Wood Magazine - Issue 259 - March 2019 - Full

TAKE YOUR CNC BEYOND WOOD p.
38
o 72440 14072 1
Better Homes & Gardens®
TAKING MEASURE
WOOD"
Story sticks
March 2019
Vol. 36, No. 1 Issue No. 259
EDITORIAL CONTENT CHIEF DAVE CAMPBELL
DEPUTY EDITOR CRAIG RUEGSEGGER
W
henever I build a project for someone else, I try to include some- ART DIRECTOR KARL EHLERS
thing that gives the completed piece a story; some interesting SENIOR DESIGN EDITOR KEVIN BOYLE
tidbit the recipient can share with those who might ask about it.
DESIGN EDITOR JOHN OLSON
For example, when building a new conference table for my church, I went
TOOLS EDITOR BOB HUNTER
searching for some solid-wood banding to hide the plywood edges. My
DIGITAL PRODUCT MANAGER LUCAS PETERS
hardwood dealer had a whole rack of old-growth oak harvested from
ADMINISTRATIVE ASSISTANT SHERYL MUNYON
sunken ships at the bottom of Lake Michigan. Bingo! A merely functional
CONTRIBUTING DESIGNER ANNA GLEASON
table now had a story. Last Christmas, I made "pegs
CONTRIBUTING CRAFTSMEN JIM HEAVEY, BRIAN SIMMONS,
and jokers" games for both kids from a Philippine
BOB BAKER, BRIAN BERGSTROM
mahogany shelf I'd salvaged while remodeling our PHOTOGRAPHERS JASON DONNELLY, SCOTT MORGAN, BRIE PASSANO
first house. CONTRIBUTING EDITORS LARRY JOHNSTON, BILL KRIER,
So, when my son, Colby, married his fiancee, RANDY MAXEY, ROBERT WILSON
CONTRIBUTING ILLUSTRATORS LORNA JOHNSON,
Jenny, last November, I wanted to build them a gift
ROXANNE LEMOINE, KURT SCHULTZ
that would have a special story. PROOFREADERS SAM CADY, BABS KLEIN, IRA LACHER, THOMAS MORIARTY
Earlier, WOOD& magazine's Tools Editor, Bob ADVERTISING AND MARKETING
Hunter, had shown me a unity cross he had made VICE PRESIDENT & GROUP PUBLISHER SCOTT MORTIMER
for a family wedding. One cross nests inside the ADVERTISING ACCOUNT EXECUTIVE DANIEL WELLS
other, arid, during the wedding ceremony, the ONLINE MEDIA KIT WOODMAGAZINE.COM!MEDIAKIT
bride and groom tap in dowels to permanently BUSINESS MANAGER DAmN TOLLEISON CONSUMER MARKETING MANAGER EDUCIlINSKY
PROllUCllON MANAGER SANDY WILLIAMS PRiPRESS DESKTOP SPEClAUST RANDY J. MANNING
bind them together. The symbolism-that the
COl.ORQUAlITY ANALYST TONYHUlIT
only way to separate the two is to destroy each of MEREDITH NATIONAL MEDIA GROUP
the individuals-was too JON WERTHERpRESlDENT
powerful to pass up. MERllllTlI MAG.lZINES PRESIDENT DOUG OLSON
PRESIDlNT. MERIDITH DIGITAL STAN PAVWVSKY
To give it a story, I made PRESIDENT. CONSUMER PROOOcrs TOM wmcJI]
the inset cross out of offcuts C~EF R1VENUEOfFICER MICHAlLBiOWNSTIJN
from the beautiful ash altar CHIEF MARKITING & DATA OfFICER ALYSIA BORSA
MARKETING & INTEGRATED COMMUNICATIONS NANCYWEBER
furniture made for our fami-
SENIOR VICE PRESIDENTS
ly's church. (I'd been saving CONSUMERRIVINUE ANDYWD.SON ffiGITALSAUS llARJ.ANEWJU.N RESEARCHSOllmONS BRllTACi.MLAND
them for 15 years, waiting for PROoucr AND TF.CHNOlINY jUSTlNLAW ~IT DIGlTAlomcER lIAITMlNOFF
COll'ORAllSAIISBRlANKlGI!ITJNGER
just the right project.) Because
VICEPR£SIDENTS
Jenny was born in Illinois, I RNANCIAl CHRIS sumL BUSINESSPLANNING & ANALYSIS ROB SILVERSTONE
used quartersawn white oak-Illinois' state tree- DlRICl MEDIA PATTI FOLLO STRAllGIC SOURCING. NEWSSTAND. PRODUCTION CHUCKHOWILL
for the frame cross. On the back I laser-engraved CONSUMER MARKITING STEVE CROWE
~CE PllESIDENT. GROUP EDITORIAL DIRIClOR Ll2 VAGCARl!lJ.ll OR S1tPHEN ORR

"What God has joined, let no one put asunder" to
DlREcro~ EDITORIAL OPERAIDNS & RNANCE Al1:X BRIZ OR GREG LlYKO
really hammer the message home.
It was tremendously rewarding to contribute to 8 meredith
the most important day of Colby and Jenny's life MEREDITH CORPORATION
together. PRESIDENT & CHIEF EXECUTIVE OFFICER TOM HARTY
CHIEF FINANCIAL OFFICER JOSEPH CERYANEC
Bob shared the unity cross idea with me, so I'll go CHIEF DEVELOPMENT OFFICER JOHN ZIESER
a step further and share with you my plans for build- PRESIDENT. MEREDITH LOCAL MEDIA GROUP PATRICK MCCREERY
ing the cross at woodmagazine.comlunitycross. SENIOR VICE PRESIDENT, HUMAN RESOURCES DINA NATHANSON
That's in the new "Member Plans" section of our EXECUTIVE CHAIRMAN STEPHEN M. LACY
VICE CHAIRMAN MELL MEREDITH FRAZIER
website. When you check it out, I hope you'll share
the story of one of your own projects by posting "'For subsuiptionhelp:
Online: woodmagazine.comtmya<count
photos and some Simplehow-to. E-mail: wdmcustserv@cdsfuifillmentcom
Phone: 800-374-9663, select option 1.
"'To find past artides: Search for p<evious articles, plan corrections, and article updates
See you in the shop! online at woodmagazine.comlinde~
••• To order past articlesand issues: for articles, search woodstore. net for issues,
visit woodmagazine.comlbackissues.
To download patterns from this issue,

~ Dave Campbell
visit woodmagazine.com/259pattems
Our subscriber list is occasionally made available to careflilly selected firms whose products may
dave.campbell@meredith.com be of interest to you. If you prefer not to receive information from these companies by mail or by
Facebookand Twitter:@WOODeditor phone, please let us know. Send your request along with your mailing label to Magazine Customer
Service, PO Box 37508, Boone, IA50037·0508.
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~~~~:~~h~~;~~~~i~~r~~~~~t~~l~~:~I~~;~t:
~Y~~~~::~~nithe
~ U.s.A. /~@"'A
to photocopy the included patterns solely for personal use. L\.
Any other reproduction of these patterns is strictly prohibited. ~"
woodmagazine.com
IN THIS ISSUE OF
WOOD®
MARCH 2019 . ISSUE 259
PLANS
24 Arts & Crafts Display Case
You'll love the heirloom look of this curio
afforded by the seeded glass panels.
34 Stacking Seed Starter
Kick off the growing season early (and
learn a new interlocking joinery method).
44 Mil-spec Apache Helicopter
Full-size patterns make building this
iconic aircraft a downdra ... er, breeze.
58 Pie and Cupcake Carrier
Transport sweet treats in style with this
box-jointed beauty.
64 No-lathe Salt and Pepper Shakers
"Turn" these tapered cylinders using only
common power tools.
TOOLS & TECHNIQUES

30 On the Cover: Get Quality Lumber
It's easy to find affordable hardwoods-if
you know where to look. We'll show you.
38 Simple CNC Tricks
George Vondriska teaches how to robo-
rout different patterns and materials.
50 How to Get a High-gloss Finish
Know how to polish your lost shaker of
salt (and other small projects)? Buff it!
54 The ABCs of Abrasives
Stop guessing at grits and staring at
stearates. Here's all you need to know.
62 Preserve Your Plunge Router
Ensure your router plunges when it
should, and doesn't when it shouldn't.
68 Power Sander Primer
Learn how to choose and use the right
motorized sander for the job.
72 The Slat-wall Storage Solution
Get groovy and embrace your hang-ups
with this simple system.
76 Tools & Materials
The best portable workstations, a bigger
compact router, and more.
DEPARTMENTS
1 Taking Measure
Story sticks.
4 Wood-Wide Web
Post your project plans.
6 Sounding Board
Your voice, your projects, your shop.
16 Ask WOOD
Build a better birdhouse.
18 Shop Tips
Light tight spaces and more.
88 What's Ahead
A sneak peek at your next WOOD.
2
[
WOOD-WIDE WEB
WOODMAGAZINE.COM
Share your build with the Happy Hammock Stand

woodworking community! Lucas Peters, posted on Oct 22/ 2018
It's easy! Log in or register at woodmagazine.com, hop over to woodmagazine.comj

memberplans, and click "Create Your Own Member Pian." Then, follow the directions
to teach other woodworkers how to build your amazing project. While you're there,
browse through the projects from other woodworkers for inspiration.
Turn these ... . .. into this!

Materials or Supplies Tools
Two 8' pine 2x2s
One 4)(8' Sheet of particle board Jigsaws/Saber saws
FOUlIeen 8' cedar 2X4s Mitsrsaws
West System IlJlOl(Y and hardener
Lag screws Bandsaws
Strow hooks On.mSanders
Clear. ooldoor finiSh Clamps
Nuts. bolts. washers handsaw
STEP 1
Trammel
First I created • large carved mold from particle
board. To stan, I marked a centerline on the
particle beard, Then I boilt a makeshift trammel
from hls. I attached the trammel's lower 2x2 to
the underside of the board in line with the
centerline. And 1 supported the opposito end
sort of tenuously on a piece of plywood scrap.
The pivot of the trammel is just i screw. There
is a particle-beard spacer between the
2x2s. Then I drilled a hole for a pencil 89" fiom
the pivot screw. (The distance of the arc from
the bottom of the particle board i,n't critical.
Just make sure the apex of the arc doesa'r gc beyond 2' so you can get two fiomthe •• me piece of
particle board, You can see my pest-it-note plan in the foreground.
STEP 2
Mold Parts
After removing the trammel {Don't throw it
away!),l cut out the art \Io1th a jigsaw, st:lying
about 1/16" away from the line. Then, I traced a
second arc on the other half 0 the parride board
md cut it out I clamped the two half, together
md used a belt sander to sand the radius smooth
to the line. Then, 1 drilled some luge clamp
seeess heles.
I then cut up the trammel Into 3" blocks and

used a trim nailer to tack them between the
bottom and radius of me arc as shown to form
the mold. I added plastic beck-binding tape to
Digging out the Splinter
Just curious: Did the all-wood Splinter supercar project after earning his master's degree in But, inspired by the invitation, he made it street-
you featured on the cover 10 years ago (issue industrial design (for which the car was created) legal in time to display at the show.
186, October 2008) ever make it to the street? and married Caroline, one of the build-team Although he says the car has lived up to his
-Wendell Barrick members. expectations, Joe confesses he's never licensed
via e-mail After being asked in 2016 to show the mid- the Splinter nor driven it at speeds anywhere near
engine supercar-90 percent of which is made its 200 m.p.h. capability. The birth last year of his
Yes, but technically no, Wendell. Its progenitor, from wood-at the Essen Motor Show, Joe daughter, Jemma, has made that less of a priority.
Joe Harmon, took a few years off from the initially declined because the car wasn't done. See more photos at splintersupercar.com.
One good turn deserves a

non-turned brother
After seeing the Woven Bowl project in issue 253
(May 2018), I was inspired to make a "woven"
container for a small extinguisher I keep near the
fireplace. But without access to either a band-
saw or a lathe, I needed a different technique
to make the vessel round. Here's the method I
came up with.
First, I used an adjustable circle cutter in my
drill press to create a ring-shaped MDF tem-
plate with the inside and outside diameters of
the vessel. Then, after building
the first layer of the weave,
Wait-they did what? As a woodworker who uses and appreciates old I used the template and
Your article on sharpening handsaws in issue 257 handsaws, I read with interest your article in issue a bearing-guided flush-
(November 2018) brought back memories. When 257 I cringed when I saw an angle grinder and trim bit to rout the inside
Camp Phillips at Salina, Kan., was being wire brush being used to clean a rusty saw. Any and outside shape of
dismantled after World War II, they used etching (which can help identify the make, model, the layer. As I built each
handsaws to cut the barracks in half for moving. and age of the plate) remaining under the rusty additional layer of the
My dad was the saw sharpener on that job, and surface can be damaged by your method. A more weave, the previous layer
he taught me to sharpen them. I remember he prudent approach is a synthetic abrasive pad, a served as that layer's
always cut off the teeth within 2" of the handle, spray bottle of household cleaner, and a little routing template, limit-
saying they never cut wood and would snag your elbow grease. The process is also made easier by ing construction to one
pant legs. removing the handle from the saw plate. layer per day.
-Lowell Johannes -Bob Norcott -Dave Pettitt
Hays, Kan. Sebec, Maine Santa Barbara, Cal.
6 continued on page 8 WOOD magazine March 2019
SOUNDING BOARD
YOUR VOICE
Dust separator Color correction

no longer a pipe In the color-spectrum
LEDlights
dream chart on page 64 of
65000K
I was doing research to build issue 256 (October
my own dust separator 2018, "Let There 60000K
when I picked up issue 255 Be [Better] Light"),

____ S~5:illOOL.!\°K e- Sunlight at
(September2018). There, on the color tempera- midday
SOOOOK
page 18, was my solution. ture of sunlight at
My build went quickly midday should have CFLs& 4S0QOK
fluorescent
because I used PVC pipe for been listed at about 400QOK
the legs instead of 2x4s, as 5500oK, as shown
shown here. Thanks to Ed here. 3S000K
Halogen
Piche for the great tip! 30000K
-Rick Munroe Incandescent 2S000K
Visalia, Calif
___ -'2C\i'OO,!JlO°J',__
K Candlelight
lS000K
10000K
What's your hurry?

