16" x 43" SWIVEL-HEAD

WOOD LATHE with Digital Readout

Mot or: 2 HP; 110V.
PreciSion groo oo east iron bed & cast iron legs
Swing over bed 16

TACIIOMUUI:

ItU(l()VT
I " x 8TPI RH headstock spioo'e
Mn2 & lailstccic tapers
10 speeds, SCo-2400 RPM
ApPfol(.
shipP11'l1l
we'ght
300 Ibl .
G0462
REG 149511l""
Sale
'445
00

THE ULTIMATE 10" LEFT-TilT
CONTRACTOR STYLE TABLE SAW
Motor. 2 liP l tOW220V, S fl!;1"-phase
PI8Ciwo'lg,ound caS( 11011 table !It ..... h gs
Table SIze 27' x Arbor:""
Cu\tl ng c8paclty: 3'i'- 90.2'''' @ 45'
Aipcaptcity; 30" Approx shipping
wei ght 317l bs.
MAPEl"
100tOOl
FACTOity
SHOP FOX
Ai.UMA-CLAUIC fnC'
G057. ONLY $775
00
14" INDUSTRIAL RESAW BANDSAW

enol Motor: 2 HP; 110VI220V.

-
SI ngl e-phase, TEFC
Pr OCl sion ground Iron
lable si",: 19'1.' x 14'/","
n ble tilt: 8'L, 45'R
cutting 10"
BLade sile' 106"l X 'f." . >I,'W
81ade speed: 3000 FPM
sh PP'1I9 _ ,,,hi;
284 11K.

G0457
REG
Sale
$795
00
10" WET SHARPENING SYSTEM
speed: 90 RPM
220 9r1t yrinding wheel
Orrndlrl{l wheel sile: 10' el ia, 2" ... ,de
Luthe, stroppi ng wheel size, B" elia, I,,' wide
Inc1udas Ilnillers.ol jig, a"gle ""ide 8r
polishing/ho"i"g
Approx. shipping we'ght: 42 Ibs, M,u'IN
fERMAN"'!
r10010
REG,
Sale ' 159
95
10" TILTING ARBOR
SUPER HEAVY-DUTY TABLE SAW
MOlar J HP, mv, sUlgle-phase, reFC
P' ec'SIOn g'OIJnd cast i' on 'able
2 solid cast !lGn eWnsion wings
' HOP fOX
elAttie fErtet
Table Jile w- wngs attached 21'.40' Arbor: %"
Cuning capacity: S' l, 26" R S' 8ndarel 1\1 dado
Inserts
Approx.
sh'pp,ng
weog ht:
420 Ib!i
Motor: 2 HP, 11OVl220v,
si rl{l l ephase, TEfC
Pr..:; ision grourld cast IrOIl
tabl e SI1e_ 17" square .. 11''- thict
Table tl lt to' L, 45' A
Max. 12"
Blade Slle 131"l 'II' , I'W
Blade speed", 1700 & 3500 FPM
App,o" .. Ight:
3411 .....
hlAPE III 1st!
8101 rACTORY
G0513
REG. 9-85'"
Sale '715
00
PURVEYORS OF
FINE MACHINERY.
SINCE 1983!
10" JOINTER/ PLANER COMBO
Motor: 2\', HP, 220V, sirog le phase, 3400 RPM
Jointer lable siza,
Cutterhead knilles' 2 HSS
Max depth of cut:
Joimer - Yo'
Planer 7',,'
widlh of
Joimer -
Cutterhead speed: 6500 RPM
PI "ner table sile: 9'1( x 23' ...
Planer feed ,ata; 16 FPM
Appro. sh'pp,ng .... eo"ht 3181bs Pla_ - !;" I,,'
flU SAfETY
PUSHAOCICS
G0675
REG. 'JJ-95<"
Sale '995
00
10" LEFT-TILT CABINET TABLE SAW
with Riving Knife & Extension Rails
Motor J HP, 210'1, Singlephase, THC
PreciSion ground Cas! " on table & iro, OOlf.
Table sile 27" x 63"
Arbor size' W Arbor Speed. 4300 RPM
App<ox. shiPPIng weight: 644 lbs
G0691
Sale '1215
00
1'h HP Z STAGE CYCLONE
DUST COLLECTOR
Motor: 1'7 HP; 110f22GV,
TEFC, 3450 RPM
Air suction capa<;ity: 866 CFM
2, 013'
In'3l<e port: 6" ' Impel'er: 13';"
Folty mobr le casters
Overall dirnellSions' 38"W
2(,' Ox 68-112' H
" App'oK. d'ipping",e ght:
1931bs.


G0703 0
$825
0

I-BIlO-5e3-4777
3 GREAT SHOWROOMS!
BELLINGHAM, WA
MUNCY, PA
SPRINGFIELD, MO
1!CIINIC"'L S.ElMCE FlO:' 800-43.8-%'01

GET REDUCED PRICES ON MANY ITEMS &
FREE SHIPPING ON OVER 200 MACHINES
NOVEMBER 2nd UNTIL DECEMBER 31st, 2009
GRIZZLY GIFT
CERTIFICATESTAKE
THE GUESSWORK
OUT OF GIVING'
6" PARALLELOGRAM JOINTER
with Spiral Cutterhead
Motor: W, HP. nov/nov Single-phase
Precision ground cast iron table size: 6" x 55Y,'
Rabbeting capacity: 'I," Max_ depth of cut Y,'
Cutterhead speed: 4850 RPM fREE SAFEty
Center mounted fence system: PUSIt IROCKS
poSitive stops @45'&90
Built-in mobile base
Approx. shipping
weight 362 Ibs,
8" JOINTER with 2 HP MOTOR 8" JOINTER
Motor: 2 HP. 110V1220V, single-phose, TEFC with Built-In Mobi le Base
Precision cast iron table size: 9'1.' x 75'
Motor: 3 HP, 220V, TEFC, 3450 RPM
Rabbeti ng capacity: y, ' Max, depth of cut W
Precision ground cast iron tables size' 9' x 72'h"
Cutterhead knives: 4 HSS
Rabbeting capacity: y,' Max, depth of cut 'I. '
Cutterhead speed: 5500 RPM
Cutterhead speed 5000 RPM
Deluxecastironfencesize:38"Lx W,''Wx4' H
Deluxe Cost iron fence size: 35' L x 5"H
Approx, shipping weight 558 Ibs.
Built-in mobile base
Approx. shipping weight: 5561bs.
G0586
G0656
Safe FREE REG.
'57500 _ "mv S<Ote'715OO,
PUSH
12W' LEAN & MEAN PLANER 15" PLANER with Built-In Mobile Base 20"
Motor; 2 HI': l1QV, single-phase Motor: 3 HI': 220V, single-phose MADE IN
Mox. cutting height: 6" INeLIIDU Precision ground cast iron Motor: 5 HP. nov, single-phase IW 9001
Feed rate: 32 FPM "MIFE SETTING tables & wings Precision ground cast iron table FACTOII:V
& WRENC+!
Knives: 2 double edged HSS Table SIze: 15" x 20' Table size with
Cutterhead speed: 10,000 RPM n/ I Max, cutting height: 8" extensions: 20' x 55'1,'
Top mounted return rollers Mox_ cutting depth: y,' Max. cutting height 8W
Cuts per inch: 52 Feed rate: 16 & 30 FPM Max, cutting depth:
Approx, shipping Cutterhead speed: Cutterhead speed:
weight 781bs. 5000 RPM 5000 RPM
G0505 Built-in mobile base Feed rate: 16 & 20 FPM
Approx. shipping Approx_ shipping
weIght 6751bs_ weight: 9091bs.
CAST IRON APJUSTABLE BEP ROLLtRS
G0453 REG. G1033X REG.
-'--_-+--="S, ::: <Ote = '::-: 8::, 50=- ' ::: ' '2245==OOiiUMlSAiiioi
PROFESSIONAL SPINDLE SHAPER U
with Router Bit Adapter
Motor: % HP.l10V, single'phase wlreversing switch
Precision ground cast iron table siZ: 15'4' x
Spincle cop. under nut 2W
Spindle speed: 8900 RPM
Spindle travel: '/,' '''!
Spindle dia.: W
Spindle length: 3'
Split fence deSign
wi sliding wood faces
Approx_ shipping
weight: 172 Ibs,
Motor: 5 HP. 220V, single-phase, TEFC
Precision ground cast iron table size: 35Y, ' W x 28"0
Table counterbore: 7' x '/0' 0
Spindle travel: 3'1<'
Spindle sizes: '/.", l' &
I t<' x 7 Y,' L
Max. cutter dia: 5';.
Spindle speeds: 3600,
5100,8000 & 10,000 RPM
Approx. shipping
weight: 602 Ibs.
G5912Z REG,
S<Ote'1995O
Sanding motor: II'> HP, 110V, singlephase
Drum surface speed: 4000 FPM
Conveyor feed rate: variable, 2 12 fPM
Max. Slack dimensions:
36-' W x 4';" thick
Min, board length: 6"
Min. board thickness:
Sanding drum size: 4'
Dust collection port:
Approx, shipping
weight: 3541bs.
STAND ALONE DUST
COmCTION W/DUST BAG
G0458
ONLY '950
00
grizzly. com
l lMfTt'O

24 HOUR ORDERING OVER 12,000 PRODUCTS ONLINE!
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PROJECTS
18 Shop Project: (lamp Rack
28 Made-from-scrap Bud Vase
30 On the (oyer: Blanket Chest
42 Super-tough Plywood WorkbelKh
54 Surprisingly Simple Mantel (lock
62 To)' h(aYatol
SKILL BUILDERS
22 Fixing an Out-ofsquare Drawer
18 Work Wid" Stock on Your Dovetail Jig
Ta kt d,,,J go the limi ts of)'OlJr
j lq
40 Howa Jointer and Planer5av(' You $$$
Th(e IWlIlool\ PdY for in oruer,
SO 14 Senets for Setting Up Router Bits
66 Make and ImtallBaseboard iI"d (flair Rails
Pan } of our on cUS10m-1r Iflllf.w) }our hump
TOOLS'" MATERIALS
16 Aromatic (I"dar: Mothbuster or Not?
20 Wise Buys: Forstner Bit Sets
24 5 Tools for Fine-fining Joints
58 Tool Test; Tablesaw Bladl's Under SSO
72 Shop-Proven Ploduch
Rldgld hybrid Yble\dw. Laguna 1l1OI'<'.
DEPARTMENTS
6 Sounding BO;Hd
8 Shop Tips
78 Ask WOOD
92 What's Ahead
I
28
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W1764 Baby Power Feeder Save $25 W1767 I HP Power Feeder Save $75
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..
" .,

Only Jr1 dt t he ",me tinle. A re1urn c-feither afthe mi\chine.
will be reduced by Sf'cond milchine il I only through Authorized D;,trl buto" in t hi' even\.
Pledse contdCl Woodstock I to lOCilt,. a participating d istribut o r neM you. Offer vill id on pur chilses milde between 9/14/09 and 11130/09_
SHOPFOXBIZ 1-800-840-8420
!'Ml.ks" sl\.:.pfux.bl'<: WHOLESAl.F. ONI. Y ,,,. I 1<" \ I 1<.' 'I ''', t ox ". ",.",,,J "J. o>t W"""',,, k '" ,. _" " , I.
I 1""'1
November 2009
,
l ett relaxe, in the Mo,,",
choir and ottorn"" he
buiK for hi; home.
woodmog.,i"."tom
Vol. 26, No.6

SlttKRIER
Man"9'''9 Editor o.,puty Editoc
MARLEN KEMMET DAVE CAMPBELL
A.rt Director Senior De'ign ,dotDr
KARL EHLERS
T.cr.niqus ,d'itor rool I< lechni<1ue> Edotor
B08 WiLSOI'I BOB HUNTER
Mukimed;" Editor
LUCAS PETERS
o.,Ogn Editor
MERTZ
Mu'timedid ,ditor
CRAIG RUEGSEGGER
"'"oc;"te Art Director


Issue No.1 94
Produo::lior\Iortice Manaqer "'''''IMIt
MARGARET SHERYL MUNYON
Phot<>gropl1er,
JASON DONNelLY, SCOTT LITTLE,
OiVg de; igned a,1<I built
thi' TIl (dbi""t for h"
family '''''rn u,ing cherry
ar>d ,t.i ned popl .,.,
COI1tributing IIlumator, TIM CAHILL. LORNA JOHNSON. ROXANNE I.eMOINE
T.,hnicol Co",ultM\!, BOB BAKER, DOIJG
COI1t"but""l Crilfmm n JIM HEAVEY
Contribuliflg Proot"oder> BABS KLEIN. IRA SMDERS
SU8SCRIBERSERVIn
Go to ()( I'",te tu
WOOD rmg.;;ine. P.O. Box 37439, 8"""". IA 500370-139
PutMisher MARK L
io.4 .,.keting AMANDA SALHOOT
Advert"ing Monqr JACK CHRISTIANSEN
Response Adverti''''9 Representative LlSAGRfENWOOD
A:5,,,t,,,,t TIM BAAROA
ATLANTA, Navigdte Medi:!
DETROIT, RPM A"o<;"tes
Bu;in"" M..-...ger JEFFSTILES
ConlUmer M.,r<e(in9 Dir.o(or TODD BIERLE
A,so(idle Direct()( 0/ M.,.keting-Nw"liond TOM
Production M,009'"' SANDY WILLIAMS
Ad""rti>ing ep.,rolm Mon"9er 11M NELSON
EComme"" MATT SNYDER
Pub.,h", TOM DAVIS
MEREDITH PUBUSHING GROUP
Pre,idem JACK GRIffi N
b:ecullve Vice P' e<jd""t DOUG OLSON
Chief Rev"""e ()'tice, TOM HARTY
Finan(e " Mmini,trotion MIKE RIGGS
Manufocluring BRlJCE HESTON
Comumer M.rketir>g DAVID BALL
C()(porole Sill", MICHAEL BHDWNSlElN
Meredith 360 JEANNINE SHAO COLLINS
Inte,,,tive Medio LAUREN WIENER
Corpor.te M"-'eling NANCYWEIER
Rese..-ch BRITTA WARE
Technology Oft;c", TINASTfIL
Med', M"-"t,,'9 "'",Ie" ANDY WILSON
[)jre<:t Re>IX)m. <>I 1d T,.vel PATTI fDLLO

In Momori. m _ E. r. III (1933-2003)
Our ;ub<crib." I 't i, oc,.,ic",.1y made avai lobi to ,..-efully ",re,ted
whm. product' m.y b. 0/ "ter"t to you. If you prefe' not to
receive ir>formotion from these comp,," i'" by moil or by phone, .. e.",
1,( u< know, 'i.oo your .. que't a.fmg with your """Ing label to Magilline
Cum.mer ' . rlli,., P.O, So, 37452, Boone, IA 50017-0452
" (opJrIgIo' Morrrli,n (orp_,on 2009, AU ,I"t' ,,,,,,,.d. Mnt. d 10 til< U.\,A.
\.01..
Rao!I", <on oN., <op<"; of for r<l.
by ' -"''".1 j .. niI" r.. ><' ti<n<,.cti(h ,,,,"
woodmagazlne,com
5
It i, I
floor" w[){)dwork wood or
fiberglas> door\,
provides the deep
tones of 3[\ oil-b3>e-d st3in with low
odor, 13st drying and e3sy clean-up of a
wa\er-b3\ed slain,
In additi on, the Phau
Resin Dispersion ut ilizes
environmental ly frie ndly res on , thM
resul t in a VOC wmpl ia nt product
With delicious new colors, Ultr3 Max
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good for the environment.
For mOn! information
or a dealer nur you
vi.11 www.ugl.comor
Cillll800 2723235.

Our bulletin board for letters, comments, and timely updates
Try high-yielding cypress for outdoor projects
grained and often knot-frt;'t;'. Native to
the southeastern United States, cypress
might cost a little more than cedar in
some parts of the country, but that CO'it
can be offset by the high yield of each
board. r buy it "green" and then air-dry
it to save money.
WOOD


Readers approve of digital
magazine editions
Thank you for puttlllg online the
digital version of WOOD magazine.
Now I can make thl;' type a'> large a'i I
want, and print Ollt only tho'iC articles
that need to go out to the shop. I still
like the ink-on-paper ver,>ion a'> well,
and plan to make good use of both.
-Bill hJh, New GOJhen, 100
After reading the article "From Knotty
to Nice" in b'iue 190 (May 2009), I
want to recommend cypress a'i another
good wood choice for outdoor projects.
I live near dozens of mushroom
growers who build their growing racks
from cypress became of its excellent
resistance to rot in that humid envi-
ronment. Cypress is relatively <;traight - Tom Mc,iyGy, Newark, Del. I want to -ay how impres<;ed f am with
the electronic version of your maga-
zine. The content is organized in an
6
Turn your best project and technique ideas into CASH!
Have you de'iigned and built a project that you feel othl;'r WOOL>' magazine
reader'> would I;'njoy building? \Ve're talking bIg or small projects, simple or
complex, for the home, deck, garden, or '>hop. Have you come up with a
clever time- or money-saving alternative for getting great reulb ill your
,>hop-perhaps a smarter or safer way to machine parts, cut joints, or get an
eye-catching finhh (jU'it to name a ft;'w)!
If so, please take a few minutl;'s to tell us about your project or technique.
You can I;'arn up to '>1;'VC'ral hundred dollars if we publish your idea. (And, of
course, you'll bl;' tht;' I;'nvy of your woodworking buddies.)
Simply 'iend up to five photO'> and describe your project or tedlllique in
100 words or less. If we choose your idea we'll get back to you for more
information, so don't forget to include your e-mail addre" and daytiml;'
phone number.
Send your material'> via e-mail or
writl;' to WOOD magazine, 1716 Locu'>t 51., LS-221, Des I\.-Ioines, Iowa 50309.
-WOOD magazine editors
HOW TO REACH US
for woodworking
POll )'OUf woodworking questiOOI Uillnery, finlsn-
ing. tools. tumirlg, <:iIJS\ CollectIon, etc.) on one of 16
oollne furuml ilt
To contact OUI editors:
>end (omml'llts viil e-milll to
woodmail@woodmagazine.oom; or 10
WOOD r'ldgilllTre, 1716locUlt 51., lS--221,
Dts MoilN's, IA 50309
Submiption
To notIfy us of an oddress change or to WIth
)'(lll" subsc:riptNln, vi>!t woo-dmlgazine.com/service.
Or write to WOOD milgazin1, P.O. 37439, BooTJ, fA
50037-1)4 J9. endolt yOUf oddrels from a
recent issue,
To find past articles:
5e! OIJr ilt woodmagazlnMom/inliu
easily accessible format and the user-
friendly navigation buttons make it
easy even for those of us who are not so
computer,>avvy.
-Mike Ti!tf[Jult, Cent"', Ont
If you subscribe to the print version of
WOOD magazine, the digital version is free.
Just go to woodmagaline,comldlgitaimag.
WOOD magaZIne editors
Please work safely
In order to show you precise details in
photos, we frequently remuve safely
guards. In your work, be sure to use all
safety devices, as well as wearing vision
and hearing protection.
-WOOD magazine ,w,/ars
To order past and artidM:
For poIIlt of WOOD our >pedal
(l" dowriaodobl! ilnkles, VISIt oor oolil1! stor! ilt
woodmagaziM.cDIIIIstorl. SoITll' i\\lJt", are sold oot
Updates to previously published projectl:
ror an up-to-date ci changes In dimeflsion5
Mld buyill9-guidt >OlJrCel from is>ue 1 tnruugh todilY,
go to
WOOD Navemi:ter 2009
Shop Tips
Helping you work faster, smarter, and !;afer
No-guesswork frames with mitersled modification
If rOU\'C ('WI IfiN to lila\.;(' pkWre
'"OU IIlltkr\tand Ihe challenge or
si zi ng 11:(' !came mcmber\ 10 flt vOur
photos tx'(au '-C the (111 .... .. 1
the l('n<:l h o f the rahl)c1
on t hl' ....... k of t hi' fl aml'-hiddcn when
II hard to si ze the
frame side"
Rut t h" 'pt'('[atfl.ed mi ler 'It'd it
easy. The hi' to how it wall s: The
of the IIHltch .. the
dept h of the pktllrc tramc rabbet. The
rabbet over].)p" t he 1('I1CC during t he cut.
>" lake the first cut on the rtghl side of
the t(,!lee: then sIVitch to the left !Oelll il
to fi nal lengt h For C\X"11 mon,' cfficienq-,
mCa5u rt" from the \aW kerf a nd marl.
,-ommo n i mage 5iz ..... o n thl'" left ' (,!In'', iI\
\ hoWII rhen iu\ t align the fr.lIl tl.'
so the rablx't crOS'>CS the fl." ncl.' at llw
(or red mar" and (ut. cmurC'\ that
the frame accomodares Ihe picture. I" n:
('\'en created an angled Ihat
onto the fence for ma king
multiple of t he same
-Brent H,U. IJpmt, Uto/!
Thidne of
fence eqUJt s
depth of
Frame rabbet
""('rlaJ}S fence.
Bandsaw blade badge
preserves particulars
To remember til!' slats (Sin'.
widt h, teeth pcr melt) of your
replacement blade),
Cut th e info from thl' (ind
affi x it to the coill:'<.! blaul' mlns
a t wi\t tie. Wheu hl\tali
the bl ade m till' hang tlw
tag from the door
hand le. It\ a helpful rc!eTl'lh;e
when you frequent ly change
bl ades for d it feren! Uo,l"S
--k"'" '-hili
8


. . . . . . . . . . .

