Canadian Woodworking 018 (June-July 2002) PDF

PLANS PROJECTS JIGS TIPS PAT T E R N S
JUNE/JULY 2002
Vol.5, No. 3
Make a
Model
Truck
Build an Outdoor
Dining Set
2 New Intarsia
Patterns
Handsaw
Review
Wiring Your Shop
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VOLUME 5, NO. 3
CONTENTS JJ UU NN EE // JJ UU LL YY 22 00 00 22
EDITORS
PAUL FULCHER, LINDA FULCHER
WRITERS
CARL DUGUAY, MARK EATON,
HANK ETHIER, REA GIBSON, GORD GRAFF, FEATURES
GARNET HALL, JIM KOUDYS,
GRAHAM MCCULLOCH, LOU PEETERS, 6 SHARK
DANNY PROULX, PAUL ROSS, BY GARNET HALL
JOHN SEDGWICK, MICHEL THERIAULT,
JIM THOMS, CHESTER VAN NESS,
HENDRIK VARJU
9 OUTDOOR DINING SET
BY DANNY PROULX
ADVERTISING 9
PAUL FULCHER, LINDA FULCHER 14 “C” CAB STAKE TRUCK
BY JIM THOMS
CIRCULATION
NEWS STANDS ACROSS CANADA,
SUBSCRIPTIONS VIA CANADIAN POST
17 15-MINUTE SAND TIMER
CORPORATION, PARTICIPATING BY PAUL ROSS
WOODSHOWS ACROSS CANADA,
CANADIAN WOODWORKING ADVERTISERS, 19 SEVEN PIECE CROSS PUZZLE
WOODSHOW EXHIBITORS & COMPETITIONS BY REA GIBSON
CANADIAN WOODWORKING
IS PUBLISHED SIX TIMES PER YEAR:
20 WIRING YOUR SHOP
FEBRUARY/MARCH; APRIL/MAY; BY HANK ETHIER 14
JUNE/JULY; AUGUST/SEPTEMBER;
OCTOBER/NOVEMBER; 25 WOOD STORY:
DECEMBER/JANUARY TWO SIMPLE WORDS
SUBSCRIPTIONS BY GORD GRAFF
1 YEAR: 6 ISSUES PER YEAR $15.99 GST INCL.
ATLANTIC CANADA $17.99, USA $25.99, 26 WOOD STORY:
OVERSEAS $45.99 CDN WHO WILL NOTICE?
2 YEAR: 12 ISSUES $28.83 GST INCL., BY JOHN SEDGWICK
ATLANTIC CANADA $30.99, USA $48.83,
OVERSEAS $88.83 CDN
SINGLE COPY $3.99 + GST = $4.27
29 INTARSIA CLOCK
BACK ISSUES $5.75, USA ORDERS ADD $3.00, BY RICK CAMPBELL
OVERSEAS ORDERS ADD $5.00
INCLUDES GST, POSTAGE AND HANDLING 33 BOOK REVIEW:
17
ROUTER BENCH GUIDE
G.S.T. REG. #120447560
ISSN #1497-0023 BY MICHEL THERIAULT
MAIL PUBLICATION AGREEMENT #40035186
COPYRIGHT 2001 BY CANADIAN WOODWORKING
MAGAZINE DIV. OF VISION QUEST INCORPORATED
39 ROUTER SPRING REMOVAL
BY MARK EATON
CANADIAN WOODWORKING MAGAZINE
RR#3 BURFORD, ON N0E 1A0
TEL. (519)449-2444 FAX (519)449-2445 41 DUST COLLECTION: PIPING
email:letters@canadianwoodworking.com BY CHESTER VAN NESS
website: www.canadianwoodworking.com
REPRINTING IN WHOLE OR PART IS FORBIDDEN EXCEPT
BY WRITTEN PERMISSION FROM THE PUBLISHERS. DEPARTMENTS
Please exercise caution when working with any tools or machinery. 3 EDITORS LETTERS
Follow common safety rules and precautions as outlined in any manuals
related to the equipment being used. This publication is sold with the 4 DEAR EDITORS
understanding that (1) the authors and editors are not responsible for the 21 TOOL REVIEW
results of any actions taken on the basis of information in this publication,
nor for any errors or omissions; and (2) the publisher is not engaged in 24 QUESTIONS & ANSWERS 29
rendering professional advice/services. The publisher, and the authors
and editors, expressly disclaim all and any liability to any person, whether a 37 PRO TIPS
purchaser of this publication or not, in respect of anything and of the 38 T O O L U P D AT E
consequences of anything done or omitted to be done by any such person
in reliance, whether whole or partial, upon the whole or any part of the 44 TOOL TEST
contents of this publication. If advice or other expert assistance is required,
the services of a competent professional person should be sought. Cover photo by
Ray Pilon, Ottawa
Visit our website at: www.canadianwoodworking.com CANADIAN WOODWORKING 1

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editorsletters
LINDA FULCHER PAUL FULCHER
Y L
ears ago, I read a true story about a carpenter named inda and I are always asking ourselves how we can
Rosa. There are many things about this story which I improve the magazine. Whether it’s the colour, the
find inspiring: learning from a parent, having a paper stock, the articles, the photos – it seems that
dream, and using the skills gained to see the dream there is always something that we can do to “raise the
through and pass it on to others. Here is the story, as I bar”.
remember it.
You can imagine our excitement then, when
Rosa grew up helping her father, who was a carpenter. I believe recently, we were contacted by a highly recognized and prolific
that they were building boathouses, sheds and other small buildings Canadian photographer. He had been watching the magazine and
in forested, lake country. She must have started helping him at a was contacting us to say that he was interested in helping us take
fairly young age because, by the age of 12, she had managed to the magazine to the next level.
spirit away enough of her father’s lumber and she had accumulated We met shortly after and our visions for the magazine fit together
enough skills to build a small cabin, hidden away in the forest. like a couple of intarsia pieces. So, with this issue we are really
excited to introduce our new cover photographer, Ray Pilon. You
This little building was made using all the correct techniques for will probably recognize his work. If you’d like to see more of his
making the roof, window frames and doorways. It even had little photographs you can go to www.storm.ca/~rpilon. While you’re
shelves in it. It was not long, however, before Rosa’s hideaway there, let him know you saw his photo on the cover of this
cabin was discovered and, for reasons which I am sure magazine. He’s got some amazing cover photos planned for
were not obvious to a 12-year-old girl, the cabin was upcoming issues. Be sure to watch for them.
dissembled.
We’re also very excited about a couple of stories
Rosa was heartbroken. However, as kids do (even that we are featuring in this issue (see pages 25 &
with broken hearts) Rosa grew up. As an adult, she 26). They are both moving and inspiring accounts of
worked to buy a substantial piece of land. On this, a parent’s influence on their child’s woodworking.
her own land and with her own materials, she once Perhaps you would like to share them with the
again set about building herself a house. This time it person who inspired you in your woodworking.
was larger and this time when she finished it, she
leaned against one of the inside walls and cried. She This issue also features a fun new project: a model
cried for the loss of her first building, but more than that, stake truck – designed by Jim Thoms and illustrated by
she cried because this was her house and nobody was going Len Churchill. We are striving to offer more and more
to take it from her. plans/projects in upcoming issues, so if you have something
that you would like to see, or if you have a project that you would
Rosa lost her first house, but she did not lose her dream. The like to submit, please let us know. Don’t worry if it’s not all
whole thing gets better. The story of Rosa spread and soon many perfectly illustrated. We’ll take care of that.
women were showing up at the house that Rosa built. They, too, In the April/May 2002 issue I noticed a trend and wrote:
wanted to learn how to build a house. So she taught them what her “No longer are isolated woodworkers toiling away in their
father had taught her. In return for the teaching, the apprenticing workshops . . . now they are ‘getting out there’ . . . sharing tips and
women built more buildings on her land, which housed more tricks, giving ideas and suggestions, offering new resources and
women, who continued to come to learn how to build. showing each other their stuff.”
I don’t believe that it is necessary to tackle something On the day that issue went to press I received an email
as big as building a house for the same benefits to be that not only confirmed my observation but showed me
gained. Even simple projects can have beneficial that it was only the tip of the iceberg (see the letter on
effects, for example, Rick Campbell building page 5).
birdhouses with his daughter and her Girl Guide
group (see Apr/May 02 issue). There are gains in In a nutshell, the email said: “hobbyist wood-
confidence and self-esteem and an excellent working is a solitary activity, and a person can end
opportunity for bonding – not to mention feeding the up feeling lonely . . . that some woodworkers almost
birds! preferred WOOD FORUM participation to building
things!” He goes on to say, “these forums are a great
However, real life unfolds much more slowly than a way to ‘meet’ like-minded people.”
story, so don’t be disappointed if these benefits are not So get in on this growing trend: if you are a solitary
obvious or immediate. As in Rosa’s story, and in two other great woodworker, feeling lonely as you work away in your shop, have
woodworking stories in this issue by John Sedgwick and Gord heart. There are thousands of woodworkers across Canada feeling
Graff, sometimes it takes a lifetime of woodworking before you, or the same way. Drop into our WOOD FORUM and say “hello”.
your children, can look back and even realize what you’ve gained. You, too, might find out that the forum can be as fun and as
rewarding as building things!

