HALF-BLIND DOVETAILS 9 steps to sure success Page 42

Better Homes and Gardens

«tY/»M»lY ORKING MAGAZINE FEBRUARY 1997 ISSUE NO. 95 P FENCE ROUNDUP WE TEST 21 MODELS Page 53

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MUST-BUILD

Country buffet •Circle-top shel n IH I i L*l*l III [•IHfJ MM Bandsawn box^_^ I Turned pocket watch ~~~~ Kid's stilts ^— Cockatoo bank

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Please display until February 11 The New Force of Grizzly!

Both Come With A

Carbide-Tipped Saw Blade!

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!j-J W2M INTRODUCTORY PRICE INTRODUCTORY PRICE $ 00 $109500 j! 449 I tools. The Z-SER1ES represents top of the We are proud to introduce our Z-SERIES line of woodworking sought after features in a tablesaw and line" versions of our standard table saws. We've taken the most contractor or cabinet-style incorporated them into the best saws you can find. So, whether you are after the call- won't be disappointed! tablesaw, you owe it to yourself to give us a you G1022Z G1023Z • Front rail-mounted magnetic Belt driven from the rear-mounted motor to the arbor switch for easy access 4" - with dust port and clean-out Heavy-duty rip fence IMPORTS, INC. micro-adjustment knob • SHOP FOX* Fence Quick-lock fence locks front and back New saw guard

All ball bearing mechanism Purveyors of • Beveled table edge Beveled table edge Fine Machinery. Motor Cover • H.P. Single Phase, 11 0/2 20V motor Vh • T miter slots Sturdy stand 3 H.P., 220V motor Precision-ground cast iron table • Triple V-belt drive and extensions • Shipping weight: approx. 425 lbs. Shipping weight: approx. 270 lbs. TOLL FREE 24 hours a day! West of the Mississippi Ask for your East of the Mississippi FREE • • • \ 1 • • 523 • 4777 1 800 541 5537 '96 catalog! 800 1-800 -438 -5901 FAX: 1 • 800 • 225 • 0021 FAX: http://www.grizzlyimports.com ClfClo No. 860 Ask for Department # 66C Better Homes and Gardens® THE EDITOR'S ANGLE

A creative use for THE WORLD'S LEADING WOODWORKING MAGAZINE

FEBRUARY 1997 • Vol. 14, No. 2 • Issue No. 95

Editor LARRY CLAYTON Managing Editor JIM HARROLD Tired-Out Trees Art Director C. L. GATZKE Design Editor JAMES R. DOWNING Senior Editor/Features PETER J. STEPHANO don't know about you, Senior Editor/How-To MARLEN KEMMET Assistant Managing Editor/Products BILL KRIER but I've always been fas- Senior Editor/Special-lnterest LARRY JOHNSTON Icinated by chainsaw General-Interest Editor KERRY GIBSON carvings. Whenever I watch Director PERRY A. McFARLIN Associate Art taking shape Assistant Design Editor/Project Builder JAN HALE SVEC one quickly

Project Builder CHARLES I. HEDLUND under the skillful hands of Production/Office Manager MARGARET CLOSNER the carver, I feel like I'm Graphic Designer CHERYL A. CIBULA witnessing a miracle. Administrative Assistant NATALIE COOLEY Correspondence Writer DON MOSTROM Lately, it seems like I've Contributing Editors KIM DOWNING, DAVE HENDERSON, been seeing more of these LORNA JOHNSON, ROXANNE LeMOINE, BOB McFARLIN carvings than ever, mainly

©Copyright Meredith Corporation 1997 used as outdoor sculpture. All rights reserved. Printed In the U.S.A. Recently, on the way home Better Homes Gardens® WOOD® magazine (ISSN-0743- and from work, 1 spotted one in 89'iX) is published nine times a year in January, February. April, June, August, September, October, November, and the shape of a turkey in December by Meredith Corporation, 1716 Locust St., Des someone's front yard. Moines. 1A 50309-3023. Periodicals postage paid at Des Moines, Iowa, and additional mailing offices. Better Homes Then, at the Iowa State and Gardens trademark registered in Canada and Australia. Fair last summer, I was in a Marca Registrada en Mexico. ONE-YEAR SUBSCRIFITON PRICES: U.S. and its possessions $25; Canada, S36; other coun- large crowd that watched as tries, S45- Canadian GST Reg. »BN 12348 2887 RT. POSTMAS- TER: Send address changes to Better Homes and Gardens WOOD carver Brian Ruth, of Magazine, P.O. Box 55050, Boulder. CO 80322-5050. Hartsville, Pennsylvania, transformed a red maple log into a 24" tall roadrunner CUSTOMER SERVICE INFORMATION: For service on your magazine subscription including change of with his chainsaws. address, phone toll-free 800/374-9663. Or, write to California chainsaw carver A.J. Lutter (left) and interesting use Better Homes and Gardens WOOD Magazine, P.O. Box The most Bill Mays standing beside one of the five lO'-tall 55050, Boulder, CO 80322-5050. Please enclose your sculpture I've of chainsaw bear sculptures that grace Bill's property. address label from a recent issue. EDITORIAL INFORMATION: Address letters and ques- seen, though, is in the yard tions to THE EDITOR, WOOD Magazine, 1912 Grand of Bill Mays, a retired executive, Thanks to this conservation- Avenue, Des Moines, LA 50309-3379. in suburban Des Moines, Iowa. minded property owner's quick Bill's odyssey began after the city thinking, and to one terrific m decided to widen the street adja- carver, the world is now a more cent to his lot. According to Bill, lighthearted, more beautiful as a result of the city installing a place. Thanks guys! WOOD ONLINE™ retaining wall along his property, If any of you have a tree on your several 65- to 80-foot pine trees property that you're thinking at http:woodmagazine.com next to the wall died. about getting rid of, give Bill's •Do you have questions on proj- Faced with the prospect of hav- solution some thought. To locate ects, tools, finishes, or woodwork- ing to saw die trees into firewood, chainsaw carvers in your area, ing in general? If so, post your Bill opted for what has turned out first call local chainsaw dealers. If questions on our Discussion to be a traffic-stopping solution. that doesn't produce results, Group. Most questions are He hired A.J. Lutter, a talented check with the local artists' asso- answered within a few days. California chainsaw carver, to cre- ciation. No luck, there? Then •We've added several new share- ate five humorous bear sculptures write to me, and I will try to help ware programs for your computer (one is shown in the photo you locate someone who can to help solve shop problems. You above'). Bill tells me that the work on your project. (Note: A.J. $100 to can now download all of the pro- bears, which A.J. created without charges anywhere from grams for free from our drawing pattern lines, have $300 per foot for his carvings.)* Woodworker's Software Library. become such a popular tourist •Use our searchable index to find attraction that city officials and articles and projects from issue no. the police now offer interested

1 to the present. parties directions to Bill's lot.

WOOD MAGAZINE FEBRUARY 1997 ^m&tfmomm ISSUE NO. 95 FEBRUARY 1997 Better Homes and Gardens® EI/tDGO THE WORLD'S LEADING WOODWORKING CONTENTSMAGAZINE 27 His sticks are made for walkin' When Tom Smith retired, he leaned on his woodworking skills for a new life. 42 Half-blind dovetails Learn how to use your dovetail jig to make to ugh, tight-lining joints. 48 A pro's pointers for preparation Discover the finishing secrets from the WOOD® magazine workshop. 53 Rip fences Before buying a new tablesaw fence, see our test results inside. 66 Wiring your shop Let us help you figure the electrical needs for your shop. 70 Salvage: the new way to log old timber Discover unique sources for old-growth fir, pine, and hardwoods Page 32

Woodworking projects in this issue Page 60 32 One cool catchall Bandsaw a fine flip-top box in an evening using contrasting woods. 37 Chubby choo-choo Make a locomotive for show or play. 44 Cockatoo cache Build a bird that's really a bank. 50 Arched-top wall shelf Display collectibles effectively on this mir- rored painted project. 60 Country buffet & cupboard Construct the buffet, then top it with the cupboard from issue 95. 68 Stupendous stilts Page 44 Let kids walk tall with this design. Page 70

SHORT-SUBJECT FEATURES

1 The Editor's Angle 24 Great Ideas For Your Shop 4 Talking Back 74 Yesterday's Tools 10 Tips From Your Shop (And Ours) 78 Products That Perform 1 6 Router Review 100 Pocket Watch 20 Ask WOOD 103 Finishing Touches Tbls issue's cover wood grain: Hackberry

WOOD MAGAZINE FEBRUARY 1997 THE THINGS YOU BUILD WILL BE STANDING LONG AFTER YOU DIE. LEAVE A GOOD MARK.

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Artists sign the bottom of the canvas. Athletes set records. Yours is a more subtle signature.

But if you do it right, your legacy won't fade. And it will never be broken. BOSCH ENGINEERED FOR PERFORMANCE" www.boschlools.com GIANT TALKING BACK SELECTION Converting decimals How to reach us to fractions We welcome comments, criti- A part of the course in cabinet- BIG SERVICE cisms, suggestions, and even making that I took about 50 compliments. And you're sure to years ago included a way of Small Prices hear us, changing decimal measurements back from perhaps on this page! You can "talk back" by Get your hands into fractions. This technique on some of the one of several ways: came to mind when I read "What best woodwork- • your letter woodworkers need to know: Via mail. Send to ing tools and Talking Back, WOOD' magazine, Calipers" in the September 1996 supplies 1912 Grand Ave., Des Moines, IA around. All at issue. Here's how it works: 50309-3379. the lowest 1 Take the decimal measurement • Via computer. Send your e- prices every- reading from your dial caliper mail to one of these addresses: day. Hundreds (I'll use the .768 from the arti- of items only CompuServe: 74404,3516 cle) and multiply it by the frac- available from us. Internet: tional denominator you're most [email protected] FREE CATALOG likely to use (32 for working in Vi2" measurements): Call or write us today to receive your FREE catalog of over 900 .766 2 Round the answer to the closest unique woodworking tools. X32 whole number, in this case, 25. ALL GUARANTEED FOR LIFE! 1536 This becomes the numerator of Martville lool Oonmpany 2504 your fraction. So, .768 roughly 1 3 1 63 Market Ave N Depl. BHG297C equals 25/32". Hartvillc, OH 44632 24.576 —Donald Burrows, Euclid, Ohio 1 -800-345-2396 Circle No. 865

Better Homes and Gardens® An addition to miter jig Advertising ^"TOTY TPrrTl I made Tim Hanson's miter jig as However, I did make one addi- ! \_/L Li 'LL «LU® &Marketing shown in the September 1996 tion to my version. I applied THE WORLD'S LEADING WOODWORKING MAGAZINE Talking Back letter "Improvements sandpaper to the entire face of Publisher WILLIAM R. REED on the miter jig." It was quick and each fence, using a spray adhe- Advertising Director MARK HAGEN easy to make, and the blade guard sive applied to the paper. This Display Advertising: 333 N. Michigan Ave., Suite 1401, Chicago, is an excellent safety feature. helps prevent the workpiece IL 60601 Phone: 31 2/353-2890 FAX: 31 2/580-01 13 Eastern Advertising Manager JAMES N. FORD from slipping while cutting the Western Advertising Manager WILL MURPHY Glue sandpaper miter. And for cutting crown Administrative Assistant JENNIFER HAMMEL faces of to moldings, I add a second piece jig fence. Direct Response Advertising: 1912 Grand Ave., Des Moines, IA of sandpaper to the top surface 50309-3379 Phone: 515/284-3785 FAX: 515/284-3343 of the jig. Direct Response Advertising Manager LISA WIEMKEN Liberti, Direct Response Advertising CINDY ANDERSON, Jim PATRICK MADDEN San Jose, Calif. Administrative Assistant MICHELLE GLOWACKI Classllled Advertising: Phone: 800/424-3090 FAX: 312/464-0512

Ancillary Sales Director MAUREEN RUTH Marketing Manager RICK PALLISTER Marketing/Ad. Services Supervisor PAT HENDERSH0TT

Circulation Director SUSAN SIDLER Associate Circulation Director KATHI PRIEN Business Manager JANET DONNELLY Senior Product Manager RICK GROW

Publishing Director MAX RUNCIMAN MEREDITH PUBLISHING GROUP

CHRISTOPHER M. LITTLE, President

BILL MURPHY, Custom Marketing; JERRY KAPLAN, Group Sales; MAX RUNCIMAN, Controller; BRUCE HEST0N, Manufacturing; HAL ORINGER, Circulation; DEAN PIETERS, Operations ^^eredith CORPORATION JACK D. REHM, Chairman ol the Board

WILLIAM T. KERR, President and Chiel Executive Olllcer

E. T. MEREDITH III, Chairman of the Execulive Committee UtBrltfMk WOOD MAGAZINE FEBRUARY 1997 uper cuts in veneered plywood, wlamine, chipboard-end solid woods.

8"SUPERDAD0 mmiKKB«CKO&Qi rUAMETER TEETH: 24 OUTStt mr max. cut 4CHPPERS

ULTIMATE CUTS IN VENEERED PLYWOOD. MELAMINE.

CHIPBOARD AND SOLID WOODS.

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smooth flat bottom dadoes. told us you needed a dado to cut plywood, solid wood, hardwood veneered plywood, laminates and melamine

chip-free. You told us that' it needed to cut precise slots and maintain accuracy. And it especially needed to aw.nmmodate today's undersized plywoods. ^^P o we engineered a dado that would not only meet your needs, but would surpass your expectations.

First we started with our superior tri-metal brazing to bond a special tooth design to an extra stiff blade body.

You wanted dadoes with super smooth flat bottoms so we included 4-wing chippers. You said you hate it when chips build up in the chippers, so we perfected a gullet which ejects the chips. And then we eliminated

the hub on the outside blade so chips cannot build up between the blades. The Super Dado will cut all your

materials chip-free with a dado so smooth, you'll hate to cover it up.

To make it even better, we added something no other dado manufacturer has...a sixth chipper that is l h" thick. That doubles the number of possible slot widths (from '/«" up to !9/w" wide), and allows you to set Shim set included.

the dado to fit today's undersized plywoods. To make it even more flexible, we've included a set of precision

steel shims for fine adjustments. Here is a dado that matches the slot width flexibility of an adjustable dado while maintaining the safety and finish of a stacked dado system. And speaking of safety, we used the same anti-kickback technology associated with

our saw blades and router bits. It's the

anti-kickback shoulder design that re-

/® duces the chance of kickback from over-

feeding. This higher level of safety lets you dado with confidence.

We also packaged all this in a

Precisely What yOU need, sturdy carrying case. Once you use this ,.,.,.,,,.„,,,,,.. * ' ~„ Exclusive 3/32" Chipper perfectly , ',... „ , lets you adjust the new dado, you II agree that it really is a , • High Point, NC 27264 800-472-7307 width of |he cut for , od 8 undersized , ood Super Dado. "

TALKING BACK Continuedfrom page 4 Tips for buying router bits

I enjoyed the new column "Router Bit Review: together with the better

Lock Miter Bit" in the February 1996 issue. I start- technologies involved in ed checking the cost of these bits and found that producing the advanced the prices range all over the place. Locally, a home cutting geometry. improvement store had this style bit for $129. A When we select a bitfor mail-order company listed the bit at $45 (standard) our shop here at WOOD® and $90 for the anti-kickback design shown in the magazine, we first look article. Docs the anti-kickback feature justify the at the quality of the cut- The sliver of gray on the Freud ter additional cost, and which bits would you recom- in relation to the bit is all the carbide that can mend? amount of use ive expect grab the wood should a kick- —Andy Grinthal, Green Township, N.J. the bit to receive. In our back occur. The larger exposed area of carbide on the December 1994 review of bit in front can cause a much router bits, Andy, for an answer to your question, we contact- the two top- harder kickback. edJim Brewer at Freud. Jim stated, "We often find rated manufacturers ourselves dealing with the erroneous perception were Freud and CMT. We'd most likely consider that the anti-kickback feature adds to the cost of a buying one of these router bits for situations where router bit. However, when Freud introduced the we know the bit will receive heavy use. For a bit anti-kickback technology about 6 years ago, we that we may use on only a feiv projects, we'd be did not increase the price ofour bits. more likely to consider the less-costly Taiwanese- "The price difference thatyou see between router made bits. bits with the anti-kickback technology and those The second area we consider when buying a without generally reflects the difference in the router bit is the shank size. We recommend you quality of the bit rather than the addition of the select router bits ivith a W shankfor cutterprofiles anti-kickback feature. The additional cost lies in that remove a lot of wood (such as a W cove, W the use of better-quality and thicker carbide, roundover, or panel-raising bits as shown above.,)

$50 REBATE. 14" Band Saw with 3/4 hp $50 REBATE. Model #28-275 Contractor's Saw" 14" Band Saw with 1 hp with any Unifencef Model #28-280 Biesemeyer" Fence or Precision Saw Guide. (Shown here with Biesemeyer Homeshop Fence and accessory table board and legs.) Personalizing the mailbox Knobs help protect precious fingers My husband Carl decided to build the "First-Class I just finished building Mailbox" featured in your February 1996 issue, as he the "Kid's Country

thought it would look great on our house. However, Cottage" from the April to add just the right personal touch, he replaced the 1996 issue. And I am word MAIL with our last name—GRICE. And boy, did astounded at how much

it ever turn out great! We've received many compli- fun my 4-year-old daugh- ments on it. Thanks for getting us started. ter Ashley is having with —Allison Grice, Mllllnglon, Teim. it, even though it's still sitting in the basement For those ofyou with names loo long tofit on the mail- waiting for warm weath- box, you may want to include your house numbers. er to arrive.

However, I noticed a

couple of things as I watched her play with the cottage. After she would

I walk through the door, she would try to close it. This resulted in her getting her fingers pinched. To solve this problem, I added a knob on the inside of

the door, similar to the knob on the outside. I also 11 31 M W added interior knobs on all the windows for the same reason. I replaced the acrylic in the door and windows with screen material to allow for air circulation. J This also lets Ashley and her friends play in the s house and keep the insects on the outside. —Ken Kaplan, Oakridge, NJ.

TODAY, YOU'LL $25 REBATE. 12" Variable Speed Lathe APPRECIATE THE REBATES. Models #46-700/701 with or without stand. LATER ON, YOU'LL

$50 REBATE. APPRECIATE THE QUALITY. 15" Planer with stand Here's a chance that doesn't come along every day. Model #22-675 A chance to put Delta Quality in your shop and get a check in the mail from Delta to boot. But only until March 31, 1997. Granted, that rebate check will probably be spent

by the time you get around to cashing it. But that new Delta machine will become more valuable each time you flip the switch. And you can take that to the bank. Call for the name of your nearest partic- TUF ipating Delta dealer. Delta International i»*iiii5rf» Machinery Corp., 800-438-2486. hi Canada, POWER 519-836-2840. Qf ||f[ PROS

Delta is proud to nationally fund these two PBS programs for woodworkers. 77ie New 'Yankee Workshop hosted by DELTA WOODWORKING Norm Abram and The American Woodshop with Scott Phillips. MACHINERY A Pentalr Company ' A

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Try the American-made bits from CMT Tools Dear Friends, This special introductory For over five years I've been proud offer lets you experience to bring you the finest woodworking CMT Tools' quality first tools. During that time, woodworkers across North hand! You'll get three bits America have come to recognize the CMT Tools with features like Fatigue- Orange logo as a symbol they can trust. Proof® steel and micrograin What does our Orange mean to you? It stands for carbide cutting edges, all for the highest quality products, it's a reminder of the about half our regular price! orange color of our router bits (a registered trade- mark of CMT Tools) and it represents a solid com- color on router bits is a The orange mitment to service and customer satisfaction. registered trademark of CMT Tools The CMT Tools Orange is also symbolic of our Florida home. Florida is where we started in 1 99 800-702 800-701 and it's where our bits have been manufactured since 1/4" Shank, 3-Bit Set. 1/2" Shank, g 3-Bit Set, $ 90 *J/2 90 early 1996. Reg: $69.60 Special. 34: Reg: $72.70 Special:

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PS: If I can be of assistance please give me a call, and don't forget our famous guarantee: Ifyou aren't Tampa Bay your purchase, we'll take it hack for imme- area happy with diate refund or exchange, period. ^ visit -ifefe-LS Come us •- on the Web! Can ye" one ltos°L--?fir- Check out CMT TOOLS' Surer""""- wKtiow Web site for special deals and lots of information. 3D Router http://cmttools.com/catalog/ Carver'" System Win a trip for two to Florida! E-Mail: [email protected] One lucky winner and a friend will win three days in Florida! The winner receives h*sj° Our tree catalog airfare, lodging, a day of fishing in the Gulf of Mexico (weather permitting), a superb dinner and of course a factory tour. Just fill in the entry form and return it toll-free by April 30, 1997 to CMT Tools, 310 Mears Blvd., Oldsmar, FL 34677 To order, call 24-hours a day: Contest rules: Official Contest Entry Form

• No purchase necessary Please print or type, must be completed in full • Entries must be received by April 30, 1997 CMT Tools employees & families ineligible. Name. 1-800-531-5559 • Void where prohibited Address. • Entrants must be at least 18 years old. Toll Free FAX: 1-800-870-7702 1 Winner will be drawn at random from all shipping orders over *200. 00 complete entries on May 1, 1997. Free on • Only olliclal entry forms accepted. (SS.OO shipping & handling tor orders under $200.00) City_ • Entries must Include name, address, tele Dealer inquiries welcome! phone number and signature. State -Zip- Export orders: (813) 891-6160 FAX: (813) 891-6259 • Prize includes airfare, lodging, fishing and dinner for two. Winner Is responsible for Daytime Phone:_ CMT TOOLS, 310 Mears Boulevard, Oldsmar, FL 34677 nny other expenses. Signature: 4b In Canada, call: ToolTrend Ltd. 1-800-387-7005 TIPS FROM YOUR SHOP (AND OURS)

Use extension blocks to cut tapered legs After trying to cut tapered table legs by shimming them in my

taper jig, I decided there had to be an easier, more accurate way. My solution requires a little more For submitting the Top Shop Tip for stock, but the results are well this issue, Glen receives a Porter- worth it. Cable FN250 16-gauge finish nailer. I start by ripping the legs W Glen Kraig spends a lot of free time longer than finished length (Step Using my tablesaw taper jig, I relaxing in his workshop. 1 of the drawing below}. Next, I cut the tapers on two adjacent Chickens once roosted in drill a W pilot hole 1" deep cen- sides (Step 4). Then, using the Top Shop Tip winner tered on the bottom end of each reference marks I made earlier, I Glen Kraig's workshop. leg (Step 2). After making refer- reattach the extension blocks to

But they've long since flown ence marks on each leg, I trim the the legs with 1" screws (Step 5). the coop, and the San legs to finished length (Step 3) The blocks keep the legs properly Bernardino, California educator and set the waste extension positioned when making the final has converted his hen house blocks aside. two taper cuts (Step 6). into a spacious workshop that —Glen Kraig, San Bernardino, Calif. gives him plenty of room to spread his wings. Glen calls himself an "eclec- tic" woodworker, producing projects ranging from an inlaid backgammon board to an oak corner cupboard. He devel- oped the tip right while build- ing a sofa table. We think it will be a real time saver for anyone who has to cut tapered legs. To become a prizewinner like Glen, tell us how you solved a particular woodworking prob- lem. We pay $40 for all tips published. If yours is selected as the Top Shop Tip, you'll win a tool prize valued at $250 or more and be featured in this column. Send a letter, including your daytime phone number, with a photo or drawing of your idea, to: Tips from Your Shop (And Ours) WOOD® Magazine 1912 Grand Ave. Des Moines, IA 50309-3379 We try to publish original shop tips, so please send your idea only to WOOD magazine.

CiliNI-KAL-INTEREST BDIT< Hi

Continued on page 12

WOOD MAGAZINE FEBRUARY 1997 ^IMDftGGB(fcaC(fl@lte 11 TIPS FROM YOUR SHOP (AND OURS)

Continuedfrom page II

It's "crown down" when table-routing long workpieces When molding long workpieces Fealherboard Crown down js the correct way to rout warped stock. on a router table, the workpiece clamped to fence "1 must be held flat against the table Fence and fence in order for the router

bit to cut a consistent, smooth |§ profile. Even with the help of featherboards, bowed workpieces used to cause me fits because they Router table wouldn't lie flat. Narrow stock, which nearly always has some bow in it, was always the worst. To cut consistent profiles on bowed stock, I examine these workpieces and place them with the bow down for best results. This takes the spring out of the board that occurs with the crown of the bow up. I still use feather- boards, but holding the work- piece firmly against the tabletop and fence at the router bit requires much less pressure with the crown facing down. —Jim Downing, Design Editor, WOOD magazine

"* m e the st ten UUU ^ \ ce /cr U;s^

72A SAW

Made in America'. SET IT... LOCK IT!

With the recent changes that have developed in the fence market, ride against.The important thing to note is how easy it is s Powermatic set out to design the best fence system available. This to change or adjust these side panels. It takes only a few

seemed only fitting since it is going to be paired with the best table minutes- not an entire dayl The ACCU-FENCE side saws! panels do not have exposed mounting screw holes that Powermatic" engineers and designers have developed could catch your material as some fences do. slides the premier fence system. . . The ACCU-FENCE. The ACCU-FENCE on The ACCU-FENCE head slide is designed without any Fluoroway, a reinforced Teflon material, that "play" as you move the fence into position. The locking lasts a life time. The ACCU-FENCE is available as

mechanism is made from extremely high wear resistant standard equipment on Powermatic" table saws. It is material which gives a positive lock. These important feat- also sold as an accessory item that can be mounted on

ures allow you to Just Set It and Lock It! No more trying any table saw. to find your mark two or three times. You spend your time Try the ACCU-FENCE today and notice the difference! cutting - not trying to set your fence. The ACCU-FENCE has laminated covered side panels that provide POWERMAnClui a super slick surface for your material to 66 SAW Internet Home Page:http://www.powermatic.com CALL 1-800-248-0144 FOR YOUR NEAREST POWERMATIC DEALER 12 Circle No. 81 WOOD MAGAZINE FEBRUARY 1997 Quick-Grip clamp helps keep crosscuts square

When an elbow injur)' made it dif- iliary fence to my miter gauge, auxiliary fence, ensuring a square ficult for me to squarely crosscut then clamp the workpiccc to the cut. It also provides me with a long vvorkpieces, 1 had to find fence with a Quick-Grip clamp as convenient handle to help push another way to get the job done. shown below. The clamp holds the piece through the saw. My solution was to mount an aux- the workpiece tightly against the —Dave Rickett, Sylvan Lake, Alberta

Quick-Grip clamp used to hold parts in place while sawing.

Continued on page 14

The hottest NEW woodworking projects...Humidors

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Step-by-step plans with detailed elevation Components also sold separately. drawings! Plus, our kits include hard-to-find Call for a FREE catalog today! hardware like hygrometers, brass inlays, . CLASSIC HUMIDOR holds 40 to 50 cigars 4" regulators, specialty hinges —everything and measures 1 0'// x 1 3'/?" x Since 1954 35180 Plan $12.95 except the wood! Ask about Spanish Cedar. 19209 Hardware kit $89.95 SI IS A. TRAVEL HUMIDOR holds five 8'A" long 42 . GLASS TOP HUMIDOR holds 80 to 1 1 ring cigars and Measures 10" x 5W x 2" cigars and measures 18" x 11'/;" x 6'6". The^mr, 35065 Plan $9.95 35081 Plan $14.95 Woodworkers' 35073 Hardware kit $19.95 35099 Hardware kit $89.95 Store' Order today at 1-800-279-4441 Hardware, Wood, Tools & Know How Plus, stale lax shipping and where applicable Circle No. 965 Department 63117 TIPS FROM YOUR SHOP (AND OURS) Continuedfrom page 13

Trapdoor lets workbench dust and chips fall free The trough on my carver's style bench is great for keeping tools close at hand, but it also collects a lot of dust and chips. Instead of building a ramp to sweep waste up and out of the trough, I cut away a short section of the trough's bottom panel and installed a sliding trapdoor, where shown below. Now when I want to clean out the trough, I just place a trash can under the bench, open the trapdoor, and push the dust and shavings through the hole. Gravity handles the rest! —RB. Himes, Vienna, Ohio

Plywood trapdoor

' . Cut-out opening in bottom of tool bin.

VexT #8x1"F.H. - guides wood screws

.X The New Grizzly G1067Z

Our new G1067Z 7" x 40" Swivel-Head Spindle indexes every 15° Wood Lathe beats the competition Headstock 90° hands-down when it comes to quality swivels and value. Can be used for spindle & 180° for turning or the headstock and tool rest outboard can be rotated for convenient bowl turning turning. Automatic speed control has Reinforced stand six settings. No more changing belts! will not flex!

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Circle No. 860 Rake out the big pieces Glue setscrews to keep tablesaw insert level A garden rake isn't standard shop equipment, but it sure comes in My tablesaw's throat insert used handy for separating hose-clog- to cause me grief. Vibration from ging chunks from a pile of shop the motor loosened the setscrews debris. I rake through the pile a bit over time, and the insert before I vacuum. dropped down below the table-

—C.J. Jones, FieUlale, Va. top. When I tried to rip a board, the bottom edge of the forward end would catch, resulting in an endgrain tearout. To keep the setscrews firmly in

place, I put a dab of Loctite 242 glue on the threads. The glue pre- vents the setscrews from moving, but a hearty twist with an alien wrench breaks the glue bond. —R.J.Lemerise, Utica, Mich. About.

Sift through sawdust with a rake tor large pieces of waste before vacuuming floor.