Tw"t tie
. . ,
\ :
I
: : J:
. . . . .
<:::iJ.
.. ' .. . . .
eo; ,,,d blolde
Brent HIli onl), ,elu( limtly admits t hat
he manaycd softwdrl.' projecI5 for t he
IR S. " I II slldll y lu,1 say, 'I worked for the
govetnmc:nt ." My woodworking
,Ir e a lot more fun." Now
retired. Brent refocused
cne'\:jic!. on pi cture frd mlng. With 12
grandchi ldren, he of use from
hiS tool-winning Jig, left.
For In t 'lIS ,s.ue. l op Shop Ti p,
B.ent receIves <II JOS An-Tech 7S0-ER air
fil trat ion sys tem. Great '<lb. Brent!
Top tips earn tools!
l eff us how )'Q,.,'\le J workshop
sl umper If we print it, YOll'l l \:jet S1 00
and a copy of 450 .. Best- Ever Shop Tips
(woodmaga;lne And, if
yo ur l(l "a gdrocr$ Top Shop Tip honors,
wc' 11 also rcwald )'ou with i\
too l prizc worth Jt IC: Jst B OO.
Send your best ideas, dlong
wit h photos or d raWings and
your dayt ime phone number,
to; Shop Tips. WOOD
Magazine, 1716
St. , lS 221 , Dh Moines.
IA 50:109-:102:1 Or. by
C-Olill!; 'WoodmJgazine.com.
Ind ude your contact Info in the c ma;!.
Becduse we tr), 10 publish ()(iginal
tiPS, please your tips only to
WOO)' maq;tlone Sorry, !iUbm.tted
materials Coln'l be returned,
Shop Tips
Drum sander adapter breaks thickness barriers
I love my drum Slln.k:r lor thlcknthing
lumber and ItJ.ving a lolnooth
But I wam the same finish
on wOrkPIl'<:t'S larger than machine's
j " max imum thickness, such as wll ln
don;tails flush on a drawer. So, I
adapl cd my drum sander to sand on the
lOp of the drum by con structing the box
you see at nsfrl. It jll)t fit.s t he bed, wnh
t lwends pr":>lrudingdown to "eep it
from nloving. It's high enough to
accmmnodatc t he OpCTll'd sander.
1b create the slot for the drum, 1
instalk'd J6...grlt l>aIX'f, clamped the box
In place, turned on thl: drum (but not
the feed belt) and ral-;('d It untlllt
touched the undel'lkle of the tabletop-
iUS! t'nough to JcJVC a m.lrJ,:. Theil, I
rclTlovcd the top, anll I"OlJlOO y. ,,!" slots
through the top at elt il l' r elld of t he
mark to accommodate Ihe exposed ends
of the drum where Ihe sandpllpcr does.n't
reach. I replaced the top arK.! $Iowly
raised t he '\andlng dr um unt il It pro-
truded slightly from t he top.
_Paul Milo, AliI.
10
">.l"llIng drum
HUGE
Pro
1;2HI' S1l\!d 1{2HP Ya., iIll)e
Miilj LalJle
,[(.1.'00 !\;flo . n;tP'U;:;
Aeq $1499i Ret
S e no J5 b,e no $22')95
I'lus. save lip to S150 on 6 TllrllGraller Pro
I'en Slarter Sets.
Of WlSiI_w.pelIllSla\e;nd comnatheSale

Magnet! tnpe, and
glue ilf hI. brush
I u .. <I, ..
m<tal-handlc<l

glUt 0<\ wood-
>W:llna
but I al,,"aYS I<'Cm
10 t ... ... k 1m
blUsh oIf In.,
bench and Imo
'he .. wdus!.t 1M
wOfSt jlOI>sibl.
ti,ne' My lOIu
Tal'" ,mall
m'1J;n('l to 'hI' gl LK'
i>oIt!('"hh
m.t>lo.I"K t"pe
bruoh con'
roll Ind .. hn>lle> >Ill clean
.""".
Shelvc s secure sh!:!lvl:!s
I inl\o.lI.,d Wtvlns b<,wt'<" lb"
or><" "",11 oj my 8""'g< <hop 10
tol.J: od ... of u.. unuoeJ '1""'<.
Tl"l n '"I:' in opon view
ellY I<) '1>01. Ilow=r, illl00
, .. ,-.:, ,,"vents /loi,h .. within
,_" of small hooo, !O I ll<'eded
""V to rhlkiprooo' 'hem Ttw',
when 1 1',,,,,1(1 Wlf(' d""'T
iJK'1\oo'1C(n1<'r. 11 ro",,,, l n 16"
.. ;JIII,.....'h. \,'ffl ( "a,""'''' <Iud
'I""''''''' .. ,Id Cln ".,i,,1I'-'<I" """11
tI.., Ind"<k<)llIrd"",,, a> """'ll..
t-""", u n Ix: Ioxt."jlll all out-of-
.u:h J ","w1
(.II.h {I, .n cyt' 1\(>01,:
w""dm ' n.,>m
From lIobbVist to Industrial
TIP Award....." In
S111C111993.
Indape.dent Tests
Some of OUf Industry Awards:

.t::J
1II1II l1li ..... In .... USA.
1alil. DIrICII,. to Our
llC1M11C11 slIn ...
Eq' Plirs
UY. hIIO_.
S' .... ISlaR ..
$51.10
Dutl System

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Shop Tips
Just flip and rip with
this thin-strip tip
As i was the t htll-)trip lIppi ng
guide from til,. (\()q-mlkr 200S iSsu.:' of
WOOD, magazine- 187, p.1g{" 63).1
sa" an oppollunlt) \0
efficiency, Afle r atl':Khing thl' miler-slot
IlIn ner to the h()' l"I, I II IlP '<I lhe board
in half, and Ihi' n r(';lttachoo the two
hol ln-s wl1 h bciore Jdding Iht'
nut a nd guide tx>1t t hol t .lcts as a SlOp.
\\lith the width I poSI tion Ihe
table!wlw #;;ncl' and flip the IIg guide out
of the way to make the ( ut. I flip the
gui de had. down agdi n to the
workpiece and I(' [\CI' fot tlw Ill''''! cut.
The !...nob on till' lunged gUlI.!c si mply
makes it casi.:'r to flip_
011':" [OIlS!, Mound City; Mo.
12
After '.ettlng fe-<>re
\ Il,pout ,ftht"a)/.
"
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lor ytlUl shop Of GhC CWliCatlon
Unmasking a burn-free edge
\'our {oXen! 011 rcmo\' lng rQute:!
hum m.u"s (July 2009, no 191, F"gc
22) was w r y tldl,ruJ, Il cl;;>\ 11K' lIldhod
I Us.<' wht'n template routing,
AIl el c:ulti ng CkoSl' to Iht' t raced
kmplat<' lim: wit h t he I "!'ply
two or thcc;;> layers of Inaskmg t"IX' to
I'm a sole magnet!
'10 protect the blade and sole of your
hand planes when not In usc, pick up a
shed 01 magno.:tic air durt grill ,0Vtl
frtlm t he halelwar" \tore. Trace
,hape of th.; " lane >ole on t ht' magnetic
Ihe: edgc of t he ix'forc "Hi :>.illg
il to tht workplcce, Aft er using a
patt ern hit to ma"" an Initial I
{e:lHove the tape alld 1II00 "e a
fi nal shallow wi th the mutl'r,
eliminating any hum mOl rh,
-EvrrPlf BIau, flo,
,mel cut 11 out With scl\sors, Your
new nugnetlC cover shields lhe blade
and >ole from hump. and [ostks, ...... Tn
in the ix)\\om of a looll:x),'I:,
......(;grr w(I/)./l, m
Hand plane
COlltjllllf'<IOI1 rUSe 15
13
He's a
tough gUY.
But he
cleans
UP after
himself.
No Residue Duer Tape
ScotchToughTape.com
3M
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Doten PI.fd De\91 ...... ..<1"" "" 01 )M

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Priced
\ ,"" " ... wwwbu<.lhordwooill.n'nl'"
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btf,""",I"....,) ," '"
C/
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He<e is a IMI doeo./l 'I tome alan: ........ \' dil!'.
"- elY""" to put QiI<ll,I, in )'Our .... CII1<Shop at wIlolesall prices]
NIl'OI throui\l . t-','
.... hardwale.colll, participati ng deale,s.
Offer ""P'rl!S Oclller 31 . .2009
#800.519.11
TURNS ANY WET-DRY VAC INTO A SUPERHERO.
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l"IO:f1 tile llOl!!.! get ""'per rJeJoups without clOUtIS
Siiwdust. o;Iryw311 (IUS\. Wille-r - none- of lIlem star.:! a Chance agll iMt
the dynM'lc duo - )(lurWllt-ojry ,,", F'IW.
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Dust lias mel Its rna/en.
DPO(l 1l6 SS 95
[)ow" OiIII a.y rJ Ihese for .... ,n:n
Ot ' I!'!fIawg!llmolge,1'II ,.... __
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(aoIIdSJ Pill' plu.! S+ttl U .. ... .,. .... ...,. 1111.
Pll'Ze h3vt toV :m", uta
\'I')11
Shop Tips
Spring-enhanced hold-downs
r use this jig in place of a featherhoard \)(3)<6' scrap of wocxl to accommodate
hold-down on my tablesaw and romer the tah. Then att,lch the spring
tilble because it's inexpensive and easy with brad nails. Clamped to your fence
to make. To huild one, you'll need ,111 the spring action holds the workpiece
inexpensive windO'IY \il5h You agaimt the table during
can get them for ahout SMpair at the feeding.
hardware store. Cut it small kerf in a -Dale Robbim. 5tockton, Calif.
Childish solution to brittle chalk
Growing tired of my chalk breaking
when I tried to mark on rough
I took a from childrt;'Tl\ crayons.
I wr,lPP':'d t<lpe around the
tape
woodmag azine.com
chalk to reinforce it. After the chal k
WC<lI\ dowll, I jUq kar off a litt l", tape
to ex(X)se more. Works like a charm .
-Io!e 501010(, Indian Springs, Nev,
15
Transparent DuctTape
ScotchToughTape,com
3M
,2009 3M, 5<:01>. ''''' $,;",,1> 10.., Duc, T.p.
0."3" ,,,d the P1>id [)"'i!l" aro ".demar", of lM,
A
ramalic rcd cedar
(J1fllipt1fr1.1 l'itgilli<1lllil bCl:'n
tho;> traditional choice for bla nket
and closet linings for 8en': I3tI011.\
bet:au'\e 01 Its purpor ted mOl hrepcllant
properlit' ,lnd fresh h It a
miracle wooll o r tOO good to be tnl!;'?
Mothbusters1
Two culpyJt s commonl y <la mag!;' dot h:
the ca*maki ng dot h!;'s lIl<'th, \howrl
bl'lllW, and the webbing clot hes moth.
t he'il;' crill en (about v.
I<' ng with a Ih" don't
l\."'SCmbl(' yOur .. J polI,h hght
mutils. II yuu St'i.' th..'rn at .. II, II !lily
be 100 late to save your sweaters
because n's the Tnt hel t han thl'
adult moths, t hnt nlUnd1 un wool, fur,
,11Ki feat hen.
LlFl AND OF TIlE MOTH
16
Cedar
So how docs aromatic cedar contrib-
ute to y<>ur pest-control solution? When
concentrated m a tightly-sealed
such d blank.et th\,' lilpor \ frum
wood will kill hat( hi ng
moth lan'ae. !lut thme vapors have
little or no on larger la rvae, adult
mot hs, OJ Ic"ggs, amI less effe(t
wid!;'- open areas, such doo;ets,
That '>aid, iI has been found that
aromatic cedar blocks bugs no bt'tt t'r
tha n si mply sealing dut hIe'S
i n a plast ic cuntainer ur bundling them
In tapl'\t-up butch!;,T P'lP't".
Skip the finish
Top-coati ng aromatil: U'dar In,
and Iherc{ore its
repellent But you ,hould
al so avoid ilpplying ilny stain, paint, or
finish to the nOll-cedar interior surfaces
(If II cellar chest. That's becausl;' the
rl,'s\n5 111 (Cd,IT share
wIth tuqll'nttne, ,mu the solvent-like
I'apms can cause oil- and water-based
stains, p.1Ints, and fimshC':S to softCIl.
nlJking lids (ano clot hes) st ick If you
i ncl ude t he opt ional Cl"dar tray i n t he
blanket chl:'St on 30, lean' the
inlenor un linishrd.
The cedar.lined
bottom line
If rou want to give \'OUT blanket-chest
proi-xt a tra,1lt lonallook (and smell),
'>Catch no further than auxlK,lIc t1;'llal.
Howevcr, 3\ a pt"St lt:lde, aromat ic tmar
a l.o ("tler pre\'entath'e !lIcdici ne
th,m it c! 0(') an ulthna!e curt', So don't
expert umaclcs .
10
r

?

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I
Great Ideas f9LYour Shop

Easy-Store
ClaDl
Rack
W
h.'n WI! fir" ran aero's this
ciJlllp.r."K.1i cleslgn, we did a
bit of J dO\1b1\> takl!. It holds
clamps by t heir not by thl'
fixed jaws. ,IS wc'd Sl't"' 11 lIme ...
Wit h "brKkward" dC)lgn. clamps
can" fall offltle rack, and It kC'Cl'sthe
movable jaw frorn down the bar
when hung.
rhe key to bullcling tilt s damp llOldel
is to minimiz.e tht gap UctwCl!rl the
front ,m" bad. pit-en. Thl' light!:'! the
opening around the damp handle, tht!
more vertical a clamp will hang-J v."
gap works I,d!. A slight rOtlnd-ol'er
,llong the top in)lde l'<lgl' of t he front
mini mizl!' marring I h{' clamp. handle
fi nhh when h.lnging the clamps .
Hote: P,n'it w ij'll1e!. ,hllp at well ai till)w
1'( 12 otlwr tnjl-Sh{,p fllmeo'/'y viSitilrg
\ Jl1 r \\' 2iM)lI
"
r
,
,
,
I
'",, " Plio! hok:

i
r
L
,
, .
_8 , 3" Hi wQ()(j .crew
0:""1,,,00 011('1 wall stud
",",,' hole.,
_. __ __ 4\,oonter,unk
Slight tOO tld-over
along imide
top edge ,"''''-"
(
FRONT
Le<tgth 10 fil
",all
/'
_8 2" F-H.
wood'iCrew
NotI!;I\J1 plywood.
0""
_8x2"FH

WOOD .. .., .. NcNemb...- 2009
Wise Buys
Our Experts Test
Forstner
Bit Sets
FREUD,
#PB 100, $200
16 bu.:
21'." in ' ' ,ncrements
Editor rating: * .... **
Editor test-drive:
Before It'SI il"l9 :)f' 1, t UJ,f'd d !)el"ll'flC,
1I1:< pt' lhive WI vi blh III m y
4nd gol alung lifll' But what a
di\lerf' I1(f' wht lll l>f'g:m lI)1ng Freud's
bit ;. ' It ' s how my
dleafJ bib lulled me into
accepting li tt le l ear-out here or li Ltll'
burning Ihrrl;' Wit h a lm' '1 I1 f' wavy-I'd-
rim dpsign, bits I1I'Vf'1 torf' out any
of the wood, thJ! I used fur testing,
induding vent'red plywood and
Mm. The wavy edgt!s Clit so ) mOul hly
and arld reqlll rt!d 1,ltle effort
tiM! it sUlpri;ed me . They 31w ell!
flawlessly o n iluglt!-d -entr y holt
To learn mote:
800 334 4107; Irf' U(J l uuIS.com
- T.,.ted by Chuck "'''',,,,d
13 Y""'S Ma)le' Craflsman
al WOOD mJ9a.!ine.
35 of p.ofes,"on .. ,
woodWOlking
'0
Why buy?
A workshop needs Sf'Veral t ypf'S of drill bit;: 5tdnddr d twbl, br adpoin\. and
bits. The first t wo dl ill hole. pr lmanly V..- or less in (Iiamt'ter. But fontner
bit> create hole, from . to greater thim " . l hese bi t s not ooly bore cil'<ll1, preci se
hole), but t hey also e)(cel at aI1g1t"d holt>_1 and counlN\)orl's. and Il' awo U<ll bottoms
ideal tor insert ing European-style (UP hUl 'lI' >, ch<l ir MId or
coins_ Al l hough you can use t hem in a h .. ndht'ld dnll, tOi safety
imd best result s we suggt>st using I" o. larger bllS In a slowrunn,ng drill wil h
your cl amped 10 tht> lab 11' _ Atll'r le;ling ""gh l b01<1'(1 of Forst ner:., we
recomm",nd the Ihree belm"_ Alileal Urf' prmlt"d or Imbf>d(lt'(I diamett'r m<l rkings on
the prt'fefence-becaust' miukln9S rWOil r I ll", It"ld to wt'ar ovt' r l ime
due to 5lLpp<tge in the chuck.
HAHN" JVSTEM
.,. ..... Topo11he 'ine ,. .. "' .. q .... hty ."' . Solid 101' pn, ..
LEE VALLEY,
#06J80.13, $79
13
'!," to 1" in increments
Editor rating: ****
Editor test-drive:
Excepl for Ihf' 1 h' bit I use lor cup
hlnge\ I rarely uw Forstner bits
t han r So thl5 01 blh , mad .. in
China, me fine, even t hOllgh I
(<In gf' t more bits for If' H money else-
where. Thew hl gh-speed-steel,
rimmf' d bits proved sharp and accur ate as
they bored crisp, lear-Dulfree hole:. In
oak, walnut, fir, birch plywood, and MDF.
They make perfect flat-bottom holes.
With onl y a ,/. -deep di vot from the
centN s pur. I also tf'sted Lee Va lley's
16 pit'<:.e 5<"t ot sawtooth bi ts (1 'I, to 3' by
'I.' Incrernents, S2 50, #06J80.16), and
they performed Nlually well.
To learn more:
800-871-81 58; leevalley,com
by Kevin Boyle
8 Yed" '" edilor at
WOOD mdgil line,
'12 yea. s 01
wood,.ork,ng e"p"""uce
WOODLINE USA,
#WL FR2000, $65
20 b,U,
,,," to' " In ." Inne ment s:
1'/0" to 2" ln ,,,"
Editor rating: ***
Editor test -drive;
In Ihf' pa51, I"vt' bought rorstllH bits like
rvutt'!' blh Oll f' al a l ime, as needed. But
lur t hf' P"(I" of it halt-dozen Individ ual
blrs, Igol Wondhne's ChUM-made
20-p' t'(.f' The 12 bits small er t han I '
feature Smoot h ( uttl ng rims, whil e the
IMger one:. tl3ve d sawtooth design. Both
type:. cut cleanly Wit h no 1
bored holes III pill e, birch plywood, white
Odk. and eVf'n tough as nail s hickory. a
bonus, t ltanlum nitride coating help>
1t'(luce du lli ng fro m 11I'at build up. They
al:.o havl' ippf'(j shanks lor dna-sli p
gl'lP in til l' ( hUCk, Wllh the re<:ommended
Sf}et'd prinlt'd on the ,I hank .
To lE'arn morE':
800 472-6950; woodlmt',com
- Te:HW by Bob Wil,oll
S }-ears editor ill
WOOv
25 of
.... 00d .... Ol k,"9

INTROOUCING OUR NEWEST SAW
Go to sawstop.com!wileapproved alld we'll s.elld her a p<Jl"suasive
Informalton KII, mclLJding a OVO that will close the deal.
How to Redo
a Misassembled
Drawer
Don' t get bent out of shape over an
out-at-square drawer. You' ve got one
last shot at achieving a first-rate fit.
T
hat's some magic trick YOUI newly
built drawer pull(>d-levltatlng
one of Its corners off rour
workbench [Phot o A1. Before \'OU make
the whole drawO;' I try thb
technique for separating li nd reassem
bling t he drawer
Your lucky brt!ak
Separat ing a glue join: by force works
best if rou catch the problem the
glue cure completely, so drawers
for flatnts.\ and MlUtlre a.\ soon as yOll
lem(Ne the clamps. You ha"e 1\\'0
options for \\eakenlng glue joi nts To
soften type-l (noll , \\',lt(>[rdistailtl
yellow glue, thoroughly soak till' joInt
with vinegar until you fl'pi the ronno!c-
lion fleA. FQr tyr ... -2 or tYp.!-3 ydlol\'
"
repeatedly soak t he joint with
acetone in a well-ventilated area. For an
odor-free alternative way to soften all
types., heat the joint with a hair
[Photo 8].
Immooiately after softening the joint,
damp one side to your bench. place a
scrap block against t he joint, and strike
the block wit h jUst enough force 10
separate the parts, as shown "WI\'.
IkpeCit for the remCiin ing joints,
soaking or heating one and separatIng
It ""'forl' on to the next.
Once separated, .... ' nd t he joint parts
without sandmg to barl' wood,
which can throw off the fit. Remove
any glul' build-up within dadoes and
rabbets that would affect reas..embLy,
then sand end grain smooth.
Drawer assembly, take two
To avoid repeatIng the same mi stakes,
check drawer parts for Identical lengths
of opposIte parts., such as sides. Check
that dadOs and rabbets on all opposite
pa rts \\".::re cut the same. Then use a
\tralghtt!dgt' to ensull' your bench top
rests dead flat. If it 's nO( fl at, do the
Il'assembly work on your table-saw
It's flat.
The first glue-up filled the wood
pore\, '>0 \wi rch to a non(ll'fletrat ing
adheshc, \uch as hl.minutl'epox)'.
Assemble the dral\d and damp t he
sides, front, and b..1Ck as rou normally
wouLd. This tlmt'. though, add two
more cI"mps to hold the drawer
against your flat work surface
\ PhQtQ CJ. Thl'tI chl'"Ck for square .
"
WOOD ... ;og ... r""""m_ 2009