LETTERS
deareditors
fulcher@canadianwoodworking.com woodworking magazine. I grow weary of Router Academy, Rideau Cabinets and
Re: April/May 2002 issue: In the article all the U.S. publications. others). Just thought you would like to
on the various saw blades that were tested, Thank-you, know so when their contracts expire you
I found some of the information a bit Dave Eisenbeis can show proof that us Wood Forum users
misleading, in particular the references to Sherwood Park, AB do support those that support you!!
the three Forrest blades. The results of the Best regards,
tests were a glowing endorsement of the Dave Dan Madill
Forrest blades. However, some of the Thank-you for your kind words. We have
applications for the different blades were had several requests for a regular carving fulcher@canadianwoodworking.com
incorrect. column and we are in the process of setting My free listing in the classified section on
For example: Forrest Woodworker I that up. Watch for it in upcoming issues. your web site was a great success. I posted
This blade is made especially for the two items (scroll saw and band saw). I
radial arm saw and is a fine cross-cut Editor’s Note: received exactly what I was looking for
blade. It can also be used on a table saw, If anyone is interested in writing some and all sales were cash. If I ever need to
but only for cross-cutting. carving articles, please let me know. I am sell another woodworking item the free
Forrest Woodworker II currently considering submissions. classified section, on your web site is
This is a true combination blade for use exactly where I plan to go. I still check
on a tablesaw and can be used for both fulcher@canadianwoodworking.com out the site and recommend it to other
ripping and cross-cutting. I received the free sample yesterday. I woodworking enthusiasts.
Forrest Duraline HI-AT enjoyed reading it, so I have subscribed. Thanks,
This blade is designed primarily for One of the things that impresses me with David Bell
man-made materials such as plywood, your magazine is that it is Canadian. Ymir, BC
laminate and melamine board. This blade Although I have enjoyed articles from the
cuts these materials and leaves a clean cut US magazines, I find that Canadian
fulcher@canadianwoodworking.com
on the bottom side. This is of particular magazines are more relevant for me. They I feel that our advertising with Canadian
importance when cutting melamine board, tell me of Canadian retailers, as I refuse to Woodworking Magazine has been very
especially when a chip-free cut is required purchase anything in US dollars. Also, successful. In fact, we had calls as soon as
on the bottom side. This blade is in a class would it be possible in one of your future the issue became available. Your magazine
by itself, and should not be isolated as a issues to print a list of all Canadian online is packed with interesting articles and the
cross-cut blade. woodworking retailers or US retailers that kind of information that woodworkers are
Regards, have the decency to post costs in Canadian searching for. Thank you from O.M.S Tool
John Withrow currency. Company, manufacturers of the DOWEL-
www.mulecab.com Thank-you, MAX jig.
Denis Daigle Marie Lindsay
Timmins, ON www.dowelmax.com
fulcher@canadianwoodworking.com Denis:
Sorry for the delay in getting you Thanks for your note and comments. As fulcher@canadianwoodworking.com
the most recent stats for for a complete listing of Canadian I was referred to your WOOD FORUM
candianwoodworking.com. The 176 Mb Woodworking retailers: ideally they will by a regular visitor there who said, among
logfile was brutal on our machines. all, one day, be advertising with us! other things, that he almost preferred
Internet Service Provider, However, in the meantime we are adding forum participation to building things! I
Technical Support more and more each month to both our thought about that, and you know, hobbyist
magazine and our website. Keep an eye on woodworking IS a solitary activity, and a
Internet Service Provider: our web site, as an update is in the person can end up feeling lonely. These
It might be time to upgrade your system, works, and will include a page of Canadian forums are a great way to “meet” like-
because those stats showed we are getting retailers. minded people.
more than 1,754,000 hits/month with over Thanks,
1,600 user sessions per day . . . and fulcher@canadianwoodworking.com Ken Cawthorne
growing! And this is our slow season. I enjoy your web site and especially your
Watch out when the woodshows start back classified section! fulcher@canadianwoodworking.com
up and we really get active. Hans I read the forum everyday!
Barry’s Bay, ON J. Kidner
London, ON
fulcher@canadianwoodworking.com fulcher@canadianwoodworking.com
I am a wood carver and would be very I have used your free classified section. fulcher@canadianwoodworking.com
happy to see your fine magazine include I had about half a dozen responses. It took I recently received my April/May issue of
wood carving as a regular column. I would about two weeks to sell and I got my Canadian Woodworking in the mail. I
also like to compliment you on your asking price. I will definitely post again enjoy the magazine and compliment you
magazine. I picked up a copy at a wood and am totally satisfied. on offering a good Canadian product. I
working show and sent in my subscription. Just to let you know, I have spent lots of would also like to compliment you on the
It is very refreshing to have a Canadian money through your web site (i.e. National web site you run. It is both informative and
4 CANADIAN WOODWORKING Visit our website at: www.canadianwoodworking.com
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woodcraft BY GARNET HALL
Shark
T
his project is a fairly simple Transfer the pattern together.
one and should be a good Start with 3/4” thick MDF. Transfer The top dorsal fin is lowered and the back
craft seller. the pattern to the MDF. Because you are of the shark will be shaped down to the
It has only 8 pieces, working with MDF and are going to paint dorsal fin’s thickness.
including the eye. This the project, grain is of no concern. Attach Shape as usual. Try to give the shark a
project is different than the pattern as a whole rather than separate rounded look. Shaping will also create a lot
anything that we’ve done before as it is pieces. I call this technique non-directional of sawdust so, again, wear a good mask.
made out of MDF and painted. I hear a lot intarsia. Cut on the lines and the pieces will Sand as usual. I don’t sand past 220, as I
of intarsia artists comment that it is hard be sure to fit. Make sure your blade is don’t want to create any more dust than
to find good material for their pieces. square to the table. I found a #7 precision necessary.
Everyone should be able to find MDF. It’s skip blade worked well for this material
inexpensive and easy to work with. It also and project. Backing
comes in a variety of thicknesses which Once you have the sanding done
makes raising and lowering easier. Shape assemble the project onto the backing
However, it does make a lot of sawdust, so Once it’s cut out assemble and get ready material (1/4” oak or birch plywood).
be sure to at least wear a dust mask. for the shaping. Did you notice that there is Make the back in the “set back” style
no fitting step? That’s because the pattern (i.e. the back a bit smaller than the actual
was attached as a whole, so when you cut project). Trace around and cut the back out.
along the lines the pieces naturally fit back
Pattern reduced
to 75%.
Can be sized
Paint Colours
to preference.
W - White
G - Grey
L2 - lower 3/8 in.

L4 - lower 1/2 in.
Painting 1/4” and paint them black.

Paint the pieces before you glue up. Glue the project onto the backing. MATERIALS LIST
It’s a good idea to prime the MDF before Add a hanger and it’s done. 1 sq ft 3/4” thick - MDF
painting it, as MDF soaks paint up like a
sponge.
1 sq ft 1/4” thick - Plywood
If you would prefer to make the shark in a
I used a gray latex paint (two coats). more traditional style, look for some gray for backing
I made the eye out of a 3/8” dowel and mahogany. If you check out the mahogany 1 pc. 3/8” x 3/4” long - Dowel
painted the end white with a black dot. boards you can sometimes find pieces that
Paint black the area on the backing board have a real nice gray colour (almost silver). If you prefer not to use MDF, 1 1/2
that will be under the gills. Alternatively, Cut the pieces separately taking the grain board feet of 1 x 6 gray mahogany.
you can save the gill cutouts, lower them direction into consideration. GARNET HALL is an intarsia artist living in
Stoughton, SK. 1-800-729-2473 www.sawbird.com
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featureproject BY DANNY PROULX
Outdoor
Dining Set
■ Photo Credit: Michael Bowie, Lux Photography, Ottawa, Ontario

T
his is an easy-to- I used construction grade cedar for this you. Bring a few tools up to the cottage and
set because of its availability and the build this outdoor dining set. But, be
build dining set relatively low cost. However, the choice of careful not to show it off too much or
materials is optional. Most lumberyards you may start getting orders from your
that’s sturdy and allow you to select your own wood. Pick neighbours.
won’t cost you a small through the construction grade pile and
choose the best pieces. You can build the
BUILDING THE CHAIR
fortune for materials. But set with a select grade of lumber but the
costs will rise. The material choice isn’t
don’t let the simplicity fool important. The quality of your final project STEP 1
depends largely on the hardware, Cut the four vertical legs (A) and
you, the table and chairs adhesives, and finish that you use. horizontal legs (B) to length. Each leg
will serve you well for many You will be able to build additional requires a 3/4” deep by 3” long rabbet on
pieces using this design. The leg loop style both ends. You can make the cuts with
years. of the chairs and table supports follows the hand tools or with a table saw, router table,
same principal of construction that you can radial arm saw or circular saw. Set the
I designed and built a prototype set for use for other projects, such as benches or blade depth on your circular saw to 3/4”.
my deck over five years ago and we’re still side tables, by extending the seat and back Make a series of cuts across the face in the
using it today. The table and chairs have boards. joint field. Use a hammer to break away
been outside each summer and they are If your budget limits you to a circular saw the waste and clean the joints with a sharp
still as sound as the day they were built. and a few hand tools, this is the project for chisel.

If you plan to make a number Install the screws 1” apart and 1 1/2” in comfortable seating. Attach the boards
TIP of sets for friends and family,
a tenoning jig is a great
from the outside corner of each joint. with the longest dimension of the angle 7”
from the rear of the seat supports. Use glue
and 2 1/2” screws to secure the back
accessory for your table saw. It easily and If you plan on building a few
accurately cuts rabbets and tenons. It’s
one of my favourite tools because of the
TIP chairs, or extra small tables or
benches, remember that the leg
supports. Driving the screw through the
seat support makes the lower connection.
Be careful at this point because you are
accuracy and safety features. Best of all, loop assemblies are all the same. now creating a right and left assembly.
it isn’t that expensive. Construct an assembly frame jig with a
scrap piece of any sheet goods and attach STEP 6
four boards to form an outside perimeter Each chair requires six boards (C) to
STEP 2 of 24” x 26”. This jig will ensure that all
form the seat and back. Start by installing
Join two vertical and two horizontal legs the bottom back board, resting it on the
to make one side assembly. Use waterproof your leg loop assemblies are accurately seat supports. Attach all the boards with
adhesive and two 1 1/4” exterior rated constructed. glue and 2 1/2” screws from the rear and
screws at each joint. You can also use wood underside. The boards are flush with the
dowels for the joinery. Each leg loop STEP 3 outside face of the supports. Space them all
assembly should be 26” high and 24” wide. Sand the frames and cut each corner at 45 1/8” apart. Let the adhesive set up and
degrees. The mitres should be 1” back perform the final sanding on your chairs.
from the corner intersection of each leg.
MATERIALS LIST Use a handsaw or power miter to cut the BUILDING THE TABLE
All materials are 1 1/2” thick corners.
construction-grade cedar unless STEP 7
STEP 4 Prepare the vertical members (F) and the
otherwise noted. horizontal members (G) by cutting a 3/4”
Use a 3/8” round over bit in a router to
deep by 3” long rabbet on both ends of all
CHAIR (1) soften the inner and outer faces on both
assemblies. Sand the sharp mitred corners the boards. Then cut a 1 1/2” deep by
4 3” x 26” with a belt sander to soften the cuts. Then 1 1/2” wide dado centered on each of the
(A) Vertical Legs install the two seat supports (D) with their horizontal members. Assemble the frames
top surface 15” above the bottom of each by joining two vertical to two horizontal
4 3” x 24” assembly. Use glue and two 2 1/2” screws members. One frame must have the
(B) Horizontal Legs per joint. notches open to the inside and the other
frame has the notches facing out. Use glue
6 5 1/2” x 23” and 1 1/4” screws to assemble the frames.
Be sure to pre-drill holes in
2
(C) Back and Seat Boards
1 1/2” x 24”
TIP the seat and back supports. You
will be installing screws very
However, one horizontal member on one of
the frames should be attached with screws
only. This will allow removal when the
(D) Seat Supports close to the ends of these boards and they frames are joined.
will split without a pilot hole.
2 1 1/2” x 16” STEP 8
(E) Back Supports
Sand the frames and miter only the
TABLE
STEP 5 bottom corners at 45-degrees. Round over
The bottom of the two back supports the inner and outer face of each frame with
4 3” x 47 1/2” must be cut at 18 degrees. This cut a 3/8” round over router bit. Remove the
(F) Vertical Members will create the back slant needed for horizontal member that was only screwed
4 3” x 28”
(G) Horizontal Members
4 1 1/2” 32 1/2”
(H) Support Stringers
45˚ cuts at both ends
7 5 1/2” x 40”
(J) Table Top Boards
STEP 1 STEP 2
HARDWARE and SUPPLIES

1 1/4” Exterior-rated Screws
2 1/2” Exterior-rated Screws
Polyurethane Glue
Sikkens Cetol 1 #077
Cedar Finish STEP 3 STEP 4

Back Boards C
Back Support E
18° cut
3/4"
7"
15" 3"
Seat Boards C
Seat Support D 15"
Cut corners at 45°

1 1/4" then sand to rounded
exterior rated screws VERTICAL LEG
or 5/16" x 1 1/2" dowels DETAIL
Table Top
Boards 1/8" gap
Horizontal 45°
Leg B 3/4" deep x
3" wide rabbet
Vertical Leg A
1 1/2" x 1 1/2"
Support Stringer H notches
Support Stringer H
Vertical Member F
Vertical Member F
28"
Horizontal Member G 47 1/2"
Horizontal Member G
3/4"
3" Cut corners at 45°
then sand to rounded
HORIZONTAL LEG DETAIL 3/4" deep x