Link clamps to fit work Band clamps work well on large, or irregular-shaped objects, but as a turner, I often need multiple clamps spread out along the Height- Introducing length of a cylinder blank. I found adjustment that stainless steel hose clamps setscrews The Glue are an inexpensive alternative. r Anything To Tablesaw throat insert Available in a variety of sizes, sev- Everything eral clamps can be linked end-to- Glue. end when I need to encircle larg- ProBond™, the er pieces. Added bonuses are that >\J A FEW MORE TIPS FROM super-strong, glue squeeze-out is easily scraped OUR WOODWORKING PROS waterproof glue off the clamps and they don't rust. that can bond virtu- —Wayne Gaul, Shannon, III. •When gluing a face-to-face lam- ally anything to ination, the layers almost always anything. Wood, slip out of alignment as you Glass, Ceramics, tighten the clamps. A crosswise Metal, Stone, Most

clamp, as shown in the photo on Plastics. It's stain- WATERPROOF able, sandable, page 68, can prevent the problem. BONDS innwAtiv EVERY JI4IIVC • Need to make a pivoting joint? scrapable and Requires Install a panhead screw with a :£ paintable. : «* no mixing, contains washer into one end of a short no volatile solvents, dowel, as shown in the Pivot Pin so it's perfect inside Detail drawing on page 45. Join several and outside. Pros the electrical ser- 1PT(16FLC together for •How does demand it, so larger pieces. vice in your shop rate? Find out should you. how to bring it up to par on Hose 66.Q PkwsjsS clamp page

, ELMERS.,

6 Elmer's Piodiicls.lnc.,1997 WOOD MAGAZINE FEBRUARY 1997 15 ROUTER BIT REVIEW

Vertical raised-panel bits

These cutters have grown increasingly popular in recent years because they don't require a big, variable-speed router (as horizontal raised-panel bits do). But, there are trade-offs that you need to consider.

The pros and cons of router bit for a consistent cut. It vertical raised-panel bits also helps to keep your hands Because vertical bits don't exceed away from the bit. 1^" in diameter-, you can run After building the fence, clamp them at full speed (about 24,000 the guide bar in place, adjusting it rpm). So, most single-speed so a panel snugly fits between the routers with at least Wi hp will bar and fence. The handle them. panel should slide You can buy these bits for $45 to smoothly, but without $60 each— about the same price any slop. We positioned as or slightly less than horizontal the bar by placing two bits. Vertical bits have Vi" shanks, pieces of scrap panel and cut the same profiles (ogee, stock between the fence cove, or straight bevel) and the and bar as shown in same reveal (about IK2") as full- illustration A. sized horizontal bits. Now, install the bit and As you will see in the next sec- adjust its height so that tion, vertical bits will cut almost all but V\6" of its carbide as smoothly as horizontal bits, but cutting edge is above only if you take your time and the table surface. Clamp work slowly. You won't find their the fence to the router slow pace a big problem if you're table so the bit makes a not in a hurry and are making just cut about V\c," deep. a few panels. Finally, vertical bits can only make cuts along straight edges. TALL ROUTER-TABLE FENCE So, they won't help you make WITH GUIDE BAR arch-topped panels. Width of router table +3" How to get smooth results Note: Build the frame that the panel willfit into before you start the following procedures. Then, you can test-fit your first panel and be confident that all of your panels will fit in theirframe grooves. These bits are designed to be used with W-thick stock.

With vertical panel-raising bits, you stand workpieces on edge as you feed them, so you need a tall router-table fence for support. We've had our best success with the fence shown at right. It has a Guide bar guide bar that holds the bottom of the panel in firm contact with the

Continued on page IS

16 -'100*1 t=jf WOOD MAGAZINE FEBRUARY 1997 A flood isn't the worst thing that can happen to you.

Not heing insured for one is.

A flood moves with frightening and 30% of flood insurance claims 1-888-CALL FLOODexc 148 speed. In minutes, a flood can wash come from "low risk" areas. It could Please send me information about NFIP. away everything you and your family happen to you. MAIL TO: FEMA/MSC, PO BOX 1038, have spent a lifetime building. JESSUP.MD 20797-9408 Give yourself peace of mind. Do you haw an insurance agent or company? YesQ NoQ But often the worst isn't the flood. If yes, who is your insurance agent and/or company!

It's finding out, too late, that you're Fortunately, now you can protect

not covered for flood damage. your home and property with flood Mag. Issue Date_ insurance from the National Flood You're probably not covered. Your Name Insurance Program. Address The truth is, 90% of all natural Return the coupon or call your

City disasters in this country involve insurance company, agent or this toll-

floods. Yet, as many find out too free number: 1-888-CALL ROOD, State. -7-iP- _Tel.( )_

late, most homeowner's insurance extension 148. Act now, since it takes

policies don't cover flood damage. 30 days before your coverage begins.

Everyone runs the risk of being a Because with floods, you can never National Flood Insurance Program Admlntelctcd by FEMA flood victim. In fact, between 25% say never.

We can't replace your memories, but we can help you build new ones. fSj rsiFiF Kjttoml FVx

Vertical raised-panel bits

Hold your panel as shown in Depending on the wood, you As you approach the final depth illustration B, and make a cut may be able to take deeper cuts (the panel edges should be about along the end grain. Hold the top without any problem. But, it's V*" thick), check the panel for fit of the panel in solid contact with best to err on the side of shallow into the frame groove according the fence, being careful not to tip cuts—even when you get smooth to the guideline in illustration D. the bottom of the panel into the results with deeper cuts. Why? If you're making multiple panels, bit. Feed the workpieces slowly to Large chunks of wood can unex- clamp some stops onto the table prevent scalloped cuts and grain pectedly break free from hard, in back of the fence as shown in tearout (the ends are especially open-grained woods such as red illustration E. These will guaran- susceptible to tearout). Don't oak, seriously marring the panel. tee cuts of uniform depth on all pause as you feed, or the bits will of your pieces. burn. Make the same cut along the opposite end, and then cut The final verdict the edge-grain sides. If you already own a 3-hp, vari- With a pencil, mark the position able-speed router, or can afford to of the fence on both ends of the buy one, go with horizontal bits table as shown in illustration C. for panel raising. They don't These marks will help you reposi- require any special jigs, but you tion the fence for subsequent pan- may need an auxiliary tabletop if els. Then, readjust the fence for your router-table plate doesn't another W'-deep cut. Make the have insert rings for bits of vari- cuts, remembering to cut the ends ous diameters. And, you'll get bet- first, and again mark the position ter results in much less time. of the fence. Repeat this proce- Vertical raised-panel bits make dure until you cut the profile to sense if you need to make a few its final depth. panels and don't want to spend $210 or more for a big router. Just remember to be patient and take your time.^

D Thickness of panel tongue should fit door frame groove loosely enough to move freely.

7 ADJUSTING DEPTH OF CUT

Written by Bill Krier with Jim Downing Illustrations: Kim Downing

18 WOOD MAGAZINE FEBRUARY 1997 1

Shipping thru 2/28/97 FREE For INFO OR ORDER CALL 1-800-733-7111 FREE $45 IN SHARPENING COUPONS GOOD ON ALL FORREST OR OTHER MAKES OF CARBIDE 10% tO 20% OFF (Listed Items) BLADES OR DADO SETS. Coupons expire 12/31/98. SUPER HOLIDAY COMBO SALE Musi mention WOOD magazine lor discounts & coupons with purchase.

BUY 1 BLADE OR DADO AT 10% OFF SALE PRICE, OR BOUUS OFFER BUY 2ND BLADE AT 20% OFF (EQUAL OR LESSER VALUE) CUTTING 15% OFF DADO AS SECOND CHOICE.

WOODWORKER II- 6" -7 1/4" -14" PROBLEMS? BONUS ALL PURPOSE RIP & CROSSCUT Call the factory for WOODWORKER II LIST SALE 10% 2(T% 12-X40TXV SI 83 $129 $116 $103 FREE technical help!! 10T(40TX1/8-or3/32- S156 $119 $107 $ 95 BOHUS 8-I/4-X40TX 3/32" S136 $ 99 $ 89 $ 79 1-800-733-7111 8-X40T3/32" SI 36 $ 99 $ 89 $ 79 7-1ATX30T S112 $ 69 $ 62 $ 55 I just purchased your WOOD- OTHER SIZES AVAILABLE -30T LINE ALSO WORKER ll 3/32 blade, and I AM TICKLED PINK with It. My BONUS RYOBI BT 3000 saw acts like it BONUS OUR 30T & 40T OUTPERFORMED (f-EXCELLENT; 23 other 40T & SOT premium blades both foreign had a 3 H.P. motor in it. Cuts so quieter & domestic on Ply, Melamine, MDF and Oak /Rip! much easier and and smoother. Don't need my Fine Woodworking Mogozine test Oct 96 page 43 OK 3I» Grot shop Tip of RHW9 Lop tap ffltf Willi any san jointer or Bander now. libit or lliulu lirttd X pirnhual from this :ul. \ ou mu>i Dcotfoa vim nuu iliN Offer in \\ (Hil) Mapuint. when onltrin^ THE ONE BLADE THAT Offer Expires February 28, 1997. P. Rose, PA One book per order. LEAVES A SMOOTH-AS- ORDER NOW SUPPLIES ARE LIMITED. After installing your blade and SANDED SURFACE! 5 in. stiffener the vibration in my saw went down another 20%. BUY OUR BEST SELLER 10" X 40T FOR I ran several pieces of hardwood CHOPM'ASTER FOR ONLY $107 OR $95 ON SECOND through the saw, both crosscut BLADE. SLIDING COMPOUNDS and ripping, and was amazed at the smoothness. It was like RECEIVE WITH EVERY SAVE ANOTHER & MITER SAWS cutting butter, smoother. FORREST BLADE OR maybe Now specs, 5° Neg. Pis. & Hal. runs EXTRA* I have never a blade that TAKE DADO LISTED, had saw out less than .002 tor perfect, tight, _ ^q% 20% OFF 9 SHARPENING COUPONS cut this smooth. smooth, splinter-tree miter joints. COMBO SALE! WORTH $5.00 EACH! $45490 NEW SIZES AVAILABLE AFTER USING rVEwDELUXE usi SfliE TRY A FORREST DADO-KING! Delta Sidekick 6-1/2-x40Tx5/8" $149 $ 89 SHARPENING COUPONS AS AS $184 NET CARBIDE BLADE TODAY! LOW Sears 8-1/4" & Delta 8-1/4x60Tx5/8 SI70 $ 99 AFTER USING SHARPENING COUPONS Hitachi 8-1/2'x60Tx5/8' $179 $109 1/4" WOODWORKER I -CROSSCUT — 7 -14" DeWalt 8-1/2' & Ryobi B-1/2"x60Tx5/8' S179 $109 For TABLE and RADIAL SAW -10% to 20% # ******* 0ella9-x80Tx5/8- S204 $119 - Ryobi-Makita & all 1 x80Tx5/8' $207 $129 LIST SALE C-4 Carbide Tips — 4 on each chipper with DeWall. Makita. B&D, Hilachi l2«80Txr S229 $139 14-X60TXV <*%k_ S224 $159 special negative face hooks. 14"x100Txr I2-X60TX1 or5/8'1/8-K *»- $198 Ryobi-Makila $266 $179 ^t $139 LIST SALE 151. ,, m - Hilachi 15'x100TxV $277 10'*60Tx5/8 3/32K : $162 $129 $189 6 0. 5/8" Bore NEW $299 $269 $242 $229 $150 8-1/4"X60T $109 8" 5/8" general D. Bore S321 $289 $260 $245 For good purpose cuts use Woodworker II 30T & 8'X60T $150 $109 ^Hr 10" D. 5/8' &V Bore $389 $349 S314 $297 40T or Woodworker I. Use small slitfener where possible. 7-1/4-X60T $150 $109 12-0.1'Bore S499 $449 $404 $382 OTHER SIZES AVAILABLE- ' W- M' (Bore up to 1-1/4" Add $25 — Plus $5.50 S&H)

Standard C-2 Carbide (below, led) and DURALINE Hl-A/T FOR TABLE & RADIAL SAWS FORREST still sharp Oxidation and Corrosion Rnsislanl Sub-Micron C-4 Carbide (btfow.

right). Each shown after cutting 3.500 leet ol 5/8" 1-1/4' BLADE DAMPENERS-STIFFENERS ALL FLAT FACE HOLES. Boring up to $7.50 extra. MDF. Similar results obtained cutting particle Larger holes-time basis. Shipping S4.50. board, inelamlne, and plywood. FOR BETTER CUTS on all brands of

SIZES AVAILABLE LIST blades, use our large 1/8" DAMPENERS- Faster leed rales & SALE absolute splinter control. 7-1/4"x60Tx3/32"K $149 $129 STIFFENERS against one side. Slops splintering on OAK/ 8'x80Tx1/8'&3/32-K S202 $169 BIRCH PLY VENEERS « 4" 9-x80Tx1/8- & 3/32- K $207 $179 $21 MELAMINE. - - o 10 x80Txl/8" & 3/32 K $207 $159 5" - $24 Other sizes available 12"x80Tx1-1/8 K $212 $181 O 1* 5* - 6" SPECIAL COMBO SALE Above bore standard. O $25 CARBIDE IS THE HARDEST OF THE " EXTRA 10%-20% STILL SHARP 7 AND LARGER AVAILAB E C-4 GRADES AND 40% STRONGER, NOT WEAKER! OFF ' AFTER 3.500 FEET FOR 300% LONGER LIFE. 50% TO -FCUTTINGI REDUCE!5 NOISE 50%-7 5%

WE RECOMMEND OUR FACTORY SHARPENING us some loiol sharpening creates problems with MICRO-CHIPPED EDGES reducing blade life 8 culling quality.

3-5 DAYS OH THESE AND AIL MAKES OF FLAT FACE 8 CONCAVE CARBIDE TIP SAWS. Ship via UPS. Typicol 10x401 $1 7.00, 60T $1 9.00. Add return UPS $5.00, SI .00 each additional blade.

1 BUSINESS OPEN ACCOUNTS AVAILABLE FOR SPECIAL PRICE COUPONS Quality is w/iy we're different. MENTION WOOD:, MAGAZINE.

PHONE TOLL FREEI 1 (800) 733-7111

(In NJ: 201-473-5236) FAX: 201-471-3333 Fl, NJ, NY Residents Plecwe Add Sales. Tax Shipping Charges wilh book: moking 8 sharpening since 1946. Fine American sow Sawblodes S9; Dado S10; Stiffener S2 INQUIRIES WELCOME SATISFACTION GUARANTEED OR FUll CASH REFUND. DEALER (800) 733-71 1 1 or (201) 473-5236

FORREST MANUFACTURING COMPANY, INC. • 461 RIVER ROAD, CLIFTON, NJ 07014 FAX (201) 471-3333 ASK WOOD Have a question for our woodworking experts? Here's how to reach us.

I want it measured in board feet No matter how simple or perplexing a wood- Do you have an easy formula working problem you're faced with, we would for converting lineal feet to love to hear from you. We'll do our level best boardfeet? to solve your mystery, and you might even —Jackjolley, Bellville, Texas find your question and our reply on this page. You can reach us by one of several ways: Here's how to do it, Jack: •Mail. Send your letter to Ask WOOD*', 1912 1 Multiply the length of the board (in Grand Ave., Des Moines, IA 50309-3379. inches) by its average width. • Via Computer. Send your e-mail to these 2 Multiply this figure by the thickness of the addresses: rough-cut board (4/4=1" rough, or about l V\6" CompuServe: 74404,3516 when planed. 5/4 lumber =1.25", or lVus" after Internet: [email protected] planing, etc.). 3 Divide your answer by 144 to obtain the final measurement in board feet. A 4/4 board (1" thick rough, about 3/4" thick Here's an example, using a 5/4 thick board 60" planed) of the same width and length would be long and 4" wide: calculated this way:

4" x 60" = 240 square inches 4" X 60" = 240 square inches

240 x 5/4 (or 1.25) = 300 240 x 4/4 (or 1.00) = 240 144 300 * 'a 2.06 board feet 240 -r 144 a 1.67 board feet

Give Yourself Some Breathing Room. ^-^ MODELimnci 8-120.10 MODEL10-16

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T) ecent medical studies show that breathing wood dust can be hazardous to All components UL Listed INyour health. TheJDS AIR-TECH 2000 will dramatically improve the 00 Lifetime Warranty quality of the air in your workshop. $299! 95% ASHRAE Tested Main Filter Our model 350 delivers 350 CFM of filtered air. This will clean the air in a Model 350 30 Day Money Guarantee. 20 x 20 x 8 foot shop six and a half times per hour. For larger areas, our dual Back speed model 8-12 will deliver 800 or 1,250 CFM offiltered air for only $495.

Our model 10-16 will deliver 1,000 or 1,600 CFM of filtered air for $695. Another quality product from The AIR-TECH Manufactured in (he U.S.A. JDS 2000 systems will remove 99% of dust particles as small COMPANY as five micron and 80% of the particles as small as one micron. To place an order or for the dealer Our unique design makes ceiling 1-800-382-2637 both installation and filter changing quick nearest you call us toll-free. and easy. And give yourself some breathing room. # .

Great Router Bits! SgfcV&iKBRi **W "»«• sniE WOODLINE & Shaper Cutters Available in Ogee, Roundover, and W* » cunte s panel raiser m Cove & Bead profiles Great tit! -No ARIZONA, Inc unoercujteb. changing bits or reversing the pieces. •" These tiger stripes P.O. Box 1530 • Payson, AZ 85547 •All Major Credit bras Accepted PANEL RAISER W/UNDERCUTTER. 3\f» "Zl. 3 profiles: Ogee, 15° Face Cut, and -=:'|95. 00s •Skipflag Is onlf $3.7S per order C aren't in the zoo Convex avail, Tongue thickness 7-v. /"<£" • 24 hours I deft dip i ueek perfectly matches groove in Rail & t °l Y„„ I've projects that s seen some mere 1-800-472-6950 Stile-everytime! 49.°°e built "Tiger-stripe oak." from SUPER BUY! SUPER SALEU P(teed awW^t^- give me some informa- J Can you Great sets in attractive Cutters & Bearing Sets Jii $1 C oo „„4- cnange J* ea - tion on this wood? wooden boxes! Available (to deplh orcut) trtSB* • .- Two-Flute Cutters avail. s 00 in 1/4" and 1/2" shank 39. —John Evans, Kansas City, Mo in 1/4" or 1/2" shank. Allen wrench included. i pc. Joint Making Set ? ?T%*£* 1 5/32' Kef I c' 3 bearings, cuts slot to fit all biscuit sizes. Simple tag oi bscuiis M. the "tiger 2 Straight Bits. 6 DovetailS-y^-i _ John, we've seen term Rabbeting Bit w/ 4 bearings for rabbets of 1/4", 5/16", 3/8" & 1/2" depth 6 pc. Roundover Set ,,55.°?^. , , 1 1/4" Kert Slot Cutter bearings cut slots t/4", 5/16", 3/8' 1/2' stripe" used in two different ways W.3/16",1/4",5/ie ,3/8 ,1/2"o«uJ^fX w/4 & depth 5 Cove Set when referring to oak. However, pp. CS 49.00 C" • Best Prices • Same Pay Service • Super Selection 3/16-.1/4-.5/16-.3/8M/2- racfius 32-page Catalog included with every order uses refer to a grain pattern both Circle No. 1395 in the wood rather than a separate species of oak. In the first usage, "tiger stripe" becomes interchangeable with '' the terms "fiddleback" or "curly." Introduces In this grain pattern, the annual rings move up and down in rela- tion to the face of the board as the The New Improved T50 grain runs the length of the board. This results in the grain at the sur- face of the board alternating - between light-reflecting side grain Staple Gun Tucker! and light-absorbing end grain, creating a striped pattern (see the photo below /eft). Some woodworkers also use "tiger stripe" to describe All Steel Construction medullary rays that appear on the surface of rift cut oak boards. Long-Lasting Reliability These rays appear as lighter stripes running across the Hard-Driving Power longitudinal grain of the wood. j This type of wood was commonly used in better pieces of Mission- And How... I style furniture, and in trimming Craftsman-style houses. See the photo below right for an example of this grain pattern. Easier to Squeeze THAN EVER BEFORE! ARROW'S T50P uses 6 different size staples: 1/4", 5/16", 3/8", 1/2", 9/16" and 17/32" Ceiltile.

All ARROW staple guns and staples are built in the USA under the strictest standards of quality assurance. It's been that way for over 65 years! ARROW products are available at home «El»U» centers, lumber yards, hardware stores and wherever fine tools are sold. You work hard for your money. So, spend it wisely. The all-steel T50P will last and last and last.... MADE IN

1MPANY, INC., 271 Mayhlll Street. Saddle Brook, N.J. 07663 ARROW FASTENER (U.K.) LTD., 14 Barclay Road, Croydon, Surrey CRD UN JARDEL DISTRIBUTORS, INC., 6505 Metropolitan Blvd. East, Montreal, Quebec H1P 1X9 © 1996 ARROW FASTENER CO. INC.

WOOD MAGAZINE FEBRUARY 1997 21 9

ioo% SATISFACTION visit our web sin, GUARANTEED! ;l \SHIPPINC1\ FOR ALL ITEMS SHOWN BELOW! TOOLS *mk±- mtp://www.hsptiarrrefgni.corn

MACHINERY I CENTRAL [ 1 CENTRAL MACHNEHY [ CHICAGO HfflffHPowerTooisl 10", 2 HP, SAVE OVER BENCH 16" 30% FROM SAVE 20% OUR FALL'96 FROM OUR TABLE CATALOG FALL '96 SCROLL CATALOG 6" SAW SAW Die cosl aluminum INDUSTRIAL table 25-3/4" x 16". • Precision milled 14-1/2" x £ TRIM has ad|ustable 17-7/8" x 2" rip fence and -'• table Mis 0° lo 45° i RABBETING inch/metric scale for precise culling • Uses pin end blades. 5-1/2" long ROUTER • Maximum depth ol cut ol 90°: 3-1/8"; at • Heavy duly cosl icon frame and base JOINTER Now you can tackle those jobs Ihot were too 45°: 2-1/2" (fT, reduces vibration • 7/8" blade stroke «SJ™»**"*'"' • Inleedlable size: 22-1/2" line or exacting lor a standard routet. This • Blade capacity: 10" wllh 5/8" orbor '*»' • 1/8 HP. 110V. .83 amps • Outleed table size: 19-1/2" compact router weighs only 4 lbs. for easy • Miter gauge adjusts 0° - 60° left and right • 1750 5PM blade speed • Motor: 1 HP. 110V, 4 amp. 4900 to 5900 operation Includes a straight and ad|usling • Motor 2 HP. 115V. 60 Hz, 10 amp. 4500 ITEM RPM cutterhead speed conductor to assist in trimming and engrav- RPM • Blade sold separately, below $ • Maximum depth ol cut: 3/8" ing in both straight and circular patterns. • 34618-OSXA 59" Shipping weight: 36 lbs. 1/4" ITEM • collet ITEM s • 30,000 RPM no load speed FOOT SWITCH WITH 30289-5SXA 199" 3S715-2SXA *79" GUARD • 110V, 3-1/4 maximum amp draw REPLACEMENT BLADE SET • 8-1/2" overall length 10" 40 TOOTH CARBIDE TIP lo use. Steel housing and 8 ft. cord. Ready • 4 lbs. tool weight . SAW BLADE *^„„ ITEM $Q99 ITEM $Q99 ITEM $'3Q99 •5/8" arbor JQ"" 0049S-6SXA 33271-1SXA 33833-3SXA W W ITEM 00529-4SXA

LIMITED DeWALT DeWall CHICAGO ADELTA HITACHI DW705 QUANTITIES 12" Delta 36-510 7-1/4" HEAVY DUTY CIRCULAR COMPOUND SAW MITER • 115V, 10 amps. 60 Hz. single phose TRIANGLE • 5500 RPM • Tool weight 8-3/4 lbs SAW DETAIL SANDER • Maximum cutting depth: 2-1/4" • 13 amps, 4000 RPM no load speed 3-3/4" 10" Hitachi C7SC [q] Use triangle pads lo reach Into • Spindle lock • Electric broke W 99 corners conventional senders can'l. • Stainless sleel miter scale with /fij\ BENCH SAW ITEM 35120-8SXA$64 ^* • nov. 1.2 amps - 9 positive stops • 40 lbs. ship wt. • OPM Big sow capacity in a portable unit. 8-1/2" SLIDE • Includes 32 tooth blade 10.000 (IT)'* Easy and safe lo use wllh up-front con- 0-48° • Hook and loop sandpaper holder W COMPOUND MITER SAW • bevel capacity • I" round arbor • Includes dust collecllon bag trols off switch. • 0-48° miter left and right and removable on From Hitachi C8FB • 5-1/4" • 5 pc. sanding assortment 40. 80. 120. and rear locking rip fence and miter $J§"i099 Capacities crown moulding; 2x8 ^-^" 200. 240 grits at 45° bevel; 4 45° and _ _. _ _ gauge maintain full sized accuracy. ITEM 31876-8SXA x 4 & 2 x 6 at miter A • Head lock down wllh handle for eosy ITEM $1Q99 • Motor: 13 amps. 115V. 4700 RPM 3/8" 9.6V DRIVER DRILL Iransporl • 38 lbs. lool weight 35838-1 SXA M M • 5/8" arbor • Table: 16" x 26" WITH KEYLESS CHUCK • 100% ball bearing construction • Capacity: 3" max. depth. 2-1/2" max. S PC. TRIANGLE SANDING Hitachi D 10DF2 Q99 • Factory reconditioned, ol 45° $0 depth (Jf) LIMITED factory perfect PAD ASSORTMENT • Dimensions: 15" x 26" x 19" ITEM 34641 -7SXA "* QUANTITIES • 40. 80. 120. 200. and 240 grits • 40 lbs. tool weig 4" DISC GRINDER ITEM ITEM Hitachi G 10SD1S * E/199 99 ITEM 99 35734-4SXA *109" ITEM 34644-7SXA J*T 51594-4SXA $299 36082-OSXA *3 3/8- 9.6V CORDLESS DRILL 2 HP, Mm Mcculloch WITH KEYLESS CHUCK 1200 PSl, DSELEKTRA Hitachi FDS10DVA 1.6 GPM A» McCulloch 3214 $ OQ99 ITEM 34998-6SXA jPW PRESSURE 4-1/2" ANGLE GRINDER 14" WASHER 115 PC. Hitachi G12SA $ JCQ99 TITANIUM GAS POWERED ITEM 35015-4SXA J JT m NITRIDE COATED CHAIN SAW 9.6 VOLT CORDLESS 1/4" • 32cc engine handles tough jobs IMPACT DRIVER DRILL BIT SET • Hard chrome cylinder bore for longer Hitachi WH80C2 < f ^099 These titanium nilridecoated high speed steel Stans when you pull Ihe trigger, stops when you engine life ITEM 3S254-2SXA IJ7 bils last up to six limes longer than standard lei go Exclusive "Power-On- Demand" system • Gear driven automatic chain oiler bits. Cool turning titanium bits ore a must for dramatically increaseslhe lifespan of your pump • 3 posilion choke for easier starting metal workers. All bits can be resharpened Includes safety lock off trigger, fan to pinpoint • Safely trigger prevents accidental spray noz?le. delergenl cup. 19 ft. high pressure Slroighl shanks. acceleration • 15 lbs. ship. wl. hose, ondqulck connectionbayonet wand. Hooks Includes: 29 fractional sizes 1/16" • lo your gardenwaler hosewith no special adapt- Spark orrestor screen reduces fire hozard Ihru 1/2"; 26 letler sizes A Ihru Z, 60 • Features: chain ers, for performance and value, this is an incred- brake/hand guard, chain OFF numbered sizes 1 thru 60; Heavy duty 1/2 ibledeol • Buill in pressure relief safety valve catcher, throttle latch, muffler shield, and metal drill Index • 120V, 13 amps . low kickback chain £jM^% 99 • 10-1/2 1-1 fl. oz. fuel lank capacity CORNER CHISEL ITEM SQQ99 ITEM 01 61 SXA ™#jP • Factory reconditioned, slight hammer could give perfect 50956-1SXA LIMITED A tap you US PC. M-2 HIGH SPEED STEEL factory perfect corners every time. Perfect for hinge plates QUANTITIES PRESSURE WASHER TURBO NOZZLE DRILL BIT SET W/INDEX • 5/8" working depth j, Increase your cleaning j, » -» ^ M4% ^^^ • Same sizes os above A g% • 3/8" culling edge power by 70%' ^^ ^^ g% ITEM Jfl*f7 $ MM 9 • $ 99 M-2 high speed steel !} ~J %M 77 51 502-1 SXA 79 ITEM 07975-3SXA ITEM 35935-OSXA ITEM 00528-1 SXA -Am W tutu * Within the 4 fax toll Call To Order or Ask for Free Catalog; free: 1-800-905-5220 CHARGE Order 24 Hours a Day/7 Days a Week ~" — 4 0r Send 0rdl!r " Tools, ] I O \J V/ ^rZ3 ""2567 check or MonDV ,0: H ,bor Freight 3491 Mission Oaks Blvd. Box 6010, Camarillo, CA 93011

Circle No. 46 irmnmr Visit our M siu. FOR ALL ITEMS SHOWN ON THESE TWO PAGES! LOW PRICE GUARANTEE! hltp://www.harbopfpeight.cnni WE'LL BEAT ANY COMPETITOR'S PRICE ON ANY IDENTICAL ITEM - EVEN IF IT'S AN ADVERTISED SPECIAL