M
a.:1I1I10;''<' (ut joints fast. but not
an"uIJ te-ly. "I hat's the
time to bri ng in hand tools
because sanding blocks. ( hlsoCi s. a nd
p lmes Io;'mo\'o;' wood in thous;lodths of
Lin mch lOr':' snux joint IPbotI)AI.
If you don't havo;' a ulcw,J. plane- or
moulder plane, don't rush OUI and buy
them-yet. Stall simrlc With a sandIng
bl ock you can mJk.;o fOr p\'Hni('!; U,IIl!:
scraps, ..amlp<l per, and spraY,ldh\'5he.
Then add a good St.'l: of bevel-edge-
bench chisels, your joinery
improve, save time by supplt'meming
)'OUt sanding blocks with well- hO!k'd
block and shoulder
"
Take your jOints from
" not quite" to "super
tighC using these basic
tools and' methods,
Sanding blocks:
Slow but simple
Uses: Reduce tellon Ih itknt;' .... by
Iht;' ehed.. s, a nd m.akt;' t he
e\'en with each ot her [Photo
BI; scoring from tablesawcut
rabbets or didoes or stub-tenon ,;rooves
for dea ner edges ,l nd a stronger glue
JOi nt [PhotoC]; and adjmt half-l.ap
d'->Plhs to mako;' parts fl ush I'or a
CUT\ed sanding block to flne-tune
coped end, on molding, wfap sand-
paper around dowels of di ffo;'reot ...
.. secret<.: Match th(' grit to the
amoum of stock to r('move-.'>tart at 80
grit for removi ng det'p <;cor ... llno;'.'>; 120
between the and facl'!'i.
gIlt w(){ks great for minor tenon
Theil match the block
10 Ihe lob . o r example, plane a
blod . 10 the of rOUt dado
then mount :.aod paper 10 Ihe
edge fo r a sanding block that ,..ork, tile
ent Ire dado with each pass [Phl)to Cj.
Choo-.e h;l(I\\'Oo(l 'klnJ i ng-l'llock ,tock
lll3t will hold l crlsp edge, and attach
to only One surface, not
dd[oioing (,fee Of edges. That lets
,Idlust one dimen,ion of d loint without
lIlt' OIlwrs [Photo 81. Abra'IVI'S
on smal l SOl ndlng blocks wear In a
hurry, SO chal\ge pdp{'r frequently.
comllmcd 011 page 26
just,Right J.oinery
Chisels:
The ioint-maker's edge
Uses: Trim smooth willb and square
on d rilled [PhOIO 0 [; on
hand-cut dtwelai b, strail;ht Ij nes
lor clean joints and Sh:lVl' pHIS 10 fll the
tails; sq\lare rahh",ts [PhOIo El
Success secrets: Hone lilt' ht'\el ;lnd
nallen llie had: for an ed):t' sha rp
enough 10 sh;ne th ... t!dirs on YOllr arm.
A ch i!oel grain as it r'Or
paring ("uts with the gram, cut from the
i f \'Ou negl n to
thl' (:hisei iJown inlo Ihl' wood.
Where that's not an option, hold the
chisel perp{-ndlcular ILl the grJin and
tap it to mak .. V,.' stup CUb. Thl' n
remove thl' wood between the stops.
Use the whks! fi ts till'
joint area you're cutting. To trim the
walls of a 2'-wide morti se, for exa mple,
two cuts with a 1" m 1'/, ' chlscllenvc
cleaner, str,llghter linC5 than four or
five cuts with a '!.{-wide chisel.
26
workpleCI! htlp.
90"to the l'dgc.
Block planes: Perfection
comes .002" at a time
Uses: Flush-trim edge!i on p;!rts jOined
Inlh a machined dovetail; clean up
edges to be glued; chamfer IImoo
e nd s a nd panel edges for easy i n!.ert ion
[Photo Fj; clean up CfU5S-grain ruts,
as mitered ends on hand-sa\\ n
frame pieces; trim t'Ilds or edges t hat
stand proud of an adlacent
make drawer side edges flush with the
drawer fmnt.
sec:: .. Ch{'Ck the plane
for flat ness. The best plane worb only
a. well b the sharpness of the hlade
(For a video un how to hone a rawr-
sharp edge using sandpaper, go to
wood magazine.comJsharpcningv id.)
Test the plane's cutting depth on
unW each pass takes a
translucently thin curl [Photo G1. Before
tackllng a workpiece, practice contrOl-
li ng the plane balanced on the edg .. or
end of a ,/,'-thick practice scrap.
PIIUl!ion lheedge of a scrap blade
prOd llW tight cur ls of even thkkneu " om
. ide to "de.
Shoulder planes: Tools
that work: lying down
USII:S: \\IUh hl ades that cut a hair wiJer
than the plan(' body, these specialized
straighten tenon s houlders and
shave tenon cheeh wi l h Other
i nclude dado, rabhet,
;md IW\OI'e bol to ms, as shuwn l't'lfll"'_
Su ccess '\"ccn: ts : You' ll nften pla ne
cross-grain with t hh 1001. making a
razorsha rp blade ""!.ential ror
Celli;:>, Ih.: hlJde on Ihe plane bod)'
[Photo HJ. Th L' n .ldjusl the cutting
dept h to make shallow pa...ses I\ith no
tearout [Phot o I). Because it cuts fasler
than a sanding h!ocL.:, stop frequemly
to parts .
Sources
ShOUld" plane. oo.05P41.o1
Iwlth h.Ird A2 steel b f",le$s m5. Lee
Valley lools. 8008718158
Block r hine. AplOI'1 f'I.1ne no. OSP27.G2, $85
W1t h !Ill A:l bLIdoe, Let Valley Tool .
WOOD .... a.guln.. N"""mber lOO9


.IE
ase
Curves as gentle as a flower petal surround a glass vase
nestled within this simple project.
Cut a base and vase holder
1
Glue together a vast'holder blan k
from three piec('s of '/.><2
'
k><7
J
/.'
slod: (we used walnut), and tri m it to
size [Dril wing 1). Cut the to sl:te.
2
cemer and Jtlach the .... ut' holder
to the base using doublef,lee<! tape.
Drill and drive four scre ..... IDr,wlngs I
and 1]. Copy t il.: Vase Holde. patt ern
from thl' Ivt'X)/) l'aUelrl) Instr, and
spray-mount it to a vase holder sIde.
3
1m!0I 1i a -'I.: cO\'I;' bit i n a !<lDIe
mounle..! rouler :Iud the fenle
fl ush with the b'a rlng (tkawlng 2. ).
CIJrnp stophlocks on the infclod and
outfeed fences 'l, lk' from Ihe center of
the bit. Then rout stopped COV\!S on t he
sides imd of t hl' base IPhoto AI,
4
Remove tile vase holder from the
base and rout VI" roundovers on
the top edse$ of till' 1)<1 $';>.
Drill long ho les accurat ely
1
Ch eck yOur ddl1 PI,"SS to ellSure the
table align. 9()" to Ih," chuck In all
directions [Photo B]. Clamp on a tall
fence shimmeel 90 to the t"htt!. (See;1.
free vieleo on ho\\< to fUlc t line a drill
.It w(X)(\milg.:u: ine . .-omi<.1rillpress.)

a FOTst ne[ bit t he same size

as or '/",' 1,1[g('r t han the gla,s vase
marne!e[ r or the I ',,"dla metc, gl:'l\'"
vase we bought at a hobby , tole (LIbbey
*2824), we used J t '!."di31lli'ter bIt.
(Drill a test hole io ,,: rap a nd te-.Iflt the
glass vase.) t he center of th.;-
\ast' holder dnl! center II he\()',v l ho:
bit. Cldmp J ()Q0 squaring brace to the
TO s.eCUft' the pJf l
D EXPLODED
VIEW
GLASS VASE
I ... d,am. 7'h'
VASE

\10" round' O\fe"
"
Add to ma ke the drill Idbl t 90" 0
rod ,n Ihe chucK. Check thl' In
directions a $qua. e.
D BASE (Bott om view)

w;,mw.sunl<
3
Drtll halfway through the vase
hulcl l'r [Photo q. Depending Oil
\'O\l r bI t and drill you may !lc.!d
to SlOp to r:l.i)<' the tabl .. .1s yOll drill)<J
that the chuck reaches deepI'I into t hl'
hole, n .ill until the b:1 rt"Jchl.'S 3,.
d"t'p. l hl'1l fli p t he \.1* holde. O\o:r,
t he !kll'lle .1g.11II SI the
ft: !ll.'l.' Cla mp It in pos.ition and d. W
unt l1 th .. holes meet.
4
R.lnCb.lW till' vas.;> holder ill\(j
to the p.utern hnes. If the holt:s
drilled In St .. p 3 didn't ml'et perfectly-
ours Werl' off by than 'Io"-)and
thl'lH WIth lOO-grit
II fence
EZ!I BASE ROUTI NG DETAi l
sam1paper wrapped arr.JlInct a '"l1owel.
fake C,l le to maliltalll the hal f round
shape on both halve5.J]lcn f i nish
alllXlfb to gut
5
Rl'COllrtect the two \',lkholdel
halves to the oow. Color th .. OO'iol!
cO\'cs wi th a blocl permanent marl er to
make them less \' Isi ble, I hi.'ll apply a
dear finish, \\ \'e u;;ed thlt .. 'e (o.lt) of
Jer050l \o1l tin IJcquer, with 320
between coats. )
by Hob Wit,on I'mh ,,,If Me r . <
PrOIe<! de<lgn; Kevin Hoyle
III'''!''\I<'''' Rounne Le M" ln" John.on
"
Overall dimen$ions: wide
19
l
/." deep 'fgh
(Country fre1h ver!.ion
high: Casu.ll COlltcmpor'ary
version 2)1/ .. high)
30
woo,
N
!
j
,
i
I
AT A GLANCE
Lid-stay torsion hingE'<; keep the lid
open at any i\ngle .
for joinery, base profile, and
wood selection provide custom looks.
B
uild this chest with your prefer-
ence:; for :;tyle ami complexity in
mind. The Traditional Amencan
look in mahogany (left) require:; dove-
tailed corner joints, cut by hand or with
a router jig. To simplify matters. try the
Contemporary version in con-
tra>ting woods such as ash and walnut
(be/ow), with rahbeted corners joined hy
plugged screws, The Country Fresh
option (be/ow right), shown in pine, also
feature:; rabbeted corners. For that stylI;;',
we reoommend cut nails to hold the
joint together.
If you like the dovetailed look but
don't have a jig, challenge yourself by
hand-cutting those joints. You might be
surprised with how nice your results
turn out. Start by cutting practice jOints
in scrap, following the steps on these
pages. After a few attempts, you should
feel ready to show off your new skills.
And here's an extra safety net: On pages
34 and 35 you'll find two easy tips for
fixing any less-than-perfect joints.
Prep the panels,
then cut some tails
1
Glue up material for the front/back
(A) and sides (B) [More Resources, page
36) and cut them to size [Materials List,
page 36]. When cutting dovetails, it's
especially important that the panels be
flat and of con:,istent tllickness. If you're
building the chest with rabbet joints,
refer to Joinery Options on puge 35.
Same chest, different styles
Label each corner and top edge so you can
match pieces properly when laying out the
dovetails and assembling the joint.
Use a ratio to set a
dovetail angle
Set the gauge to V.," more than the panel (A,
B) thickness so the pins and tails protrude
slightly. Sand them flush after assembly.
You'll often see the angle of a dovetail
expressed as a ratio of slope to rise (1 :8, for
example) instead of in degrees. Why? Because
it's easier to set a bevel gauge using a ratio
instead of a degree setting. Here's how.
For the 1:8 angle used on the blanket chest,
mark a 1"-long segment on the edge of a piece
of paper. Then, beginning at one end of the
line, draw a perpendicular line 8 " long. Use a
straightedge to connect the ends of the two
lines to make a triangle, then place your bevel-
gauge handle along the edge of the paper and
pivot the blade to align with the long line.
2
c'amp the front/back (Aj and sides
(B) together, label them [Photo Al,
then layout the dovetail spacing on
each cnd of the front/back [Drawing 1a].
Different woods and base profiles provide a variety of looks forthe blanket chest. See
Joinery Options onpQge 35for detaIls of the rabbet joints used on these versions.
3
QU"Ic TIp! GUlIge your layout."\rlw
Use a marking gauge instead of a II
pencil to mark baselines. The gauge
cuts a clean line that provides a trough
for your chisel later and emphasize:, the
hand-cut look of the jOint. Set a marking
gauge as shown in Photo B; then scribe a
baseline across both faces on each end
of each panel. Set a bevel gauge to a 1:8
angle as shown in the Shop Tip above.
Then extend the dovetail spacing marks
from each end of lhe front/back (A)
down to the baseline. Mark the waste
areas between the tails [Photo C[.
.,
woodrn"g .. ,lne.com
4
Clamp a front/back (1\) in a vise orto
the front of your bench. Staying on
the waste side of the lines, cut to the
baseline on both faces rPhotoD]. 1\ gUide
block with a 1:8 angle on the end helps
start your nIt accurately [Photo D inset].
5
With a panel facedown on your
bench, a chisel into the base-
line in the waste area between the tails
to establish an edge. Then make chop-
ping cuts halfway through the panel's
31
Mark
D CASE EXPLODED VIEW
--
iI!l LlOCLEAT

PreU your chisel in <lit 10 a

yom cui j line. ( le an edge. Then, from the baseline. dlOp
down 10 down aboul halfway Ihrou9h Ihe
45',0'
___ ---------1 \it" bumper
.. . cemered over
lopedgeof@
.'
f- H,
wood sere ....
(,(lolh. lld-stay hinge
m OOVETAIL DETAIL
m LI D PROFILE

Ame"(8"

Lonlempo'i 'Y
ChClt
____ \0" cha.11I ....
i
[PhotoEj. Chip out part of the
waSte from the end; then flip the panel
and repeat this process [Photo Fl. Work
your way back to the baseline, angling
the chi-;el ,lightly to undercut the base-
line [PhotoGI_
Pin it down
1
Clamp the panels together again to
create a box, matching the comer
labels, and with the front/back (Aj
against the end grain of the sides (B).
Align the inside of the with
the baselines on the inSide faces of the
fwnt/back. Using a marJ...ing or crafts
knife, scribe the of the dovetails
onto the ends of the sides [Photo HI. Use
a square to transfer the marks from the
ends of the sides down the inside and
outside faces to the baseline.
2
Secure a side (Bl in a vise or to the
edge of your bench and Cut down to
the baseline, staying ju,t outSide the
lines [Photo I]. Remove the bulk of the
waste between the pins with a coping
saw [Photo J], then use a chisel and
scribed
on both
woodm"gazine.com
knlft
Push or pull: See how we saw
Senior Design Editor
Kevin Boyle made a
discovery as he hand-cut the
dovetails for the chest:
Sometimes the tool you
know and love isn't the be>t
one for the job. "The
Japanese pull saw (dowkil
I've favored for years wasn't
cutting as straight as I
wanted. After the blade
wandered off course once
too often, I switched to a
Western-style gent's saw that
cuts on the push stroke_ The
thicker blade helped fTe cut
true. I still use my dozuki for
lots of jobs when I need a
handsaw, but for dovetails,
the gent's saw i, now my
go-to tool."
Kevin
II
switched to a gent's saw.
33
and cauls apply on the front
b<lck (A), pressing tho! dovel lJilJ Ilghlly t o
thi (8).
D BASE
u'O!'" s<:,ap of plywood thO! iii
the bottom (F) to position the glue blocks IE)
below the top edge of thO! basO! (C/O).
451, '
EDOPTlONAl BASE PROFilES
- -------"'.,"- -----
c
Full'llle
pJuern
COUNTRYFRESH CHEST BASE
._ 451;,'-------_ _ _
CASUAl. CONTEMPORARY BASE
scrapwood gUide hoald to establish a
clean baseline [Photo I(J. Quid Tip! {fjJ
star' lUI 'he! Imsdltu. ij"
Pl aC"t"' th' end 0 1 "UUf ,hlsel in o n('
end of the- 5("11,",,- "'"<1 WWh ne. t h,; n
the guide up 10 it anJ cllmp II in ,,;a("l.'
[ lu t he same tOf the ()th('f ('Ild of
gu ide Clam? Ih('" co.'ntu ... d l t()
34
vent fh-xi ng. A. wilh the tai ls. Slightl y
undercut the ba.elinl' when removmg
the rest of the waste.
3
Try dr}-fill ing a joint t-. lake a note
of any tight that pre'\'l' nt the
joint from coming together. Use a chisel
10 trim th...>se edges of the pi ns to fit
tNt.wen the tails. Take your l i me and
Orill countuwnk s ....... hole. through the
bottom (F), then s<:,ew the bolse ilssembl)!
Ie- F) to the use IAtB).
Em FRONT SECTION VIEW
SHOP TIP
Patch a pin
If }'Oil overtrim II pin, glue on a
patch. then start !rimming again
aller the 911,1(' dril!s. The end grain
of t he patch in t he
assembled jOint.
awa> small amOU1I\s, test ing t ile fit
oftl!lI. the Shop Tip 11b.11\' if rou trim
:r pin too much. WOf1,: rour way .lround
Ihedlest, (jilin!> on(' [oint at it ti me.
4
onc(' all four joi n ts t it together,
apply glu('" II) t h ... edges of the pins
and glu,' up l li(' box IPhotoL]. Quid
Tip! g1,,. lip DoIl'I \J
bother gluing the face grain of the pim
or tails. These surfaces contact end
grain-a weak bond. Use clamping cauls
behind the pins to draw the joint tight
across the full width of the front/back
(AJ. Check for square by comparing
diagonal measurements.
S
After the glue dries, sand the pim
and tails flush with the adjilCl1t
faces. Avoid rounding over the corners
by clamping a scrap to the adjacent
panel, flush with the surface of the panel
you're sanding. Quick Tip! Zap (@
gaps. Fix gaps under YJ2" by squeez- ij
ing in a small dab of glue, then sand-
ing the panel with 220-grit sandpaper.
The sanding dust StiCk5 to the glue. cre-
ating a patch that blends with the joint's
end grain.
Give It a base to stand on
1
Cut two 4><4S' blanks for the base
front/back (C) and two blanks
IIOPTIONAL TRAY
for the base sides (0), Note: The bu.ws (or
tile Casuul Camempomry uud Call1ltty
Fresll versions arc width, [MOIteri -
OIls Lists]. Ti lt your tablesaw blade to 45
and miter-nit the base pieces to 1 W' lon-
ger than the outside dimensions of the
IDrawi ng 2J.

a copy of the Traditional Ameri-

can Blanket Chest Base Pattern (or t he
pattern for the chest you're building)
from the WOOD Patten/.I insert and
spray-adhere it to a piece of Yi' plywood
or hardboard. Cut the pattern to shape
and sand the edges smooth. Use this
template to layout the profile on the
ends of the base front/back (C) and sides
(D). Cut each profile to rough shape on
the bandsaw, then sand and file up to
the lines.
3
Rout a profile around the top edges of
the base front/back (Cl and sides (D)
fDrawings2a, 2b]. Cut 16 glue blocks (El to
size and set 12 of them aside for the
moment. Glue up the base with a glue
block vertical in each corner, pulling the
corners tight with band clamps. Then
glue and clamp the remaining glue blocks
in place [Photo M, Drawing 2] .
A Cut the bottom (F) to fit inside the
(CID/E). Drill one countersunk
pilot hole in each horizontal glue block
(E) IDrawing 2bJ and screw the base to
the bottom.
S
FliP the case (A/B) upside down, cen-
ter the base (C-F) on it and screw the
base to the case IPhotoN].
Build a drop-proof lid
l
Edge-glue stock for the lid (G) and cut
it to size. Sand the lid to 150 grit, then
rout a profile around it [Drawing 1c].
shank flole.
bottom face, with 'I ... " pilot hole

Joinery options
Instead of dovetails, these versions
of the chest use rabbet joints, rein-
forced with cut nails or screws.
On the ends of the front/back
(A), cut rabbets the same width as
the thickness of the sides (B). Lay
out the fastener locations, then
clamp the front, back, and sides
together. For the cut-nail chest,
drive the nails. For the screw-and-
plug chest, drill counterbores with
shank and pilot holes and drive the
screws. Glue walnut plugs into the
counterbores and sand them flush.
CUT-NAIL JOINERY
::;c ...

W rabbet ./
\4"deep /
-.. -. ., ........
(
1 V>" common standard cut nail

c,
.,...
til x 1)1, " F.H.
wood screw
"'")CUI Ihu'- lid cle .. ts ( m to dll ll
L.."Oufl tcrsunk pilot h(')ies and counter-
bores IDr ... wi ng 1b] and screw the cleats
to Ihe underside of the lid [Drawing 1].
Do nOI use gl ue.
3
Screw the lid-sl;!)' torsioll hinges to
tI1.e lid (G) and ellSt' (AlB) IDrawing 1,
PhotoO). We used tI'O tiO- lb hinges with
J :UI-Ih hinge in the middle. Hott: The
IIl1mlJ,rr n{ InllS6 ''',/lIir ... 1 011 the
,j7(' ./Ild wt'ight Of rOllr liol tor:;;Of!
c,I/rlll.llor pro;'ided uri web sire
(rr)(kier.(lJm) iT needed. Adhere three rub-
ber bumpers to the fronl underside of
the lld SQ they rest on the front (A) when
the lld is cla;ed.
4
Remove the hinges, Ihe
Chesl lo 220 grit , then apply a Illl ish.
We used boi led linseed oil inside and
QUI, then applied twO coals of water-
b3sed polyurethane 10 Ihe outside. If
you won't have a crdar tray In the chest,
you can apply the polyurethane inside
as well.
Add a cedar tray
a chest that stores clQ(hes or blan-
l>elS, con,lder making this tray to sit on
Ihe bottom. "!I.fade from aromatic cedar,
1\ helps ward off moths natural ly-and it
smells great.
1
Cut the (I) and cleat) (Jj to size.
Houl round-overs where shown in
Dr,wing).
2
C1am;> ihe slats (I) and cleats U)
together with the
Drill ("ountersunJ... pilot holes through
the ,,-oct into the slats; then screw
the tray toget her [Drllwlng l ]. Add rub-
ber bumpers to the bottom oi the cleats
to Ilit the tray oif the bottom oi the case.
Do not apply a finish to the tr<ly '>0 the
"roma of the cedar ("al) fi JI thl'chl'st .
Materials List
Traditional American
,

""
IS\->" .. -
'M
B
''''
,-
15)0"
,,-
'"
C-
.... ,"""""" .-
,-
45:4'

0-
.... -
.-
,-
19,.