As Iread through your router-accessories article in issue 255 and the $600 Speed infraction
worth of "gotta have" accessories, my mind turned to golf and bowling- In the chart on page 16 of issue 258 (December/January 2018/2019, "Ask
two pastimes in which the better you are at it, the less time you spend do- WOOD"), the maximum speed of 2%-3" bits should be listed as 12,000-
ing it. WOOD® magazine's editorial seems to have taken the same attitude 14,000. The corrected chart is shown below.
toward woodworking: Get the latest and greatest gizmos and get things
done QUICKLY so that you spend less time in the shop. Huh?
-BobWey
Router Bit Speed Chart
via e-mail Max. speed x
. Bit diameter My router
1,000 rpm
Bob, we cherish our shop time as much as any woodworker. Being accurate
Up to 1" 24
and efficient in the shop doesn't necessarily mean getting out quicker. (But
for those time-strapped by a job and other activities, that's a bonus.) It
1 Ys-2W' 16-18
means getting more done in the same amount of time. It means extra time
to tidy up the shop at the end of one project, so you can hit the ground
2%-3" 12-14
running for the next one. It means making 25 toy cars for the children's
hospital instead of 20. And finishing up a project sooner gives you time to
3Ys" or larger 10-12
learn a new woodworking technique that you can enjoy on a future project.
Connect with us
A potentially hot IIr.I facebook.com/ !II..M twitter.com/
shop topic • IIwoodmagazine • WOOD_magazine
I enjoy reading WOOD magazine, a\ pinterest.com/
'l:l woodmagazine
~
~
instagram.com/
woodmagazine
especially the neat readers' shops
you feature. But in many cases, the
E-mail woodmail@woodmagazine.com; or write to
location of the fire extinguisher is
WOOD magazine, 1716 Locust St., LS-253, Des Moines, IA
not very well thought out, as if the 50309; or call 800-374-9663, option 2.
owners just placed them where
they had a blank spot on the wall. WOOD· magazine never uses outside parties to
In one shop, the extinguisher was solicit subscription renewals. The safest, easiest
hidden behind the bathoom door. way to renew your subscription is with a credit
A fire extinguisher should always card online at woodmagazne.com/myaccount. If
be hung next to the entry door, in you have questions about a renewal offer you've
plain sight, and with the handle at received, please call our customer service line at
about hip level. 800-374-9663, and select option 1. We're
-Dennis Murphy happy to help.
Bismarck, N.D.
8 continued on page 10 WOOD magazineMarch 2019
SOUNDING BOARD
YOUR PROJECTS
Oklahoma-bornFloyd Beeson, now of San

Diego, loves to build wood projects for his
backyard, including this from-scratch
replica canoon The only purchased
components are the 3" PVC barrel and
the wood cannonballs.
When Nell King, of Black Mountain, N.C.,

designed and built these stools for his kit~hen
island, the goal was to create a simple,
comfortable design featuring clean lines and
through-tenon joinery. The frames are
leopardwood, accented by zebrawoodseats John Wright, of Sacramento, Calif., built this
and backs. walnut-and-maple reading stand for his
daughter. The sturdy ledge supports a book,
laptop or tablet.
Thomas Martin, of
Webberville, Mich., Co/in Smith, of Hurricane, Utah, built this elaborate cabinet to
salvaged some discarded display mementos collected during a trip to Russia with his wife.
limbs from a tree that was Colin did all of the carving, marquetry, and gildinq by hand.
being milled and then
waited for just the right Send us a photo of your work
project to come along. It finally arrived on th~ cover of issue 225 (May' Want to see your work showcased in WOOD®
2014) with the Garden Bench, where he incorporated the crooked magazine? Send a high-resolution digital photo of your
limbs into one end. completed project to woodmail@woodmagazine.com.
10 WOOD magazine March 2019

J ,
~ -_
-.
PORteR + CRBLE
_;..
Ed's main workbench incorporates a large face vise A wall-mounted shelf keeps Ed's pancake
W
hen Ed Kassof converted his two- made with pipe clamps, and a conventional wood tail vise. compressor accessible and frees up floor space.
car garage to a woodworking shop, A roll of paper at one end protects the benchtop during The drop-down door reveals accessory storage.
glue-ups. His benchtop router table and sander tuck
he exiled the family cars to the
underneath to maximize space.
driveway, a decision he hasn't regretted.
The shop features many creative solutions
for storage, mobility, and multipurpose use.
For example, the hideaway tablesaw (page
14) and mitersaw workstation with flip-up
wings both store small, but work big.
Ed designed his shop with lots of open
floor space. Putting casters under benches, a
Router table
lumber bin, tool cabinet, and. clamp rack underneath
means that "no tool in the shop is ever in the
~
way of any production," Ed says. Clamp rack
Two custom-made workbenches fill specific
needs. The top of the tablesaw workstation Mobile
tablesaw
consists of a hollow-core door sandwiched Mobile assembly bench bench
between two layers of plywood. At the front of 18'
Overhead
the bench, an outlet strip nestles between the door
plywood layers. Large drawers hold tablesaw
blades and accessories.
The main workbench provides a rock-
solid project-assembly worksurface. Its
sturdy 2x4 frame supports the 2l4"-thick
solid-wood top; a pair of vises and rows of
dogholes add secure work-holding options.
Ed framed in a series of wall cabinets
before the drywall was hung. Securing the
cabinets directly to the wall studs and ceil-
continued on page 14
ing joists increased their weight-holding
capacity. Sliding \4"-plywood doors hide the
contents and create a clean look.
You won't see much sawdust in Ed's shop.
He keeps things tidy using a shop vacuum
Ed's benchtop tablesaw stores on a platform below this workbench (top left), then
attached to a Dust Deputy miniature cyclone glides out on full-extension drawer slides. The platform lifts up to bring the tablesaw
system. This assembly rolls where it's needed surface flush with the benchtop. The end of the workbench stores the rip fence, miter
on a cart Ed made. gauge, and blade guard.
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and are designed for easy use, consistently great results, and long
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Hand Tools are sure to become favorites in your shop.
V·SYSTEM~
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The folding wings on Ed's mitersaw station support long workpieces, then fold down
for compact storage. Two casters on the back, and handles up front, make easy work of
moving the workstation.
A 24" wall-mounted Air King fan helps

circulate air when the garage door is up.
"But it's still warm when the temperature
hits 100 degrees outside!," Ed quips, as he
reaches for his glass of sweet iced tea .•
The Oneida Air Systems V-System'" patented
Ed Kassaf, a design has a compact shape and sound
disabled veteran
with 35 years of dampening features which make it the
combined military Show us perfect solution for garage and basement
service, retired your shop shops where size and noise playa significant
from the New York Send high-resolution factor. Optional Stacking Sound Filter
Police Department. digital photos of your
During 40 years of shop to
available to make it even quieter.
woodworking, he woodmail@
has built projects woodrnagazlne.corn
for his home, family, and we may showcase it
and workshop. in the magazine!
woodmagazine.com 15
ASK WOOD
YOUR QUESTIONS
Build feather-friendly
birdhouses and feeders
I use all sorts of wood scraps and recycled • Birds enjoy a tidy house, so include drain-
materials to make houses and feeders for age holes in the floor. And allow a means to
songbirds. Some of those projects attract clean out the house after the nesting season.
flocks of feathered visitors, but others don't. Scrub down the interior with a solution of
What can I do to improve results? one part bleach to nine parts water .
-Dan Polson, Durango, Colo. • Finally, always remember to build and
position a birdhouse to minimize the amount
A
The material you use and how you treat it can of rain that can get through the entrance
have a big impact on whether a birdhouse or hole. An overhang helps, as does making the ~Shop birdhouse
feeder will appeal to its target audience, Dan. hole no larger than necessary. Online, you and birdfeeder plans.
For better visitation, try these pointers: can find many charts showing best hole size woodmagazine.comj
• Like us, birds prefer to stay out of the heat in (as well as interior dimensions) for many birds
the summer and the cold during winter. So bird species .•
don't use plastic decking that gets hot in the
sun. Tin and other metals also heat up in a
hurry and provide little insulation.
• If possible, don't place a birdhouse in direct
sunlight. Of course, some species, such as
bluebirds, require houses out in the open. For
those, make walls and roofs frorn two wood
layers, with a ventilating space of I" or so
between the layers. At the least, provide ven-
tilation holes near the tops and bottoms.
• Thick, solid wood insulates well. Woods
that stand up best to Mother Nature include
cypress, cedar, redwood, and white oak.
• Avoid treated wood, which could prove
hazardous to birds. For the same reason, stay
away from pallet wood, which may have been
chemically treated.
• Resist the temptation to gussy up your
birdhouse or feeder with paint, stain, or other
finishes. Birds don't like the residual vapors,
and dark colors will amplify the sun's heat.
Birds also prefer structures that blend into
surroundings rather than attract attention
from predators. If you can incorporate bark,
branches, or other natural wood features into
the project, all the better. On feeders, bark
and branches help birds feed on the seeds.
• Staying with the natural theme, avoid
sanding the wood. Rough surfaces help adult
birds cling to the side of a box when bringing
in nesting material or feeding young. And the
fledglings will find it easier to scramble out
for their first flights.
Have a question?
Drop us an e-mail.
askwood@woodmagazine.com
16
SHOP TIPS
W 0 R K FA S T E'R, SMA R T E R, SA FER
Light tight spaces when turning vessels

While turning the inside of deep vessels, I struggled to see the tool's cutting
action, even while using a flashlight to peer inside. Then, it occurred to me
to mount a flexible-neck penlight (woodmagazine.com/streamlight)
directly to the tool. Mounted as shown, the light can be repositioned on the
tool, as dictated by the shape of the vessel.
-Peter Messinger, East Amher~t, N. Y
Tipseam up' For sending this

'@:tmmw
issue's Top ShofJ Tip,
to $150. Peter receives an AccuRlght'
Bandsaw
If your tip is tngpest ofthe issue, . assortment of bandsaw Blades
. it wins Top Shop Tip honors, accessories from
a~d you receive a tool prize worth Carter Products
worth $330.
at least $300. ,
t
Send your tip, photos or drawings,
and contact info to
shoptips@woodmagazine-:tom
Because we try to publish original tips,
please send yours only to WOOD' magazine.
18 WOOD magazine March 2019 continued on page 20

SHOP TIPS
Easy-build cart solves
several shop issues
I organize and store hardware in shallow fishing-tackle
boxes, with clear lids that enable me to quickly see
what's inside. Those boxes began to take up a lot of Aluminum
: room on my workbench, so I came up with this cart to angle
hold all of them.
Build the cart from %" MDO (medium-density over-
lay) plywood for the top, bottom, sides, and middle
divider. The divider adds structural integrity and cre-
ates more storage on the other side of the cart. Deter-
mine the cart's dimensions, using your tackle boxes as
a starting point. Dado the sides to hold W' hardboard
panels supporting each tackle box. Attach trim strips
to the front and back edges to keep the panels from
sliding out.
I added aluminum angle around the top for appear-
ance's sake, durability, and to keep small items from
rolling off. The top also makes a good spot for bench-
top tools. I built a slightly larger top that fits over the
cart top for jobs that require a' bigger worksurface. The
loaded cart will weigh a lot, so use good casters, two of
them the locking type.
-Kevin Schendel, Saint Cloud, Fla. %" MDO
(medium-density
overlay)
Never forget a great tip

I love a good shop tip but often forget it when an
opportunity comes to apply it. To jog your memory,
Trim
print out tips you're likely to use on a sheet of paper strip
and clip them to the size of labels. Then, use clear
packing tape to laminate and stick the tips where
you're likely to see them when opportunity knocks.
-Scott Hunter, Chicago
'A"
hardboard
panels

SHOP TIPS
In-the-bag solution to elusive Rare-earth
Gap in frame leaves
router-table sawdust room for the cord
cup magnets
The dust port on a router-table fence

collects most of the dust above the table,
but some still escapes below. To keep that
debris off the floor, I built a lightweight
poplar frame, large enough to fit around
the router, with ample room for cooling
air. I tacked fabric around the sides and
bottom of the frame. Rare-earth mag-
nets mounted to the top of the frame
attach to metal washers on the underside
of the router table. The collector catches
all falling debris and detaches easily for
emptying. Note that I left room for the
cord to exit the collector by leaving a gap
in the frame at each corner. That way, no
matter how you replace the collector,
there's a notch positioned for the cord.
-Tom Moss, Bradenton, Fla.
Curved caul-like clamping

with this crafts-stick cure
A wood caul, with its slightly bowed
face down, helps distribute clamping
pressure to the middle of a long work-
piece such as a face-frame rail. To get
the same effect without having to
make bowed cauls, use a straight piece
of hardwood or aluminum channel
for the caul. Then, insert crafts sticks
under the caul where you need a little
extra downward pressure.
-Fraser MacLean, Langley, B.C
WOOD magazine March 2019

WIN A
Put it in reverse for simple
FREE
frame finishing
By reversing the jaws of a one-handed
clamp (making it a spreader), you can WEEKEND
WITH ,
use the clamp to hold a trivet or pic-
ture frame while you apply a finish with
your other hand. Expand the jaws into
the frame's rabbet, where missing finish
<II
won't show. Then, insert a hook through
the hole in the end of the clamp bar and
•
hang the hook from a wire loop for dry-
ing. I leave off the clamp pads for better
jaw bite on the thin rabbet edges.
-Dave Whiting, Townsend, Mass.
Attend North America's

Premier Woodworking
Educational Event
May 16-19, 2019
at the WOOD® magazine shops
in Des Moines, Iowa
Flatten natural-edge tabletops ...without a router sled
Want to make a tabletop from a wide slab face. Then thickness-plane the
with natural wavy edges, but don't want to Arrange the boards in natural order, and Prize includes
go to the hassle of making a router sled and glue them back together, using strips of
railed platform for flattening the slab? extruded foam as clamp pads. The foam tuition, hotel, and more.
Here's a simple way to get the job done with
a portable circular saw, jointer, and thick-
conforms to the irregular edge to protect it,
and gives the clamp jaws a somewhat-square
And YOU could win it all!
ness planer. surface to press against. •
First, rip the slab into boards no wider -Bob Hunter, WOOO® magazine
than 6" using a straightedge, (A thin-kerf learn more and
blade minimizesmaterialloss, better hiding
a glue line.) Joint the sawn edges and one
enter TODAY at
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"::J: Approximate
I/) , materials cost:
~
zL:nM
Ox
-0
$375
1/)'
~
z~
~ x
4
sided view
~:s:
-;;:!
11
sq. ft. display
WOOD magazine March 2019 Q~ area
:
EXPLODED VIEW
'1'2" rabbet %" deep
'/
Shelft ,i
4>-- .\
-v.,
N
o matter how you look at it-from --- -c ,
the front, sides, or top-this case
showsoff collectiblesin the best pos-
sible light, thanks to lots of seeded (wavy
with tiny bubbles) glass. Have the glass cut ror images. Mark part letters and orienta- ~ Learn rnethods to
Note: Although the to size, or cut it yourself followingour step- tion (right, left) on the outside faces with rnake mortise-and-
front stiles (A) and rear by-step instructions. chalk. Form the stile (A, B) mortises and tenon joints.
stiles (B) have different then cut the rail (C, D) tenons [Drawing 1a] to woodmagazlne.com/
initial widths, they will Make the case fit the mortises. Use a fairing stick to draw mt4ways
appear symmetrical in Cut side frame parts A-D to size [Materials the arc on the lower rails (D) and bandsaw
the final assembly. 1 List, Drawing 1], and arrange them as mir- and sand them to shape.
1;'4" rabbet W' deep 131,4" W' rabbet %" deep
on inside face t----- -----; on outside face
DSIDE ASSEMBLY
(Inside face shown)
1,4" rabbets 3/8" deep

routed after assembly
1f4" holes %" deep

%" from inside edges
34%"
23%"
12'/8 X 235/8"
single-strength
seeded glass
.; W~I
131f4"~
woodmagazlne.com 25
Squaring braces orient side and face-frame assemblies while riser blocks
make room for bar-clamp heads.
EJ F4CE FRAM E
__"" face ::~::::~F:::::;:'===:::]
Sh::=O::=W:":)
14 x 1 Yz" mortise'
%"deep
W' groove 14" deep

Yz" fromoutside edge
mFACE FRAMERAILS
34%,' W' groove W' deep

Yz" from outside ~tI
Y4 x 2 Yz" mortise
%"deep
1;\6" charnhlr
2 Glue and clamp the side frames. With the
glue dry, rabbet the front and rear edges
and drill shelf-pin holes [Drawing 1]. Cut
4 Cut face frame parts G-I [Drawing 2].
Form the stile mortises and then cut the
rail tenons [Drawing 2a] to fit the mortises.
dadoes for the bottom [Photo A]. Rabbet the Groove the stiles (G) to fit the tongues
inside edges of the frame openings and formed on the side stiles (A). Bandsaw and
square the corners with a chisel to receive sand the arc on the lower rail (I). Tip! Dry-assemble the
the glass. Finish-sand the sides.
3 Cut the glass stops (E, F) W longer than

listed [Materials List]. Finish-sand the stops
5 Glue and clamp the face frame. With the
glue dry, finish-sand it.
Cut the bottom (J) and trim (K) [Exploded
sides, face frame, and
bottom assembly to
check the fit of the parts
and set them aside. G View]. Glue the trim to the bottom, flush before gluing.