CHICAGO _. DRILL 1 CENTRAL MACHINERY UU MASTER FREE ACCESSORIES: Stand, 6" bell. 9" disc, open-end wrench, and hex TIN SAVE UP TO 5 SPEED key wrench 25% FROM OUR BENCH COATED FALL '96 BOOK 8-1/4" SAVE S30 COMPOUND DRILL FROM OUR FORSTNER BIT SETS PRESS FALL -9S Tilanium nitride runs cooler, cuts easier, ond MITER SAW CATALOG lasts longer lhan standard steel! Includes • 620 10 3100 RPM 3/8" shanks and individually organized • Electric brake slops blade in seconds • 8-1/4" maximum distance wooden case Rockwell hardness range from • Powerful 1-3/4 HP molor, 120V. 9 amp. COMBINATION spindle lo lable • 1/2" chuck 55-65 HRC. 4900 RPM no load speed • 2" stroke. 8-1/4" swing 6" BELT AND • 5/8" arbor 20 PC. SET • 22-1/2" high, 49 lbs. shipping weighl • Culling capacity 2-1/8" 5-1/8" miler. • 20 sizes from 1/4" to 3/4" by 16lhs. 7/8". x • 1/3 HP motor ^ _, ,^-k-* 9" DISC SANDER bevel, and compound cut 15/16", 1" to 2" by 8lhs ITEM 1 HP. 110V,8amps.3450RPM. oil ball bearing • Miler positive slops al 0°. 15°. 22.5°, 30'. $A\St" 05901-OSXA "f motor; Overall height. 40"; Table till 0° lo 50°; ITEM left right V and AS" and $'9A?9m Table surface: 6-1/2" x 12-3/4"; Two position 31130-7SXA W • 8evel positive slops alOMo 45" left ^ 151 DRILL PRESS WITH work table for disc or bell use; Olsc speed: • 20 lbs. shipping weighl 6" KEYLESS CHUCK 1720 RPM, Bell: W x 48" I; Belt speed. 1280 16 PC. SET • Includes tree 8-1/4" multi-purpose blade FPM: Weight: 121 lbs • 16 sizes from 1/4" lo 2-1/8" by 8lhs ITEM $9999 ITEM $ 95 ITEM $OQ99 01078-2SXA 34231 -3SXA \^ I 06852-6SXA 169 32404-8SXA Jb W

CHICAGO 3 CENTRAL MACHINEFfYT

I JEHffHPowei Tool 18 GAUGE 3-1/4" AIR BRAD PLANER SAVE UP NAILER TO 33% This unit has the features you need: safety 1 From V-groove lo help base has a guide trigger, adjustable nailing depth, durablealu- in chamfering blade cutter n 2 CONTROLLED PRESSURE, minum magazine, and easy jam clearance. Depth adjustment knob (j NON-MARRING • 55-95 operating PSI • 1/4" NPT inlet 1 Includes rabbeting guide plate/fence, • 3/8" to 1-1/4" brad length capacity sharpening holder, blade setting jig, HARDWOOD CLAMPS • 100 brad maximum capacity replacement brushes, replacement bell These hand screws will clamp wilhoul saddl- • 18 gauge brads • Tool wt,; 2-3/4 lbs. 1 D-handle with lock-on button ing or marring your workplece. Hardwood • Stainless steel driver & cylinder 1 1/10" maximum depth of cut; 3-1/4" laws distribute pressureevenly, ond can eas- DOVETAIL planing widlh MACHINE SAVE 24 % ily be adjusled for non-porallel surfaces and Just place slock and pull handles i 110V, 5 amps. 17.000 RPM cam FROM OUR odd shapes PRICE ITEM *A9"$2Qvise opening: clamp, and 1/4", 3/8". and tures an easy grip handle ond chrome vana- fold away deplh adjustment for easy ITEM 1/2" mortising chisels and bits dium bit. 1-5/16" overall length. transport $099 • 1/2 HP, 110V. 2.3 amps • 5" throat • 27-1/4" x 20-1/2" x 15" overall dimensions 31848-1SXA REGULAR PRICE: $1.99 • 5" maximum workpiece height • 68 lbs tool weight HEAVY DUTY A. 3/16" AND • CHICAGO • Accepts 745" chisel shanks Factory reconditioned faclory perfect EE3Sapo«.i«« 4- 1/4- STANDARD pise GRINDER • 3580 spindle speed • 13-3/8" x 6" table QQi ITEM • 99 115V. 5.18 omps. 10.000 RPM • 10-7/8" x 7-3/4" base • 60 lbs. ship. wt. ITEM 35438-1 SXA W 06177-1SXA $299 • 5/8"-ll spindle wllh 7/8" arbor adapter • 11" B. #1 AND #2 PHILLIPS PLANER BLADES long. 4-1/2 lool weight |n] U99" $ ITEM 99 UtUMM $1Q99 ITEM ITEM 35437-1SXA 99* m 33075-OSXA *I9 ITEM 01 71 1-4SXA WW 35570-1SXA 1W

* Within the 48 States / S2.95 handling on all orders ^sss^v FAX TOLL FREE: 1-800-905-5220 CHARGE Call To Order or Ask for Free Catalog: oJvdz-. Order 24 Hours a Day/7 Days a Week C_ Or Send Check or Money Order to: Hatbor Freight Tools, Most Phone Orders Snipped in 48 Hours 3491 Mission Oaks Blvd. Box 6010, Camarillo, CA 93011

Circle No 46 GREAT IDEAS for your shop Dovetail-jig stabilizer fence

It offers firm support and aids alignment

Have you ever struggled to model 5008 Dovetail Templet, but position the dovetail jig in the keep boards properly you can adapt the fence to fit your groove and mount it with screws. aligned in your dovetail jig? particular jig. Drill '/(" counterbored holes Most jigs rely on a small cam to To make the fence, cut the where shown in the front plate position the board; but don't pro- body pieces (A, B, C, D, and E) to (B) and fence plate (E), and insert vide enough support along the size. Using your tablesaw, rip a Wt" Kix2" carriage bolts in the holes. length of the board to prevent groove Vt" deep in the top plate Clamp the fence plate (E) in posi- racking. Without proper align- (A) where shown on the tion, making sure the top of the ment, the dovetails vary slightly in Exploded View drawing. Reset plate is flush with the face of the length, resulting in a poor fit. the blade depth to '/>", then cut jig. Then, attach the fence plate Our dovetail jig fence provides the rabbet in the front plate (B) with screws as shown. support on both horizontal and where shown. Cut the fence bars (F and G) to vertical planes. And, the fence Fasten the top and front plates size and cut a >AxW rabbet on one bars adjust so you can fine-tune (A and B) to the clamping and edge. Using a Yic" bit, drill holes as them to match your jig setup. We support blocks (C and D) with shown in the Slot Detail drawing built this fence for a Porter-Cable glue and screws as shown. Then to create the Vic" slots. Install the fence bars with washers and wing Vs" rabbets X13/4 nuts as shown. 'A" wing nut

SLOT DETAIL

~~&S /s/i6" holes Use chisel " to trim 3/4 excess from / sides of slots. •3/„"

Project Design: Chuck llctllund

/•i" wing nut Illustrations: Roxanne LeMoine Photograph: John llctherington

J ':'0G&

Scrollsaw thicker stock and then sand to your desired thinness. Even the most delicate fretwork, as thin as 1/64", can be sanded I without breakage.

Imagine the satisfac 16-32 Plus tion of sanding a wide surface (up to 32") to within .010" uniform thickness

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Tools of the Trade Any woodworker knows that using the right tools for a froject makes all the difference. That's why the Titebond* amily of Wood Glues has been the choice of professionals for more than 35 years. Recognized as the premier name in wood glues, Titcbond has five specially-formulated glues for your next woodworking project. Titebond II Premium Wood Glue—Weatherproof Ideal for outdoor projects-passes Type 11 water-resistance Titebond Original Wood Glue—Stronger than wood Strong initial tack-heat resistant and sands easily Titebond Dark Wood Glue-For darker woods Offers all the benefits of Original Titebond

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To find out which glue will work best for your next project or to find out where you can purchase Titebond in your area, call our Technical Service Team at 1-800-347-GLUE. j

Save 55% on MLCS MLCS Woodworking Raised Panel Door Accessories MJl^ff^i Bit Sets 25pc Brad Point Drill Bit Set Carbide Drill accurate holes in wood, Tipped! plastics & composites. Bit sizes from 1/8" to 1/2" by 1/64" increments.

Bits are deep fluted to clear chips quickly. ITEM #1413 REG. $34.95 SALE $1895 Make Beautiful Raised Panel Doors with your 1/4" or 1/2" Router, Biscuit Joining Set or with your 1/2" or 3/4" Shaper. 5/32" Slot Cutter-1/4" Shank

and 250 #20 Biscuits I f/j Our professional produc- "Biscuit Joining with your Router" tion quality router bits Instructional sheet included, make it quick and easy to ITEM #1385 produce attractive raised REG. $35.00 SALE S2995 panel doors. Our reversible combination bit makes a matching rail and MERLE stile frame. The panel The ADJUSTABLE raising bit with ball bear- CORNER CLAMP® ing guide makes a perfect Adjustable, uniform clamping raised panel every time! pressure on all corners • Great for Includes instructions * Reversible Combination Rail & Stile Bit wide cabinet frames (for center or tips I 7/8". & professional Works with stock from 11/16" to edges) • Forces a frame into perfect DOOR SETS square • Almost NO capacity limitation, Carbide Tipped RAISED PANEL | SET* BIT STYLE RAISED PANEL LRQ. DIA. SET PRICE ships with 23 FEET steel banding • Aluminum & Steel construction #1301 1/4" Shank Router *2" $69.95 #1302 1/2" Shank Router * 3-1/2" $79.95 ITEM #1420 #1303 1/2" & 3/4" Shaper 4-5/8" $99.95 REG. $39.95 SALE $2495 *Ball bearing Included

QUANTITY DISCOUNT 1/4" SHANK Router Speed Control When ordering 3 or | CARBIDE TIPPED more router bits deduct Gets the best results with the wood $1.00 each! ROUTERBTTS and bit you are using! • 3-1/4" Works with all routers HP „'?<&*« i OGEE RAISED PANEL / - 120V UdustCoyerj #1423 2' Large Diameter $29.95 or LESS 15 Amp O TONGUE AND GROOVE • Full horsepower and torque at all speeds #1333 Straight $29.00 • Gives your router a feature only available on $29.00 #1335 Wedge routers costing hundreds of dollars! BULL NOSE ITEM #1304 #1330 1/2- Dia. ol Circle $16.00 »., F «WiiiOK95 #1331 3/4- Dia. ol Circle $21 .00 REG. $49.95 SALE $34 PATTERN/FLUSH TRIM - #1340 1/2 Dia., f Cutting length $15.00 Brass Piloted #1341 3/4" Dia.. 1" Cutting length $17.00 ROUND OVER Router Bits #1314 (1/8" Radius) $11.00 New bit saves hours of hand sanding! #1315 (3/16" Radius) $11.00 Rout into those tight spaces and sharp corners! #1394 (1/4" Radius) $13.00 grade router bits have smooth #1316 (5/16" Radius) $14.00 These professional 5/32" #1369 (3/8" Radius) $15.00 running Brass Pilots, measuring only #1370 (1/2" Radius) $17.00 (approx.) in diameter, instead of the usual 1/2" FLUSH TRIM Unique ball bearing. Save hours of hand sanding or filing gg Brass ^^ #1337 3/8" Dia.. f Cutting length $8.50 Pilot: and get a more consislent edge. - JB #1338 1/2 Dia., r Culling length $9.50 Approximately Order 3 or more bits 8 deduct $1.00 each! Q RABBETING KIT 5/32' in diame ITs 11/32" Change ball bearing guides and select 4 deplli of oils: ted Smaller than 3/8", 7/16", 5/16", m". Set 1/4" shank rabbeting bit, typical ball 4 bearings (3/8", 1/2". 5/8", 3/4") and hex key. bearing. #1425 1-1/2- Large Diameter $25.00 FREE SHIRRING i^Msaarsss-

Order By Credit Card or Send Check To:

MLCS, Ltd., ILEalS P.O.Box4053D N Woodworking Products Rydal, 19046 fc*y ©1887 Professional Order by Fax (215) 938-5070 PA TWW-TSsTTra- Kentuckian Tom Smith supports h his fishing with a unique brand of woodworking, and he couldn't ^" be happier.

m&i .out jtpry liked to carry Iking sticks. F.vcn uses had one," says . .*****: htucky slickmakcT Tom .Smith, resting on thanks him for that. "In one of his early letters from what, a wall near his farm.

' was then the frontier, ol' Daniel spelled Kentucky \

'Kantuckeucke:' I continued his. style," explains Tom Smith \ Just J,"

Continued "My best-selling stick is the spiral in walnut, the diamond is The twisted sassafras for the tall hiking stick comes from next, then the plain," notes the stickmaker. The 52" stick left of Tennessee. Tom taps his supply of old tobacco-drying sticks center, with its brass tip, retails (or about S200. Tom also does to offer the simple, rectangular model. The design far right he custom sticks, such as the wading staff for fishing, at left. calls the Tootsie Roll.

That christening four years ago bright brass hame knob from a like a companion. Why, even has resulted in a retirement enter- horse collar and adorned with a Moses carried a stick." prise that has grown beyond the woven leather lanyard, the 52" Back on their 63-acre farm out- 65-year-old's greatest imagination. stick has a price tag of $200. side of Frankfort, Tom began some A member of the Guild of experiments in stickmaking. "I Kentucky Craftsmen, Tom now tal- Moses carried one, too went directly from working with lies nearly three dozen retail out- A few years before he retired from steel to wood," he says. "I never lets for his sticks across the nation. his job as a steel inspector with had much to do with wood, but Those accounts, plus the five or so the Kentucky department of high- my dad once operated a sawmill

craft fairs he does each year, keep ways, Tom was giving serious right when I was born, so maybe his stick production at around 450 thought to how he would spend there was sawdust in my blood

annually. That leaves plenty of his future days. "Then one day and it finally came out."

time for fishing. Sissy [his wife Elizabeth] and I The sawdust took a while to

"All I wanted to do in retirement were visiting a craft fair and saw emerge, as Tom tells it. "I got to was keep active—find something this old gentleman," he recalls. playing with the idea of making to do to help support my fishing," "There he was, walkin' down the sticks and made two or three pro- Tom laughingly admits. "But golly, street in bib overalls and gum totype models. Just whittled on in my wildest dreams I never boots like you wear around the 'em with a knife. Finally, Sissy

thought 1 could make anything cattle barn. He was carrying this said, 'Why don't you make some

that someone would pay so much long stick with a bandanna kind of design on them?' So I money for," he says in wonder- wrapped around the holdin' end. carved some spirals and some dia- ment. In his hands he displays a Well, that sight started me thinking monds. But it was really tough." satin-finished walnut walking stick, about walking sticks. Seems that Tom, a problem solver, figured

its shaft decorated in a carved dia- people have always wanted some- there had to be a better way. And mond pattern. Topped with a thing to aid their walking, kind of there was, right at his fingertips.

28 WOOD MAGAZINE FEBRUARY 1997 ** Seems that people have always wanted something to aid their walking, kind of like a companion. 99

Notice the metal "saddle" to the left of the

bit. It was added to prevent bowed wood from getting a deeper bite from the router.

The Craftsman Router Crafter gives Tom a design versatility and the speed to keep up with orders. He routs spirals with a 1 vi-hp router and an ogee bit.

Router to the rescue knew I had to do something to get stick. I clean them up and leave

"I got to lookin' through the Sears better speed and quality, l-'inally, I some bark on, varnish them, and Roebuck catalog and saw this bought kiln-dried wood." add a leather thong. They look Router Crafter," Tom remembers. Tom now uses nothing but. And more like a hiking stick, and the "II was like a lathe, with a router he buys the hickory and walnut outdoor types buy them." riding on top. Fitted with a bit, I stock already round in the form of Yet it was horses more than any- could index it to cut designs on 1"- and 1 Mi"-diamcter dowels cut to thing else that ended up offering the sticks as they turned. But I 36" and 48" lengths. Tom the most unusual adornment needed a lathe, too. Eventually, I that now makes his sticks stand ordered a Router Crafter and a Horsing around out. "Sissy and I took a day to tour lathe, then wasted a lot of wood for the perfect stick Shaker Village of Pleasant Hill. until I got the technique, and the Tom was busy perfecting his turn- There, they have a beautiful team right wood, down pat. You see, I ing and cutting techniques while of draft horses that pull a wagon was using green wood at first —I'd still making sales at craft fairs. He around the village," he says. "They just go back on the property and was purchasing preturned finials really looked good, with oiled har- cut down a wild cherry tree or a and attaching them to the top of nesses and polished brass fittings. yellow poplar, split it out, then put his walking sticks. He also had Well, I got to looking at the brass the splits on the lathe to round found a source for a different style hame knobs that guide the reins. them down to the diameter I want- of stick. Why couldn't I put those knobs on ed. With the Router Crafter, I'd "I met a guy from Tennessee who my sticks?" add the designs. had a supply of sassafras sticks," Why not, indeed. But Tom had to "But the green wood fuzzed up," Tom explains. "Where he lives, find them first. he continues. "Then, the sticks young sassafras saplings get Some turned up at flea markets. cracked as they dried. But I was entwined with wild grape vines. More were found at farm sales, starting to sell them anyway, and The result is a naturally twisted especially in Amish areas. Garage Continued WOOD MAGAZINE FEBRUARY 1997 29 M A while back, I was thinking that maybe I was sales turned up a few. To this day, his house and his favorite tavern, was missing a whole end of the the search goes on for horse col- and he wanted something strong market — the low end," he says, lars with the valued name knobs. to carry walking through it." reaching to snare yet anodier stick "Friends and neighbors keep on Tom fulfills more personalized from his stock. "These are tobacco the lookout for them," says Tom, requests, too. Such as a special sticks, used to hang tobacco

"but as yet I haven't found a reli- type of wood, or a brass plate leaves up in the barn to dry. In able supplier for new name knobs." engraved with names and dates. this part of the country they're

So far, Tom and Elizabeth have He even provided a shovel fitted mainly white oak. I cut them off discovered five different shapes of widi a hame knob to the governor to 45", sand the heck out of them knobs. "I started out by putting lit- of Kentucky for an official ground- and varnish them, and brand on tle round ones on my sticks, but breaking. Usually, however, the 'Kentucky Tobacco Stick.' Then, I everyone called them doorknobs," requests are minor, and he han- wholesale them with a leather notes Tom. "Now, I try to use only dles them on the spot. thong for seven bucks apiece. My the longer type, which weigh "One time we had a short man other sticks start at $35 wholesale. three to four pounds." from California come up to our And I've got about 5,000 tobacco It's a logical thought: With a booth. He wanted a walking stick, sticks out in the barn left from die heavy brass head and downright but a littler one. I told him I could time when I raised tobacco." tough wood like hickory, Tom's cut a 36" one down, and proceed- sticks might play a role other than ed to saw off an inch, then anoth- Round and round, that of a walking companion. The er inch, and he kept nodding to he makes his mark craftsman downplays the idea of keep going. Finally, it was down Key to getting an impeccably cut his sticks as a means of self- to about two feet long before he design on a walking stick is cen- defense, though. "That's not part said that would do. 'You had bet- tering and indexing, advises the of my sales pitch," he says. ter buy it now,' I said, 'because no stickmaker about his main tool, "Although I did have a fella come one else will.' And he did." the Router Crafter. "Of course, I by at a show and ask for a plain And when a new opportunity start with a round stick blank hickory stick—no carving—with a arises, Tom doesn't hesitate to add that's usually 36x1". To find the heavy hame knob. Turns out there to his lineup of sticks. "A while exact center of each end for was a bad neighborhood between back, I was thinking that maybe I mounting, I use a center finder,

30 WOOD MAGAZINE FEBRUARY 1997 missing a whole end of the market-the low end,"

then make a hole at each point 48". "I also added a support under once with polyurethane varnish

with an ice pick." the rails because the longer sticks and lets it dry. A light sanding with Tom mounts the stick to be rout- want to whip," he notes. "The 60-grit cuts the raised grain. "The ed onto the machine, lining it up compression of the stick between last coat of polyurethane, followed with the index points for the num- the drive center and the tailstock by a sanding with 120-grit, gives ber of cuts per inch of stick cir- also exaggerates any bow. Without me a durable finish tiiat looks just

cumference he's selected. that support, I couldn't use 40 per- like I want it to," says Tom. "I

Next, Tom turns the crank on the cent of the wood I buy!" don't want my sticks real slick and Router Crafter to check the After routing the design in a shiny, but I like the yellowish cast

straightness of the wood. "If the stick, Tom removes it from the of the varnish. It brings out the

stick has a little bow in it, I'll go to machine and clamps it in his shav- color of the wood." a less demanding design, such as ing horse. There, he hand-sands For the finishing touch, Tom fits fewer spirals," he says. "For the the cuts smooth with a teardrop- the stick with a shiny hame knob

spirals, you see, I can cut four to shaped sander made of foam rub- of solid brass and predrills the six for every inch. No closer than ber covered with 120-grit paper. screwholes with a hand brace. A

six, though. To get the diamonds, I The handwork takes about 20 min- few twists with a screwdriver and set the index, say to four, then go utes, except for hickory sticks. another Kantucke wolken stik is

down the stick. When finished, I "Hickory is so hard that I have to ready for market. Tom admires his reverse the stick end to end and go make two or three passes on the work, then says: "I've gotten so

down it again. I do it all with a Router Crafter to just one for wal- now that I have a piece of power Vermont American ogee bit nut. It often burns in the routing, equipment for every major step

chucked in my l!4-hp router." too, so I have to take a flexible- that I need to do on my walking To counter any bow in the stick, shaft carving tool with a sanding sticks. But it always makes me feel

Tom devised a half-round metal wheel and clean it out," says Tom. good to end it up with a good old saddle mounted on the router base While Tom has the stick clamped hand tool."* ahead of the bit (see close-up, in the shaving horse, he takes the page 29). "It acts like a bumper to opportunity to shave one end of keep the bit the same distance the shaft with a drawknife to For a bit of Olde Kantucke from the turning stick so that it accommodate the name knob. For To receive a catalog sheet won't tear out if the wood has a final sanding, Tom mounts the describing Tom's line of walking

bow in it," he notes. cleaned-up and shaved stick in his sticks, send your request with a

For 4' sticks, Tom uses his second lathe and sands it with 80-grit. SASE to Olde Kantucke Wolken Router Crafter. He extended its For a finish, he coats the stick Stiks, Inc., 1280 Old U.S. 60, original 36" rails to Frankfort, KY 40601.

Far left: Tom built the solid cherry shaving horse to grasp sticks for detail sanding. Here he shaves the end of a stick with a drawknife in order to add the hame knob. Note the harnesses hanging about.

Middle: Today, the lathe gets little use for turning. Tom mounts sticks there for sand-

ing. "But I did waste and use up an awful lot ," of wood at it says the craftsman.

Near left: Tom predrills screwholes with a hand brace to attach the brass hame knob, just part of the handwork that goes into his line of walking sticks.

Written by Peter J Stephano Photographs: John F. Schultz

WOOD MAGAZINE FEBRUARY 1997 31 bl Catchall A beautiful box that's a breeze, to build

Desktops and dressers act like clutter magnets—stuff always seems to be drawn to them. This clever little box can help contain it all. And building this bandsawn beauty is so simple, you'll want to make several for family and friends.

Bandsaw the lid and bottom 4 Adjust your bandsaw for a 6" 1 Cut two pieces of stock cutting depth. Then, standing the 1 H6x4x5W for the lid (A) and bot- lid (A) on its unpatterned end, tom (B). (We used walnut.) Stack saw along the inside line. Then, them, then look at the edges. The saw the bottom, as shown right. grain should run in the same direc- 5 Sand the lid and bottom inside tion, giving roughly the appear- and out with 100-, 150-, and 220- ance of one thick piece of stock. If grit sandpaper. Wrap your sandpa- not, turn one piece around or flip per around a length of dowel rod

it over to achieve the most seam- to sand the inside corners, as less look. Mark the mating faces shown opposite page. Using a disc for orientation. sander, sand about Mr." from one 2 Chuck a W round-over bit in end of the lid, making it shorter your table-mounted router. Rout than the body. This will allow the the upper edges of the lid and the lid to open freely after assembly. lower edges of the bottom where shown by the Lid and Bottom Side The ends come next View drawing. 1 With double-faced tape, lami- 3 Transfer the inside cutting lines nate two '/2x3x5" pieces of stock, from that drawing to the lid (A) good faces together, for the ends. and bottom (B). You can photo- Choose a wood that contrasts

copy the drawing, cut it into the with the body. (Wc used maple.) two parts, and adhere them to the 2 Photocopy the Ends pattern. stock. Or, you can lay out the cut- Adhere the copy to the laminated

ting lines directly on the stock, stock with rubber cement or Stand the lid and bottom on end to saw measuring from the drawing. spray adhesive. the inside contours.

32 ^(a^QDDfearjfflGfe WOOD MAGAZINE FEBRUARY 1997 (A) LID FULL-SIZED PATTERNS Wasleis Inside cutting line'' ,,„., ,,., . shaded darker. ,/e hole Vz deep

LID AND BOTTOM -1 5/8" W round-overs SIDE VIEW

Insert spacer for assembly DIVIDER SIDE VIEW '3/16" V8" holes V2" deep (see text). ® W stock ® BOTTOM HANDLE 4"- FRONT VIEW

4'/2"

ENDS© Bottom location - SIDE VIEW

1/2" stock

- Vs" hole

3. Drill the three W holes through then sand down to it. Remove the both ends where shown. For paper pattern, and separate the accuracy, employ a drill press. two pieces. Remove traces of Back the workpiece with scrap- adhesive with lacquer thinner. wood to prevent tearout. 5 Rout a W round-over along the 4 Bandsaw around the outer pat- front, back, and top edges of the tern line. For a smooth edge, saw outer face on each endpiece. slightly outside the pattern line, Rout the parts facedown on a router table, making multiple shallow cuts.

Glue on the ends 1 Sandwich a spacer about V16" thick between the top and bot- tom. (We used the cardboard back from a memo pad.) Bind the pieces together with masking tape as shown nextpage, keeping the ends and edges flush. 2 Clamp the ends to the bottom/lid assembly. Position the ends flush with the top of the lid and the back (hinge side). 3 With a drill press, drill two W»" of the Sand the inside curves with sandpaper holes in each end body and wrapped around a dowel. one in each end of the lid, using Continued WOOD MAGAZINE FEBRUARY 1997 33 Catchall the holes in the ends as guides. a dowel pin into the two lower Dress up the lid Drill W deep. (The total depth of holes on the end. Repeat for the 1 Photocopy the Handle pattern the holes from the face of the end other end. Clamp until dry. (E). Adhere the copy to the best should be 1".) 6 Adhere a photocopy of the face of a piece of stock %x*4x5 34". 4 Remove the ends. Sand both Divider pattern (D) to a '/

HANDLE drilled in it. Center the handle,

and position it so the lower sur- face fits flush with the lower edge of the lid at the ends. Clamp with rubber bands. When dry, sand the ends flush with the lid. 4 Slightly sand W at one end of each remaining dowel pin for a ^^ I I w snug, rotating fit in the lid holes. The lid will hinge on these pins. Then, place the lid in position. Push a dowel pin, sanded end Insert a VW" spacer between the lid and first, through the end holes into bottom before fitting the ends. the lid. Glue the pins to the ends. ©END 5 After the glue dries, sand the dowels flush with the ends. Finish as desired. We sprayed on a clear, semigloss finish inside and out.*

3/e" round-over

Glue this dowel into hole in end only, do not glue dowel into hole in lid. ® DIVIDER

EXPLODED VIEW

No round-over on bottom edge. Project Design: James R. Downing Photographs: King Au; John Hetherington Illustrations: Kim Downing: l.orna Johnson

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Turns your work surface into a clamping center.

1896 AMERICAN TOOL CHOO-CH

Let's get things rolling with 3 Cut the cowcatcher (C) to size, Add a cab to house the walnut chassis assembly but to 12" in length. The extra the conductor 1 Prom 34" walnut, cut die chassis length is necessary when cutting 1 Cut the cab floor (D) to size. (A) to the size listed in the Bill of the beveled front end to shape. Glue and clamp it to the top of Materials. Mark a 3" radius on 4 Cut the front end of the lVis"- the chassis (A) where located on each end of the chassis where thick cowcatcher (C) to shape as the full-sized chassis pattern. shown on the chassis (A) pattern illustrated on the Cutting the 2 Cut the cab sides (E) to size on the WOOD PATTERNS® insert Cowcatcher drawing on the fol- from W stock. Use double-faced in the center of the magazine. lowing page. Also, see the full- tape to adhere the pieces face-to- Handsaw the ends of the chassis sized cowcatcher pattern on the face, with the edges and ends to shape. Then, sand the ends pattern insert for reference. flush. Transfer the full-sized side smooth to remove the saw marks. 5 Crosscut the cowcatcher to final pattern from the pattern insert to

2 Cut the spacer (B) to size from length (4'/6"), and glue it to the the taped-together pieces. Drill a W stock (we resawed this piece bottom of the spacer (B) where !4" blade start hole, and cut the from '/>" material), and glue it to shown on the full-sized cowcatch- window to shape. Then, cut and the bottom of the chassis where er pattern. Keep the back end of sand the back edge of the cab shown on the full-sized chassis the cowcatcher flush with the sides to shape. Separate the pattern on the pattern insert. back end of the spacer. pieces and remove the tape. Continued WOOD MAGAZINE FEBRUARY 1997 * PGffittQGDfeaDGfeQS 37 .

15/ie x 23/4" finial 3 3 3 BOILER DETAIL A" x 1 V2" finial with /s x /s" tenon -= with V2 x V2" tenon

Candleholder top cut to 4'A" long

3/s" hole 7/i6" deep, centered

,5/i6° hole 3/4" deep, centered

Vb" round-over on both edges of

Candleholder base -

V2" button

V2" hole '/•)" deep'

%2 x 1 Vi6" axle peg

Partially assembled piston and connecting rod Glue wheel 3/i6" from end of dowel. V2 x 1 V2" flat wheels

Vb" chamfer on ends EXPLODED VIEW

7 /32 x 1 Vie" axle pegs

barrel

CUTTING THE COWCATCHER

STEP 1 Angle miter gauge and saw blade, and then cut through the STEP 3 Switch miter gauge to the slot on the left-hand side of the auxiliary fence. blade, and cut through the fence. Mark a reference line square to one edge, align reference line with kerf, and make the second cut. STEP 2 Mark a outline on the bottom side of (5). Align marked outline with kerf cut in fence, and make the first cut across (5).

