192 Build an Fine Woodworking Fine TAUN TON’S Adirondack chair, p. 54 ADIRONDACK CHAIR GLUE TEST FINISHING REPAIRS DRILL-PRESS TEST FIGURED WOOD CABINET BACKS CABINET WOOD FIGURED TEST DRILL-PRESS REPAIRS FINISHING TEST GLUE CHAIR ADIRONDACK How strong is your glue? 6 types tested with surprising results How to: Fix finishing mistakes Buy a benchtop drill press Choose and use figured woods Design a cabinet back Use chisels precisely Build a door frame July/August 2007 July/August August 2007 No. 192
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contentsJULY/AUGUSt2007 issue192
features 36 How Strong Is cover story Your Glue? We take six types to the breaking point, shattering some common wisdom in the process B y m a r k s c h o f i e l d
41 10 Best Fixes for Finishing Mistakes Cures for common problems, and how to prevent them in the first place B y t e r i m a s a s c h i
48 A Back for Every Cabinet The right choices balance strength, appearance, and efficiency B y s t e V e l a t t a
CEntEr-GUIdEd 72 drAwErS
Cover photo: Mark Schofield
w192CT.indd 4 5/10/07 11:52:09 AM UNDERSTANDING up front 92 WOOD FIGURE 6 On the Web 8 Contributors 10 Letters 14 Methods of Work N Shopmade stand holds carving gouges N Carry sheet goods with ease ADIRONDACK CHAIR 54 20 Tools & Materials N Bosch shop vacuum N Blue Spruce dovetail chisels N Pinnacle honing guide
NEW 26 What’s the Difference? Natural vs. synthetic brushes 54 Adirondack Chair Build this comfortable, 28 Fundamentals lightweight version Get the most from your of an American classic bench chisels BY TOM BEGNAL 68 Benchtop TOOL TEST Drill Presses in the back 62 Mitered Molding The best do everything a furniture maker needs 84 Readers Gallery Simplifies BY CHARLIE REINA Traditional Doors 86 Q & A Power-tool technique N Sharpening a curved scraper works for any molding profile 72 Center Guides N Dovetailing a lipped drawer BY LONNIE BIRD for Drawers Shopmade guides 92 A Closer Look ensure smooth action Understanding figure in wood for wide drawers 104 Master Class BY MARK EDMUNDSON Maple-leaf marquetry
78 Elegant NEW 110 How They Did It Veneered Boxes The back cover explained Veneer creates striking Back Cover patterns, yet construction One unreal egg is straightforward BY SETH JANOFSKY
BENCHTOP 68 DRILL PRESS TEST FineWoodworking.com
w192CT.indd 5 5/10/07 11:52:27 AM onFREE THIS the MONTH ON FineWoodworking.com web Free online extras available June 5 W at www.finewoodworking.com/extras VIDEOS EDITOR Asa Christiana Assembling an Adirondack ART DIRECTOR Michael Pekovich Tom Begnal (“Adirondack Chair”) walks through the MANAGING EDITOR Mark Schofield assembly of this backyard classic and demonstrates beginner’s techniques for cutting the parts. MANAGING EDITOR, ONLINE Matt Berger ASSOCIATE EDITORS Glue Testing Thomas G. Begnal, Steve Scott, Go behind the scenes with Mark Schofield (“How Thomas McKenna, David Heim, Charlie Reina Strong is Your Glue?”) to see how we performed our ASSISTANT EDITOR Anissa Kapsales methodical joint-breaking test. ASSISTANT EDITOR, ONLINE Gina Eide Radial-Arm Drill Presses SENIOR COPY/PRODUCTION EDITOR Liz Healy Charlie Reina (“Benchtop Drill Presses”) reviews two COPY/PRODUCTION EDITOR Julie Risinit more drill presses that offer extra reach and a tilting head, and talks about why you might want one. ASSOCIATE ART DIRECTOR Kelly J. Dunton ASSISTANT ART DIRECTOR John Tetreault PROJECT PLAN SHOP MANAGER John White Dead-Flat Assembly Table ADMINISTRATIVE ASSISTANT Betsy Engel Build a torsion-box assembly table with plenty of storage below in the first of CONTRIBUTING EDITORS Christian Becksvoort, Gary Rogowski, our exclusive Web-only project series Garrett Hack, Roland Johnson, Steve Latta hosted by