this lip. This makes the youve achieved a nice, clean fit between perimeter of the drawer fronts, as well.


back NOTE: Groove in drawer
front is &/8" from bottom Router table
fence Align top of cutter
!/2 !/4 T U with lip of drawer
Drawer #/8
front 1
!/4 S
!/2 !/2"
!/2 bit

Groove for Bottom. After cutting Half-Bullnose. Form the profile on the
the dovetails, set up a dado blade to drawer front by routing with a roundover
cut a groove in all the drawer parts. bit around the perimeter.

44 Woodsmith / No. 217

WS217_044.indd 44 12/9/2014 2:03:36 PM

NOTE: Top is #/4" plywood.
Edging is 1"-thick hardwood. a.
Fillers are !/4"-thick hardwood
Y Cherry veneer
1!/2 Back
49#/4 Top
16!/4 edging Veneer
52#/4 Front
NOTE: Edging edging
profile routed TOP
after veneer 49#/4 VIEW
is applied Y
13#/4 EDGING

Y X Y 1

1!/2 1!/4 1!/2

After the bottom panels have been cut to the edging strips, and then the profile is !/4 Z
final size from plywood, youll be ready routed on both the edging and the veneer.
to assemble the two drawers. This creates a seamless look between
INSTALLING THE DRAWERS. To allow the draw- the edging and veneer. Also, the edg- easy to apply. You simply cut the veneer
ers to slide in and out of the cabinet, I ing is thicker than the top panel that its sheet slightly oversize, and then apply it
needed to add four drawer supports. glued around. This gives the top a beefier using contact adhesive and a roller. Roll
These are nothing more than pieces that appearance that looks great in the finished from the center out to smooth and adhere
are cut to size and installed at the top of project. However, I also needed the top to the veneer to the panel below it.
the cabinet with pocket screws (details sit flat against the cabinet, so I added thin Once the adhesive has dried, a simple
a and b, opposite page). After that, filler strips to make sure the edging sat routing sequence will complete the top
its time to install the drawers using full- flush with the cabinets top edges. assembly. The sequence starts with trim-
extension drawer slides. See page 18 for a MAKING THE TOP. Despite all this, making ming the veneer flush with the edging
helpful article on installing them. the top assembly isnt difficult. Start using a flush-trim bit.
CABINET TOP. With the drawers in place, by cutting the top panel to size, then The other two routing steps are shown
its time to close off the top of the cabinet cut and glue the edging strips around in the box below. First, position the top
with a top panel. Its simply a plywood it (detail a). Next, plane down some assembly face up, and rout around the
panel with decorative veneer on top and stock for filler strips to rest flush with sides and front with a 12" roundover
profiled edging strips glued around it. the edging on the underside of the top bit. Then flip the top over, and use a 14"
There are a couple of interesting things panel. Finally, cut and glue these strips roundover bit to complete the profile.
that I want to point out about the top to the underside of the top (detail b). With the top assembly complete, you
before you get started. For one, youll note Now its time to add the veneer. I used can position it above the cabinet and
that the veneer is actually applied over a paper-backed veneer (page 67), which is attach it using glue and clamps.




Edging Veneer
bit Riser block !/4"
Side Front roundover Veneer
edging edging bit

EdgingFrame& Veneer.
& Cleat.After
up on the edging Top Profile. With the top facing up, rout Bottom Profile. Flip the top
a veneer
and cleat,
to rough size and adhere the sides, and then the front edge, using panel over and complete the
to thetotop
using contact adhesive. a 12" roundover bit in a hand-held router. profile with a 14" roundover bit. 45

WS217_044.indd 45 12/9/2014 2:03:49 PM

are identical SHELF DOOR
(11#/4" x 15!!/16") UPPER

9#/4 a.
BB 2!/2
(11#/4" x 30&/16") DD 9#/4
1!/4" SIDE VIEW Edging
(cut to fit) 19
HH 14!/2
MOLDING 11 Bullnose
(miter to fit) molding #/4

F F !/2
#/8" overlay DOOR
with the same cope and stick joints used
c. Face frame on the back. Each door features rails
Hinge lower stile
with coped ends joined to stiles with a
mating groove. A plywood panel fits in
NOTE: Shelves are #/8 the groove. The difference here is that
#/4" plywood. Panels
are !/4" plywood. Edging the bevel profile is on the outside face.
is !/4"-thick hardwood.
Other parts are NOTE: Cut rabbet #/8 After cutting the door parts to size, you
#/4"-thick hardwood around perimeter
of door to fit opening TOP VIEW can create the joinery using the same pro-
cedure shown in the box on page 43. Then
assemble the doors with glue and clamps.
Install the DOORS & SHELVES The last cuts to make on the doors are
rabbets along the back edges to fit the
Youre just about finished with the base left drawing). After that, simply rip the openings in the face frame and a rounded
cabinet. The mating dadoes and grooves molding strips to width. Measure and profile on the front. These steps are shown
near the bottom of the cabinet are filled miter the molding strips to fit around the in the lower left and middle drawings
with decorative strips of hardwood cabinet, as shown in the main drawing. below. Then youre ready to mount the
molding. The molding features a bull- SHELVES. Perhaps the simplest parts of doors into the face frame on no-mortise
nose profile on the outside edge. this cabinet to make are the two shelves. overlay hinges (refer to detail c above).
To make the molding, youll want to Thats because theyre nothing more FINISHING TOUCHES. At this point, youre
thickness stock to fit the dadoes and than pieces of plywood with solid-wood just about ready to turn your attention to
grooves, and then cut some blanks edging strips glued to the front. They sit the hutchs upper cabinet. But you can
that are extra-wide and extra-long. The inside the cabinet on shelf supports. take some time now to apply stain and
next step is to head to the router table, DOORS. After building the cabinet back finish to the components of the base cab-
where youll rout both edges to form assembly, the three cabinet doors should inet. Youll find all the finishing informa-
the bullnose profile (refer to the lower be familiar territory. Theyre assembled tion you need on page 67.


Fence Bullnose rip
molding fence Align top of cutter
!/2 #/8 with edge of rabbet

Waste Align
top of Door
cutting edge
w/centerline #/8 Door

!/2" roundover Dado !/2" roundover

bit blade bit

Bullnose. Two passes along the bullnose Rabbet. Rabbet the door with a dado Profile. Use a roundover bit at the
molding blank take care of the profile. blade buried in an auxiliary fence. router table to rout the door front.

46 Woodsmith / No. 217

WS217_046.indd 46 12/9/2014 10:46:23 AM

Materials, Supplies & Cutting
Diagram for Base Cabinet
A Base Cabinet Sides (2) 34 ply. - 1712 x 33
B Upr./Lwr. Dividers (2) 34 ply. - 1612 x 473 4
C Vertical Divider (1) 4 ply. - 1612 x 1914
D Face Frame Outer Stiles (2) 4 x 3 - 33
E Face Frame Upper Rail (1) 4 x 1 - 423 4
F Face Frame Mid Rail (1) 34 x 112 - 423 4
G Face Frame Lower Rail (1) 34 x 3 - 423 4
H Face Frame Lower Stiles (2) 34 x 112 - 1812
I Face Frame Upper Stile (1) 34 x 112 - 412
J Back Pieces.
Frame Outer Stiles (2) the
Clamp x 3 - 33 A table saw
4Miters. Base.makes
The base cabinet
Cleats.of Thethecleats
hutchare glued in place
K Backpiece
frame UpperinRail (1)
position on 4 x 11quick
2 - 433work
4 of the
makeson a great
the frameunit.and bottom rail
the tables bottom rails. 3 the 3
ends of each shelf cleat. pieces.
L Back Middle Rail (1) 4 x 3 - 43 4
M Back Lower Rail (1) 4 x 514 - 433 4 X Cabinet Top (1) 3
4 ply. - 1614 x 493 4
N Back Upper Stile (1) 3 1 3
4 x 5 4 - 4 4 Y Top Edging 1 x 112 - 150 rgh. (6) #8 x 112"Fh Woodscrews
O Back Lower Stile (1) 3 1
4 x 5 4 - 16 Z Top Filler Strips 1 1
4 x 1 4 - 140 rgh. (54) 114" Pocket Screws
P Wide Lower Panel (1) 14 ply. - 2718 x 16 AA Bullnose Molding 3
4 x 12 - 90 rgh. (2 prs.) 16" Full-Extension Drawer Slides
1 3
Q Narrow Lower Panel (1) 4 ply. - 12 8 x 16 BB Long Shelf (1) 3 3 7
4 ply. - 11 4 x 30 16 (7) 114" Antique Brass Knobs
R Upper Panels (2) 1 3 3
4 ply. - 19 4 x 4 4 CC Short Shelf (1) 3 3
4 ply. - 11 4 x 15 1611 (3 prs.) 3 8" Overlay Hinges
S Drawer Fronts (2) 3 1
4 x 5 - 21 8 DD Shelf Edging 1 3
4 x 4 - 50 rgh. (8) 14" Shelf Supports
T Drawer Sides (4) 1 x 41 - 163
2 4 4 EE Door Upper Rails (3) 3 x 21 - 93
4 2 4 (1) 24" x 96" Sheet Paper-Backed Veneer
U Drawer Backs (2) 1 x 414 - 195 8 FF Door Lower Rails (3) 3 x 3 - 93 4
2 4
V Drawer Bottoms (2) 1 ply. - 1612 x 1918 GG Door Stiles (6) 3 x 212 - 19
4 4
W Drawer Supports (4) 3 x 51 - 161 HH Door Panels (3) 1 ply. - 9 3 x 141
4 2 2 4 4 2