Saw blade and fence are set the same as in Step 1

38 WOOD MAGAZINE FEBRUARY 1997 Bill of Materials

Finished Size Finished Size Part W Part W

CHASSIS ASSEMBLY BOILER %" - CUTTING DIAGRAM A chassis 3V4 SW W H' bands V>" 3V4" dia.

2" 3" B spacer w I* discs 1V5»' dia. W C cow- J" discs V." 3'/*" dia. W 33= ..-"/". catcher 1VW 3'/a" 4'/e" w

3'/«" CAB K' disc dia. w 3/* x 5V2 x 24" Walnut 'Initially cut parts marked with an ' oversized. D floor 2W 2W W Trim to finished size according to the instructions. E sides 3W 5¥*" W Materials Key: W-walnut, M-maple F front % SW w Supplies: VST, %*, Va", and V*' dowel stock, 4-'/;>"

G roof flat washers, clear finish. V2 x 5'/2 x 24" Walnut

jex fat Position miter-gauge guide so edge of plywood flush is "Plane or resaw to bandsaw blade. 1 /.i" dowel the thick- 2" long to nesses listed CIRCLE-CUTTING in the Bill of % x 5V2 x 24" Maple JIG Materials. kv r%h 3/a° plywood

1'/2"for© 24" 5/32" hole, counter- 1 Vie x 5V2 x Walnut sunk on bottom side 7 mating hole is a /64° pilot hole 3/8" deep.

#8 x 3/4" F.H. wood screw Clamp a stop to the bandsaw Guide sized to fit miter- gauge slot in bandsaw table for the end table of the guide to stop against once the jig is correctly positioned.

With the square boiler-band blank mounted on the dowel in the jig, slide the jig until it hits the stop, and bandsaw the disc to shape.

3 Cut the cab front (F) to shape. Lay out the notch locations along the edges, and cut them to shape. 4 Glue and clamp the cab sides (E) and front (F) to the floor (D). 5 Carefully lay out the hole cen- terpoints on the chassis sides (A, 6 Cut the cab roof (G) to size. A boiler gives this engine C) where dimensioned on the Sand the top to the shape shown power to spare Chassis/Cab drawing on the fol- on the pattern insert, being care- 1 To form the boiler bands (H) lowing page and on the full-sized ful to keep a W flat area along the and discs (I, J, K), you can cut the pattern. Drill the holes where edges. (We used double-faced discs freehand or build a circle- marked. (For support and consis- tape to adhere the roof to a 2x4 cutting bandsaw jig like the one tent placement, we used a fence to act as a handle when sanding.) shown on the Circle-Cutting Jig n on our drill-press table when 7 Center the cab roof side-to-side drawing. Cut four pieces of Vi - drilling the holes. A vernier on the cab assembly, with a W thick maple to 3V2" square for the caliper came in handy when overhang over the front edge. boiler bands (H). Draw diagonals checking the depth of the %z" Glue and clamp (or tape) the cab to find center. Drill a Vt" hole at holes in C.) roof in place until the glue dries. the marked center of each piece. Continued

WOOD MAGAZINE FEBRUARY 1997 39 fiwJEEe^

Center roof from side to side onto cab.

Front edge of roof overhangs Va" past cab.

CHASSIS/CAB

Radius front and 9/ie" hole, back end of the centered on joint chassis. line and drilled after Use a disc sander to sand a flat area on the bottom of the boiler for mounting cab is assembled the boiler to the chassis later.

5 Using a Va" carriage bolt 4" long with a washer and wing nut, glue

and clamp the three inner discs (J, K) together. The carriage bolt allows you to clamp and align the 1 3/4" three pieces at the same time. 22.5° bevels Later, remove the bolt, and use a disc sander, with the table tilted 2 To use our handy jig to cut the to 12° from horizontal, to sand

discs to near-perfect shape, posi- the edges of each J. tion the jig on your handsaw table 6 To finish-sand the edges of the

so the center of the hole being center section (J, K), remount it used in the jig is directly across to the carriage bolt, and chuck from the center of the blade (we the threaded end of the carriage recommend a Ki" bandsaw blade). bolt into your drill-press chuck. Without moving the jig, clamp a Start the drill, and sand the edges stop in the miter-gauge groove smooth, as shown in Photo B. directly behind the jig. Mount one Repeat the process on your drill of the square boiler-band blanks press to sand the edges of the

on the 'A" dowel in the jig. Start front and rear discs (I) smooth.

the saw, and push the jig until it 7 Drill a hole Va" deep cen- Chuck the threaded end of the carriage W comes in contact with the stop. bolt into your drill press, and sand the tered in the front end of the can- When doing this, you'll have cut center boiler section smooth. dleholder base piece used to form into the square blank. Now, rotate the front of the boiler. See the the blank to finish cutting the disc- move the 'A" dowel to the other Boiler detail for reference. Then,

as shown in Photo A. Turn the hole in the jig, and cut the I parts drill a 'A" hole through the center

saw off, and remove the disc from to 3" in diameter. Note that the I of the V2" hole. the jig. Repeat to form the other parts are cut from 1 Vic" material. 8 Using a 12"-long piece of Va" all- three boiler bands. 4 Fit your table-mounted router thread rod, glue and clamp the 3 Using W stock and the jig's 3'A"- with a W»" round-over bit and a V- remaining boiler pieces H, I, and diameter setting, bandsaw the notched fence, and rout the edges the candleholder base to the cen-

boiler discs (J, K) to shape. Then, of the boiler bands (H). ter boiler section 0. K).

40 WOOD MAGAZINE FEBRUARY 1997 Immediately remove any excess glue with a damp cloth. PISTON/CONNECTING Vl6" ROD ASSEMBLY r Finish forming the boiler 7 and add it to the chassis /32 x 1 Vie" axle peg ) 1 Flatten the boiler bottom by J 3 6" — W hole (Glue /s x it against a disc sander Sand a slight round-over holding dowel in place before on front end of x 6" dowels. and sanding a slight flat area as % drilling this 'A" hole.) shown in Photo C. See also the 5 1V8X1 /S' 3/b" hole 'A" deep Boiler detail accompanying the barrel Exploded View drawing. 3/8" dowels 6" long -- Sand a slight 2 Drill the three holes for the can- round-over on dleholder top and finials centered outside end. in boiler parts I and K where shown on the Boiler detail. 3 Clamp the candleholder top in your woodworker's vi.se or in a handscrew clamp. Then, use a handsaw to crosscut the bottom flanged end off the candleholder. Glue the finials and candleholder (smokestack) into the boiler. 1V8X1W barrel Add the piston/connecting rod assembly 1 Cut the V6", 56", and ¥t" dowels 7 Sand all the parts. Glue and opposite Vh" dowel and barrel in to the lengths noted on the clamp the boiler to the place, keeping the barrels aligned Piston/Connecting Rod Assembly chassis/cab assembly. Add the fin- with each other. drawing at right. ish to the chassis/cab, wheels, 11 Push the connecting rods 2 Sand a slight round-over on one dowels, and toy barrels now. To (56x6" dowels) through the holes end of the 54x54" dowels and one enhance the beauty of the walnut, in the toy barrels, and pin the end of the 56x6" dowels. we used an oil finish. opposite end to the rear wheels 3 Using the same drawing for ref- 8 Glue the TAixVAt" axle pegs in with the axle pegs. If you've built erence, drill a 56" hole '/t" deep place to secure the four 1 V^'-diam- this for a child, consider adding a into the 54x54" dowels. Now, glue eter front wheels to the chassis. screw eye with cord attached to the 56x6" dowels into the W holes 9 Glue one 5"-diameter rear wheel the top edge of the cowcatcher in the 54x54" dowels. Later, using to the W dowel, leaving ¥\/6" listed in the Bill of Materials. Kit 6 Drill a 'M" hole W deep in the dowel onto one end of the front no. W952, $29.95 ppd. Heritage outside face of each rear wheel %x5-%" dowel. Slide this dowel Building Specialties, 205 North where shown on the Exploded through the %" hole in the front Cascade, Fergus Falls, MN 56537. View drawing. of the chassis. Then, glue the Or call 800/524-4184 to order. Written by Marlen Kemmet Project Design: Wayne Edwards Illustrations: Kim Downing; Lorna Johnson Photographs: Bill Hopkins WOOD MAGAZINE FEBRUARY 1997 41 great-looking Most likely, your dovetail jig 9 steps to will have a set of stops on both ends that the edges of the workpieces butt against. Set these according to which tem- plate you are using.

f,

Simple dovetail jigs such as the one here help you make tight-fitting half-blind dovetails quickly and easily. Follow these key steps and tricks for using your dovetail jig, and you're sure to enjoy success. T\ 'O rtgi *e:

Note: To make your dovetail jig faster and easier to use, build the " dovetail jig fence on page 24. If you make a lot of dovetail joints, you'll find that this handy accessory more than pays you back for the small investment in materials and time required to make it.

\ ' Sv®l_- Dovetail jigs come with a tem- \ 9\ 1 plate or "comb," with a series of "fingers" that you guide a router along to cut the dovetails. A Now, select your stock and standard Vi" template works in con- 4 plane or resaw it if neces- junction with a Vi" dovetail bit, and sary. Drawers typically have typically has fingers spaced W %"-thick fronts and !^"-tliick sides apart as shown right. However, and backs. With our Porter-Cable we've seen some templates with 1" jig, the Vi" template requires spacing. And, manufacturers offer workpieces at least W thick. The optional templates with smaller fin- Vk" template works with drawer ger spacing. For example, with our fronts at least W thick, and sides Porter-Cable jig we occasionally use at least 5/i6" thick. a Vi" template that has fingers Cut your workpieces to size, 7 spaced /i6" apart. Measure the spac- making sure they are square, and ing and make note of it. arrange them as shown below. Mark the top edges and number all of the matching inside corners. Make the width of your work- pieces an increment of the finger spacing. For example, a template with %" spacing will work nicely with 3^"-, 4Ys\ or 5Vi"- wide pieces. That way, your workpiece will have equal half dovetails at the top and bottom of

the joint as shown left. This also leaves a full tail correctly positioned for a drawer bottom. Plan to center a W'-wide, W-decp bottom-holding groove on this tail after you machine the dovetails.

42 WOOD MAGAZINE FEBRUARY 1997 ", :':- O i .i "i ,'v Grab two workpieces with The inside (numbered) surface flush with the end grain of the same-numbered corners. of the drawer parts should be fac- vertical piece. Place them into the jig with ing away from the jig, visible to To speed things up, place work- the numbered ends together, the you. The workpieces should be in pieces on both ends of the jig as drawer side positioned vertically, contact with the stops, and tight shown above. This only works if and the front or back sitting hori- against each other, with the face the width of your pieces is less zontally as shown above. grain of the horizontal workpiece than half of the jig's capacity.

Mount the correct guide Now, check if the dovetails 6 bushing into your router's 9 go together so that the face base. Our jig requires a grain of the drawer sides bushing with a fte" outside diame- aligns flush with the end grain of ter (O.D.) when using a Vz" tem- the front or back. If they won't plate, and V\c," O.D. bushing for its align flush, you need to increase y*" template. Secure the necessary the length of the dovetail cuts by dovetail bit, and use a metal rule adjusting the templates in, away to adjust its height according to from the router. If the dovetail the instruction manual. cuts are too long and the work- pieces go more than a hair past flush, adjust the templates out, Note: Perform the following steps in scrap stock that's of the toward the router. With our same dimensions as your workpieces. After you're satisfied with Porter-Cable jig, we do this by

the results, cutyour actual workpieces as described in Step 7. loosening a holding screw and micro-adjusting a setscrew in or out with a hex key as shown. Working from left to right, If you run into grain splin- 7 move die router in and out 8 tering near the end of the of each of the template fin- cut, add a scrap piece as gers. Go slowly, especially near shown below. The scrap may the ends of the cut, to ensure splinter, but it will help keep the clean results. workpiece clean if the two are Remove the two workpieces and tightly butted together. check their fit with one another. The dovetailed ends should slide together with firm hand pressure or light tapping with a rubber mal- let. If the joint requires more force than that, or won't go together at all, decrease the height of the bit and repeat your test cuts. If the dovetails fit sloppily, increase the together too Writicii 6y Bill Kricr with Chuck Hedlund bit height. Illustrations: Brian Jensen

WOOD MAGAZINE FEBRUARY 1997 43 A bird with lots of cents

Kids love to stash their cash away. That's why we're sure any youngster will welcome this colorful cockatoo as a roommate: This bird conceals a bank under one wing, as shown in the inset photo.

Begin with the body 1 Photocopy the Full-Sized Body Pattern (A), in the WOOD PAT- TERNS® insert in the middle of the magazine. Using rubber cement or spray adhesive, adhere it to a l!/fcx6xl0" piece of stock (bass- wood, poplar, or pine would be good choices for the painted bank). Bandsaw the body. 2 Chuck a Va" bit in your drill press, and drill through the body at the center mark for the .W-dia. hole. Piloting on that hole, bore about halfway through the body with a J>W hole cutter. Flip the body over, and bore in from the other side to complete the cavity. 3 With a W rabbeting bit, rout a Wi"-decp rabbet around the hole on the patterned side of the body.

4 Drill a !'i<." pilot hole through the body at the eye location. Guiding on the pilot hole, drill a Vi" eye hole about l4" deep on each side of the body. Drill a W hole Vi" deep and a W hole through the body where shown. On the right side of the body, counterbore the Vi' hole W deep with a W bit. 5 Install a W round-over bit in your table-mounted router. Rout the body on both sides, starting in front of the line marking the front of the notch for the feet. Continue around the body to the tail notch at the back.

44 ^m&m$fmm PIVOT PIN DETAIL (SECTION VIEW) 6 Glue a Vi" length of W dowel rod into the Va" hole on the left Led side of the body. Sand down the SEE THE wing - Right wing WOOD PATTERNS® INSERT protruding end so it extends FOR FULL-SIZED PATTERNS -. #4 flat about W from the body. washer f 7 Carve a V\c" V-cut along the dot- ted line at the front of the body to indicate breast feathers. A V\a" V- tool or the corner of a rotary carv- ing burr will make the cut. 8 To make the cover for the rab- beted side of the coin opening, cut a 4"-diameter disc of k&"-tbick EXPLODED clear acrylic. (You could use tem- VIEW pered hardboard or Baltic birch plywood instead, if you wish.) 9 Drill a W blade start hole where shown in the cover's coin slot. Va x 4"-dia. acrylic with Scrollsaw slot, or drill coin slot cut into it the overlap- ping holes and file it out. Drill and 5/32" hole, countersunk countersink four y«" screw holes in the cover where shown. W dowel 1 V8" long

Shape the wings 1 Stack two Vzy.5Vix.6Vz" pieces of stock together with double-faced tape. Adhere the Wing pattern (B) on page 47 to the top of the stack, and cut out the wings. 2 Separate the cutouts, and desig- nate one the left wing and one the right. On back of the left one, drill a 'A" hole W deep where shown. 3 On the face of each wing that will lie against the body, mark the area shown at the lower back cor- ner of the pattern. Relieve the area by sanding, bringing the wing's thickness at the bottom rear tip to about Vi". This will allow the wings to clear the tail when installed, as shown by the © photo next page. Then, sand the 1 dowel 5V2" long outer face of each wing to shape. Round over the front edge and 'A" chamfer taper the back, as indicated by the pattern's Cross-section view. 4 Carve a shallow V-groove on the Wing stop notch outer face of each wing, where cut Vi" deep. shown by the broken line. Carve WING NOTCH DETAIL h x 8"-dia. base Vic" deep with a Vis" V-tool. Continued

WOOD MAGAZINE FEBRUARY 1997 45 v^ockatoo Cache

Turn to the tail 4 Glue the tail to the body. After Complete the bird bank 1 Adhere the Tail pat- the glue dries, sand the tail and 1 Sand the body and wings. Paint tern (C) below to Vi" body contours to match. Fill the white, and apply bright color high-

stock. Cut out the tail. joint, if necessary, and sand. lights where shown. Airbrush or 2 Taper the top sur- aerosol-can application gives the face to about W thick Details make the bird best effect. Apply a clear coating. at the wide end, carv- 1 Cut the crest (D) from W stock. 2 Now, attach the wings, starting ing the tops of the Taper it to about W thick at the with the pivoting left wing. First, feathers as you go. To feather tips, sanding each side to a cut a piece of '/(" dowel rod \W do so, carve a V-groove between gentle curve rather than a straight long for the pivot pin. Insert one the two feathers numbered 1. slope. Glue the crest to the head, end into the hole on the back of

Then knife-cut each remaining straight along the centerline. the left wing (do not glue it). Sand feather line. 2 Cut the beak (E)—or is it a trea- the other end to turn freely but 3 Employing a shallow carving sury bill? —from '/»" stock. Sand the without play in the \A" hole gouge or a narrow chisel, carve front round, starting from the bro- through the body. from the center of feather 2 ken line. Glue the beak into place. 3 Press the left wing against the toward feather 1 on each side, 3 Cut two feet (F) from %" stock. body side with the pivot pin going slightly deeper as you Sand the front and back round through the hole. Mark the pivot approach the knife-cut line. where shown by the broken lines. pin at the bottom of the counter-

Similarly, carve from feather 3 to 4 Chisel out the )fc"-deep notch for bore, and cut it to that length. feather 2 on each side. This will the foot on each side of the body, 4 Drill a %i" pilot hole in the sand- create a layered appearance, as then glue the feet into place. ed end of the pivot pin. Drive in a shown in the detail photo. Carve Position the outside face of each #4x.Vi" panhead screw with a V-grooves for the feather lines on foot flush with the body. washer, as shown in the Pivot Pin the bottom of the tail. 5 Drill a W hole W deep where Detail drawing. Be careful not to shown in the middle of split the pivot pin, and make sure

each foot. (We held the it turns easily with the screw in. Va" hole - body upside down in a 5 Remove the screw and washer, deep Va" © vise and drilled with a and glue the pivot pin into the TAIL cordless drill.) Glue a %" wing hole. After the glue dries, length of W dowel rod install the left wing with the screw V2" stock into each hole. and washer. Then, scrape the

Shape the inside of the wings to clear

the tail. Fan the tail feathers out from the middle.

46 WOOD MAGAZINE FEBRUARY 1997 —

paint from a few mating spots on Bandsaw the base. Saw outside the the feet make carbon-paper marks the back of the right wing and the cutting line, then sand down to it. on the crossbar. Drill a W hole Vt" right side of the body, and glue the 2 Rout a 'A" chamfer around the deep at each mark. right wing into place. top edge. Drill a W hole W deep 6 Sand and finish the stand. You 6 Swing the left wing down until it at the center. Sand the base. could paint it or, as shown, stain it contacts the stop dowel. Mark the 3 Cut a $W length of W dowel and apply a clear finish. After the contact point, then carve the stop rod for the upright (H) and a 5H" finish dries, position the cockatoo notch into the underside of the length of %" dowel rod for the on its perch, engaging the dowels wing, shown in the Wing Notch crossbar (I). Drill a %" hole W in the feet into the holes in the

Detail drawing. deep at the center of part I. crossbar. For greater stability, glue 7 Glue in the eyes. (We used black 4 Glue the crossbar (I) to the the feet to the crossbar.^* plastic eyes from a craft shop; upright (H). Then, glue the assem- Project Design: Raccoon River Scrollworks. P.O. Box 41308, Des Moines, Iowa 5031 1-0506 black-painted buttons would work, bly into the base hole. Photographs: John Hetherington too.) Position the plastic cover in 5 Lay a piece of carbon paper Illustrations: Kim Downing; Lorna Johnson the rabbeted opening. Drill V\6" across the stand's crossbar. Then, pilot holes, and secure the cover slide the cockatoo's feet with four #3x-%" flathead brass down onto the cross- wood screws. bar—making sure the bird is centered Build the perch and press down 1 Scribe an 8"-diameter circle on so the dowels in l'/2"-thick stock for the base (G). —

^ THE °<*\ PERFECT FINISH A PROS POINTERS

periodically you do have to give Chuck Hedlund, the piece another coat to keep up magazine's the protection." WOOD® What about water-based finishes? project builder, "Water-base has more of a natural gives look on the wood. It doesn't give you it a yellow cast, which takes some his tips for people a while to get used to," says Chuck. "The trouble with getting a water-base is that it raises the great finish. wood grain, making more work for you in the application. Sometimes what helps, though, is to first sand the wood, then wipe it with a damp cloth, and then

sand it again. But don't saturate the wood. There's only so much grain to raise." Choosing the right finish is really the easy part. The biggest— and hardest—aspect of getting a great finish is the preparation, Chuck believes. "It's like painting a car the spraying is the easiest and quickest thing. But if the surface a ccording to Chuck Hedlund, tinues. "I put more coats of finish, isn't prepared correcdy, the paint /% there isn't a "perfect" fin- usually double, on flat surfaces job won't look good. No matter X jLish. Why? He explains: "It like table and desk tops. Edges how well you can spray or brush, depends on the application. As a should get multiple coats, too. if you don't prep the wood right, woodworker, you have to look at And it's important to seal the bot- you won't get a great finish." the project and its use, the design, tom side with the same number of and the wood before you select coats. You don't have to rub out Proper preparation the finish to put on it." the finish on the bottom, but you begins with gluing should put on the same number To Chuck, about the worst con- Selecting the right finish of coats." tributor to a bad finish is glue

"Basically, if you have a piece of Chuck admits that part of lac- squeeze-out. "You have to get it furniture that will take a lot of quer's widespread appeal is its all off the wood because even touching, like the wooden arms of sprayability and fast-drying nature. with sanding, sometimes the glue a dining chair or a table top, that's But he believes there's a place for only shows up after you stain the where polyurethane is appropri- oil finishes, too. wood or apply the final finish," he ate," Chuck explains. "You could "Oil [tung, Danish, etc.] is appro- notes. "Then, it's a real problem use lacquer, but then you have to priate on anything made of what I to repair. You have to go back be more careful and aware of the call 'elegant' wood, such as cher- through all the sanding steps." finish because you can't treat it ry, black walnut, and figured So, what can you do about glue roughly. I have an oak rolltop maple," says the project builder. squeeze-out? After all, there has to desk at home that I sprayed with "Sure, you can put polyurethane be some. lacquer, but I protect the writing or lacquer on all of them, but it "If you don't have any squeeze- surface with a desk pad and use a won't bring out the richness of out, you'll have a starved joint coaster to rest cold drinks on. I the color and grain. Oil soaks into that could eventually separate," also paste-wax it twice a year. the wood, and one of the easiest says Chuck. "If you have too

"And that desk top has at least is Minwax Antique Oil because it much, you end up with a chore in six coats of lacquer on it," he con- builds up quickly. But with oil, removing it. I've found that

*5 tOOfflSO® WOOD MAGAZINE FEBRUARY 1997 " FOR PREPARATION

"However, no matter with what brash poly or a water-based finish, grit you start, don't skip a grit you can use a disposable foam

because it will just take longer to brush [lacquer eats foam J." remove the scratches from the So, how do you start? "I usually previous one," Chuck cautions. start in the left corner away from "And if you plan to stain the me and bring the finish to my wood, remember this: The coars- right, working from back to er the sandpaper you end up front," says Chuck. (See below.')

with, the darker the surface will "That's so I don't drop anything stain; the finer the grit, the lighter onto the fresh finish by reaching the stain will be. That's because across the full width.

Here's what the squeeze-out of a good pigment collects in open pores." After applying the finish, Chuck glue line should look like. Chuck inspects the piece for areas he

removes it with a chisel before it's dry .

squeeze-out the size of a pencil

lead is just about right. [See photo

above.] I wait until the squeeze-

out thickens, then I lift off the glue with a chisel, putty knife, or

scraper. If you wait and let it set up overnight, you risk pulling off some of the wood when you remove it because the glue bonds. How Chuck Hedlund Unless you plan to resand the sur- brushes on a finish face, you don't want to let it dry." To remove a messy run of finish requires scraping the excess with a chis- You can sand too much el, light sanding, and then buffing the might have missed or didn't Don't skip a grit is a woodwork- area with a polishing compound. apply enough to. After the finish ing commandment. Yet, that dries, if he finds any runs, he doesn't necessarily mean sanding One good way to brush scrapes and sands them down. progressively through all the abra- Many, if not most, home wood- "About the only way to correct sive grits. workers rely on their hands rather imperfections is with scraping,

"The number of grits I go than a spray gun to apply finishes. light sanding, and buffing," he through depends on the circum- And Chuck has some advice says, then adds some final words stances," Chuck comments. "For regarding that. "Buy a quality, nat- of advice. "Don't get in a hurry. example, with penetrating oil ural bristle brush for lacquer Finishing takes time. You put a where you'll actually feel the because the better the brush, the lot into making the project, so wood through the finish, you'll better the result. There's nothing spend the time necessary to fin- normally want to go from 80 to more irritating than a bristle com- ish it correctly, even if it takes as 320. But if you use a lacquer or ing out on the final stroke. To long as the building. "# poly, which are surface finishes that build up, you can stop at 150 More great finishing tips from Chuck grit. Of course, if you have a thick- •Use cotton swabs to spread finish into corners and crevices, and to ness planer that puts out a nice unclog dowel holes. smooth surface on the wood, you •Remove the back of a cabinet before spraying. Take off handles and

might be able to start with 1 20- or anything else that you can remove. 150-grit. If you don't need 80, stay •Stuff cotton balls in any dowel holes yet to be filled.

away from it and any coarser grits. •Keep stains stirred throughout application.

That's because any time you use a •Don't let stain dry before wiping it off. Always keep a wet edge. On coarser grit you're visibly scratch- a large surface, first stain two-thirds and then wipe it down. ing the surface.

Written by Peter J. Stephana Photographs: John Hctherington Drawing: Brian Jensen

WOOD MAGAZINE FEBRUARY 1997 49 ARCHED-TOP

Want to add a little sparkle to a ho-hum entry or brighten up a dreary hall? If so, you're going to love this simply ele- gant shelf. All it takes is a tablesaw, jigsaw, sander, and an evening or two of your time. It's that simple.

Start with the plywood back and side pieces 1 Cut a piece of Yi" plywood to \2W wide by 34" long for the back (A) and two pieces to 5Ht" wide by 22'/i" long for the sides

(B). (Because it has more plies and is void free, we selected Baltic birch plywood for this project. Select your own stock, or see the Buying Guide for our source of this quality plywood.) 2 Cut the pattern pieces for the full-sized mirror and back (A) from the WOOD PATTERNS® insert in the center of the maga- zine. Note that the pattern comes in two pieces, and that you'll have to tape a 1656" piece of paper between the patterns. Then draw lines to connect the patterns and add the middle horizontal piece. Trace the full-sized mirror pattern from this paper pattern. The paper pattern gets destroyed when cutting the back to shape. 3 Transfer the full-sized back (A) and side (B) patterns to the respective stock. Drill a blade start hole inside each marked opening. 4 To cut the openings in the back (A) and sides (B), use a scrollsaw if you have one with a large enough throat. If not, use a jigsaw to cut the pieces to shape as shown in the photo at right. (We used a jigsaw fitted with a Dewalt trim/coping blade, #3715 for the curved cuts and a Dewalt fine cut/smooth finish #3710 blade for the straight cuts. If you have a

QGOOeO© 50 T WOOD MAGAZINE FEBRUARY 1997 A delightfully different showcase for prized collectibles ^< jigsaw requiring a bayonet-style Duct tape on back blade, we recommend the AEG of mirror to prevent hanging hardware 254061 jigsaw blade. (A quality from scratching Plastic blade is important to minimize mirror back. mirror clip chipping when making the cuts.) See the box at the end of the arti- cle for three tips on making smooth cuts with a jigsaw. 5 Using the one side piece cut to shape as a template, transfer the pattern to the second piece of ply-

wood, and cut it to shape. 6 After the cuts are made in the back and sides, remove the pat-

terns, and fill any voids (we rec- ommend Durham's Rock Hard Putty). Sand each opening.

It's time to cut the dadoes and grooves 1 Fit your tablesaw with a Vt" 22W dado blade, and cut '/»" dadoes \A" deep in the sides (B) where dimensioned on the full-sized pat- tern and Exploded View drawing. 2 Switch blades and cut a W groove Va" deep along the back inside edge of each side (B) where Continued

' 'Initially cut parts marked with an oversized. Then, trim each to finished size according to the CUTTING how-to instructions. DIAGRAM Material Key: BP-Baltic birch plywood.

Supplies: 3-'/«x4*ix127i<,' glass for shelves, to<11x31 V mirror, 2 picture hangers with screws Va x 24 x 48" Birch plywood and #4 picture wire, 6 plastic mirror clips with screws, primer, paint. SEETHE Buying Guide WOOD PATTERNS® of pieces shown on the Hardwood kit. All the INSERT FOR Drill blade start holes, and then cut the Cutting Diagram cut slightly oversized from 14*- marked openings on the plywood back thick Baltic birch plywood. W951, $24.95 ppd. FULL-SIZED PATTERNS to shape. Heritage Building Specialties, 205 North Cascade, Fergus Falls, MN 56537. Or call 800/524-4184 to order. WOOD MAGAZINE FEBRUARY 1997 51 shown on the Exploded View hold them parallel to each other easily. We also had the shelves cut drawing. (We cut scrap stock first and square to the back (A). W wider, front-to-back than the to ensure the width of cut was 3 Glue and clamp the sides to the opening so the shelves protruded equal to the thickness of the ply- back as shown in the photo slightly from the front of the wall- wood used.) Adjust your blade below. Use the spacers to hold shelf sides.) until the mating back piece (A) the assembly square until the glue 2 Before painting, check to see fits snugly inside the groove in dries. Remove the clamps and that you have filled all the voids each side (B). spacers. Finish-sand the assembly. and that you have sanded all the surfaces. Prime the project, and Assemble the pieces, Add the shelves, then paint it to the desired color. and check for square mirror, and finish 3 Using the Mirror Clip detail, 1 Slide the back (A) into the W 1 Use a piece of hardboard or secure the mirror to the back side grooves in the mating sides (B). cardboard to form a template for of the plywood back (A). Temporarily clamp the assembly the V6" mirror. Measure the size of 4 Add a pair of picture frame together, and check for square. glass needed for the shelves. Have hangers and wire to the back of 2 Carefully measure the distance the glass and mirror cut to shape. the assembly. Add a piece of duct between dadoes in the side (We had our glass shelves cut W tape to the back of the mirror so pieces, and cut two pieces of less in length than the opening so the hanger doesn't scratch the sil- scrap to fit between the sides to the shelves would slide in place vering. Hang the project, add the glass shelves, level the shelf, and Use two spacers to hold the sides square to the back until the glue dries. Clamping add your collectibles.^ blocks prevent the project from being marred when clamping.