3" wide rabbet
Illustration by Len Churchill

A SPACE SAVING, RELIABLE AND ACCURATE WORK STATION
“the prescription for damaged furniture.”®
Titebond Wood Glue

from one of the frames. Then join them STEP 10 used to anchor the umbrella to the table.
by fitting the dadoes inside each other. Centre the frame on the seven table-top There are quite a few design options
Re-install the top member using glue and boards (J), spacing them at 1/8”. Use glue available. Chair seats can be slanted, the
screws making sure the dadoes fit properly. and 2 1/2” screws from the underside to backrest angle can be easily changed, and
Use glue and 2 1/2” screws to lock the secure the boards. Sand the table and the chair width is variable.
frames together at the dado joints. soften the sharp edges to prevent cuts and You can build an oval table by altering
scrapes should anyone bump the corners. the frame dimensions. One long and the
STEP 9 Apply a good exterior finish making sure other short, with the appropriate stringers,
Align the support stringers (H) flush with all the surfaces are coated. I used Sikkens will allow you to build a large table to seat
the tops of the frames. Secure them to the Cetol 1 #077 Cedar to finish my set. six or eight. However, you will need extra
frame with glue and 2 1/2” screws. chairs.
And finally, you can further reduce the
CONSTRUCTION NOTES construction costs by using pressure
The easiest way to attach the treated lumber. Avoid direct contact with
TIP table-top boards is by laying
them on a flat surface with 1/8”
Changing the length of all horizontal
frame members easily alters the table size.
Or, you can create a round table if you
pressure treated wood by wearing gloves
when handling it and using a dust mask
prefer that look. when cutting. This material is only suitable
spacers between each board. Centre the if you plan to paint the set with a solid
frame on the boards so the stringers run
The table can be fitted with an umbrella
by drilling a hole next to the intersection of coloured exterior finish.
parallel with each side and install the the two horizontal frame members. If you DANNY PROULX is a woodworking author and teacher.
screws. drill the hole accurately, the frame can be www.cabinetmaking.com or
email danny@cabinetmaking.com
STEP 5 STEP 6 STEP 7
STEP 8 STEP 9 STEP 10
5 Reasons you should be using

Circa 1850 Bowling Alley Polyurethane
1. Dries so fast — re-coat in 2 hours
2. Non-yellowing formula lets beauty of
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3. Extremely low odour
4. Cures to an exceptionally hard,
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5. Get cash back on purchase of 1 litre
or 3.78 litre can
See all our innovative products at

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woodenmodel BY JIM THOMS
“C” Cab
Stake Truck
• Cut all parts to size.
• Cut two pieces of 3/4” stock for
motor block and glue together.
• Sand and round edges.
• Drill axle holes, shift rod hole
and steering rod hole.
• Dry fit parts. Sand for proper fit
(if necessary) before gluing.
• Start at front of truck and glue
motor block in place. Work towards
the back of truck. Dry fit and glue pieces
in place.
• Varnish or paint to finish.
Here are two more of Jim’s pieces.
JIM THOMS, a retired general builder, is a model and
mold maker from Midland, Ontario. You can see more on his web site:
(705) 526-4040 http://woodencars.tripod.ca http://woodencars.tripod.ca
email: woodencars@sympatico.ca

MATERIALS LIST
4 2” tread wheels
4 axle pins
2 beehive 3/4” dia.
head lights
1/8”, 1/4”, 3/8” dowel
6” x 6” x 1/8” to 1/4” piece of
wood panel or plywood
6” x 3” x 1/4” stock lumber
3” x 3/4” x 6” stock lumber
1 square = 1/2"
10"
DASH
2-3/4" 3"
CAB SIDE 1-1/2"
FENDER
Roof 1-1/2" Box post
Cab Back
Cab Side
Box Stake
Front
Post
Box Bottom
Steering
Wheel
1/8" dowel
Dash
Seat
Back Box End
Seat
Bottom Box Spacer
1/4" dowel Rad Cap
Rad
Rad Core Base
Beehive Headlight
Motor
Block Seat Spacer
Shift Rod
Bumper
Fender
Bumper 2" diameter Wheel

Guard
Illustration by Len Churchill
FREE
80 Page colour
catalogue
Call Now
1-800-565-5066
Order On-Line
www.woodparts.ca
THE WOOD CONNECTION

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Copenhagen, Ont N5H 2R2
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CALL 888-366-0357 OR VISIT www.woodshowscanada.com

woodturning BY PAUL ROSS
15-Minute
Sand Timer
F
or this project, we To prepare the top and bottom, cut two
pieces of hard maple 1/2” thick with a
incorporate a little diameter of 3”. Then glue a waste block on
to one side. This allows the piece to be called the outside cut. This brings it true.
faceplate turning with grabbed by the chuck. To mount the waste Cut it down until it is approximately
block, sand a flat surface on the waste 2 7/8”. Remember, you want to get the
some spindle work. Both block and a flat surface on the maple. Then bottom and top the same diameter. For this
are relatively simple to apply some “Cynoacrylite” gap-filling I used a little 3/8” bowl gouge with the
consistency glue to the waste block and flute facing the direction of the cut. I just
do, however, some fairly spray accelerator on the maple. took a few cuts, watching the top of the
Next, clamp the two together and it will profile so as to produce a horizontal
accurate measurement is be ready in seconds. The reason for using surface.
this glue is twofold. It’s fast and its tensile Photo #2 shows the rest across the face.
required when turning the With the same gouge, take a facing cut to
strength is extremely strong. However, its
spindles. With this particular shock resistance is very weak. That means produce a flat, clean surface. Aim for the
that you can turn, holding the piece on the best possible finish with the gouge. This
piece, I used hard maple waste block and when you want to release limits finishing cuts with the scraper. As
the piece, you just have to tap it with a shown in photo #3, use a 3/4” square end
for the top and bottom and chisel and the waste block falls off. This is scraper, to scrape the surface flat. This is
Padauk for the spindles, to very effective for turning small pieces, now the inside of the bottom (or the top)
such as the spindles in this project. piece.
provide contrast. Both top and bottom are done the same Now cut a little dimple to accept the little
way. The first cut, as shown in photo #1, is bubble of glass at the end of the timer. This
must be a custom fit. Allow for a little bit of
1 2 3
4 5 6

silicone to cushion the timer (photo #4). and the bottom, on the inside. This way if, of the body of the sand timer, add about
Now put your rest back to the outside and, after turning the spindles, you need to 1/16”. This is the distance in between the
with either a parting tool or a 9-in-1 tool, make the little dimples in the middle shoulders of the tenons.
cut a couple of beads for a decorative finish larger, they will easily remount back into Turn a couple of beads, on either end, on
on the outside. Sand starting at 120, and the chuck. the spindle. Taper it thinner in the middle.
proceed through 180, 240, 400 “J-flex” Bead as shown, or use your own design.
paper. I used EEE compound, which is a Turning the spindles. Sand and finish. For a finish, I used a
fine Tripoli in a paste. This takes out the As shown in photo #6, rough down to a friction polish, which is fast and comes to a
400 sanding marks and prepares the cylinder, using a skew. This is a fairly small nice high gloss.
surface for whatever finish you apply. piece and the wood is a little oily and easy Now that you have top and bottom
Mark with a pencil, in from the edge, to cut, therefore, this can easily be done turned, spindles completed and you have
about 5/16”. This is the radius in which the with a skew from square to round. Size the checked that everything fits perfectly, it’s
3 holes are drilled to accommodate the tenons with a small 1/8” parting tool time to pop off the waste blocks and flip
spindle tenons. With an indexing ring, (photo #7). At this point it is critical that both top and bottom so that you can turn
divide by 3. On the lathe I use (One-Way the distance from the tenons be exactly the the ends. There are many ways of doing
1018’) the indexing ring has 24 positions, same on all three. You want to ensure that this. I chose to put it in a vacuum chuck
so 24 divided by 3 equals 8. So every 8 they are spaced to just cradle the sand and just turn the ends slightly concave.
positions, I lock the ring and drill the holes, timer. To measure this, take a pair of Scrape the ends after cutting with a gouge
using a hand drill (photo #5). The larger calipers and measure the exact length of (photo #8).
“One-Way 2436”, has 48 positions. That, the sand timer from end to end (NOT Next comes the assembly of the timer.
divided by 3, would mean that you would including the little glass bubbles at the Put a little dab of silicone in the one end
drill every 16 positions. First turn the top ends). Now that you have the exact length and let it set. This develops into a rubbery
consistency. When you are ready to
assemble, put another little dab in the
dimple and glue (yellow carpenter’s glue)
in each of the holes in the top and bottom.
Place the three spindles in the bottom, set
the sand timer in place and then, carefully,
align the top. Gently, clamp the timer until
the glue is set.
PAUL ROSS owns and operates Chalet Woodcraft and
7 8 teaches woodturning in Boston, Ontario.
(519) 443-5369 www.chaletwoodcraft.com
ONEWAY 100%
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woodenpuzzle BY REA GIBSON
Seven Piece Cross Puzzle
T
he object of this puzzle is to make a
“cross” from the seven pieces.
Cut out the seven pieces from plywood,

cardboard or plastic.
There will be two “A” pieces. There will be two “B”

pieces 5” long and 6” long. There will be three “C”
pieces.
Unlike some of the puzzles in this series, this is not a

particularly difficult to solve. That, along with the
fact that it is easy to cut these shapes, makes this an
easy, fun party puzzle.
REA GIBSON owns and operates Forest Hill Studios
and lives in Mount Forest, Ontario.
email:egibson@golden.net
Solution
From last issue’s Magic Four Puzzle.

workshop BY HANK ETHIER
Wiring Your Shop

S
o, you’ve added a table saw and a equipment will be running at the same you will use undersized extension cords to
dust collector to your collection time. If you have the table saw, dust plug into a multi-outlet gizmo that allows
of large stationary tools. You’re collector and air compressor on the same you to harness the whole shop into one
happy with your purchases and circuit you could be in an overload circuit. This eventually overloads the
are making more and more situation. You will be running the collector circuits causing a fire hazard or ruins the
wooden projects. In fact, it’s at the same time as the saw and if the motor on a power tool, which you will then
going so well that you are now thinking of compressor should happen to kick in, the have to replace. Do it right the first time.
buying more equipment. Unfortunately, breaker will likely trip. Clearly some If you do not feel competent enough to do
your present electrical system will not equipment should have it’s own circuit. your own electrical work, hire a qualified
handle the load. These would include anything that draws a electrician. Go over what you plan to do in
Before opting for a short-term solution, lot of current such as larger table saws, the shop. They may have a few ideas you
such as adding just one circuit to handle dust collectors and large air compressors. never thought of.
the extra load, why not look at your future Be aware that some large motors will draw
needs right now? Make a list of the more than the 15amp rating of a standard Wiring Tips:
equipment that you will someday acquire. plug and breaker combination. They may Put the plugs at least 1.3 meters above
Make a scale drawing of your shop floor draw 17 amps, in which case a 20-amp the floor. This allows you to lean a sheet
and of the equipment that will fill it. The circuit would have to be installed. of plywood against the wall and still find
equipment drawings can be simple box Also, take into account how many people the plug.
representations. Be sure to include will be using equipment at the same time. Run all your wires on the surface of the
workspace with each unit. For example, a wall using conduit or armored cable. This
If you are a one-person shop then putting makes adding or moving a plug a very
table saw top isn’t that large, but once you the drill press, spindle sander, band saw, easy operation. Also, if you outgrow the
add the clearance space in front and back scroll saw and lathe on one circuit may not basement shop and build one in the
for cutting a sheet of plywood there is a be a problem because it is very unlikely backyard, you can take your electrical
significant amount of area required. Now they would be on at the same time. plugs and boxes with you instead of
place your equipment cutouts on the shop However, if two of you share the shop, leaving them buried in the walls.
floor and move them around until you get make sure the circuit will handle whatever Make plans for tasks lighting at tools
them set up the way you want. Don’t forget equipment is used simultaneously. that are used for detail work such as the
the upgraded lighting that you may want to If you find that the number of circuits is scroll saw and lathe.
You may want to wire the shop through
install so you can see what you are doing more than the present panel will handle, an a main shut off located near the door. You
with your new equipment. upgrade in this area may be needed as well. can then shut off all the power to the
Make another list separating your Sound expensive? It is, but you should shop with one switch. You don’t have to
equipment into units that will run on 110 consider electricity as a very important worry about leaving a fan, compressor
and those requiring 220. Try and run tool. Without it, woodworking becomes or soldering gun on. It can also be a
everything you can on 220. The same 2-hp very labor intensive and may not be very effective safety device to prevent
motor will draw half the amps on 220 as it possible. If you skimp here and have only unauthorized use of tools.
will on 110. This will help you decide how two plugs in the shop so you can unplug
HANK ETHIER is a furniture maker and refurbisher in
many circuits will be needed and where one machine to plug in the next one, you Prince Albert, SK. Tel. (306) 922-3323 Fax (306) 763-3739
the plugs will go. Pay attention to what know what will happen. Sooner or later email: ammena@sk.sympatico.ca
Nova 3000 Lathe Super Nova