V4 X 1 Yz" mortise
'W'deep
~
6"
1
•
__ .
,· ·1
.1
,
139116" x23%"
single-strength
seeded glass
3,4"
micro pin
I) V4x1%,'mortise
%"deep
EmDOOR RAIL
at the top and bottom and centered end to

end. With the glue dry, finish-sand the parts
and chamfer the front edge.
Build the doors
II>Download a free
plan for making your
7 Assemble one side (A -D) to the face frame
[Photo B]. Glue the bottom assembly (J/K)
into the side dado and to the top edge of the 1 Cut door parts Nand 0 and form the mor-
tises and tenons [Drawings 3 and 3a]. Glue
own squaring braces. face-frame lower rail (I). Glue and clamp the and clamp the doors. With the glue dry, rab-
woodmagazine.com/ remaining side to the bottom assembly and bet the rear edges of the door openings and
brace face frame. square the corners with a chisel. Drill holes
for pulls [Sources]. Finish-sand the doors.
B Cut the stretcher (L) and rabbet the
ends and edge [Exploded View]. Glue and
clamp the stretcher to the sides, flush at 2 Cut the door glass stops (P, Q) Yl" longer
than listed. Finish-sand the stops and set
the top. Drill counterbores in the edges of the them aside.
upper rails (C) for figure-S fasteners [Drawing II> Hang perfectly
la, Sources]. Sand YI6" chamfers on the bot-
tom ends of the stiles (A, B, G). Cut the back
3 1nstall the doors in the case with no-
mortise hinges [Drawing 3, Exploded View,
Sources], leaving equal gaps all around.
spaced inset doors.
woodrnagazine.com/
(M), finish-sand, and set it aside. Install magnetic catches [Sources]. fittingdoors
woodmagazine.com 27
Top it off
1glueFor the top (R), cut two }4 3;:ts x 43" rails
and edge-join a }4 x 10 x 12" panel. With the
dry, crosscut the panel in half. Assemble
X
the top [Drawing 4, Photo C].

With the glue dry, trim the top to length,
2 and rabbet the upper inside edges of the
opening [Drawing 4]. Bevel the ends and front
edge [Exploded View, Drawing 4a] on the table saw.
• Finish-sand the top .
It Finish up
Remove all hardware. Inspect all parts and
1 assemblies and finish-sand where neces-
sary. Apply a finish. (We used water-based
satin polyurethane.)
clamp the panel halves between the rails, creating an opening for the top glass.
DTOP (Top face shown) [ElBEVEL

i------- 42%"------4
Materials List
FINISHED SIZE
Part T W L Mall. Qly.
Case
A side front stiles %11 lW' 34W' QO
-53f&"~ B side rear stiles *n 2" 34W' QO 2
C side upper rails ¥." 4" 13!4" QO 2
Cutting Diagram D side lower rails -%11 5%" 13!4" QO 2
E' side vertical stops Ytlll Y<t1l 23¥." QO 4
f::' ~6'i Qr~~aw"whit, oak

4l)E--------l
J
-
*Plane or resaw to the thickness
listed in the Materials List.
F*
G
H
side horizontal stops
face-frame stiles
face-frame upper rail
face-frame lower rail
bottom
1;4"
*11
%"
%11
*"
¥I"
2"
2"
3"
14¥." 37W'
ll¥."
34%"
36"
36"
QO
QO
QO
QO
OP
4
% x 7~ x 48" Quartersawn white oak
Il
trim 1"
8,.-------· j K ¥411 34W' QO
~ r-...I
G G stretcher ¥.tn 2" 38" QO
:%. x 5% x 96" Quartersawn white oak M back *11 38" 28¥2" OP
Doors and top
It I:
% x 9~ x 96" Quartersawn white oak
G
G l N
0
P'
Q'
door stiles
door rails
door vertical stops
door horizontal stops
¥."
%"
!Ali
1;411
2"
1;411
IA"
27Ys"
2" 141'116"
23o/a"
13¥16" QO
QO
QO
QO
4
R' top %11 17W 42W' EQO

'Parts initially cut oversize. See the instructions.
Materials key: QO-quartersawn white oak, OP-white oak
~.,'
I plywood, EQO-edge-joined quartersawn white oak.

Supplies: #8xo/a" flathead screws; ¥." micro pins; !4" shelf pins
(8); 12Yax23o/s" single-strength seeded glass (2); 13o/16X23Y2"
single-strength seeded glass (2); !4xl0o/ax32¥a" glass, edges ground
0 and polished; 14xl4o/ax36lB' glass, edges ground and polished (2).
> Blade and bits: Dado set; 14' and ¥a" rabbet router bits.
:%x24x48" Sources: Figure-8 fasteners, 20-pack no. 13KOL50, $3.30 pk.
White oak plywood (1 pack); ball-tip full-wrap inset hinges, dark antique English finish no.
0IH30,32, $4.70 ea. (4); ¥s" rare-earth magnets no. 99K32.03, $0.75
ea. (2); ¥So panel magnet cups no. 99K32.72, $2.90 ea. (2); Y2" steel
washers no. 99K32.62, $0.60 ea. (2), Lee Valley, 800-871-8158,
Produced by Jan Svec with Kevin Boyle and Brian Bergstrom leevalley.com.
® Project design: Kevin Boyle Vertical pulls with cast drops and antique finish no. MS-28, $23.25 ea.
Illustrations: Roxanne LeMoine, Lorna Johnson (2), Horton Brasses, 800-754-9127, horton-brasses.com.
:.'4 x 48 x 48" White oak plywood 28 WOOD magazine March 2019

Note: Seeded glass in
the sides and doors
2widthHave single-strength glass cut to fit the
sides and doors (Vs" less in length and 3 Install the doors and hardware. Secure
the top with figure-8 fasteners. Move the
than the rabbeted openings) or cut it case to its ultimate location and install the
Tip! To get the best fit for
the top glass panel, take
the finished top (R) to a
provides an antique yourself from glass you already may have on top panel and rest the shelves on shelf pins glass shop and have
look. U;e standard hand [Skill Builder]. Have 14" glass cut and the [Sources]. Arrange your collection on the them cut and finish the
glass for th~ top and edges ground and polished for the shelves shelves, step back, and see it sparkle! • glass to leave a 'll6" gap
shelves. and top panel. Trim the glass stops (E, F, P, all around.
Q) to fit and install the glass. (We used a
micro-pinner to secure the stops.)
SKILL BUILDER
Cut glass, save cash
That assortment of perfectly good single- and
double-strength window glass in the corner of
your shop is worth around $3 per square foot.
Here's how to safely and effectively cut that
glass to size for anything from cabinet doors to
picture frames.
Cover a flat, sturdy worksurface with a heavy dropcloth to prevent scratching the glass and gather your
Make a straightedge using any sturdy ¥<In-thick Wipe the area of the cut with a clean damp cloth to Position the straightedge and drip or brush paint
material from tempered hardboard to aluminum remove dirt and grit. thinner along the cut path. The thinner lubricates the
bar stock. Apply self-adhesive bumpers to prevent cut, ensuring a cleaner score line, and prolongs the
slipping. life of the cutter.
Grip the glass cutter between index The score line should be even and continuous with Position the score line just off the edge of the
fingers. Apply firm, even pressure with your index no gaps. Do not rescore the line, as doing so usually worksurface, firmly grip the waste piece, and snap
finger as you draw the cutter over the glass along leads to a bad break. the glass along the score line with a quick, firm
the straightedge in a single stroke. downward motion.
woodmagazlne.com 29
Find exotic wood species at retailers that specialize in hardwoods, such as
Most hardwood retailers offer short boards and sample lots at reduced Woodworker's Source, shown here. These imported woods offer distinctive
prices. Take advantage of those to try working new wood species without looks not common with domestic species, but at a premium price due to their
much risk. origins and greater shipping costs.
fter tools, the wood itself typically Woodworker's Source, Hearne Hardwoods,
A takes the biggest bite out of a wood-

worker's wallet. Home-center lumber
proves a hard-to-resist temptation because
and Talarico Hardwoods, buy (or mill the
wood themselves) in great enough quanti-
ties to offer competitive pricing. The wood
~Hardwood: Any tree of the convenience. But that premilled lum- from these sellers usually comes skip-planed ~ Skip-planed: Wood
that sheds its leaves ber, especially hardwood, sells at a premium just under its designated thickness. For planed on both faces
annually (deciduous). price, compared with buying it roughsawn example, 4/4 lumber (starting at I") might just enough to reveal
Softwood: Any tree or partially milled. Starting from the log, be 1'8" thick. You can plane away any slight the grain, but retaining
that has needles every handling and machining step that's warping that might occur after the wood some milling marks.
rather than leaves and done before you buy it adds to your cost. So stabilizes, and still get ¥I"-thick boards. Roughsawn: Wood
stays green all year the closer you get to the log, in most cases, Unless you can visit the business, most that still has its
(coniferous). the more you save. You'll also have to do times you have to trust their selections with- just-off-the-sawmill
more of those machining steps, but you can, out seeing the boards. Shipping costs can surfaces.
over a few projects, save enough money to quickly eat up the savings oflower-cost lum-
pay for a jointer and planer, two machines ber though, so shop around and compare; a
crucial to dimensioning rough lumber. You retailer located closer to you will likely have
can also find a greater selection of sizes and lower shipping costs. Check with trade
species by shopping at businesses dedicated groups, such as the Hardwood Distributor's
to selling wood. Let's look at the options. Association (hardwooddistributors.org), to
find nearby retailers.
Woodworking retailers When shopping for lumber online, you
These businesses specialize in all things might be able to view specific boards, but
woodworking: tools, machinery, bits, blades, more often will be "buying blind" and
hardware, glues, finishes, and, yes, some simply getting what the retailer sends.
kiln-dried wood. For example, Woodcraft Also, unless stated, you won't know the
~S4S: Wood that has and Rockler sell selections of S4S hardwood moisture content of the wood and how it
been surfaced on all boards, veneer, and natural-edge slabs. If will react to your environment. Be sure to
four faces and edges. you live near one of these stores, you'll save check the company's return policy for
money by not paying for shipping, and gain wood. You might get a break on shipping
the ability to sort through the boards to find costs by buying in greater quantity or
~ Learn more about what you want. Some stores will cut boards price. Some retailers offer online shopping,
hardwood terminology to shorter lengths. where you can see and select specific slabs
and grading or lumber lots, complete with photos. And
specifications. Hardwood retailer/wholesaler many of these businesses also sell high-
woodmagazine.com/ Companies that specialize in selling kiln- quality sheet goods in a wide variety of
bdft dried wood, such as Jewell Hardwoods, hardwood veneers.
woodmagazine.com 31
Flalneawn (all boards) Quartersawn Riftsawn
Sawmill/custom sawyer and stack the lumber. Also, you can direct "Watch a video of
Purchasing from a local sawmill or sawyer how the sawyer cuts the log. An experienced, a bandsaw milling a
often proves one of the best values in lumber skilled sawyer will typically cut logs for log, as well as tips for
buying. These mills typically buy logs from maximum yield with the least amount of stacking the lumber.
•• Learn more about within a few hundred miles of their loca- time and effort. This results in more plain- woodmagazme.com/
wood moisture content tions. So your choice of wood species will be sawn lumber (above). To.get more quarter- bandsawmil
and how if affects limited, compared with national retailers. If sawn or riftsawn lumber, you'll get less yield
lumber. the mill has its own kiln for drying lumber, and pay more for the extra labor. As soon as
wooornagazme.com/ expect to pay more than for air-dried you've cut the wood, stack it to dry (shown
wood moisture boards. Air-dried lumber will likely mea- below left) in a barn, shed, or anywhere out
sure about 12-15 percent moisture. (Ideal of direct weather.
working moisture is 6-10 percent; that fig- If you prefer, you can buy your own band-
ure varies by climate.) This wood will typi- saw mill (below center) or chainsaw mill
"To locate a sawyer' cally be roughsawn; to work this lumber (below right) and saw your own logs into
near you, search the you'll definitely need a jointer and planer. lumber. Entry-level bandsaw mills start at
websites of bandsaw- If you have your own logs, a sawyer with a around $4,000. Many chain saw mills sell for
mill manufacturers. bandsaw or chainsaw mill can often bring less than $1,000, but you'll need a hefty
Most have locator the mill to the logs, or you can take the logs chainsaw (another $800 to $1,300 plus rip-
services for customers to the mill. Either way, you pay for the saw- ping chain) to power it. Most chainsaw mills
who use their mills yer's services, but keep all the wood. Some require a great deal more physical labor in
professionally. sawyers discount their fees if you help cut milling logs, compared with a bandsaw mill.
Stack fresh-cut boards to air-dry with narrow A bandsaw-mill operator will custom-cut logs to A chainsaw mill has the added benefit of being
spacers (called stickers) between each row. Let the your specifications. These mills cut the thinnest kerf, the most portable, letting you cut a log where it
wood dry for at least one year per inch of thickness. wasting less wood. fell, eliminating the need to drag or move the log.