3 tips to ensure smooth jigsaw cuts

1 After selecting a jigsaw blade, cut a piece of scrap stock from the same material as the back and sides, and check for smoothness. We noticed that one side of the blade cut smoother with less chip-out than the other. With this in mind, we used the good side of the blade to cut next to the marked pattern line and the poorer side of the blade on the waste side of the stock. 2 Also, if you have an adjust-

able jigsaw, set it so the blade cuts straight up and down and not in the orbital motion. This is a less aggressive cut and results in less chipping. 3 Finally, we primed the sur- face of the plywood before applying the pattern. The primer seemed to bond the wood fibers slightly, making for a smoother cut.

Writien by Marlen Kcmmci Project Design: James R. Downing Illustrations: Roxanne LeMoine; Lorna Johnson Photographs: Hopkins Associates

52 WOOD MAGAZINE FEBRUARY 1997 1 What you need to know before upgrading You say you're not getting the results you hoped for from your tablesaw? The problem may be its fence. Fortunately, there's a whole fleet of high-quality rip fences capable of trans- forming any tablesaw into a precision cutting machine. Read on to find out what we discov- ered about the 21 models we tested.

•All of today's high-quality fences will improve great- ly the performance of a tablesaw outfitted with a standard, low-cost fence. If your tablesaw has a cast- iron top and an induction motor, it probably makes sense to upgrade your saw with one of the fences reviewed here. •Most high-end tablesaws already come with one of the fences reviewed here, or offer you the option of choosing among several of these fences when buy- ing the saw. •You can save up to $75 by buying one of the down- scaled versions that we found plenty accurate and suitably durable for most part-time woodworkers. Rip Fences

First things first—do Your product choices close-up you need a new fence? Rip fences of the quality reviewed Biesemeyer and its clones in this article have become standard • Biesemeyer. The Biesemeyer •Jet. The Xacta commercial and equipment on most tablesaws T-square is the original aftermar- home shop fences closely mimic priced over $1,000—with good rea- ket rip fence, and it has the great- the Biesemeyer fences, with a son. High-quality fences help bring est name recognition in this cate- couple of modifications. In place out the full potential of any table- gory. As shown below, a of the plastic-laminated plywood saw—high or low-priced—by mak- Biesemeyer fence has two heavy faces on a Biesemeyer fence, the ing it more accurate and convenient angle irons that bolt to the front Jet fences have slick plastic faces to use. Here's what to consider and back edges of a tablesaw. made of high-density polyethyl- before taking the plunge: These help support an extension ene. The Jet faces are easier to •As our hands-on tests show, a high- table on the side of the tablesaw, replace because they have acces- quality fence will remain parallel to and the front rail provides a rigid sible screwheads. With the blade cut after cut. The same mounting surface for the front Biesemeyer faces you have to cannot be said for most standard, tube. The fence pinches against remove the laminate to access lesser-quality fences. A fence that the front tube when you lock it the screws. Despite this advan- doesn't reset itself parallel to the in place by lowering its lever. tage, we prefer the Biesemeyer blade contributes mightily to poor- Biesemeyer, like several other faces because we found that they quality cuts, and the possibility of brands, offers a down-sized ver- wear longer and mar less easily workpiece kickback. sion of the "commercial" model than the Jet faces. The Jet rails •High-quality fences cost $210 to shown here. These "home shop" and tube are made from slightly $420 as an aftermarket item, and fences have slightly less beefy thinner steel than the corre- will add nearly that much to the components and shorter fences, sponding parts on the cost of a new tablesaw. but are accurate, and built plenty Biesemeyer fences we tested. •If you work with wood for several well for the dedicated wood- hours or more every week, you'll working hobbyist. • Powermatic. Although the appreciate the speed and conve- Biesemeyer's no-nonsense, all- Accu-Fence Commercial model nience of a built-in tape measure. steel construction and years of appears to be a copy of the

All of the tested units have hairline proven service have made it a Biesemeyer Commercial model, it cursors on the fence that you align top-selling aftermarket fence. It's features two improvements. First, with a tape measure mounted on no wonder, then, that it has as shown on the right side of the the front rail. Doing this is much recently been imitated with vary- photo tight, it has T-slots milled faster than pulling out a tape mea- ing results by General, Jet, into the back sides of the fence sure and checking the blade-to- Powermatic, and Modulus. Let's faces, and nut-access holes in the fence distance for every cut. look at those models. underside of the fence body. These allow you to easily change Do you need • General. We could find no faces without tearing off the plas- a rear-locking fence? major differences between the tic laminate. All of the tested fences lock in fences offered by General and Like the Biesemeyer locking front, and several also lock to a rear Biesemeyer. handle, the Powermatic handle rail. In the WOOD, magazine shop releases the fence completely we use fences that lock only in the front. We've never had a problem with the back end of the fence lift- ing or deflecting. But, we don't use a power feeder, stock hold- downs, or a scoring blade. If you do, you should consider a model with a rear lock. Or, you can simply clamp the rear of any of die tested Biesemeyer Commercial fence fences if the need arises. All in all, we don't find a rear-locking device to be an essential feature. r^^ma\imcmm 54 WOOD MAGAZINE FEBRUARY 1997 when you pull it up, and locks a Biesemeyer fence, you can add the fence when you push it the Modulus rear-locking kit for •Vega. The Vega down. But, the Powermatic fence $7995 list. (For more discussion Pro model shown has an intermediate position that on rear locks, see the section "Do above, and a holds the fence parallel to the you need a rear-locking fence?") down-scaled version called the blade as you fine-tune its position If you frequently work with Utility model, have proven to be by tapping it to the right or left sheet goods, and have had times reliable performers for a number slightly before locking. when you wish you could posi- of years. Both of these fences, and tion the fence farther to the front the new Vega Commercial model • Modulus. You can purchase or back of the sawblade, you shown beloiu, have a micro-adjust three similar fences from this should take a look at the largest mechanism. With this feature you company. They come with rails Modulus model, the SSF-100. It can lock the fence approximately and front tube, or without them has a 60"-long fence that slides where it belongs, then dial it to an (in case you already have forward and back. As shown exact position with a threaded Biesemeyer rails and tube). All below, a mechanism within the knob. This feature also comes in three models have a mechanism fence body controls the sliding handy when you need to "tweak" that locks the rear of the fence to motion, and front knobs lock the a precise cut. the back rail. If you already own fence in place.

Rear lock

Nut-access hole

Sliding Micro-adjustment mechanisms, like this mechanism one on the underside of the Vega Commerical model, have threaded knobs that help you conveniently move the fence in controllable increments.

• Sears Exact-I-Rip. This unit is made almost entirely of beefy extruded aluminum components. The rails are light in weight, but stiff and straight. It has a micro- adjuster with the same benefits Front lock described for the Vega models. Note: Fences are and instructions shown upside down. The hardware packed with the Exact-I-Rip make

it easy to mount to a Sears saw, Operating knob but mounting it to another brand for rear lock can be a challenge. This fence performs well, and we see it as a The Modulus SSF-100 (left) and Powermatic Accu-Fence look like Biesemeyer good upgrade for higher-end fences, but they feature significant modifications. Craftsman tablesaws. Continued

WOOD MAGAZINE FEBRUARY 1997 55 Rip Fences

Product choices Continued

•Excalibur by Sommerville Sommerville Design rails, but they you already have a good idea of Design. Unlike the other fences still proved finicky during installa- how the Paralok works. Although discussed so far, this fence "floats" tion. We found the fit of some of some woodworkers fear the com- along its rails because it rides on the internal components, as well plexity and doubt the durability of wheels both front and back. as the finish of the rails, needing the cable system, our tests Finger pressure alone propels the some improvement. revealed otherwise. Installation fence left or right. Like the was straightforward and took only Modulus, the fence grips solidly in • Delta. Like the Sears Exact-I-Rip, about 45 minutes. The Paralok the rear as well as the front. the Delta Unifence has a beefy easily outperformed the other In our tests we found this system extruded aluminum front rail and fences in our tests of repeatability somewhat finicky. The rails flex fence. And, similar to the Modulus of parallelism, parallelism over rip- more than any others in our test, SSF-100, the Delta fence slides for- ping range, and deflection. so mounting them straight and ward and back as shown below parallel with each other proved to right. But, unlike any of the other •Voss Technologies. The be a challenge (but it can be done tested units, the Unifence can be Evolution I and its little brother, if you have some patience). And, repositioned for ripping thin the Pro Rip, struck us as a cross uneven spring pressure on the stock as shown in the photos. between the Delta and Vega front wheels prevented the fence To complement the time-tested fences. Like the Deltas, both Voss from repeatedly setting itself pre- Unifence, Delta recently has come models have U-channel front rails cisely parallel to the blade. We out with a down-scaled version that capture the fence-locking tried a second fence, but ran into called the Precision Saw Guide. mechanism on the inside of the the same problem. Although it has a less-substantial channel. But, unlike the rigid alu- extruded-aluminum front rail than minum Delta rail, the thinner •Shop Fox. This relatively new the Unifence, it performed well in steel rails of the Voss models had entry most resembles the our battery of tests. a tendency to flex. Like the

Sommerville Design unit because Vegas, the Evolution I and Pro Rip it locks front and rear and moves • Paralok. If you've ever used a have micro-adjust mechanisms. on wheels. It rolls along a pair of drafting table with pulleys and angle irons as shown. These are cable for controlling the position considerably more rigid than the of its horizontal straightedge, then

The face on the Delta Unifence slides for- ward and back as shown above to meet various cutting tasks. And, it can be mounted in a high position (above) or low for cutting thin material (below). Let's review the charted test results We performed three key tests that measure repeatability of paral- lelism, parallelism over ripping range, and deflection for each of the tested fences. From these results we assigned performance ratings for the main chart. •Repeatability of parallelism. For this test, we set the fences for a 12" rip and adjusted them exact- ly parallel with the miter gauge slot (which was exactly parallel with the blade). Then, we subject- ed the fences to some typical shop use, reset them for a 12" rip, and with a dial indicator measured how well they maintained paral- lelism with the miter gauge slot. We did this several times, ripping various boards and sheet goods. The Paralok was the champ. It consistently reset itself exactly parallel. The Delta Unifence was nearly as good, consistently reset- ting itself to within .001" of paral- The Vac-U-Fence excels at helping you rip thin strips, among other things. lel. For complete results, see the chart on die nextpage. Two products that are completely different • Parallelism over ripping Most of us can get by just fine workpieces of various thick- range. Here, again, we adjusted with one of the fences already nesses in contact with its face. the fence parallel to the blade at a mentioned. But if you have spe- The accessory consists of a 12" ripping capacity. Then, we cialized needs, the Incra Ultra TS section of extruded aluminum moved the fence away from the fence or Vac-U-Fence Saw Guide with two chambers. Each cham- blade in 12" increments and mea- may be what you're looking for. ber has different-sized holes so sured the change in parallelism Like its famous cousin, the that you can flip the fence from the front to the rear of the Incra Jig, the Ultra TS shown top depending on the thickness of fence. If the rear of the fence uses plastic saw-tooth racks that your workpieces. cocked itself toward the blade,

automatically locate the fence at It worked well in our tests by this registered as a plus (+) read- exact and repeatable positions holding stock against its face ing on our dial indicator. Fences (to within .004"). We found the without significant resistance to cocked away from the blade gave fence ideal for small-scale work our feeding pressure. As shown us a minus (-) reading. that demands incredible preci- above, we found it especially In our tests, workpieces tended anytime sion. But, it isn't rugged enough helpful for ripping thin strips. to lift off the tablesaw top .005" for ripping large boards or sheet The suction ensured consistent- the fence was more than out goods. And, in our tests large ly thick strips during the cut, of parallel in the plus direction. At badly workpieces caused it to deflect. and prevented the strips from +.015 the stock burned and The Vac-U-Fence is actually an flying back at us at the comple- kickback became imminent. attachment for your existing tion of the cut. Its price: $179 Dado-cut quality dropped when than .005" out fence. It uses suction provided for clear annodized aluminum, the fence was more by your shop vacuum to hold or $195 for colored. Not cheap. of parallel in either direction.

WOOD MAGAZINE FEBRUARY 1997 57 — 1

Rip Fences RIP CAPAC (INCHF. / OF PRIC • Deflection. As you feed a work- piece shifts in relation to the VERSIt piece through a tablesaw blade, blade, and telltale sawmarks (shal- the workpiece exerts enough low arched notches) appear on pressure on the fence to make the the edge when you slow or stop rear of the fence deflect away the feed pressure. These marks, from the blade. To test this deflec- as well as chipping on dado cuts, /I 1 / / tion under actual working condi- showed up with any of the fences / tions, we ripped a sheet of W ply- that deflected .005" or more. COMMERCIAL 12 50 wood and measured the degree of BIESEMEYER HOME SHOP 12 40 deflection during the cut with a Still "on the fence?" top vauit [ dial indicator. See the chart beloiu Here are our choices UNIFENCE 8 ' 52 right for complete results. The Paralok fence system 3HB DELTA ——-— The Excalibur, Paralok, Sears stood clearly above the field ' PRECISION SAW 11 29 TOPWVLU*. GUIDE Craftsman, two Modulus fences, for its dead-on precision. We EXCALIBUR BY and Woodstock International were also impressed by the INDUSTRIAL T-SLOT 12 50 SOMMERVILLE SAW FENCE fences— all rear-locking units Powermatic Accu-Fence and DESIGN earned "excellent" ratings in our Delta Unifence. T50F42 12 52 main chart right. If you're looking for some- GENERAL The problem with excessive thing a little less expensive, HOME SHOP 12 40 deflection is that when you let up buy a home shop fence. Here,

on feed pressure, as inevitably the Delta Precision Saw Guide INCRA ULTRA-TS 16 26 happens unless you use a stock was tops in our opinion, with XACTA feeder, the fence tends to the Biesemeyer home shop COMMERCIAL 12 50 "spring" back toward the blade. fence a close second.* JET XACTA 12 30 Then, the positon of the work- HOME SHOP

SSF-100 SLIDING SUPER 12 50 PARALLELISM OVER DEFLECTION FENCE-COMMERCIAL RIPPING RANGE SF-100 MODULUS STANDARD SUPER 12 50 FENCE-COMMERCIAL / READING IN DEFLECTION BRAND / SF-10 / THOUSANDTHS / (IN INCHES) STANDARD SUPER 12 52 / OF AN INCH AT FENCE-HOME SHOP / 12" RIPPING / CAPACITY 27x6' 16 50 Biesemeyer Commercial .006(6/, PARALOK -SPS? BRAND / INCREMENTS oo") Biesemeyer Home Shop .006 ACCU-FENCE 24" 36" 48" . 12 50 / / / Delta Unilence .004(low)- .008(high)' mTOPWTOOL « COMMERCIAL Biesemeyer Commercial -.004 -.008 +.010 Delta Precision Saw Guide .006(low)- .OlO(high)- POWERMATIC ACCU-FENCE 12 50 +.006 +.006 Excalibur by HOME SHOP Biesemeyer Home Shop .0003 Sommerville Design Delia Unilence -.001 -.002 -.005 .006 SEARS General T50F42 EXACT-I-RIP 24 30 Delta Precision Saw Guide .000 .000 +.003 CRAFTSMAN General Home Shop .006 Excalibur by +.006 -.011 +.014 Incra Ultra-TS .015 Sommeruille Design PRO 10 50 Jet Xacta Commercial .014 General T50 F42 -.004 -.013 -.017 Jet Xacta Home Shop .009 General Home Shop Nol available for testing VEGA UTILITY 8 26 Modulus SSF-100 .005 Incra Ullra-TS -.003 Modulus SF-100 .001 Jet Xacla Commercial +.002 +.004 +.013 COMMERICAL 12 30 Modulus SF-10 .001 Jet Xacta Home Shop +.006 +.008 Paralok 27x6' .0005 Modulus SSF-100 All Modulus lences tested on botli Biesemeyer and Powermatic Accu-Fence .005 EVOLUTION 1 10 50 Modulus SF-100 General rails with results VOSS comparable to Biesemeyer Sears Craftsman Exact-I-Rip .001 Modulus SF-10 and General TECHNOLOGIES Vega Pro .005 PRO -RIP to 50 Paralok 27x6' .000 .000 -.001 Utility .008 Powermatic Accu-Fence -.003 -.006 -.010 Vega WOODSTOCK Vega Commercial .008 SHOP FOX S'h 25 Sears Craltsman Exact-I-Rip -.005 -.008 INTERNATIONAL Voss Technology Evolution 1 .010 Vega Pro -.011 -.008 +.005 Voss Technology Pro Rip .006 NOTES: Vega Utility +.001 Excelloi Woodstock Int'l Shop Fox .005 1. Most models ate available 3.| | Vega Commercial -.001 -.008' -.005 in smaller capac ties. Also, rfi ' JGood Voss Technology Evolution 1 +.001 -.008 +.005 Readings taken with fence face in high capacity can be hltted lelt Li? positions. lor models. and low or right most Fair Voss Technology Pro Rip -.001 -.008 -.004 | Aluminum extrusion [p Written by Bill Krier 2. (AE) Poor Int'i . ] Woodstock Shop Fox +.002 006 stet Product testing: Dave Henderson (RS) Round 1 ^ • Reading taken at 30' rip capacity. (SA) Steel angle Photographs: Win. Hopkins. John Hetheringion (SE) Steel edge (SU) Steel U-ch nnel

(TS) Tubular ste il 58 WOOD MAGAZINE FEBRUARY 1997 RIDING THE RAILS WITH TODAY'S RIP FENCES

MAXIMUM RIP CAPACITY (INCHES) MATERIALS PERFORMANCE AVAILABLE WITH (mCHES) (2) (3) 2" e" OTHER VERSIONS (1) & / / fm / * / & / 1 M /cb / > / / 1/ i 1 f / * Mifs / *

Similar to Biesemeyer Commercial model, but with AF, SL, 24 52 36 2 TS TS N N N u 260 less-beely components. Plenty stoul lor part-time E E E G E E G G XT woodworkers.

Vz A solid perlormer with a unique lence that changes CO. ME, B'/4 96 43 AE AE N N N SL u 360 Irom low to high in height, and slides lorward and or E G E G G E E G XT 3'h back.

AF, FS. Although lence glides along rails with ease, and LONGER RAILS 45 AE/SE AE Y N Y LF, SL, c 325 locks solidly, we tound installation and repeatability MADE TO ORDER 2'k G F F E E F F E SP to be a problem.

Nearly identical lo Blesemeyer home shop model 48 144 42 2V; TS TS N N E E E G E E F G N SL.XT c 330 except lor tape measure that includes a metric scale.

Nearly identical lo Biesemeyer home shop model 24 52 36 2 TS TS N N NOT AVAILABLE FOR TESTING N SL.XT c 295 except lor tape measure that includes a metric scale.

Extremely accurate fence for small-scale work, but OTHER VERSIONS 36 2'h TS AE N Y Y u 360 not rugged or versatile enough lor everyday use In NOT AVAILABLE F G E G E E F I a typical shop. Modeled alter the Biesemeyer Commecial, but it AF, LF, 122 TS TS N N u 330 has thinner- gauge components and lence sides 48 42 2'h N G E E G E E F F SL.XT lhal wear more quickly.

AF.SL, Similar lo Jel Xacla Commercial, but down-sized 12 52 36 2 TS TS N N N u 260 G E E G E E F G XT lor the part-time woodworker.

A long lence that slides forward and back, along 420/ lor 60 2V» TS TS/AE Y N G E E G G G G* G Y c 315- with rear- lock mechanism, make II ideal use wilh sheet goods.

LONGER RAILS 350/ Similar to SSF- 100 above, but has an average- 41 2>h TS AE Y N Y c - MADE TO ORDER G E E G G G G* E 240 length fence that does not slide lorward and back.

300/ - SF - 100. 41 2 TS AE Y N G E E G G G G* E Y c 205' Less beely version ol the

Our lavorile fenco because it never went more than 16 78 36V* 3'h. SA AE Y N G E E G G E E E N u 350 00V oul ol parallel al any position. Cable system wasni problematic during installation or operation.

Identical lo Ihe Blesemeyer Commercial model but 48 122 42 2'h TS TS N N G E E G E E G G N SL.XT u 340 has easily replaceable fence sides and three- posllion Iront lock.

12 28 36V; 2 TS TS N N NOT AVAILABLE FOR TESTING N SL.XT u 300 Down-sized version olAccu-Fence Commercial.

Extruded aluminum components are light in OTHER VERSIONS 36V* Y Y c 270 weight, but stoul, making this a good choice lor NOT AVAILABLE 3 AE AE Y G F F E E E G E Sears conlractor-slyle saws.

Vega's original lence is still one ol Ihe easiest to LG, SF, 10 50 42V, 2'h RS AE N Y G E F G E E G G Y SUSP u 320 Install. Us performance was about middle-of- Ihe-pack

LG, SF, A smaller version ol the Vega Pro intended lor Ihe 8 50 36'/! 2'h RS AE N Y Y u 220 G E F G E E G G SUSP occasional woodworker.

A new. all-steel model lor heavy-duty use. Like 12 50 41 2'h TS TS N Y G E E G E E G G N LG.SL u 295 other Vega models it has a micro-adiustmenl feature. A much-improved version ol previous models, N u 299 Easy lo install. Has micro-ad ustment mechanism 60 42 2V> SU TS N Y F E G G G E F G AK. CO. Iront-lock handle. LF. OF, and three-position ng SL, TS, XT version ol Ihe above model, 10 50 38 2 SU TS N Y F E G G G G F G N u 259 Down-sized

Has locking mechanism similar to Paralok s. and £•' 275 roller system similar to Excalibur's, but rails 8Vi 50 40 3V; SA AE Y y G G E F G G E Y SL AK.TJ T were loo rough for top performance.

WHERE TO CALL FOR MORE INFORMATION:

Blesemeyer Jel Powermatlc Vega 4. See article lexl lor more explanation. 6. (C ) Canada 800/782-1831 800/274-6842 800/248-0144 217/963-2232 Taiwan (') Modulus fences tested on Blesemeyer commercial rails. (1 ) 602/835-9300 206/351-6000 615/473-5551 (L ) United States Sears Craftsman Voss Technologies 5. (AF) Auxiliary (ence (OF) Oltset lence Delta Modulus visit 719/635-2557 (AK) Anti-kickback device (SFJ Stock-leed system ) Modulus prices 800/438-2486 800/633-8587 Call or your (CO) Cut-oil lence (SL) Extension table support legs given with/without 41 2/963-2400 802/865-0569 (US only) local store (FS) Flip-up work slops (SP) Stock pusher Blesemeyer- General Paralok Excaliburby Woodstock International (LC) Laminate culling guide (TJ) Tenoning jig lype rails. 819/472-1161 800/423-9611 Sommerville Oesign 360/734-3482 (LF) Longer lence (TS) T-slols 503/281-6096 800/357-4118 (ME) Mlter-gauge extension (XT) Extension table Incra 905/831 -4755 972/ 43-7 I43 COUNTRY BUFFET

match our popular Tocountry-style kitchen table at far left, we designed diis handsome buf- fet and accompanying cup- board. Here we'll show you how to build the buffet. In the next issue, we'll present the matching cupboard.

Featured in the August 1996 issue of Keep in mind that these are WOOD® magazine, our country-style terrific-looking stand-alone table features a rock-solid top, turned (or equally mail-order available) legs, and a terrific pieces that work well paint job for a fine dining experience. as a matching set. Continued

"ST I'M. 60 WOOD MAGAZINE FEBRUARY 1997 & CUPBOARD-Partl

V2" round-over bit

7 /m" pilot hole V2" deep 1 [tr

3/8"

1/2" partial round-over

V2" partial round-overs along the front and ends Sand a slight chamfer on face frame members where bead is applied.

' 1/4" bead (two Va" round-overs) 5/32" hole, countersunk on bottom side

BUFFET TOP DETAIL (SIDE VIEW)

35V4"

EXPLODED VIEW

See pages 92 and 93 for Parts Views of buffet

WOOD MAGAZINE FEBRUARY 1997 61 COUNTRY BUFFET & CUPBOARD

Build a carcase to form thickness of your plywood. Shim dado blade as used in Step 2. the basic substructure the blades if necessary. Then, cut Now, lower it W and cut the 1 Cut the carcase sides (A) and '/2"-deep dadoes and rabbets in the dadoes in the panels and shelf. bottom banding strips (B) to the side panels (A) where dimen- 5 Cut a W rabbet V>" deep along sizes listed in the Bill of Materials. sioned on the Carcase drawing. the back inside edge of the side Glue and clamp the maple bottom 3 Cut the top and bottom panels panels (A) and upper and lower banding to the bottom edge of (C), drawer shelf (D), center panels (C) where shown on the each plywood side panel where panel (E), and kickers (F) to sizes. Carcase drawing. shown on the Carcase drawing. 4 Mark the dado locations on the 6 For adding the solid maple top Later, sand the banding flush. upper and lower panels (C) and (S) to the carcase later, mark the (Since the bottom dado is so close drawer shelf (D). Note that the centerpoint and slot locations on to the bottom edge of each side upper panel (C) and shelf (D) the bottom side of the upper panel, we found it helpful to add have four dadoes where located panel (C) where shown on the the bottom banding now, before on the Parts View drawing of the pattern insert. Drill the holes and cutting the bottom dado.) buffet on pages 92 and 93, while form the slots. 2 Install a dado head in your table- the lower panel (C) has just one 7 Glue and clamp the bottom saw. Test-cut scrap stock to verify dado where dimensioned on the panel (C) and drawer shelf (D) that the width of cut is the exact Carcase drawing. Use the same into their respective dadoes in the

62 WOOD MAGAZINE FEBRUARY 1997 —

CUTTING DIAGRAM

Bill o M aterials

Finished Size Finished Size 'Plane or resaw to Part Part 75 thickness listed in T w L * T W L £ ® <8> the Bill of Materials. CARCASE DOORS % x 48 x 48 Birch plywood A sides H" 15%" 34%" BP 2 T stiles %" 3" 25%" M ;

B bottom U upper banding %• *»" 15%" M %' 3" 19%" 2 rails M 2 © ® V lower C panels %" 15%" 47%" BP 2 — rails %" 4Vfe" 19%" M 2 D drawer ® © (F) % 15%" 471/2" shell BP 1 W panels W" 14V4" 18%" BP 2

E center %" 18%" 26%" X vert, slops 14" M 4 /aN rr^ panel W teW BP 1 ^£> (£; V F drawer Y horz. stops %• 13%" M 4 W 3 96" kickers % 15%" 6%" BP 4 /4 x 48 x Birch p ywood DRAWERS G back w 47%" 33%" BP 1 '•: Z fronts 5V.:" 19%" M 2 H shelves w 14%" 22%" BP 2 AA sides %" 5% 15%" M 4

1 shelf %" %" banding 22%" M 2 %" -0\ BB backs 4%" 18%" M 2 © © FACE FRAME AND TOP CC bottoms %" 13%" 18%" BP 2

J side stiles % 2y," 35'/." M 2 DDguides ¥b' w 14%" M 4 © ® ® K center 'A x 48 x 96" Birch plywood %" ' stile 2W 35%" M 1 'Initially cut parts marked with an oversized. Trim finished size according to the instructions. L upper to rails Vf W 20" M 4 Materials Key: BP-birch plywood, M-maple, ; V,,"' U -V M bottom -J

R catch blocks yt 1%" 3" M 4 %" S' top 17%" 50" EM 1 3/4 x 5'/2 x 48" Maple ~ sides (A). Take diagonal measure- h x 5V2 x 72" Maple ments to check for square, and make sure the front edges are flush. Slide the center panel (E) in V2 x 5'/2 x 60" Maple place. Drill countersunk holes, and screw the panel in place. 8 Glue and screw the upper panel Vi" plywood. Set it aside for now, (C) to the top of the assembly you'll screw it in place later. with the drawer kickers (F) in 1 Cut a pair of shelves (H) to place. Drill mounting holes size, and add the banding (J). through the upper panel and through the drawer shelf (D) to The face frame comes next secure the mating pieces where 1 Cut the side stiles (J) and center shown on the Carcase drawing on stile (K) to the sizes listed in the the opposite page and the Front Bill of Materials. Sand a chamfer Section View on page 93. on the mating edges of the sides Glue and clamp the stiles to the carcase and side stiles where 9 Measure the rabbeted opening, first. Then, measure the distance (A) O) and cut the back (G) to size from between the stiles and add the rails. shown on the Carcase drawing. Continued

WOOD MAGAZINE FEBRUARY 1997 63 COUNTRY BUFFET & CUPBOARD

2 Dry-clamp (no glue) the side 3 Cut the upper rails (L) and the shown on the Exploded View stiles (J) and center stile (K) to the bottom rails (M) to size. Check drawing. The inside faces of the cabinet, keeping the outside their fit between the stiles, and upper vertical beading (O) should edges of the side stiles flush with then glue and clamp them to the be flush with the inside surfaces the outside surfaces of the sides carcase. The top edges of the bot- of the drawer kickers (F). (A). You'll notice a Vk" reveal tom rails should be flush with the 4 Cut the ball-catch blocks (R) to along the front edges of the draw- bottom panel (C). size, and glue them in place on er kickers (F). This will cover up 4 Cut the glue blocks (N), and the back side of the center stile when installing the 'A" decorative glue them in place. (K) and surface of (E) where beading. Trim the stiles if neces- shown on the Carcase drawing. sary. Now, as shown in the photo Add the decorative beading 5 Glue and clamp-up enough on the previous page, glue and 1 From the edge of ^"-thick stock to form an oversized blank clamp the stiles to the carcase. maple, rip '/i"-wide strips for the for the solid-maple top (S). Later, beading (O, P, Q) to size plus 2" trim the top to finished size, and LAP JOINT DETAIL in length. joint the front edge. 2 Install a !&" round-over bit into 6 Rout partial round-overs along 2Va"-wide lap joint W deep your table-mounted router, and the front and ends (not the back) position the router-table fence of the top (S), using the Buffet Va" rabbet V2" deep flush with the edge of the pilot Top detail for reference. bearing. Then, rout the front 7 Position the top (S) on the car- edges of each strip, using a case, centered side-to-side and feather board for safety and to with the back edges flush. Clamp

ensure consistent round-overs. it in place. Using the holes and 3 Sand a slight chamfer along slots in the upper panel (C) as the front edges of the face guides, mark the locations, and frame members that will drill pilot holes into the bottom

' Back side of door. receive the beading (O, P, Q). surface of the top. Secure the top Miter-cut the beading strips to to the carcase with flathead wood - V2" rabbet Va" deep length, and glue and clamp screws and flat washers. The slots them to the face frame where allow for wood expansion.