Chuck
This super special includes:
2” Jaw Set, 1” Jaw Set, Made from M2 Made in England
High Speed
Woodworm Screw and Steel (Rockwell 62/64) with
insert of your choice ergonomically designed ash handle. We also
$
139900 FREE stock turning accessories, finishes, pen kits,
Super Nova glues, etc.
with 1 HP Leeson Motor Made in Chuck
New Zealand
Hamlet ASP2030
$
189900 •16” swing over the 24” cast iron
bed (20” bed extensions available)
& ASP2060 Turning Too ls
edge 3
with 1 HP Baldor DC Motor, •Swivel cast iron headstock for easy Made in These tools hold their sharpened HSS.
LL-SNCSZ to 4 times longer than conventional
21495
New Zealand
variable speed controller outboard running •8 speeds $ More Turning - Less Sharpening!!
with reverse switch and (212-3600 RPM) •Cast iron
wiring harness tailstock
Visit our website for ‘on-line’ shopping from our Woodturning Catalogue
110 Woolridge St. Coquitlam BC Canada V3K 5V4
KMS Tools & Equipment Ltd Phone: 1-800-567-8979 or 604-522-5599
email:sales@kmstools.com

toolreview BY CARL DUGUAY
Handsaws Part 1
Part 1: Western Saws saws into five categories. Measurements group has a solid feel to it, with excellent
There is a level of satisfaction and are shown in inches, and prices in balance. A commanding presence. The
enjoyment I get from hand planing a Canadian dollars (rounded to the nearest Lie-Nielsen (Independence) Dovetail (top
surface or hand sawing a tenon that I don’t dollar and without shipping and taxes; US in photo above) is the smallest and lightest.
get in using a jointer or table saw. Maybe it dollars converted at 1.45). Like holding a butterfly in your hand. The
has something to do with the whining noise Pax saws come with a traditional closed
and shower of sawdust. Or maybe it’s that Gents style handle (an optional open handle is
intimacy you develop with a well-made, available), while the Independence saws
finely tuned hand tool. come with the open handed pistol grip.
Whatever it is, I like hand tools. So I I found that the pistol style handle offered
was quite excited at the prospect of trying better control: you can really feel whether
out saws from some of the leading the saw is being held in the correct
manufacturers. In this first of a two-part position. The hardened steel blades
series, I’ll cover Western style saws and in and brass fittings on both the Pax and
Part 2, Japanese style saws. Independence saws are top of the line. In a
Stanley Tools needs no introduction. fine cutting Western style saw, these are
They’ve been around since the 1840s, and The Stanley saw has the widest kerf and unsurpassed in quality. The Pax saws are
produce about every kind of hand tool roughest cut. The handle is small, and not less than half the price of the Independence
known to man. Bahco Tools is Snap-On as comfortable as the others. It’s also about saws. The question, then, comes down to
Inc. is Sandvik (corporate amalgamation). twice the price of the other saws. The style preference and price.
Sandvik has long been synonymous with Sandvik (bottom in photo above), with a
quality and innovation in hand tools. thinner blade and finer set produced a Mitre
Thomas Flinn has been in the saw business noticeably better cut, and the handle was a
since 1923, and the Pax line has been bit more comfortable. Both the Stanley
continuously produced for an amazing and Sandvik seem more suited for the
225 years. Flinn is the only company carpenter or home handyman. The Thomas
that exclusively manufactures handsaws. Flinn (Pax) saws (fixed handle - top in
Lie-Nielsen produces the finest hand photo above) produced excellent cuts and,
planes available today, and are carrying at under $20, are excellent values. The It seems to me that mitre saws are slowly
on that tradition of quality with their teeth on the offset handle Pax are only set fading into the sunset. Pity though.
handsaws. on one side, which helps account for its Coupled with a good mitre box, they make
Briefly, Western saws can be loosely narrower kerf. Both have very comfortable quick work on accurate 45˚ and 90˚ angles.
divided into three categories. Backsaws – rosewood handles with brass spines and The Stanley 15-672 with its triple edged
including gents, dovetail, tenon, mitre and fittings. I found the offset handle a bit more tooth design cuts very fast, but at the
inlay saws – have a rigid spine attached to awkward to use, although this may be due expense of smoothness. The Stanley
the blade. Most fine woodworking saws on to my unfamiliarity with this style. 15-636 (see photo above) and the Sandvik
the market fall into this category. Frame Nonetheless, the Pax gent saws are 318 cut slower but produced smoother
saws – which have a blade under tension excellent. cuts. For cutting mitres on the job, either of
between two fixed ends – include frame, these two will do, with the advantage that
veneer, bow, bucksaws, coping, fret and Tenon and Dovetail you can re-sharpen the Stanley 15-636
jeweller saws. Finally, we have Handsaws (teeth are not tempered). The handles were
which have a wide blade fixed to a single comfortable on all three saws.
handle. These include crosscut, rip, panel
and general purpose saws. A good Handsaws
overview of handsaws is found in Graham
Blackburn’s “Traditional Woodworking
Hand Tools” (Random House).
I began by laying out the saws and
conducting a quick visual inspection of the
blades, teeth, rigid backs and handles.
There were no glaring deficiencies. I then
made a prescribed set of cuts on hardwood These are gorgeous saws that feel
and softwood with each saw (flush, tenon, wonderful in the hand. They cut smoothly
mitre and dovetail as appropriate for the and quickly. The Pax tenon saw (bottom in Every shop needs a good crosscut saw for
saw). For convenience I have grouped the photo above) the largest and heaviest in the preparing rough stock. All these saws
Visit our website at:www.canadianwoodworking.com CANADIAN WOODWORKING 21

produced cuts of comparable quality. The proper sharpening and setting. the cut is more of an issue. And if you
Pax (top in photo above pg 21) has a The photo below shows cuts from four do a lot of handwork, then the feel and
slightly smoother cut than the rest. It has saws (from left to right, Pax Gents, Pax balance of the tool is also an important
excellent feel and heft, and with a handle Tenon, Independence Dovetail and the consideration.
that is 2” wide, is best suited for those with Stanley 15-636 Mitre saw). As expected, The Pax and Independence saws are
large hands. It also has that nice skewed saws meant for general crosscut and clearly more suited for fine work, while the
back. The classic looking Sandvik 277 rip work give the roughest cuts. With Sandvik and Stanley seem more positioned
(bottom in photo above pg 21) is, like the increasing point size the set becomes finer for general purpose sawing.
Pax, taper ground, and probably better and the cuts get better. In general, all the While Western style saws still dominate
suited for someone with a longer arm. An saws I looked at cut reasonably fast. the market, Japanese saws are making
advantage of either of these saws is that Perhaps, for carpenters, the speed of big inroads. In the next issue we’ll look
they can be re-sharpened. The Stanley, cutting may be an important consideration at some traditional and contemporary
with its aggressive tooth pattern, cut the but, for most woodworkers, the quality of Japanese saws.
fastest. It lacked the balance of the Pax or
Sandvik 277. The Sandvik 3090, with its
ultra modern look, is the saw that seems
tailor made for the work site. It has a very
comfortable handle, silicon treated rust
resistant blade, is lightweight and has
excellent cutting properties.
General Purpose
Gents (photos on pg 21)

Stanley 15-252 Sandvik 312 Pax offset Pax fixed
Overall Length 15 15 16 1/2 13 3/8
Blade Length 9 3/4 9 3/4 10 8
Blade Height 1 3/4 1 1/2 1 1/4 1 3/4
Pitch 13 15 15 20
Stanley tools typically have Blade Thickness .030 .022 .022 .022
induction-hardened teeth with an Kerf .042 .030 .025 .027
aggressive tooth design that incorporates Tooth Cut crosscut crosscut rip rip
three cutting surfaces. Sandvik saws Tempered no yes no no
incorporate a universal toothing pattern Price $39 $22 $20 $17
that has every third tooth short and set,
while the other two teeth are straight and
unset. Both companies make a number of Tenon & Dovetail (photos on pg 21)
saws that fit into the “General Purpose”
Pax Independence Pax Independence
category. These saws are often referred to Tenon Carcass Dovetail Dovetail
as box saws or short cut saws, and can
Overall Length 17 1/4 16 13 1/8 14
withstand rough handling better than
others. They are ideal for toting around the Blade Length 12 11 8 9
work site or home. They do a decent job Blade Height 3 1/8 2 1/4 2 3/8 1 5/8
crosscutting or ripping, and you can use Pitch 13 15 20 15
the handles to quickly layout 90˚ and 45˚ Blade Thickness .027 .020 .020 .020
angles. The cuts made by these saws were Kerf .033 .025 .025 .023
fairly similar, with the Sandvik 300 Tooth Cut crosscut crosscut crosscut rip
(bottom in photo above) producing the Tempered no no no no
narrowest kerf, and the Stanley (top in Price $94 $192 $94 $175
photo above) cutting the fastest. The
handles of the Sandvik 2500 and Stanley
are particularly comfortable. The teeth are Mitre (photos on pg 21)
impulse hardened. They make an excellent Stanley 15-672 Stanley 15-636 Sandvik 318
companion to the larger handsaws. Overall Length 17 1/4 19 1/4 16
Blade Length 12 14 12
Summary Blade Height 3 1/4 3 1/8 3 1/2
As with any hand tool, when purchasing Pitch 12 13 13
a new saw you need to think carefully Blade Thickness .040 .030 .027
about its intended use. It is unlikely that Kerf .058 .041 .027
any one saw will serve all you needs. In Tooth Cut crosscut rip crosscut
general, a good quality saw will last you Tempered yes no yes
many years. Saws that do not have Price $35 $22 $31
tempered teeth, can last a lifetime, with