Other- cost-saving options
• Auctions. Many farm and estate auctions • eBay. Like craigslist, this online buy/sell
include stacks of lumber, sometimes. includ- site reaches nationwide, but you can limit
ing gems, such as walnut, cherry, or white your search to po stings that originate within
oak. Auctioneers typically sell this lumber by a certain radius of home, using the
the stack, and often at bargain prices. When "advanced" search option. When buying
assessing a stack of lumber, determine the boards from a seller too far away to drive,
species, quality, and approximate board foot- expect to pay shipping costs. Wood on this
"Board foot: The age. If possible, scrape a few boards to get a website tends to involve specific boards or
measure by which peek at the grain. And beware of potential slabs, or unusual pieces, such as burls.
hardwoods sell. A pitfalls: The lumber could contain nails, nail Always check the seller's rating: IOO-percent
board foot equals 144 holes, splits, cracks, or worm and insect dam- positive feedback helps ease worries about
cubic inches, such as a age. Armed with this information, bid buying something sight-unseen. And you
1x12x12" or 2x6x12" accordingly. Also, be sure you have a way to can, in most cases, readily return items pur-
board. transport the lumber-most auctions require chased on eBay-something not possible
you to take your prizes home that same day- with craigslist or auction sales .
as well as a dry place to store it. • Club links and discounts. Woodwork-
• Craigslist.org. This online buy/sell site ing clubs or guilds might provide members
can be both a gold mine and a junkyard, so with discounts at local retailers. Many clubs
browse and shop with a discerning eye. To also provide links and contact information
make it easier to see and get the wood, search for trusted retailers along with sources for "If you do buy your
only the area within driving distance. Ask wood and other supplies. So that club mem- lumber from a home
"A few tools to carry for details, such as board sizes, condition, bership might pay for itself in savings avail- center, read more
with you when looking and moisture content. Always look over the able only to members. And, club members about how to shop for
at lumber: moisture wood in person before handing over money! tend to share information about sources, the best quality.
meter, tape measure, Inspect and measure the boards to make and even sell their own lumber at times .• woodmagazlne.com/
pocketknife, block sure you're getting the correct species and homecenterlumber
plane, calculator. amount advertised. Produced by Bob Hunter
" Safari Ate Edit View History Bookmarks Window Help
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(Rosevile, MN) S2000 (North St Paul, MN) S2000 (North SI Paul, MN) """
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Searching for lumber online can lead to occasional gems, but be diligent in determiningwhat the seller has before going to take a look. Some sellers
overestimate or don't know exactly the type and amount of wood they have.
woodmagazine.com 33
Seed Starter Tips
Seed starters protect seedlings from temperature extremes until they're ready to plant in a garden. Here's how to use your new project:
• To check the temperature in the seed starter without going outside, install a remote-sensor outdoor thermometer [Sources] inside the frame. Some models
even record high and low temperatures.
• Before starting plants, practice controlling the temperature within the box. Monitor the heat buildup on sunny days and prop the lid open as needed to
release excess heat.
• For better temperature control, line the inside walls with 1"-thick foam insulation board. Leave a 1" gap between the top of the foam and the top edge of the
wooden box.
• To seal in warmth at night, lay a foam board on the top edges of the foam liner. An old blanket draped over the whole seed starter also helps.
• Place jugs of water inside the frame. The heat they store up during the day releases gradually at night.
• If you position the seed starter on a deck or patio to grow seeds in pots, rest it on at least one layer of foam board.
EXPLODED VIEW
DCORNER JOINTS
E ~i---~.....,.---...;-"_
-~-_ n
----1---;2
Profile 1 BOX FRONT/BACK Profile 2
Profile 1
it : 0 43
1%"
1 3'"
BOX END
14 1'12"
1'12" [ElJOINT DETAILS
1%~.
Profile 1
&tP
13,4" Profile 2
~ Avoid using pressure-

treated lumber when
growing edibles such as
herbs or vegetables.
Build the box

For each layer (A/B), you'll cut different but Clamp two box fronts/backs (A) and two
mating profiles at opposite ends for a chasing 2
ends (B) on edge with the outside faces
assembly. Three layers stack to lOlh" high, but away from you and the ends flush. To estab-
you can add more to boost the height of the lish the shoulder of each joint, cut a 1%"-deep
sides. Repeat Steps 1-6 for each layer. . kerf Ilh" from the flush ends [Drawing 1, Photo
Cut the box fronts, backs, and ends (A, B) A]. Flip the pieces onto their opposite edges,
1 to length [Materials List]. Label the outside make the unsawn ends flush, and clamp and
face of each piece. With the outside face saw as before.
toward you, mark the left end "Profile I" and To cut the Profile 1 ends, tilt the base of a
the right end "Profile 2" [Drawings 1 and 1a]. 3
jigsaw to 15° [Photo B]. Mark a centered line
rJ
Align the ends of the box pieces (A, 8) for consistently positioned kerfs and a wide, stable surface for the With your circular-saw, crosscut a scrapwood block
saw base to ride on. at 15°. Use the block to set the jigsaw blade angle.
woodmagazlne.com 35
Make the angled cut slowly on the waste side to Press a handsaw blade against the "keeper" side the angle from the cut end to the inside
ensure a straight cut that, if necessary, can be fine- of the kerf and cut at an angle to remove the waste, face of the mating piece. A square helps ensure the
tuned with a chisel. edges stay flush as you mark.
on the inside face of a front/back (A)_ Jigsaw

along the line to the circular-saw kerf [Photo CJ- 2 Cut the lid backs and fronts (D, E) to
length, but wait to cut the bevels. Glue and
4 Complete the cut using a handsaw [Photo

DJ- Repeat for the other Profile 1 ends,
screw two lid wedges (C) to a lid back and
front. Add the second lid back and front and a
third wedge.
5 Scribe a Profile 1 end onto the inside face
of its mating piece [Photo EJ _ Set the jigsaw
base back to 90° and cut along the scribed 3 Sand or plane bevels [Drawing 2J on parts D
and E to match the lid wedges (C).
line [Drawing 1, Photo FJ- Repeat for the remain- Cut the lid rails (F) and stiles (G) to size, ~Use a wood glue
ing Profile 2 ends. 4 and glue and screw them together, Glue rated for exterior use.
6 Test-fit each joint [Photo GJ- Screw the

frame pieces together [Exploded ViewJ_
this assembly to the lower assembly (C-E).
5 Plane or sand bevels on the lid rails (F)

[Drawing 2J- Then sand the lid assembly
Tlpl For smooth cuts Top it with a lid (C-G)_
from your circular saw, Layout the lid wedges (C) [Drawing 2J on a
use a 40- or 60-tooth
blade.
1 2x4_ Rip them to shape [Photo HJ before
cutting them to length.
Ripping the lid wedge (Cl angie from an oversize

Cut on the waste side of the scribed line connecting Adjust the fit of the for flush frame edges piece of stock makes it easier and safer to cut with
the end of the board to the circular-saw kerf. with no gaps between the pieces. a circular saw.
EJ LID ASSEMBLY
1" hexhead screws with sealed washers
~1 ~ 1
~ or -
#9x2%"
deckscrew~ 6° bevel added
after assembly
Add the finishing touches Materials List

FINISHED SIZE
Apply exterior-oil finish or paint to the lid Part T W L Mall. Qty.
1 and frame assemblies. (We used natural- A box fronts/backs 1W' 3W' 48" DF 6'
2-
tone Thompson's Waterseal timber oil.) 8 box ends 1W' 3W' 24" DF 6'
Note: Drilling l4" holes Cut two 26"-wide clear panels 27" long C lid wedges lW' 3%2" 24" DF 3
in the plastic allows the [Sources] using a 40- or 60-tooth blade.
D lid backs 1W' 3%2" 21%" DF 2
panel to expand Drill I4" holes in the valleys of the corruga- %11 1W'
E lid fronts 21%" DF 2
without buckling. tion [Drawing 2]. Cut foam closure strips to
Avoid overdriving follow the corrugations. F lid rails 1W' 1W' 48" DF
washer screws-the G lid stiles
gasket should not
squeeze out around the
3 Center the panels on the lid (they overhang
on all sides), and screw the panels and
foam to the lid rails (F). Install the hinges
1W'lW'
'Cut additional parts to build a taller frame.
Materials key: OF-Douglas fir.
21W' DF 3
washer. [Exploded View]. Supplies: 26"x6' clear corrugated roof panel, foam closure strips
(8' total), 4" exterior butt hinges (2), 1" hexhead screws with sealed
4 To install the cold frame, prepare a flat
location on bare soil. (Add soil amend-
ments or nutrients as needed.) Rest the bot-
washers, #9x2\2" deck screws, #10x1\!!" flathead screws.
Blade: 40- or 60-tooth circular-saw blade.
Sources: 26'<6' clear corrugated roof panel and foam closure
tom frame on the soil and drive 2x2 stakes at strips available at most home centers.
the inside corners, leaving enough of each ThermoPro PT-60S digital indoor/outdoor thermometer, $17.99,
woodmagazine.com/outdoortemp
stake exposed to hold the remaining stacked
frames and lid assembly in place .•
Produced by Robert Wilson with John Olson
Project design: John Olson
Illustrations: Roxanne LeMoine, Lorna Johnson
woodmagazlne.com 37
You gotta obey the speed limits
For best results running a CNC, you must control the feed rate and rpm of the router. You do this all the time with handheld routers, probably without
thinking about it. Handheld routers constantly provide tactile feedback and you respond by changing feed rate, reducing the depth of cut, changing the
rpm, or all of the above. A CNC router can't respond like a human, so you need to tell the machine what to do. Otherwise, it will quickly dull or break bits,
and produce poor-quality cuts. Check the machine's owner's manual to learn how to set rpm and feed rate. II>Try a free trial
This article serves as a starting point rather than a comprehensive feed and speed guide. If you use different router bits or materials (such as of a speed and
aluminum instead of brass) you'll need to experiment, and possibly change the listed parameters. Some CNC routers yield good cut quality at faster feed calculator.
feeds, others require slower feed rates. Good cut quality and router bit longevity depend on chip load-the size of the chip the router bit makes. If you woodmagazme.corn/
see dust, not chips, the setup needs tweaking. Find chip-load calculators on the web; router bit manufacturers also can help. cncfeedspeed

Wood sign: Incised letters
~Watch a free video When people first consider what they'll make
demonstrating each with a CNC router, making wood signs tops
of the projects shown. the list. Master this simple process and earn
woodmagazine.com/ back some of the money you invested in the
cnccuts machine, or just knock out some cool gifts.
" For the letters and cup:

• Router bit: 60° Yzn V-bit
• RPM: 12,000
• Feed speed: WOn/min
~ Toolpaths
I \l.: V-Carve I Engraving Toolpath
Notes: To create an
incised sign, select only
the letters and the
coffeecup when you Edit .••
create the V-Carve/
Engraving Toolpath. An engraving toolpath requires no depth of cut. The
software automatically "fills" each letter based on
Cut most hardwoods the angle and diameter of the V-bit.
with the feedand speed
shown here. For cutting the exterior:
For the rectangle border: • Router bit: ]i4" upcut spiral
• Router bit: 60° Y2" V-bit • RPM: 12,000
• RPM: 12,000 • Feed speed: WOn/min
• Feed speed: WOn/min
j Toolpaths q.1
1 Toolpaths
I~ 20 Profile Toolpath
~ The designs and
toolpaths used in this
article were created in
Cutting Depths VCarve Pro, software
Cutting Depths Start Depth (0) 10.0 I inches commonly used
o.::~ Start Depth (0) 10.0 1000es t --........ Cut Depth (C) 10.725 I inches with benchtop CNC
llCUt Depth (C) 10.06 I OO1es I o Show advanced toolpath options machines.
o Show advanced toolpath options a Tool: End Mil (0.25 Ind»
Find it at vectric.com.
a Tool: V-Bit (60 deg 0.51 I Select .,. I I Edit .•. I

I Select •. , I I Edit ••• I 61
Passes: I Eelt Passes .•• I
Passes: 1 I Edit Passes ••. I Hachine VectOr5-.
0
!'lachine vectors., @ Outside I Right
o outside I Right o
W
Inside I Left
o In"side I Left OOn
@On I' Direction Octmb ® Conventional
Direction o Climb @ Convention~
-_ AIowance offset 10.0 1000cs
AJIooN<YICCoff~et 0.0 inches Duse vector start points (don't op!inVze)
D Use vector start pOOts (don't optimize) VCarve Pro automatically chooses the number
T~is toolpath requires Cut Depth as it "traces" a of passes based on bit diameter and material
single line, not a letter with boundaries. The .06" thickness. You can modify this as needed, with
(about 1116") creates a visible detail. Don't worry about harder material requiring more passes.
the image under Cutting Depths that shows a square
profile rather than a V. This is a standard image for
this toolpath, regardless of the bit being used.
woodmagazine.com 39
Wood sign: Raised letters
These first two projects show how using dif-
ferent toolpaths on the same design can
dramatically affect the final look. This
shows the versatility of CNC router work.
For the letters, coffee cup, and border:

• Router bit: W' upcut spiral
• RPM: 12,000
• Feed speed: 100"/min
Note: To get raised

letters and graphics, For cutting the exter~io~r~:
~- •.•• __ ~~:~,
select the border, letters, • Router bit: upcut spiral
and coffee cup when • RPM: 12,000
you cr~ate the toolpath. • Feed speed: 100"/min
• Router bit: 60° Yz" V-bit
• RPM: 12,000
q.
1 Toolpaths
Cutting Depths
Start Depth (0) 10•0 lindles
V-Carve I Engraving Tootpath t Cut Depth (C) 10•748 I inches
o Show advanced toolpath options
~ Tool: End Mil (0. 25. inch)
I Select ... I I E<it. •• I
Toot V-6It (60 deg 0.251 Passes: 6 I EditPasses ... I
I Select... I I Edt ...
f>1achine Vectors...
o Use Flat Area Clearance Tool
tlJ
@ Outside I Right
End Mil (0.25 inch) o Inside /left
,-'I I
Ir-~-'..-:-- Edt. .. 000
Direction ()arOO @Conven!iooal
Flat Depth tells you how much the
letters and cup will project beyond the Alowllnce offset 10•0 I inches
background. The %" bit serves as a Flat o Use vector start points (don'toptmze)
Area Clearance Tool, removing waste faster
than a V-bit, which routs the finish details. You can cut Outside, Inside, or On the line you've
This one tool path shows both bits but they created. This controls where the router bit cuts
wil , of course, be used separately. relative to the design.
Toolpaths q. Although VCarve