FineWoodworking.com’s METHODS OF WORK Jim Richey new contributing editor, Marc Spagnuolo. PUBLISHER Anatole Burkin MARKETING MANAGER Melissa Robinson ADMINISTRATIVE ASSISTANT Christina Glennon CIRCULATION DIRECTOR Dennis O’Brien plus: SENIOR SINGLE COPY SALES MANAGER Jay Annis O FURNITURE GALLERY ADVERTISING SALES MANAGER Peter Badeau O READER TOOL REVIEWS SENIOR NATIONAL ACCOUNT MANAGER O WOODWORKING BLOGS Linda Abbett Rob Brown Step Tansu NATIONAL ACCOUNT MANAGER John Lagan Peterborough, Ont., Canada Rob Brown Peterborough, Ont., Canada CORPORATE ACCOUNTS MANAGER Judy Caruso SENIOR AD SALES SUPPORT ASSOCIATE members only: Marjorie Brown Become a member for electronic access to 30 years of Fine Woodworking articles, how-to videos, and exclusive Web content. WOODWORKING BOOKS & VIDEOS EXECUTIVE EDITOR Helen Albert
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The Taunton Guarantee: If at any time you’re not completely satisfied with Fine Woodworking, you can cancel your Whatever your project, the WoodRat gives subscription and receive a full and immediate you strong, elegant, well fitting joints. refund of the entire subscription price. No It’s fast, accurate, fun and makes virtually
questions asked. 406 Pearl Street, Walnut, IA 51577 1-800-521-5458 any kind of joint without compromise. Unique Planes, Sharpening Jigs & Portable Workbench Get the demo DVD today: $7.00 Copyright 2007 by The Taunton Press, Inc. No reproduction 1-877-WOODRAT www.woodrat.com without permission of The Taunton Press, Inc. www.blumtoolco.com READER SERVICE NO. 104 READER SERVICE NO. 94
JULY/AUGUST 2007 contributors Ss
I NDEPENDENT PUBLISHERS SINCE 1 9 7 5
TAUNTON, INC. (“Elegant Seth Janofsky Founders, Paul and Jan Roman Veneered Boxes” and Master Class) learned photography at The THE TAUNTON PRESS Cooper Union in New York City. But President Suzanne Roman after a few years of photographing Executive Vice President & documents in the city’s archives, Chief Financial Officer Timothy Rahr he decided to study woodworking Executive Vice President & at the College of the Redwoods Publisher, Magazine Group Jon Miller in California. He now does his Chief of Operations Thomas Luxeder woodworking at the old Alameda DIRECTORS Naval Air Station near Oakland. Creative & Editorial Director Susan edelman His shop space is a bunkerlike room once used for testing aircraft Human Resources Director Carol Marotti engines, with foot-thick reinforced- Technology Services Director Jay hartley concrete walls and an explosion- Controller Wayne Reynolds proof steel door. Advertising Director David Gray Fulfillment Director Patricia Williamson Financial Analysis Director Kathy Worth Mark Edmundson (“Center Guides for Drawers”) has a passion Circulation Director Dennis o’Brien for more than woodworking. When not making furniture or spending time with his family, Edmundson can be seen in T h e Tau n To n P R e SS the wild, shredding powder on the ski slopes or tearing up Books: Marketing: Melissa A. Possick, Audrey the mountain-bike trails he’s carved through his property in Locorotondo. Publicity: Nicole Salvatore, Janel Noblin. Sandpoint, Idaho. Most recently, he’s been making snow skates, Editorial: Helen Albert, Kathryn Benoit, Peter Chapman, Steve Culpepper, Pamela Hoenig, Courtney Jordan, a snowboard/skateboard hybrid. Carolyn Mandarano, Nicole Palmer, Jennifer Russell, Erica Sanders-Foege, Kathleen Williams. Art: Chris Thompson, Alison Wilkes, Nancy Boudreau, Amy Griffin, Sandra Mahlstedt, Wendi Mijal, Lynne Phillips, Carol Singer. Lonnie Bird (“Mitered Molding Simplifies Traditional Doors”) Manufacturing: Thomas Greco, Laura Burrone. teaches woodworking at his school near Knoxville, Tenn. Bird and Business office: Holly