Handsaws (photos on pg 21) General Purpose (photos on pg 22)
Pax Sandvik Stanley Sandvik Sandvik Stanley Sandvik
277 20-065 3090 2500XT 20-045 300
Overall Length 25 5/8 29 5/8 29 5/8 22 3/4 Overall Length 22 1/2 18 16 1/2
Blade Length 22 26 26 19 1/2 Blade Length 18 3/4 15 13 3/4
Blade Height 5 1/4 5 1/2 5 1/2 4 3/4 Blade Height 4 3/8 4 1/4 3 3/4
Pitch 10 8 12 11 Pitch 10 9 15
Blade Thickness .037 .039 .035 .045 Blade Thickness .037 .037 .029
Kerf .060 .062 .062 .063 Kerf .061 .060 .038
Tooth Cut crosscut crosscut crosscut crosscut Tooth Cut crosscut crosscut crosscut
Tempered no no yes yes Tempered yes yes yes
Price $65 $76 $48 $43 Price $38 $36 $20
Sources
Brand For Information Available From
Stanley The Stanley Works Most hardware stores across Canada, including Canadian Tire,
1-800-263-6292 – www.stanleyworks.com Home Hardware and Home Depot
Sandvik Bahco Tools Inc House of Tools, Home Hardware, Revey, Pro Hardware, Home Depot,
1-800-296-4787 – www.bahco.com Reno Depot, TSC Stores, Kents, Rona and the Building Box
Pax Thomas Flinn Co. Promax Tool Corp: 877-967-8966,
www.flinn-garlick-saws.co.uk www.promaxtool.com
Independence Lie-Nielsen Toolworks Inc American Craftsman Publications: 877-967-5966,
www.lie-nielsen.com woodhead@nbnet.nb.ca
CARL DUGUAY is a writer and woodworker from

Sidney, British Columbia. 250-888-5067
carl@finewoodworking.ca www.finewoodworking.ca

questionsanswers BY JIM KOUDYS
Q I asked a guy with a mill to come in and

cut my lumber. I ended up with a lot
more than I thought I would. My
problem now is that it’s dry and I’m not
ideal if it was heated but expense becomes
a major factor when calculating costs in
storage of their lumber.
controlling the humidity level and
climatizing your lumber are two of the
greatest factors in minimizing the expansion
and contraction of your lumber.
sure where I can store it, since I have limited
space in my work shop. Any suggestions?
As long as its been dried properly
Q Hi! Can you provide me with the
expansion/contraction co-efficient of
3/4”red oak? I’m building a deacon’s
bench, which has the base/floor locked Q A couple of years ago I cut down a large
cherry tree, but it fell the wrong way
down a gravel embankment. It was late
A (8% to 14%) you can store lumber

pretty much any where, as long as
it’s out of the elements. When
selecting your storage space, try to
in. I anticipate expansion to occur, which would
wreck the piece, if it’s not precalculated. I also
plan on installing hardwood floors in my home
and the movement is a major concern. I’m sure
in the year and I was not able to drag it
out. It has been leaning against the embankment
(almost vertical) ever since. If I can drag it out
this spring, will it still be worthwhile sending it to
find a spot that isn’t subject to large humidity there must be reliable figures on this, and I the mill to be cut into planks?
and temperature swings. Places like under appreciate any help you can provide
the porch can have a lot of wetness and the
A
I’m not sure if trying to use Yes, but take a good look at the log.
temperatures in a garden shed, in the middle
of the lawn, may rise to such extremes that it
dries your wood to a dangerously low
moisture level. As lumber reaches oven-dry
EMC, which is no moisture in the wood, it
A formulas for expansion is of any
help in building furniture or laying
floors. These formulas are more
orientated to help a structural engineer
You may have to cut some off to get
a good look. It may have some rot in
it. Species like cherry, maple,
butternut and so on, are subject to spalting
understand what a large wooden structure but this may not be a bad thing. Even though
weakens, making it unusable in your spalting is a form of rot, it can create a unique
projects. A second important step, after is going to do in different environmental
conditions. I find understanding “why” and pattern in the grain, which gives your project
finding suitable storage, is that you bring the a one-of-a-kind look. If you have a mill come
lumber you’ll need for your project inside, “how” wood absorbs or looses water to be
more practical. A good book on this subject is to you, then you will have more say in how
about two weeks prior to use, and sticker it in it’s made into lumber. This may cost more,
your shop. This will allow the wood to “Understanding Wood” by B. Hoadly. From
such information you can learn techniques, since its only one log, but considering cherry
climatize to the humidity level of your shop runs between $5-$13 a board foot (depending
and, hopefully, your shop is close to the such as building floating kitchen panels, to
handle the problems of gain and loss in on grade) cost savings are easily realized.
humidity level of where your project will end Even though it would cost you to have it cut
up. A few hobbyists I know share the rent on lumber. When laying a floor, it is important to
make sure your wood is climatized first, up, you would save yourself a lot of money
a small, unheated storage shed at one of those and possibly have a project like no other.
self-storage places and bring in what they before laying it down, and to make sure
need to their respective shops. It would be that the humidity level in your home is JIM KOUDYS is the owner/operator of Kootur Lumber
stable from season to season. In summary, in Smithville, Ontario. (905) 957-4217 jkootur@yahoo.com
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woodstory BY GORD GRAFF
Two Simple Words ecently, a newcomer to wood- oak veneered particle board and solid oak to “not bad” and then he left for home.
R
working asked me, “How did build a wall unit. This would be my first wall Not bad?! I was furious. I was livid. I was fit
you get to be the woodworker unit and what a chance to show the old man that to be tied. How dare he? Not bad?! Standing in
that you are today?” I thought his son was a pretty good woodworker. I the kitchen I swore, that day, in the fall of 1984,
for a minute and wondered if worked hard on that wall unit and, in a matter of that never again would anyone, especially the
this fellow was ready for what I weeks, it was finished and proudly placed in our old man, say “not bad” to anything I would ever
was going to tell him. Then I told him that I owe living room. I told my wife, many times, how build. Since then, I have endeavored to be the
what I am as a woodworker today to two simple proud she should be of me because I was such a best possible woodworker that I can be. I have
words, ”Not bad.” In response to the puzzled fine woodworker. I was so full of myself I could spent thousands of hours honing my skills and,
look on his face, I told him the following story hardly wait until that old carpenter laid eyes on along the way, I have learned much more than I
behind the two little words that have had such this wonder in wood. could have ever imagined.
an impact on my life. The old man showed up one Saturday Over the years, I came to realize that my
When I was first married, we needed furniture morning and went to sit in the living room while father was a wonderful man; gentle and caring.
and, as the son of a carpenter and cabinetmaker, I made coffee in the kitchen. Any minute now, I A year or so before he passed away, I asked him
I was expected to make it. I never asked the old thought, he would say, “My gosh, Gord, it’s why, all those years ago, he had said, “not bad”
man for advice or for help because, after all, I beautiful.” I waited and waited, but it never to something he knew I had worked so hard on.
was the young man who he dragged around came. I went into the living room with the He said to me quietly, “I knew that you were
town doing side jobs with him. I must have coffee and he just sat there and did not even capable of better, and inspiration has only come
learned something working all those weekends acknowledge that this beautiful wall unit was to you when you were pushed, so I pushed you.”
with him in his shop instead of having fun with staring him in the face. He finished his coffee Today, that wall unit can be found standing in
my friends. I did well for someone with no and said he must be going. By this time I was a place befitting it’s design and construction, in
formal woodworking training, or at least I ready to hit the roof! The old man had said my neighbour’s garage, filled with gardening
thought I did. Unknown to me, my world was nothing about this work of art. I could not help tools. After all, in my opinion, it’s “not bad”.
about to change in a way that even today, 18 myself, I just had to ask him, “Dad, what do you
years later, I am affected by. think of this fine wall unit?” He paused, for GORD GRAFF is a fine furniture maker & designer,
woodworking instructor and writer
As luck would have it, I came across enough what seemed like an eternity, and quietly said, living in Newmarket, Ontario.
email: moe-dern@rogers.com
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woodstory BY JOHN SEDGWICK
Who Will Notice?

M
y mother died recently, off-center by about 1 1/2”, making one leg else will notice it.” He turned to leave the
just a few days before narrower than the other. I pondered the workshop and as he left said, “You will,
her 94th birthday. While options and decided to ignore it. It was son.” He was right.
sifting through a 1956, power tools were not part of
lifetime of memories anyone’s home workshop in England, or I My mother loved it and I am sure she
and birthdays, I specifically recalled her suspect anywhere else. I did not relish the never noticed the mistake. That summer
12th birthday. No that’s not a “typo” – she idea of hand-sawing another side, after all she showed everyone who sat in the
was a leap-year baby – a fact she would it was only for the use in the garden and I garden. “Bring John’s garden stool over
take full advantage of in later years when was sure my mother would not notice. here,” she would say as she put the tea tray
asked her age. on it. “You know John made this. He’s
Just then my father came in and said, really good at wood working, just like his
I remembered the first time I had become “What are you making, son?” I told him father. Isn’t it handy? See underneath,
really aware of the leap-year phenomenon. and he cast his eye over the pieces which I there is a place to put my gloves and small
Her 12th birthday was a special occasion had cut and was beginning to assemble. I garden tools.”
for my mother, who really was turning 48. stood quietly and hoped he would not
She was just two years from an age when a notice my mistake. My father was right again, I would only
woman, in polite circles, was referred to as see the mistake and I always wondered
“a woman of a certain age”. With six more if my mother’s friends also saw it but
“
months before my 14th birthday, to be such were just being polite when they would
an age was inconceivable to me, as I am
I stood quietly and congratulate her on having such a clever
sure it is to all children. hoped he would not son.
”
For this special occasion, I decided to notice my mistake. Recently I was making a drawer and I
make something for her to use in the had cut the slot in the back – that holds the
garden – a seat/stool/carry-all. You know drawer bottom – on the wrong side. There
the design; perhaps you still have a gnarly He paused, and as I know now, he was was adequate thickness to cut another on
old one covered in paint spatters? Most trying to find a way comment about the the opposite side and no one would be able
everyone has seen one but cannot mistake without discouraging me. Without to notice the mistake. After all, it would be
remember who made it. It has a hand hole saying a word he picked up one side and on the outside back of the drawer. Who,
in the top to carry it, with two sides about laid it over the other, clearly showing the and how, would anyone ever see it? I
10” to12” wide and 18” high, and a “V’ error. “It’s a great idea and looks really should have known better than to think of
notch cutout at the bottom of both sides good, son. Your mother will love it, but if I anything else but replacing it. For many
forming two legs (see plans, page 27). were you I would cut another side.” times since that day long ago – although
I explained my reason for thinking it my father is not there to see any mistakes –
A simple project when I think of it now, unnecessary and I said he noticed it I can clearly hear him say, “You will, son.”
but back then I made a mistake cutting the because he looked closely at the pieces.
“V” notch in one side so that it was “When it’s together,” I said, “no one JOHN SEDGWICK, Marquetry and Inlay Restoration,
Stoney Creek ON, jandm@skylinc.net
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easyproject BY RICK CAMPBELL
Intarsia
Clock
M
ost of the woodworking I the angles with a combination square –
do requires a great deal of they need to be precise so everything will
planning, countless hours fit together properly.
of shop time, and a Assemble the sides and spine with glue
substantial investment in and clamps using a square to ensure the
materials. Usually the time spent on these mitred tips align. In most cases, regular
major projects is enjoyable but sometimes carpenter’s glue will do the job but, for
I like to slow down the pace and turn my mine, a two-part epoxy was necessary
attention to something less demanding. because of the unusual characteristics
A perfect example of what I’m talking of the South American padauk I used.
about is this easy to make intarsia wall The natural oils in padauk prevent
clock. The entire project can be built in an traditional adhesives from curing properly
afternoon from scrap wood found lying – something to keep in mind whenever you
around the shop. use an exotic species of wood. Removing
I used South American padauk and rock the surface oils with acetone before
maple for my clock but any combination of applying the adhesive will also improve
Continue by mitering all four corners of
contrasting materials that look good the chances for a good bond.
the blank at a 45 degree angle leaving a
together will be fine. You will also require While the glue dries you can begin
1/4” wide flat area in the middle of each
a battery powered clock mechanism, a set working on the shell shaped end caps. The
end to match the center spine. Refer to the
of hands, a clock face and a pendulum. All plans show that these are slightly wider
plan for complete details. Test fit the
of these parts are relatively inexpensive and thicker than the main section of
mitred ends in the “V” shaped openings
and are available at most specialty the base. Begin by cutting out a 4 1/2” wide
formed on the main base and make any
woodworking stores or by mail order from x 12” long blank from 1” thick material to
necessary adjustments. When you are
suppliers such as those advertised in this yield both end pieces.
magazine. It is best to
buy all your clock
parts before you
begin in case you
need to adjust the
project dimensions to
fit.
Building the Base