E
",."""" .-
,-
,.
M
,
""-
17\<'
43"'-

G id lO" 19)0"
4S""
"'
"
lid citalS W
, - \41<."

,
,
,
,
"
... "
, ....
\10" 110" 42" N: 6
"'. 2"'- 16' N: 3
Mat ""I" I. key.
/' -<vomaf't: wttr.
Suppll .. : Sp<..,. odh",,",,,,, ISxW" Ratheod WO(lod
screws (30; ti6 If buildi ng opt ional nay), J8:<1 ,,"
flathead wood screws (9).'11" bumpers
(3; 7 if build,n.g opt,onal tray).
f<w cut ... l Add l);' cornmonsUnd.rdo,.c
-"" F. , "'_II nd-P"g )oInery: Add l20l .8><1 )''-
f\aI:hekI '-'OOd!(reon, \1, . wairoJtplugsUOi.
Bib: lormn "9""bit for T<aditoONl AmelOAffie<t
\1,' ,oo..nd-c)lttf bot lor Comity fw..h cht-sl.4S' chamf"
bltio! c.su"t W rouod-<:Wf bit 10,
optional !T3y.
Sources
Tonlon hl"!!u: 604b.11k1arj no. 21171
(padtd 21. S3799: D-Ib. hdWo\V hll1Qe (1) 1"IQ.28B14 [pod:
c:I. 11 $19.99.1loc.de<, 800279-4441. rod.Ieo.com.
e", n.ll f! I." (l)mI1"OO mIOdd(2Ol no 4 It 1bJ.
S 725, T.tmOnl Nai, 800-8350121, tremonIn.JOI.<Dm.
Wilinut plugl::;O' ftt(top l2Q) 2087S [p.Jd '" 5lll.
SH9, Roo:X1e<
Cutting Diagram
Materials List
CasualContenlporary
Chest
,," , I
c...... I \\ I
,
ft"Or1ti'bad<
"
IS"'" .. -
"
B ....
,- 15)4"
,,-
"
C" bMe fronllback
,-,,-
W
0-
......
Jr.' 19!4" W
E
... -
.-
,-
T

,

.. lH," F
G
'"
,' 1914" 4510\" e.
"

,- ,-
14""- W
,
"
'p, rt1 I!y See the ""'ructions. kid d""effi"""
,","'fft<tnt /r(rYI TruOl">!ll AJAa'lCincht>!.
Mllt .... l. lIey' EA-<.-dge-gbd<>lh,
BP-bod"lplywood; EW-edge-glued ....
Materials List
Country Fresh Chest
, . \ . '\'"
C"." T ,\ I .:' "
,

". 15111"
..-
" ,
.'"
,-
IS""
.,-
"
C"
bMt f,OI"It/bd: ..
,- 45',,-

0-
.... "'"
,- ,-

E
... -.
,-
..
,.
,

,-
17\'." 43i!1" ..
G
.,
.. 1901'" 4S","
"
"
lidcieau
,- ,-
14""
,
,
..
,

,,,,4i!lEterI11'CIII cIwst.
1<*1' l'--edge-qlued pine P-pone;lI'-borrh
-.
- - - - -
w,IHen by ClIllg R"eg.eH " with brin
P'OIKt deoig" Kevin Bor' .
Ito.a .... e h Moh.t. ,.,..." .. Johnoo"
MORE RESOURCES
FR[[ VIDEO
C\ao'l'll..,.,dSand P1Jrw!If\at" at ,
R(LAnD ARTICLE
""8uId lOO5)
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36
Q Q Q Q Q Q
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'I< x 24. 4lI" II"ch pfywood
WOOD m .. g .. Novemt>er 20()9
*:: How to' get the" perfett HoUday gut ...
tEventissue ol;WOOD' 'Magazine
ooOVD-ROM! 'y ,
Step 1: Fold magazine back on Step 2 ~ Postlon magazine where Step 3: Act surprised about
itself, this page up, as shown. your significant other can't miss it . receiving your ultimate Holiday gift!
25 years of WOOD on 5 BIG volumes -
every issue, every project, every tip,
technique, and tool review.
Get one-get 'em all-for illS little as $29.95 each!
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S
O your through dO\'f'\;ai! ilg only
a("("('pts boards up to 12" WI(\t>. T h ll
dot'sll.'\ lOl"an you can't u ' it h) CIlI
joi nts in palWls as wldc h )OU CHe \0
make. Simply the \.:mpl<lte from the
rt"$\rk-\lom of thl.' Jtg b.UE' and take 11 to
the panels. Herc's how.
Setting up
You'll need !WI) tOuters: onl:' for the dove-
tail bit and one for Ille stra!ght hit !hilt
cuts t he pins. ThiS S\\'itchillg
bits in ,wd out (Jf <lI'te [,)1.11('[ .. net {L'sct
tin g bit hl'lght5. Also PtL'P.lIC two tl'st
boards the sam.' Width and thkknl-S\ as
your project part', You'll ('lLt dovetails on
Oll\' Ithe tail board) and pins 011 tho: otl1.;r
(the pill hoard)
RelllO\'O;' tht: through don;tall Icrllplate
from the jig .1nd rcmO'lt' dny )tops or
br,lckcts. tt lakc> IWi) 'p.1Cf'r bloch ,.\lout
.lS long the tcmplatf', 3" wide, and
thick .>!laugh to !::<tcnd It:" Into $1015
on both edges of ellc H:mplalc. on ....
bind. 10 Ihe unlierslde of Ih{- tC"llIplalc
and 5<"1 thl:' <>IhC'r ... for ut.w.
38
a oo-.elinl: on Ihe inside fact- of
Ihe tail hoor(\ by sean(\ing ehe pi n b()..lrd
on end, flu.a with thl: end and edg ... of
tht tall board. Scribe tr.... pin
thickne .. on the tail board.
Clamp tal' test board. \0 opposll ...
sides of the spacer block, with thtlr
"
"
,
Sp".e r
blo.k
"
Inside fa(\') out , :lUd tlghl to the under"
of t h .... l .... mplae .... [Photo AI. Turn the
asst.-mbly h.' mp!.lt .... side up, pi1\(\' t he
olhN "P.1C\'f h.:twt1.'n Ilx' pand., t hen
clamp this ,nst:moly in l vj.,e or 10 Ihe
trollt of your I.)o..'!lch with till lail lxloard
t,lclng you [Photo81
clamped to your
ri ser-bkKk things

,
11 1
)

bou d
the I(l.il" Then sel each bit ,0 the pins and
tails st,md proud of the panels. Sand them flush "fter assembly.
the router only into slots above marh. Rout slowly enough 10
reduce chip-out but nol so slowly that the wood burns.
Mark pi ns for removal. Those across from a tailg,,! an "X," leave any
pin directly across from a space between tails.
After repositioning the template and clamping the panels tot he
spacer, lay out the remaini ng dovetail cuts.
I\ow marl:: with an the matt'r;al
you intend to rout away. For variahly
spaced dovetails, such as those on the
blanket chest on prl.s;f 30, don't rout in
each dovet ail slot. For the blanket chest's
15;'-wide panels, for example, we
IIJJfked below the first two slots, then
skipped one and marked below the
fourth slot IPhoto C], skipped two more
and marked below the seventh, then
skipped three to mark below the
enth slot.
Finally, set the bit in each rOLJ h'r to cut
VJ2' below the baseline on the tail board
[Photo Cj .
Cutting the joint
Rout tht:' tails first lPhotoDj. Then
routers and cut into every slot on the pin
side of t he template. Especially when
routing the pins. keep the router flat on
the template. Tipping creates an uneven
edge between the pins.
Loosen the upper clamps and slide the
template dOlVn to center the newly cut
pins in the slots IPhotoEj . (You may need
to tap the block with a mallet to
woodm"g.ozine.com
slide the template.) Mark the pins across
from a t'lll. Clamp the panels and spacer
again, making sure the boards are snug
against the template and that their edges
are fl ush; then rout away t he marked
pins. Depending on the jig, this may
leave a small you can snap off, or
you can slide the template again for fur-
ther cleanup with the router.
With the pins cleaned up, loosen t he
upper clamps again and slide the tem-
plate so the unrouted edge of the tail
board splits a slot in the template [Photo
Fl . Make mark'> to complete your tail
layout. (For our panels, that wa,; just one
Then repeat the routing process to
complete the joint.
Fine-tuning the fit
Assemble the joint if you can. To dial in
a perfect fit, mow the template forward
or backward on the spacer. For a too-
tight joint, shift the telllplate toward the
tall side of the spacer. For a too-loose
jOint, move the template toward the pin
side. Cut the ends off your test boards
and try again until you get a snug fit.
After t he test joint fits properly, rout
joints on your project parts. Remember
that you rout opposite corner on
each end of the jig: With the tail side of
the jig facing you, the front left and back
right joints start on the left end of t he
jig. The front right and back left start on
the right end. (This pub the dovetails
on the front and hack panels_) Before
routing your project pieces, damp them
together and label each piece and corner
so you keep them straight. .
Wriu. n by Cr .. ig Ruegsegge r WI\h Kevin Hoyle
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See tl";. tedll1lque in .l<tiorl
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"Dovetail Showdown: Man V5. Mocrone" F,oo 001
,t '1', faster dovetilil, by hand ()( w lh d
rooter dnd)g ,( woOOmagJZine.com/dtvidro
RELATED ARTICLE
"Through-Dovetail J,g,Under$3SO: issue 175
(Mi\I'ch 2007) $
($ =DowI1k>3d 11-0, ,md. Nom /0,
..-noll fo._ Typ< "\r.ough 00."" , " i" \Oe ", .. ct. boJ:.1
39
-'
.-
-. ,.

.. ,
N
o matter wooo, the cost pef
bwrd foot goes up for every
mill ing Stl'P performed by your
lumbo.'f supplier. Straight.hnt' rip one
edge (SUUE)? i\dd l Surlacc oolh
(SZS)? Cr:lnk UI) \ 11,.\ pr iet', Surfa(c
fOllr sh.lcs tS4S}! You had Ix>rh,r be roll -
Ing In dougll.
L!y the time fully ml!h:d wood \Jidcs
Into home-ccnte-r lumber bIn (af ter
being individual!y tagged. ,hrink-
wrapp..'<1 . and pallt'l lzed), the COst ha,
skyrockett'd. WOf\<:, If tho.:' y,' lhk!;'
hO.1ld or even you
can', mill oul the def('Ct wIthout going
hdow }t', That' s why If polys to i ntercept
wood as carly as possIble In th" milli ng
prOCeSS, from either a local sawmlll or
and mill it your'i<!l l .
Do I need both
a jOinter and planer?
[n a word: "es. Thuugh tllcy remove
wood 1 n Similar ways, <'"lell tool provides
only tlll l!" of t h e milli ng L'quatioll . First
you Olle face of the 011 t he
lolnkr. Next, With the flat fat", pressed
the joi nter len<:'1:!, an adja-
celli t'dge. And finally, JUdi-;e the oppo-
lace p:ual1d to Ihe first usi ng a
plall('r. A few pass ... s \\'111 n.'du(e the
board to a uniform
Skip- pl ..
Sawmills eoitMr . oughsawn o. skip-
plane-d Skip-p/ar>l!d boards giV1.'YOU
.. dll!Me. picture of a board'. colo
WOOD mll911d" " N,"",,,"\I>f,2009
A case study: Banking "bread" while building blanket chests
Homea'nlL'f ( Oli\ Luml>cr yard cost of profect$ below break-even-
(rough. sawn)
5197.52
$'lii_,-\'J $JOl.n
SUO.05 SSI:US
,) 4:U3
C05tfOf 501id-wood part5 to build the Blanket Chest project on page 30. We placed the savings against a Delta 6" benchtop jointer ($240 at
lowes.com) and a Ryobi 13" benchtop planer ($200) at a total cost of $440 at the time of writing.
But ca n I afford t hem?
Again, yes. L{'t's walk tluotlgh the math.
We'll use t he Blanket Chest on pagr 30.
an example, because it is a medium-
Size project constructed primarily of
solid wood.
For an apples-Ia.apples comparison,
we priced only the primary, solid-wood
parts, not the plywood, hardware,
optional cedar tray, and any hidden
pmts that can be made out of scrap
woods or offcuts.
Because home centers typically sell
wood in common size>, we
came up with a hy-the-board shopping
list to pit agam>t our hy-the-hoard-foot
lumberyJld order, at ri:.;ht, abnve. \Ve also
added a generous 25 pdcent to the lum-
beryard order to account for waste in the
milling proceSS.
Then we priced several species of lum-
ber at a local home center and a local
A planer lets you thickness lumber t o the
needs of tile project rather than conforming
the project to OVer- Or undersize lumber.
w<><>d",agnlne.com
..... et dMtt Ihopping Iltu._.
Ho ... Cpt..,
8pc 1 .. 6 .. 72'
4pc
4pc 1><6><48'


roughsawn
Instead of pre-dimenSIoned lumber, you'll
buy by the board foot at the lumberyard.
Board feel is thelhicknessxlenglhxwldlh in
Inches divided by 144.
lumberyard. The "Case St udy" chart,
top, shows the cost differences in red
o<ik, ml'ple, <ind pine. Remarkably, the
lumberyard oak cost 11'55 than half as
much as home-center oak. Ruild only
about fOUl projects this size and you'll
save enough lumber money to buy an
entry-level jointer ,md planer.
Besides saving you money, shopping
at a lumberyard opens up new species
possibilities. For example, you could
upgrade to rough-sawn mahogany from
a home center's premium-priced red oak
and still save $29.22 per chest. The ash/
walnut comhination descrihed in the
plans costs $107.62 less per chest than
home-center oak.
And if you fed like adding in the
optional cedar tray, don't count on find-
ing pr.:surfaced aromatic eastern red
cedar in a home center. For presurfaced
material, you're likely limited to mail-
order sources which will add $27 per
blJnket ch.:st oYer rough-sawn aromatic
cedar from a lumberyard.
Enough math. Time to shop!
For our cost comparison, we priced the
Ddta 6" henchtop jointer (model jT160,
$240, 800-223-7278, deltJportercable .
com) and the Ryobi 13' benchtop planer
(model APUm, $200, 800-525-2579,
ryobitools.com). These entry models will
>erve you well. But spending a little
more here can pay big dividends.
For example, stationary jointers' lon-
ger, heavier infeed/outfeed tJbles
improve accuracy and control on long
workpieces. Both the infeed and outfeed
tables adjust for fine-tuning the cut. And
their more-powerful induction motors
last longer than the noisy universal
motors on their benchtop counterparts.
Pricier, sure. But if you're going to he
milling the Jmount of lumber thJt
demands such a machine, you'll find it
for itself in due time as wdl.
Now leave this article lying som.:place
where your home's hudg.:! maker will >1'1.'
it. (Sorry, you're on your own for that
motorcycle you've had your eye on.)
Written by Lucas Peters with Jeff Mer tz
MORE RESOURCES
FREE VIDEO
'"Prepptlg Slock with" ..Iointer .rid Planer"" at
wood mag"" rte.cQrTh',\ockprepvid
FREE PLANS
.io<m:er knifeodjustment jig. jointe<
auxiliary pl.lner bed, <'dgepl.lningJigl, and mOfe
at wood .)mljoi nti n 9
RELATED ARTICLES
"Nofa" Routinel for Jointing Id Pl.lning:
issue 189 (March lO(9) $
'T roublesl1oolJng ..IoIMIS"
168 (Feb.lMar. 2006) $
"Get the Moltfrom Your Planer""
173 (Noo;.1OO/il $
41
Takes-a-Beating, Budget-Friendly
Workhenc
This weekend, build a
workbench that's big
enough to hold furniture
projects, yet portable
enough to tuck away.
.,.
W
ee! this bench into action
fa,,>!. A pair of legs adjust to suit
uneven floors, while dual
locking casters keep the other end from
budging. And you can do it all for around
$125 in materials and hardware.
Make the case and frame
42
1
Cut the sides (A), shelf and bottom
(B), and top cleats (C) to size [Materi-
als List. pr.We 441. Drill shank holes where
shown on the bottom. (I'm tile #8 screws
in this project, drill Y'l' shank holes.)
PROJECT HIGHLIGHTS
Overall 57' wTde x 28"
deep x 36" high.
Materials needed: Pine dimensional
lumber and birch plywood, both
available at home (ellter,.
Pocket hole screws make the face
frames easy to assemble.
Benchtop overhangs let you install a
vise later.
Squaring clamped tathe
upside down) during glue-up keep the sides
(AI perpendkulartathe bottom (B).
2
With a dado hlade as wide as the
plywood cut a dado on
the inside face of (;'ach ,'>id(;' (AJ [Drawing
1J. Add an auxiliary fence to your rip
fence and cut the rabbets in th(;' sid(;'s.
3
sand the side,,> (A) and the shelf and
bottom (B) to 180 grit. Glue and
clamp them [Photo A].
4
Drill }1." mounting holes in the top
cleats (C) where shown [Drawing 11.
Then glue and clamp them to the sides
(Al using ,>quaring
5
Cut to Sill' the face-frame stiles Wj,
top rails (E). and bottom and middle
rails (F). Drill pocket holes on the ends
of the top and bottom rails. Then glue
and screw the frames on a flat SUI face
[Photo BI. After the glue dries. glue and
screw the middle raih in place.
6
sand the frames to t80 grit. Then
glue and clamp them to the case
with the stiles fJush with the sides (Al
and the raiJs flush with the bottom (B)
and top cleats (C).
Now add the feet
1
Measure the caster height, then rip
the foot (G) to that width and cut it
WOOD magazine 2009

;.
-..,
I 5" '- --
J
1m'
,
1
".
J
20',"
('
!to " washer
\100 ]" < .. "iag@boh
;;'" rubbe< k.>g tip_ A
ASSEMBLY DETAIL
O x 3"
carriage bolt
Location of@
t-
'1" (O<.Iflte<bof('
",' deep with a hole
2" det'l) if's.dc
I

rill void with

"'" ,ubt>e<legtlp
Clamp the (E. F) and Stll"'5 (DJ whil .. driving the
pocket S(lews. A clamp on t op of the Join! holds the plecei flush.
10 lengt h !MMerials list l_ CUi the foot
br3C('\ (H) and CJSle r support II) In
2
u* a jigSdw or oondsaw to CUI the
foot (G) to shape; sand '1Ui);)\ t\
[Orawlng 2). Dnll l' cQuntcrborCi a nd
}i.' ha l.:>, where shown. Seat the T-nuts In
countcrbnres.
3
Glue and suew the n)ot braces (HJ tn
the foot (G). Glue and damp the r(\('lt
aS$ClIlbly (GIH) to the c,]sc, \eavillA a :y..-
["(>\"eal. Glue and screw the caster
( I) to) the C"d!oe where shown.
Top it off with 2 x4s
1
Cut to lengt h 16 2)oo "s for the
top 0). l'lane both faces of ('.leI! for
gluing Then IOlnt or
rip aile edge of each to r('move the
round-overs and rip thl"ll to width t(l
remove the opposltl' rO\lnd-overs.
Qu;ck Tipf MtWI: f ast er than t he IS)
wood. Construction lumber typically ij'
contains more than Id!tldned
hardwoods, alld machining can release
new stresses ill t he wood fremly
exposed d ry out. Allow t he
wood at lea$t 1 IV" days 10 acclimate to
your shop. but gill e the top together
immediatel y aft er pl aning and ripping
th" wood to limit movement problems.
41
""Make %,.2,, 12" l1:m1wood cauls 10
Control stock during glue-up. Place
wax paper between the and top 0).
Then glue ,lilt! d amp l iIe lop In two
groups of eight bo.lrds {PhotOi C and DI .
and rcmO\"c squce:I'.( oul Ix'fore 1\ drles.
3
Mter the glu(' dries, pia lie \>o\ h faces
of t>oth hal\'('S 10 the same
Depending 011 t he fI.lwS in Ihe lumber.
t his can be from 1" h) \h ld;. Wille
surface flaw:. mar n('oo to be fil led with
epoxy, as sho"l1 In the Shop Tip b('/ol" .
A Glue and clamp t he top (l J hal\es
""'ttogether. S3lld the hal\b fl ush Oil
the 1<)1' and ends to 180 gflt. Then rout
v." rouml-overs along Ihe edges
You're on a roll
ctamp$
l
l'illlsh-sand any rClI1allling spots 1<)
180 grll and apply a finish. (We U)ed
I IVO coalS of ollbased wif>c-on varnish.)
Drill and )Clt'W the 10 t he caster
suppor t (I) about I/;' In from t'arh end.
rubber leg ti(h. Fill the area around the
bolt heads with caul k 1<) h,)ld
the on the belli After the
caulk curb, imert the levelers halfway
into the T-nuts in the foot (G).
through IllC lop dcals (C) m,mnting
holes Into I he lop Now wheel your new
bfmch 10 I he cent er of yOUT shop and put
it t o work .
by Bo b WII,,,,, with Jell Me rtz
2
l\lilke two levelers by placing the
of ,",,), ca rr iage bulb into W 3
Center the top Ul on the case. Drill
and drive lag screws and washers
PrOIKI des"Jn, Oal . ra"lnlch, Sequim, Wash
Illull,alior\S, R" .... nne Le Moi ne , Lor na Johnson
44
Patching \'olds in the 2 ....4 top (ollis fOf
a tough filer. a disposable
spreader by sandin9 a bevel on a
hardboard scrap. Then ml)l Smlnule
epo>eyand force it into Ihe VOids until
they're r Ued. Afler lhe epo"'y hardens
overn ghl, sand t flush with the top.
Cutting Diagram
._-
--
' 48 x gc" S'lCh plywood
( bI! II)
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PI<r'II foI a SqUoIIt'I9 a t
"l 'br .e
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"'I'IQIImogm '''''' ",",U;.en(hpI.1m
FIiIIten ... unevtnbenr:IIIq>.oI
-...:;IQd
Materials List
., t . ,
r .. rt
,
"'"
,
sl1e1ffoou om
C ... ts
0
F
mi
,
"