V2" dado 7/ga" pilot hole %" deep Va" deep 'AT groove Va" deep 'At" from bottom edge

25Va"

-dia. Shaker knob #8x1"F.H. W groove 'AT deep DOOR wood screw "At" from bottom edge

%a" hole, DRAWER 3"-wide lap joint countersunk W deep Dovetails are Va" half-blind, using a 14° dovetail router bit, groove '/»" 4"-wide lap joint W deep \ 1 and a standard routing jig. Va" deep stopped " from front of drawer sides

64 WOOD MAGAZINE FEBRUARY 1997 Machine a pair of See our dovetail jig article on page while you drill the holes and drive frame and panel doors 24 for more information on using the screws. Repeat for each draw- 1 Cut the door stiles (T), upper these handy jigs. er guide. rails (U), and lower rails (V) to 4 Cut the dadoes and grooves in size, and lay out the parts to form the drawer parts where dimen- Finishing and final assembly the two doors. sioned on the Drawer drawing. 1 Cut the Shelf-Hole Template 2 Mark the front face and inside Then, drill a mounting hole in shown on the WOOD PAT- edge of each stile and rail. Then, each drawer front for attaching TERNS® insert in the center of the cut Vi" rabbets W deep along the the Shaker knobs later. magazine. Drill the ,A" holes inside back edge of each piece. 5 Rout a ¥i" stopped groove in the where dimensioned. Then, use 3 Cut mating lap joints across the outside face of each drawer side the template to drill the shelf-pin ends of the stiles and rails to the for mating with the drawer guides holes in the carcase. sizes noted on the Door drawing (DD) later. 2 Remove the top, doors, hinges, and accompanying detail. 6 Glue and clamp each drawer and catches. If not already 4 Glue and clamp the stiles and together, measuring diagonally to removed, remove the panels from rails together for each door. check for square. Drill counter- die doors. Sand everything to 220- 5 Mark the knob-hole centerpoint sunk mounting holes through the grit. (We sanded the knobs by on each door. Measure the diame- drawer sides (AA) and into the chucking them into a drill press.) ter of the tenon on your Shaker ends of the back (BB) where 3 Apply a clear finish to the inside knob (they can vary in size), and shown on the Drawer drawing. of the carcase and face frame (just drill the mounting hole. Screw the back in place. Drill to the sanded chamfer at the joint 6 Measure the rabbeted opening, holes through the bottom (CC) between the stile and side panel). and cut the 'A" birch plywood and into the bottom edge of the Add finish to the top (both sur-

panels (W) to size minus 'A" in back (BB), and secure it in place. faces), the back, the door frames each direction. 7 Cut the drawer guides (DD) to and stops, the drawers, and all the 7 Cut the stops (X, Y) to size. Drill size, forming a W radius on the knobs. (We used Minwax Fast- pilot holes through the stops and front end of each. Mark the cen- Drying Gloss Polyurethane for the

temporarily install the stops and terpoints, and drill four counter- first coat, and sanded it with 220-

panels to check the fit. Remove sunk holes through each. grit sandpaper after it had dried. them; you'll finish the panels 8 To accurately locate the drawer Over this, we applied two coats of before nailing them in place. guides (DD), cut the two 2"-wide satin polyurethane.) Do not get 8 Install the doors using the no- spacers to the size shown on the the finish into the knob holes or mortise hinges. See the Exploded Drawer Guide Template drawing on the knob tenons. View drawing for hinge locations. on page 93- Now, using the photo 4 Mask off the face frame stiles, Install the catches. below for reference, use the spac- and prime the carcase sides and ers to hold the guides in place the door panels (we used Krylon Construct a pair of Sandable Primer, #1315 Primer drawers for handy storage White). Sand lightly with 320-grit 1 Cut the drawer fronts (Z) to sandpaper after the primer has size. Set aside a piece of stock the dried. Paint the primed areas (we same thickness and width as the used Rust-Oleum American drawer fronts to use when setting Accents Heritage Satin Finish Teal up the router dovetail jig later. 7929). Let the paint dry, and 2 Cut the drawer sides (AA), remove the masking. backs (BB), and bottoms (CC) to 5 Glue the knobs into the doors size. Set aside a piece of stock the and drawers. Screw the top and same thickness and width as the back in place. Install the panels in sides and front for cutting and the doors and fasten the stop in testing the dovetail joints. place with #17x1" wire brads. 3 Rout dovetails on the extra Mount the hinges on the doors pieces cut in the previous steps. and reinstall the doors in the car- Verify the dovetail jig settings, and case. Reinstall the catches. Wax Use a pair of spacers to accurately posi- rout dovetails on the mating ends tion the guides. Then, drill mating holes the drawer guides, and slide the of the fronts (Z) and sides (AA). in the kickers for attaching the guides. drawers in place.*

Written by Marten Kemmet Project Design: Jan Hale Svee lllusiralions: Kim Downing; I.orna Johnson Photographs: Bill Hopkins WOOD MAGAZINE FEBRUARY 199" 65 ^G

For a safe, smooth-running panel), you may want to add a mate amperage ratings for tools of home woodworking shop, subpanel to handle the load. For different horsepower.) Also, if this kind of job, you should seek two large tools normally run at start by providing a suitable an electrician's advice. the same time, such as a tablesaw electrical supply. and jointer, they shouldn't be on Whether your woodwork- How much electricity will it the same branch circuit. And, if ing shop is a corner of take to power your shop? one of your tools requires 220

the garage, the base- Although most portable power volts, it needs a separate circuit. ment, an old storage room, or a tools operate well with 15-amp separate building out baek, ade- circuits, you may want to build in Always put lighting quate and safe wiring is a neces- some overload insurance with 20- on a separate circuit sity. So if you are considering a amp circuits. The cost difference To avoid blackouts, don't com- new shop or reworking the old, is negligible, and the higher bine circuits that serve power here are some helpful guidelines. capacity lowers your chances of tools with those that provide elec- Note: Reference for this article popping a circuit breaker. Two tricity for lighting. One 15-amp was the current National such circuits (plus one for light- circuit probably will handle the Electrical Code. Before beginning ing) are adequate for most home entire lighting job. any job, consult local codes at shops, since all the tools won't be But just in case, here's how to your city building inspector's running at the same time. calculate your lighting needs. office. And unless you have luiring If you suspect you'll need more Each square foot of shop space experience, get the advice and ser- than that, read the owner's manu- should get three watts of light. So vices ofa qualified electrician. als that came with your tools, or if your shop measures 20x20', you check the tools' labels to see what have 400 square feet times three, Is your present electrical amperage they draw. You'll need or 1,200 watts. Divide 1,200 watts service adequate? this information, called load, to by 1 1 5 volts (actual performance) The electricity your local energy plan the size and number of cir- and you get 10.43 amps. company supplies is distributed cuits in your shop. For example, if If you feel that you need more throughout your residence from a one of your tools requires 20 light, add up all the wattages service panel located in your base- amps, a 15-amp circuit won't do. (bulbs and fluorescents) you need ment or other utility area. If you (The chart below lists approxi- or want. Then, divide that number live in a house 30 or more years by 115 volts to arrive at the num- old with the original wiring, you ber of amps drawn if all fixtures may have only a 60-amp service POWER TOOL AMPERAGE were on. Don't plan on exceeding panel. With such little capacity, 80 percent capacity of the cir- you probably won't be able to run HP VOLTS AMPS cuit's rating, though. That is, for a more wires to power your shop. 15-amp circuit you wouldn't want Newer homes—and electrically Vk 110 4.4-6.3 to exceed a 12-amp demand for updated remodeled ones — have your lighting. 110 5-7.2 100- or even 200-amp service. % With such large capacity service Use wire large enough Vz 110 7-9.8 panels, there may be unused cir- to do the job cuits available for your shop. Or, ¥4 110 11.5 Always use grounded wire, with if all circuits appear to be in use, one black insulated wire (the

1 110 it's often possible to split an exist- 13-15 "hot" wire), one white insulated ing circuit or two to satisfy mini- wire (the "neutral" wire), and a 1.5 110 16-19 mum requirements. bare wire (the "ground"). For dry Depending on your needs (the 2 110 19-23 areas, run type NM wire. In damp number of large stationary power locations, use type NMC. For 220-volt motors, figure half the tools in your shop and the shop's The wire gauge (diameter the 110-volt amperage rating.) — distance from the main service smaller the number, the larger the

^1 ''{ill (CG&c 66 WOOD MAGAZINE FEBRUARY 1997 — See Talking Back, August 1997, page 10 for updated wiling diagram. Click here to view Q) What you need to know to power up properly

wire) you use will be determined reached, or could come in contact cal leakage in the ground circuit. by the distance from the service with moisture. If there's a leak, GFCIs shut off panel to the outlet as well as the The conduit itself must be voltage instantly. They prevent circuit amperage. For example, a grounded. Metal outlet boxes and electrocutions that happen when 15-amp circuit utilizing 14-gauge connectors make the grounding a person working with a portable wire can safely reach 30 feet. By simpler. Don't use plastic boxes power tool becomes the electrici- using 12- gauge wire, you could because they don't conduct elec- ty's path to the ground. GFCIs go to an outlet 47 feet away from tricity. Also, you'll need to reeval- also protect electrical motors the panel. uate wire size with conduit, since from power surges. In many cities, all wiring must be it reduces amperage capacity as Numerous building code sec- enclosed in metal, thin-wall con- much as 20 percent. tions specify the use of GFCIs duit. Check what your local build- those pertaining to bathrooms, ing code requires. Usually, Grounded outlets protect basements, kitchens, outdoor out- though, the rule of thumb is if you and your tools lets, and more. Basically, if your your wiring isn't enclosed in a A GFCI, short for Ground Fault shop is in a garage or unfinished pro- wall, it must run in conduit. Circuit Interrupter, is a device basement, you must use GFCI Generally, you should install con- installed either as a breaker in the tection. If you're not sure you duit anywhere wiring can be seen, service panel or as a receptacle in should, use a GFCI anyway. It felt, touched, inadvertently the outlet box that senses electri- only costs a few dollars extra.*

(iilillaiul, PI:, Illustration: Kim Downing Written by Peter J. Stephsmo with Mike GSP

67 WOOD MAGAZINE FEBRUARY 1997 Laminate the blanks tions on the foot peg blank as 1 Cut two -%x2'^x73" ash strips shown opposite page top. Repeat and one piece of mahogany for the other foot peg. V4y2.V1y.iy. These three strips 6 Set your tablesaw's rip fence 1" will be laminated into the blank from the blade. Rip two legs from for the two stilt legs (A). the blank, sawing so that an edge 2 Glue the strips together for with countersunk holes rides the lamination, sandwiching the against the fence each time. mahogany between the two ash 7 Set up your table-mounted layers. Clamp, using plywood router with a W round-over bit, strips to spread the pressure and and position the table fence flush protect the ash faces, as shown with the bit's pilot bearing. Clamp below right. Place waxed paper a stopblock to the fence, then between the bottom plywood and rout a 2!/2"-long round-over along the lamination to prevent sticking. each corner on the lower end of 3 Construct another blank for the each leg. foot pegs (B). For this one, lami- nate a Vtx4xl4" piece of The footsteps follow mahogany between two %x4xl4" 1 Determine the hole size pieces of ash. Glue and clamp as required for the Vi" threaded you did the leg blank. inserts you're using. (Ours called for %" holes.) Chuck a bit of the You need legs to stand on proper size in your drill press, and 1 After the glue dries, unclamp drill the holes in each foot peg the two blanks. Joint one edge of blank where marked. Drill the each lamination. holes 16" deep to keep the foot 2 Rip the leg blank (the long one) peg screws from bottoming in the to the maximum possible width, holes before they're tight. and trim the ends to 72". Rip the 2 Stick the two blanks together foot peg blank to $Vi" wide, and with double-faced tape, aligning cut two 6" lengths from it. the edges and ensuring that both 3 On one edge of the leg blank, tops point the same way. Lay out lay out the foot peg holes where the foot peg profile on the top shown on the Leg drawing in the piece, referring to the Foot Peg WOOD PATTERNS® insert. Center drawing. Bandsaw the curve the holes on the edge, which slightly outside the line, then sand places them in the middle of the down to it with a drum sander. mahogany strip. Draw another Separate the parts. line across the edge 1" above the center of the uppermost hole. 4 Chuck a lA" drill bit in your drill press, and center the bit on the edge of the blank. Drill the five holes through the blank where marked. Countersink the holes on both edges for 'A" flathead machine screws. 5 Place the edge of a foot peg blank against the marked edge of the leg blank. Align the top end of the foot peg blank with the line Strips of plywood help spread clamp pressure along the lamination and pro- on the leg blank above the holes. tect the surface from clamp marks. Put place, Clamp it in and mark the on crosswise clamps (the orange ones) top. Then using a hand drill with a first to keep the edges of the lamination Yi" bit, mark the hole loca- aligned while tightening the clamps.

Print this article WOOD MAGAZINE FEBRUARY I'W Va". chamfers Walking tall made easy

3 Open your compass to a 2" radius, and draw two 4"-diameter circles on W ash for the footsteps (C). Draw a line across the center 1 /8" chamfers of each circle perpendicular to all edges the grain direction. Cut out the 3/s" ash footsteps, and sand. LEG 4 Using one of the footsteps as a 'A" mahogany pattern, draw two circles on W Mark the hole locations on the foot peg mahogany. From these, bandsaw blanks by drilling through the holes in arcs for four l'/2"-wide the disc the leg blank. segments (D) at the leg tops. To lay out the segments' straight foot peg. Fasten the footstep to EXPLODED VIEW sides, draw a line across the cen- the foot peg with #8x1 Vi' fiathead Vb" chamfers ter of the circle, then draw paral- wood screws and glue. Plug the all edges lel lines '/i" on each side of it. counterbores, and sand flush. 5 Fit your table-mounted router 3 Glue the disc segments (D) flush 45° chamfer bit, and adjust with tops where shown. with a the leg 33A° diameter it to cut a W chamfer. Chamfer They glue to the solid ash faces, nonskid tape disc the legs, foot pegs, footsteps, and not the laminated edges. disc segments where indicated on 4 Finish-sand all parts with sand- the Exploded View and Parts paper from 100- to 220-grit. Apply 3 View drawings. Stop the chamfers two coats of satin exterior /b" plug 'At" long 2" above the uppermost hole on polyurethane, sanding with fine the inside face of each leg. When abrasive between coats. J 1 routing die small parts, push them 5 Install a " rubber tip on the bot- #8x1'/2"F.H.

: wood screw over the bit with a foam-faced tom of each leg. Cut two yA" cir- Stop chamfers on jointer pushblock. cles from 4"-wide 3M nonskid inside face. 6 Sand a flat W deep (the depth tape, and apply one to each foot- 3/s" hole V4" deep of the chamfer) on the inside edge step. (We bought the tips and with a 5/32" shank of each footstep (C), perpendicu- tape at a hardware store.) hole centered lar to the line. Drill counterbores 6 Fasten the steps to the legs with inside and screw holes where shown. 'A-20xlV2" fiathead brass machine 1/4-20 X Vk". J—L/ FOOTSTEP screws. Start at the lowest setting, F.H. brass Put the parts together then move the steps up as your machine 7 screw Insert /64" pilot hole 1 Install threaded inserts in the stilt-walker gains competence.^ 1 for a " deep foot pegs (B). Coat the holes with 1/4" bolt Project Design: J;m Hale Svcc five-minute epoxy before driving Photographs: King Au FOOT PEG in the inserts. To drive in an Illustrations: Roxannc LcMoine; Lorna Johnson insert, put two nuts on a '/(" bolt Bill of Materials about 2" long, then screw the Finished Size insert onto the bolt. Jam the first Part W chamfers nut against the insert and the W holes, -^ 72" countersunk other against the first nut. Then, A" legs LAM on outside 'At" mahogany screw in the insert, using a ratch- B'foot pegs ZW LAM face J. 3/s" ash et and socket. Hold the foot peg C footsteps 4" dia. in a vise to prevent splitting. Stop round-overs 114" 3%" 2 Assemble the stilt steps by D disc segments 2V2" from bottom. 3 to the /e" round- attaching the footsteps (C) "Make these parts oversized initially, then cut to overs foot pegs (B). To do so, place the finished size following the how-to instructions. 0" 1" rubber tip foot peg on your bench, back Materials Key. LAM-laminated ash and edge down. Center the footstep, mahogany; A-ash; M-mahogany flat side down, at the peg top. Supplies: 1/4-20x114" fiathead brass machine PATTERNS® Guiding through the holes in the SEE THE WOOD screws, 14-20 brass threaded inserts, #8x1 vi" flat- INSERT FOR PARTS VIEW pilot in 1" footstep, drill holes the head wood screws, %" wooden plugs, rubber

tips, 4"-wide nonskid tape, woodworker's glue, five-minute epoxy, satin polyurethane finish. WOOD MAGAZINE FEBRUARY 1997 69 Removing metal is a time-consuming aspect of wood salvage. Jon Hoffman displays a sampling of what he has found on and in old timbers. Inset. Remarkably, this horseshoe imbedded in a beam was bypassed in its original sawing 100 years ago.

Reclaiming lumber from the nastiest-looking old beams, reputation in the Midwest as a century-old buildings and but once you saw into them, it's source for old-growth longleaf the bottoms of waterways is 'WOW! Look at that wood!' That's (called "heart") pine, Douglas fir, backbreaking work. But it some satisfaction. And to think, and white pine, as well as hard- has its rewards in premium for years most of these great old woods such as white and red oak, longleaf pine, Douglas fir, timbers went into local landfills." walnut, and chestnut. white pine, and fine- With just three years' experience Jon reclaims these and other grained, old-growth hard- in the wood-reclamation business, species from 19th-century build- woods as well. Jon, 38, calls his Joliet, Illinois, ings slated for demolition: ware- company "the new kid on the houses, stores, factories, gra- Jon Hoffman gets easily excited block." Nevertheless, the J.M. naries, barns, and even water stor- when he talks about reclaimed Hoffman Lumber Company, age tanks. His secondary source is lumber. "That's the neat thing "Purveyors of Premium Reclaimed sunken wood—whole logs of yel- about this work. You can dig out Lumber," has earned a first-class low ("red") birch, hemlock,

WOOD MAGAZINE FEBRUARY 1997 " g, aCDteaooOsite The New Way to Old-Growth Timber

cypress, heart pine, and white pine — recovered from the bot- toms of lakes and inland water- ways that before the turn of the century were the principal "high- Flooring products made from reclaimed ways" for travel to the sawmills. you? "In this business, there isn't a timbers and beams of heart pine include, from left, rustic tongue-and- standard grading system," he says. that you can groove, select plainsawn, and select Wood "We basically offer three grades in quartersawn. hardly find anymore flooring: rustic, select plain-sawn, The hard, yet attractive boards and quarter-sawn, all sold by the vary. "I can't beat West Coast from the heartwood of longleaf square foot, surface measure. reclamation prices for Douglas fir pine that were used extensively They're appearance grades, and because there is lots of it out for floors, staircases, and millwork the boards are mostly A/A (1") there. On heart pine and white

in the most elegant Southern man- thickness. Heart pine, for pine, I can be more competitive," sions have long been history. The instance, our most popular wood, Jon notes. Southern pine you see today Jon's company, although it comes from second- and third- does sell boards—and dressed growth plantation trees that timbers for beams— primarily rarely grow to 18" diameter markets heart pine remilled before they're harvested. and profiled as tongue-and- The same is true for clear, groove flooring to high-end straight-grained white pine that commercial and residential came from big trees in the vast construction. Historic restora- stands that once covered the tions have their place, too. Upper Midwest. Now we make "Last summer, we supplied do with smaller, knottier stock. Douglas fir flooring for a And restricted logging in the restoration project in St. old-growth Douglas fir forests Louis," says Jon. "They speci- of the Pacific Northwest has fied that the new porch wood meant limited availability of this match the original, which was slow-grown wood that's as all clear, vertical-grain Douglas strong as it is goodlooking. fir. We ran that job and also These are the reasons Jon is in supplied them with antique the wood-reclamation business. white oak beams."

"What I sell costs more than the lumber normally available," Salvaging stock from says Jon. "First, there's time- the demolition forest consuming preparation work, Most of Jon's timber comes such as cleaning and metal from the demolition of build- detection. Then there's the ings throughout the Midwest. waste factor— at least 50 per- Before salvaged wood is sawn, workers must go For sunken river and lake logs, find cent in remilling salvaged over it thoroughly with a metal detector to he contracts with divers from nails, bolts, and other objects that would damage wood, with the cracks and Wisconsin and Michigan to an expensive blade during remilling. everything. So right there the Alabama and Mississippi. price of the raw material doubles. sells for $5.60 a square foot in ran- "At first, I geared up to do the I a front-end But there's nowhere else to buy it. dom widths of plain-sawn, the demolition. had flatbed trail- It's the only available stock of that middle grade. Quarter-sawn stock loader, a truck with a quality, and when it's gone, it's would be in the $7 range." er—the whole works," recalls Jon. gone." But depending on the wood "My first demo job was a 40-60' How much would Jon's stock, species—and where the building radius water tank on the ground made from salvaged timbers, cost was located —Jon's prices can in Bettendorf, Iowa. It was all Continued 71 WOOD MAGAZINE FEBRUARY 1997 SALVAGE clear-heart, vertical grain red- wood. I moved a lot of that stock

to sign makers. But I soon learned that I couldn't do it all. So now I buy from demolition people or subcontract the work." Jon's involvement with reclaim- ing wood normally begins with assessing a building to be razed. "I never buy a building sight unseen," he says. "I go to the job site and look it over. With a chain- saw, I'll cut out some wood from beams at different places— a ran- dom sampling. In barns, I look for signs of powder post beetles. In industrial buildings, it'll be water damage, or deep stains from chemicals or oil. Next, I check for tight-grained lumber, which indi- cates old-growth. Wood with wider growth rings is okay for resale as timbers, but not resaw- ing and milling." After he has given the building a Above. Not many years ago, beams such as this 10x15" of old-growth heart good onceover, can offer the Jon pine from a razed building were wasted owner or the demolition contrac- in local landfills. tor a "ball park" price for what Right. Jon mills heart pine and Douglas salvable wood might be in it. "But fir into heavy-duty, high-end flooring. only when the wood is on the ground can I give them a final barn made from walnut," says price because they lose a lot in Jon. "But back then they built the removal," he says. "Our peo- from what was on hand. That's ple have to come in and sort it, where you get buildings with wal- band it, stack it, and have it ready nut, chestnut, white pine, locust, to go on the truck. Demo contrac- and other unique hardwoods." tors won't assume that cost. Five At this writing, Jon was prepar- Want to shop salvage? or so years ago, they were paying ing a bid to salvage the now For a price list of salvaged wood to have this stuff hauled to the closed Joliet Army Ammunition and other products, write to landfill. Now, they think they're Depot. "The buildings I'm inter- J.M. Hoffman Lumber Company. sitting on gold." ested in are all Douglas fir," he 1919A Cherry Hill Rd., What type of wood does a typi- says. "And there are between Joliet, IL 60433. cal industrial building yield? 2,000 and 3,000 white cedar tele- 708/799-8877 "Around here, first would be heart phone poles. Boat builders would Written by Peter Stephana pine, J. then Douglas fir, although I be interested in that wood."* Photographs: John L. Schultz just bid on a big six-story struc- ture in Milwaukee that is all white pine. That's pretty unusual. And Editor's note: As landfill fees go up and environmental awareness the wood in industrial buildings is increases, wood salvage and reclamation businesses are springing good sized: 8x10", 8x12", 9x13", up around the nation, offering unique and usually hard-to-find old- 10x12", 10xl5",15x20"." growth wood species, sometimes "as is." For a business near you, Barns and other farm buildings check the Yellow Pages under "demolition contractors" or "sal- often hold surprises. "Recently, I vage." Your state's environmental quality agency or department of talked with a guy out in western natural resources also should be able to steer you to a source. Illinois who has a 100-year-old

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TEMPLATE, instructions * catalogue send $3.00 US (refundable) to: "Router Redi" 160 Main Street Box 92558, Brampton, Ontario, Canada L6W4R1. "WOODWORKING SOUTHWEST STYLE!" Professional designs having the and machines. include 36 plans for mailbox, wine rack, birdhouse, tables, doors Sometimes, and more. Detailed book, $15.95 to: A-Pro Design Studio, right tool gives you a leg up That makes John PO Box 20578-W, Sedona, AZ 86341. http://www.epciiet.com/apro on a particular job. But with suspect that the craftsmen's TIRED OF HAPPY LITTLE SNOWMEN? Unique Scrollsaw designs based on original artwork. All skill levels. Send $1.00 for calipers like the ones shown motives may have been information: Drew Phillips. PO Box 4384, Carson, CA 90749. above, craftsmen of years gone by slightly raffish, that the calipers FURNITURE PLANS. Easy to follow. Easy to make. Computer Generated. Catalog $3.00: Lake Superior Design. Box 751, could have a leg up on every job. were an early-days equivalent of Grand Marais.MN 55604-0751. Dancing-master calipers, as they later pin-up posters and calendars. TOYS OF WOOD, Full-size Plans/Patterns cars, trucks, trains. Free were called, originally appeared in You probably won't find any two info. Tarjany Designs, Box 8846 Dept. W, Calabasas, CA 91302.

PANEL SAW FOR PENNIES. Make straight precision cuts for the late 1700s. Who first made the calipers alike; they were all hand- less than $25. Plans $9.95: ACME Enterprises, PO Box 767485, legs of a caliper anatomically cor- made. "Some are masterpieces of Roswell. GA 30076. rect (or nearly so, isn't technical FREE SCROLL SAW CATALOG. Describes over 70 patterns anyhow) workmanship, with covering Holidays, Sports, Music, Farm, Careers, Outdoors. Call known. But, doing so certainly elaborate hinges," John says, 1-800/233-3231 today. It's FREEI gave new meaning to the act of "while others are masterpieces of UNIQUE KILN PUN. For less than $500 you can build a 1 ,000 to 4,000 board feet kiln. Tested for 7 years. For complete plan and how stepping off a measurement. art, with lovely forms." The best to instructions. Send S29.95: Henagar Cabinet, 102 Gilbert Road, Henagar, AL 35978. 1-205/657-6250. We may never know why of the calipers combine technical SHOWS/SPECIAL EVENTS machinists began making these and artistic merit. "They are as 13th Annual Canadian Workshop Show Feb 28, & March 1-2, unique calipers either, but tool varied as the machinists who 1997 Toronto. Ontario. North America's Premier Workshop & Do-lt-Yourself Event. Three exciting days of seminars and collector John Gillis of Yucaipa, made them," John says. live demonstrations. Shop the latest in tools and take advantage of California, has some ideas. "Maybe Nobody knows how many danc- the Canadian dollar! For further information call 905/837-5095. Exhibitors Welcome. machinists were just trying to ing-master calipers machinists TOOLS/EQUIPMENT express their artistic side," he sug- turned out before the practice DRY YOUR OWN LUMBER. Ebac's user friendly dry kilns 200BF- gests. "During the Victorian peri- died in the 1940s. Flea mar- 40.000BF. Mix species in same load. Great 3-year warranty. Over out 6000 systems worldwide. Call Today. 1 -800/433-901 1 od [1837-1901], many wood- kets and tool auctions are the best ATTENTION working machines and tools were places to find them today. You'll CLASSIFIED ADVERTISERS elaborate in design—almost works run across many selling for Now you can reach over 1,100,000 responsive of art. The [dancing-master] $30-$50. But, the price can soar woodworkers and do-it-yourselfers in the calipers of that period tend to be for a great pair of legs.* WOOD® Classified Mart section. voluptuous," he says. The next closing date is February 7, 1997 for Tools from the collection ofJohn Gillis. the May/June 1997 issue. Yet many of these calipers pre- Yucaipa, California For rates and information date the Victorian era and its call: Photograph: John Hethcrington 1-800/424-3090 • Fax: 312/464-0512 emphasis on the beauty of tools Written by Larry Johnston or write WOOD® Classified Mart 500 North Michigan Avenue • Suite 2010 Chicago, IL 60611. 74 *—>> asGQOsste WOOD MAGAZINE FEBRUARY 1997 !

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22-675K nailer 419 Kit «'d 1 HP, 650 CFM L 5" SN325. 6D-12D 15" $159 Dustless Rando "-2" SFN-1Plus 1 linish nlr 349 $199 Dust Collector "nfr 97310 laminate trimmer kit 189 Orbital Sander Planer SN60 New lull hd slick nlr 449 3/8 4ampleyiessdrll74 511 lock Installation kit 159 DW106 $214* yj;!/ 5/8"-1-5/B"brnllkit $99 SLP-20 279 0-4000 drywall drivr 89 $1149* 9345 6" Saw Boss kit 134 DW250 DC-1200 2hp1200clm cllectr429" SLS20 New linish stplr w/cs 249 voll drill 0-2500 deck scrwdrivr 89 37-190 6" jointer w/stand 499 9314 4-1/2" trim saw kit 169 361 0K 14.4 w/2 batt 194 0W254 DC-1900 3hp1900 dm clleclr 619 SKS 1/4" crown finish stplr 279 3107OVSK 5" rdmsndr kit 119 DW280Kall purp scrwdrvr kit 119 36-850 1 phase stock feeder 499 7539 JSG-66" bell/12" disc sander 599 3310K 12vThndlw/2bat174 OW421K 32-325 13 spind boring mach 999 After Mail-In Rebate 3-1/4 HP •Price 1276DVS 4x24 vs bell sndr 219 5" Hook & Loop Duslless 31-280 5 Speed ThnkLtn. 3270DVS 3x21vs sndr w/bag 164 Random Sanding Center Plunge Router 1615EVS 3-1/4HP pi router 269 powERMancmr LS1011 Sander w/Case With Stand $274 11224VSR 7/8" Bulldog hmr 224 10" Compound $74 $799 1660760 7116 24" Omni jlg&video 309 1613EVS Miter Saw 10" 1149 DW423K5"vs rndrn sander w/cs94 36-755 cabinet saw 66 Saw 3 HP 1-1/2 hp handle router 164 2 HP, VS, 691 D 10" $429 DW443 6" RA H&L rdm sndr 144 36-751 cab w/30" unil 1299 Accu-Feifce_ 698 router-shaper table 144 Microline w/50" 36-752 10" w/50" unil 1399 6095DWE 9.6v vsr dr w/2 bat 124 DW411 1/4 sheet sndr w/bag 59 cab 697 router table w/router 234 Plunge $1999 7-1/4" saw w/cs 119 DW431 3"x21"vs bolt sander 189 50-901 7403 paint remover 179 5007NBK Router 1270100 «7shpr3hp1ph2099 2708W 8-1/4" Ibl saw w/br 309 DW995K 3 HP, 230V 9737PK 1610050 8"|ntr1.5hp1ph 1699 12" planer 499 $209 2012 portable 18 Volt 1/2" '«C» Cyclone 2 Stage Quick Change 1 791 21 64 Artisan w/Accu 749 , 3612C New 3hp pi router 269 B4050 In-line jigsaw 119 VSR Drill Kit Dust Collector 179121164 Artisanw/50"Accu 849 Tiger Saw KiK^U miter sw 779 3-1/4" planer kit 179 LS121112"cmpnd 3296K 1791208 osc. spndle sndr 299 12vhicap kl 2bt 179 $229 $1849 center detail 6311DWHE I sander 74 $164 (S^OC* B7000 1791209 New 15" planer 1329 sharpener 214 DW991K-22 14,4v3/8"dV/dr k219 50-902 5hp3ph cycln collects 949 corner detail sndr 94 9820-2 blade 7499 rYewcuFoultool 69 B7001 vs 1791051 6"jointer w/sland 549 3-1/4" drill/saw kt 349 50-903 5hp230v cycln colclr2249 sander 144 N1900B planer w/cs 134 0W991KS-214.4V 97549 top handle vs jigsaw 144 3725DVS 5"vs H&L 1791070 1-1/2 hp dust col 399 3901 New plate joiner 199 DW972K-2 12v3/8vsr dr, 2 bl 184 •Price After Mail-In Rebate 693 1-1/2 hp plunge router 184 3727DVS 6"vs H&L sander 149 |" MOST PORTABLE TOOLS SHIPPED FED-EX Order or lor Technical Support Call TOLL-FREE r€0 To S500MORE -**> FAX US YOUR ORDER! 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Ryobi shrinks biscuit joiner to focus on detail work Biscuit joinery used to be reserved fit loosely. Surprisingly, though, for large scale projects, but that's joint alignment and strength no longer the case. With Ryobi's didn't appear to be compromised. new DBJ 50 Detail Biscuit Joiner, Ryobi made the DBJ 50's see- you can use biscuits on projects through fence both simple to use such as face frames, picture and accurate. Built from high- frames, small boxes, and mold- impact, tinted plastic, the 90° ings. You also can edge-join edge of the fence has a printed pieces as thin as 'A" and as narrow biscuit scale extending from both as %" with the DBJ 50 and Ryobi's sides of the centerline. This makes own miniature biscuits. aligning the joiner on your work- Ryobi offers its "Accu-Biscuits," piece a snap. 7 in three sizes— Rl ( /d2X%"), R2 A rib on the fence fits into a zero on the scale, the DBJ 50 will (%2X%"), and R3 C'/Sxl"). These series of parallel grooves on the cut a perfectly sized hinge mortise compare with the three standard- stationary base frame. Because of in the edge of the stock. sized biscuits—#0 (yir.xl%"), #10 this, the fence adjusts in Vie" incre- The DBJ 50 comes with a conve- n Q/4X2W), and #20 P$46X2% >. ments, and it stays aligned perfect- nient, lO'-long cord and carries a Power comes from a 35-amp, ly parallel to the blade throughout two-year warranty. Priced at $69, direct-drive, 10,000 rpm motor the adjustment range. it's a handy tool that will find a mounted vertically over die blade. Height-adjustment scales printed place in many workshops. —Tested by McFarlin Ryobi uses this same basic design on both sides of the frame help Bob in its popular JM80K standard- you quickly reset the fence for dif- sized biscuit joiner. ferent material thicknesses. To PRODUCT SCORECARD The DBJ 50 comes with a IW- make 45° cuts, you remove the Ryobi DBJ SO Detail Biscuit Joiner diameter, high-speed steel blade two knurled hold-down knobs, Performance * • • * & that cuts slots easily in both hard- rotate the fence 180°, and then Price About S89 and softwoods. I found the length reinstall the knobs. Value • • * • * and depth of the slots was fine, an added feature, Ryobi offers As Ryobi America Corp., 5201 Pearman but because of the aggressive set biscuit-shaped hinges chrome or — Dairy Road, Suite 1, Anderson, SC in the blade's teeth, which left a brass in R3 size —for use on small 29625-8950. Call 800/525-2579. .120" kerf, the .100"-thick biscuits boxes. By setting the fence to

ScrollSander ends tedious hand sanding

Hand sanding intricate scrollsawn Vi" strips were too wide to fit the For beginners who leave a lot of projects requires more patience throat opening on my Excaliber saw marks, the ScrollSander takes than many woodworkers possess. saw, but the lA" version worked the tedium out of sanding. More However, a new product called fine. The manufacturer, advanced scrollsawyers may also the ScrollSander turns scroll- Crawford-Adams Enterprises, find it to your handy— have on hand. saw into a power sander. plans to introduce another model Tested by Dave Henderson The ScrollSander consists of a that uses .055"-diameter abrasive strip of cloth-backed abrasive cord. The cord should accommo- with polycarbonate plastic tips date saws with narrow throat molded onto each end. The plas- openings and permit sanding in tic ends come in versions for any direction. most pin-type and pinless blade Each package contains one each holders, except those on RBI and of 120-, 180-, 220-, and 320-grit Reliant scrollsaws. strips and they did an excellent ScrollSander strips currently job, even on brittle material and come in 'A" and W widths. The fine edges. With light pressure, they maintained a square edge PRODUCT SCORECARD and didn't break until I intention- ScrollSander ally overloaded one. When one half became worn after roughly Performance * • • • # 30 minutes of continuous use, I Price $6.95 (package of 4) flipped the strip end-for-end and Value *•••£• used the other half. Crawford-Adams Enterprises, P.O. Continued on page SO Box 1086, Verdi, NV 89439. Call 702/345-1660. Mil, 78 x-Ti [ yODO© £CQ0eO© WOOD MAGAZINE 1UURUARY 1997 '

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Continuedfrom page 78 Create moldings with these profile bits Most homecenters carry just a few sizes and profiles of molding. These cost a lot, and rarely do the stores stock anything other than pine or oak. But with Eagle America's carbide-tipped Large Crown Molding Bits, you can rout your own molding from any wood you choose. about 10,000-12,000 rpm. For wood in your projects at a reason- The cutting lengths of these bits additional safety, I ripped my able cost. And you won't be measure 2\A", except for the cove workpieces W wider than the forced to use moldings carried at molding bit, which measures 2W. height of the cutter. This left a retail outlets. All come with W shanks. I found small strip at the top and bottom —Tested by Dave Henderson the bits well-balanced and proper- of the workpiece to follow the ly sharpened—important consid- fence on the exit side of the PRODUCT SCORECARD erations you're spinning router table. when Large Crown Molding Bits this much steel in a router. Even with these precautions, Performance * • • • # To use these bits, you need a you still need to remove wood in Price $65.95 each ppd. router table, a fence tall enough small increments, taking four to Value to support the workpiece, and a six passes to complete the cut. • • • • a Eagle America, 510 Center St., P.O. featherboard. And you should But if you're willing to take your Box 1099, Chardon, OH 44024. Call bits will help chuck them into nothing less time, these you 800/872-2511. than a 2^-hp router running at make moldings to match the

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587F Ventu Park Ril. - Dept. 801 uummmm • mm am? Thousand Oaks, CA 91320 Circle No. A3 Water- based wood filler low on fumes, high on convenience

To meet stricter air quality stan- you avoid depressions caused dards, manufacturers have when the filler dries and shrinks worked hard to develop solvent- below the wood's surface. free finishing products. The FI:X worked well, even on verti- Darworth Company not only cal surfaces, adhering tightly to developed a water-based wood the edges of holes without sag-

filler, but also came up with ging. It is odorless and dries slight- I did achieve better results if I

unique and handy packaging. ly slower than most solvent-based applied stain immediately after I

FI:X Wood Patch comes in a tillers, but I found I still needed to sanded it. wide-mouthed tube that allows work fairly quickly. FI:X's ease of application, odor- you to easily squeeze out just the Sanding was a snap. It easily free formula, and handy packag- right amount of filler where you sanded flush and smooth without ing make it well worth trying.

need it. The large, screw-on cap scratches and didn't load up the —Tested by Dave Henderson seals tightly and serves as a base sandpaper, traits not found in to stand the tube upright for stor- some fillers. I drilled clean pilot PRODUCT SCORECARD FI:X Wood Patch age — both features which help holes in it and found it held screw extend the filler's shelf life. threads well. It cleans up with Performance * • • * # The rounded shape of the tube's water, but you need to catch it Price $3.49 other end works great for shaping before it dries. Value • • * * * and smoothing the filler. Unlike a lone I found The drawback was Darworth Company, 7405 putty knife, the pliable plastic in staining. Like most fillers, it Production Dr., Mentor, OH 44060. allowed me to easily overfill the failed to accept stain as readily as Call 800/624-7767. holes in the wood. By overfilling, the surrounding wood. However, Continued on page 82

R Econ-Abrasives Look Familiar ? WE MAKEABRASIVE BELTSANYSIZE, ANYGRIT! Standard Abrasive Sheets ABRASIVE BELTS CABINET PAPER Belts are resin bond cloth with a bi-directional splice, specify grits. 50/pk 100/pk 1X30 $ .81 ea 3X24 $ .93 ea 60D $16.70 $30.00C 1X42 .81 ea 3X27 .96 ea 80D 15.60 27.80C 1X44 .81 ea 4X21 3/4 1.06 ea 100thru150C 14.50 25.60C 2 1/2X16 .85 ea 4X24 1.10 ea FINISHING PAPER 3X18 .86 ea 4X36 1.35 ea .90 6X48 3.50 80A $11.15 $18.90C 3X21 ea ea 3/4 .93 6x89 6.24 100 thru 280A 10.00 16.70C 3X23 ea ea OTHER SIZES ON REQUEST NO LOAD PAPER(white) HEAVY DUTY SPRING CLAMPS 1 00 th ru 400A $ 1 2.25 $21 .25C Clamps*Mip ROUTER PAD(24' x 36') Scroll Sam 5" 60 $ .48ea JUMBO Original manufacturer 5' [.'''.' It will not allow small blocks of wood 30" Illustrated 80 ,46 slip out under router or sanding 5" 100 thru 320 .45 ''VV to w, fci i iTJjtUfj^^Z^ applications. ROUTER PAD Available in 5 hole pattern SOW1MERVILL * * ONLY$8.95ea. DESIGN •Wide Belts*Rolls*Flap Wheels STICK Discs JUMBO BELT CLEANING j fl Years of quality, dependability an d service •Pump Sleeves*PSA •Router & Wood Bits*Wood Glue ONLY $8.80 300 Peart Street, Buffalo, New York, 14202 •MasterCard, VISA, C.O.D. or Check 940 Brock Road., Pickering, Ontario, LiW 2A1 Econ-Abrasives •SATISFACTION GUARANTEED!!! P. O. Box W865021 dealer •CALL FOR FREE CATALOG For your nearest factory authorized Piano, TX 75086 - TX & NV add appropriate sales tax JJJH (214)377-9779 - Continental U. S. shipping add $5.50 -Call 1-800-357-4118. ^TOLL-FREE ORDERING LINE (800)367-4101

Circle No. 1229 ' STEVE WALL LUMBER CO. LOG RUN PRODT THAT PERFORM Quality Hardwoods and Woodworking machinery For The Craftsman SPECIALS and Educational Institutions Continuedfrom pti^e 81 'S 1 1 100 bd. ft. Bundle 4/4 Cherry $120 Ash 4/4 Select 2.15 S 71 .00 Save money on broken Basswood 4/4 Select 1.80 line S61.00 4/4 Walnut $140 Bitch 4/4 Select 2425 UPS S 73.00 $6300 Butternut 4/4 1C 2.00 ..„-. ,....„ Add $20 for S2S bandsaw blades Cherry 4/4 Select 3.40 •Specials;:::!^ Hickory - Pecan 4/4 Select 1.85 Motor Freight Only 90.00 Mahogany (Genuine) .. 4/4 Select 3.40 $ FOB Mayodan It's a fact of shop life — bandsaw Maple Hard) 4/4 Select 2.40 „ _ $ 75.00 Maple (Soft) 4/4 Select 1.80 $ 63.00 blades often break before they Poplar 4/4 Select 1.55 _.._ _... $ 58.00 Red Oak 4/4 Select 2.35 $ 74.00 STEVE H. WALL dull. Rather than throw away a Walnut „ 4/4 Select 3.25 _ $89.00 LUMBER CO. blade, you to try While Oak 4/4 Select 2.30 $ 73.00 good may want 60.00 Cedar (Aromatic Red) . 4/4 ICtBlr. 1.55 ...„ $ 287 BOX . repairing it at home with the Cypress 4/4 Select 2.15 _ $ 68.00 MAYODAN, N.C. 27027 While Pine 4/4 F.G. 1.10 $49.00 Deluxe Blade Bnt7.er. This kit Yellow Pine 4/4 Clear 1 .60 $ 69.00 910-427-0637 jig, flux, Above prices are lor 1 00' quantities of kilndned Above prices are 20 bd. ft.bundles ot 1-800-633-4062 includes a blade-holding 3"- 0" • 3'-7' rough lumber sold by the Bd. Ft. clear ktlndried lumber 1 wide 910-427-7588 FOB Mayodan, NC long (Random widths & lengths) Sur- FAX flux brush, and silver solder. Call (or quantity discounts. Other sizes and faced 2 sides or rough. Delivered UPS Send S1.00 For Lumber Catalog grades available. prepaid in the Continental U.S. To begin repairs, you place the Circle No 592 broken blade ends under a flat bar on the jig. Tighten the two thumb screws to secure the blade ends. Then, bevel-grind the broken QUALITY THAT RUNS blade ends to approximately 45°. Next, butt the blade ends tightly IN THE FAMILY together on top of the jig and spread flux around the joint. Heat Notliing beats an original CMT for a quick, flawless performance. the blade with a propane torch, as Whether it's our #1 rated router bit* or our award-winning dado blade**, shown below, and apply the silver if it's made in Italy, it's a CMT original. cools, The one that's prized for its durability and precision. Valued by serious woodworkers the world over. solder. After the weld clean And only available through the manufacturer and selected, authorizedjjgajgjj^^^ it up on the grinder.

#1 rated quality... bit or blade, it's a CMT family I found it easy to make strong welded joints with the Blade Brazer. The kit's instructions were clear and helpful. According to the manufacturer, the flux and silver solder should last for 80 welds on 14" blades. So, this jig will pay for itself after just a few repairs. —Tested by Dave Henderson PRODUCT SCORECARD Deluxe Blade Brazer Performance • * * * # Price $41.95 ppd. Value • * • • * Wood Systems, Inc., P.O. Box 510744, New Berlin, WI 53151- 0744. Call 800/321-0834.

82 WOOD MAGAZINE FEBRUARY 1997 {Woodworker's Marketplace

I Tins section features advertisers offering products by mail. Additional information can be found the Circle No. } in the Woodworker's Resource section. Please contact the advertiser directly or use to the right of each ad to request information through the Woodworker's Resource envelope.

Put some Uncommon tools wood to work for you and achieve Uncommon results! TOY, Our tools are uncommon, and unmatched, in quality. Supplies for woodworkers and * Patterns antique restorers! variety and value. Over 60 pages of woodworking * Parts the largest selection of router • Ising glass tools provide you with * Wheels • Curved & bubble glass tables and accessories available in the U.S., as well * Many New • Roll lop accessories Patterns In as, other unique and useful tools. More than a • Hoosler accessories many Choose from.

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PARTS VIEW COUNTRY DRAWER GUIDE 5/32" shank holes, Round forward end of 1 "/16" 1 Centered countersunk — BUFFET L/„L drawer guide to match See article on page 60 slot in drawer. " ' I

7 4V4" 4 'A" 4W

\ . V** rabbet 1W-R^ 14W 1V16" V2" deep

%2" holes, 22V4" • countersunk 3ft" © UPPER PANEL IVa"

^- 3 4%° 153/4" — A" dadoes Vs" deep -13"- Lower panel ©has only one dado where shown on 1. 3/16" slots the Carcase drawing. V2" long

47Va"

22'A" •

233/s" -23/4"

. %2" holes, DRAWER SHELF countersunk 15V2" ©

- 3/4" dadoes Vs" deep -=; W dado Ve" deep 5/32° holes, countersunk -— on bottom face of shelf on bottom side

92 WOOD MAGAZINE FEBRUARY 1997 6

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WOOD MOISTURE METER—Avoid moisture defects Featuring Henry Taylor. Sorby, Richard Rattan and Dale SCREW-ON CARBIDE TIPPED ROUTER BITS— such as cracking, warping, splitting, delamination. The pin- Nish workshops. Catalog price refunded with order. Reverse Helix design for clean cutting. Wide variety of type moisture meter "Mini-Ligno" can read surface or core CRAFT SUPPLIES USA. $2.00. Circle No. 830. sizes—H" lo 1Si" ±.015. NEW Replaceable Carbide Tip moisture in any thickness ol lumber, Irom veneer through GRIZZLY IMPORTS, INC.—Celebrate 1996 with our Router Bils, available from :4" to 1 \'f ±.015, eliminates the heavy timbers. A Hat surface is not necessarily required, need for sharpening; maintain the exact size, each insen 1 78-page full-color catalog packed with an incredible — thus the Mini works on rough sawn lumber and curved or selection of quality machines, loots, and accessories has four cutting edgesl Dependable quality tooling. at round pieces. 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WOOD MAGAZINE FEBRUARY IW 96 SCROLLSAW SAFET" One Stop Wood Shop

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Boulter Plywood Corp. 24-WD Broadway. Somerville, MA 02145 Where the finest cabinetmakers select & blend domestic & exotic hardwood In plywood, veneer & lumber.

Circle No. 512

Keep scrollsawing an accident- free woodworking experience by following these helpful tips: •Know your owner's manual and follow it to set up, adjust, and maintain your saw. •Plug the tool into a properly grounded outlet, and make sure any extension cord you use is in safe condition. •Protect yourself against saw- dust. Arrange the sawdust-blower tube to direct the airflow away from you, off to the side, or better yet, toward the back of the saw. Wear a dust mask. •Wear eye protection. Goggles keep sawdust out of your eyes, as well as other flying debris that might come from the tool or the wood you're sawing. •Dress for success. Avoid loose clothing and dangling jewelry. Tie back long hair or wear a cap. •Keep your workplace tidy. Don't let sawdust and cut-off pieces pile up in front of the saw. Provide plenty of task lighting. Special magnifyer lights work best of all. •Hold the stock down firmly with your fingertips when cut- ting for maximum control. Keep Keith Hone, a Utah 11a the work flat on the saw table. land in hand. Using the new ultra high speed engraving techno!! beat Don't try to saw unsupported developed by the Paragraphias Corporation, Keith can engrave designs on virtually any surface. The demand for this type of work is tremend stock. If the work catches on he blade and starts flapping up and Ifs fast . . . and easier than you might think! down, stop the saw. With an easy-to-use stencil system, you can transfer any design, artwork, or logo to •Before you start the saw, any hard surface. By simply tracing lines using the Paragrave handpiece spinning carvings mk\ ensure that the blade is prop- at speeds of over 300,000 rpm, you can create beautiful erly tensioned, that the blade engravings and the system does the work for you. It's that simple! teeth point down, and that the Cull 1-800-624-7415 and hold-down and table-tilt knobs are t^\ 8e* you i' demonstration adjusted and tightened.* video today to learn *COK1'pKATIO\' I about how yon fi$f>> more money and ||^ / can make 1-800-624-7415 have fun too! 1455 W. Center Orem, Ut 84057 WOOD MAGAZINE FEBRUARY 1997 97 V-"^•^ Circle No. 2160 ! 1

1996 i QuautyPerformance...widerangeof SUBSCRIBERS: M AG AZ I N E 1' desmbii features. ..atarir price, PLEASE N0TE1 Better and Gardens* WOOD* Homes Many of our customers arc mail-order buyers. October, 1996 These consumers are interested in receiving offers for other products and services from our The RBI Hawk Ultra company (Meredith Corporation) and for prod- ucts and services offered by other reputable 220 Scroll Saw companies. • Ultra-Smooth Cuts In order to promote our other products, we • Clamps Quick Release Blade retain your name and address in a prospective • Visual Blade Tension System customer file. We also provide that name and address to other reputable companies who • Excellent Cutting Control offer products we consider to be of value • Stack Cut up to 2-H" and interest to our customers. • Control Variable Speed However, we also respect the rights of those • and Torque customers who prefer not to receive additional DC Power . mail-order offers. • Large Table Design • Heavy-Duty Steel Legs Should you prefer to have your name restrict- ed, please fill out the coupon (below), clip it

• i' out, and mail it to the address shown. Please be sure to indicate whether you wish to restrict all offers or just those from other companies. V -11

I will accept offers from Meredith Corporation only.

O 1 prefer not to receive any offers.

Include a current magazine address label with

Visit the RBI Home page at this coupon, and mail your request to: http://www.rt3iwoodlools.com rtjindustries, inc. Magazine Customer Service America's Woodworking Machinery Manufacturer P.O. Box 10263 Des Moines, IA 50336-0263 • Box 369 HarrlsonviUe, MO 64701 I 1801 Vine Street PO

The World's Most you were stranded on an island... Versatile Dovetail Jig, Period. What is the one machine you*

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• 38" Rip Capacity Saw

• 10" Table Saw

• 50" Cross Cut The Leigh D4 Dovetail Jig and your router will cut half- blind and through dovetails with Infinite adjustment of • Mortiser pin and tail spacing! And all with a beautiful hand-cut

look. Creativity has never been easier. Also cut sliding,

simple obtuse, acute, compound, and angled dovetails. • 20 seconds to change functions ^^P And our optional Fl Finger Joint Template gives you nine different sizes of box joint from %? to V. • 12" Jointer/Planer • Three 3HP German Motors Call For Your Free 32-Page Catalog Now! • Cast Iron Tables • 3 HP Reversible Shaper 1-800-663-8932 Don't get left stranded in the sand.^M (800) 234- 1 976 today,

for your FREE L-AGUMA TOOLS Today Joining Tradition with video. demonstration • Laguna Beach 9265 2265 Laguna Canyon Road CA Utgti IndustilB ltd., P0 Boi 357, Port Cuqultlam, BC Canada V3C 4K6 800-234-1976 • FAX 714-497-1346 [email protected] Tel. 604 464-2700 Fax 604 464-7404

Circle No. 615 EARN $$$ as a Home Inspector!

ROOFING

Home Inspectors Are in Demand!

Turn your interest in home construction into a lucrative career! Whether you want to start your own business or PLUMBINGS earn some extra money on the side, you could be in demand as a PIPE SYSTEMS Home Inspector. Every day, approximately 10,000 existing houses are bought and sold, many with the help of a qualified Home Inspector. Consumers, banks, and mortgage companies often hire Home Inspectors to check for hidden diagrams. And with DIAL-A-QUESTION®, our toll-free 24-hour hotline, problems in order to protect their investments. And at an average of $100.00 to qualified instructors will give you answers to your study questions. Plus,

S300.00 per job, Home Inspectors earn good money for their work! your training is accredited by the Accrediting Commission of the Distance Education and Training Council—listed by the U.S. Department of Get Complete Home Inspection Knowledge! Education as a nationally recognized accrediting agency of all distance- You don't need any previous experience—ICS teaches you all the education schools. fundamentals! With the ICS Home Inspector Program you'll learn how to check Start Now! the complete home site, spot hidden defects in structural supports, inspect the interior walls, floors, ceilings, heating systems, and more. You'll learn inspection Get free information on the Home Inspector Program or one of the procedures for insulation and air quality, plus how to do pollutant inspections other great ICS programs. Check the ONE box on the coupon that and energy audits. You'll become familiar with VA inspection forms, ADA corresponds to the program and SEND FOR FREE FACTS TODAY! inspection checklists, and code compliance—all the skills you need to take advantage of home inspection opportunities. Convenient, At-Home Training SCHOOL OF PROPERTY MANAGEMENT Learn at home in your spare time—ICS sends Dept. A80S27S, 925 Oak Street, Scranton, PA 18515 lessons, supplements and equipment directly to your door! Study as fast or as slow as you want— A C/O • Send me tree facts about how 1 can train for an exciting new career. you set your own schedule. You can earn your Choose any ONE of the programs below, fill in your name and address, and mail

Career Diploma in as little as nine months, or take it to ICS. 1 understand 1 am under no obligation, and no salesman will visit me. up to two years to complete your training. The Inspector D25 Gun Repair 70 Small Business Management ; D15 Home lessons are clear and illustrated with easy-to-read 79 Electronics Technician 43 PC Fundamentals* i D 04 Automotive Mechanics 87 TV/VCR Repair 33 Motorcycle Repair 27 PC Repair j Electrician 60 Business Management 44 At Cert. Test Prep." i Q06 High School 14 Air Conditioning S Refrigeration (ASB Degree Program) 07 Mechanical Engineering Technology D 55 Diesel Mechanics 89 Small Engine Repair I D62 upon is missing, or (AST Degree Program) 22 WilrJIKe/Forestry Conservation Computer Programming r\ call toll QuickBASIC ice, free: Civil Engineering Technology 31 Professional Locksmithing 01 j D63 PC Specialist 37 Visual Basic i (AST Degree Program) 38 1-800-595-5505 36 Visual C++ PLEASE PRINT "For personal enrichment 2398 Name Age ill M> "ip t Wt't'k-

htti>.,7www.ics!earncorii Address -Apt. = _

City/State _ -Zip . 7 Phone ( 20-lvlXN!'"UTETIMEPIECE A quick, easy turned watch

Busy schedule? Here's help in the point up to the blank to draw the circle accurately keeping it—an attractive and on center. pocket watch that shows the 5 Using the pencil mark as time at a glance. Even better, a guideline, turn a \W- you'll spend only a few min- diameter recess W deep utes turning it. with a flat bottom to hold onto the the clock insert. To begin, threads, then Project Prep come straight into the face of screw the post Stock the blank with the parting tool, just for the watch %"-thick domestic or exotic hard- inside the pencil line. Cut in about chain into the hole. Press the clock wood, large enough to yield a deep. Shut off the lathe, and insert into the case recess. round blank about 3" in diameter. W Turning tools check the diameter of the circle. If 4 Drill out the post's eye hole to Vie" (or other small size) gouge it's \W, finish cutting straight in to %-(". Support the post with scrap- Vfe" gouge a depth of A",] and clean out the wood, and drill the hole with a W roundnose scraper recess with a small gouge. Check drill press, as shown beloiv. Snap Va" parting tool the fit of the clock insert in the the chain hook into the hole.* Lathe equipment recess. 3" faceplate 6 Turn the edge and front profile, following one of the Full-Sized Turn the front first Section Views or your own design. 1 Trace around your 3"-diameter Sand the front and apply a finish, metal faceplate onto one side of a then part off the turning.

1 "-thick piece of scrapwood. Glue a piece of W'-thick stock for the A jam chuck completes it watch body to the other side of 1 Hold the blank with a jam chuck this wasteblock. (The side glued to while turning the back of the case. 1%"- the wasteblock will be the back of To make the chuck, form a Support the post with scrapwood while the watch body.) diameter tenon on the wasteblock. you drill it to accept the chain hook. 2 Bandsaw the lamination around The recess in the turning must fit the faceplate outline. Drill pilot snugly over this tenon to complete Buying Guide holes in the wasteblock, and screw the turning, so test the fit frequent- Clock insert, watch chain.

it to your metal faceplate. ly as you turn it. Quartz insert, Roman or Arabic 3 Mount the faceplate on the lathe. 2 Turn the back of the watchcase to numerals (specify choice), and With the lathe running at about one of the profiles shown. Or, cre- watch chain with post and belt 1,500 rpm, turn the blank to 2W ate your own design. Sand and fin- clip, 15" long overall, item PW-KIT diameter and flatten its face. The Vz" ish, then remove the completed $23.95 ppd. in U.S. Schlabaugh gouge works fine for this. case from the jam chuck. and Sons Woodworking, 720 14th 4 With the lathe still running, 3 Drill a Via" hole Me" deep cen- St., Kalona, IA 52247, or call mark a W-diameter circle on the tered on the top edge of the case. 800/346-9663 to order. face of the blank. To do this, lay a In the bottom of the hole, drill a Photographs; King Au; John Hetlurington pencil on the toolrest, then bring %\" hole yir." deep. Dab epoxy glue Illustrations: Roxannc LcMoinc

5/64" -1%" hole W' deep hole hole 'A" deep 3/ie" hole T-rt 5/i6" deep Vie" deep FULL-SIZED (7 SECTION w "el 3/ie" hole — VIEWS 5/m" hole Vi6" deep - 2W 5/i6" deep

100 ^5«JGfltiGiJBi WOOD MAGAZINE FEBRUARY 1997 . !

"Out Ahead of 14" BAND SAW $265" the Pack..." — American Woodworker 10/96

WOOD Magazine, CREATIVE WOODWORKS, AMERICAN WOODWORKER, and thousands of Hegner owners agree that HEGNER saws offer many advantages over all other brands. Try one yourself and discover the benefits:

clean, accurate cuts with no sanding easy blade change smooth quiet operation

long blade life Safety-Stop upper arm » r " Space-saving design f Choice'* : 6 year warranty VV <^-

II" IEWY MY UllfMI 1996 $1,075" MAGAZINE

/j.aiil-J-Di^OiiO/ TOP TOOL, 'Ji'dat Units l--MO->j:i-//0-J

CP TOOIS, INC. 61 I DUGOAN AVC, Axujo CA 91701

Circle No. 15

STEEL BUILDINGS FREE INFORMATION

|

Call or write for your FREE 1997 Catalog 1*800.322.2226 (Please mention Ad 770) ADVANC6D MACHINERY P.O.Box 312 • New Castle, DE 19720 http://www.advmachinery.com

Perfect Back-Yard Shop Save on Select Sizes:

i Send FREE information on ^*3G° 30*40 I me Easy Financing Available 45x82*50x120 Hegner Scroll Saws Build-lt-Yourself Name

Address Ask about out factor/ speciak and saw even motel til. City . State. .Zip.

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Circle No. 2030 Circle No. 3 ,

ORDER 1-800-328-0457 MAILORDER HOURS M-F 7:00-5:30 C.S.T. SAT 8:00-1:00 DEWALT TOOLS AIRY AIR NAILERS DELTA TOOLS WAP VACUUMS Model Description - List Sale Model Description*.——-List Sale .———List Sale Model Description ...... List Sale Modal Description — ,— Brad Nailer 3/8"-1 9/16* -....160 96 Jigsaw Kil 300 164 0241SK 769 10 oaHon turbo vacuum...... 845 465 DW321K NEW 31-280 Sanding Center w/sland... 1250 766RDF 0250SK Brad Nailer 3/4*-2* 296 164 lurbo vacuum DW364 7-l/4*Circ.Saww/brake....294 158 31*695 6" Belt/9* Disc Sander ~ 441 349 766RDF-D"Orywaller" 10 gat 0626SK l/4*CrownStnpler3/8'-l*..l94 104 DW610 1-1/2 HP 2 handle Router .266 152 23*700 Wei/Dry Grinder 206 149 .. 915 549 0645 1/4* Crown Stapler 3/4" 1-9/16' 1/4 Palm Sander 88 58 23*710 New Sharpening Center 217 169 766RDF-DAS Above vac w' auto slan950 589 DW411 sheet „„ 310 175 4amp,0-2500ipm!18 68 23-6B0 6" Bench Grinder 1« HP 80 69 DWI00 3/B" Drill, Above Nailers come w/case, fasteners, DW682KBiscu.l Joiner wllh case 448 199 11-950 8" Drill Press 176 128 MAKITA TOOLS oil & wronches 2* DW705 1 Compound Milre Saw ..734 359 0565T Angle Fimsh Nailer 1'-2-1/2-3B6 205 31-460 4" Belt/Disc Sander 198 135 6172DWE 3/6" v/spd Drill Kit 2 balt222 109 3HPv/spdPlungeRouter.Sale 275 40-560 16' 2 speed Scroll Saw 230 165 5090DW 3-3/8" Saw Kit 9,6 volt 260 148 DW625 DW625 router comes wllh RECORD WOODWORKING VISES 40-540 NEW 16" var/spd Scroll Saw249 169 DA391D 3/8 angle Drill 9.6V- 166 109 Opening List Sale DW6966 fine depth adjuster and Model JowiWtdth 11-990 12' Bench OrHI Press ~.2S5 184 DA391DW 3/6" angle Drill Kil 9.6V... 341 179 53E to-1/2*\15" Quick release 248 I 1-090 32' Radial Bench Drill Press 405 305 8-plece template guide set 1 ML900 Incandescent Flashlight 9.6V. 37 718" Quick release Willi dog 218 52D 43*505 1/2" Bench Rouler/Shaper- 398 299 DW621 NEW2HPPIungeRouler..400 169 85 12" 369 DW675K 3-1/8* Planer wllh case 292 164 22-546 Bonch Top Planer Sale 6095DWE9 6 volt Drill Kit w/2 batt...Salo 125 52-1/2D 9*\13" Quick release with dog Sander 184 36-220 10" Compound Mitre Saw.... 294 199 6095DWLE2 5095DWE w/flashlight-Sale 135 DW431 3x21 v/spd Boll ....338 231 95 28*185 Bench Band Saw 213 168 DW421 5' Palm Ran. Orb Sander... 144 74 6095D 6095DW Drill only S cseSpeclal 65 37-070 6" v/spd Bench Joinler351 259 DW444 6* Ran Orb Sander... „ 268 139 PORTA NAILER NEW 632007-4 9.6 volt Battery 47 30 14-650 Hollow Chisel Mortiser ,.380 239 DW444w/hook Sloop pad. 266 139 401 Porta Nailer complole. .295 209 632002-4 7.2 volt Battery 39 28 DW443 501 Face Nailer complete . .295 209 33-990 10" Radial Arm Saw. 981 779 DW673KNEW Laminate Trimmer Kil 364 199 6201 OWHE 9.6V 3/8" Drill Kit w/2 ball351 159 33-055 8-1/4" Sawbuck comp w/legs846 665 DW635K 14.4V 5-3/8*Tnm Saw Kit 6211DWHE 12V 3/8" Drill Kit w/2 batt368 169 DAVID WHITE 36-905 30*Un!len»_ 346 245 with 2 batteries 444 237 6311DWHE 12V 1/2" Drill Kit w/2 balt399 205 LP6-20 Sighl Level package 20x..,329 215 36-906 50' Delta Unllence ..444 319 LP6-20XL LP6-20 w/9056 tripod & 7620 rod Arbor Saw Sale 1019 36-755 10'Tilllng NEW CORDLESS DRILLS DEWALT CORDLESS DRILLS 269 17-900 16-1/2" Floor Drill Press 490 399 DW952K 3/8' variable speed w/ two 9.6V XR WITH 2.0 AMP HIGH CAPACITY BATTERIE: LT8-300 Level Transit - 26>._... -739 489 37-190 6" Deluxe Jointer 603 489 batteries 284 139 3/8" Drill Kil 325 185 LT6-300P above Level with optical plum 1/4" 6213DWAE 12V 36-275 8- Builders Saw 358 268 DW962K-23'8* variable speed w/ two 9.6V XR _ 869 565 6233DWAE 14.4V 3/8" Drill Kil - 358 199 10" Mitre Saw.... 344 225 36-210 Compound batteries „,-.--.. 330 179 LT6-900 Level Transit - 20x _ 419 269

36-040 Compound Mit/e Saw 190 135 - B-1/4' SPECIALS DW972K-23/8* variable speed w/ Iwo 12V XH ALT6*900Auto Level Transit -l8x ....666 429 10" 217 165 SUPER CORDLESS 36-070 Mitre Saw— batteries 362 189 ALTP6-900 above Level with tnpod S rod 325 6073DW 7 2V cdls Drill Kil Variable speed 1 34-555 Sliding Table 487 12 volt flashlight 48 29,95 „„ 799 499 charger, case DW904 34-444 10" Contractors Table Saw.Sale 659 cMch. Complete with battery, & ALP6-I8HD above Level with tripod S rod Sale 99 DW9T2K-2 drill & DW$04 llasliHghl Sale 205 36-250 10* SKo Compound Saw.- 825 489 Super _ _ 599 395 Stapler Kit. Complete with 36-230 12" Compound Mitre Saw... 480 345 T220DW 9.6 voll LL100 Finish Line Laser level 199 135 DW991K*23/8"vanable speed w' Iwo 14.4V battery, charger. case Supor SbIo I Visible Beam Lasor....979 799 31-780 Oscillating Spindle Sander . 253 195 & ML200 NEW XR baltenes - 415 225 ML200I ML200 w/o detector i tod bracket 1/2- variable speed w/ one 1 4.4V 9900B 3'x21' Bell Sander w/bag. 347 179 DW994KQ 749 625 DELTA REBATES I 458 235 Sander wibag. 360 169 XR baneries Prices shown are before rebate I 9924DB 3'x24* Belt DW994KO-2 above drill w/2 boll ..Salo 259 RY0BI SPECIALS Rebates valid thru 3731/97. 4301 BV Orb. var. spd Jig Saw 3.5A 292 155 OW996K 1/2- v/spdw/ two 14.4 XR ball 245 RE600 3 HP Plunge Router -.500 228 S25.00 rebate JR3000V v/spd Recip Saw w/cose. 264 135 Above drill kits come w/ charger & steel BE321 3"x2l-v/spdBellSander..,310 139 46*700 12-WoodLalhe 575 465 9820*2 Blade Sharpener 433 215 easel BT3O00 10' Table Saw w/ stand 1125 529 S5O.0O rebate N1900B 3-1/4- Planer with case 263 129 NEW DW99 1 KS-2 DW991 K drill. DW935 trim saw, AP12 12" Bench Planer 884 389 28-275 14" Band Saw 3/4 HP Sate 635 1912B 4*3/8- Planer,,... 352 169 Dewalt 18 volt & case ...... Sale 349 OSS450 Oscillating Spindle Sander..340 159 28-280V14" Band Saw 1 HP motor .Sale 798 N9514B 4- Olsc Grinder 4.6 amp ... 118 65 HT20VSK NEW Mulli Tool 115 55 34*445 10" Table Saw w/30" lence Sale DA3000H3/8- Angle Drill 355 175 Cordless Drills CD125K l2Vcordie5s Drill w/2 ball 175 109 15" 8-1/4- HITACHI TOOLS 22*875 NEW DC380 Planer Sale 1176 270BW Table Saw 637 309 3/8" Drill Kil 275 159 C8F82 6-1/2'Skte Compound Saw1169 489 CTH1442K 14.4V 43*355 3/4" Shaper 1-1/2 HP Sato 799 6405 3/8" Drill Rev. 0-2100 rpm. 115 65 WDS1600 16*x32" Drum Sander, 980 569 C10FC 10* Mitre Saw - 533 199 S75.00 rebate 3/8* Drill Rev. O-I050 rpm. 188 98 69 6510LVR 10* DBJ50 NEWDelailBlscuilJoinler-114 6" C10FS Slide Compound Saw. 1627 739 37-154 Jointer DJ-15 Salo 1289 6013BR 1/2' Drill Rev. 6 amp,.,. 270 145 DW995K NRB3A Framing Nallor 2 - 3-1/2 Full Head 8401 4* < 24" Bell Sander w*ag468 219 Msxo6362 FEIN Tiiangio Sander v/spd . 199 _ 900 425 5007NBK7I/4" Circ Saw w/ case..,. 250 125 1/2" Drill Kit MSX625 FEIN Now Air Triangle Sander 195 NR83AA Framing Nailer 2 - 3-1/2 .... 922 439 MILWAUKEE TOOLS 5037NB NEW 7-1/4" Circular Saw.. 288 148 LPN672 PONY Air Palm Nailer w/glove 89 Brad Nallor l 2-1/2.749 325 Sawzall with 169 Sale 229 NT65A I6ga. RTM0I ROIOZIP Drywall cut out unit 68.95 6527 NEW case 343 LS1011 10* Slide Compound Saw. 995 429 Sawzall wAvired cord 339 185 NV45AB Coil Roofing Nailer 7/8 - 1-3/4 6528 above LS1211 12" Slide Cmpnd Saw..,., 1620 779 935 435 QUAL-CRAFT PRODUCTS 6537-2 6527 w/quicklok Wade change224 175 -376 199 3901 Rate Joiner Kit 79 0406*6 12VDritlw/kylscliuck82ba.t380 172 DW997K EC6B I HP Oil Compressor 540 279 2200 Pump Jock — 58 361 2C NEW 3 HP Plunge Router 492 259 Brace 30 20 3/8* magnum.. 236 132 EC6C 1 HP Oil-loss Compressor... 580 295 2201 Pump Jack 0224-1 Drill 4 5 amp LS1040 NEW 10* Cmpnd Miter Saw460 259 1/2" Drill/Hammer 1/4' Circular Sale 2203 Pump Jack guard rail holder ....31 21 0234*1 1/2' Drill 4.&A mag 0-850 rpm-255 129 C7SB 7 Saw 89 llashkghlSale 2204 Workbench S rail holder combo 53 39 0235-1 1/2" Drill w/koyless chuck .... 255 129 Drill Kit FDS10DVA 9.6V Dnll Kit w/ 99 SENCO AIR NAILERS 2500 Adjustable Roofing 8racket ...9.95 7.95 0244*1 1/2" DHIU.5A mag 0-600 rpm255 129 SFN1-. Finishing Nailer 1*- 2* W/CS448 345 Sale 249 Buy any 6 (can be assort.) deduct 10% 0222-1 3/8" Drill 3.5 amp 0-1000 rpm213 119 B1ESEMEYER FENCES SN325 Nailer 1-7/8* -3-1/4* 665 419 2601 Wall Jack 167 108 0228-1 3/8" Drill 3.5 amp 0-1 000 rpm207 118 8-50 50' Commet. Saw ... 443 325 SLP20 Pinner W/CS 5/8 -1-5/8* 422 275 Lots ot 4 deduct additional 10% 0375-1 3/8" dose quarter Drill 255 148 T-SOUARE52 52' Homoshop 360 269 SKS Staplor 5/8*- 1-1/2" 390 275 DW936K 0379-1 1/2" close quarter Drill 288 165 T-SQUARE 40 40"Homeshop 335 249 PORTER CABLE SN70 Framing -Clip Hd 2'-3-1/2* . 725 449 6546-1 cdls Scrwdvr 200 8 400 rpm 150 89 Saw Kit T-SQUARE 28 28' Homeshop- 325 239 9444 Now Profile Sander Kit 220 119 SN60 Framing -Full Hd2--3-1/2*.. 708 449 6547-1 6546-1 w/bits. 1/4" chuck Scs1 85 108 Ultimate Cutout tool -119 69 459 7499 194 SN65 15% more power than SN60709 Sale 249 5399 1/2" D-hdle Hammer Drill Kil 356 PONY CLAMP FIXTURES Lots 97499 7499 w/ case 8. bits, — , 150 89 SFN40 Finish Nailer 1-1/4 -2-1/2... 569 309 6507 Original SawZalt with case .. 278 149 Model Description List Sale ol12 690 1-1/2 HP Router 8 amp 278 142 309 159 5397-1 3.8" v/ spd Hammer Drill Kit 275 145 50 3/4- Black Pipe 15.45 8.10 92.50 90690 690 Router w/ steel case BOSTITCH AIR NAILERS ... 5371-1 1/2" v/spd Hammer Drill Kit 360 194 52 1/2- Black Pipe 12.6S 6.95 74.95 691 1-1/2 HP Routor D-handle .303 158 Stick Nailer Super Sale 339 Plunge Base338 184 3107-1 1/2" v/spd right anglo Drill Kit4i 1 234 N80S-1 693 I -1/2 HP Router N80C-1 Coil Nailer Salo 339 6931 Plunge Rouler Base 139 79 3300-1 1/2' v/spd right angle Drill... 378 199 BOSCH Nailer 3/4 - t-3/4845 369 1-1/2 HP Router/Shaper 418 235 5680 Router 2 HP w/ collets 367 165 RN45 Coil Root 695 Model Description List Sale Shaper Table 238 135 6142 4-l/2'GrlndBrw/cseSacc..224 125 N60FN-2K Finishing Nailer w/ case. 557 299 696 Heavy Duty 1587VS Top Handle "CLICJig Saw . 292 139 165 Brad TacKer 5/8* -l-3/8\.. 254 155 352VS 3»21v/sBeltSanderw/bag...321 6365 7-1/4- Circular Saw 13 amp. 229 125 BT35-2 149 1587VSC l587VSsawwllhcase....Salo 360 3"x24* Bell Sander w/bag -.397 214 6368 6365 w/lence, btde.S cse 259 142 BT35-2K BT35-2 w/ cse. oil, 8 brads279 165 1584VS Bwrol*CUC*Jig Saw 2S8 139 362 4*x24* Bell Sanderw/bag—412 224 6256 Top Handle Jig Saw 278 149 CWC100 i HP Pancake Compressor440 289 Bosch Melal Case for above Jig Saws ... 24 97751 1/2' v/spd Hammer Drill w/cse274 155 6490 10' Mitre Saw 496 265 MIIIFS Flooring Stapler 15 gauge 902 529 Bosch 30 Wade assortment lor Jig Saws 28.99 9125 NEW 3-1/4' Planer Kit w/ case250145 6491 6490 w/ carbide blade Sbag594 328 S32SX-1 Finish Stapler-l/2*- 1-3/8*245 155 DeWALT 1584VSor1587VS 9116 Porta Piano Kil 7 amp 400 229 oil 165 6494 10' Compound Mitre Saw.... 585 315 S32SX-1 K S32SX- 1 Willi case 8 . 269 High Pe-farman-B InduttiiaiToolt with steel case and 30 Bosch bladesSale 175 505 1/2 sheet Pad Sander —249 129 0431-1 12V Dlill w/2 batteries 441 239 handle Jig 4.8 3270OVS 3*<2I* v/spd Belt Sander. 301 165 97549 Top Saw amp w/ 6266-6 NEWTop Handle Jig Saw....315 165 SKIL TOOLS blades ...- 275 144 1276D 4"x24' Bell Sandor -.379 219 case & 6496 10" Slide Compound Saw.. 1050 569 77 7- 1/4" Worm Drive Saw SBle 144 330 Speed Block Sander 1/4 sheel120 65 1275DVS 3*x24* v/s Bell Sndr 379 219 Sale 139 77M NEW 77 Mag Worm Saw -. Salo 165 556 Biscuit lolner w/5556 fence . 1276DVS 4'x24' v/s Boll Sndr 408 219 FREUD CARBIDE TIPPED SAW BLADES 345 6" Saw Boss 9 amp ...... 207 114 1347AK .1-1/2' Grinder w/cs & ace... 172 105 345 comp. w/cse fi carb bide 237 138 5/8" Bare - Industrial Grade PANASONIC CORDLESS^ 9345 !194VSR!/2*v/spdHan-meiDDust Collection system — . 24.50 _ 438 249 5* Quiet Blade 10' 40 95 3725DVS Random Orbit Sander .256 149 Grip Rndm Orb Sander 133 72 F410 EY6101 EQKW Same as above but has two 332 Palm F010 Quiet Blade 10" 135 3727DVS 6* Random Otbit Sander. 266 154 333 above sander with dust bag -148 79 Ironman batteries...-. Solo 249 TK303 7-1/4" Finishing 38 B3915 10* Slide Compund Saw... 1050 589 334 333 Sander with PSA pad 148 79 EY3502EOKW NEW 4-3/8" 12V Melal TK906 10* Combo 53 B70Q0 Corner Detail Sander 126 68 550 Pocket Cutter with case 352 195 Cutting Saw Kit 500 289 Tiimmer 152 SD308 Dado - Carbide 230 119 B7001 B7000 w/ variable speed ..Sale 69.95 310 Production Lam. 270 7-1/4" with SD506 6" carbide w/case & shims 292 145 B4050 in Line Jig Saw 206 112 347K "Framers" Clro Saw PASLODE IMPULSE GUNS 250 129 SD508 6* carbide w/case S shims 344 168 11230EVSSDS*maxl*l/2*RlryHmr910 519 plastic case - IM250 Trlmpulse Finish Nallor Kit. 1130 548 7- 1/4" "Framers" Circ Saw with FB100 16 piece Forslner Bit Set 338 194 11231EVSSDSmax 1-3/4* Rolary Hammer 743K IM325 Impulse Framing Nailer Kit 1130 548 case - lell hand version 250 129 94-100 5 PC Router Bit Door System 320 169 1363 765 CT325SS Cdls Framing Nailer Kil .. 1 1 20 495 447 347 Saw with brake 259 139 BF3 NEW Router Table 495 289 11223EVS SDSmax 2* Rolary Hammer 7800 Drywall Sander 589 335 FJ85 NEW Top Handle Jig Saw 229 125 , -„ 1 595 915 SANDERS 9737 Tiger Reclpro Saw 307 165 CLAYTON OSCILLATING SPINDLE 7/8* 11224VSR SOS Rotary Dnll 404 229 -18 1*1 144 4-1/2' spindle 559 BN125 Brad Nailer glS/r* tools have a 530.00 rebate. 140 Porlable sndr w/ 625 The following BN200 Biad Nailer -IS ga.3/4*-2*-. 238 139 146 Porlable sander w/ 9- spindle ..685 609 Price shown Is before rebate. STABILA LEVELS FN200 FinlshNailer.16ga.3/8"-2". 270 165 100 Floor mount sndr 4-1/2' splndle785 709 FT2000E 3-1/4 HP variable speed Plunge 24740 24* Angle Seller Level ....Sale 14.95 FN250 Finish Nailer IS ga 1*-2-l/2"362 215 106 Floor mounl sander 9" spindle. 845 759 Router 410 205 24640 24* Level w/ hand holes.,, 62.20 43 DA250 AngleNailer lSga.1 l/4*-1-1/2* 219 JS102 Biscuit Jointer wilence & cs 355 179 24670 48* Level w/ hand holes -79.70 55 .„ 412 SIOUX TOOLS Framing Nailer clipped head 558 319 24680 72* Level w/ hand holes. 145.45 99 FC350 3/8* var/spd Drill 263 145 FR350 Framing Nailer round head -558 319 NEW Freud Carbide Dado Blades 8030 48" 71 49 27170 Level w/o hand holes Kit Drill 9830 NEW 9.6V Drill w/2 ball... 284 139 SD508 B" dial-a-widlh dado 389 199 8000 3/B' var/spd close qtr ...211 125 27000 78" Level w/o hand holes.... 146 105 1 1 Drill Kit w/ 2 bait .... 382 79 6" 369 189 690 5* Air Random Orbit Sandar228 132 9B62 NEW 2V SD606 dial-a-widln dado 80LMS Laser Level System... 532 365 NEW 9B72 NEW 1 4.-1V Drill Kit w/2 ball. 424 205 .in-ina a- economy dado 155 85 FREE FREIGHT TO THE CONTINENTAL STATES ON EVERY ITEM • GIFT CERTIFICATES NOW AVAILABLE

Circle No. 92 —

FINISHING TOUCHES

West Virginia showcases the handmade How about hand- Several states actively promote from a multi-level partnership of friendly hand tools? and market the work of their state agencies, industries, com- crafts people. Some even have munity leaders, business execu- retail outlets for their "Made in tives, artisans, and agricultural (state name)" products. producers, the center showcases No state, though, has gone the the work of 1,200 juried crafts length that West Virginia has with people of the state. In addition to the opening of its 59,000-square- the retail complex with its foot retail crafts and cultural cen- 10,000 handmade products, ter, called Tamarack. Resulting there's a theater, a restaurant, craft studios, sculpture herb Furnituremaker John Wesley Williams and designed and built the bird's-eye maple gardens, a gourmet food store, desk and chair to sell at Tamarack, The and a festival park. Tamarack will Included in Stanley's new line of Best of West Virginia. He is one of the also offer programs and appren- economically designed hand tools are 1,200 juried West Virginia crafts people a measuring tape, handsaw, utility knife, ticeships in the crafts. showing their work. and a hammer. Planned as a travel destination, Tamarack is adjacent to 1-77 in Ergonomics, the science of fitting Beckley, a day's drive from major the job task to the person doing East Coast cities. Call 1-88TAMA- the work instead of the other way RACK (304/256-6843 in West around, is a buzz word in industry Virginia) or Fax 304/256-6877. today. One possible reason: In U.S. of The architecture of West Virginia's 1994 the Bureau Labor Tamarack crafts center appears as Statistics tracked 332,100 cases impressive as the thousands of hand- associated with cumulative trau- made items for sale inside. ma disorders (CTDs), the injuries that can result from repetitive work tasks. The National Council on Compensation Insurance calcu- lates that the average claim for those injuries was $12,617. Stanley Tools jumped aboard the ergonomic bandwagon by intro- ducing a user-friendly Contractor Grade line of hand tools at the National Hardware Show in Loggers liked icy roads Chicago last August. They offer In the late 1800s when loggers were clearing northern Wisconsin's more comfortable grips, better pine forests, winter was the time of greatest activity. That's because control, and in the case of the sled loads of logs— as many as 20 tons at once handsaw, teeth that cut 50 per- could more easily be pulled by oxen or horse cent faster. You can identify the teams on the snowy logging roads. To new ergonomically designed tools make the going even faster, sleds by their yellow and gray colors with tanks of water made fre- and distinctive packaging, as quent trips up and down the shown above. roads spreading water so that In addition, Stanley has co-pub- ice would form. But on down- lished with the National Safety hill portions, a "road monkey" Council a 12-page booklet that or "hayman" had to toss straw explains common cumulative under logging sleds' runners trauma disorders and hand-tool to stem their speed. ergonomics. A copy of the publi- cation will cost you $1 (U.S.). Write to: Introductory Hand Tool Ergonomics, Heggen & Associates, Inc., P.O. Box 5025, Evanston, IL 60204-5025.*

Illustration: Jim Stevenson Photographs: J.W. Fnrrell; Stanley Tools

103 o» ;^^tffl&ati&b If youte in line to buy a new pickup, take a number

#1 in Available Payload #1 in Available Towing #\ in Available Power #1 in Available Torque #1 in Interior Room #\ in Total Quality Two Years in a Row

'94-'95 'We calculated resale using avg, trade-in values for full-size models vs. MSRPs, published in Jan. '95-Sepl. '96 N.A.D.A. Official Used Car Guide" monthly editions. Use of these values does not constitute NADA's endorsement. 'Won Strategic Vision's 1995 and 1996 Total Quality Award™ in its class. Based on Strategic Vision's 1995 and 1996 Vehicle Experience J Studies™ of 31,440 ('95) and 35,652 ('96) Oct.-Nov. new vehicle buyers of 170* ('95) and 200+ ('96) models after the first 90 days of ownership. J.D. Power and Associates 1995 & 1996 Automotive Eerformancc, Execution, and Layout Studies™, based on 27,859 ('95) and 25.492 ('96) consumer responses. Pickup buyers have to factor in all kinds of considerations. But ^ after you've done your Chevy or GMCJ That's not surprising, homework, you'll either. It's won the Total Quality discover tfiat one Award™ in its class from pickup meets all your Strategic Vision two years in a 2 requirements. Dodge Ram. row. And it's been ranked the

It can out-tow and out-haul "Most Appealing Full-Size any other pickup around. No Pickup," by J.D. Power and surprise there. Dodge offers Associates as well-for the 3 the single most powerful engine second straight year. on the market. With more And you thought buying a available torque, gas or diesel. It new pickup would require a lot appears you get more of every- of hard choices. thing in a Dodge Magnum® engine. Want to know more? Call

Plus it has a higher resale value than Ford, 1-800-4-A-DODGE. Or check our Web site at http://www.4adodge.com

America's Truck Stop mffl The New Dodge rebate a bright idea!

JWS-18H0 JPM-13 Shaper Planei Mokter

Buy these JET tools today and see woodworking

in a whole new light!

Offer effective Oct. 1, 1996 through Feb. 28, 1997.

EQUIPMENT & TOOLS Auburn, Washington

For the name of your local JET dealer, call 1-800-274-6842 or e-mail to [email protected] • http://www.jettools.com raBGB PATTERNS FEBRUARY 1997 ISSUE 95

Dear Reader, As a service to you, we've included full-sized patferns on this insert tor irregu- lar-shaped and intricate project parts. You can machine all other project parts using the Bill COCKATOO BANK of Materials and the drawings accompanying the project you're building. Full-sized patterns Page 44

Chubby Choo Choo Page 37

Stupendous Stilts Page 68 m CocJ

® Copyright Meiadith Corporation ,1996. All rights rasarvaJ. Printed in the U.S.A.

3Vi"-

I

Locate spacer block ©here on bottom side of chassis

CHASSIS (TOP VIEW) CAB SIDE (2 needed)

7" COWCATCHER 3W- (TOP VIEW) QVa"

9 /ie" hole, centered on joint line and drilled after cab Is assembled L V*' 2W 1/4" Locate cab floor (D) here on top side ot chassis. TRAIN Locate chassis (a) here .3Vs"- Full-sized patterns Ve"-"

-4- Page 37

4Vs" W Sand a crown on top surface. Locate spacer block(g)here.

7/32" holes V2"deep j ©

4"-

5 -9/i e% .2"- &he"- /e" ROOF 1_ (END VIEW)

- 3W- 7/64" pilot hole STILTS Part Views (Not shown full sized) Page 68 SHELF-HOLE TEMPLATE V'deep FOOT PEG (Not shown full sized) DISC SEGMENT

3/4" mahogany

Holes for

1 /4" holes spaced 2" apart Ve" chamfer

/$" chamfers on all edges<""

Stop chamfer 2" above the upper-most hole on the nside face of leg.

T 4"

Foot peg holes \ f 4" W holes, <. countersunkV on outside 4" face Tt

%" round-overs on all corners, stopped 2V2" from bottom

35/8"