From 3/4” thick
stock, cut out the two
sides of the base with
45-degree mitres on
the ends (Photo 1).
Then rip a 1/4” wide
strip of contrasting
material for the center
spine. Double check 1 2 3

satisfied, cut the base ends to length Next, we tackle the circular frame that assembly aside to dry (Photo 11).
discarding the waste from the center of the surrounds the clock face. Like the box for The last piece you need to make is the
blank. the clock mechanism, you may need to pendulum weight. I turned mine on the
Next, use a compass to layout a 2 1/4” customize the frame dimensions to fit the lathe but if you prefer you can buy a
radius curve on the square end of each end dial you have purchased. I cut out my commercial version from your clock
piece and then cut away the excess frame from a single wide board but you supplier. If you make your own the plans
material at the bandsaw. When you are may find it necessary to edge join two or provide the dimensions.
done, sand to remove the saw marks. three narrow boards together to make
Complete the base ends by rounding over yours. Putting it all Together
the top edges using a table-mounted router Begin by using a compass or trammel The clock housing is attached to the base
and a bearing guided 1/4” radius bit. to lay out the inside and outside of the using two 1 1/2” #8 screws inserted from
While you’re at it, you may as well round circular frame on the square blank (Photo the back. No glue is used here so the
over the outside edges of the main base 6). Cut the outside of the frame at the band housing can be removed to change the
section. Start in the middle and work your saw (Photo 7) and the inside using the batteries. Be sure to pre-drill for the screws
way to the ends in both directions to scroll saw (Photo 8). When you are done, to prevent splitting the thin housing
prevent breaking off the mitred corners. sand to the pencil lines using a stationery material. Counter-bore the heads so they
Finish sand all the parts, then glue the sander for the outside and a drum sander are flush with the back. The position of the
caps to the base. A web clamp works best for the inside. housing on the base isn’t critical just as
to hold it all together while the glue cures Return to the router table to round over long as it looks good to you.
(Photo 3). the outside edges of the frame with Attach the dial to the backer board with
the same 1/4” radius bit used earlier, double-sided tape and then drill a hole
Time for the Clock then switch to a bearing guided 45 degree through the center to receive the clock
The clock mechanism is mounted inside beveling bit to chamfer the inside edge, on shaft. Next, install the mechanism in
a square housing that also serves as a the top face only. Complete the frame by the housing, then attach the hands and
spacer between the base and the clock face. creating a 3/8” wide x 3/8” deep recess in pendulum according to the manufacturer’s
Begin by cutting out the four sides of the the back to receive a Plexiglas dial cover directions. Before attaching the frame to
housing, then mill 1/4” deep x 1/2” wide using a bearing guided rabbeting bit. the dial board insert the Plexiglas cover in
rabbets on each end of the vertical I cut out the Plexiglas dial cover using the the recess but don’t glue it in place yet.
members as shown in the plans (Photo 4). bandsaw after first laying out the circle With this done you can secure the housing
Make the rabbets using a straight bit with a compass (Photo 9). Make the insert to the base and verify that everything fits
installed in a table-mounted router, or 1/16” wider than necessary, then sand the together properly. Now disassemble the
nibble the material away at the table saw. edges to achieve a perfect fit. clock and prepare to apply the finish.
Next, cut out an opening in the bottom The clock face is mounted on a piece of
piece to provide room for the pendulum to 1/8” hardboard cut 1/2” smaller than the Finishing Touches
swing. The size and location will depend diameter of the wooden dial frame. Drill a Sand all the parts through 220-grit paper
on the mechanism you have purchased. 1/8” diameter screw hole on each side of and apply a clear finish to highlight the
Now you are ready to assemble the the hardboard circle to mount the board to contrasting materials you have selected.
housing with glue and clamps (Photo 5). the frame (Photo 10). Use a two-part epoxy If you used padauk as I did, avoid using
When the glue has cured, round over the to secure the backer board to the clock any finish applied with a brush or a cloth
four corners of the box with a 1/4” radius housing but be sure it is perfectly centered because these may cause the dark orange
router bit as before. before applying the clamps and setting the colour to bleed into the surrounding lighter
4 5 6
7 8 9

materials. For my clock I used several This is a great way to personalize your hanger and you’re ready to display your
coats of spray lacquer sanding lightly with clock with a meaningful message or maybe handy work in a prominent place where it
600-grit paper between coats. the image of a loved one or a favourite is certain to be admired for its beauty.
After the last coat is applied reassemble scene. Only you will know it was made using
the clock, this time securing the Plexiglas Cut a key slot in the back or add a picture material rescued from the scrap bin.
cover in place with a few dabs of epoxy
applied in the recess. You may have
noticed that my clock has “Canadian Contemporary
Woodworking” printed on the face. I did
this using my computer to print the Clock 4 1/2"
customized dial on heavy glossy paper. 1/4" Radius
Round Over 1 3/4"
2 1/4"
radius
Decorative 5"
45 degree
End Detail bevel
2 1/8" 1/4"
1/8" Lip
2 1/8" 45 Degrees
Clock Dial Detail

10 3/4"
12
11 1
10
10 2
9 3
Materials List Canadian 3/8" Deep
8 Woodworking 4 Recess
For Clear
For the Base 7 5
Insert
3/8"
6
2 Sides 3/4”x2”x 28” Padauk
1 1/8"
1 Centre Accent 3/4”x1/4”x24” Maple
1 End Cap 1” x 4 1/2” x 12” Maple
(blank yields 2)
For the Clockworks 3 1/4"
2 Housing Sides 1/2”x1 1/2”x4” Maple

2 Housing Top/Bottom 1/2”x1 1/2”x3 1/2”Maple 1/4" Round Over
1 Dial Ring 3/4”x11”x11” Maple

Spacer Box
1 Backer Board 1/8”x10 1/2”x10 1/2” 1 1/2"
Detail
3 3/4"
Hardboard Weight Detail
1 Dial Cover 11”x11” Plexiglas 2 1/2"
1/2"
Hardware List 1/4"
Clock Mechanism, Clock Face,

Pendulum, Hands 2 1/2" x 1" Pendulum
Opening In Bottom
RICK CAMPBELL is a writer and woodworker living in ILLUSTRATION BY RICK CAMPBELL

London, Ontario. (519) 668-1775
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bookreview BY MICHEL THERIAULT
Router Bench
Guide
T
his “Bench Guide” is part of your bits, depending on what you will
the series of Bench Guides use them for.
by Sterling. Similar to the Cutter maintenance is also covered in the The next chapter reviews some
other bench guides, it is a 2nd chapter, including sharpening and care specialty accessories you can use with
comprehensive look at the for the pilot bearings. your router, including a router turning
tool it covers. The third chapter covers clamping systems, the RouterRack router system and
Taylor starts by discussing the basic techniques that are commonly used when the Woodrat routing system.
operating principles in the first chapter. He routing. He has included a number of Commercially available jigs and fixtures
then covers the different types of routers clamping solutions that you can make in that can make your router more versatile
and their uses, including the various your shop as well as commercial products. and efficient are covered in Chapter 9,
features you can find on a router. Using The fourth chapter is a short one, briefly including Dovetail Jigs, Surfacing, pivot
illustrations, his chapter guides you discussing how to effectively cut various frame, Ellipse Jig, incised carving and
through the various components in a way materials including but not limited to letter routing. The last chapter is devoted to
that will be most useful to someone buying wood. router safety.
their first router or thinking about adding a In Chapter 5 and Chapter 6, Taylor covers Finally, an extensive glossary is included,
2nd router to their shop. a variety of routing methods and as is a summary of currently available
This first chapter also includes informa- approaches, including a variety of routers along with their basic specifica-
tion about maintenance and care of your commercially available accessories that tions such as power, speed, collet sizes
router, discussing how to keep your base make routing easier and more efficient. maximum adjustable depth and weight.
plate, plunge bars and collets in top shape, Template routing is covered in Chapter 7,
as well as other elements which are less including cutters, guide bushes and pilot MICHEL THERIAULT is a Canadian writer and
likely to require regular care, including the bearings and templates. woodworker living in Guelph, Ontario
www. woodstoneproductions.com
switch, brushes, bearings and cable. mjtheriault@sympatico.ca
The second chapter deals with the most
important part of routing – the cutters. CONTENTS: Workpiece Clamping Templates
Router Components Techniques *Template Applications
In this chapter, Taylor discusses the & Features *Factors that Determine
difference between steel and carbide *Guide Bushes
*Operating Principles Clamping Technique *Pilot Bearings
tipped cutters, as well as some details of *Types of Routers *Types of Clamps
their construction and what to look for Special-Purpose Machines
*Advantages & Disadvantages Wood, Metal & Plastic
when selecting your router bits. Next, he *Turning
of Fixed-Base & Plunge Cutting Guidelines
discusses the many types of cutters and *Joint-Making Machines
Routers *Solid Wood
their variations. This includes how they are *Features *Cutter & Router Jigs and Fixtures
used as well as considerations for selecting *Components Speed Guidelines *Miscellaneous Jigs
*Router Care & Maintenance *Man-Made Boards *Dovetail Jigs
Cutters *Metals For Safety’s Sake
*Solid-Steel & Carbide-Tipped *Plastic & Related Laminates *Workshop Safety
BOOK TYPE Technique/Reference *Selecting Cutters Router Applications *Safety Techniques for
*Buying Cutters *Freehand Routing -Router Components
LEVEL All Levels *Types of Cutters *Fixed-Router Techniques -Cutters
AUTHOR Zachary Taylor *Care of Cutters Router Principles & Techniques
-Routing Operations
-Freehand Components
*Installing Cutters *Routing Speeds
PUBLISHER Sterling Publishing *Removing Cutters *Direction of Feed
from Collets *Routing Techniqes
SOFTCOVER, 8.5" x 10", 160 PAGES, $22.95 CDN
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Tel (905) 640-2350
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jigcontest BY LOU PEETERS
Thorne Clamp Jig

The first winner of the Canadian
Woodworking’s Jig Contest is Bill Thorne,
an avid woodworker and mechanic from
London, Ontario.
Bill’s winning jig follows the
woodworking rules that we regularly
mention in this article: safety and you can
never have too many clamps.
His jig keeps your fingers safely away
from cutters while machining small parts.
It’s especially useful around the shaper or
table-mounted router. The pinned block
(adjustable every 3/8”) combined with
sliding clamp block (dovetail mounted)
provide full adjustment over the working
range of the jig.
The abrasive on the clamp blocks is
backed with pressure-sensitive adhesive
(PSA) and provides the grip required to
stop the work piece from slipping. Clamp
pressure is supplied by a standard toggle
clamp.
For his winning entry into the Canadian
Woodworking Jig Contest, Bill will
receive a heavy-duty 12v cordless drill
from DeWalt.
You could be the next winner in our
Canadian Woodworking jigs contest.
Don’t be shy. You don’t need to do any
fancy photos, charts or diagrams. You can
leave that to us. Just contact Lou Peeters at:
loupeeters@hotmail.com and he’ll take it
from there.
Remember, jigs can help make your
woodworking safer. They can also increase
your speed and accuracy. So help out your
fellow woodworkers by sharing your jig.
And be sure to watch future issues of
Canadian Woodworking to see how other
woodworkers jigs can help you.