#/4"x 7!/2" - 84" Cherry (4.4 Bd. Ft.)


#/4"x 7!/2" -96" Cherry (5 Bd. Ft.)
FF FF FF 48" x 96" Sheet of
#/4" Cherry Plywood,
K E One 48" x 48" Sheet
of #/4" Cherry Plywood,
#/4"x 6!/2" - 96" Cherry (4.5 Bd. Ft.) and One 48" x 96" Sheet
J L of !/4" Cherry Plywood

#/4"x 7!/2" - 96" Cherry (5 Bd. Ft.)

#/4"x 5!/2" - 48" Cherry (1.8 Bd. Ft.)
!/4"x 4" - 72" Cherry (2 Sq. Ft.)

!/2"x 5" - 48" Hard Maple (1.7 Sq. Ft.) !/2"x 5" - 72" Hard Maple (2.5 Sq. Ft.)

1"x 4" - 84" Cherry (3 Bd. Ft.)

Y 47

WS217_046.indd 47 12/9/2014 10:46:56 AM

2!/4"-dia. holes
hole (for
puck light)

Assemble the TOP




Since the hutchs upper cabinet is 3!/2 Top

enclosed by glass on three sides, its Side
built a little differently than the base frame
cabinet. However, it does share many #/8 D
similar features that Ill point out as the D
construction process unfolds.
Like the base cabinet, the upper cabinet SECTION
NOTE: Top VIEW #/8
is enclosed on the top and bottom with and bottom are
3 #/4" plywood. C
4" plywood. But the sides are frame and 42
Other parts are
panel assemblies with glass panels. #/4"-thick hardwood
TOP & BOTTOM PANELS. As before, you can
start by cutting the plywood top and SIDE BOTTOM !/2 A
bottom to size. Then drill pocket holes RAIL BOTTOM
on the top face of the top panel and C
the bottom face of the bottom panel,
as well as three larger holes for puck Top panel
lights in the top panel (detail b). Next 1#/4
2!/2 8#/4
up is sizing the rails and stiles that will
form the side assemblies. 4 8#/4
SIDE ASSEMBLIES. By now, youre probably VIEW

familiar with the joinery used to con-

1!/4" pocket 2!/4"-dia.
nect these rails and stiles to one another. to fit the glass. This is easy to accomplish screw hole
Theyre made with the same cope and with a rabbeting bit, as shown in the
stick router bits that are shown on page lower left drawings. As you rout around
43. So youll set up and rout the ends of the perimeter of the frame, youll end !/2
the rails and the edges of all the parts up with rounded corners, but its easy
just as you did for the base cabinet back to square these up using a sharp chisel
assembly and doors. After that, the sides (lower right drawing). well as the bottom. You can use spacers
are ready to assemble. ASSEMBLE THE CASE. You wont be adding to position all the panels properly before
The base cabinet back and doors fea- the glass to the frames until later on in you glue and clamp them together. Then
ture plywood panels captured in the the project, so nows the time to join the drive in pocket screws to lock the sides
grooves of the rails and stiles. Here, how- top and bottom panels to the side assem- tightly to the top and bottom panels.
ever, youll need to add glass to openings blies. Note that the sides overhang the FACE FRAME. At this stage, things will
in the frames. And that requires a rabbet panels by a 12" at the front and back, as start to seem a little more familiar when



Center bearing D
on edge of groove
Rout clockwise !/2
using a rabbeting bit a.

Rabbet. After gluing up the side assemblies, youll need to rabbet the frame to accept Chisel. After the rabbet is complete,
panes of glass later on. This is easiest to accomplish with a hand-held router equipped use a sharp chisel to pare the rounded
with a rabbeting bit. Set the bearing to run along the inside edge of the frame. corners of the frame square.

48 Woodsmith / No. 217

WS217_048.indd 48 12/9/2014 2:04:53 PM


43#/4 Face
G 13!/4 3!/2 frame
FRAME 1!/4" pocket
RAIL screw
42 39!/2 VIEW NOTE: Bevel profile
1!/2 I
F L faces inside

35!/2 !/8" chamfer

L 2!/4
G PANEL outer stile
42 bottom
13#/4 !/2

Face frame
lower rail

NOTE: Back panels K

are !/4" plywood. BACK
All other parts are BACK LOWER RAIL Like the base cabinet back, the outer
#/4"-thick hardwood OUTER
STILE stiles are rabbeted on the edges first, and
4 then the joints in the rails and stiles are
cut at the router table (refer to page 43).
compared to the base cabinet. Thats the outer stiles first, just as before. Then The plywood panels are simply cut to
because the face frame is composed of measure between them to determine the size to fit between the grooves in the rails
a series of rails and stiles assembled length of the other parts, cut them to size, and stiles. The sides are also chamfered
with pocket screws, just like the base and join the entire assembly together just like before (detail a).
cabinet face frame. using glue and pocket screws. ENCLOSE THE CABINET. With both the face
In fact, as you can see in the drawing BACK ASSEMBLY. The back assembly should frame and the back assembled, its time
above, this frame is simpler, with two also be looking familiar at this point to add them to the cabinet. The rabbets at
outer stiles, two rails, and two inner stiles. rails and stiles joined with cope and stick the edges of the two assemblies should
Youll want to rabbet the outside edges of joinery that surround plywood panels. fit right over the sides with glue and
clamps holding them in place. Finally,


drive pocket screws through the top
and and bottom panels and into the face
frame and back rails to really lock the
NOTE: whole assembly together.
NOTE: all holes SHELF SUPPORT HOLES. If you look at the
Holes #/8"-dia. 2
on visible holes drawings above, you may notice one
in face parts of 2
frame #/8" stiles detail that I left out that usually would
match bit
those have been taken care of by this point.
shown a. And thats the shelf support holes. This
on back #/8"-dia.
shelf support time, because of the glass on the cabinet
sleeve sides, I drilled the holes in the stiles of
2 the face frame and back assembly.
#/8"-dia. I also waited until after assembly to
hole, #/8" 2
deep 23!/2 drill all the holes. Thats because it was
!/4" shelf
Position support easier to ensure alignment between each
on bottom set of holes by using a hardboard tem-
plate rather than the drill press, as shown
Drill for Shelf Supports. To drill the shelf support holes in the in the box on the left. After drilling all the
face frame and back stiles, I used a template and a hand drill. holes, I installed shelf support sleeves in
The shelf support sleeves are press-fit into the holes. each of them to create a nice look since
these holes are much more visible. 49