Smith, Gayle Hammond, Patricia his family also enjoy the outdoors and their small horse farm in Marini. Legal: Carolyn Kovaleski. Magazine Print the foothills of the Great Smoky Mountains National Park. You Production: Philip Van Kirk, Nicole Anastas, Jennifer Kaczmarcyk. can view his class schedule at www.lonniebird.com. Circulation: David Pond, Andrew Corson, Catherine Hansen. Distribution: Paul Seipold, Walter Aponte, Frank Busino, David DeToto, Leanne Furlong, Deborah Greene, Frank FineWoodworking.com Associate editor Tom Begnal (“Adirondack Chair”) began his Melbourne, Reinaldo Moreno, Raymond Passaro, Alice Saxton. woodworking career as a hobbyist in the mid-1970s. Eventually, For more information on Finance/accounting: Finance: Brett Manning. our contributors, go to his interest in the craft evolved into a full-time furniture-making Accounting: Patrick Lamontagne, Lydia Krikorian, Judith www.finewoodworking business in northwestern Connecticut. After spending time at O’Toole, Elaine Yamin, Carol Diehm, Dorothy Blasko, .com/authors. two other woodworking magazines, he joined our staff in 2000. Susan Burke, Lorraine Parsons, Larry Rice, James Tweedle, Priscilla Jennings. Fulfillment: Diane Goulart. Fulfillment Systems:Jodi Klein, Kim Eads, Nancy Knorr, Thomas Kuzebski. Customer Service: Ellen Grassi, Kathleen Baker, Bonnie Teri Masaschi (“10 Best Fixes for Finishing Mistakes”), a Beardsley, Deborah Ciccio, Katherine Clarke, Alfred frequent contributor, operates a thriving finishing and furniture- Dreher, Monica Duhancik, Paula Ferreri, Eileen McNulty, Patricia Parks, Deana Parker, Patricia Pineau, Betty restoration business from her home near Albuquerque, N.M. She Stepney. Data Entry: Melissa Youngberg, Anne Champlin, also teaches her finishing techniques at woodworking schools Mary Ann Colbert, Caryne-Lynne Davis, Maureen Pekar, and shows across the country. Between classes, she searches Debra Sennefelder, Andrea Shorrock, Marylou Thompson, Barbara Williams. for old furniture that she can take home to New Mexico to human Resources: Linda Ballerini, Christine Lincoln, rejuvenate and sell. Dawn Ussery.
FINE WOODWORK IN G
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Information Technology Services: Applications Development: Heidi Waldkirch, Jun Lu, Frank Miller, ENTER for URNITURE RAFTSMANSHIP Robert Nielsen, Linda Reddington, John Vaccino, Daniel C F C Woodhouse. Desktop and Network Support: Kenneth Jones,
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Motyka, Nicole Pallatto, William Sims. Promotion Operations: Amatory Chair by Instructor David Upfill-Br Diane Flanagan, John Cavallaro, Sandra Hannan, Kate Rockport, Maine 207-594-5611 www.woodschool.org Krentsa. Taunton Creative: Michael Amaditz, Sarah Opdahl. Video: Gary Junken. Publishing Services: Deborah Cooper. Publishing Technologies: Mark Merritt, Tracy Goodpaster. Photography: Scott Phillips. Prepress: Richard Booth, William Bivona, David Blasko, Richard Correale, William Godfrey, Brian Leavitt, Chansam Thammavongsa.Advertising Production: Laura Bergeron, Lisa DeFeo, Steven Molnar, Patricia Petro, Kathryn Simonds, Martha Stammer.
Tau n TO n D I R E C T Donna Capalbo, Keri DeGross, Michele Ladyko, Kathleen McGreevy, Michael Valanzola. Tau n TO n I n TER aCTIVE Jodie Delohery, Robert Harlow, David Hall, Christopher Casey, Mark Coleman, Trish Dardine, Ruth Dobsevage, Lisa Durand, Erika Foreman, Geoff Krajeski, Steve Lombardi, Victoria North, Michael Stoltz, Dawn Viglione. Tau n TO n T R a DE Kevin Hamric, Director; John Bacigalupi, Brett DeMello, READER SERVICE NO. 84 READER SERVICE NO. 47 Allison Hollett, Elizabeth Quintiliano, Rebecca Shafton. Single Copy Sales: Jay Annis, Mark Stiekman, Valerie Droukas.