• Scroll Saws • Compressors
• Table Saws • Air Nailers
• Blades • Planers
• Routers • Intarsia Patterns
• Router Bits • Books
• Jointers • Bandsaws
• Produce high quality lumber with your own chain saw

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BLADES ARE EXPENSIVE.

Who would you
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irs
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36 CANADIAN WOODWORKING Visit our website at http:/www.canadianwoodworking.com
protips BY HENDRIK VARJU
The Jointer
SAFETY TIP: ward pressure as possible on the board QUALITY TIP:
With any woodworking machinery you while jointing it. To get a really clean surface on the
must keep your hands clear of moving The best test for flatness is to set your jointer, you have to feed the boards with
parts that can hurt you. The jointer has a cutting depth to just a hair above 0 (like the grain. In one direction, the wood fibres
cutter head with three or more “knives” 1/128th of an inch) and see if your jointer are severed cleanly. In the other direction,
spinning at high speed to produce a smooth cuts the board for its entire length. You can the fibres are raised and then torn. This is
surface. Although push blocks are judge by sound because your jointer will known as “tear-out” and looks like pits or
provided by the manufacturer to keep your become very quiet if it isn’t cutting part of craters on the finished surface.
hands away from the cutting action, it the board. Only when the jointer cuts for To plane in the proper direction, imagine
is virtually impossible to use a jointer the entire length when set at such a small petting a cat. When you pet your cat from
properly using push blocks Most push cut can you be certain that the board is very head to tail, its hairs smooth down nicely.
blocks work by friction caused by pushing flat. When you pet from tail to head, the hairs
down on the board. However, you must ruffle up. This is exactly what happens
avoid pushing down to flatten a bowed with wood, except that the ruffled wood
“
board. Pushing down flexes the board fibres are also torn out by the spinning
downward into the blade and it will never Don’t put anything jointer knives. So you must feed the “head”
become flat. of your board into the jointer first and the
Using your hands, however, doesn’t questionable on the “tail” last. The jointer will “pet” the board
mean you must sacrifice safety. Your hands jointer unless you’ve done a properly and leave a smooth surface
must stay clear of the cutter head area and behind.
preferably on top of the board you are thorough inspection and Learning how to read the grain direction
jointing. If you must grip the edges of the of a board isn’t as simple as you might
board while jointing its wide surface, grip used a magnetic wand to think. I really can’t cover the issue
them well away from the cutter head and properly in a few paragraphs, but suffice it
always remember where all ten of your
check for foreign metal to say that a rag will often tell you the
”
fingers are. objects. story. If you rub a rag in one direction over
As with the table saw, a kickback throws a board, it will glide smoothly over the
the board towards you. On a jointer, that surface. If you rub in the other direction,
means that the board will be thrown from you will feel and hear the rag getting
the cutter head to the right along the infeed If your board fails this test no matter what pulled over the raised wood fibres. Once
table. So never place your hands too close you do, there may be a problem with your you have established that the smoother
to the cutter head on the outfeed side. A knife settings. Knives that are set lower results are rubbing from end A to end B,
sudden kickback would pull your hands than the outfeed table will result in a consider end A to be the board’s head and
backwards into the cutter head. tapered cut. The jointer will only cut for end B to be the board’s tail. Then feed the
In reality, kickback rarely occurs on the the first one third or so of the board and board head-first into the jointer knives.
jointer. The board will only be thrown then stop cutting altogether at the back Next issue Hendrik gives three tips on
if the knives hit something unusual. For end. You must raise your knives or lower using your thickness planer.
example, a knot could fall out while you your outfeed table to get your jointer HENDRIK VARJU is a fine furniture designer /builder
are jointing. Kickback might also occur if working properly again. who provides woodworking instruction and private
you hit a nail that is imbedded in the wood. seminars near Acton, Ontario. (519) 853-2027
www.passionforwood.com email: info@passionforwood.com
For this reason, be very cautious with old
wood like barn board. Don’t put anything
questionable on the jointer unless you’ve
done a thorough inspection and used a
magnetic wand to check for foreign metal
objects.
PRECISION TIP:
When jointing a board it can be difficult
to make it perfectly flat, especially when
jointing a wide surface instead of an edge.
This is because a board will not flex easily
on edge, but the wider surface will flex
quite easily unless the board is very thick.
As stated earlier, try to put as little down-
toolupdate BY GRAHAM MCCULLOCH
OUR LATEST
SUBSCRIPTION
Recalls DW368, DW368K and DW369CSK with PRIZE WINNER!!
date codes of 200128-F through 200152-F. Here’s Kevin Wasilka of
Roto Zip has recalled 1.9 million Roto You will find these stamped on the bottom
Zip Spiral Saws because the handles can Shoal Lake, MB with his
of the motor housing. They were sold
separate from the body and cause injury to between July 2001 and December 2001. new Vermont American Router Table.
the operator. If you own one of these and Kevin looks to be one
find that the handle does not fit tightly, you If you own one of these, stop using it happy woodworker.
should stop using the tool and contact Roto immediately and contact DeWalt on their If you want to have a smile,
Zip immediately. You can call them toll- toll-free phone line at 1-888-839-3559.
like Kevin, sign up now
free at 1-800-920-1467 or visit their web for our next subscription draw.
site at www. Rotozip.com. Ingersoll-Rand is recalling 450,000
portable air compressors that have been
You could be our next lucky
I have one of these and I called the toll- sold between 1983 and 1991 as the inner (and happy) winner!
free number. What a pleasant surprise. lining of the air tank may corrode. The See page 43 for details.
There were no recorded instructions where result of this corrosion could cause the
one has to press a bunch of digits, but a real air tank to burst unexpectedly when
voice (Lisa) after only one ring. Lisa was pressurized.
really pleasant and described in full what
they would do. I had one other problem The compressors were marketed under
with mine and that was a finicky power the trade names of Ajax, Charge-Air Pro,
switch. Lisa ordered a new Roto Zip as a Enegair, Guardian Power, MacTool,
replacement and I received it two days Power Force, Rallye, Rand 4000 and
later. Great service. Steel Drivers. The serial numbers of these
are prefixed with the letters “C” or “CD”.
DeWalt has recalled 55,000 circular Contact Ingersol-Rand at their toll-free
saws as the spindle may slip that will cause number 1- 877-552-2952 or their web site
the blade to come in contact with the lower at www.ingersoll-rand.com.
blade guard and become a hazard to the GRAHAM McCULLOCH is a woodworker and writer living
user. The model numbers affected are in Halifax, NS. (902) 479-0221 graham@shortcuts.ns.ca
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38 CANADIAN WOODWORKING Visit our website at http:/www.canadianwoodworking.com

routertips BY MARK EATON
Spring Removal
A
s I mentioned in our last STEP 2 the lock handle and then slide the router
two issues, I am always Lay the router on its back with the lock body over the column. Make sure that the
asked at wood shows how I mechanism face up. With your body threaded rod slides through the top of the
adjust my router so easily. against the base plate, and your hands on body housing. (There should be a white
Many woodworkers have the router, pull the lock mechanism. The plastic guard that fits over the hole in the
plunge routers mounted in their router base will press against you and will start to body. This keeps the threaded rod from
tables and can’t adjust the height of the slide off (photo 2). rubbing against the body itself.)
routers as easily as they see me do it.
The reason: they have not removed the STEP 3 STEP 6
springs from the plunge mechanism. I will, When there is no pressure against you, Thread the large lock nut, the knurled
therefore, take you step-by-step through grab the base and pull the base off. The nut, the waffle washer and the second
removing the springs from the most springs will be hanging from the router knurled nut over the threaded rod and turn
common routers on the market. (photo 3). them until they are about 3/4” from the top
This issue we will look at the of the rod (photo 6). Tighten with an
Porter-Cable 693. STEP 4 adjustable wrench.
Make sure that your router is always Begin pulling the springs out of the body Your router is now ready to mount into
unplugged before attempting any and as you pull, bend them down a bit. This your table and will be much easier to adjust
procedures such a those listed in this will grab the black plastic post inside one without the springs installed.
article. SAFETY FIRST! spring only. The other spring is around the
long threaded rod that runs the length of Safety Note: These instructions are
STEP 1 the column shaft (photo 4 & 4A). strictly the opinion of the author and
Lay the router on its back. The lock is do not reflect those of the
spring loaded so your router will be locked STEP 5 manufacturer. Always refer to your
in position. Remove the large lock-nut, the Slide the base back into the router body. owner’s manual for exploded views
knurled nut, the waffle washer and the The easiest way to do this with this router of your router and, if you don’t feel
second knurled nut that are at the top of the is in the upright position (photo 5). Release comfortable with these directions,
rod (photo 1 & 1A). do not remove your springs.
MARK EATON is founder of The National Router Academy

www.nationalrouteracademy.com
nra@cogeco.ca
Feb/Mar issue: Removing the springs

from the Hitachi M12V
Apr/May issue: Removing the springs
from the DeWalt 625
1 1a
2 3 4
4a 5 6

The Wood Shed Passion for Wood
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Open by chance or appointment • Closed Sundays Email: info@passionforwood.com
Ontario Agent for Gross Stabil Corporation,

makers of quality wood and metal working clamps.
www.chaletwoodcraft.com
The National Router Academy