WS217_048.indd 49 12/9/2014 2:05:06 PM


a. #/16 !/4
M !/16


are identical BACK RAIL O
M 14#/8

NOTE: All parts Glass 2

are #/4"-thick (!/4" x 10"- 43#/8")

plate 1%/8
with 46#/4

b. Connect
SIDE RAIL N cabinets with
(2" Wide Overall) stacking
SHELF plates


BUILD THE SHELVES. The shelves require a

Bring in the few cuts to complete, but theyre not

difficult. After cutting the front, back,

SHELVES & DOORS and side rails for each shelf to size, the
first order of business is to cut a rab-
bet along the inside edge of each rail to
With the basic framework of the upper GLASS SHELVES. The solution I arrived at hold the glass. This was easy to accom-
cabinet complete, the shelves are the is shelves with glass panels surrounded plish by burying a dado blade in an
next order of business. And since the by wood rails on all sides. The glass auxiliary rip fence. The dimensions are
upper cabinet is a decorative space to allows the light from the top to filter shown in detail a above.
display fine dinnerware, it needs a little down through the entire cabinet. Next up, you can move to the router
different treatment for the shelves than table to transform the back rails into dec-
just simple plywood panels with hard- 3 orative plate rails for displaying plates.
wood edging strips. To do this, youll use a core box bit, as
!/2 shown in the far left drawing. Carefully

How-To: BUILD SHELVES Side rail

reset the router table fence after cutting
a groove on each back rail.
(back end) Finally, youll cut the lap joints on the
ends of the rails in order to join them
together. These are shown in the draw-
Side rail !/2 ings, near left. The laps on the side rails
(front end)
Back rail
are cut to the same depth as each other,
1!/4 #/4
but the lap on the back is wider than
a. END the one on the front to accommodate
#/16 the plate rail (refer to the top two draw-
ings). Then you can lower the blade to
cut the mating lap on the front and back
#/8" core Front/
box bit rails (lower drawing). In all cases, make
back rail
(face down) !/4 some test cuts until you get it just right.
Then the shelf frames can be assembled
Coves. The shelf back rail is transformed Laps. A dado blade handles the and set aside for now.
into a plate rail by routing two coves with lap joints. Cut the shoulders UPPER CABINET DOORS. Cope and stick join-
a core box bit at the router table. first and work toward the ends. ery is a common theme throughout this
dining room hutch project. (Youll find

50 Woodsmith / No. 217

WS217_050.indd 50 12/9/2014 2:05:49 PM

a. !/4 U
DOOR TOP RAIL TOP RAIL FILLER NOTE: Center door has no fillers,
P S knobs, or hinges and is
13#/4 2!/2 glued to face frame
Glass U
(#/32" x
!/2 11#/8" -
NOTE: Secure
stops with U
#/4" brads GLASS
the basic overview on page 43.) And the to fit) #/8"overlay
Glass hinge
upper cabinet doors are the last compo- (#/32" x
9%/8" -
nent of the hutch that uses this joinery 35#/8")
method. After cutting the rails and stiles
for the three doors, youll complete the
joinery just as before routing the stub
tenon on the ends of the stiles, and then
cutting a mating groove in all four parts. 1!/4"
Then join the frames together.
These doors have glass panels just
like the cabinet sides, so the next steps
involve rabbeting the back of the frame 3

to accommodate the glass. Youll find the

details for doing this in the drawings at
the bottom of page 48. DOOR BOTTOM
REINFORCED DOORS. I wanted to add a little Q
strength to the two outer doors to sup- 2!/2 NOTE: Rails
DOOR and stiles are
port the glass panels. So I added another STILE 3 #/4"-thick
detail to reinforce the doors. As you can hardwood.
2!/2 Stops are
see in the drawing above, I glued on filler !/4"-thick and
strips that cover both the rails and the NOTE: Refer to
fillers are
T !/8"-thick
ends of the stiles at the top and bottom of page 65 for technique
BOTTOM hardwood
on adding filler strips
each door. The result is a much stronger RAIL FILLER
door. You can find the full instruction for
building these reinforced doors in Shop b. TOP SECTION VIEW
Notes on page 65. Face frame !/2" rabbets
COMPLETING THE DOORS. Like the doors #/8 middle stile
on the base cabinet, these doors are
partially overlaid in the openings in Middle
the face frame. This involves cutting #/8
a rabbet around the outside edges of Refer to Right
page 46 to door
each door frame, as well. For this cut, rout profile
simply use a dado blade buried in an
auxiliary rip fence at the table saw. The
dimensions are shown in detail b. doors, and the shelves. Before installing the base cabinet. And the hinges are
Finally, theres a rounded profile on the glass, separate the two cabinets and the same, too no-mortise hinges
the outside edges of each door, too. Its then stain and finish all the components that are specifically designed for
easy to cut this profile as shown in the of the upper cabinet (Sources on page 67). doors with a 38" overlay. As you get
lower middle drawing on page 46. The glass in the shelves simply rests ready to install them, just be sure that
The middle door of the cabinet is in the rabbets once the frames are in the outer doors are aligned with the
fixed in place in the face frame. So you place, but its secured in the doors and middle, fixed door.
can glue and clamp it into position now, sides with thin strips of glass stop. You STACKING PLATES. With both cabinets
before adding the glass. can cut these to size, stain and finish stained and finished, you can set the
GLASS & HARDWARE. Youre almost ready them, and secure them carefully behind upper cabinet above the base cabinet to
to put all the components of the upper the glass with small brads (detail a). check your progress. I used the stacking
cabinet together. Nows a good time to The two outer doors feature a small plates that are shown in detail b on the
obtain the glass for the cabinet sides, the knob thats the same as the doors on previous page to connect them. 51

WS217_050.indd 51 12/9/2014 2:06:15 PM

NOTE: Cornice molding is
a. 1!/4" pocket screw 1"-thick hardwood. Other
parts are #/4"-thick Y
Molding side X hardwood
1!/2 1
#8 x 1!/4" Fh V
woodscrew Y
Puck VIEW 48#/4
light W W
Cabinet top


Completing the 16!/4



At this point, the dining room hutch bottom and routing the profile on the Y
W 2!/4
is nearing completion. All thats left front edges. (Its the same as the profile
is a three-layer cornice assembly that on the bullnose molding thats shown
tops off the upper cabinet. Then youll on page 46.) Then miter the pieces to fit !/2"-rad. V
(refer to
be ready to add lighting and move the at the front as shown above, and cut the page 46) 3
hutch into your dining room. back piece to size to fit between the sides.
CORNICE ASSEMBLY. A project this involved Drill countersunk holes in all the parts That just leaves the cornice molding at
needs a worthy crowning touch at for attaching them above the cabinet, and the top. Theres nothing too complicated
the top, and the cornice assembly fills then glue and clamp the frame together. here, but its important to note that the
this role nicely. Its a three-layer sand- Next up is the cornice wall, which roundover on the bottom edge of the
wich made up of a bottom, wall, and is made up of three pieces that are molding is different from the roundover
cornice molding at the top. mitered to fit above the cornice bottom. on the top. Also, youll want to make the
You can start at the bottom of the cor- Simply cut them to size, miter them to cuts with a hand-held router after assem-
nice and work your way up. Begin by fit, and glue and clamp them in place bling the three parts, so the roundovers
cutting some extra-long pieces for the above the cornice bottom. transition smoothly between them. The
drawings at left show you how its done.