Pro has an on- board
dragknife gadget built
Imported Toolpath into the software, it
shows up here as an
imported tool path.
Cutting Depths
Start Depth (0) §::JOOles
Cardboard templates Cut Depth (C) ~inches
Notes: This tool Create shapes in drawing software, such as
comes with great setup SketchUp, then turn them into templates you Tool
instructions. To create can trace onto your project parts. Instead of a ~ Dragknife End 14
the toolpath within router bit, cut with a utility-knife
VCarve Pro, use the
DragknifeToolpath • Tool: Donek D4 drag knife
The selected toolpath has been created
Gadget. The knife cuts • RPM: 0 in another p(ogram.
materials up to j,f' • Feed speed: 100"/min
thick, such as Only the ~edr etes and start depth can
be modified here
cardboard, styrene, and
vinyl-letter material.
i Toolpaths q.
Notes: In addition to
Cutting Depths controllingfeed rate
tr~:: Start Depth (0) 10.0 I inches and rpm, be careful
CUt Depth (C) 10.27 I Inches about DOC when
[;1 Show advanced toolpath options
machining nonjerrous
metals. Dividing the .27
II. Tool: End Mill (0.125 inch) Cut Depth by the 10
[Select ... I [E'diC"J passes results in a light
.027" DOC with each
Passes: 10 C edit Passes... I pass. You can use a
3GO-brass bowtie Machine Vectors •••
similar setup to cut
11>360 brass is a Yes, a CNC router can cut non-ferrous aluminum or coppel;
0
@ Outside I Right but different materials
metals. Add aluminum, copper, or
specific type of readily
available brass brass inlays and other decorative
o Inside /left
dictate slight changes in
[Sources]. items to your projects. OOn these settings.
Direction o Climb @ Conventional
• Router bit: YB" spiral "0" Allowance offset 10.0 I inches I

single flute o Use vector start pOOts (don't optimize)
• RPM: 18,000
Cutting non-ferrous metal requires light cuts, so
• Feed speed: 40"/min the machine makes many passes.
Engraving granite
Diamonds are a CNC's best friend, espe- Notes: The diamond drag comes with excellent
cially for engraving glass, granite, or steel. A setup instructions. Increasing DOC on the
diamond-tipped stylus etches amazing spring-loaded tip applies the additional pressure
detail on these materials, and others. requiredfor harder material. It may take some
experimentation to get the best cut, depending on
• Tool: Diamond drag the material. Use this tool on plastic, glass,
engraving bit aluminum, brass, and steel. Choose a 120° tip for
• RPM: 0 engraving, and a 90° tipfor scoringglass so you can
• Feed speed: 30"/min snap it on the score line.
j Toclpaths q.
I~ Quick Engrave
I~. Tool: Diamond Crag

I Select •.• I I Edit ... I
Find lots of options
to experiment with Depth I Pressure ~OcheS
in the Quick Engrave J
tool path. Stepover
controls line spacing
within the engraving. A
1r 0 Outline T @FlII
small number places Stepover ~ Inches
the lines close together
making the final result o Offset @Hatch
T
appear more opaque. Hatch Angle
Hatch Angle is the angle
at which the lines are ~degreeS
engraved. I commonly
use 45°-experiment to
o Cross Hatdl
see what you like.

woodmagazlne.com 41
Polycarbonate
Etch polycarbonate to create a translucent
sign to hang in a window. Or back- or edge-
light it with LEDs for a cool glow.
For etching the letters:

• Tool: W' spiral "0" single-flute,
plastic cutting used for all operations
• RPM: 16,000
Note: When making • Feed speed: 70"/min
signs in polycarbonate,
reverse the image and
cutfrom the back, j Toolpaths q.
leaving the front
smooth.
Pocket Toolpath
Cutting Depths
~ StNt Depth (D) 10.0 lin<hes
Cut Depth (C) 10.07 lin<hes
For cutting the exterior:
o Show advanced toolpath options • RPM: 16,000
a Tool: End Mi (0.25 inch)
I Select ... I I Edit ... I l Toolpaths q.
Passes: 1 I Edt Passes ...

A light Cut Depth suffices for etching letters or
I 19 20 Profile Toolpath
artwork in polycarbonate and typically can be done Cutting Depths

in one pass. 9.:~ Stan Depth(D) 10.0 I inches
L Cut Depth (C) 10.22 I inches
For boring the hanger hole:
Tool: End ~1iI (0.25 inch)
• RPM: 16,000
• Feed speed: N/A I Select ... I I Edit ... I
j Toolpeths q.
Pas.ses: 3 I Edit Passes '" I
[~
Cutting Depths
~
.
Drilling Toolpath
Start Depth (D)

Cut Depth (C)
10•0
10•26
IndleS
1nd1eS
I r-1achine Vectors_
@ OUtside I Right
o Inside /left
000
Direction
Alowance offset
@Cinb
10.0
a
o Conventional
I inches
l Tool: End Mil (0. 2S inch) oUse vector start points (don't optimire)
I Select ..• I I Edit •.• I last Pass
10 Use Peck DriDing
o @Retract above the OJttng start
depth :L inches
I It
,.,.~ oprevious
Retract above the height of the
- oReverse di"ection
pass Choosing Do separate last pass optimizes the
surface finish of the cut. In this case, the part gets
Retract Gop (R) ~ inches cut .015" oversize. The last pass skims off that
small amount of material, providing a smooth edge.
Peck Depth (P) 0.125 i1ches
Note: Ped; depth is controlled by the

'Pass Depth' for the tool
When you Retract above the cuttmg start depth,

the bit repeatedy drills, then raises. That clears the
flutes of material prone to sticking to the bit.

Foam insulation
Prototype a project before cutting into
expensive wood by cutting and carving
foam insulation. Thick foam serves well for
paintable letters, decorations, and more.
For initial 3D roughing:

• Tool: \12" spiral upcut
• RPM: 12,000
~ Tootpaths
Rough Machining Toolpath
Q Tool: End MI (0.5 inch)

I Select... I Edt ••.
r-tachining limit Boundary

® Model Boundary For cutting out the exterior:
o !>lattrial6oundary • Tool: Y2" spiral upcut
• RPM: 12,000
o Selected Vector(s) • Feed speed: 100"/min •
Boundary Offset 1 0.0 Inches
Notes: Standard i Tootpaths
TOuter bits will easily
cut pink or bluefoam
insulation sold by home
•...•achlning Allowance
I ~ind1e$
In most cases you machine 3D artwork to the
19 20 Profile ToolJ»th
centers. Painting the
Model Boundary; literally the edges of the artwork. Cutting Depths
final result? Use latex You can choose to cut all the way to the edge of I Inches
paint to prevent
melting thefoam.
material (Material Boundary), or to a shape that you
created (Selected Vectors).
f: Start~ih
Cut Depth (C)
(0) 10.0
12'.02 I inches
Q Tool: End Mil (0.5 inch)
For 3D finishing: I Select... I I Edit ••• I
• Tool: Y2" roundnose router bit
• RPM: 12,000
Passes: 12 II'--e<itp~ '" I
• Feed speed: 100"/min Nachlne Vectors.••
0
1 Tootpaths q. ® Outside I RIght
o Inside /left
Finish Machining Toolpath OOn
Direction OCknb ® Convenliorull
l Tool: 6<111 t\'o$e(0.5 inch) Allo';\'~'Keoffset 10•0
o U~ vector start points (don't optln'ize)
1i1thes
I Sdtct... I Edit ..•

Use the Edit Passes function if you want to increase
Nachinlng limit Boundary or decrease the number of passes.
® !>Iode!8ou'Idary Sources: Freud 60· Yl V-bit, no. 20-152; Freud W upcut spiral, In addition to classes at
Ol'l~terial Bound¥v no. 75-102; Amana Va' spiral '0' flute aluminum cutting, no. 51454; Vondriska Woodworks in
o SelectedVettor(s) Amana W spiral '0' flute plastic cutting, no. 51404; Donek D4 drag
knife; WidgetWorks Unlimited diamond drag engraving tool; Whiteside
Hammond, Wisconsin, George
teaches at woodworking shows,
W upcut spiral bit, no. RU5200 (for l' foam you can use a shorter bit); guilds across the country, and
1 _ ___.1 inches
Boundary Offset •..•0_.0 Whiteside W ball nose bit, no. 1408. The link below places all of the Weekend With WOOD. Get more
True ball nose bits are CNC specific and a must- above bits in an Amazon cart; you can remove any you don't need. GNG instruction in George's
have for small-scale 3D work. For this large 3D woodmagBllne.com/cncblts book, 'GNG Router Essentials:
artwork, a :1/2" roundnose router bit works fine. 't4x 2 x 12' G360 brass plate, Stoner Metals, stonermetals.com, The Basics for Mastering the
719-629-9525 Most Innovative Tool in Your
12 x 12' granite tile, Home Depot Workshop.' woodmagllllne,com/
Polycarbonate sheets, home centers cncessentlnls
woodmagallno,eom 43
MiI-s
z x
C
o~ turboshaft
x
engines
cn~ enable a
z:E
~~'" 152
knots top cruise
~~
-;;= speed. (Yours
may vary.)
t:I~
irst seeing service i!ID. 1986,
F "Apache" attack helicopter

tanks, bunkers, and other
toy displays much of that firepower, Ul:;g UJ.~.!j:.1!I
as maple dowels. Easily shape the
iconic angled fuselage profile by
full-size patterns. And we've ga1:helre:!i1:
the hardware and specialty parts in:
you can get started quickly [So_.
TlpI LfiJaofJ how to easj~ applM

and remove par·teFliIs.
woodmsgazlne.com/applypattems
'/6" chamfers 'J)
EXPLODED VIEW
%z"axlepeg
1"long
'16" dowel
1"long
W'chamfers
7hz" axle peg 1" long
Build the fuselage assembly

Cut the fuselage (A) to size [Materials List,
1 page 47]. Apply a copy of the Fuselage Side-
view Full-size Pattern, pages 48 and 49, to it. Cut
the fuselage profile and save the cutoff from
under the tail. Drill the Va" hole centered on
the width of the tail.
2 Apply the Top-view Patterns to the fuselage

(there will be a gap between them), and
tape the saved cutoff back in place. Cut the
nose and tail profiles [Photo AJ and the fuse-
lage front [Photo BJ. Remove the pattern
remnants, and finish-sand the fuselage.
wood magazine.com 45
Auxiliary miter-gauge fence
~ Engine/eXhaustblank
I!l
Attach a tall auxiliary face to your miter gauge to steady the engine/exhaust
blank as you cut the kerfs.
Cut the sponsons (B) to size. Apply cop- Cut the rotor base (E) to size and shape
"Much of the
Apache's avionics
reside in the sponsons.
3 ies of the Sponson Patterns to each. Drill out
most of the waste for the landing-gear
5 [Drawing 2]. Round the edges,drill the hole,
and glue it to the fuselage[Exploded View]. Drill
pocket, then clean up the pocket with a through the hole %" into the fuselage.
chisel [Photo C]. Cut the sponsons to shape,
finish-sand them, and glue them in place Give it wings ... and arms • The scanning
[Exploded View]. Cut the stub wings (F) to size [Materials systems on the nose
Tlpl Use cyanoacrylate
glue and a spray-on 4 Cut two 1's x 'l's x 12" blanks for the engines
(C) and exhausts (D). Kerf one end of
1 Ust, Drawing 3]. Round the leading edges
and chamfer the trailing edges. Bevel one
allow the Apache to
operate day or night
accelerator to join small, each [Photo D, Drawing 1]. Round over the end of each at 6° to match the fuselage.Glue and in bad weather.
difficult-to-clamp parts. edges, then miter-cut an exhaust from each the stub wings to the fuselageand sponsons
blank. Bevel-ripthe long edge of each engine with the chamfer facing up.
at 6° [Drawing la], then crosscut the engines to Cut the pylons (G) to shape [Drawing 3a]. •• The Apache's
.Learn to cut and
shape small parts
length. Glue an exhaust to each engine,
angled outward. After the glue dries, drill
2 Cut the missile hangers (H), missiles (I),
en
and rocket launchers to size. Sand a point
helmet-mounted
display allows either
safely. the hole in the engine and glue in an axle on one end of each missile, and drill the the pilot or gunner to
woodmagazine.com/ peg [Source]. Glue the engines to the fuselage holes in the rocket launchers [Pattern]. Glue aim the 30mm cannon
smallparts [Exploded View]. the missiles to the hangers [Drawing 3]. After where they look.
o ENGINE AND EXHAUST

(Top view, port engine)
DMISSILE ARRAY/ROCKET LAUNCHER
7 " +---- 2314" ----~
aY"':" 1 :::~~::::::J Ya" round-overs

%z" hole 1 " deep
[ElENGINE
(Front view, port engine.
Starboard engine is mirror image.)
Ya" round-overs
EJ ROTOR BASE
(Side view)
'/a" round-over

ID FRONT·GEAR STRUT the glue dries, adhere the missile assemblies View]. Assemble the rotor assembly with
(Side view)
(H/I) and the rocket launchers to the pylons. machine screws, a washer, and lock nuts
Glue these assemblies under each wing. [Drawing 6], then secure the rotor assembly by
Cut and shape the front-gear struts (K)
3 [Drawing 4]. Glue them into the recesses in
the sponsons (B).
gluing an axle peg through it and into the
rotor base (E), leaving enough space to allow
the rotor hub to spin. Likewise, secure the
4 Cut the cannon (L) to size and drill the

holes [Exploded View]. Glue the dowels in
the holes and set the assembly aside.
wheels to the struts [Exploded View], and glue a
length of dowel in the tail of the fuselage .•
5 Cut the scanner mount (M) and scanner

(N) to size [Exploded View]. Chamfer the
ends of the scanner, then glue the mount to
Materials List
Part T
FINISHEDSIZE
W L Mali. Qty.
the nose. After the glue dries, glue the scan- A fuselage 1%" 2W' 16W' C
OTAIL
ner below the mount. Cut an axle-peg head
to serve as the night-vision turret and glue it
B
C*
sponsons
engines
*"'Va" W'
'Va"
6'1:>"
2%"
M
M 2
to the top of the mount.
D* exhausts 'Va" 1'a" 1'a" M' 2
Rear tail and rotors E rotor base Y<l1f 1%" 2Ys" M

lAir
Following the Full-size Pattern and Drawing 5,
1 cut the rear wing (0) and tail (P) to shape.
Drill the hole in the tail, round over its lead-
F
G
stub wings
pylons Y<l.1I
JAil
1%"
o/'slt
2%"
1Y16"
C
C 4
H missile hangers %" %" M
ing edge, and chamfer the trailing edge. missiles %" diam, 21f2" MD 8
Glue the wing and tail to the fuselage
rocket launchers %"diam, 21f2" MD
[Exploded View].
K front-gear struts ¥<til %" 10/8" M 2
2 Cut the tail rotors (Q) to size [Exploded