TaunTOn MaGaZInES Fine Woodworking • Fine Homebuilding Threads • Fine Gardening • Fine Cooking Our magazines are for people who are passionate about their pursuits. Written by practicing experts in the field, Taunton Press magazines provide authentic, reliable information supported by instructive and inspiring visuals. TaunTOn BOOKS Our books are filled with in-depth information and creative ideas from the finest authors in their fields. Whether you’re practicing a craft or engaged in the creation of your home, Taunton books will inspire you to discover new levels of accomplishment. READER SERVICE NO. 114 WWW.TaunTOn.COM Our website is a place where you can discover more about the interests you enjoy, converse with fellow enthusiasts, shop at our convenient on-line store or contact customer service. EMPLOYMEnT InFORMaTIOn ! To inquire about career opportunities, please visit our website at careers.taunton.com. You may also write to The Taunton Press, Human Resources, 63 S. Main St., Box 5506, Newtown, CT 06470. CuSTOMER SERVICE We are here to answer any questions you might have and to help you order our magazines, books and videos. Just call us toll-free at 800-477-8727. The Taunton Press, Inc., Taunton Direct, Inc., Taunton Trade, Inc., and Taunton Interactive, Inc., are all subsidiaries of Taunton, Inc. READER SERVICE NO. 86 READER SERVICE NO. 58
JULY/AUGUST 2007 letters
Jointer/planer combo machines The newest machine in my 50-year-old workshop is a Hammer A3 31, named “Best Value” in your recent test of 12-in. jointer-planer combo machines (FWW Spotlight #190). It is worth every cent I paid. Equally valuable are the accessories I ISSUE NO. 191 bought: The handwheel with digital June 2007 readout and two jointer extension tables. p. 74 The tables go on quickly and double the length of the bed to 118 in. (jointer-table HEAVY-DUTY LATHES? length was cited as a reason the Hammer was not “Best Overall”). The extension In “Tool Test: Heavy-Duty Lathes,” author Andy Barnum says that his review is also can be used on the planer bed. limited to machines in the $1,200 to $3,200 price range because higher-priced —DENIS LOCK, Bedfordview, South Africa lathes are “sized and priced strictly for the pros.” Because of this, he has neglected Watch your math to include a number of machines a buyer might consider: Stubby, VB36, Oneway, In FWW #187, Christian Becksvoort’s Robust, Vega, Vicmarc, to name a few. article on moisture content contained an Spending more than $3,200 on a lathe does not require one to sell work nor to elementary math error. Repeatedly, it says a change from 6% MC to 16% MC is a 10% hang out a shingle any more than spending $10,000 on a bass boat makes one increase. It’s not. It’s a 167% increase, or a professional bass fisherman. It is clear that Mr. Barnum’s idea of “heavy-duty” an increase of 10 percentage points. and mine are not the same. —VAUGHN J. MANTOR, Tucson, Ariz. —BILL RUBENSTEIN, Stubby Lathe USA, St. Charles, Mo. Review missed a Woodcraft router bit Editor Asa Christiana replies: Your point is well-taken. We’ve received a number of I was disappointed that the recent article similar letters from dedicated wood turners. The editors deserve the heat for the “Tool Test: Router Bits” (FWW #191) did headline, not the author. We chose this specific group of lathes, and called them not include a selection from the Woodcraft “heavy-duty,” because the majority of our readers are furniture makers who will see router-bit line. Woodcraft’s Classic Roman Ogee Bit (#144125) has the same profile these lathes as a major upgrade. Every machine review is a massive undertaking. as the bits tested. While the #144125 is not We try to define a manageable group that will be relevant to our readers. In this listed in the Woodcraft catalog, readers case, we stopped short of the highest tier: massive, very pricey, zero-compromise can find it at www.woodcraft.com, where lathes—meat and potatoes to some, agreed, but caviar to others. A ceiling of there is an expanded offering of both Woodcraft and Whiteside router bits. $3,000 made sense. At the last minute, the street price of the Powermatic 3520B —JODY GARRETT, vice president, Woodcraft Supply we reviewed went to $3,200. FineWoodworking.com
Octagonal peg in a round hole pegs into place and have never suffered a Meet the contest winners Matthew Teague’s “The Pegged Joint, joint failure or loosening because of it. Six months ago, we asked readers to Exposed” (FWW #191) was well done. —RICHARD O. BYRNE, Staunton, Va. tell us “Why I Deserve a New Shop.” The One thing that should be added to the reader with the best story would win a repertoire of pegged joints is cutting them Park machines like cars complete set of machines, power tools, and hand tools, plus a daylong visit by our to more-or-less octagons and then driving Regarding your illustrations of casters tool expert to get set up. After reading them into the hole. The odd dimensions (“Choosing and Using Casters,” FWW 9,000 essays, we chose a worthy winner, will cut their own channel and lock the #190), a cart handles better with the swivel Tim Carroll, the woodworking instructor peg into place. As a furniture conservator, wheels on the back, below the push bar. at Harrisburg (Pa.) Career and Technology I have disassembled many 18th- and 19th- Years ago, I learned from valet parking Academy. Four runners-up won router century mortise-and-tenon joints where attendants that backing cars into spaces packages. Go to www.finewoodworking the pegs were not glued in, thus allowing makes parking and retrieving much faster .com/extras to read the winning essays the piece of furniture to be taken apart and easier (and safer from scratches). and watch a video about this special for needed repairs. I seldom, if ever, glue —RICHARD ELLERS, Warren, Ohio teacher, his students, and his new shop.