Router classes
for all skill levels
(905) 826-4720 or
1-800-370-3834
2900 Argentia Rd., Unit #11, Mississauga
Just south of the Hwy. 401 off Winston Churchill Blvd.
www.NationalRouterAcademy.com
dustcollection BY CHESTER VAN NESS
Piping
L
ast issue we looked at fans, the The correct fitting for dust collection is Flex pipe
heart of the dust collection on the left: a 3” ABS long radius elbow. It Flex pipe comes in various materials,
system. This issue, let’s look at is better than the short radius PVC elbow each of which has been designed to convey
piping, fittings and flex hoses. beside it. Do not be deceived by the specific substances. For dust collection, we
In the following photos, I will smooth exterior of the flex hose 90 – it is are looking for three things: a smooth
point out the different types of piping smooth on the outside but very restrictive interior surface, flexibility and strength, so
available and help you to identify and and rough on the inside. The rough interior that it won’t collapse under vacuum.
select hoses and fittings to build a system would interfere with the suspension of the
which will work safely and efficiently for particles in the air.
you.
Heating and ventilating piping.
Piping is made from either plastic or
steel. There are different types of piping
available in each:
Plastic
• ABS plumbing pipe (black- for water
and vents) 4
• PVC sewer pipe (generally white
and thinner than ABS) On the left we see pipe which is not
Steel acceptable because of how rough it is
• spiral lock pipe 2 inside. This plastic big “O” style hose is
• snap lock pipe (one longitudinal seam) fine for drainage but not dust removal. The
On the left is an adjustable HVAC next hose to the right is a length of
In order to determine which type of 90-degree elbow. Next are two 45-degree wire-reinforced rubberized cloth hose. It is
piping is best for dust collection, the first elbows, joined by a short piece of straight not totally smooth inside either but, as you
thing to realize is that the material that we pipe. To the right is a DSW long radius die can see, it is better. Next in line is a plastic
are handling is, in fact, a fluid. Do not stamped welded elbow. Using the HVAC hose with plastic reinforcing. It is the most
confuse the term “fluid” with “liquid”. 90-degree elbow is like adding 10 feet of available plastic hose and it comes in 3, 4,
The two are not the same and they act straight pipe to your system and it also 5 and 6 inches. It can also be found with
differently when they travel through hinders the flow of shavings. The DSW wire reinforcement. This hose is basically
piping. We are dealing with a fluid, which long radius elbow is totally smooth inside smooth inside. The last piece of hose
is primarily air with dust or shaving and is like adding 6 feet of pipe. The less shown is aluminum spiral. A spiral hose,
particles suspended in it. When conveying expensive alternative would be the set-up which is not smooth on the inside, acts as a
a fluid, the object is to keep all the in the center with the two 45-degree long cyclone; the air will spin, throwing
directional changes as gentle and gradual elbows. the dust and shavings to the outside,
as possible, in order to keep the particles eventually plugging the hose.
suspended. With this in mind, let’s Galvanized snap-lock smoke
compare the elbows in the following pipe and spiral seam pipe To summarize, when it comes to piping
photo: Note that both pipes are smooth inside. in dust collection, select materials which
will create gradual and gentle directional
changes and which have smooth inner
surfaces. The right materials will keep
particles suspended in the air to give you a
safe and efficient dust collection system.
CHESTER VAN NESS is a Dust Removal Consultant

in Scotland, Ontario. (519) 484-2284
chester.van@sympatico.ca
1 3

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Send a picture/diagram of your
Contest closes August 31, 2002.
Enter now! home-made jig and explanation to:
Canadian Woodworking Jig Contest
(Prizes have a retail value of approx. $250)
Enter often! c/o Lou Peeters
Contest prizes will be awarded bi-monthly. RR #7, Woodstock, ON N4S 7W2
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CONTEST CLOSES SEPTEMBER 31, 2002
INFORMATION IS THE MOST

IMPORTANT TOOL IN YOUR WORKSHOP!
tooltest BY GRAHAM MCCULLOCH
Shop Flash thing because the pins are so fine, it is reasonable price and the Tooltech bar
Some of us go into our woodshop just to difficult to see for some older eyes. clamps fit that bill quite nicely. We rate
relax and do the things we like to do best. We have given the Senco Micro Pinner them at ★★★★’s.
For others, however, we have a business to ★★★★★ ’s because it works so well and
run and missing phone calls could be can be used in so many situations, picture Log Splitter
expensive. With machines running, a framing being just one of them. We drove Delta is going to make things a lot easier
telephone’s ring may not be heard. Now, pins into oak, maple, teak, mahogany and and less expensive for you people that have
there is not much chance of that. some softer species and, in every case, the a small woodlot on your property. Up until
Busy Bee Tools & Machinery has a pins were recessed perfectly. now you would have to borrow or rent a log
product called Shop Flash. The Shop splitter. The alternative would be manual
Flash sells for under $50, and that’s quite a labour and that is not a pleasant chore.
bargain, considering what it does. You Buying a wood splitter can be expensive
simply plug the power unit into an outlet, for the small woodlot owner, often over
stick the microphone pad on the side of $3,000 and they are the gas engine type.
your phone and plug it into the Shop Flash Or, you can rent one for a weekend and that
and hang it on a wall. Now, when the phone makes you dedicate an entire weekend to
rings you can choose either a loud ring, a wood splitting.
flashing light or both. The flashing light is How about one that will fit nicely in the
a strobe light that is bright enough to alert trunk of your car, weighs 97 pounds and
anyone in the shop and the loud ring will will split logs 20” long with a diameter of
easily be heard above the loudest tools. 12”. That’s what Delta’s 38-610C Log
The Shop Flash is not a new idea, Radio Splitter will do. In addition, it will exert
Shack has had one for a number of years. 8,000 pounds of pressure on that log.
The Shop Flash, however, is a big Senco sells the Micro Pinner in a plastic
improvement. It is both louder and case and adds a bottle of oil, a 1/4” NTP
brighter. fitting and some sample pins. This is a neat
We’ve rated this as a ★★★★★ tool tool for furniture mouldings and to use
because just one missed business call while glue is setting up.
would more than pay for it.
EZ-GRIP
Micro Pinner Clamps are expensive! Wow, that’s an
Senco has just released one of the slickest understatement! There is now a great price
air nailers that I have used for some time. breakthrough that certainly pleases this
Senco calls it a Micro Pinner and it drives woodworker and I’m sure that when you
a 23 gauge pin that is so fine that it is hard see bar clamps at better than half price, you
to see the entry hole. The Micro Pinner will agree.
will shoot pins from 1/2” to 1” in 1/8” The clamps are not unlike the hand
increments and in the thousand or so pins compressed Quick-Grip clamps that most The 38-610C is electric and is powered
that we drove in our testing, there was not of us use. In fact, they work much the same by a 1 1/2 HP 110 v induction motor and
one failure or nail jam. One of the reasons way. These new clamps are from General hydraulics. The large wheels and handle
for this is the magnet located in the drive Tools and they are currently labeled EZ- make this new log splitter easy to move
head, this makes sure that the pins are in GRIP. You will soon see them under the around. A 100-foot, 12-gauge extension
position to fire. new label Tooltech and you will find them cord worked well in our test and we could
at the Home Hardware and Tim-Br Mart split 16” maple logs in an 11 second cycle
stores across the country. time. That’s fast enough for me.
The Tooltech clamps are currently in 4”, The Delta 38-610C has a safety feature
6”, 12” and 24” sizes and larger sizes will that ensures your hands will be kept out of
be on the market soon. What makes the the way. One hand must be on the power
Tooltech clamps an even bigger bargain is switch while the other operates the splitter
that they are spreaders too. A wing nut at slide.
the end of the bar is removed and that half Delta gets ★★★★★’s for this great niche
of the clamp is reversed. filler at a price below $650.
Gluing pressure? In our tests we found
that the pressure applied is as strong as GRAHAM McCULLOCH is a woodworker and writer
The Micro Pinner that Senco calls the living in Halifax, NS.
Finish Pro 10 takes strips of pins and a your hands can apply by squeezing. I was (902) 479-0221 graham@shortcuts.ns.ca
slide lever adjusts for the length of pin that able to get 142 pounds out of the 12” size TOOL TEST RATING SYSTEM
you are using. You cannot intermix sizes. and that is enough for glue squeeze-out. ★ .............. below average quality
There is a “chamber empty” flag to let you The pressure release is neat. The plastic ★ ★ ........... average quality
know when to re-load. button is easily pressed with little ★ ★ ★ ........ very good quality/value
The pin strips have an arrow on them to kick-back. ★ ★ ★ ★ ..... excellent quality/value
indicate the pointed end and this is a good We liked getting quality clamps at a ★ ★ ★ ★ ★ .. top of the line

Two Kinds of Tools:
Enhanced engineering
Exhausts direct gives XtremePro tools
oil and dust the industry’s only
away from YEAR YEAR 2-Year warranty!
work surfaces.
1 2
TY
AR
W
TY
AR RAN
RAN
Resilient comfort
Adjustable depth-of- overmold grip reduces
drive controls assure vibration and fatigue.
consistent and
controllable
nail depth.
Convenient belt
hooks let the tool
go where you go.
EZ-Clear magazine
minimizes time
Low Load indicator freeing jammed nails.
alerts when more
fasteners are
needed.
Slender in-line magazines improve
balance and line of sight for right
and left-handers.
Tenacious stud-biting teeth

for precise positioning.
Framing Tools. Finish Tools. In Two Levels of Tough.

The pros who swear by SENCO expect two things from our engineers: Build it tough, and make it perform.
Now, the company that invented pneumatic tools builds you two kinds of tools – tough and tougher.
ProSeries tools are rugged enough to stand up to the toughest users, with all the features pros look
for in a professional fastening system. And now, for the most exacting pros, our new XtremePro (XP)
tools set a whole new standard in pneumatic tools – with upgraded parts and engineering so superior,
they carry the only two-year warranty in the business. Check out our new tool lineup at www.senco.com,
or call 1-877-280-0243 for your nearest authorized SENCO dealer.
www.senco.com
©2002 SENCO Fastening Systems
www.cid.ca
DRILL WITH PRECISION.
ROUT
WITH
Skil, a leader in quality power tools
GRIND
and accessories and long-time,
preferred brand for professionals
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With advanced engineering and

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Visit the new Skil resource website for DIY projects,
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PLANS PROJECTS JIGS TIPS PAT T E R N S

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LePage’s woodworking adhesives have high initial tack and bond

Visit our website at: www.canadianwoodworking.com CANADIAN WOODWORKING 1

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THE MUSKOKA WOODSHOW

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L2 - lower 3/8 in.

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visit our website ... informative, friendly, easy WE CATER

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Roller Bearing 12” Cut Height

SBW-4300 17” Wood Bandsaw c/w Fence

TOOLEX INTERNATIONAL INC.

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■ Photo Credit: Michael Bowie, Lux Photography, Ottawa, Ontario

Visit our website at: www.canadianwoodworking.com CANADIAN WOODWORKING 9

HARDWARE and SUPPLIES

10 CANADIAN WOODWORKING Visit our website at: www.canadianwoodworking.com

Cut corners at 45°

Horizontal Member G 47 1/2"

HORIZONTAL LEG DETAIL 3/4" deep x

Illustration by Len Churchill

“the prescription for damaged furniture.”®

Titebond Wood Glue

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STEP 5 STEP 6 STEP 7

STEP 8 STEP 9 STEP 10

5 Reasons you should be using

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Roof 1-1/2" Box post

Bumper 2" diameter Wheel

THE WOOD CONNECTION

RED DEER SASKATOON WINNIPEG KAMLOOPS

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For a FREE Catalogue or a

Dealer near you, call Toll Free

• 121/2” swing (9” over banjo), • 110V input, 1hp AC vari-

24” between centers able speed inverter (drive)

• 1” - 8tpi RH spindle thread with dynamic braking

• #2 Morse taper in headstock • Patented clamping mecha-

• 2 step pulley • Two position controller box

18 CANADIAN WOODWORKING Visit our website at: www.canadianwoodworking.com

Seven Piece Cross Puzzle

Cut out the seven pieces from plywood,

There will be two “A” pieces. There will be two “B”

Unlike some of the puzzles in this series, this is not a

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Wiring Your Shop

Nova 3000 Lathe Super Nova

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Gents (photos on pg 21)

22 CANADIAN WOODWORKING Visit our website at: www.canadianwoodworking.com

CARL DUGUAY is a writer and woodworker from