View]. Drill the holes, and secure the
rotors to the tail (P) with an axle peg and
L
M
cannon
scanner mount
%"
Va"
%"
1'a"
%"
1%"
M
3Va"
Va" chamfers~
washers. Trim and sand the axle peg flush N scanner %" diarn, 1 Va" MD
both faces I with the opposite face of the tail. 0 rear wing Ya" 1 Y16" 3%"
To form a blank for the rotor hub (R),
i
!
3 laminate two pieces of Ys"-thick stock with
their grain perpendicular to each other. Cut
P
Q
tail
tail rotor blades
%"
Ya"
1%"
¥a"
3Y16"
2'1:>" M
the hub to shape [Drawing 6], and drill the holes. R rotor hub %" 2" 2" LM
~ Va" round-overs, I Cut and shape the main rotor blades (S) S main rotor blades, Ya" Y2" 7" M 4
, both faces
4 and spacer (T), and drill the holes [Draw-
ings 6 and 6a].
T spacer %" diam,
'Parts initially cut oversize, See the instructions,
%" CD
5 Apply a finish to all pieces. (We sprayed

on satin-finish aerosol lacquer.) Use CA
glue to secure the cannon in place [Exploded
Materials key: C-cherry, M-maple, MD-maple dowel,
LM-Iaminated maple, CD-cherry dowel.
Supplies: Y32xl" axle pegs (6), Y.>" axle peg (1), 1"·diam, wood
wheels (2), 8·32x 0/8" machine screws (4), 8-32 lock nuts (4), #10
washers (5), % x 12" maple dowel, % x 24" maple dowel, Ysx 12"
maple dowel.
Bits: Ya" rcund-cve; 45° chamfer router bits, ¥S" Forstner bit.
Source: Order a kit with the hardware, axle pegs, wheels, and
dowels required for this project (no lumber), No, RS·01209, $5,95,
888·636·4478, woodmagazine,com/apache,
[J BLADE ASSEMBLY
~ MAIN ROTOR BLADE DETAIL
Produced by Craig Ruegsegger with Kevin Boyle

Project design: Kevin Boyle
Illustrations: Roxanne LeMoine, Lorna Johnson
woodmagazlne.com 47
L.
C
;:;-
r- ::r-.::!
r;-(j)"TI
Ul-c '"~ '"e+
-s
1ii
N?il
£T1 Ul 0
£T1 •
-s
:::s
\ISS;: (J\
,,'\ ~~ »£T1G)
=4~£T1
<;
"-(_~i
~5)
£T1
~
. ...._____
~
FULL·SIZE PATIERNS
•• Download full-size patterns for this

project. wooomagezlne.com/apeche
41) I,,
PORT SPONSON
~-----T-----li
, --r-
TOP VIEW
FULL·SIZE PATTERN : : I': 11"
I<!t-
t
, I
, I
'
41)
PORT SPONSON
INSIDE FACE SIDE VIEW 0-fLanding-gear pocket
FULL-SIZE PATIERN
+- 1--------------;
6Y2' -------jl'------t-
/ /
41)
STARBOARDSPONSON
TOP VIEW
FULL-SIZE PATIERN
41)
r
/"
STARBOARDSPONSON
Landing-gear pocket INSIDE FACE SIDE VIEW
FULL-SIZE PATIERN
t-------------\----\------- 6Yz"----------------------1
\ \

'\
Location of
parte!)
f)
FUSELAGE
TOP VIEW
FULL-SIZEPAITERN
7
f)
FUSELAGE
SIDE VIEW
FULL-SIZE PATTERN
------------
<,---- --------
~
7h2" hole
%"cleep
o
REAR WING FULL-SIZE PAITERN
16%"
111116"
t-------------I---
I
3%"--------_1 \--r-----------
Location of
parte
o
ROCKET LAUNCHER
FULL-SIZE PATTERN Join patterns
here.
woodmagazlne.com 49
A lathe-mounted buffing
system shines turnings
and much more.
B
An oil-varnish mix brings out the color of the wood and seals the pores while Sandpaper removes lint that might otherwise find its way onto your project.
creating a foundation you can polish and wax. . Paper protects the lathe from loose polish.
or an eye-catching shine on turned [Photo A, Sources]. Youcan also use Danish oil,
F projects, use the same tool that made

them-your lathe. Then, stretch your
equipment investment by using the same
but avoid water-based finishes that can
soften from the heat of the buffing wheel.
Let the finish dry until you no longer smell
setup to finish other projects small enough solvent on the surface.
to hold. You'll need a set of three buffing While you're waiting for the finish to dry,
wheels, an adaptor for mounting the wheels, begin preparing your wheels. Attach a strip
tripoli and white-diamond buffing com- of adhesive-backed 100-grit sandpaper to a
pounds, and a bar of carnauba wax [Sources]. piece of flat scrap. Then, mount one of the
buffing wheels on your lathe and set the
Begin with a good finish motor speed to about 1,800 rpm. Note: For
A glossy finish starts with smooth wood, so wheel preparation and buffing, wear eye
sand projects up to 320 grit before you begin protection and a respirator to guard against
Sources polishing and waxing. On turned projects, airborne lint and abrasives.
Wood Buff Kit (three buffing follow up sanding on the lathe by hand- Turn on the lathe and press the abrasive
wheels, buffing compounds, wax, sanding with a 320-grit sanding sponge. If against the fabric hard enough to slightly
and a wheel adaptor), $73, you're working with a hard exotic wood, flare out the sides of the wheel [Photo 8]. You
The Beall Tool Co., such as cocobolo, continue sanding up to can reduce the mess by having a helper hold
800-331-4718, 1000 grit. the nozzle of a shop vacuum near the spin-
bealltool.com. You can polish and wax bare wood, but a ning wheel while you press the sandpaper
Waterlox Original Sealer/Finish, film finish provides better protection. We against it. Then, turn off the lathe and vac-
$31.50 per quart, Woodcraft, prefer one with a penetrating oil to make the uum lint and loose sandpaper grit from the
800-225-1153, grain "pop," so the bowl shown received layers of fabric. Repeat this process for the
woodcraft.com. four wipe-on coats of Waterlox Original remaining two wheels.
wood magazine. com 51
Linen/cotton
wheel
Linen wheel
A linen wheel loaded with tripoli polish evens out scratches left by the 320-grit Hold the white abrasive stick against the linen/cotton wheel for only about 2
sandpaper. A low gloss already has started to emerge. seconds to load it for extremely fine polishing.
3 steps to a glossy finish

1 Begin the polishing process by mount-
ing the all-linen wheel and turn on the
lathe, again at 1,800 rpm. Press the stick of
Flannel wheel
red tripoli polish-a dustlike silica-against
the wheel edge until it turns red. Unlike the
finer polish and wax you'll use later, you can
load the wheel with this polish. The tripoli
abrasive breaks down into smaller particles
as you work, so reload the wheel when it no
longer removes the sanding scratches.
To prevent buffing wheels from flipping
the workpiece back toward you, hold it low
against the wheel [Photo CJ and apply light to
moderate pressure. Keep the project moving
arid avoid polishing anyone place for more
than a couple seconds to prevent heating
and softening the film finish.
Frequently check your progress in an
angled light. You should see an even sheen
that contrasts with the duller less-polished
areas. Once you achieve an even sheen, stop.
Then, wipe the surface with a soft cloth. Buffed and waxed to a high shine, this turned bowl reflects light evenly around
its entire surface. Should you need to renew the finish, simply buff on another
2 Replace the linen wheel with a softer
linen/cotton wheel. Turn on the lathe
and touch the white abrasive stick against
coat of carnauba wax.
the cloth [Photo DJ. You only need a small fabric. You'll need even less of this than the
amount of this extremely fine abrasive. white abrasive.
Polish your project as you did with the The wax doesn't polish the finish; it fills the
tripoli wheel, but use a lighter touch and fine scratches left by the white abrasive for a
keep exposing new surfaces to the wheel. glossy surface. Work the surface until the wax
For flat surfaces, polish end to end, with the leaves an even shine. If you notice smudges as
grain, in overlapping passes. you handle the project, you're using too much
After you buff to the desired sheen, wax. Wear off excess wax on the wheel by
3 replace the linenlcotton wheel with a
flannel wheel. Turn on the lathe and lightly
holding a piece of clean scrap against the edge.
Then, buff again until the wax hardens with-
press the carnauba wax stick against the out smudging .•
andpaper seems to be simple enough stuff: sand bound to paper, right? But if you
S read the packages on store shelves, or shop online, your choices in abrasives can
be overwhelming and confusing.
Hundreds of products, many aimed at auto-body shops, industrial cabinet shops,
metalworkers, painters, plumbers, and drywallers, leave many woodworkers in a
quandry. Industry terms and marketing-speak further muddy the waters.
Fortunately, what you really need to know boils down to five items: the size of the
abrasive; how densely the abrasive is packed; the type of abrasive; the backing material;
and whether the sandpaper has stearate or not. So let's sort out these choices.
The truth about grit Closed-coat papers have nearly 100 per- ••.. A swarf buildup clogs
••.. Learn more about First, consider grit size when choosing sand- cent grit coverage and offer quicker sanding the sanding medium,
the two different, but paper. Large, coarse abrasives of 40, 60, and on hardwoods because the swarf on these reducing effectiveness.
similar, scales for 80 grit easily strip paint and perform the species isn't sticky.
grading grit. initial smoothing of rough surfaces. Use
woodmagazine.comj 100, 120, and 150 grit to remove minor sur- Types of abrasives
sandinggrits face imperfections created by cutting and Many, but not all, sandpapers list their abra-
milling. Grits of 180, 220, and 320 serve for sive media on the packaging or back of the
••.. Following an orderly final sanding before finishing, and smooth- sheet. Although any sandpaper abrasive will
sanding process ing between finish coats. Grits 320 and smooth wood, three types work best for
saves time and yields above buff finishes to final smoothness. woodworking, with a fourth that we'll also
excellent results. discuss.
woodmagazine.comj The open and closed case Find garnet [Photo Bj, a natural mineral, on
sandingbasics Abrasives labeled "open coat" [Photo Aj have inexpensive sandpapers best used for hand-
about 30 percent less grit, providing space sanding. The granules, initially sharp, wear
for the dust, or "swarf," to go as you work. quickly, especially when used with power
Choose open-coat paper when sanding soft sanders, which explains why garnet has
or resinous woods such as pine and fir. fallen out of favor with many woodworkers.
P320
Open-coat papers may be labeled as such. Closed-coat papers typically have no Garnet has been used on sandpaper for decades. It's inexpensive, but it doesn't
designation on the label or backing. last long in use, so you end up using more to get the same results achieved with
other abrasives.
Hard but brittle silicon carbide [Photo C] enough to break them. Manufacturers may
fractures easily, creating fresh cutting edges blend ceramic with other abrasives, such as
as you work. The brittleness makes it less aluminum oxide or silicon carbide, to create a
suitable for coarse grits but a good choice for longer-lasting sandpaper [Photo E].
finish-sanding by hand, as well as for rub-
bing out finishes.
Aluminum oxide has become the go-to
abrasive for woodworking [Photo D]. This
low-cost compound excels in nearly every
aspect of surface preparation, from paint
removal to final finishing. The very hard
••. Find each of these granules wear slowly and can be used in
abrasives in a full both hand- and power-sanding operations.
range of grits from 60 Though better suited for metalworking,
to 220, with silicon you may see ceramic in retail stores, touted for
carbide and aluminum woodworking. Ceramic grains break consis-
oxide offering even tently, constantly exposing fresh cutting
finer grits. edges, but some woods may not be hard
Aluminum oxide wears down during use instead of fracturing. As a result, it

sands finer as it wears.
In to smoothing wood, silicon carbide excels at buffing the edges cut Ceramic typically costs more, so if you find a ceramic-mix sandpaper at the
glass and plastics, or producing a bright sheen on aluminum or copper surfaces. same price as other abrasives, its durability makes it a good value.
wood magazine.com 55
shiny. When folding film-backed sheets, the
so the paper holds its bent shape without slipping.
Backing determines flexibility

and durability
Cfog.SHJE1DTM ~ HI-performance coating
Several types of materials serve as backing reduces pitch bUild-up & cloggmg
for abrasives. Manufacturers use an alpha- CJog-SHIELO"'C Re\letement haute
performance redueant t'accumulation de
betical scale, with A as the lightest weight, POIX et Ie boucnaqe
and heavier, more durable backings desig- [I ft'(I,!Jrm/l(!fIv oo at,', "l'dll''li3' It' ft!.i ,l~l {;J
.lwmll JL,O'1 ae res f)J , ts O!,J:Uo1L I) I
nated with subsequent letters. Choose
papers weightedA, B, or C for hand -sanding,
with C and D holding up better to the
demands of the coarsest (36-80) grits.
Lighter-weightpaper flexesmore, so choose
it when sanding profiles or small interior
spaces [Photo F].
Although you can use A-C weight paper
on a quarter-sheet sander,they will wear fast
and may tear. Instead, look for papers with
D, E, or F weights.
Some manufacturers offer film backing
that provides great flexibility and resists
tearing [Photo G]. The film won't slide around
on rubber sanding blocks or pads, improv-
ing results. Film withstands moisture and
provides a flatter surface, making it a good Stearate might be listed on the package, but look for other words, such as non-
choice for wet-sanding with water or oil to loading, no-fill, zinc stearate, or anti-clog.
bring a finish to a mirrorlike sheen.
Discsfor random-orbit sanders come with when sanding resinous woods or painted
paper,film, or fabricbackingsin weightsthat surfaces. Usually applied to aluminum-
withstand the demands of the tool, so you oxide or silicon-carbide papers, this dry
don't get to choose the weight. Papers and lubricant causes no finishing problems,
fabric backings labeled as water-resistantor such as fish-eyeor orange peeling.Although
suitablefor wet applicationshavebeen treated hardware stores and home centers carry
to withstand moisture. some stearate-coated abrasives, you'll find
them well-stockedat auto-parts stores.
When to choose stearate Regardless of the grit, material, or back-
Stearated or self-lubricatingsandpaper adds ing, it's important to discard any abrasive
a dry metallic soap between the grains of when its cutting action falls off. How do you
grit [Photo H]. Swarf doesn't stick to the stea- know?Rub your fingers overthe pieceyou're
rate, as it would to the resin binder that using, then over a fresh piece of the same
holds the granules, so debris falls awayfrom grit. If the old one feels significantly
the paper as you sand. That reducesclogging smoother, discard it. ••
Approximate
materials cost
$50
including a
handle and
acrylic door
Build
multiple
shelf types
for maximum
versatility.
EXPLODED VIEW
o.p.
0" Ya"groovS
~
(
1Y4"deep
Ya"dowel
5/a"long
2Y4"hole Ya"chamfer Yax 12x 12%"
clear acrylic
'j
Ya"dowel
%"Iong
use as key stock in the jig, also cut a 12 "-long

scrap to a thickness and width matching the
thickness of the sides and top.
First, make the sides and top
Box joints lend loads of strength and good
looks where the carrier sides and top meet. A
2 Install in your tablesaw a Yz"-wide dado
set, and adjust its height to match the
thickness of the sides and top. Attach a
lower rail and back stretchers further tie the %x6x24" plywood box-joint-jig face to your
case together, with their ends exposed in the miter gauge, positioned so the dado set will
sides to complement the box joints. For wood cut through the face's approximate center.
we chose relatively light, but strong, lyptus. Stack two of the cutoffs face-to-face and
1 Glue up panels for the sides (A) and top