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Clipboard with Cove for tool drawing Shelf
Tool tray
Slat
Block for other tools Carving gouges
Dado provides finger space. Best Tip Carver’s stand holds 30 gouges
I specialize in making reproduction 18th-century accept a pencil, an awl, a mallet, and furniture, so it’s not unusual for me to use 30 carving other tools I use when carving. gouges on one piece. With that many tools in play, So that I can efficiently pull and replace gouges, an efficient storage system is a must; otherwise, I’d I use a logical tool marking and placement system. spend more time looking for tools than using them. First I mark each handle with the radius number An award- This double-decker stand lets me grab the right tool and blade width in millimeters. Then I place them winning builder almost from memory. in ascending order by radius and width. After using of reproduction The design is my impression of what an this system for a time, I can locate the tool I need furniture, Eugene 18th-century furniture maker might have built. The with just a glance. Landon frequently stand has two sides, two tool trays, and a rack on —EUGENE LANDON, Montoursville, Pa. teaches at the Olde top to display a sketch of the carving. All the parts Mill Cabinet Shoppe are pine. Screws hold everything together. A Reward for the Best Tip in York, Pa. The tool trays are the heart of the stand. They feature multiple coves, one for each tool. I plowed Send your original tips to Methods of Work, Fine Wood- them with an antique round-bottom plane, but you working, PO Box 5506, Newtown, CT 06470, or email [email protected]. If published, we pay $50 for could either drill 1-in. holes into 2-in.-thick stock an unillustrated tip; $100 for an illustrated one. The and then rip it on the bandsaw, or use a dado blade author of the best tip gets a pair of Brian Boggs to cut recesses in 1-in. stock. I also cut a dado the spokeshaves (one flat, one curved) made by Lie- length of the tray about where the tool handles meet Nielsen Toolworks. the blades. This allows me to grab the neck of each tool easily with my fingers. Each tray also features a slat at the back to elevate each tool slightly. Finally I added blocks, hooks, and holders to the sides to
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Introducing Cabot interior wood stain. Now the things that make wood unique are the very things that make it beautiful. Whether it’s a cherished family heirloom or simply the family room floor, Cabot enhances wood’s natural beauty by adding richness and depth. Made using only the finest-grade oils and pigments, you’ll find heritage, pride and commitment in every can. cabotstain.com Our performance is legendary.™ methods of work continued
Improved sharpening-stone holder For years I have been securing my honing stones in a Sharpening stone metalworking bench vise, protecting the stone from the metal jaws with a towel. This required careful adjustment of the vise— Holder too much clamping pressure would crush the stone, too little Vise would allow it to fall to the floor. I was never happy with the arrangement. Today, I hit upon this better solution. To make the holder, start with a scrap block of wood as long as the stone. Cut a dado in the top of the block just wide enough to accept the stone. Also, cut rabbets on the bottom, so the block can be clamped in the vise. Now, from opposite ends, cut two sawkerfs, each about two-thirds the length of the block. Just make sure the kerfs have enough width so that you get an adequate amount of squeeze when the block is tightened in the vise. The fixture is easy on the stone yet holds it securely. —Joseph scannell, novato, calif.
Sawkerf Quick Tip To prevent safety glasses from fogging, use a bar of soap like a crayon to rub soap on each lens. Polish the lenses with a cloth. No more fog. Eventually, the soap loses its effectiveness. Keep a bar of soap handy in the shop, in a Dado to plastic bag, so you can quickly recoat the fit stone Rabbet to lenses. fit vise — J a m e s a r t h u r s , Gibsons, B.C.
Car jack simplifies cabinet installation Plywood platform When installing the upper sections of kitchen cabinets, you need to hold the cabinets at just the right elevation until they are attached. The setup shown here is both effective and simple. Plus, the height is variable. Screw the 1⁄2-in. plywood platform to a 2x4 stiffener. Drill a hole halfway through the underside of the stiffener the same diameter as the threaded shaft on the jack. 2x4 clamp Cut another 2x4, about 5 in. long, for the clamp. Drill a hole through the center of the clamp the same size as described earlier. Cut the clamp in half (to remove one sawkerf of material) and verify that the two pieces, when placed around 2x4 stiffener the shaft and screwed back together, will grip the shaft tightly. Screw one half of the clamp to the stiffener and then, with the 2-ton hydraulic jack clamp on the jack’s shaft, screw the second half to the first and then to the stiffener. To use, simply set the fixture on the lower cabinet top, set the cabinet on the fixture, jack to the correct height, and screw the cabinet to the wall. As you operate the jack with one hand, use your other hand to keep the cabinet from tipping. —lyle Bristol, cocoa, Fla.
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