How-To: ROUNDOVERS After that, though, its simply a mat-

ter of gluing and clamping the mold-
ing assembly to the top of the cornice
wall. Stain and finish the entire cornice
assembly, and then attach it to the upper
NOTE: Rout cabinet with woodscrews.
ends first,
then front edge FINISHING TOUCHES. If you know someone
who owes you a favor, now is a good time
to call them up. Moving the hutch from
Bottom face of
cornice molding Top face of the shop to the dining room is a bit of a
cornice molding chore. Its best to move the two cabinets
separately, and then reconnect them with
!/2" roundover #/8" roundover stacking plates, as shown on page 50.
bit bit
Once its in place, you can wire up the
puck lights and slip them in place at the
Bottom Edge. After assembling the Top Edge. Flip the molding over, top of the upper cabinet. Then its time to
cornice molding front and sides, rout a switch to a smaller roundover bit, and start loading up the hutch with all your
roundover around the bottom edges. complete the profile on the top edge. best dishes. The project is sure to be an
elegant addition to any dining room. W

52 Woodsmith / No. 217

WS217_052.indd 52 12/10/2014 10:13:39 AM

Materials, Supplies & Cutting Diagram for Upper Cabinet
A Top/Bottom (2) 4 ply. - 1412 x 4714 N Shelf Front Rails (2) 3
4 x 2 - 463 4 (44) 114" Pocket Screws
B Side Top Rails (2) 4 x 312 - 1112 O Shelf Side Rails (4) 3
4 x 2 - 143 8 (48) Shelf Support Sleeves
C Side Bottom Rails (2) 4 x 4 - 1112 P Door Top Rails (3) 3
4 x 212 - 93 4 (16) 14" Shelf Supports
D Side Stiles (4) 4 x 212 - 42 Q Door Bottom Rails (3) 3
4 x 3 - 93 4 (2) 114" Knobs
3 3
E Face Frame Outer Stiles (2) 4 x 3 - 42 R Door Stiles (6) 4 x 212 - 40 (6) 3 8" Overlay Hinges
F Face Frame Mid Stiles (2) 4 x 112 - 3912
3 S Top Rail Fillers (2) 1
8 x 2 - 133 4 3
4" Brads
G Face Frame Rails (2) 4 x 114 - 423 4 T Bottom Rail Fillers (2) 1
8 x 212 - 133 4 (1 pr.) Stacking Plates w/screws
3 1
H Back Outer Stiles (2) 4 x 3 - 42 U Glass Stop 4 x 12 - 480 rgh. (2) 14" x 10" - 433 8" Glass
I Back Middle Stiles (2) 4 x 214 - 3512 V Cornice Bottom 3
4 x 3 - 140 rgh. (2) 3 32" x 113 8" - 353 8" Glass
J Back Upper Rail (1) 4 x 312 - 433 4 W Cornice Wall 3
4 x 214 - 90 rgh. (3) 3 32" x 95 8" - 353 8" Glass
K Back Lower Rail (1) 4 x 4 - 433 4 X Cornice Molding Front (1) 1 x 23 4 - 543 4 (14) #8 x 114" Fh Woodscrews
L Back Panels (3) 4 ply. - 133 4 x 3512 Y Cornice Molding Sides (2) 1 x 33 4 - 1514 (3) Puck Lights
M Shelf Back Rails (2) 4 x 3 - 463 4

#/4"x 5" - 96" Cherry (3.3 Bd. Ft.)


#/4"x 6" - 96" Cherry (4 Bd. Ft.)

D tt D

#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)


#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)


#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)


#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)


#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)

#/4"x 7" - 96" Cherry (4.7 Bd. Ft.)


1" x 7" - 60" Cherry (3.6 Bd. Ft.) !/8"x 5" - 36" Cherry (1.3 Sq. Ft.)

!/4 "x 4" - 48" Cherry (2 Boards at 1.3 Sq. Each) ALSO NEEDED:
U One 48" x 48" Sheet of #/4" Cherry Plywood,
One 48" x 48" Sheet of !/4" Cherry Plywood 53

WS217_052.indd 53 12/9/2014 3:36:16 PM

workin ls
with too

tuning up your
Drill Press
The drill press is one of the unsung much about it. But like any machine in The bearings can be checked by remov-
heroes of the workshop. You expect it the shop, a little maintenance goes a long ing the belt and turning the shaft of the
to excel at its main function of drilling way to help ensure consistently good motor by hand. If you notice any side-
straight, clean holes in wood and metal. performance. Fortunately, a drill press is to-side play or if the shaft doesnt rotate
When everything is working just right, a pretty simple machine. A motor drives with a smooth motion, the bearings may
you get great results and dont think pulleys, which in turn spin a shaft inside be worn. You can usually replace the
the quill to rotate a bit in the chuck. Here bearings yourself. If youre not comfort-
are some tips for keeping those parts able doing it yourself, another option is
humming along year after year. taking the motor to a repair shop.
START WITH THE MOTOR. It goes without say- While youre having a look at the
ing that the hardest-working part of a motor, take some time to use a shop vac-
drill press is the motor. Now, theres not uum to remove any dust and debris. Its
a lot that can go wrong with a motor, so important to keep the cooling vents clear
its usually not a concern. But there are a of dust. If a vacuum doesnt do the trick,
couple of things to be aware of. try using compressed air.
First of all, pay attention to how much CHECK THE BELTS & PULLEYS. With the belts
noise the motor is making. It should run removed, give them a once-over too.
smoothly and quietly without complain- Check for any cracking or fraying, as
ing. If you notice excessive noise like rat- shown in the photo at left.
tling or grinding, however, its time to Theres something else to watch for
{ Check the drive belts for wear and tear. If investigate the cause. It could be a sign when inspecting the belts. Some old
you see any signs of cracking, fraying, or that the bearings are worn or one of the V-belts can develop a memory if left
splitting, its time to invest in new ones. pulleys is damaged. tensioned on a pulley for extended

54 Woodsmith / No. 217

WS217_054.indd 54 12/10/2014 12:07:45 PM


{ To ensure the table is square to the quill, use a bent wire. Rotate the { After removing any rust with an abrasive, apply a protective coating
chuck by hand to ensure the wire contacts the table all around. For of rust inhibitor or wax. This is especially important if youre shop is
a more high-tech solution, refer to the bottom of page 8. unheated or you live in a humid climate.

periods of time without being used. The automotive parts supplier or hardware I like to shoot for about 12" of flex, as
belt conforms to the shape of the pulley store to ensure you get the right size. shown in the middle photo at left. On
and loses some flexibility. This can cause LINK BELTS. If you want the ultimate in most drill presses, adjusting the tension
a thumping sound as the belt rotates smooth operation for your drill press, means sliding the motor and its mount-
around the pulleys. The result is vibra- invest in link belts, as you can see in ing plate forward or backward.
tion that ultimately translates to rough the main photo on the opposite page. The mounting plate is attached to two
drilling. If you find any signs of exces- Theyre more expensive than traditional rods that slide into the drill press casting.
sive wear, its time to invest in a new V-belts, but go a long way to smoothing Loosening a clamp lever allows you to
belt. Take the old one with you to an out the vibration. They wont develop a make this adjustment (lower left photo).
memory as they age and they can If you find the motor doesnt budge, tap
be made any length you need. the mounting plate with a rubber mal-
2" deflection CHECKING THE PULLEYS. Before you let or a block of wood. This would be
is ideal
install the belts, inspect the pul- a good opportunity to wipe or spray a
leys for damage. Make sure each light lubricant on the rods to allow them
of the flanges on the stepped to slide easily any time you need to make
pulleys are straight. Any bends, adjustments to the belt tension.
cracks, or nicks in the flange will On drill presses with three pulleys, the
wear the belts prematurely. center one moves slightly to allow ten-
If you find that the pulley is sioning of the front belt. As you tighten
damaged, you have a couple of the rear belt, check to make sure the front
choices. You could simply avoid one also has the right amount of tension.
placing the belt on the damaged SQUARING THE TABLE. Now that youve
area of the pulley. The problem addressed any issues with the drive
with this is that it limits the adjust- train, you can close the housing over
ments available for setting the the belts and turn your attention to
speed of the drill chuck. the table. The first order of business is
Another solution is to replace adjusting it square to the quill. In the left
the pulley. You can usually find photo above, Im using a stiff wire bent
parts from the manufacturer into a Z shape. With it chucked in the
online. Just make sure that the pul- drill, rotate the shaft by hand and check
ley diameters on the new pulley that the bottom end of the wire contacts
match those on the old one. the table in all positions. If not, adjust
PROPER TENSIONING. After inspect- the angle of the table and recheck it by
ing the belts and pulleys, re- rotating the chuck 360.
install the belts. When doing this, CLEANING THE TABLE. While tending to
its important to have the right the table, spend some time cleaning it
amount of tension. Too much (photo above). Remove any rust with
tension and you can strain the an abrasive and apply your favorite rust
{ Adjusting for proper belt tension (upper photo) bearings on the pulley shafts. Too inhibitor. This is especially important if
means sliding the motor mount forward or back. A little tension and the belt can slip you use an auxiliary table, which can
clamp lever (lower photo) allows this adjustment. on the pulley. trap moisture underneath. 55

WS217_054.indd 55 12/1/2014 1:30:25 PM

{ You can easily check for runout in the chuck by using a dial { If the overall runout is significant, youll want to remove the
indicator with a magnetic base. A precisely ground piece of drill rod chuck and check the runout on the arbor or shaft where the chuck
serves as a good reference for checking overall runout. mounts. If the runout is minimal, its time to replace the chuck.

The next few tune-up tips I want to talk bit, sometimes called runout. The first In the photos above, Im using a dial
about go a little deeper into the mechan- and most obvious place to check is the indicator for this task.
ics of your drill press. This includes bit itself. If the bit isnt straight to begin The first thing to do is chuck a straight
making sure the chuck and drill bit run with, youre better off tossing it and buy- object in the chuck. Here, Im using a
straight and true without wobbling. And ing a replacement. Simply switching bits short length of drill rod. After making
you can give the rack and pinion gears on in the chuck can tell you if the problem sure the rod is centered and tight in the
the table mechanism a little attention, too. is with the bit or if theres a deeper issue. chuck, rotate the chuck slowly by hand
CHECK THE BIT. A drill press isnt much use If switching out the bit doesnt seem to and watch the needle on the dial indi-
if it cant drill a precise hole. If the end fix the problem, check to make sure that cator. Anything less than 0.005" of total
of the bit is wobbling from side to side the bit is centered in the chuck. Some- runout is acceptable for a woodwork-
as the chuck spins, it can be difficult to times, as youre tightening the chuck, the ing drill press. If theres more than that,
accurately start the hole. Plus, a wob- bit will get caught between two of the its time to take a closer look at the drill
bling bit often results in an oversized jaws instead of being gripped by all three. chuck. (Note: Youll want to place the
hole, especially in wood. CHECK FOR RUNOUT. If you know the bit dial indicator close to the chuck to avoid
Fortunately, its fairly straightforward is straight, then you need to dig a little exaggerating the error.)
to track down the cause of a wandering deeper to find the source of the runout. REMOVE THE CHUCK. As simple as the
mechanics of a drill chuck are, they can

Replacement Chuck: BY THE NUMBERS still wear out over time. And this may
lead to inaccuracies when drilling. To
eliminate the chuck as the source of
Finding a replacement chuck for runout, you need to remove it from the
your drill press may be as simple as arbor. How you do this varies with the
looking at the numbers. Most drill make and model of drill press, so youll
chucks are stamped with a model want to consult the owners manual or
number, Jacobs taper number (33, in contact the manufacturer.
this case), and the capacity. There are two common methods used
With these numbers in hand, you for removing a drill chuck. Theyre
can find a suitable replacement. shown at the top of the opposite page.
You can find replacement chucks One method makes use of a tapered,
online or at a well-equipped hard- steel drift pin. This procedure is used for
ware store or machinists supply. a chuck that is mounted to an arbor that
has a taper at each end. The chuck fits
< The numbers stamped on your old drill onto a short Jacobs taper. A No. 33 Jacobs
chuck should give you enough taper is a common size.
information to get a replacement. The opposite end of the arbor fits into
a Morse taper socket in the quill. You can

56 Woodsmith / No. 217

WS217_056.indd 56 12/1/2014 1:30:57 PM

see what the arbor looks like in the left
photo at the bottom of the page.
Removing this style of arbor is shown
at right. Insert the appropriate sized drift
pin into a slot in the quill. The size of drift
pin is based on the size of Morse taper (0
through 7). Most drill presses up through
2" capacity use a No. 2 Morse taper. Sim-
ply tap the end of the drift pin until the
arbor drops free from the quill.
Other drill press models may have
their chucks mounted directly to the end
of the drill press shaft. They use a Jacobs
taper, as well. To remove the chuck on
this style of drill press, youll need a pair < Use
U e a drift
Us d if pin to remove
of wedges as shown in the lower pho- the arbor and chuck
tos at right. Use a C-clamp to force the assembly from the quill.
wedges together to remove the chuck. A
few light taps with a hammer will also
work to drive the wedges together.
removed, clean the end of the arbor or
shaft with solvent (left photo below).
For a Morse taper socket, twist a rag
dampened with solvent into the socket
to make sure its clean also.
Now you can check the end of the shaft
(or arbor) for runout, as in the upper < Some drill presses require a
right photo, opposite page. Chances are pair of specialty wedges to
youll find minimal runout. Again, less remove the drill chuck from
than 0.005" of total runout is acceptable. the arbor.
If theres more than that, then Id suspect
that the shaft bearings might be bad. with a model number that can help you you dont need to worry about misplac-
REPLACE THE CHUCK. If your investigation verify this, as shown in the box on the ing and tracking down the chuck key.
showed significantly more runout at opposite page. The owners manual for Installing a chuck is as simple as seat-
the chuck than at the shaft, Id look into your drill press may be a good resource. ing it back on the shaft or arbor. Retract
replacing the chuck. Just make sure that If youre investing in a new chuck, now the jaws first so you dont risk damaging
the size of taper on the replacement fits would be a good time to consider a key- them. Give the end of the chuck a couple
your drill press. Chucks are stamped less chuck. It makes bit changes easy, and of firm whacks with a brass or wood mal-
let to fully seat it on the shaft.
CLEAN & LUBE THE GEARS. Theres just one
more thing I do to complete the tune-
up. And thats to clean and lubricate the
rack and pinion gears used to raise and
lower the table. Use a stiff bristle brush
to remove built-up sawdust and grime.
Follow up with a lubricant. Some manu-
facturers recommend a light grease. I
use a dry Teflon lubricant that has less of
a tendency to attract sawdust.
To find out were to buy drill rod,
wedges, and drift pins, turn to Sources on
page 67. Youll also find out where you
can buy replacement drill chucks.
PERIODIC MAINTENANCE. Using these tips on
{ To avoid having the drill chuck or arbor { Cleaning the rack and pinion gears then a regular basis will keep your drill press
fall out of the drill press accidentally, make applying a lubricant ensures that the table working as it was designed. The results
sure that the shaft and socket are clean. raises and lowers easily. will show every time you use it. W 57

WS217_056.indd 57 12/1/2014 1:31:23 PM

in the

upgrade to
LED Lighting
Its my opinion that you cant have too OUT WITH THE OLD. The lighting in my HOW THEY WORK. LEDs are solid-state
much light in a workshop. When set- shop is a mix of bare light bulbs in por- components mounted to a circuit board.
ting up and using tools or doing layout celain fixtures and inexpensive fluores- This means there are no burning fila-
work, ample lighting makes these tasks cent shop lights. Since the phase-out of ments that eventually break, as in con-
easier on the eyes. One way to ensure old-style incandescent light bulbs, I had ventional incandescent bulbs. You can
adequate lighting is to upgrade to LEDs. been using compact fluorescent bulbs see the rectangular-shaped LEDs in the
They have a lot of benefits in the shop. (CFLs). But they contain small amounts photos at left and below.
of mercury and should be recycled LEDs dont produce a lot of heat
Plastic properly. Theyre not the best solution. on their own. However, the circuitry
shroud Instead, Ive been replacing some of the required to transform your household
bulbs with LED lighting. current to the low voltage required for
IN WITH THE NEW. While browsing the LEDs can get pretty warm. Thats why
aisles of my local home center, I real- some bulbs incorporate a heat sink to
array ized that LED bulbs are becoming more dissipate some of that heat (left photo).
prominent. And for good reason. Light-
emitting diodes (LEDs) are super-bright
and very energy efficient. So much so
that some manufacturers are shifting
Base away from fluorescent bulbs and tubes
to producing LED lighting instead.
Heatt sinkk

{ Replace the fragile halogen bulb in a

{ LED bulbs are available in work light with a bright, long-lasting LED
a variety of sizes and styles. replacement bulb.

58 Woodsmith / No. 217

WS217_058.indd 58 11/22/2014 9:40:05 AM

{ To replace fluorescent tubes, start by { At one end of the fixture, connect the { Reassemble the fixture and install the
cutting the power wires and the wires to wires from the new tombstones to the new LED tubes into the tombstone sockets
the old tombstone sockets, then remove power source to supply the LED tubes. before reconnecting the power.

Low voltage operation makes LEDs too (photo at right). Theyre just start-
much more efficient than other forms of ing to appear in some home centers but
lighting. For example, to get the 60-watt you can also order them online. Theyre
equivalent, an LED bulb will only use pricey, at between $30-40 each, so you
about 10 watts. Thats a pretty significant may want to replace the tubes in only
energy savings. one fixture at a time.
Another benefit to LEDs is their long You can buy replacement LED tubes
life. Some LED bulbs are rated for a life- that plug right into a fixture that has an
time of over 20 years, assuming that instant-start ballast. Other LED tubes
youll use them for three hours a day. require you to rewire the fixture to
THE COST. LED bulbs cost more than your bypass the ballast altogether. But this { The result of replacing fluorescent tubes
traditional incandescent bulbs. But the means you wont have the buzzing and with LED tubes is brighter and more
fact that LEDs are more efficient helps to flickering that you may have experienced efficient lighting in your workshop.
offset the higher cost. Even better, in the when turning on the light.
few months Ive been looking at them, The process I used to make the conver- DAYLIGHT FOR THE SHOP. When shopping for
the prices keep dropping. sion to LED tubes is shown in the pho- bulbs and tubes for the shop, I look for
FLUORESCENT REPLACEMENTS. Switching out tos above. Some suppliers provide new the brightest (higher lumens ratings).
light bulbs is one thing, but what about tombstones youll need to use for the And I prefer daylight, or cool white.
replacing the fluorescent tubes in your new tubes. Other tubes have a wire pig- Its the best, cleanest light for shop tasks.
shop lights? Believe it or not, there are tail that you simply tie into the wires that For other shop uses for LED lights, check
LED replacements available for those, supply power to the fixture. out the box below. W


LED lighti
lighting has other applications
besides ge
general shop lighting. I use
LED task llights near my workbench
and tools like my drill press and
scr saw. The portable flex
li from Lee Valley shown
a left is one example. You
c focus the light right
w you need it.
One other
oth LED light Ive installed
in my shop is an emergency exit light
(right pho
photo). Consider what might
{ A flexible
flexible neck allows you happen if youre in the shop and the { Stumbling your way out of a dark shop when the power
to aim the light wherever power goes out. A battery-operated goes out can be dangerous. This fixture comes on during
its needed. LED light will help you get out safely. power outages to light the way to the door. 59

WS217_058.indd 59 12/10/2014 12:08:11 PM

ork ing
woodw tials

Bar Gauges
Ive always enjoyed learning traditional WHAT THEY ARE. In short, bar gauges are CHECKING FOR PARALLEL. One use for bar
woodworking tricks and techniques. basically two sticks held together to take gauges is checking for parallel. This
Especially if that old trick helps me do or transfer a measurement. I want to talk comes in handy for cabinet work, as
the job more quickly and accurately. about a few commercial ones, as well as shown in the photo above. Its helpful
One of those basic techniques Ive come a few shop-made versions, and explain to make sure cabinet sides are parallel
to appreciate is the use of bar gauges. how you can put them to use. and not bowed in or out before attach-
Theyre deceptively simple, but once For any bar gauge, you size the length ing a face frame or installing a door.
you get in the habit of using them, of the strips or rods to suit the task at I made the bar gauge shown in a little
youll find your tape measure remains hand. Its convenient to have a few differ- over an hour using a block of wood with
in your apron pocket more often. ent lengths on standby to keep you from a threaded insert and a thumbscrew to
having to stop and make a special set in hold a pair of 38"-dia. dowels.
the middle of a project. Whether theyre NO TAPE MEASURE REQUIRED. Taking a mea-
shop-made or purchased, bar gauges will surement and transferring it to set up a
find many uses around the shop when tool is another great use for a bar gauge.
building projects. For example, you can obtain the length

{ Two wood strips held with a binder clip { The bar gauge can be used to transfer measurements to set up the table saw for accurate,
make it easy to obtain an inside dimension repeatable cuts. In this case, the bar gauge is used between the blade and a stop block
to size the length of a door stile. attached to an auxiliary miter gauge fence to cut door stiles to precise lengths.

60 Woodsmith / No. 217

WS217_060.indd 60 12/10/2014 12:08:58 PM

of a door stile in an opening. Then use
the bar gauge to set up a stop on an
auxiliary miter gauge fence at the table
saw. One end of the gauge is butted up
against a tooth on the saw blade. Then
the stop is placed against the opposite
end. This positions the stop for precise
and identical lengths for all of the stiles,
as in the lower photos, opposite page.
PANEL SIZE. In the upper right photo, { Bar gauges can go where tape measures cant. Here,
Im using a bar gauge set available from the tapered tips of the gauge fit inside the grooves on a
Rockler to determine the size of a drawer drawer to size the bottom panel.
bottom. You could use the same tech-
nique for sizing a panel for a frame and
panel door. This task is awkward when
using conventional measuring tools. Bar
gauges eliminate the guesswork and
math involved in taking the depth of the
groove into consideration.
The Rockler gauge also uses 38"-dia.
dowels and comes with a variety of
heads for various measuring and mark-
ing tasks. These are shown in the inset
photo. You can also use the set as a tram-
mel for laying out arcs and circles. The
great thing is, your only limitation is the
length of the dowels used.
CHECKING FOR SQUARE. Bar gauges excel { Measure across the diagonals to check an assembly for square.
at checking assemblies for square, as Brass pins can be threaded into the edges of the hardwood
well. In the right photo, Im using a set strips to act as large calipers for taking meausurements.
of Veritas bar gauge heads from Lee Val-
ley. You supply the strips of wood of any Instead of pins, you can bevel the ends brass tips allow you to complete a vari-
length. With the Veritas kit, brass pins of the strips to allow them to fit into cor- ety of measuring tasks for your projects
are included that you can thread into ners or grooves. simply by swapping the tips.
the edges of the strips. This turns the OUTSIDE MEASUREMENTS. Verifying outside The wide, mushroom-shaped tips
bar gauge into a large caliper. Im using dimensions or the dimensions of mul- engage the outside edges of a workpiece
the pins here to check a drawer assem- tiple parts is another easy task with a or assembly. Here, Im measuring for a
bly for square. The pins fit into the cor- bar gauge. The Veritas bar gauge shown panel that to be glued to the edges of the
ners across the diagonals of the drawer below comes with steel rods of varying box. With this method, theres no need to
assembly. When the fit of the bar gauge lengths that can be threaded together remember numbers from a tape measure.
is the same, I know the drawer is square. for custom lengths. Three styles of solid The nice thing about the Veritas bar
gauge is that it can convert this outside
measurement to an inside measurement
for setting up your saw to cut the work-
piece to size. The brass tips are designed
so that the distance between the inside of
the mushroom-shaped tips is the same as
the distance between the ends of the ball
or pointed tips. So by leaving the rods
locked in position and simply switching
to the ball heads, for example, you can
then use the bar gauge to set the rip fence
for cutting the panel to size.
MULTIPLE USES. By now, its easy to see
how bar gauges can fit into your arsenal
{ Interchangeable brass tips make this bar gauge a useful of shop tools. To find out where to buy
accessory for many measuring tasks. It comes with various one of the commercial versions, turn to
lengths of steel rod that can be threaded together. Sources on page 67. W 61

WS217_060.indd 61 11/22/2014 9:41:51 AM

as te ring
m saw
the ta ble

Blade Preferences
One of the first and best pieces of advice ripping to crosscutting, and even for cut- be overwhelming. To help you make the
I received when I bought my table saw ting joinery. For some, its the only blade best choice, I asked a few woodworkers
was to buy a high-quality combination they use outside of a dado blade. around here about the blades theyve
blade. This one step worked like an While a combination blade carries the added to work hand-in-hand with their
instant upgrade to help my benchtop lions share of the load, most woodwork- combination blade. Their experiences
table saw make smooth cuts. ers have at least one other blade in their will allow you to invest in a blade that
Just as its name implies, a combination kit. But with all the choices available, youll turn to often and wont just end
blade works well for a variety of tasks from deciding which other blade to get can up hanging on the wall gathering dust.


got by with a Freud Premier Fusion com-
bination blade. The blade rips efficiently
and crosscuts so smoothly he didnt see
the need for another blade.
That is until he started building some
cabinets out of red oak plywood. The
stringy nature of the red oak face veneer
resulted in tearout when making cuts
across the grain.
The solution came in the form of an
80-tooth blade designed for making
glass-smooth crosscuts in hardwood
and plywood. (Randy uses an Irwin/
Marples 1807370.) Besides the increased
number of teeth, the top of each tooth
is steeply beveled. The bevels alternate
{ Red oak plywood is notorious for tearing out when cutting direction to score the sides of the cut.
across the grain. A dedicated crosscut/plywood blade with 80 When paired with a zero-clearance
teeth helps eliminate the problem. insert, the results cant be beat.

62 Woodsmith / No. 217

WS217_062.indd 62 12/2/2014 10:06:59 AM

tasks in building a project is ripping
wide boards into smaller parts. A com-
bination blade rips well, but cuts signifi-
cantly slower than a dedicated rip blade.
If theres a lot of ripping to be done, that
extra time can really add up.
For Wyatt, even a regular rip blade
wasnt the answer for his contractor-
style saw. The blade often struggled to
cut hard woods. And it left noticeable
marks that needed to be smoothed out.
The solution was a thin-kerf, glue-line
rip blade (Freud LM74R010). This blade
has 30 teeth that are slightly beveled on
the top edge. This blade cuts quickly com-
pared to a combination blade and leaves a
smooth edge thats ready to glue up into } A thin-kerf blade removes less material than a standard 18"
wide panels with no sanding needed. blade does. That reduces the strain on your saws motor and
Sounds like a win-win situation to me. makes it less likely to stall when cutting hard lumber.

} A traditional rip blade with 24 teeth and a flat-top grind make JOHN DOYLE, DESIGNER/BUILDER. Theres much
quick work of cutting grooves and tenon cheeks. The teeth more to table saw work than crosscut-
leave a crisp, square corner at the bottom of the groove. ting and ripping. Like many wood-
workers, John turns to his table saw to
cut joinery. And for tasks like cutting
grooves or tenon cheeks with a tenon-
ing jig, he employs a 24-tooth rip blade
(Freud LM72R010). The key features of
this blade are the 18" width and the flat-
top grind on the teeth.
In addition to ripping hardwoods effi-
ciently, a full-kerf blade means John can
cut grooves for a stub tenon and groove
joint to match the thickness of a plywood
panel in just two passes (right photo). The
flat-topped teeth leave a crisp flat groove
instead of the pointed bat ears a com-
bination blade leaves. Plus, fewer teeth
keep the saw from bogging down. W

Versatile: DADO SET

Every woodworker I talked with agreed
theres one other blade to include a
stack dado blade set, like this one from
CMT (230.012.08). A dado set consists of
a pair of scoring blades that you com-
bine with the chippers and shims.
Used alone, the scoring blades cut a
1 "-wide kerf. Add chippers to obtain any
width from 14" to 1316". It turns your saw
into a joinery powerhouse. Now you can { A high-quality stack dado blade set simpli-
quickly and easily cut rabbets, grooves, fies the task of cutting a variety of joints,
tenons, dadoes, and more. like these custom-size dadoes. 63

WS217_062.indd 63 12/2/2014 10:07:29 AM

tips frop
our sho



!/2" -rad.
Position template
flush with edges 1
of benchtop
8&/16 3

Shop Notes 15!/4


Cutting Perfect Slots

The benchtop for the scissor-lift workbench on page 20 has CLEANING UP THE WASTE. Figure 3 shows the rest of the process for
four evenly spaced slots on its surface. These slots are sized to completing the slot. Start by using a pattern bit to remove the
allow a bar clamp to fit through, providing for a wide range majority of the waste (detail a). Because most bits arent long
of clamping options. In order to keep all four slots uniform in enough to reach all the way through the benchtop, youll then
size, I made the template shown above. The template acts as have to switch to a flush-trim bit. Just turn the benchtop over
a guide during the three-step process used to create the slots. and remove the remaining waste, as shown in detail b. You
TEMPLATE CONSTRUCTION. Start by cutting the template to size can then flip the template to the next position (above) and
from 14" plywood. Carefully lay out the slot location on the repeat the process to complete the rest of the slots.
template and drill two holes at the drill press. These holes
define the ends of the slot. Use a jig saw to remove the rest of 1 &/8"
the waste between the holes. Youll want to spend a little time bit
with a file and sandpaper to ensure the slot walls are smooth.
ROUGH SLOTS. Position the template as shown in Figure 1, at
right, and clamp it in place. (A few spacer blocks under the
benchtop ensure you wont drill or cut into your workbench Template
surface.) Using a drill bit that is slightly smaller than the final
width of the slot, drill the two holes at the ends of the slot. Just
as with the template construction, use a jig saw to remove the
rest of the waste between the holes (Figure 2). Be sure to stay Spacer
to the inside of the template edge.

2 a. 3 a.
Cut slot to inside
of template edge END
VIEW against VIEW
template (first pass)
Benchtop NOTE: Use
template to
make first
pass b.
Spacer Waste
Waste surface
of benchtop


(second pass)

64 Woodsmith / No. 217

WS217_064.indd 64 12/5/2014 2:05:59 PM

1 a.

Tall aux. Aux. rip

fence Door
rip fence frame

cabinet END
door VIEW

shown on door
bottom. Cut on
top is 2" wide { Filler strips add
Rip strength to the
hutchs doors.

Reinforced Door Frames 2 3

The cherry hutch on page 40 features
frame and panel doors joined with cope
and stick joints. When the doors hold a roughly
thin plywood panel in the grooves in the !/4" thick
frame (as with the hutchs base cabinet), Plane to
Filler strip !/8" thick
the joints offer plenty of strength. But the blank Waste
hutchs upper cabinet features thick glass Double-sided
Planer tape
panels in large doors. So I added one extra sled
detail to make the doors stronger.
FILLER STRIPS. The solution I arrived at
was to cut away a portion of the doors at
the top and bottom, and then add filler
strips to the doors. This essentially creates a lap joint at the Now you can set up the table saw to make a light cut at the
top and bottom of the doors, adding a lot of strength to the top and bottom of the doors (Figure 1). Just set the height of
assemblies. Plus, the final appearance offers a nice, clean the blade to the bottom of the rabbet for the glass.
look, too (photo, above right). All thats left at this point is adding the filler strips. I started
ADDING THE FILLER STRIPS. To reinforce the doors, I started by by resawing some stock at the band saw (Figure 2) and plan-
cutting the joints and assembling the doors as explained on ing it down to final thickness (Figure 3) before gluing the
page 43. Then I cut a rabbet around the inside opening of the strips on. Then you can complete the assembly of the doors
door frames for the glass (refer to the drawings on page 48). as detailed on page 51.

The Key To Face Frame Alignment

Assembling the hutchs face frame isnt difficult. The parts are
simply joined together with glue and pocket screws. But one
detail that was important to get right was the alignment of the
outer stiles with the lower rail. Thats because the stiles have
dadoes that need to align perfectly with a groove on the rail.
Fortunately, the answer here was fairly simple. I just cut 34"-
thick hardwood keys to insert in the grooves and dadoes
during assembly (drawing below). This ensured that the parts
would stay aligned as I assembled the face frame.

key aligns
groove with dado

Face frame Open Your Eyes

outer stile Face frame Springs on the the router mortising machine (page 30) retract the
lower rail
router carriage to its raised position. The springs are attached
to eye bolts and a screw eye. To get the springs installed, you
Clamping filler need to open the eyes slightly. The photo shows how I used a
cold chisel and hammer to get the job done. 65

WS217_064.indd 65 12/9/2014 7:11:26 AM

Cutting a Ramped Dado Spacer block
I use a toggle clamp to secure a workpiece to the fence on the
router mortising machine (page 30). With just a flick of the lever, Clamp base
it provides the right amount of holding strength to keep the
workpiece from shifting during a cut. !/4
It works well on its own, but I added a few upgrades to Waste
make it work even better. A strip of sandpaper on the fence
and a wider hardwood clamp face increase the grip. The other
improvement I want to highlight here is to angle the toggle
clamp. This way the clamping pressure is directed slightly 2!/2
down against the table, as well.
USE A SPACER. For this to work, the clamp sits in a ramped dado
I cut at the table saw. To make this cut, I used a thin spacer
block to raise the back edge of the clamp base, as shown in the
upper right drawing. The block is sized to match the deepest
part of the ramp. Fasten the block to the back edge of the ply-
wood blank with double-sided tape.
Then all you need to do is make several passes over a dado
blade. The photo at right gives you the general idea. Like the
spacer, the dado blade is raised to match the deepest portion
of the ramp. I started cutting the ramp by using the rip fence
to roughly center the base on the dado blade.
SEVERAL PASSES. Make one pass, then flip the piece end for end
to make a second pass to center the dado. Now you can move
the rip fence closer to the blade and make another set of passes.
Repeat this process until you reach the layout lines.
The final step is to clean up the score marks on the surface of
the ramp with a sanding block.

1 NOTE: Cut grooves using A Long Hole Without Drilling

a regular table saw blade Overall, the router mortising machine is a straightforward proj-
to sneak up on a good fit
with the threaded rod ect to build. But there are a couple of head scratchers that youll
9%/8 run across. The hardwood handle for lowering the router car-
Handle riage is a good example and deserves a closer look.
blank The rounded wood handle is comfortable to grab, but I
wanted to make sure it would be strong enough for long-term
a. END use. And I needed to make a solid connection to the arms.
block The solution to both of these challenges was to run a length of
threaded rod through the handle. Sounds simple enough, but
%/16 %/32 drilling a long hole through end grain isnt easy to do. So rather
than invest in a long bit, I took another route.
TWO-PIECE CONSTRUCTION. Instead of making the handle out of a
single piece, I glued it up from a pair of blanks. Take a look at
Figure 1 to get the gist of the idea. By using two pieces, I could
2 cut a groove along each piece so that when the two halves
were joined, the result is the hole I needed.
Figure 1a shows how to cut the groove with a 18"-wide blade.
This allows you to make a pass, flip the workpiece, and then
make a second pass to create a perfectly centered groove. With
Rip fence a few fence tweaks and several more passes, you can size the
groove for a nice fit with the threaded rod.
Waxed ASSEMBLY. Gluing up the halves into the handle presents
another challenge. The two parts need to stay aligned. So I
used my table saw rip fence and saw table to create a form, as
shown in Figure 2. A sheet of waxed paper prevents you from
getting glue on the saw table. Speaking of glue, use a small
amount so you dont get any squeezeout in the hole. W

66 Woodsmith / No. 217

WS217_066.indd 66 12/5/2014 2:07:35 PM

hardware & supplies
Most of the materials and sup- Green milk paint. After sanding LED LIGHTING (p.58) MAIL
plies youll need to build the to simulate wear, a burnt umber ORDER
projects are available at hard- glaze was applied. The stain, LED Tubes . . . . . . . .B00IT1DVB2 SOURCES
ware stores or home centers. For paint, and glaze are from General Lee Valley
specific products or hard-to-find Finishes. A spray lacquer was used
Project supplies may
LED Work Light . . . . . . 15J77.01
be ordered from the fol-
items, take a look at the sources for the final two coats. Emergency Light . . . . 99W20.42 lowing
listed here. Youll find each part companies:
number listed by the company MORTISING MACHINE (p.30) BAR GAUGES (p.60) Woodsmith Store
name. See the right margin for McMaster-Carr Rockler 800-444-7527
contact information. Push-Button Nut . . . 98150A730 3-in-1 Bar Gauge . . . . . . . 53052 Rockler
Extension Spring . . . . 9654K332 Lee Valley 800-279-4441
BAMBOO (p.10) 5
16" Through Knobs . . . 5993K64 Bar Gauge Heads . . . . 05N31.01
Northwest Bamboo Inc., Plyboo, 16" Studded Knob . . . . 5993K26 Veritas Bar Gauge . . . . 05N29.01
and Woodworkers Source are a few 1
4" Through Knob. . . . . 5993K22 American Woodcrafters
online sources for purchasing Toggle Clamp. . . . . . . . .5127A13 TABLE SAW BLADES (p.62) 800-995-4032
bamboo lumber. Nylon Bushings . . . . 94639A216 Rockler
Lee Valley Freud Premier Fusion . . . 20141 Enco
MORTISING BITS (p.12) T-Track. . . . . . . . . . . . . 12K79.22 Freud Glue Line Rip . . . . . 28768
Enco Woodcraft Marples Crosscut/Ply. . . . 49104
1 Grizzly Industrial
4" End Mill . . . . . . . . . 325-2264 10 Drawer Slides . . . . . . 27D11 Woodcraft 800-523-4777
16" End Mill . . . . . . . . 325-2266 18 Drawer Slides . . . . . . 27D15 CMT Dado Set . . . . . . . . . 147986
8" End Mill . . . . . . . . . 337-5355 Hardware Source
2" Roughing Bit . . . . . 328-0859 DINING ROOM HUTCH (p.40) Get the all-new Season 8 DVD set 877-944-6437 of the Woodsmith Shop! The set
DRAWER SLIDES (p.18) Cope & Stick Bits . .B001GI7TCM includes two DVDs with all the Lee Valley
Rockler Lee Valley episodes plus a CD-ROM with
Drawer Slide Screws . . . . 42334 114" Knobs . . . . . . . . . 02W26.22 bonus plans and articles. Collect
Shelf Supports. . . . . . . .05H20.41 the entire series by ordering indi- 630-833-0300
SCISSOR-LIFT BENCH (p.20) Support Sleeves . . . . . . 05H20.45 vidual seasons for $29.95 or save
Grizzly Industrial 16" Drawer Slides . . . . 02K42.16 with package deals. Learn more Northwest Bamboo, Inc.
Hydraulic Table . . . . . . . . H8099 Stacking Plates . . . . . . . 01S07.01 at! 503-695-3283
Rockler Puck Lights . . . . . . . . . . 00U50.20 DVD Set: Season 8..................... $29.95
7" Bench Vise . . . . . . . . . . 68888 Hardware Source Plyboo
3 866-835-9859
Magnetic Tool Holder . . . 81281 8" Inset Hinges . . . . . . . 400171
Dust-Free Shop Tray . . . . 43500 Veneer Supplies
Veneer Supplies
Cherry Veneer . . . . PBCHRFC28
SPICE CAROUSEL (p.26) The hutch was stained with a mix-
Lee Valley ture of three parts Zar cherry stain 800-225-1153
Friction Disks . . . . . . . 88K59.08 and one part Wood Kote Jeld stain
Spice Bottles . . . . . . . . . 12K82.10 (cherry). Then it was sprayed with Wood Kote
6" Lazy Susan . . . . . . . 12K01.03 two coats of lacquer. 800-843-7666
Bumpers . . . . . . . . . . . . 00S20.05
American Woodcrafters DRILL PRESS TUNE-UP (p.54) Woodworkers Source
2" Birch Knob . . . . . . . . . KB-200 Rockler
To finish the maple carousel, Link Belt . . . . . . . . . . . . . . 52233
Pecan water-based stain was used To remove the drill chuck, youll
and the inside of the holes were need to use wedges or a drift pin.
painted black. For the painted You can find these and the drill rod
carousel, Somerset Gold milk paint at McMaster-Carr or Enco.
was followed by a coat of Basil 67

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looking inside
Final Details

{ Router Mortising Machine. Transform the motor of an

ordinary router into this precision mortising machine. All
it requires are some basic materials and hardware. Youll
find full details for building it beginning on page 30.

{ Spice Carousel. This easy weekend kitchen project looks

great and keeps all your favorite cooking spices close at
hand. For a small project, its still packed with interesting
woodworking techniques. Turn to page 26 to get started.

{ Stylish Cherry Hutch. This eye-catching hutch would be a great

addition to any dining room. It offers loads of functional storage
in a stylish, heirloom-quality package. Beginning on page 40, each
step of the construction process is explained in detail.

?> Scissor-Lift Workbench. Save your back and increase

your shops efficiency with this unique workbench. Using a
lift cart as the base, it can be set to a wide range of heights
to suit working on any project. Plans begin on page 20.

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