(B), making the top as wide as the sides
for now [Materials List]. When trimming the
place them against the rip fence. Slide over
the rip fence until the cutoffs contact the end
of the jig [Photo A]. Lock the rip fence.
panels to length, save the cutoffs to use as
spacers in the upcoming box-joint jig. For 3 Make a dado cut through the jig's face
[Photo B]. Unscrew the face from the miter
Box-joint-jig face
Precisely space the box-joint-jig face from the rip fence using two thicknesses Cut through the face and check the fit of the key stock in the notch. If the fit's
of cutoffs from the sides or top. not snug, adjust the dado set width and/or height.
woodmagazine.com 59
Butt the jig's end against the rip fence and rescrew . Raise just a hair before cutting the second notch. Doing that ensures
slide the fence out of the way. the box-joint's fingers stand slightly proud for flush-sanding later.
Hold the workpiece securely against the jig as you make the first box-joint cut. Work your way across the width of the panel, positioning the most recent cut
over the key in preparation for cutting the next notch.
gauge and glue a 2" -long piece of key stock stopping 1" from the edge of the panel [Drawing
into the notch. Reposition the jig's face as 1]. Repeat on the other side panel.
Cut box joints across the full width on
notch [Photo 0]. Position one of S
shown in Photo C.
4maketheCuttheanother
sides (A) tight against the key and
both ends of the top (B). Then rip Yz" of
material from the back edge of the top and
first box-joint cut [Photo E]. Place that
\4" from the front. Cut the rabbet on the
notch over the key and repeat the cuts [Photo F], underside of the back edge [Drawing 2].
0n the sides cut the groove near the
6 front, two square mortises near the back,
II SIDE EJTOP
'14" rabbet 14" deep
on inside face

DTOP SECTION VIEW
3/8"rabbets
4%"
~--'--~~(7-L' r
L:_ y~' dee~
Ya" hole
l» : ~ fti'dre p
DRAILS
1'6" groove 1 \'4" deep
for acrylic door
DOOR RAIL
Keep the assembly square using a spacer and clamping cauls. The stretchers (0)
stand a little proud, but will be trimmed later. 1'6" hole %" deep
o
and the notch on the front edge [Drawing 1].
Glue a filler (C) into the bottom of each
groove [Exploded View]. CASE RAIL
Just a few more parts to go

Cut the stretchers (D) about W' longer
1 than listed. Dry-fit the sides, top, and
stretchers. Check that the top sits back Y-J" 7 Finish-sand all parts. For the door cut a
piece of Ys" acrylic to fit [Exploded View]. Slide
Tip! If your acrylic sheet
comes with a protective
from the Ys" groove (for door clearance). the acrylic into the door rail (E), center it side- film covering, leave it in
Once satisfied with the fit, glue and clamp to-side, and pin it in place with dowels. place until after you apply
finish to the project. If it
the assembly [Photo G].
2 Drill holes in the back edges of the sides

into the stretchers (D) [Drawings 1 and 3].
8 Apply your preferred finish (we sprayed
three coats of lacquer). Add a handle
centered on the top. Now let's get baking! •
doesn't have a covering,
mask the acrylic prior to
Glue Ys" dowels just a bit longer than 1" into applying finish.
those holes and trim flush. Trim the stretch-
ers flush. Materials List
FINISHED SIZE
Cut the door rail (E) and case rail (F) to
3 size. In the door rail cut a groove to fit
your acrylic [Drawing 4]. Layout and cut both
Part
A sides
T
1'2"
W
13"
L
131'2"
Matl. Qty.
2
B* top Y211 12W' 13"
parts to shape. Set the door rail aside for
C fillers Va" iii" %" 2
Tip! Use a pin nailer to now. Glue the case rail in place and reinforce
hold light, unclamped the joint with dowels [Drawing 4, Exploded View]. D* stretchers 1'2" 1'2" 13" 2
pieces, such as the slats, Cut to size the slats (G, H), then rabbet E door rail 2" 12"
4
o/sn
in place while glue dries. four of their edges '[Drawing 3]. Glue only F case rail 0/8" 2" 13"
the center third of each slat to allow seasonal G narrow slats %11 3Ys" 13'4" 2
expansion/contraction. H wide slat %" 4:y,." 13'4"
S Cut the cleats (I) to size and round over

their bottom front ends [Exploded View].
Screw them to the sides.
cleats
shelves
¥211 1/2"
1'2" 12t'16" 11Ys"
11'4" 4
2
'Parts initially cut oversize. See the instructions.
6 Glue up and cut to size the shelves 0).

Round over their front edges [Exploded
View]. Cut holes and rout their top edges to
Materials key: L-Iyptus.
Supplies: #8xW flathead screws, Vs" dowel 36" long,
Produced by Bill Krier with
Kevin Boyle
Project design:
Vsx13x13" acrylic, W pin nails, 4" wire pull. Craig Ruegsegger
customize the shelves for holding a pie or Blade and bits: Dado set; 45° chamfer and W round-over Illustrations: Roxanne LeMoine,
cupcakes. router bits; countersink; 2W Forstner bit. Lorna Johnson
woodmagazine.com 61
If your plunge router hangs up or slips down when it shouldn't,
use these quick tips to get it back on track.
62
If the plunge action catches or drags, the guide rods may be dirty. rust or stubborn particles, above left. Finally, lubricate and protect
Use compressed air, as shown on previous page, to blast offloose dust; the guide rods by applying a nonstick tool spray, such as Bostik
then, wipe the rods with a rag dipped in mineral spirits to remove GlideCote (no. 124627, $21, 800-225-1153, woodcraft.com), above.
If the base doesn't grip the motor tightly, it may cause the bit's cutting depth to Plunge lock not enough purchase? Tighten the locking stud on the plunge-
suddenly deepen as the motor slips. Snug the clamp tension screw to get a better lock lever. Be careful to not overtighten it, or you may not be able to plunge at all! •
bite on the router motor.
~ For tips on getting the most from your plunge router, visit woodmagazine.comjplungeroutertips.
~See top editor-rated plunge routers at woodmagazine.comjreview.
~Learn more about using routers: woodmagazine.comjrouteruse.
woodmagazlne.com 63
·sBlf a/dw/S-lzeJo OMJ pue
~9lqel JalnOJ ~Mesalqel ~ssaJd I/IJP e
~ulsn sJasuadSIP asaql aJfew
n just a few hours, shape two small pieces
I of wood into custom shakers, each with

affordable metal components [Source].
EXPLODED VIEW
Prep the blanks

1for Create two mx1~8x4Yz" blanks (A, B)
[Materials List]. We used maple and walnut
a no-brainer color connection.
Tip! Add character to
your shakers with
exotic·woodturning blanks
Shaker body
•• Learn to layout 12 Draw diagonals to mark the center on each from Penn State
equidistant points
around a circle.
2 end, and mark the endpoints of each of the
12 facets on the bottom of each blank.
Industries, our source for
the hardware components.
woodmagazine.com/
12points 3 Drill holes for the tube, cap, and plug
[Exploded View, Photos and
A B].
1 %" counterbore
5/16"deep
D
Drill the counterbore at the bottom of each blank. Secure the blank in a clamp,
with the blank aligned precisely with the bit.
Tube
Tip! If you drill the

through·holes from each
end and they don't
connect perfectly, simply
wrap sandpaper around a
¥.in·diameter or smaller
dowel and sand the
Il transition until the
Switch to a 1" bit and bore each blank fully through. If your bit or drill press
won't reach the full depth, simply turn the blank over and drill from that end. tube fits.
woodmagazine.com 65
Bevel-rip to shape
1 Build the beveling jig [Drawing 1, Materials
List]. Install a short dowel in the divider
(D) to provide better purchase for the screw
that holds down the top (E).
II> Watch the correct

sequence for cutting
2 Secure both shaker blanks (A, B) in the
beveling jig with the blank bottoms
against the stops. Tilt your tablesaw blade to
the 12 facets. 30°, and rip 12 facets on each blank [Photo C].
woodrnagazlne.corn/ Save the first two cutoffs-they become part
shakerbevels K in the next step.
Rout the tapered flutes

Build the fluting jig [Drawings 2 and 2a].
1 Retrieve the two cutoffs (K), and glue
them to the base and riser, spaced to cradle a
shaker blank. Bevel-rip each shaker blank by keeping one of the original flat surfaces resting on
the jig. and cutting to the lower layout mark on the edge over the blade. Flip the jig
2 Install a 1\4"-diameter (%" radius) round-
nose bit in your router table. Set the bit \4"
above the table and center the bit on the
end for end and rip the other blank. Reposition the blanks and repeat until finished.
Sand the shakers smooth and apply a fin- Note: To safelyrout

width of the jig. Rout the length of the jig.
Raise the bit to Yz", clamp in a blank, and
rout the first pass on all facets [Photos D-F].
3 ish. We applied three coats of Varathane
aerosol satin lacquer.
flutes in the shakers
without them working
r~
Raise the bit and make shallow passes until Adhere the tubes and caps to each blank loosefrom the jig, make
the flutes extend the full length of the shaker
blanks.
4 with two-part epoxy. When cured, fill
each shaker, insert the plug, and add zest to
the cuts in three or
fourpasses.
favorite food, .•
II BEVELING JIG
. () /
2"
3" . / /
~~
:'
..
%2" pilot hole

Clamp a shaker blank in the fluting jig with one facet directly over the bit, and Raise the. bit until it cuts a flute the full length of the shaker blank. The flute
rout the full length of the jig. Rotate the blank and repeat for all 12 facets. should connect two of the 12 points at the shaker bottom.
Rotate the blank a half-tum, resting on the wedges, and mark the flute's
"smile" on the jig's front. This mark will help you register the blank for routing the
last four flutes, which can be difficult to register without a flat surface.
Materials List "'When you finish

FINISHED SIZE routing the flutes, throw
Part T W L Mall. Qly.
out the jig. It might be
Shakers
too unstable to use for
A salt 1W' 1%" 4W' M making another set of
B pepper 1Ys" 1%" 4¥2" w shakers.
Beveling jig
C base lA" 4" 5" MDF
D divider W' 1%" 5" MDF
E top ¥.t1l 2" 3" MDF
stops %11 %" 1W' MDF 2
Fluting jig
G base 14 4"11 10" MDF
H front -%n lYs" 4"
I back %11 21'16" 4"
J
K
nser
wedges
lAir
t
%11
t
4"
4W'
MDF
M/W
Em FLUTING JIG SIDE VIEW
t Cutoffs from shaker blanks. See the instructions,
Materials key: M-maple, W-walnut, H-hardwood, MDF-
Produced by Bob Hunter with
medium-density fiberboard core (or plywood). John Olson
Bits: 1 Y<I"-diameter roundnose router bit; 1" and 11's" Forstner bits. Project design: John Olson 3° bevel
Source: Salt and pepper shaker kit, no, PKSANDP, $9,95, Illustrations: Roxanne LeMoine,
Penn State Industries, 800-377-7297, pennstateadcom. Lorna Johnson
woodmagazine.com 67
Portable Sanders
Dual-mode
Belt sander Orbital sander Random-.orbit sander random-orbit sander,
Typicallyheld with one hand, some portable The pads of most sanders in this class '" Read reviews of
sanders require two hands for better control. have eight dust-collection holes, and the random-orbit
All types (belt, orbital, random-orbit, detail) abrasive discs on the market match them sanding discs.
come in corded versions, with many also perfectly. The included bag or canister filter woodrnagazlne.com/
available battery powered. If you already provides good dust collection, but for even sandlngdlscs
own tools in a particular battery platform, it better performance, attach a fine filtering
might make more sense-cord freedom!- shop vacuum. If possible, choose a random-
to buy sanders that use the same batteries. orbit sander with variable speed so you can
• Belt. This handheld sander transports choose the best speed to match the work-
an abrasive belt around drums at each end piece and abrasive grit. A few models offer
of the tooL The aggressiveness of a belt dual modes, letting you choose between a
Tip! Stick with coarse sander works best for rapid material fine-finishing, smaller orbit and a larger,
grits (60-120) and use removal rather than fine finishing. Most more aggressive orbit for rapid removal.
these tools only for use one of three common belt sizes: 3xI8", • Detail. A cousin of orbital sanders, these
rough-sanding. When 3x21", or 4x24". Belt sanders come with a tools use smaller triangular or rectangular
done, switch to a finish dust-collection bag, but most struggle to pads for sanding into corners and tight Tip! Avoid using coarse
sander. capture the large volume of fine dust cre- spaces. They remove material well, but it can abrasives, which can
ated. Overcome this by setting up a dust be difficult to blend their scratch marks accidentally scratch
collector or shop vacuum with a large with those made by another sander. Weview adjacent surfaces that
hood to capture dust that escapes the tool. detail sanders as a tool of last resort, when might already be ready
• Orbital. Primarily used for finishing, no other will do the job. (Sanding project for finish.
these sanders have a square or rectangular parts prior to assemblyhelps avoid the need
pad that vibrates in tiny circles, or orbits, to to sand into tight corners.)
Tip! Sand one grit finer abrade the wood. Sandpaper sheets attach
(usually 320) with this tool with either built-in clamps or hook-and-
than you would with a loop pads. Newermodels feature holes in the
random-orbit sander to pads for improved dust collection, with
remove unseen swirls that included punch pads to create matching
would reveal themselves holes in your abrasives. Orbital sanders pro-
under stain or finish. duce smooth surfaces,but often leave swirly
scratch marks that show up when you stain
or dye the wood.
• Random-orbit. If you don't own a power
sander, get this one first. A random-orbit
Tip! Replace the 5-hole sander's 5"- or 6"-diameter pad spins while
pad on an older sander simultaneously orbiting in tiny circles of Ys"
with an 8-hole pad from or less. These combined actions help blend
the same manufacturer; the scratch patterns, so that by the time you
8-hole abrasive discs are sand through 180 or 220 grit, the scratches
easier to find. become almost invisible.
woodmagazlne.com 69
Stationary Sanders
Most of these machines come in both robust
floor-standing models and benchtop versions
that cost less and typically have smaller work-
surfaces and motors .
• Disc. Many disc sanders for home shops
have 12"-diameter discs, but a few smaller
Tip! For most work, use and larger models exist. A self-adhesive
a l50-grit disc. It works abrasive disc sticks directly to the tool's
well enough at shaping metal platen, which excels at creating
workpieces without square, flat edges. Because you can work
burning the wood as finer only on the downward-spinning portion of
grits can easily do. the disc, it provides a limited working sur-
face, and you can sand only flat or convex
surfaces. Look for a disc sander with a
h ...• _~ ••• large, sturdy table, prefera-
bly made of cast iron; a

miter slot proves helpful
• Oscillating spindle. If you don't own a for holding jigs and
benchtop or floor-standing model, this accessories.
handheld version works well for sanding
curved edges. You'll find only a couple of
Tip! Clamp one of these models on the market (Grizzly and MLCS
tools to a workbench for a Woodworking). They come with four drums
small, but effective, and abrasive sleeves (Yz", %", 1", and 1 Yz"
spindle sander with a diameters), providing a good solution for
tiny table surface. most curves.
• Belt/disc combo. These machines have a

single motor that powers the belt and disc at
the same time. The belts come in 1-6" widths,
and the discs from 6" to 12" in diameter. Like
a dedicated disc sander, these machines pri-
Tlpl Use a coarse grit on marily sand flat and convex surfaces. But
one platen of your combo some models allow you to use one of the belt
sander for shaping, and a drums for sanding concave surfaces. The belts
finer grit on the other for excel at sanding long straight edges, such as
detail work and smoothing. tapered table legs or box sides.
abrasive sleeve that can dish out wood quickly