_top
W" JOW 27' 8P 1
20W 81' 2
j"'W ,

11':1" 4Y,"' 28'
\1':1" 3"
III 4' 28'
3'. 24" 57" LP
k<l)': iIP- budl plywood, !'-plne,
po ......
SuppMII1: rS>< ,Wtt.rheild f8><lY>'
fI!W'- lOx)" ("' I;MJI! boIIl (2).
sc/pws(4L \QeWS (8). I\' T .MlhQ),
\I.. w;lsllers J8J, V. 'endef"",1he<s 141 . )" douOk> to.:lung
Ul-Irl'1(2l. Jr.' nbbe< leg lOp' C2I.
5m,n\.WquKk-teUepoI(y.
8 1..0. altd btu; d;w;iOJel ' Fo;:nlneJ bit "" ,0\.0fId.
ow. b\I, pochethoIe Jig and bit

-- 1 14" I\oIe
IIASE HOI.DA
f Ull-StZE
PATTERN
'"
Bud Vase
Page 28
""",,","
patlems on thos insert lor irregular-shaped lind
proiecI parts.. You can mac" ine all 01"" pr.,;.et p*rta ' '''roo
Ihe Malerials and t he d raWIngs a.ccompanying tho proj_
ecl you're building.
.. Copyrigl>t ..... _hCorpor ......... 100\1 All 'i9M' ,.,., .... 'M,.d
,h. U.S A, """,,di,h C"'P. 'h< ""bhh<' 01 WOOD , .. .., ... ,
, flo <II 'Ii" 1'"", .. n iMt '0 pholo<"1')' , .... "",lOt"' """I)- lor
f'<"'""", 1 ow. """' "'...,. ' "I"ooun"", <I , ..... pot,..,.m. ",inl)- prot1it:N,,,.;,
JIB PISTON
e ......... FULL-SIZE PATTERN @

I
"
shank 001<>,
Yo" ,ound-ow"

1'4"

'1. 001<>
@
ENGINE COVER
FUll-SIZE PATTERN
"
o
,

I
, '
I
WHEElSPACER ___
'I, . CB FUll-SIZE 0- \.!J
"""
,
""
\.VBOOM PIVOT
FULL-SIZE PATTERN
11 needed)
1"<"
Excavator
Page 62
I
PATTERN to',
t:'. __
e JIB lEVER 0 .... ---'"""
4 FULL-SIZE PATTERN
" ,
r----', -- -------1
CAB
FUll-SIZE PATTERN
WHEEL COVER
<
2'1>"
BUCKETSIDE
FULL-SIZE
PATTERN
J2 needed)
FULL-SIZE PATTERN (0:, " / I

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%'"holes
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Excavat or
Page 62

BOOM SIDE
FULL-SIZE
PATTERN
f2 needed)
"
COUNTRY-FRESH BLANKET CHEST BASE
FULL-SIZE END PATTERN
.@
Blanket Chest
Page 30
TRADITIONAL AMERICAN BLANKET CHEST BASE
FULL-SIZE END PATTERN
.@
\
CASUAL CONTEMPORARY I
BLANKET CHEST BASE
FULL-SIZE END PATTERN
.@
,
Cabinel Restoralion
Ship Shape Shop
Hand Tool Rodeo
Finishing Seminar
and mom!
Top Educators featuring
D1Y'ERS!
Toolsto
Education
Techniques
10/23 - 10/25 Dallas
10130 - 1111 Costa Mesa
11/6 - 1118 Portland
11/13-1/115 Sacramento
11/20 - J 1122 Dentler
12/4 - 12/6 51., Paul
12111- 121l] Chicago
Jim Heavey of WOOD Magazine
VISIT nn:WOODWORKINGSHOWS.(OM FOR TlrnTS, COI\U'LHE CLASS & V E N D O I ~ INtO
U
1l1l'!>S}'ou'r(' m.1l.:Ulg II\,UIY Jll\Ilti
pIes ot prOj<X1 P.l tIS. it allllO:1
alwap lal..es Ie.nger to S(-t up for a
cut than It 10 actually roul t he
worJ..pi{'('('. fonunatcly, ()\'N tile- y<."ars
we'w discovered shortcuts to lI1aM> IIIOSt
St' 1lIP<; a breen'
,
'&'Shim your fence for disappearing edges
}Vhell lOuting ({'rtain t"dgl' on yOU! louter table, such thl" door lip
shown IIlly),y, the bit removes coough stoc k t hat tile profilw ("{lSi.' no longC"! bears
against the oulfeed fe nce. In these shim the olll /cell fence-we atlactll'd
j..\z-thick plastic la lllinai r wilh double-faced 1"1)('-10 prOViul' a bt'anng surfaa'
lor t he workpi("<:(' lx'yond the bit. Without this, you'll ('nd lip c ulling a snipr li ....
gnugl' whell t he ed
b
'{' clears the mlttd ferIC':-,
Add a temporary depth stop ...
,) ,'Ioutel bIt hIts II)(' bottom 01 the rollct , you can't tighten it fully, creat-
i.ng t he potent Ial for till' bit Ie:> fly Qut lI\ USl.'. And wit h some routers It's
difficult to hold the bit 3tt hl:' correct depth whill' simultanl'ously tighten-
ing the coliN nut. To prevent this, slip J snug-fitling O-ring onto Ihe bit
shnnk to holl! it lI\ pin(\' whi le yOLl tighten the nut. You could nlso drop n
small ruhber grommet Into the splndtl' to prevent hits from hottoming out.
\Vhen you t ighten t he nut tIl<;' ruhber wil l flex as the hit shank draws against
It. (You'l l find and grommets at Il"k)st hardwar e stores.)
Trim only what you need
'f1U$.h trimming sol id-wood .J/l lng on Ve llcl'rw plywooJ 01 is a
Rood job for a tr im rOUI"r bct-ause o f lU Sllia U and low celllcr o f
gral'ity. Bul ewn if you uSC a milhll.l' rOilIer, $('1 Ihc Ix'aring depl h o f
Ihe flush-trim hIt just hel&.> th<- l"lge 10 lX' 11;11111100 . 111is way, if you
accidentally lip thc lo uter, you won', c uI ill to l il( plywood's WIU'(r
And when trimming away OOglllg, roul in l climbcul d ll1."Clio ll, right
10 I<' ft in th is t':>.all1pl", to aVOid t<>arlng Otlt grain o n the ","ODd edging.
Save wear and tear and get cleaner cuts with incremental routing
When I"lOMiblt', trim away e'(cess materia l from your worLp,l!(\!S !It the ...
or bandsaw befort' rout Ing. rraee the profile of t he bit onto your
to prevent oven;:\ltting, as s!l(]wn, Whether you're routing an edge proflle, slid-
In.g d(IVl!tail, or any other task t hat rcmoW's a good bit of wood, doin.g this will
you tIme, wear on your bits a nd router motor. and a pile of shavings.

-"'"
, <II1II For a surfac ... , alway-;;
It-ave a t iny JfIlount-lW" should
do II-for a ti na! rolll ing pass to
r" mm"\! burn , )( chan",,! marks.
On a router table, b.dol'C making
the cut, apply tare to
the workpiece or router-
table fe nce. as (t wo layer\
if the tape ultra-thin). Before
the tinal pass, re move the tape
for a whlsLer-thin shave. For
handheld wnr],;, adhere Iwo or
three bmil wss to your
rout ... r's for tlle majority
of t he romlng, and t hen remove
t hem prior to t h(' fi nal pass .
... Rather than adjust the bit's heighl )"ou rernov\' matenal
to I h ... exact height from t il\' sla rt and use
remo\ .. bll' shI ms on the IJ bl"" surface. Slack I,lyers of %" hard-
board or plywood on the table using rlouble-fa':L'<I tap." with
cutout s .. round Ill" bit, and then remove <lll e la" ,' r Jtlt" each
pass. This proves l's[lCCial ly helpful if "our (II muter lift
is fussy to tIne- tune Ix'cause YOIl set \t onc(.' ,Hld locI:. It in .

51
Achieve dead-on measurements
without a ruler
Use lTlachin.::d .-": 1111' b,I I' , typkal ly \old i n kih ..
fn ml W<' to 1/.0' 111 h) set bIt depths wil h dcad-on
p n..'Cis.ion. ('xamplC', wh('u usi ng a longUC"-and-gruovc-
bil sct onY,"-lhi( k slod., Sl'I tht groove Culll"l Yo. h.)m I he
subbase ur Illblc surflla." a.\ \ Iwwn at rh"n rout tht,
longu(" to fit I he &I"<-o\e
\iliOn Mtup ban' Pilrt ' 1"-4932, $IS. WoIxIcr.lt. soo-nSllS} orwoodaaft.com .
-
.... Mler perfe('Ung a CS!X'ci311y for mating Iwo-bit "<'I ups,
!i1J(:h as (ope-amJ-\tid.: m IOngll ('-a nd-,l:rlIO.We bits (shown). keep
a pIece of lest st()(; k I rOl1l ('ncll bl\ III lise gauge bi!l(k\ for quick
sC"tup on fUlure jobs.
W him ruutl ng Ihrough 0 11 a rou ler jig, liS{' r01l1
aClual to accurate'ly )(' 1 Ihe bil 's ctll iing dept h. Erst,
tape a <,f WI,t!' onto t h,' fa C(" o[ Ihe w,"kpi<:cc that will
mall" wllh lh(' (.n('p.u'li (('UI, lelling II extend I' OT >,0 tT.,m the
em\ of the \\,orkpi('C\' /'lexl, sel I he router in position on the jig's
tempirM with 111(' 1.>11 lighlt' IWd Itl the cuilet. Lower the bit until
It tlllK;h(>\ the- scrap P1('((' lor <l dead-on setting. If you prefer to
make tails Jnd pin' J liltl.; pwud to lie trimJlled alter
.'Imply ll,w.;r the bIt anulher one-eighth 111m of the
router's d<..pth.adjustmcllt dial, and then lock the wukr's base .
-,
J._
,
.... . 'tnylime- you' re hitlh'<' mortises, unl uld the
hlllies and Si:: t Ih.:: ,)nIO onc IClf 01 elch. rhcl1
luwer the b\t unti l it tuuch,') Ih(' be- Ilchwp 1m the
deplh 101 Iho...:: 11 1118e.\.
Fine-tune settings for spot-on precision
]'I)\.' PIP l>rtween the bit and opening In the Touter's base ....
makes it d illicult to 3C\."llfatcly set a bit's depth by
a steel m\e on end. insted.d, use a rule with scales
md.rl;cd \'ertkally on the ends, preferably in Y.l.l' increme nt s.
Sttel,u1ts:6" p;lrt mJ94, S12; 1J" r .... S2O; li.lrlvifie Tool. soo.34S2196
or
.... M<llly of hxlay's routers come with a cent C' ring conC', used to
center subbase to the spindle. An exactly centefC'd bll proves
critical for joiner>' tasks that Involve gUide bushlngs, such <IS
dovetails or hox joints. Without being centered, your joints "I'Iill
likely not fit perfectly. If your router didn't come wllh a centering
cone, get an aftermarkC' t one for less thd n SIO.
Routerunttfl"'ll ,_ part 1AA1I5o. S6. Tool Bio,n,966-59738S0or tooilarlU"Otn.
To p<l\ition J routC'r-tabl.e ten,e flush with a bit's ...
bearing oc a p.lrticular point on a bit's pro!lle, get it
d oll\.' Ily eyeballing It, and lhf'n down one
eml of the fence. Holding a steel rule against both
fl.' lKC laces. pivot Ihl.' Joosc. (.Il(j until the rule hi lS the
fUJr!.. you want. Ih ... orhcr e nd of the fence
"hcli the infeed Jltd outfC1.-d tJ.c.es line up l'Iith your
r<.'8mr.l!ioll point on the bit
When fl ue tuning a bit's h ... ight wit h .I n
,Kljuslmeul lool, sudl as th ... on ... shown iK' r<', mJ.kc;! penCil mark
on til ... <tnd line 1t up with the scdk's Z{'rO rderenU'. Now
when maktng fine .tdlusnncnts up ordown you will dlw,IY' !..now
where you hegan, to avoid overshooting the startlng pOint should
you have to tJ"ck up .
by lIo b Hunt. r with Ke vin Royle ",)<j l eft Me,l.
53
M
"rho: you '\ lim" in a
bottle, lJut }OU ran bullo
beautiful d oc\.. to t rOld; its
SJgc. Dreo-s up a 5implc mitered (3<.0.: \\ lth
a few thcn i nstall
ilil lnexpensw", clod.
\\'OI'ks. (See Soureli' on ("1S'- 5"_11,'5 a 8, ,,01 1
way to pallS a few hour51n the shop_
Build a case for the face
1
Cut the Iront t,\) and lit) to
IMlltefi.ls US" {'o'.<'- $6, DrAW-
ing 1l. \\ith the hlade t illed t<. -i5,
rip both of the frollllo bring it to
finished width. Then bevel rip o!le edge
01 o;;Jch side tofinisheJ width. Rout ,\ v."
rabbet on the oppositt' edge of the sides,
2
Lay om on Ihe front IAI lhe hole for
the clod. Illo\"t'menl [Draw-
ing l J Dri ll a st arter hole Inside the lilY-
OUi l i ne and cut just imide the li ne wi l h
a ji,.:SilW or sc:rollS3w. SanJ up to the line
\\'i l h il d rum 5.amler, testing t he l it 01 t he
clock mOH' ment as you YJ.
Notli': To) lI1t1illlmn a fit. ,for, 't I'rt"iS ill
til,' "/{II tlm'tIl
AT A GLANCE
Stack router-made profil es to
create attractive moldings .
a set.it-and-forget-it
press- in clock movement.
Another option: Redwood burl
m.1Ikes striking timepiece.
3
/\ssemble the front (AI sides (S)
[Photo AJ. Afler the glue dries, finish-
.sJfK\ the case (AIR] to 22U grit. presen ing
the Shdfl) cOIners at the edges and ends
Time to make moldings
1
Cut the top and bottom (Cl, (ove
molding (D), ( ,)p IE), l1') n.:lle block
(Fl, :a nd 00 ..... IGI to Sef the oos.:
asilk (("or tht' 1ll0melli.
2
Qlllclt Tip! Hout l'IIds, ,1I1'11 -(S)
Wilen routing profiles, rout V
,)(1&.,5 an e nd lint and l>ack up the ( ut
Wlf h J ph..'\.c ("of >Clap IPhotoS]. Any (: h ip"
out gl"l s fl",l!led up when routi ng
It},l !; edge, Rout it" coves on
IhfL'(> sides OJ Ille top ami bottom (e)
ami ':(lW ,noMlng (D), If'aving the bock
Mluare [Drawing 2. Photo 81 . Change
to a Yl" Ivunu-("'cr bit Jnd ront the ends
:lnu of t he caplE). set up a
Vi' core boK Ili t 1'1" abow thi' table and
rout ,I gn)<we JrQund .111 fOUl" cdgt:'s of
til(' tw)(lIl' [>Iuc\.. (F) lPhotoC].
3
A' tilt' t'lbli'SJ\\', trim Yo' from the
lowl'r and of the handle
bl<K\.. (1- ) 10 .-wlng 2, Photo oJ. Back at
roUle' l 1,lble, rout a \1' round-ove l on
0\ the blocl's lop edge
[Photo ' I. Then 10lwr the bit and fli p the
h:mdll' block 10 compltlt the PfO-
file [Dr,wing:!l.
A Retrieve the baS<! IC) and rout %" rab
&of'bl' tS Vt,, deep a round the top <'dge
lo..-win921 Sand t he ui m pieces (C-c"
10110 gil l
,.
I
-l.
5',.' -diam. MOII""'e,,'
woodmagazine.com
board to push ,"" woe.;;;;:;;
and back the CUt , Start with the
bI t low to allow for a final pa".
,
I

,
Tick "a.s.sembly" orr the list
1
On th .. 1<)jJ face of rhe top to, malk
hm"!; I' in from each ,'n<l. Then draw
lmes Oll the hack edge)1' from the ends.
ro<ltion the top on the Cil:...' (AlIl) [Photo
FI, lh .. n drill pilot holes
and screw th .. top In plan.',
"lOnl'" lint's ct'm..red (Ill til .. ruck
L..."'dgl..'S of the top (C) '!lId (on' mold-
11Ig (0 ). Then glue and rI,lmp the ((we
molding to the top with the ct'nterlmes
aligned ,ml! with their hack <"dges flush
[photo GJ. GIlle th .. handlt' block (F) to
the (F), centt"red. WIll'n t h ... glue has
dr1t.>J, drill }II<," holes for ,he handle
th rough Ihe top J,so:mbl} (ElF) IOrawing
2). Th'n drill 'h" count crl)o.)fE"i for t he
hanellc nut5.
3
vslng double-fan'(\ lap<', tempor,H-
Ily celll .. r th .. top assembly (tiFf on
t h" cas(' (A-D). Flip I he as<;cmbly (A-F)
over ano drill two countersunk screw
holE'S [Drawing 2, Photo HI, .. the
tJI>C .1nd dri\'e <crews (don't use glud to
Sl'cu r ... t he Inp

t he Sdm .. lll('l hod dS in Step 1

'C"rl'W the Wtom \l:} to the
55
o
To provide mOre supportforthe handle block
(F) you rout the \'0" round-overs, align the
fence with the bearing of the bit.
El PROFILES
,,," roundov.,,-s
cas' assembly (A-F);
then glue the base (Gl
to t he bottom. Cut the
back (H) to fit betw('en
the rabbets in b,l( k of
t he case and uTili a I"
fi nger-pull hole [Draw-
In91J. Set the back aside
for the moment.
__ ___ ';'"corebox ',,"
I
V>" round-over
with a y",shoukl.... 'It"
cove!
I
'I,"
5
Rcmovc the top
assembly (E/F) and
apply a fini5h to all
parts. (We used boiled
li nseed oil. topped with
a('rosoi pOlyUf(,-
t hanc, sanuingbctwecn
coats with a J20-grit
sanding sponge.)
.. 1
1'>" (Qunt.,,-oore y,"pilot hole"
6
After the finish has
cured, tUTn the clock
'M" deep with countersunk
hole cent",ed
inside
upside' down, drill 'li6" pilot holes for the
f(>('t, and dIivc srcd screws to thr('ad the
holes before driving the brass 5GeWS
[Drawing '1. Secure the handle to the top
assembly (E/F) [Drawing 2], then screw
the top assembly to t he case. Set tile
tillle on t he clock movement, press it
into t he case, then add the back (H) and
turnbuttons. If al! has gone well, you
should finish with time to spare .
Written by Craiy Rueg.egger wilh Jeff Mertz
Pro],,! d.,ign: Ke vin
Roxanne Le MOine; johns!>n
Cutting Diagram
%. 'J1i. x 72"' Cherry 15 bd ft.)
-Plane or re,"w to the thkknesses li,ted in the List.
56
Y,x12xll"
Birch

top IC) It easy t o
during glue- up.
"
front
" " "
,
B'
..
'" "
,
,
top!bottom W
'"
".
,
0 wvemoldill9 W
" '"
,
,
rap .. 3W r
,
,
haroJlebiock ..
,..-
,.'
,
C
,=,
W 5Y4" 9Y4"
,
"
OK'
y,-
",.
"
BB
Materials key: C -cherry; BP-birch plywood.
Suppl lt!s: DoubJe..foced t"pe, t&1" flathead wood
screws .8x1
'
/i" fl.jlheod wood SCrEW\ 12).
Bib: W ,traight. lIi" rOll"id--(l';er, W core--box, yj" r<.>md-
over, lio" cove r<lU(ef bits, \'i", l' dnl bit>.
Source
Hardware kit (ontains: 5:4" -diom. qwr1z clock
nYJVI'meni, br." h"rrle (21<" centers), %<1y," lnss
pedestal teet (4), ond ''''''" (4). Kit no. 26888,
539.99, SOO5,62548, klodut.com.

Free "Online Videos" show you
how to join it, rout it, and clamp it, at. ..
MLCSwood
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OUf Router SpeeJ Control
reduces speed wiThout
redUCing torque! Work at
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and wood. Adjust from 0
RPM to full speed.
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"901Z ' Merle Clamp ............... $ L?95
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T1,e jig, joint templates, clamps, bushings
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"45 Different Cuts"
OUf 45 piece, carbide tipped
Router Bit Set includes straight,
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LN CO><T1C. l ,0\" ' >SA ,0. .cox ,., Dl, M. ,.00. ' >010
I
f you can't brin){ )'oursel f to spend S1200n" tablesaw blade,
we have good n(:ws for you. \Vc tested n ... arly four dozen
rip, crosscut, and mUltipurpose blades-all selling for less
than half that price-and found several Ihd! deliver cut qual-
Ity almost as good as the Jeadillf( premium blades.
Yeah, but exactly how good are they?
There') a rL'ason premIUm-pr iced bla(il's as 1l1uch J.S they
uo; They typically perform flawlessly when paill.'d with <I \\" .... 1-
tuned tabksaw. But if yuu're willing to 100 nt, !.and, 0 1 plant
away light scoring marks on cnd and I\ rain- something
many of do .:lnyway. regardless of 11'1<' blade used-you can
KCt by nicely with the blade) recommended here.
for comparison, we put two proven, premium l-tooth
blades-a Forrt's! Woodworker II and Freud [' rl'mier-Fusion
N IO--through 11'Io;? samlC' paces as the 5ub-S5(1 blades. and they
)01.'\ the standards for what consl:llItes an A grade In each ClIt.
AlthouSh none of tbe lesser-priced blades
board A marks, mor.:: than half delivered Bs or higher.
Key findings
SOlUe blades du il ul1. For most ohhl.' work you'll do with
hardwoods and softwOO<!s. a 40-1001h general-purpose or
TEAR-OUT EVALUATION RATINGS
teottom plywood fac" shown; cuts made without zero durance insert)
. f"
I
.'
f
,
, I.
RATING:
=
= No tearout on top and bottom faces
, = No t .... '-out on topfue. slight tu,out 01'1 bottom face
= little to no tea, outon top face, .Igntfkant teal'out on
bottom fa ce
SO tooth combinat ion blade ddivcrs good to excellent
But sheet goods, as veneered plywood and melamine--
coatl.'CI. p.:uticleboard, require cithl'f a premIum multipurpose
blade or a speCialty blaUl' (So' lIin); for $65 to S90) made just for
thoM! makrials. As evident in the chart on the
m:xl ".ISt', none of the teSted blade, coul d nOS'iCllt birch ply-
wood without tear ing the grain on the unsupported bottom
sidc. HOWC"Cf. rOll can ImprO'o'e the of most of
thcS(' by abom onc I(-Her f(rade si mpl)' by llsl ng a zero-
dearanc". inSCTt on }'OILr
Thin is in. Most 10' blades under SSOcut 0:1 thm kerf mea-
surin); between .IZO' and .090'. The only full -ketf blado' that
carn(>d our approval Is t Amana Prestige PR lU40 (.134", just
OVli'r \4'). Our 1 I-hI' hybrid tablesaw handkd tllat blade with-
out oogglng dovm, but kS5Cc-powered perform best with
onc o f the top- rared Ihinkerf blades.
Thruwaway !k:caus.. sharpeni ng St'(vlces chargi'
dbout $ZO to $35 to rcshaq)(>n a blJde on the nUIll-
Ix'r of teeth and the grind geometry), SOllie woodworko'fs dIS-
j)OSC of t hese blades after th".y occome dull. And tho'
carbide tips tend to be smaller than IhoSt: of premIum blades,
you' II get fewer ,harpenings If you do go that 100ute.
CtJII/irlUe./ on page 60
CUT-SCORING EVALUATION RATINGS
RATING:
=
. of bli>de mlrks; ;o;nr-fudr
'" Blade marks r.-qui,e light sandIng
= Dlade r.qulre heavy sanding
59
THE BESTTABLESAW BLADES UNDER $50
,
" TliltKHAi!OMAPl[ tI<oT!!1(JREDOU


Our recommendations
-
,
o
.\11 the blades in the ch.trt aoov/' pafOrml2l\ well givell their
prICe, but tht! bl.:ld. .. "tWWfl bdl'''' nudh't.'d ahead of the field to
gai n our Top
60

1. Pric!> curree! Jt time of ;WII(II do not ind .. '" >/lipW." 1'111""
Thl' Top Vnlut! honor gc>Cs ILl the GO-hXlth Irwin Classic
l5370. Thi .. CT,}SSCut (,MnNt gr.1ctes of A- or be1\cr in
five of ,i x un! ng II'S .
W"ll.n bv Bob Hunlu wilh 800
1631?
Grips wood, elevates woodworking
Rocl.:leri. new Iknch Cookies arc n-volUliol1 il.ing Ihe w(>{hhop. :dIm. ing fill routing, s,\OJmg ollll! ( "",ins
lYi dlOUf tradi lional ( hlm!_ The .ecH' I) N,m. nurnng rubber P.\Js Ih,,\ pip hoch rho: ]",mch 3JI d
t,lur " MkpILU f,)f wlid holds and !>Ctl.lp. rl us. we've designL-d rhe {knell Cookie 10 Jouhl ..
,\ Plujcd sUPIJO(!. It .,!"v.lres yt)ur work for complt"le acees.' \0 fl'fty eJge f<;lr finJ,lung ami
edge work. Sturdy. Simple and guar,lIuceJ w hdp you Create with Confidence.
.
....:2... I", " . ,,' . 'IlL' h' ROl.-kICI.I.:OIll
AT A GLANCE
dimen.sions:
6" w d," with the bucket
at ground level
Bucket capac'ty:
Appro", .00008 cu. yd. (3.75 cu, 111 .)
Boom reach: 14"
Dig depth: 8'1<"
Erlgine at 1
duly
P
ut this to\' .,nd a pilt 01 01
III front of l lll ili ren and
wa!ch Ihl'm wh,l ... t he time
'.,:oopill..; Jnd them. The
vOl IOr shiilr('S dc,j)(11 ... km ... "'>ilh Ih,;
emllt' in is\ue 1$15 ls.eptl'ml:..:r ZOOS),
page 68 More R,wurus, P<IS' <>5].
62
We start with a bucket,
then boom
1
hom V.I'-t hick sto<:k, cut tile bucket
bottom (A) and hucket back (H) to
[Materials List , pas.: 051. GlUt: the
pieces together with the grain runnin,.;
In the IoJme diI<2ction [Drawing 1].
2
l>.(ak" two of tht> Bucket Sid.
Pattern from the 11'000 J'.lIIerm
in .... n. 46. and one Jside. Trim
t he ot he l along the dashed .!round
p.UhA and B, and adhere the p.lttclIi 10
the bucket a\..<;cmbly l.-\JK) Cui d\\ dy I hl'
wasil' al tlk- oood:.al'l' [PhotoAJ.
3
eul the bucket (0 to alld
the remailling B ... (kel SIde Pal-
urn to 0110'. Stack the bucket wi t h
t heir edgc\ flush and drill holt"'i \\ht;"re
indicated Cut two LVi" lengths of
md [Shop Tip, and
screw J,Orll UU! (Hit" one end of each.
GIlII' J ll d d.l!!lp tile bucket sides to the
buc)..et (MRl [PhotoB] .
4
MC!\.;<' two of the Boom Side
P'tt".n ,Ind olle .:opy of U1<2 Jib Pat-
l.rn. "pl,lv-mount them to your stock,
11"'11 ':U\ Jnd the Jib (D) and boom
sides I t:, to shape. Spray mount a copy of
the C,b Pattt.'rn to J piece oi l W-l hick
stock lOt I1000k) ::Iml ("ut the
cab (F) to )h,II"Ie Drill tbe hole, where
II\dIo.:JIc.J on f he tbcll.:hamlt'r
t he tdg,'). Sand Ihe flJrts to 150 gri t
tll('11 glu\' til(' Shall't peg intu a bO('lll
side [Dr,wing ' 1. Nof: TIJI' peg call SfJ Oil
l'ilIk" /J()(IIII
WOOD ... N<r.rf>mber lOO<>
S
APPIY one tUpy 01 Jib l llvllr Pat
t llrn and two copI es al lhl: 800m Pivot
Patt@rn to Y.!' stock, and cut till: jib 11:\'l:r
(G) dnd boom (II) t o shape. CUI
t he li b (I) to following the
Jib Piston Pattern. Sand :lway t he (':llterm
:lnd any mtll rnMI:. 'i IVlth ISO.grit
Cut lengths of t l l readed I'I)d
for til" boom IDrawlng II, then set the
buum (D, E, G. H,
I), and cab (F) dsldl',
Turn your attention
to the pivot table
1
CUi tu Sill" and shJ(>e t he pivot t abl ...
(.I), (K), and CJ twalk
(Ll, Cut til\' t' ngi ne rover (),f ) to Sill"
1032
washer
,

(
l O-311ocknut
' ... h ok>
'., " dHp
H
the ofth'" b ucket IAlB). .od I
t hrough 1M- bucket le I them. I
[Drawing 2] and apply a o;,:upy uf tIl e
Engine Cover Pattern to it. Dril l the
in the engine cover, counterweight , and
pivot tdbl" [Drawing2[: t hen rout round-
overs on t he counterweight and engine
cover. Glue the smokestack into t hl"
engine cover and s.t:'t the cover 3)1(\1.".
2
GIUe the catwalk (I.) t o till! piv()t
table Ul wi th top .J.nd front ends
flush lDrawlng 2]. Then, glue .J. bvolll
pivot (H) to the pivot tabl e [Photo C).
",/" ,,, threaded ,oo'\lC0l.
',,"Iong
I()'Jl " "' _ \
1 ()'J2 1Il,,,.>ded ,od
Aft er til e glue set s, glue the rem<l.ining
boom PJVUI in place [Photo 0].
3
(;1t1l: and damp cuunterweight
(K) to II,.. pin't tdob! e (J) agd.i nst the
boom pivot s {HJ and centerC'd side-to-
To the counterweight hole
uvel the l!\ tlte pivot t able, push a
tJOlt thruugh both
4
ASSembJI! till:: jib (OJ. boom sides (El,
lib Il'ver (til. and lIb (I) with
t hreaded rod and Jeorn nuts [Drawing l j.
SHOP TIP
Cutting threaded
rod: It' s a snap
Cut 4 ., 6, 8-, and
lO.gauge threaded rod
quid ly J.nd d ...anly wi th a
pair of wire Slfi pper/
oJII\'rs Thread the rod
Into the appropriately
sized hole in the t ool.
then shear it to
length. Twi,t the rod out
01 the (UttH, and the tool
deans up cut threads.
Find Slrl pper!cutters at
most hardware and
home_improvement stores
for about S20.
I ()' J2 ""om nul - .......
'\
S('(ol'ld boom p,vot (HI. The
boom t>ould .... It h light
B EXPLODED VIEW
I" F.H wood ....... -----1'
64
" .. hole,
centered
- .. >I. 3' boll
tUf nta blt"
tu'I'Itabl e's teogth.
At (<leh <lssctllbly to Ihl'" boom pivots
(H). Th{?u screw (don't glue) the cab (F)
to tile pll'ol lable (1). This allows for
rellu.:l\'illll- lile ,ab to adjusl resistance OIl
the ,tIm.
Fabricate a massive chassis
1
("ul I he rhassls (N) to size and lay
(Jul t he axle holes on both
IDrawing 3al. Drill the fV hole and
C"Ounlerhor.: (entdl'd on the hottom
[Ora ... ingl1 Then cut the and drill
the holes [Photo f!J.
2
Adhcrc two copies of t he Wheel
Space' PaUern to stock. Cut
the \\hl'cl slXllels (0) to SIze. and dIm
til(" holes. Glut' Ihe spacers to Ihe chassis
IN), (cnll'red hetween t hl' t'ods and
fl ush at the l>otlolll IDntowing 111.
3
CUI t he t urntable (P) to size and
("hamrel Ihe top edg.-s [Orillw;ng 2).
(; Iut' and d Unl) the turntable to thl'
("ha:.sis, centel"l:!d. Hter the glue drie,
drill througll the tllfntabte, the
holt' in tll('chassis as a guide.
4
\PrilV-l\lount two copies of t h e Whe@1
Cover Pat tern to 1.1' slod, and ..:ut the
wheel (Q) to ,Ize and ,hape. GIIII'
thl' covers tt) the [Drawing 3a,
Photo f l
S
If needed, sJnd the axil' pegs to fit
sl!ugly II! the Jxlr holo,s ill the chas-
sis IN) :11"1.1 ... rs (0). Cut W
from tll (' J..! "long pegs [Or(!lwing31. Test
thl' til of th(' wheels and axles, but don't
glu(' thrllll!\ place.
Finish and assemble
1
R('lllo-.'(' the wheels, .lxlt'"'i, imd all of
th(' hardware and .lppl)",} fj nish. (We
spr.wffi on two CaMS of polyurethane,
bumng Co.11S with a ,nO-glit
I' " e ll ile flnish ha., d ried , ("('"as
seml)i(' th(' I)()Oll l (A/BiC, n. [ c..;, I)
using th read lock on all acorn nuts.
Atla("h t hl' boom aswmbly and Lab (f)
to Ilw pt\'ottahlt! a,..emhl ) IH/J/ KJLl.
WOOD ma.guln.. __ 2009
El CHASSIS
I" ,ounterbor<!
lI<"deepwi tha
'to" hole ,entered m<.ide
Dl CHASSIS SIDE VIEW
2
PllCC a wheel and a w,uher on each
axle peg and thl.' pegs i n place,
making sure no on the wheels
and that the wheels turn frl.'l.'ly {Drawi ng
3] . AftcJ thl.' glue dries, bol t to):ethl.'r the
of part
and pivot table/buurn
{Phot o G{. Theil Krew the
engine cover (M) in plucc {Drawing 2].
3
1'1lWCI up the "illl cookie>
and milk, PUlnt the 1m!:; toward the
marbJequan} and let them dig in. . Cutting Diagram
Wnttet' by (.aI9 ""I\h K,.ln 8 ..
ProiKI <lllign "ff Muu
R ..... n". l . M .. 'n. l o<na John.on
'ii' _
O.....:@

5'., .. plell bd. i1.j
, ,
'Pla"e 01' r ...... ' .. to the thicknesses lis ted in the USI
MORE RESOURCES
RELATED ARTICLE
"Contr<1lct""Grbdl S
II. D<>woJ<>Od ,,(IO(Itr.l\l .. I'<:< llmolW I .... Typo "or..,." In to. Soo.r<h 00>,)
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0
wheel {overs W m
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M.ter;al. warm.
Suppl i,,: S!><lt)' obI" flaIhead wood >aM
III fbI" roui>dhurl wood 1=W'(1l, blue nead Io<k
811$: 10.' (<Mod 0'IfII" 5" d\arnfut "",I .. bits; " ",
1" l-omf"Ol'! <II-. bit
Source
Wood/ h.,-d",,1n' kit : .. i"9wood
twdw_l' tolOdemwheels (41.1' ..
Itl tyo" "fI9Ie 161.'" ... P"!I' II-. .Sit.11..r peg
nl1WJl1lonwa; ......
IlUts l.ll. 10 llaccm .... sl11l.
rod (2), )Oll_hen (2J. "'.
w.W>er, 161. ",rhohud belt m It. er....
tit pM <hipping,Meise'
metseiwoodhobby.com.
Make Beauli [uJ
Baseboards and
ChairRails
DIY MOLDING: PART 2
This 15 the , c(ond of two art;ck!s 011
customizing the molding In your
home. For tips on and ins!;!I I-
ing door and window trim "\,.11
shown here, see Issue 193 (October
2009) or purdXlsc the Mtlcle by 901119
to ()m/dwtr;m.
M
05t of Ihe woo..l trim in tcx!av',
homes wa) meant tv be
ignored, not a, hulred. If \OU
look around at Ihc OO"eboorlh
and Chil lI ,ails i,l roul home alld thlnl...
I Cl)uI.i .It> oct/a, prob.II)ly rlghr.
Making ant..! installing custOUl ba'it'
boords and raib ,Kids pO! rsonalil )
and \ 'al m." to you r hOll1e
66
Tear out those bland
builder-style moldings
and install trim that
showcases your
woodworking skills.
When choosing baseoo:lrd protHes,
first decide whether you want a one-
piece molding or olle built up frum two
or more pieces [Photo A]. A single mold-
ing save-; you time and money, but a
built-up moldmg lets you combIne
for a d ramatic, e.'l:t r,l-\\'i \l<' plUfl1e.
Then decide between or painted
moldings. Stained or d ear-finished
moldings need 10 be cuI frum slraight,
dearl'>uod. A layer 01 pai nt, t hough, can
hide i ne'l:pellShe slock. such as a popla l
or an t- IDF bast-board.
There's no rule dictating \\' hal mold
ing sl7e or style looks be)1 in )our home.
In general. a roomy hou"* with c(:illngs
highl:r Ihan 8' au"ommooales lrun wid('r
t han Ihe (u mlTlOn 2,',' baY' board wId t h
wooo Magadne """"'''''''''' 1009
D
S"-wide
bauboard
To vi,uaHze OOW a room will 1001<. with new
molding'i, <;Ompare SlImpiH of Vir si z.-.s.
Omit l J>eYKIe molding on (arpeted roomS.
To ht'lp you " hilt you want,
molding from maga?ines,
hlstoril" homes, r..:al ('state open
and ["ourer hit manufacturers' Web sites.
TIltn pick a few styles, moc).: up short
samples against a wall [Phot o 81, and li\'C
with them until you sell ie on your
favorite s.ize a nd combination.
Uk IXl'IcOOanb, chair rails can he
fashioned from a single molding or com-
bination of A variety of router
t)Jh used individually or In pairs ueate
Custom chair-rail dl'signs IPhoto C]. In
the room ,hOWIl we topped a
Ix'a<kd chair raIl With a ocaded-cdge
stwl f [PMto DI.
Gear up to make moldings
Llascboards and ch:lir railS fi t between
doOJ" .md window casings, so install that
trim first [Photo E1. Dn' Molding: Fmt
2 011 {XIS" 66.) Wil en e.tlmating and
prep,1ring stock to rout for
jOil\! and plane twO extril StripS for each
type of molding 10 allow f(lf rolltlllg
t<,arOut. miscuts, and othcr mishJps.
K'ow set up rour shop to
Illoldmgs Oll! of blJnks at kast 8' long
ttO minimize splices on long walls). J"I1at
table-mOUlltlllg J
jhp router that can handle large mold-
,ng bits. Then add Infced and out fL'(' d
supports. feath(rboards. hold-downs,
alld collect ion [Photo Fl. Whi le
routlng. mamtaln a steady feed rate
..... Ithout pau;..es that k'Jlll' burn marks.
rhe most molding,
still need to be "an.led up to 180 grit
using pads, sanding or LUIl-
toured blocks t hat 101\0" t he molding
profile. You can stJin the mol<lings
bdore imtaHa tion, liS we d id here, but
apply a d eal fini sh after cutting
and Pd\ching Il,lil !lnl .. s,
woodmaglldne,com
MIX BITS FOR CUSTOM PROFILES
o
Vslr'lg on'" bit lets you crute a symmetrical
plofile. while combinong two diffetent bi ts
this look. jSee Sou.e.,.)
banboard,
COllllllon hand tools help you handle
lIlost installations, bUI a mlterSJw makes
the job easier. You' lI Jiso work fast(' r
usi ng a 15 or 16-gaugt' nailer
wllh 214' or 21,.'., naHs to attach trim 10
walls. Use an IS-gauge natler with lW
Remove nails with c::are
SOOner or !.:!tel. one of your nails
will iI hidden k.nol. drywall
nail, or some othw ollHade. Be
ready with a paIr of end CUlt('/"5
or pliers designed to grip t;ove n a
small ll<lil heild. PIJce iI shim or
scrap beside the n.lll to protect
the baseboard, and use the
of the pliers to leverage the nail
out 01 the wood.
SIMPLE STYUSH CHAIR RAILS
or I Vl' brads to attach moldings to each
other. You' ll also need a J ' lev.;-I, a 0' or S'
stralghtl'<lgt'. lape me;jSUTc, coping saw
or jigsaw with iI nal row 20-tooth-pt'r-
inch blade, a hammel, fill,) l1all-pulling
plicrs. (See the Shop Tip bdnw.)
67
Begin with the baseboards
First check walls for severe dips that will
create gaps behind baseboards and chair
rails [PhotoG]. Then locate wall5tuus to
attach the baseboards and chair rails
[Photo H]. Mark these plus the chair-rail
mounting heights at each stud-typi-
cally 36" above the floor.
Follow these general rules when plan-
ning your job:
AVOid coping both ends of a trim
piece. That makes It hard to cut aLL urate
length5. (Watch a free cope-cutting
video at woodmagalint.comjcopecut.)
Cut baseboards and caps starting
with the longest piece5 first. That way,
any miscut pieces can be reused else-
where in the room.
On walls longer than your longest
piece of trim, join two pieces with a 4S"
>carf joint [Photo 1[. Place the joint \ome-
where inconspicuous, 5uch as behind an
open door, and in front of a stud. Glue
the joint ends and then drive IS- or
J6-gauge nails through both pieces and
into the stud to eliminate gaps.
In a typical room with four inside
corners and one entry where you're
using moldings with profiles, for exam-
ple, first cut the piece for the longest
wall using straight-cut ends. Add an
extra !-is" to the length of the wall and
cut the molding this length. Then bow
it slightly, and pop it into place for a
snug fit in the corners.
For walls 90 to the long wall, cut
coped ends to go against the long-wall
molding and squared ends to go against
the opposite wall or any doorway casing
in between. Only as a last resort would
you cut molding for the remClining wall
witli cope cuts on both ends.
That's the plan: now let's go to work
on the baseboards. Unlikethecontrolled
world of the workshop, you'll need to
work around drywClIl flaws in most
houses. For example, inside wall corners
become rounded !Je.cCluse of built-up
joint compound. To compensClte, sand a
round-over on the inside end grain of
your baseboard., to fit these corners.
Now fasten the first piece into the wall
studs using Cl 15- or 16-gauge nailer.
With no profile to cope-cut for the
simple baseboards shown here. simply
butt the ends of the adjoining pieces
Clgainst your first bilseboard until you've
worked your way around the room. On
outside corners, miter the end so the
imide face ends flush with the Lorner.
Then cut the mating miter, glue the
joInt, and attach the baseboard with
68
i i
befo re you
,I
and into a stud.
SHOP TIP
Hate miters? Try this
mlterless alternative
In the same way that corner blocks
eliminate mitered door-casing corners,
these corner blocb eliminate outside
corner miter5 in baseboard molding5.
They also with5tand bumps from shoes
and vacuums. To make them, cut
blanb about 1" to Ph" square, and add
a Ji" round-over to the three exposed
edges. For a decorative touch, rout the
top end on all four faces. Then add
either a V." notch for outside corners or
chamfer for imide corners to allow for
drywall imperfections.
chair rail s.
WOOD magaIin e 2009
Cope molding ends for gap-free corner joints
IS Or nails. HcinlOrce tl'll' join!
with 18gauge bfilds IPl'lotoJ [.
'low rou"!\' ready to add Ihe C,tp-
agaiu Starling on the Jonge-.I ""til and
bowIng a vieee to fi l.
(X'(ilyS<' Irs narrower and l.-ss rlgk! than
the oo.S'boon:l, the cap hid.-.s dip) and
In Ihe drywall. So press it flnnly
agaInst both the wall and baseboard
before fastening it through to the wall
5tlJrls US111g an IS-gauge nailer.
tor ill 1>ide corners, rope the ends of
caps that \'Iill butt up against yOUr first
cap with its square-cul ('nils. To rope-cut
an end, firSl IC\'('al 1he tx0(l lf> by culling
II 4Sc mitCl, as though mal(lng an inside
mitered corner. Theil saw on the waste
side Ileal the miter edge usIng a coping
saw [Photo KJ or jigsaw' [Phot o Lillnd cop-
ing jig. (See SourClu.)
Usc a rasp or a y." dowel wrapped with
80-grit abrasive to match Iht! profile to
the miter (-dge IPhotoMj. Test the coped
end profile ag;liost a ('ap-molding scrap
01 an iO:.lalloo cap IPhclto NI.
Plan tht CdP layout to make a squaw
"""lit or outside-corrlcr mit(ll on the other
ends of any ('ope-cul pieces and WorK
your ..... ay arouud the rooul. (for a hard-
..... ood floor 1101 ShOWII, install shoe
moldings the saml' way to hide gaps
between the baseboard and floor.) Thcn,
putt)' nail holes to match the \vood.
69
Install wall moldings like a pro
Builder and flnllh Cilrpeiller David of
Del MOines SllitreS the 10110'.vUI9 tiPS t o
help you suctessf uil y tns tall oilsebocords
and chJ;r r,)lls:
p. When ( ut\lnq baseboards with
mi ters on bul h t'm.i$, grauudlly shorten
them to t he (.orrett len(}th To do thIS,
D<IYid bults one end t he stopped
blade of his milersaw, hf LS ;lnll SIMh ti le
SilW, and cuts all lust a hJ,r at d ' Ime
f or w,lIIS t h'" meet a! an ""ql (> ot her
thdn 90' on comer), ul:'at t' d bd(k
bevel, as shown ,)l far righi, on the
b(lS('uo<lrd ends so t he front lacE'S bult
to<Jet her ..... thout 9dps
, In,tead of \Isinq d level to determine
t half-filil mounti ng lines around a room,
mNl ure up from the floor I'our eyes
automatically lilt' the floor for reference
to tell whether t he (J1,, '1 rad ,Iant s.
Cut chJiHJ11 miters Wit h the
top fact' up t o m'nlm,.:t' Visible teM-OU\.
The chdir fall tea r o ut un th t'
underside of the shelf.
Now add chair rails
Wall s t hat ' >'ere fl3t at Ihe
may stili h ave wavts at t h alr-ra l! hclght .
Check wall s with a or taut
string. Then p3tch d ip> wUh j(l\ lIt com-
pound ilnd repai nt .
Ik-cauSt.' hoth ch,lJ r tad shel f
shown have routt>d protiles t hat do [\ ' t
lend themSel ves to COpe-LUI '. mIt er the
im ide and outside .:orncrs, wit h t he
baseboard. by miter cut tIng a
ch air rail tv fit t ho: 10ugC" t wall ti rq.
Attach t hilt wi t h a 1-"- o r 16-gauFe
IMII .. r at t h .. studs marl;ed
If the n .. ,t pleLt' l>e t \\een IWO
im,ide cornns. measu r .. lor I.:ng. th and
mIter the enili with graduOII cut .. until
)00 achieve a tight fit . I$..--..:- " Insta ll wall
mo ldi ng_ m .... a Pr( ' ,"' <1/)111 .-.)
70
To nit ( hai r- rai l outside (orners,
mIte r-cut the workpi t'('_e 5liqhtly oVt'r long
,md hold It 'I n Tht'n bull a s.<.rap
miter the wor kplert' mlt t' r ,)nd
dU'ck lor gaps. Gradually short en the
workpI ece unt if you St>t> ,) tight mltt>r and
no belvw
m't er or gap'
I ,
wall cau sed by part s wt
MITER CHAIR RAILS SHELVES
;
,ope cut, in t his use you woul d
for an joi nt.
When working from an inside l'Orner
to an out side corner, first miter lil e>
imide corner end and hold II iI1 position
while you mar k t he miter location at th ..
outside corner. Cut (lfi the waste side of
t hat mark until the ollter With
the corner.
r hen attach the shell es to the chair
fili ls using an IS-gauge hrad nail er on
t he lop and to the wal l {w m the fro nt
With a IS- Of It>gaug" na iler [Photo OJ.
Miter i nside shelf ( Oll1t' IS to match the
cluir-rail cmners [Photo PI. Where the
sheli met' ts door 01 wi mk.\,\, t rim, cham-
fer the shel f end to d t'ate a
[Photo 0 1 with n,) sharp CUrTI(' rs.
With t he molding installed, pall h t il"
nai l holt!l. using oil-rosed wuod pult y.
and appl r tWO coats of clear fin ish .
A penc,l under
helps you cut a back bevel to
odd wall at insI de corner'.
ildJoInlng 0:1001' frame.
l'i'itteM by 80b Wll>on WIth David n . h
MOI(l '1)(j Kevi n Boyle
Rounne LeMoi ne. Lorna John.,on
MORE RESOURCES
Ht.LAl EI) ARTICLE
12' 178(Sepl.ember

rREE RELAT[D ARTiClE
. 'Nder,Compttl!Ol' COmb(! 19(1 (M",
200'i). "'< <J<jm..-p.: ..... c"rn,,,.f .. ,(DtI'Ibo
... "' .. ".'I''' ... _J<Jo,_.....,.
lv' ...... , .. ' )I' ....... ...-- ... ,I .. !.o .... b tJ., , _)
Sourceii
Cha'" r lOi l bit ltL 99-4n $SSand
blroo.99,478,

CotM"9II,.
Tooh,800 S7131S$or ...... aIoyWITI-
WOOD .. ., l009
C2009 1,10<:1. Se",,"" S-e430 OF21$)1)4R' A",en\s<lmOO!
Bob Vila endorses and recommends
the famous EdenPURE portable heater
Millions of Americans now saving up to 50% on their
heating bills and raving about the "heavenly heat"
Does not get hot, cannot start a fire and will not reduce humidity or oxygen
The famous infrared
ponable healer, the Eden-
PliREt, which can cuI
your heating bills by
10 50'1, ha; been greatl}
improved
The n.", EdenPURP
GEN3 heater heats better,
faster. <ave, more on
healing bill, and runs al-
most siler.1
Th. can
paj for it,elf in a maHer
ofwe.ls and then Itart
putting a great deal of ex-
tra money In yoor pod.et
aft.r thal.
A major cause of res i-
dential fires in lhe United
States i, portable heaters.
But the
not cau .. a fire ThM il be-
cause the advanced in-
frared h. aling element
ne\er get; to a temperallKC
that can anything,
The outside of the
Ed.nPliRP only getl
warm to the tooch so that
it ",ill not burn children
or pet,.
The will
also keep you healthy.
That h b. cau.e,
otrer heating ,ource" i!
will not reduce humidity
or oxygen In the room.
The advanced space-
age Infrared
Portable Healer also heat,
the room ev. nly, wall-to-
wall and floor-to-ceilmg.
And, as you know, most
other IX'rtablc heater, on-
ly heat an area a few feet
around the heate-r.
Unlike other heating
source., the EdenPUREt
cannot put Car-
bon monoxide, any type
of fumes or any type of
harmful radiation into a
,=
Q. What I.s tho origin
of this amazing
element in the Eden-

A. This ad\'anced
heating clement was dis-
cowred accident.lly by.
man nan-..d John Jooes.
Q. What
does this advanced in_
frgred heating pJ"(Wess
have O,'er other heating
source produr\s?
Never be cold again
Cannot start a fire; a child or animal
can touch or sit on it without harm
Ploturod "'" i.Bob de""",t " ti ni lit. f,","us Edt1\-
I'tJlII" GENJ Modo! 1[)()(] It" t, r witlt 1,"';1\'. II .. "'" bill
mO"'1 "" jOur bill "nil< k 1"" 10"1!" w.,.,
witn 'I><" nl y nlat".
A, This infrar. d heat-
ing process was designed
aronnd the thre. malt im-
portant con.umer bene-
fits: economy,comfort,
and safety.
In the EdenPURE'"
proc. ", electricity il
to generate a t} of in-
frared real which, in rJrn.
crealeS a v. ry safe heat.
Q. Hou' can a per-
son cut their healing
bill b)' up to 50% "llh
the
A. The
will heat a room In min-
utes. Therefore, you can
turn the heat down in
your house to as low as
5{) degrees, but the room
you are occupying, which
h" the will
be warm and comfort-
able. Th. EdenPliRP is
portable When you move
to another room, it wtll
quiclJy heat that rOOm ai-
'0 Can drastically
cut heating bill,. in ,Orne
Instances. by up to 50%.
End orinter>ie .....
The Ed.nPUREl will
pay for it.elfin wed." It
willleep a great deal of
mon. y in J u<. rI
pocket. Becau,e of to-
day's spiraling gas. oil.
propane, .nd other ener-
gy co,t,. the EdenPIJRP
will provide . v. n g,-"ater
,avings as til. tm-.. goes by.
The EdenPURP
is now greatly improved
With no increase in
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along witr. a 60-d.y no
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the return ,hipping.
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Testimonials from a few of the millions
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The EdlnPURE"' has cui"" gas bin to alhird of what it
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The really puis oullhe heal tike a Wllte
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;nthe rather large room where t'm us-
Ing it. I have .Ir"ad, not io e"" 4(110 60% in Ihe
cost of my heat:ng biNs. G_ge B" Trl8nglt, N. Y.
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: SPECIAL READER'S DISCOUNT COUPON :
: The price of the E(!enPURP GEN311l00;Jel SilO $372 $17 ,hipping for :
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o I am ordering within 10 day' of the dat. ofthi, publicalion, tberefore I get a
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: 7800 Whipple AYe. N.W.
: Canton,OH-I4767 :

Shop-ProVt!I1 Products
About our product tests
We It'Sl huooredl of toob and but only lnose e,rn at least three
IliI/S f<Jf make tile fmal lUI iIIld in 'nil Prices are WJrerK
at tilE time of artide prodlJ(tiOll alld 00 not illdude shipping, where applkable.
These woodworking wares passed our shop trials
Rldgld replaces flagship tablesaw with a rock-solid winner
I've long thought highly of Ridgid's contractor-
style tablesaws, but the company's new granite-
topped hybrid model, the R4511, leaves those
saws in the dust-and at an attractive price. The
HI,' -thick granite tabletop proved worth its
weight by deadening vibration while workpiece,
glided smoothly across it during cuts. The closed
cabinet on stubby legs-complete with Ridgid's
built-in Here-U-Lift mobile base with four
swiveling casters-noticeably reduced the noise
level and dfectively channded dust to the 4" port
at the rear, I like its cabinet-mounted trunnion>
for easy top-to-blade alignment.lts \l/,_hp motor
surprised me brPlowing through tough cuts-
even bevel rips in 2"-thick hard maple-without
bogging down,
If I could change anrthing about this saw, I'd
beef up the 2"-tall, aluminum T-square-style rip
fence with taller laminate-or UHMW-covered
,>idebo,[rd,>. And Jlike the quick-rdea,>e '>plilter/
blade-guard assembly; but 10 access it I had to
first remove three screws in the throat insert.
Uust before we went to press, we learned that
Ridgid had issued a recall for this saw to replace
arbor shafts that could potentially break under
heavy load. If you bought one of these saws
Granite-Top HybridTablesaw, IIR4511
Perform3nce * * * '" '"
bfore August 2009, call Ridgid at 866-539-1710 -Tested by Doug HICK.,
Price $600
or go to ridgid.com to see if your saw qualifies for a formfr J.hop ttocher and
Ridgid
the recal1.) woodworking magOlineedltor 800_474_3443; ridgld.com
n
Heavyweight lathe turns In impressive showing
\Vith Laguna's Platinum Series 18-47 lathe YOIl can turn a workpiece
up 10 18" in diameter and 47" long. Despite turning a piece thatlarge,
J couldn't bog down its 2-hp, 220-volt motor no matter how hard I
tried. I like its digital readout and electronic variable speed that ranges
from zero to 3,200 rpm. And when finished shaping a workpiece, its
reverse feature comes in handy: I was able to ,and smoother than in just
the forward rotation.
The heavy-duty ca'>l-iron legs and ways (500 lbs IOtal weight) ellmi-
nated vibration, even when I roughed out a near-capacity bowl blank.
This machme sports many big-lathe features, including a 1';" x 8 tpi
headstock spindle and 36 mdexing stops, for a mid-size price.
However, there's no handwheel on the headstock. and the locks for the
headstock and tailstock sit on the back side of each, making it difficult to
reach over to make adjustments. And it comes with a 6" faceplate, which
work> well for large turnings, but is just too big for medium to small
bowls and vessels.
18" Wood lathe, ,A175017
Performdnce
Price
LJgun3 TOOl
800-234-1976; lagurKltools,com
* "''''* *
51,855
-T211td by Mar/en
Manoging Editor
Route r -bit set makes
no-ca nvas tambour doors
Few woooworking tasks prove more
tediom and messy than gluing slab to
canvas to make tambour roll-up doors.
Alter making one years ago, I swore I'd
never do it again. And premade
tambours cost from about %0 for a
box to nearly for a
Nnw, thanks to Amana's three-piece
tambour-door router-bit set, there's no
glue 01.. involved. You simply
shape the slats on a router table, and fit
them logether loosely in ball-and-
s.xket-type joints. as shown at bottom.
The big profile bit routs both profiles
of two slats onto one blank; the
ball-tipped bit cuts the socket. The
included lj," round-over bit eases the
sharp edges on the bottolll (tike
many woodworkers, I already have a Lj,"
round-over bit , so Amana could leave
this bit out of the set to make il more
affordable.) Rip the two slats apart on
your tahlesaw, and then fit them
together. The finished door slides he,t
in it 0/"," groove; if YOl.l don't have a hit
thut size, rout it in two passes with a
smaHer one.
-Tested byErv Robert"
wIlo 1m bffn building proW:ts or.:! testing
1001; ()fWOOD& mogazirlf (Of 18)"orl.
Tambour Door Router Bit Set, 154114
Performance
Price
Amana Tool Co.,
800-445-0077,
*****
$175
continued 011 puge 74
woodmagazin ... com 73
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heotirlg. It con rcploce or supplement your electri( heat,
s"s or oil furnocc ond woodstovcs.
Hydro-Sil rcpr".cnh economy in koting' in<idc lhe
heater is 0 scoled copper chombcr wiTh 0 horm!c.s
,ilicone fluid de.igned for heot retention The
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Shop-Proven Products
Irwin' s beefy clamps turn in weighty perfo rmance
, enEd 011 Irwi n Quick-Gllp one
handed l)at clamps for rears, so l lookoo
fonvard to using Irwin's par-diet -jaw
clllmps.. The jaws and
thick stee!Il)eam bar did not flex Und('f
prCSSUH!. Bul at 6
1
h Ibs for the 24'
clamps and 9 lbs for each 48' mod,,1,
the ht'ft up when you mov(' a
assembly off your b('nch. The
fa .... os dig into the smooth bars
when tightened. lea\ing bite minks tllilt
m(welllent on later glue.ups.
And the Hne handle Ihwads rcquifl'
OlOl'e turns 10 lighlcn and 100000n than
most other parallel-jil'" clamps.
__ rt>Slt'd bv Bob
roo.l) Ii; rahr.,'?1fe. Ed,!",
Parallel-Jaw Clamps
Performance
( .. )
p
... '
Price 24' clamp, 112026500 SlS
43" cla,.,p, .2026SOt 14S
1""';1\ tl1(lUAriai Tooh
lJWIn.com
"
NEW! SHAPE 3
SIDES IN 1 PASS!
COtTtimlt'd 011 PUS" 76
, ,
,"

mto" POWERi UL ' -SIDE
M(1D(R tnat e1fl!)tj lt
& AfFORDABLY (lJr. .. --
T&G fi no"n"
pan"Mnt. &
.. .- .,j .....
<

., Ii'

bit, ""tup t<>,
mortise (eMn jnirml
leighjigs.com 800-6t>.1-II<m R,., .. lo,no", Ii
,
'Ii' :

dnH ,bit yo" WI/ ,eve;'
, a fifetime!,
L ompah ,\1. 'i>J
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n"' ,. ,
Item 'VI l'H,,,.""lxC)
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fuo- .. k' ,0
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. high-q""lih route! bib fur ju,(
1i I. 14 euch! Thil 'r>.:fedible -.c[
"'" <>f 1:""
lei Y"U \ -smo"c, flu,h
lmll, , .101 <1ail ",.J
lIludl ""h r")''''''J.::mal
c'c .... lin", B." I
,1Iu\l ,;,.., ..t.J ""'DIu.: '.or
;.""",1 tor Y"" ol <lrcnl.,N" "'" d<.lr
_ .. b "II" .. ",-, .. I..", cr-tII' "r 10: rh.ln 0.1 mm
8,h ,,'IT'" .11 "n.Joo.!..:n rase w,ib
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range cI()lb C<\vered groll 'I*Jler> dt
tn. cOrllCJ-'. progr.mm""lc 12tr<lc1;
memo..". LCD d;'pl.}' Wilh
o\.L:X mput for com .. ,!in.
'Ourc" all,l m"n:, l'hc .... l ,,,,,.11
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Tlrt Bc.t't flat.ol4' 0,;.".;( (q #"""f,- (k 14,.,.(fit"./1
mil)' III'''''' i\<J; }OU' "I"""at"r (/If dfl 3i"
O,..-"eishl dr;\ffi;llically ibiVj)in@..
(' I'""'- r),.. ,..... r r
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"""'" 0 25'/, IMCIiIo< I>oit """"'or,
""'!&:roM .. "" DIll
lot, roo =de """"" <W1p(lCI,
Ow.prof,;" Pod.oIHoIo In
uod<lIlOn",," ,'ardard
Dr, 'N'
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Visit www.kregtool.com/beaded
lodoy 10 watch Ihe video and leorn morel
800,441.8638
www.kregtool.com
Shop-Proven Products
Dial in dead-on dadoes, grooves, and rabbets
Infinity's PreciSion Router Dado Jig
delivers just what it promises: precise
dadoes, grooves, and rabbets. This
aluminum jig adjusts to fit any strdight-
edge guide up to 'I"' thick dnd 2:1","
wide, and glides smoothly against it
with ball hearings. Mount the included
'Ii' guide bushing in your TOuter, fit it
into the 1ig, and then TOut a channel
with the desired bit. Por channels wider
than the bit, usc the micrOdd-
juster on the jig to move the router
without moving the guide. The scale
and cursor all the jig m<lke it edsy to
return to this setting later. Go to
woodmagaline.com/toolschool for a
free video of this jig in action.
-Te,/ed by jMSvec,
a former pro;eft editor and builder a/
WOOD' mogQ./ine
PI't'cision Router Dado Jig, 'PDJ-' 00
Performar>ee
Price
Infinity Cutting Tool ,
877-872_2487; infinitytoots.com
Contour sanders lay down smooth
Auto,lxxly repair shops have used cove,.t little more pressure
stiff-foam (similar to swimmlllg-pool and it enough to get that, too.
"noodles") Soft-Sanders for years, hut I had sueo:ss Oil SlTId]] r()ukd
only recently did these cOTltour-sanding profiles (ogt'cs, be.lds, etc). Getting
accessories find their way into wood- sandpaper to conform to those small
working shops. The kit features six shapes proved too difficult, rounding-
distinctly shapt:'d sanding pdds in three over crisp cOIllers instead.
densities and includes 80-, 120-, and The supplied s.:llldpaper sticks to the
180-grit adhesIVe-backed sandpapt:r. pads well during sanding. yet peels off
I began my testing by sanding a c.:lsily when changing grits. It proved
It:ngth of home-cenkr red-oa\... crown durable as I foldt"<i, wadded, and twisted
molding. I used three pads to match the it into variOUS forms, and it did not
dIfferent molding contt)urs, and wor\...ed load up with dust or pitch .
my way through the three grits tL)
produce a slippery-smooth surfJCe.
Next, I went to work on a cabinet-
door rabed p<lnel. It took only one pdd
to match the large cove. To the
contour pad's effectiveness, J scribhled
pencil lines all along the profile. At
first, the abraSive missed the apex of tht:
76
Soft-Sanders
-Tm_d by Bob Hunter,
Tods &. Tedrniques Editor
Perform<lnce ****,-'
Price $25 (4-pack replacement smdpaper, $4)
Style-Line Corporation
800-752-9863; soft-sanders.com
WOOD rnagolZine Nowmber 100'i'
HARBOR FREIGHT TOOLS
Qualit:y TOols at: t:he LQWEST prices
FACTORY DIRECT
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or HarborFreightusa.com!Wood
Ask WOOD
Answers to your questi ons from
letters, e-mai ls, and WOOD 9nline'
Hidden hazards could lurk in broken
Q
.. dropped my prQmium blade on the
concrete and the carbide broke off of a tooth. Can I
keep ufoing it?
-Todd Hubbard. O(ll;:.mrl, Calif.
A
e ::ihort rood: no. BeSIdes t he darn-
J.b'Cd toot h, othC't te'eth may ha\'c sustained mvisible
damage. The next u:.c ('ould t urn that carbide into dangerous
shrapnel.
flut t hele ally way to salv:tge your Invest ment? We called
several premium blade manufacturers posing as customers to
sec what our OptlUn) werl'.
Not surprisingly, bouncing l blade off of concrete instantly
the warrant y-so t here would be no free replacement.
And companic) offeled flW altCrnat lWS beyond purchasing a
new blade. ' '''hen prompted, most agreed that a local
service mlgflt he able 10 replace t he carbide tip
kSli cxpcmlvcJv t han replacing the bl ade.
The repre'>l:lltatlve 01 one tl1anuiact urer, FOH""t Manuiac-
tunng, to send in t he bruken blade. They offered to
check Ihe surround ing teet h tor damage. leplace missi ng
carbidl' )traighttn hent teet h. and make a lest cuI to
ensure everything was in order. They di rected tIS to thei r
onli ne pr icl' list. \\' hich had a (kla ilc-d li!'>ti ng of t lld l lees fo r
thl'se l\oCrvicl .... In llddll lon [0 CDstS, cll rblde tip
leplau-mem statLS at S7 for olle tooth down to $3 each 101
Surgery for broken screws
Q
_ While I was installing hinges on a cabinet door, the
_ he ad of a brass screw broke off. How can I remove
the screw without making a mess of my project?
_ Kennl'fh Hill, Troy, Mich
A
The IMI looking for, Kennet h, is a broken screw
. l ... traCtor. (To buy Oll e searl'll for "screw at
woodcraft.com.) WIWl t lusta lled In a drill, these diminutive
hole sJ.ws a r(,'lnovable plug of wood trom around the
threaded (>t t he brni..;.'11 screw. Because their out er
diamet('n match ("ommon plug'Lutter SlzC'i, you simply fill
t he hole with it plug CUI flmn ,I )CTitJl of the S.ime wmxt,
hiding the mistake. One word of caullon: Don't ovcr tigh ten
t h(,' chuck when inserting Ihi: ext ractot in your drill, as you
could clUsh t he tube.
Bra_'IS art fragi li:. On you r next atlemrlt, be sure to
pIc-drill a Stud p,lot hole. Then d rive dnd l emove II
sleel SClew of the lkunC SIZC <HId thread count In plow the wa)
forlhe .-.r<L'\.S tighten t he br.lSS screw b) h;md
with a to avoid twisti ng otl lhe head .
roltTi/t/led on J>t.lg, 80
7.
HAVE A QUESTION?
For Dn.wer 10 woodwork.ng qvestion. write to ASK
WOOD, 171C1 l ocust St " LS221 , Oes Moi nlts. IA 50]09]023
or e-mail us dt itskwood@woodm;ttgazlnlt.,om.Forimmediiltl'
feedback from )'OUr fdow wooowork,ers, POit your on
one 01 001 woodWorking al ..... oodm;ttguinlt.'omJfOtum5.
Hidoondarn..lge(Q\lld eq ... al dangerous shrapne-l if thi'! blok@l1bLade
is ... !Itd aglin befOfe bemg properly re paired.
fnu r 01 more teet h . A test Cllt checl..ing fol benl teeth emts
an additional S2.5O and st ra igh teni ng a ny henl teet h mSh
S2.50 per toot h.
WOOD ... agulne Novemoer 2009
Time travel at the speed of a 1935 Speedster?
The 19305 brOught unprecedented
innovation in machine-age technol-
ogy and materials. Imlustrial designers
from the auto industry translated
the principles of aerodynamics and
streamlining into ('t'('ryday oblects
like radIos and It was also a
decade when an unequaled \'arlety
of watch cases and movements Cdme
into being. In lieu of h,ll\ds to tell
time, one such complication, calkd
a jumping ITIt'challls m, utililed
numerals on a "1st vieWed through
a windOw. With its striking resem-
blance to the dilshboMd gaug.;>s and
radi o di al s of the Ihe j ump
hou r watch was illde&1 " in tUlle"
wit h t ht> times!
51,mer /QJOs /J,I l/mollic deft ly
bl end .. the mooern functionality of
a 21-jcwel alltomatic movement and
3-An,! water reSistance with Ihe
Tmt' to MrKhillt' Art eltht'liCl. the
brlls/led Il.ee/ i, (k,n 011 tilL
b,ld:, all"wil1g a pt'fJ.. lit tllf inlla w(lfJ..inSl,
Tetro look o f a jumping
dis play (not an act ual jumping
compli ca tion). The stainless steel
1 t/2" Cdse is compk mented wit h a
black a lli gator-embossell lea t her
band. The band is 9 I/Z' long and
will fi t a 7---A 1/2" wri"t.
Tr}' the Staller 1930s
\\fillch for 30 days and if YOll itre not
reccivlll g compliments. please return
the walch for a full refund of the
price. If you have an
Ilpprt'ciation for classic design with
pn'clslol1 acc uracy, lilt'
D,j3JI/rc)llic: W.ltch is buill for you.
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Ask WOOD
Shedding some light
on fixture placement
Q
. I'm in the process of com-
pleting my new shop at
, home, and I have a load offluores-
cent lights to install. How should I
space them for best effect?
- Bob Crain, Spring Valley, N.Y ..
, A. Congratulations 011 your new
. shop, Bob. You need to create
adequate illumination that overlaps
to eliminate shadows or dark
corners. Referring to the drawing,
below, here are some simple rules for
doing just that.
Start by measuring the height (A)
from your work surfaces to the
expected height of the light fixtures.
Assuming you plan to install your
fixtures in unbroken rows across the
ceiling, the distance from the
outermost fixture to the wall (8)
should be about one half the
distance of (A). The distance
between fixtures (C) should be
about I-J'/I times (A).
For example, a typical 24x24' shop
with a 10' ceiling and 36"-high work
surfaces gives you a distance of 7' for
(A). Three 16' rows of lights (each
consisting of two 8' fixtures or four
4' fixtures) spaced 8' apart (C) leaves
4' all around from fixture to wall (8).
Some shadoV\'S can't be avoided, so
add task lighting where needed to
take care of any workstations that
are 51 ill in shadow.
I
I,
!
! I
,

1- ---------------
80
WOOD magazine '.member 2009
Dead-on dowels dilemma
Q
_ Where can 1get properly
. sized dowels? When I
buy ? dowels, they always
to be slightly undersiz@d.
Chesler, Champlin, Min"
A
_ l Ook no furt her than YOut
router table. !>tMI wll h
your choi(' of <if}. st raishtgra inoo
to .woid t il(' curling rou otten
'>CC in 'tore-bought dowels. Joint and
plane a t>lanl: down to the d(",,'cl'\
diameter-In )'our caS(' v..)< Yo
square-then cut it about 3"longcl
than the dowel YOli. wll! n('('d.
Imtall a fOundover bit with a
,aJim half that of You r dowel
blank-y,. ' for dow..:! stock.
Set the fCI\(:c flu\h to the bit'S
bearing. Then, the bit hdSh! to
make an even roundevc! in your
'toek. Make a r()undovcr 011 a
cutoff to veri fy your \etup.
Mark ,IMI and lines on aU
four faces of the blank about ]' from
each cnd. By louting lx'tw('('n t he.('
marh, you keep the ends tu
act 11 .. guides .\ftcr eal h rotate
the blank 90 for the next
r-inalJ y cut off 11K' squart and
cut t he dnwel to lengt h on yuur

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Ask WOOD
A pound of panelbusting prevention
Q
. After reading about the effects of moisture on
. wood movement, "m reluctant to try tablesawn
ra Ised panels. Won't the wedged edges of the panel
spread the grooved stile to the breaking point, espe-
cially on widll pillnels7
A
. Fortunately_ Michael. tl me-Iested.
. constructlon absort the often puni5hing eflects of
\ea\oI1<11 wood mOI:(,nl('nt by capturing the movement-
prone panelln a forgIVing framO!. "' he wedged edge, of
tablesawn might!)e ,lli nlt' ]eo;s lorgiving
than ot htl de!>!gns, but Ihe 'tep' to 3\"oid wood mOWDleilt
catastrophes are th"
fir\t, make yuur panel from straight-grained, or
quartersawn wood that has tx:en properly
which is prone to mo"ement tha n cat hedral-grained
wood. Once in )'Ollr shop, let the wood accli mate for a
couple weeks before machInIng It . This allows the wood';
moistllff: cont ent to stablliz(! wit h its
After mea\uring bctw(!(!11 tll(! groove\ in the rails and
'>tiles, cut the panel to leave at leasl a '18' gap on all
sides. This lea\'Cs tIle panel free to Shrink and swell with the
changing humIdit y of the To avoid a loo,e or
rattling pan"l, Install flexible 'lich as "Space Balls'
(WoodClaft #142284, S6/packase of WO, BO(J-225-1153,
woodcraft.com\, In tht> groov('s, or glue or pin-nail the top
82
The wedge of a tableuwn raised paJli'1 i,le forgiving of
wood without plannIng for its effects.
and bottom centel of the pallel in the rail. For panel' L8" or
more wide, or If the piece will t!xpt!rlencl.' challges in
humidity, such as a Crc>S,-COUllt ry t rip from Arizona to
Florida, deepen the grooves narrow the panel to
allow for e\'ell more swelling.
Fil1Jlly, sJHink;,se might expo,e.1 '>light gap
between the panel profile an d th .. ,tile groove In tabJesawn
panels, so stain and the befofe ImerLing it ill
the frame to aVOId ,1 dl"",cl tng ullStained Hne .
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Ullra c!{jar poos have dlstirlCtive, elegNlt designs in the nib, center
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GORILLA WOOD GLUE H';lh slrer(lth.
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UNITED GILSONITE LABORATORIES
FinisI1,,\) T()Jch BrQd-we - gudr fcr best
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Blades, Cutting Tools
CMT ORANGE TOOLS Tor, qlJaity hdus:ricJ
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EAGLE AMERICA Largest 58lOCt>01l of
profess<():1al (1)3I;ly. AIT:erlC:;'1-maGe route-: tiTS
1 OOs of unq.e a=sorfc)S, Circle No. 193.
FORREST MFG. CO., INC. Top qluity
bhdos ,,")(.1 r.bdos for GIl lIltle; smoc/h finish
Circle No. 206.
FREUD SAW BLADES c:;Ubcj
j lustratff JTl baleflts fa- al Fre<,Jd
"",,W tl!ol<.les. Circle No. 219.
FREUD ROUTER BITS AI Freud router tits
de rEtlYese:1[e(j 11 tris 8L-page
'flcuJillg Incra th;:,n 130 nc'.', tits alld sets,
Circle No. 232.
MLCS WOODWORKING 8ast r'OJIl
sded'oo. kJw Froe
Circle No. 24S.
SAWSTOP SnwStor, tJtla &'WS tilc biJdo
,,p:Jn C():1tflct with skin. Circle No. 280.
SOMMERFELD'S TOOLS FOR WOOD
RoutPI' Bits. Bmbs, Toos :;nd Tips FREE
c,x;,lJg & sil;r,r.>ng' Circle No. 284.
Plans and Videos
AMERICAN FURNITURE DESIGN CO. 1 so
ot Arr\<18a.'s best f,.,-niture "ans, comprPhensive
IlSTUCi'01 '1-'00, Cdj o;j Circle No. 336.
MEISEL HARDWARE SPECIALTIES
CATALOG ?,COJ+ IlJlI-siLe r,o;a<;[ flans n,;j
rwd-to-fhd il5d\'JCf'e, Circle No_ 401.
U-BILD WOODWORKING PLANS SiCiC8
I 848' IllJno:eds of f<)l siN p'Jns, d(l'linloadfllJe
jj:;1S, low p;Yes. Circle No. 435.
86 WOOd Magazine November 2009
ARMOR CRAFTS FUII->;ize 1)l1.11S to bl l id
Grades, rocking IlcrSes, c.:>ck.l n:)j rn:xe,
Also hardwaro:;CJd wood cre'!t SliWi es,
Circle No. 556.
THE BEALL TOOL COMPANY Irrventi'le
sOlJtiC(ls for p;oIJems 'i,'00d thm:;(j'>:J
bulfng & more Circle No. 558.
GRIZZLY INDUSTRIAL, INC. 12,0C()
w(j()jwcrki:-.;) and mPla!w(\<ing machoos, toos
and accesscrips, 1.I:-;:w,-;,taJje rf>c:esl Circle
No. 563.
HARTVILLE TOOL CATALOG
W<XXJwcrk!:1g toos Jrd slIpph!s Jt thl test
ara<.l1d Circle No. 596.
WOODCRAFT SUPPLY CORP. 0-i8< 15,COJ
top ql.uity woodwcrking supples, Jnd
acCE!sso'ss. Circle No. 700.
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AFFINITY TOOL WORKS Mr,,-..J'r;ctupt' 0'
qualt)' hClld toos a,){j prcd.>::::ts fa-
caIJnptnli;,kr:-.;), carp":ltry, wco :1wcrhlg. Circle
No. 734.
KREG TOOL CO. Ya<.,- ooe SllOP fcr
evprythr1g Pocket;)crew rPiated Circle
No. 802.
MORTISE PAL Matisos m:;de oasy! Circle
No. 824.
STANLEY SWEETHEART HAND PLANES
New ;)\'if'lethecn pemilllfl h:;,Y.l rh,leS by
Stllilkly, Circle No. 829.
STEVE H. WALL LUMBER CO. Cudity
hr.,-dv,oc:ds, plywood, exo[i:; lumbe-:.
UI 'Slmotor frPliTt, W";c:ew1G rf>c:es Circle
No. 856.
WOODWORKERS SOURCE H;:,rdwoods frem
ilrOlJlld tce WOltJ. Circle No. 869.
Income Opportunities & Education
FURNITURE MEDIC OffPfil g irc;:-,m,Sf!
1.::8:13es [0 to perfcrm molJls,
o'>-site furn:II..-fJ & restcrr.,[KJ'1 se<,;CfJS
Circle No. 895.
PROFURNITUREBUILDER.COM
P1oFurnltcro8ul cfo(,oom frem f,.'IQ.,dowtnxo.;
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WOODCRAFT RETAIL FRANCHISE 0-"'1 a
Woocl:;raft S10re - frJllCilises offerBd for stcres
auoss II">:! cou:1try. Circle No. 924.
KLOCKIT Ifl(dng SUP!,I'H I)f clockmflkir1g
for over 05 years! Cin:le No. 973.
WOODEN-GEAR-CLOCKS.COM Crealp J.
wocde'1 geCJr GIld av",ili';,[je
Circle No. 1008.
AZTEC STEEL CORP. o.."-'Iily pre-ccgne.::-rBd
r.i"chstyle stpPl IJJk:Ji:19S flf tl1elowmt80st
:;:lY',tlerp. Circle No. 1064.
CENTRAL BOILER U:;ssO::; Wooo Fl,- '1a8E!S
s",jo. efido:1t hent fcr yo.r horno, Circle
No. 1105.
DAKOTA ALERT, INC. A:1 ,Jert sou:rt, in thp
house wl>ell SO/T,OO,\e e'1Ie.-s the drrve Circle
No. 1129.
HYDRO-SIL Unq."", roc:m-by-roc:m heati1g
sys:u r, Circle No. 1190.
RADIANT FLOOR COMPANY RooMI
Hez,ting Systerns-eesign, m"nufxture;}1d &,18
fcr thlLJIY Circle No. 1301.
ROCK LOCK FASTENING SYSTEMS, INC.
Post ,';,nd rni ilg d lnch,' wn[ lyY(t,v3re thd mnkes
it oasy, Circle No. 1308.
ROCKAUTO.COM CllPCk out wNw,nockAuto.
cem fo' all 11"" [:Hts your CJr or In):;k '.'Iii ever
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COOK'S SAW MFG., L.L.C. I 'cr,(!!jP
&\'lTTills, Edgers, Sharpe''<s, &;nd Btooes.
Froo CJtz,0g, VKloo avcjtlt:ip, Circle No_ 1480.
THE CRAFTSMAN GALLERY ROlitPl' Boss
joinery rf\i';chl1es n'1d qly;lil Y \'iwj"vcrhlg
toos and accp:.scr:ps. Circle No. 1495.
DREMEL MULTI-MAX T'1e npw Ummel"
M1JltiM,-;,x r" Jsclbhlg 100 system. Rrr,f.; r.
Rormoo, Restcrc Cin:le No. 1508.
FREUD POWER TOOLS 16-pc'-99 caobg
ilust'ates dfJpe<ldfllJe power loos Wltll
Fr(!<Jd q1J:;':1y. Circle No. 1532.
JET SUPERSAW Cast :ro1 si rl i,'J
GrOSSO.Jt t,;,bk'l, mk:ro aq ust fruCR Tcrafy
e'1OkJsed c:;bOlet Circle No. 1588.
LAGUNA TOOLS Rcc rnahCffl
Icr prol'Els.simiils J:)j hot:ey;sts, !lwad-'. .. mi:lg
design t:dlds",ws, [l'-cvP";,n q.Yli ty mr.dir..,s
u,'Of 2:0 )I:\H c! OXjJCrCoixoe, Circle No. 1593.
MAXNC, INC. Mfl:)Jfa8[urerS Of Amflfioa:1
rmee CNC hires n:)j routers .. ",1
z,ffordaCie pr'ccsl Circle No. 1612.
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RADARCARVE Manufacturer of
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STANLEY.BOSTITCH "INISH N,f.JLIiAS &
STAPLERS l r.a P',.f"'ftl' i ty ":I ;"'II:mg
p'olassionals whffi C(Wlt!S If' "'S ar'lJ
SlapWS_ Circle No. "68.
TOOlMAAT INC. 'N, lOOs
accesoc .... ,sh t , 1 ... .., . tPOl1f1'
. .H:, Po-... annat Ci,.;,. fII o. 1770.
WOOOMIUR PRODUCTS EIght
s.t>... .1:; ,; Idble S1<lltn ".' t" lflli' d 1( n'
S3995. Circle No. 1805.
WOOOMASTEA TOOLS Ml,M, :"''1 pl;r-etll
Ihl! 'fIC""-l. said & Circl e No. 1820.
PNjIct & MItIItIII
OSBORNE WOOD PRODUCTS. INC. 4 1' p':!
0\ lab e r.<)S, OOfll':!,S ,-r.n{j Je--.j5
Cin:le No. 1849.
OSBORNE WOOD PRODUCTS. INC.
1'1000 CO'-(!:H:L..;) 0I'Ia' (;1fl'3$jC cot)ols In a b'OO:l
rafl 98 of styleS, Circle No. 18'1.
__ --'51 ,,""- "'! ... Acclllrt.iIa
Ll GNOMAT USA, LTD. ,.m
(l,"d Pl nlellS .lY. .st. ffl " ""IHrS Ie;.<" "iooJ Free
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ONEIDA AIR SYSTEMS, INC. I"IllfiI :nfonTJJ-Ie
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cornpptp dLJ.;INOrk. Circle No. 20'9.
PENN STATE INDUSTRI5S A"".(I., ..... "9
;.m' oclJOn. Cc EICIC CycU"oes. Duclwork
and rncJ'I' Ctrcl. No. 204&.
PHASE-A-MA11C, INC. (;"I'l\t<1r! l-f1'1ASe
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RED HILL CORP. SUPERGRI '"
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WALL CONTROL C0I,"',J
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Cin:le No. 2100.
Shop Supplies
CLEANSTRIIAM PRO FILTERS \/,I1th
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BEREA HAROWOODS u..1(l11), P>'""'I kj'S uI"I(I
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HUT PROOUcn . ,;"'-. 'IS >IO\II.;s ol" SOWIIlS
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PACKARD WOODWORKS )1
V'JCODTUHNI:: ,5' (Aw:y I <I t' -os T{1 I wd
Supp'% CIrcl e No. 2143.
PENN STATE INDUSTAIIi.S leading SL'PPI'-
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Shape Up
Your Workshop!
47
101'
Luntber, Inel Supplies
Build Your Own Shop
and Save!
This spedal
publication from
the editors of
WOOD' Magazine
hal 132 pages
packed with great
ideas to keep
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COVEft4, TIC
Barrister's bookcase
L(){)ling stately in wa Inut, tllis Co bi ret stores your books bellind Ir oditiondl fiip-up, glass-ponel doors. A
drawer at the bottom glides out for access to hanging file folders,
One Jow-profile cabinet, two purposes
Hide a fiat-p.J nel televilion styli:l hly in <l II mple-to-bllild )(Irround with
bi-'old doors (ab0l1fl, or md!f a nMrow VErsion for d dort board (right),
92
Curvaceous jewelry box
Straightforward constllJCtk:<l hdes bhild fuv.ing lines
of this handwne box. Simple potteTns make 'rt eal), to cut
matching [\jrves on the drOl'll'rfroots, pulls, [JS{',
Pass the chips, please
Sm'e in style 'rom this laminated chip-and-dip
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Scrollsawn barnyard puzzle
Faell member of tlli, happy herd i, its own jilJiaw puzlle
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WOOD magaztne 2009
From the company that invented versatility,
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Visit II pllrt icipll l ing Slan/er ' dealer near rou I(J own yours lor/ay.
NO. 4
SMOOTHING PLANf
NO.62
LOW ANGLE JACK
NO. 60 1/2
LOW ANGLE BLOCI( PLANE
NO 9 1/2
BLOCK PLANE
NO.92
SHOULDER, CHISH PLANE
(itBiti'
stanl eyt ool s.co m