if you don't keep it moving. We know of two
models (Makita and Porter-Cable Restorer);
both have accessory heads available with wire
or nylon brushes for (purposely) scratching
the wood to add texture or simulated age, or
for cleaning up actual barn siding or similar
Tip! For best control, wood. You can also buy paint-removal
use this tool in a pulling drums. As you'd expect, these generate a lot
motion to resist the of coarse dust, so connect to a vacuum to
rotation of the drum. minimize the mess.
Ti(l! When sanding to • Drum. A drum sander's wide abrasive-
thickness, use 80-120 wrapped drum spins parallel to the
grit. For finish sanding, machine's power-driven feed belt. Because
choose 150-220 grit. the abrasive wraps spirally around the
drum, it requires special-shapedand -sized
abrasive rolls. You can sand the faces of a
workpiece or assembly (raised-panel door,
picture frame, etc.) to a specific thickness,
flatten a glued-up panel, or simply remove
milling marks. The drums measure 7-18"
wide in open-ended models, but you can
Ii> Read reviews of double the capacity by rotating the work-
various power-sanding piece end for end and sanding the other half
tools and machines. to the same thickness. Closed-end drum
woodmagazine.com/ sanders, such as the one shown, limit work-
review piece width, but virtually eliminate drum
deflection or sagging.
• Oscillating spindle. Nothing beats

one of these machines-with a sanding • Oscillating edge. Think of this as an
drum that raises and lowers while spin- oversizehorizontal belt sander with the up-
ning-for sanding inside curves. Bench- and-down action of an oscillating spindle Tip! Use 150- or
top models usually include at least four sander. This action extends the life of the finer·grit belts here. This
drums of different diameters; floor abrasivebelt, while also blending the scratch machine typically works
models often provide 6-8 drums. They pattern. An edge sander works great for best at smoothing and
usually come with 80- or 100-grit abra- smoothing long straight edges, such as table refining workpieces rather
Tip! Coating the rubber sive sleeves for the drums, with finer legs and spindles. You can also shape con- than rough-shaping.
drum with baby powder or grits available as accessories. Taller cave edges at the end on one of the drums,
talcum allows the sleeve spindles (8-10") provide more working usually requiring the removal of a guard .• Produced by Bob Hunter
to slide on and off easier. surface for thick or wide workpieces.
Tighten the drum's lock . Heavy-duty spindle sanders have an oil-
nut to secure the sleeve. bath gearbox for a quieter, longer life.
woodmagazine.com 71
B
esides holding weighty tools that
would uncurl a wire peg hook, slatwall
storage systems brighten a shop with a
more finished look than pegboard, or nails
in a wall.
Slatwall consists of strips or panels with
horizontal T-shaped or L-shaped slots.
Many commercial systems use plastic pan- Slatwall hangers distribute their
els, such as StoreWall's IS"-wide sections load over a wider area than peg
that come 4' or 8' long. MDF panels made for hooks. These L·shaped slots hold
retail applications commonly measure 4x8'. industry-standard hardware.
•• Learn how to rout You can also make your own panels using %"
slatwall grooves in %" birch plywood.
plywood. Hooks, shelves, and other hardware hang
woodmagazme.com/ in the slots, as shown above and on the next
slatwall page. To supplement these with your own
custom storage, attach Z-shaped tabs to any-
thing from router-bit holders, as shown on
the next page, to cabinets. Unlike pegboard
hardware, a single hook on some slatwall sys-
tems can handle more than 100 pounds.
Convenience costs, though. For example,
4x8' sheets of perforated hardboard cost
about $15, but plastic slatwall that covers the
same 32 square feet may cost ten times as
much. Slatwall hardware comes in a greater
variety, but it also costs more than peg
hooks. Prices range from about $2 per slat-
wall hook to $25 for a 2'-wide basket or $80
for a 3' -long shelf.
But you're really paying for flexibility:
panels and hardware that, unlike pegboard,
can hold a SO-lb cabinet in tomorrow's shop
as easily as an 8-oz hand tool today.
Plan a basic system

To create a slatwall system on a budget, ask
commercial remodelers about salvaging
slatwall panels and hardware from closed or
remodeled stores. If you're hanging cabinets
and shelves heavier than about 50 pounds,
install plastic slatwall panels. For example, a
heavy-duty StoreWall panel holds up to 148
lbs versus 681bs on an MDF panel.
With the wall system decided, it's time to
Hardware from StoreWall comes with a lock to keep it from pulling loose.
shop specialty stores, home centers, and the Inexpensive hooks can handle lightweight items.
web (see Sources) for hardware to suit your
needs. You can mix inexpensive hardware
for light- or medium-duty jobs, as shown
above right, with more expensive hardware
for the heavy stuff because slatwall slots are
typically spaced 3" apart to accept all types
of hardware.
On a tight budget? Start small by mount-
ing just one row of IS"-wide plastic slatwall
strips around your workshop. Position it
between chest and eye level-high if you'll
use more hanging hooks, and low for bas-
kets. Later, add more strips above the first
one to store jigs or lumber, and below to hang
more hooks, baskets, and shelves as needed.
Install panels for flexibility

A future shop reorganization may have you
GarageEscape brackets made for hanging cabinets on slatwall also can be used
move a rack of hefty pipe clamps to where a to hang shop-made accessory holders.
few ounces of band saw blades now hang, so
install all panels for maximum weight When using a portable circular saw, cut with
capacity from the start. Installation instruc- the slot face down using a carbide blade with
tions vary, but these tips will help strengthen 32 teeth or more.
any system: ~ Check with the manufacturer to see if
~ When stacking interlocking panels, install screws can be supplemented with adhesive.
the lowest panel first. Level each strip or Allow any adhesive to dry overnight before
course of panels. using the panels .•
~.Use #8xlY2" flathead wood screws on bare
studs and #8x2" screws over drywall. Sources
Several companies offer slatwali panel~ and hardware either by mail or
~ Drive a screw into every stud at each slot. through dealers, including:
Screw heads can be painted or covered with Garage Escape
color-matching caps available from some 800-548-7528, garageescape.com
Gladiator Garageworks
suppliers.
866-342-4089, gladiatorgw.com. Note: Gladiator uses proprietary
~ Cut panels as you would veneered ply- hardware that's incompatible with industry-standard slatwall.
wood: with the good (slot) face up on a StoreWall
tablesaw with at least a 40-tooth blade. Heavy-duty panels and accessories, 866-889-2502, storewall.com
woodmagazine.com 73
TOOLS & MATERIALS
SHOP-TESTED
Woodworker
Support
Group
We like these three portable workstations
for temporarily adding worksurface and
stock support to the shop.
Pegasus folding worktable and sawhorse

no. WX051, $100
The 25x31" worksurface provides lots of
space, and the sturdy legs make it rock solid.
It comes with two quick-action clamps that
recess into the aluminum channels, and
four bench dogs provide stops for clamping
workpieces. The Pegasus folds up nicely and
weighs just 30 Ibs., making it easy to store.
Worx
855-279-0505,worx.com
Track Horse
Express Folding Workbench no. KWS500, $120
no. DWST11556, $80 True to sawhorse tradition, Kreg built this stand to handle heavy loads
This workstation folds up quickly for storage and carries easily, but (1,lOO-lb. rating per Track Horse). The steel-leg base with an aluminum
shines best when set up. Made of heavy-duty plastic with metal legs, top rail supports boards and sheet goods with ease. The top rail has a
it supports up to 1,000 Ibs., according to DeWalt. We never piled on T-slot and included cam clamp to hold stock securely, and T-bolts for
that much weight, but it handled everything we stacked on without mounting a sacrificial 2x4 for sawing. Mount the clamp in one of the
buckling. Slots and holes accommodate quick-action clamps (not end brackets to secure a board on edge for routing or planing. The
included) to secure workpieces. adjustable legs let you set the top beam 24-35" high.
DeWall KregTool
800-433-9258,dewalt.com 800-447-8638,kregtool.com

TOOLS & MATERIALS
SHOP-TESTED
When you add a quarter horse,

you get a grown-up Colt
1 Y<I-hp fixed-base router, no. GKF125CEN, $130
As a fan of Bosch's 1-hp Colt trim router for more than a

decade, I've been eager to get my hands on this amped-up
model. The new 1 l4-hp Colt has more muscle: I could not
bog it down without making ridiculous cuts. With that
power comes a larger body, but it's still compact enough to
operate one-handed, and it's nimble despite the added size.
I like the variable-speed, soft-start motor, and twin LEDs
that illuminate around the bit nicely. My favorite feature,
though, is the bit-depth adjuster: Three modes on the base
lock (locked,unlocked, and microadjust) make it incredibly
easy to fine-tune a bit's cutting depth.
This Colt comes with an adjustable edge guide-a nice
touch. Bosch's Steve Wilcox says they plan to launch a
plunge base-a hotly anticipated accessory-in 2019.
-Tested by Bob Hunter, Tools Editor
Bosch
877·267-2499, boschtools.com
DeWalt vacs provide lots of suction

14 gallon, no. DXV14P, $149; 10 gallon, no. DXV10P, $139;
4 gallon, no. DXV04T, $119
DeWalt's new wet/dry vacuums range in size from 4-gallon

capacity to 16. We tested three to see how they fared. The
good news: They demonstrated better suction than most
comparably priced vacs, and did about as well as other
models at trapping the dust. If you use these vacs with
the included filters and bags, you should considerwear-
ing a respirator or dust mask to prevent breathing the
fine dust that escapes. Or, buy a finer-rated filter
($25-$45) to improve the performance of each
vac. The bigger models come nicely equipped in
terms of accessory nozzles and extensions.
The 4-gallon model works best as a detail vac
for cleaning up small areas.
-Tested by Tom Brumback
DeWalt
800-433-9258, dewalt.com
woodmagazine.com continued on page 84 79

TOOLS & MATERIALS
NEW AND NEXT
Bandsaw offers fully variable speed

Smart DVR controller with 1 %-hp motor, no. 13-926, $630
Rikon Power Tools has added a direct-variable-resistance (DVR) motor, with
electronic controller, as an accessory for its 14" bandsaws. This new package
retrofits to six Rikon band saw models and provides the ability to adjust the blade
speed anywhere from 100 rpm (45 surface feet per minute) to 2,375 rpm (4,400
sfpm). Rikon says cutting at faster speeds produces a cleaner cut with continuous
torque. And this system, they say, provides faster electronic braking at shutdown.
Rikon Power Tools

877-884-5167, rikontools.com
Skilsaw launches worm-drive slider

12' sliding compound mitersaw, no. SPT88-01, $579
The pioneer of the circular saw, Skilsaw has adapted its worm-drive technology to a
corded 12" sliding dual-bevel mitersaw. This saw features a 15-amp motor with electric
brake, 60° right-side miter capacity and 50° left with 11 detents, 48° bevel capacity
left and right with nine stops, and table extensions to support workpieces. LEDs shine
down both faces of the blade, creating an alignment shadow that indicates where the
saw kerf will be cut.
Skilsaw
877-754-5729, skilsaw.com

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Better Homes & Gardens· WOOD- magazine (lSSN-0743-B94X); March 2019, Volume 36, No.j, is published 7 times a year in March, May. July. Sept, Oct, Nov, Dec/Jan by Meredith Corporation, 1716 Locust Street, Des Moines. IA 50309-3023. Periodicals postage paid at Des Moines, lA, and at additional mailing offices. Subscription prices: $29.99 per
year in the U.S.; 544.99 (ll.S. dollars) in Canada; 149.99 (U.S. dollars) overseas. POSTMASTER: Send all UAA to (fS. (See OMM 507.1.5.2); NON-POSTAL AND MILITARY fACILITIES: Send address corrections to Better Homes & Gardens WOOD, PO Box 37508, Boone, IA 50037-0508. In Canada: mailed under Publications Mail Sales Product Agreement No .
• nn6Q])1- Canadian BN 123482887 Rr. Your bank may provide updates to the card information we have on file. You may opt out of this service at any time. © Meredith Corporation 2019. Your bank may provide updates to the card information we have on file. You may opt out of this service at any time. All rights reserved. Printed in the U.s.A.

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TAKE YOUR CNC BEYOND WOOD p.

~CE PllESIDENT. GROUP EDITORIAL DIRIClOR Ll2 VAGCARl!lJ.ll OR S1tPHEN ORR

To download patterns from this issue,

TOOLS & TECHNIQUES

Share your build with the Happy Hammock Stand

It's easy! Log in or register at woodmagazine.com, hop over to woodmagazine.comj

Turn these ... . .. into this!

One 4)(8' Sheet of particle board Jigsaws/Saber saws

FOUlIeen 8' cedar 2X4s Mitsrsaws

West System IlJlOl(Y and hardener

Lag screws Bandsaws

Strow hooks On.mSanders

Clear. ooldoor finiSh Clamps

Nuts. bolts. washers handsaw

I then cut up the trammel Into 3" blocks and

One good turn deserves a

Dust separator Color correction

when I picked up issue 255 Be [Better] Light"),

What's your hurry?

Oklahoma-bornFloyd Beeson, now of San

When Nell King, of Black Mountain, N.C.,

10 WOOD magazine March 2019

Harness Hand Tool Power Where You Need It

A 24" wall-mounted Air King fan helps

Light tight spaces when turning vessels

Tipseam up' For sending this

18 WOOD magazine March 2019 continued on page 20

Never forget a great tip

20 continued on page 22 WOOD magazine March 2019

The dust port on a router-table fence

Curved caul-like clamping

WOOD magazine March 2019

Attend North America's

1,4" rabbets 3/8" deep

1f4" holes %" deep

W' groove 14" deep

34%,' W' groove W' deep

3 Cut the glass stops (E, F) W longer than

26 WOOD magazine March 2019

at the top and bottom and centered end to

the top [Drawing 4, Photo C].

DTOP (Top face shown) [ElBEVEL

f::' ~6'i Qr~~aw"whit, oak

% x 7~ x 48" Quartersawn white oak

R' top %11 17W 42W' EQO

I plywood, EQO-edge-joined quartersawn white oak.

:.'4 x 48 x 48" White oak plywood 28 WOOD magazine March 2019

A takes the biggest bite out of a wood-

32 WOOD magazine March 2019

" Safari Ate Edit View History Bookmarks Window Help

CL 55.US. 20.4 miles > lot "1ft B> .n

&furfMtum2S 88 gallery ••. 1 ~120/22e n9)11;> relevant .••

search titles ooIy

1'12" [ElJOINT DETAILS

~ Avoid using pressure-

Build the box

on the inside face of a front/back (A)_ Jigsaw

4 Complete the cut using a handsaw [Photo

6 Test-fit each joint [Photo GJ- Screw the

5 Plane or sand bevels on the lid rails (F)

Ripping the lid wedge (Cl angie from an oversize

Add the finishing touches Materials List

38 WOOD magazine March 2019

" For the letters and cup: