the editor's ffi$"3ffi$ffi Better Homes and Gardenso

still"gfllng;#ronsJULY/AUGUST2000. Vol.17, l{0. 5 . lssueNo. 125 EditorLARRY CLAYIO]I ManagingEditor JIM HABB0LD AssistantManaging Editor/Features PETER J. STEPHAIIO ProjectsEditor BILL I(RIEB Y 'u" got to be honestwith you. When I was ProjectsEditor JAl{ HALE SVEC I ProductsEditor DAVE CAMPBEII Inamed Editor-In-Chiefof WOODomagazine in TechniquesEditor JIM POLLOCK SeniorDesign Editor JAMES R. D0Wlllilc the springof 1984,it becameclear to me in a hurry ProjectBuilder/Supervisor CHARTES L HEDtUl{D that to keep readerssubscribing to this publication SeniorAssociate ArtDirector PERRY A.McFARLII{ AssistantArtDirector CHERYT A.CIBULA over the long haul, the staff and I neededto keep Production/0fficeManager MARGARET CIOSI{EB the magazinefresh and exciting. And more than AdministrativeAssistant SHERYL MUllY0l{ ArtBusiness Office Secretary BABBARA HETPS once,I caughtmyself wondering,"Can we make Reader-ContactSpecialist BEl{ V0llRUDEll magazinesissue after issue that our readersjust ContributingEditors KIM DOWillNG, t0R1{A J0HNS01|, ROXANNELeMOII{E, CARSOI{ ODE, can't live without. Will we run out of greatideas after a few issues?" 8OBMcFAB[I1{, DAVE HENDERSOII Well, herewe areat issue#125 andgoing greatguns. ContributingCraftsman JIM HEAVEY And insteadof runningout of greatideas to sharewith you, PublisherMARK HAGEN AdvertisingDirector WILL MURPHY we havemore than ever.The only problemwe haveis get- AncillarySales and lntemet Manager MARLEN KEMMET ting them all in the magazine. AdvertisingOffice:333 N. Michigan Ave,, Suite 1500, Chicago,lL60601 Phone: 3128512890 FM: 31258O7906 You only needto take a look at this issueto seethat the AdvertisingManager JAMES N, FORD excitementcontinues. On page 44,you'll find a piece DirectResponse Adveilising CAROLYN DAKIS AccountExecutive YUWEI LEE titled, "The Adventurersof an Exotic-WoodBuyer." It AccountExecutive RON GOLMINAS chroniclesan excursionthat Keith Stephens,the owner MarketingManager GERALLIE LEGASPI SalesAssistant MARGARET TRAVIS of WoodworkersSource in Phoenix, Aizona, recently PublishingDirector WILLIAM R. REED took to Paraguay in searchof someof the world's most AdvertisingServices Manager PAT HENDERSHOTT beautiful hardwoods. ConsumerMarketing Director LIZ BREDESON you've AssociateConsumer Marketing Director KATHI PRIEN And if beenon the lookout for a nicely AssislantConsumer Marketing Manager DAVE HONOLD designedbutcher-block work centerfor the kitchen,you'll want to look at page BusinessManager CRAIG FEAR SeniorProduct Manager RICK GROW 50. This beautyis rock solid and ready for a lifetime of hard use. MEREIXIHPUBUSHING GROUP Speakingof beautiful projects,why not add to your summertimeenjoyment with PresidentCHRISTOPHER M.LITTLE our "Setteefor Two" on page 70.It took get VicePresident Publishing Director JERRY WARD a long time to CreativeServices ELLEN DELATHOUDER this designjust right, but after considerabletweaking, we think Manufac'turingBRUCE HESION we have ConsumerMarketing KARLA JEFFRIES a winner. GroupSales JERRY KAPI-AN Looking for a greatshop project? On page 41 you'll find OperationsDEAN PIETERS Financeand Adminisffiion MAX RUN0MAN instructionsfor building a Collector's-Editionwooden block plane, our first attemptat this type of project. We're zk"r*n impressedwith the way it shaveswood andhandles end WILLIAMT. KERR,President and Chief Executive Otlicer grain. And for all of you who have at one time or another E. T. MEREDITHlll, Chairmanol the ExecutiveCommittee

dreamedof making your own woodworking lumber from @CopyrightMeredith Corporation 2000 logs, be sureto read our article about transportable All rightsreserved. hinted in the U.S.A. sawmills.We field-tested Better Homes and Gardensa WOOD@magazine (ISSN-0743- five of them,and came up with 894X) is publishednine times a year in February,March, April, findingsthat could influenceyour buying decision.i May/June, July/August, September,October, November, and December by Meredith Corporation, l716 Locust St., Des Moines, IA 50309-3023.Periodicals postage paid at Des Moines, Iowa, and additional mailins offices. Better Homes and Gardenstrademark resistered iiCanada and Australia. Marca Registradaen M6xic-o.OM-YEAR SUBSCRIPTION PRICES: U.S. and its possessions,$27; Canada,$39; other countries, $47. Canada Post Publications Mail Sales Product AgreementNo. 1369350.Canadian BN 123482887RT. CANADIAN RETURN ADDRESS: Beuer Homes and Customer Service Information: For service on your subscription, including change of address,contact www.wood- Gardens WOOD magazine, 2744 Edna Street, Windsor, magazine.com/service or call Efi)/374-9663. Subscription mailing address: Biner Homes and Gardens WOOD Ontario, N8Y lV2. POSTMASTER:ASTER: Send addresschanses to magazine,_P.O.Box 37439, Boone, IA 50037-0439. Please enclose your address label from a recent issue.Edijorial Better Homes and GardensWOOD \OOD magazine,masazine,P.O. Box 37439,3J439. mailing addrtss: The Editor, WOQD magazine, 1716 Locust Street, GA3l0, Des Moines, IA 50309-3023. For ques- Boone,IA 50037-0439. tions for our editorial staff, questions about how to reach an advertiser, or to place an advertisement in our magarin" call 800/374-9663. To order back issues call 800/346-9663. For article r-eprints, wrire to editorial addreis and enclose $5 per article. t6 ^lP^l WOOD magazine August 2000 3 s tJ .i.:t"'+' '+:,':.:rl,i;n!4i ,+.a:i,

WOOD@magazine August2000 lssue 125 www.woodmagazine.com

18 whatwoodworkers need to know Get the lowdown on how to bleach color out of wood for a completely novel look. 20 hot otf the internet Tune into our online woodworking discussionsabout 1/+"washer antique scrollsaws, cutting wood plugs, planing with a andwing nut router, working with ash, and defining whitewood. 28 tips fromyour shop (and ours) 84 ask t/yOOD 9ll thefurniture repair shop Have an appraiservalue your antiques with these guidelines. features 3 the editor'sangle t0 talkingback t6 WOODONLINEo 37 the storyof wood See what insects could eat your wood for break- fast, lunch, and dinner. Ul the adventuresof an exotic-woodbuyer Travel with Keith Stephens,the president of the Woodworker's Source, as he visits the Yaguarete Forest in Paraguayto strike a deal on a container of tropical hardwoods. 56 amazingminiatures Discover how Georgian Paul Hamler fashions his unique line of functional, scaled-down, antique hand tools. 87 woodanecdote page56 Find out why the American chestnut disappeared. lll4 finishingtouches page44

Continued on page 6

WOOD magazine August 2000 this issue's highlights Continued frompage 4 WOODo mdgdzine August2000 lssue 125 www.woodmagazine.com woedw-orking proiects l4 adobephoto frame Display three photos in this Southwestern-styleproject. Use our full-size patternsfor guaranteedsuccess. fr greatideas for yourshop Make a mini router table for your high-speedrotary tool. 4l handcraftedplane This eye-catchingtool will fit comfortably in the palm of your hand while rendering yearsof quality service. fll kitchenbutcher-block table Ever think about owning a solid maple table like the one at fighfl Make one with the completeinstnrctions inside. Our design featuresa handy towel bar and knife drawer. 00 showstands for smallstuff Small accent pieces sometimesneed help drawing atten- tion. The four display standsin this collectiondo just that. page50 66 turnedfloral flask Fashion a handsomecanteen-shape pot that combinesboth solid stock and beautifulty figured veneer. 70 setteefor two Perk up your outdoor spaceswith seatingthat suits the environment.Our cedartwo-seater features fresh looks and ample comfort, in addition to sturdy construction.

page70 toolsP ffii&ials 22 productsthat perform 64 what'swhat in oil finishes Before you tackle your next project, study up on the varieties and merits of oil finishes. They apply easily, while offering a rich, natural appearance. 70 sawmillshowdown Harvest your own lumber with one of the five models in our field test. You'll find out why owning a mill makes page22 good economic sense for somewoodworkers.

page22

WOODmagazine August2000 Wewelcome your comments, criticisms, TalkingBack, suggestions,andyes, even compliments. WOODalilagazine, Weselect and publish only letters of the 1716Locust St., GA310, greatestbenefit toour readers. Write to: DesMoines, lA 50309-3023

Air cleaning system : Apoth ecary's Friend In Issue120, Winter l999,page70, you : Two drawings,the PartsView drawing DeWalt | 8-uolt bat- describehow to makea whole-shopair ; on the WOOD PATTERNSoinsert and lery packs recalled cleaningsystem. The basic idea is a good : the Divider detailon page53 in the Do you own an l8-volt DeWalt one,but you overlookedan important l Apothecary'sFriend in Issue120, Winter cordlesstool? If so,you'll be inter- feature-an accessdoor. t, 1999,show different locations for the estedto know that DeWalt is offer- -John R.Bergman, Milton, Wis. ' samepocket holes. See the drawing ing a free repairkit for DW9095 18-

1, belowfor the correctionto the divider on volt batterypacks sold between May You're right, John,you do needaccess to ,, the PartsView drawine. 1997andJune 1998 (date codes the insideof the cabinet.That's because , t1;l between9719 and9810). The clips you needto oil the bearingsin some t, ['f-----\ P on the batterypack may fail to fully ;@1 blowermotors, and checkthe drive belt ,, tI'4'=t (a-- engagethe tool, causingthe battery =) tensionperiodically. Toprovide access, i pack to fall off. Call DeWalt toll-free replacethe screwsthatfasten the side (E) ', T at 8771457-0478between 8:00 a.m. on thepulley sideof theblower with hnng- ' 5" and4:30 p.m. easterntime, Monday er boltsandwing nuts.Locate the switch : I throughFriday. or junction box in oneof the otherpanels. I

ilot sure of Bighting the writing desk Shaker saw blade A phonecall from a readeralerted us to a Drawing1.In theBill of Materialson I've beenan amateurwoodworker all my coupleof errorsin the Drop-Front page64 and the Drawer drawing on life, anda historicinterpreter in the car- Writing Deskproject in Issue120, Winter page66, the length of the drawer sides pentershop at Shakertownin Pleasant 1999.The Drawer Unit Mounting detail (N) shouldbe lUVz",as shown on Hill, Harroldsburg,Kentucky, for the on page63 is drawn incorrectly.When Drawing2. past 10 years.I readwith interest"The panel(Q) bestof Shaker"entry in "12top vacation the drop leaf is closed,its out- Bill of Materials side surfaceis flush with the slopededge stopsfor adventurouswoodworkers" in Ftntsneo!'tze of the sidepanels (C), as shownon Part G Issue120. Not to detractfrom Tabbatha T w L = a Babbit's1810 contribution of thecircular- N drawer f2 2sAa" 1jVz' P 8 sawblade, our researchshows that circular sawswere used by British RoyalNavy t/+"grooves /+" deep, shipbuildersas early as the 1790s. DRAWER 7e"f-rom bottom edje -LawrenceRay, Jr., Harroldsburg, Ky.

We can't find referenceto agree or dis- agree with your saw-bladeresearch, Larry. PerhapsSister Babbit brought the circular-saw blade ideafrom England with her and adaptedit. AIso, Spring Hill, as mentionedin thepiece, UNIT MOUNTING DRAWING1 /a" hole, centered shouldhave beenPleasant Hill. DETAIL DRAWING2

Continuedon page I2

10 WOODmagazine August 2000 tmfikfrg'?S:;;, 1;t' .iu. ContinueclJ'rorn page l0

Drill the e/n" hole completely through hex nut nursefor l0 yearsprior to startingmy the support. While still set up on the 2e/oq" own woodworkingbusiness, I've seen drill press, drill a hole /2" deep on zs/aq"hole t/2" hundredsof tool-relatedinjuries. Every the outside of the samepiece. Epoxy a deep to secure /+" hex nut victim wasamazed at the speedin t/+" nvt to one end of the Vq" threaded IMPROVED which the accidentoccurred. With the rod and insert the other end of the rod sweatbandsecuring the cord,a tool into the hole from the outside.Next, put would swinginto the userif it were a washer and t/q" nut on the threaded dropped.If theuser accidentally fell, the rod and tighten the nut down to the the threadedrod from pulling out when securedtool would be pulleddown onto wood with a wrench. This pulls the you latertighten it with the knob. thebody. expoxied nut into the hole, preventing -Phillip Watkins,Blowing Rock, N.C. I like theidea of keepingthe cord visi- ble andout of theway with a sweatband, but here'sa safermodification: Attach a Router-table twin smallpiece of Velcroto thesweatband Thank you for testing router tablesin own name.If you are interestedin our andthe matingpiece to the cord with issue#122. To setthe recordstraight, productsyou can call us at 800/786- glueor tape.Then, the cord will easily readersshould know that BenchDog, 8902or surf our site at separateif a fall or drop happens.And if Inc. manufacturesCMT's Industrio www.benchdog.com. you needto put downthe tool to pick up router-tables.We also market these -NorstonFontaine, Bench Dog,lnc, glueor changea bit, thecord removes router-tablesand other tools under our Minneapolis,MN easilywithout unplugging it. -MitchellNeal,Dayton,0hio : Shimmed finger wonrt snap off In the Not Sucha Nutty Ideaproject thenrout the grooveswithout damaging publishedin issue#l 18,you advise the fingers. forming the t/q"stopped grooves /+" -Mark Carpente6Long view, Wash deepon the insideface of the sidesand ends(parts A, B) with a router andW" Many thanksfor your tip, Mark. Since slotcutter. your letter camein, we'vealso found I've foundthat when you cut thatclose that the thicknessof the 2xl5" brass to theends (%e"), the fingers can't with- sheetshown in the lower right corner of standthe torqueof the routerand they the drawing on page 87 should sometimessnap off. But if you cut be l/ta", not 7/ta".lF matchingfinger joints in two piecesof scrap,slide them horizontally into the fingersof the sidesand ends, then tape themin place[as shown rightl, you can Tape on bottomsides.

12 Elementsof Southwesternarchitecture lend distinctive styleto thisthree-panel frame. Easy to build,it providesa fittinghome for some of yourfavorite travel photos.

Scrollsawthree southwestwalls o^|t piece of solid stock 31" 1 9"1 4) Drill thesix holeswhere shown. with 1IV2-14 teeth per inch) I vzx7x9",one piece vzx7vzx9", :1" works and r-) ltengths of dowel rod will go well. (Seethe box, oppositepage.) one Vzx7Vzxll".(We used3/+" bass- into theJeholes; measure the dowel Cut out the design elementi, thread- wood, which we planedto thickness. ft you'll be using,which couldbe under- \,/ ing the blade through light-colpredhardwoods, the start -oth9r suchas iized, and drill holesto fit it.) Sandoff holes. Take care birch,would work. to keep the sides of the Or, you couldmake any fine splinteringaround the holes. wavy lines parallel. the frame from pine, cedar, or some j r/a" oal blud. startholes inside the Cut out the picture openings. To otheravailable softwood.) af picture J openingsand the cut_out I make these long, straight cuts, P-hotgcopythe full-sizepatterns for design ! features.Drill the holesnear an changeto a wider blade. A standard#12 f- the three frames.(See the WOOD end or a corner,but be surenot to drill blade, measuring .062" wide, PATTERNSainsert.) Adhere would be eachpat- themright on a cuttingline. fine. And many dealers tern to the appropriatepiece sell even wider of wood, Scrortsawaround the outsidepat- ones,ranging from usingspray adhesive. fi .070-.110".Cut on L) tern line. A #7 blade (.045x.017,, the line and sandoff any saw marks.

14 WOODmagazine August2000 Te" dowel e/q"long 4x6" 7e" hole th" deep board ) tl ool

.All t/2"stock

th" rabbel t/q" deep

:

Seethe WOOD PATTERNSToinsert for full-sizepatterns.

reverse-toothblades reduce tearout Cuttingwith a reverse-toothblade, designated asa #7R,will reduce tearout and splintering onthe back of yourworkpiece, thanks to several teeth at the bottom thatcut on the upward rather than the downward stroke.You'll have to hold the work against the saw tablemore firmly when you use one. The paper pattern masks each frame front while you are painting the design cutouts. Join the panels into one frame t/q" r/q" ' Rout a rabbet deep around front, but don't let paint creepunder the u1-l;Join the three frame sectionswith 1x1" : the picture opening on the back side edgesof the paper.) t'.-.Jbrass hinges, as shown on the Exploded of each panel. A piloted rabbetingbit ;"',rPeel off the patterns,and remove View drawing.Drill pilot holesfor the small chuckedin a table-mountedrouter does '..,.,.,'anytraces of adhesive from the hinge screwsto make driving them easier. -li;F thejob easilyand cleanly. wood. After the paint dries, sand the Cut three piecesof thin cardboard,such r-'1 Paintthe insideedges of the cut-out front andback with 150-,180-, and220- f as a tablet back, to fit inside the rabbet- ,i:1...-design featureswith acrylic craft grit sandpaper.Sand slight round-overs ed openings.Then insert the photosand paints, as shown in the photo above alongthe outeredges for a soft look. cardboardbackings into the openings. right. You can follow the scheme Cut six rZ" lengthsof 3/s"dowel rod. Secureeach with smallbrads or pushpoints ''""'''",,'i shownin the openingphoto (dusty rose Stain or paint them brown. Glue driven into the side of the rabbet.al and turquoise) or apply your favorite theminto theholes in the sidepanels. Projectdesign: Ghristine Anderson southwestcolors. Brush on the paint ;".- ApnlV a clear finish overall. (We lllustrations:Roxanne LeMoine; Lorna Johnson carefully. (The pattern helps mask the '..-.,,rsprayed on semiglosslacquer.) Photographs:Hetherington Photography

wwrrv.wood ma gaz i n e. com 15 tU@@DGTNL'\=' itts neuer www.woodmagazine.com toolate to learnthe Selectingthe right wood basics... for yourproject Learn more aboutwoodworking-even enoughto get you started-in our latestl5 sectionscalled Puzzledby which wood to usefor your next furniture piece? Much of WoodworkingBasics. You'll alsofind link afterlink to thechoice comes down to personal taste, then cost and availability, tool comparisons,technique lessons, shop projects, dis- Butuntil you know the qualities that help you choose one wood over cussiongroups, a woodworkingmall, andmore. another,the selection process can be confusing, Forhelp, Visit theWoodworking Screws and Fasteners section to WoodProfiles where we showcase nearly 30 types turn for informationon screwsthat don't corrode.This infor- And,learn more of commonlyused woodworking woods. mationwill comein handywhen building outdoor projects aboutour choice of hardmaple for like the doublesettee featured in this issueon page 70. thebutcher block featured inthis issue, It's easyto get startedin woodworking,and we're http://www. wo o d m a g az in e. c o m /w d p rof iI e / hereto help. w w w. woodmag azi ne. c om/w oodba s ic s/ Alder.Red other top clicks Ash.White . W00DSTORE . ProjectPlans . SubscriptionServices r W00DMALL Basswood o DiscussionGrouos o FREEClassified Ads o ldeaShop Tours . ShopTips Beech o W00Dlndex o WoodworkingSources r Woodworker'sSoftware . Hallof Fame Birch.Yellow . W0ODworkingClubs o W00DSearch . WoodProfiles o FREECharts . W00DworkingNeighborhood . ii. Boxelder Downloadable Plans Butternut Withso many traditionalicebox plans on the market, we decided thatsomething different might be in order.We chose the 2|"4all Cedar.Red "icechest" shown here for our plan.Download the plan, with com- Cedar.White pleteinstructions and detailed drawings,from the Downloadable Cherry Planssection ofthe W00D ST2REfor just $S.SS. httpf / store.y ah oo. co m /w oo d sto re /

becomea Benefitsinclude: IUonthlvTool Srveepstakes.Free Downloadable Plan. WOODOI,{LIT{E IHonthlyNs'rvsletter. atttl the Citt Registrl'ttt the WOOD N{ALL"'. mentber vvvvw.wood mag ai ne. ca ml m e nt b e r si t n d e x. ht nt l

16 WOOD magazine August2000 -'l w$rum€ruwmm#w*rkms"g

get_the ;wdbdCOIGr Afterbleaching, theoak and walnut are thesame color. The grain bleach remainsvisible in bothpieces.

\f /hen it comesto altering the color Once mixed. a chemicalreaction YV of wood, woodworkersroutinely Why would you remove begins,wherein the hydrogenperoxide, turn to stains to give wood more-or a the color from wood? an oxidizer, actsto neutralizethe caustic slightly different-color. But wood Wood bleachingproves useful in situa- sodium hydroxide.Neutralized, the solu- bleach lets you remove color from wood. tions likethese: tion losesits bleachingpower, so mix . Whenthe wood you haveis too dark only what you can useimmediately. Look for a two-part bleach to for a particularproject. In this case, Quickly apply the solution to the do the iob removingsome of the colorfrom the wood. A spongemakes a good applica- You'll find threekinds of productsmar- wood mightmake it moresuitable, or tor, as shown be/on'.Keep the surface keted as wood bleaches.But only one wouldallow you to stainthe wood to a uniformly wet to minimize streaking. will remove the naturalcolor from wood: lightercolor. (We held the board at an angle and a two-part wood bleach of sodium . Whenyou haveseveral boards of the worked from the bottom up, as shown.) hydroxide (causticsoda) and hydrogen samewood for one projectand they Rinse the solution off the wood with peroxide.Other wood bleachesare chlo- varyin color.Here, you can bleachone water. To ensurethat no causticsoda rine bleach and oxalic acid. or moreof the boardsto matchthe oth- remainsbehind, rinse the wood with a Chlorine bleach,which is like ordinary ers.Or, you mightbleach allthe boards mild acid-white vinegar works well- laundry bleach,will remove dye color and stainthem to a consistentcolor. then rinse it once more with water. from wood, but not the wood's natural . Whenyou wantto stainone wood to After the wood dries, assessthe color. color. Oxalic acid is commonly look likeanother. Removing the natural You can bleachwood as many times as employed to bleachout water or rust colorfrom a wood makesmatching the neededto achievethe color you want. stains.Teak stain remover sold by boat colorof anotherwood easier.lf you (We bleachedthe pale piece of red oak in dealersis often basedon oxalic acid. bleachboth woods,you can stainthem the photo above twice, and made three All the bleachingchemicals pose boththe samecolor. applicationsto the walnut sample.) health and safetyhazards to varying Allow the wood to dry thoroughly. degrees.So be sureto read the manufac- turer's instructionsand warnings before Sand with 320- or 400-grit sandpaper, use.And always wear rubber gloves and just enoughto remove the fuzzy grain eye protectionaround bleaches. from the surface.Q

Now, kiss that color goodbye The Wood-Kote brand bleach we tried comes.like most. in two bottles.To use it, mix equal parts of the two liquids in a glassor plastic container,as shown at left. Never put either chemical into a Workfast after mixing the two chemicals. metal vessel.(Some bleaches call for Thesolution begins to neutralize-andlose bleachingpower-just as soon as you start applying the two partsseparately. Follow Applythe bleachas evenlyas possible,and to pourthe liquids together. the instructionsfor the one you're using.) keepthe surfacewet as you work.

18 WOODmagazine August 2000 n ffiinternet

Note:We have edited all entriesin the interestof brevityand clarity whitepreserving the intent of theoriginal message. 1pinions expressedhere are those 0f nurlnline participants.

Hets searching for an antique scrollsaw or reproduction model anyoneknow where lcan Pur' : New Rogers),they cut better.There i o DougCunningham in Tennessee lloes i lJchase anantique scrollsaw? The : were many companies that made saws i has Barnes Velocipede antique onesl'm lookingfor arelike bicycles- ! fro. the latter part of the 1800sto the ! scrollsaws for sale. They're the real yousit on a seatand pedalto make the i early 1900s.My personalfavorite is the i thing,not thereproduc- bladego upand down. 0r howabout a i BarnesNo. 7. i tion.You'll pay : companythat makes reproductions of -Tony Bums,Fredonia, N.Y. i at least$1,500. anold scrollsaw? -Bill Kerr,Everett, Pa. I There'san outfit calledThe Tool CompanyInc., at 812N. KurzweilRd., o A good starter old saw is the New Raymore,MO 64083,that makes a Rogers. They're very common and easy reproductionof the BarnesVelocipede. to find. Unfortunately, they do not cut Its phonenumber is 816/33l,-4499.[The very well, at least not in 3/t" or I " wood. companyalso carriesreplacement parts - If you can find either a Star or a model The Editors.l : -Tom Utah 387, both made by Millers Falls (like the -MichaelJ. Mottet,Foresthill, Calif. : SeuY,SaltLake CW,

What's the ideal speed for cutting wood Plugs? ouncesfrom Tool Crib of the North, ;justbought some plug cutters. What is other drilling and sandingaccessories, i If a plugjams andbreaks Ithenest speed to setthe drill press andyou canget afree copy by goingto I 800/635-5140). homepage and off duringcutting, just give it another whenusing them? When I went too fast, the WOOD ONLINE i shotof DriCote. The stuff works great theyburned, too slow they hesitated, clicking on FREE Charts.From that : the Drill PressSpeed on bandsawblades, router bits, mortising andthey stalled while lwas cutting wal' pagedownload i chisels,etc. nut.Was it thewood? Chart on your printer. : -Bob Falls,AnL -Tony Falatico,Lake City, Fla. This handyreference aid was devel- : Best,Niagara opedthrough our own in-shoptests. My i o Cut plugsat 1,000rpm copy of this charthangs next to my drill : r I recommendthat by trial-and-error for softwoodsand 500 rpm press,and probably has savedme a small : you alsofind the bestpress-down fortunein Forstnerbits that I was previ- strengthto avoid burning and stalling for hardwoods. i -Dave problems.Some better plug cuttersare Lehnert,Milford, 0hio ously runningtoo fast. : 4llarten Kemmet,W00D lNLINE , internally tapered(conic), which elimi- natesretention or burning of the plug. I o Dave'ssuggestions agree : plug acquiredfrom Lee with the recommendations o When usingmy Lee Valley tapered : use cutters them with Valley Tools;they work quiteweil.rl on the WooDamagazine plug cutters,I alwaysspray i -Marco AurelioR. Guimanes, Belo Hoizonte, drill pressspeed chart. This Bostik DriCote lubricant(catalog item : chartgives speedsfor many #10120,$13.99 plus shipping for 10.75 : MinasGenis, Brazil

20 WOOD magazine August 2000 rlliilpr ffiffi*ffi#rusffi*fuffi,(lis'l'lill

Dust collection: Put it wherever you want it Thanksto increasedawareness of the my drill press.With little effort,I put hazardsof workshopdust, collecting it thetip of thenozzle a fractionof an inch from somewoodworking power tools is from boththe workpieceand bit, with- nearlyautomatic. But for others,collect- out touchingeither. ing debrisat the sourceis nearlyimpos- Althoughthe manufactureroffers con- sible.Wouldn't it be niceif you could nectorsto fit 3" DWV or metalduct- positiona vac hoseright wherethe work, theydon't currentlyhave one to actionis, yet adjustit withouthassling fit 4" systemslike mine.However, a with clamps?Loc-Line Modular Loc-Lineofficial told me they'rework- VacuumHose lets you dojust that. ing on 4" to 3" and2t/2"to 3" adaptersto It's modularbecause the flexible hose simplifyhook-up to standard-sizedust- consistsof individualball-and-socket collectionsystems and vacuum hoses. joints,similar to theball joints and tie- To seeif this uniqueproduct would yourshop. But, for situationswhere rod endson yourcar. But in Loc-Line's choke-upon chips,I suckeda whole you needmaximum flexibility in dust case,the joint is hollowlike a hose, garbagebag full of planerand jointer collection,it' s wortha h^;: allowingdust and chips to flow through. wastethrough it with narya plug. ;:::rrrderson This tight-fittingball-and-socket config- Duringthis test,I did noticesome static- urationis virtuallyair-tight and allows induceddust buildup on theoutside of you to placethe businessend of the the hose;Loc-Line also comes in an Loc-Linemodular vacuum hose hoseexactly where you want it. anti-staticversion if you don'tmind Performance ***** However,unlike flexible hose, it stays spendingabout l5 percentmore. $13.95/f1.,hose; $4.95, nozzle; put.In fact,I foundthat the segmented This bringsme to my only complaint: $11.95blast gate hosesupported itself for at least3' with- At $13.95per foot for thehose (nozzles, Value *** out sagging.I mountedLoc-Line blastgates, and adapters are extra), you To locatea dealer,call Lockwood Products betweenmy shop'srigid ductworkand probablywon't wantit on everytool in at 800/423-1625.

Make flat-bottomed holes with cool-running bi s You canbore a straight,flat-bottomed , the steelcutting edge. But that'snot the drilled 2" deep the temperatureof the holewith any Forstner-stylebit on the : casewith Bormaxbits. Bormax bits never rose past "warm to market.Too often,however, they cut , A standardForstner bit relieson its the touch," while the other style turned slowly andgenerate enough heat to burn , solidouter rim to cut, andtwo gulletsto blue from the heat. the edgesof the hole as well as ruining i ejectwaste. And thatrim getsawfully The SetI teSted-%",3/1", 1", lt/t", and , hot asyou forceit into your workpiece. | 3/6"-s6r1e in a fitted wooden box. , However,the Bormaxdesign features They're about twice the price of high- i five cuttingteeth and gullets ground into speedsteel bits, and about on par with : the rim of eachbit. The rim actually carbide bits, but worth every penny for , helpscut throughand remove the wood the clean cut they leave. You also can : insteadofjust goingalong for theride. buy them one at a time as needed. : I boredholes in oak,pine, and maple, -Tested by BobMcFarlin : comparingeach Bormax bit to a solid- , rim bit of the samediameter. The : Bormaxbits requirednothing more than Bormaxhole-cutting bits i constant,easy pressure, and produced Performance ***** i holeswith glass-smoothsides and no $110, boxed set of five , burning(foreground holes in photoat Value **** I lrft). As for heatbuildup, even when I CallWoodcraft Supply at 800/225-1153.

Cctntinuecl on page 24

22 WOOD magazine August 2000 Continuedfrom page 22

An economical and accurate way to set things straight I don't oftenrecommend buying align- aboutthis accessory mentor set-uptools. They're usually is thepost that lowers expensive,and you probablywon't use the dial-indicator's them all that often.But if your work stylusto near-table- requiresdial-indicator accuracy, the TS top height.That Aligner Lite-or its upgradedbrother, allowedme to usethe theTS AlignerJr.-might bejust the widestpart of my saw answerto your setupwoes. bladeto accuratelymeasure runout. You canuse the TS AlignerLite, Besidestablesaw setup, you alsocan shownin the photo atfar right, to align usethe TS Aligner Lite for various everythingon your tablesaw-blade to alignmenttasks on your bandsaw,joint- miter slot,fence to blade,miter gauge er, shaper,and drill press. squareness,and more. One thing I liked Now, if you reallywant to get into tun- ing up your powertools, consider step- ping up to theTS AlignerJr. This kit I've usedall kindsof dial indicator TSAligner Lite and TS Aligner Jr, includeseverything you get in the Lite gaugesto setup and testtools, and built Performance ***** version,plus a precisionsteel rod and fixturesto go with them.Still, I'm Price $70,Lite; $140, Jr. an additionalaluminum extrusion impressedby the designof this system. press It's compact,easy to setup, andquite Value **** (shownchucked into a drill in the versatilewith its interchangeableparts. Formore information, callthe Ed BennettCompany photo aboveleft) to usefor aligning at800/333-4994, orvisit www.primenet.com/-ejb/. your drill-presstable and jointer knives. -Testedby Bob McFarlin

Biscuit Master makes you a big winner at slots Cutting a biscuit slot looks simple gular platesbelow slide for- enough,but it actuallyrequires you to ward andback to position apply pressurein severaldirections at edge-cuts. onceto get a perfectresult. You can I testedthe Biscuit Masteron clamp the workpieceto your bench, the sidesand ends of boards, but if you're slottingmany pieces, and on bevel and miterjoi suchas when makingface frames,you and it worked wonderfully spendmore time clampingthan actual- everytime. A pivoting post ly cutting.Woodhaven's Biscuit slidesinto the T-track to pro- Mastersolves that problemwith vide accuratepositioning for fencesthat hold the workpiecein place plungecuts on miteredends; a andguide the biscuit joiner, too. shortfence rides in the same The keys to the systemare phenolic slot to establishbevel-plunges. platesthat ride in machinedslots to The only drawbackI could find is keepeverything perfectly square. that the Biscuit Masterwon't handle Snuga pair up on eitherside of your anything over53/q" wide, which leaves BiscuitMaster biscuitjoiner andthey providea posi- out the big panelsused in cabinets. Performance ***** tive guide,yet still allow you to But suchpieces are large enough to be removethe routerfor the odd cut. The slottedfreehand, so I give this unit a Price $80 L-shapedplates adjust left and right to top rating.i Value ***** fit stockfor end-cuts.while the rectan- -Tested by DaveHenderson CallWoodhaven at 800/344-6657.

24 WOOD magazine August 2000 reat ldeas 'fq:;+' -,i" i+.1{"r}$ liJF,.l ffiwmffimffiffiffi tr{sffi#ftffitr ftmfutm for rotary tools

mail piecesoften require precise Q \J routing thatjust isn't safeon a full- size router table. And, trying to shape the workpiece in one hand with a rotary tool held in the otherisn't any better.To solve the problem, WOODo magazine reader Chuck Middleton built this scaled-downtable to househis high- speedrotary tool. To make your custom holder, start by cutting clamp blocks to fit the body of your rotary tool. Line the inside curved surfaceof the blocks with weatherstrip- ping or some type of foam. The foam allows you to securethe rotary tool betweenthe blocks without cracking the tool housing when tightening the blocks #8 x 11/e"F.H. wood screws aroundthe tool. Now, cut the table,end H supports,and back to the sizes shown I on the drawing below right. Assemble 3/+"hole the table. Secureyour rotary tool in 91lz' place, being careful not to overtigthen the knobs. Mark the hole location need- TABLE Back overhangs ed for your largest rotary bit, remove 1/2"plywood 11/2"past base for clamping the table, and drill the hole. Screw the END SUPPORTS tableback in place. 3/+"stock #8 x 1" F.H. 3lax 4" carriagebolt wood screw (2 required) Clamp the mini table to your work- 91lz' Drilaza" bench as'shownin the photo, or slide High-speedrotary tool \ I Neoprene one of the protruding ends of the back weatherstripping into a flush-mountedbench vise. (Adhereto clampblocks.) For really small pieces,we prefer to 1 Cut clampblocks \ Wryi"ifi:ff,il' hold the workpiece with a miniature to fit shape of tool. \ clamp, or even securethe workpiece to \t the end of anotherpiece of wood with dt61lz' double-facedtape or hot-meltglue. This keeps our fingers safely away from the t\ spinningbit.i a/r"ptKJ BACK ProjectDesign: Chuck Middleton, knobs 1lcx61lz x 91/a" Sulphur, Louisiana :Y_i'_i:'" \-J' I lllustrations:Kim Downing Pl'wooo i* 3/a"flat washer Photograph:Hetherington CLAMP BLOCKS , - ,,./ 3/e" 11lzx2x6" #8 x 111c"F.Hl PhotographV hole through clamp wood screws blocksand back

26 WOODmagazine August2000 No oxygen-blocker? .,.' Forsubmitting your own .1: -' this issue's Make in '.tf'*i - Top Shop To keepfinishes and paints from skinningover Tip, Kevin :, {.SF' the container,you needto createsome kind of banier between ; \ f"d Matocha scores a theoxygen in thecan and the finish. You canbuy inertgas . \ { _CMTrouter productsto form an invisiblebarrier, but whatif you don't tableand set of bits. Congrats, haveany on hand?Here's a quickand inexpensive solution. Kevin!

KevinMatocha took a TTevin Matocha believes in swing at our Top A,learning from his elders. Shop Tip and con- nected, tiig-time.tte That's why he went from his turnedthis bat while Trov. New York. home to in high school' corpus christi, Texas,last sum- mer to learn bowl-turning from his grandfather. In thebottom of a cleanhalf-gallon container, put a teaspoon Learningmust be high on Kevin's list becausehe's also of bakingsoda, then pour in a quartercup of vinegarand swirl earning his doctorate in electrical engineering. the mixture.The bubblingreaction creates carbon dioxide- Vhen he's not hitting the books, our Top Shop Tip an inertgas about 1% times as heavy as air. (Thosemeasure- winner likes to hit a softball or fwo. Kevin still uses the mentsyield about2 quartsof carbondioxide.) bat he turned while attending high school in Arkansas. As thereaction slows, quickly pour the gaseous contents of "Actually, this is the second bat I made; I busted the thecontainer (NOT thesludgy remnants) into yourcan of fin- first one," he says. ish, andreseal the can.The carbondioxide replaces the air in Tell us how you've solved a problem in your shop, thecan, providing a protectivebarrier over the finish. and you might hit a home run like Kevin. For every tip -KevinMatocha, Troy, N.Y. we print, we pay $75, and if yours is judged our Top Shop Tip for the issue,you'll also receive a tool pnze worth at least$250. This frame clamp is a sguare deal Send your best tips, along with sketchesor pho- I put togetherthe clamp,shown below, with about$5 worth tographsand your daltime telephone number to: of materials.That modest investment gave me an easy,accu- rateway to clampsmall boxes, drawers, and frames. I put Tips From Your Shop (and Ours) wax paperat eachjoint, slidethe hardwoodcorner blocks WOOD@Magazine into place,and check for squarenessas I graduallytighten 1716 Locust St., GA-310 eachwing nut' Des Moines, IA 50309-3023 -John vernet,Ettiiay, Ga.

Or post your tip on our Top Shop Tip discussion- llq x 12" gf oup at www.w oodtnagazine. com. threaded rod Sorry, but we can't return your submission.And, becausewe try to print only original shop tips, please send your ideas only to WOOD magazine.Thanks! \/ 1/+"washer /\ ,'-) andwing nut 5/ro"holes A'*@ for rods \TOODWORKING PRODUCTS EDITOR

Cotttittued on page 30

28 WOODmagazine August 2000 ffiwpw

Continuedfrom page 28

Make a gauge, save some bowls Tlrrn your block plane Woodturnersknow the cardinalrule of into a mini jointer Step 1 i_l :-:) i I bowl-turning:Don't makethe inside I wantedto glue-uppieces of exoticand colorful wood from lnil il *, ,iittt==l I biggerthan the outside. This simplejig, my scrapbox, but mostof themwere too smallto safelyrun shownbelow, gives you an easyway to througha jointer.So I madethe jig shownbelow, sized so llryl*',z1ii:--:Llr-(ii i"j P just i/ checkthe innerdepth and then compare thatmy blockplane fits betweenthe hard maple guide i chuge i I it to the outerprofile. rails.I placethe pieceof scrapagainst the stop,take a few jextension n i -Jack Turley,Chicago, lll. strokeswith the plane,and make a nice,smooth surface suit- ablefor gluing. Laminate3 pieces -John Wersosky,New Durham, N.H. of 1lq"stock. Wingnut on1" /.,' carriagebolt ,rt\ s/e"dowel #Bx 5/e"F.H. wood screws, ) countersunk ,/ 3lq' 4

Removablegauge \ extension

Mountpulley to aluminumangle. cabletie When changing scrollsaw 1/e" blades, Fut your foot down Hose lr,-ff clamp I'm hookedon scrollsawing,and now I've mademy DeWalt2}" 11lzx11lzx18" aluminumangle saweven more fun to use.I do a lot of detailed,inside cutting, which meansfrequently detaching the blade,threading it througha hole,and reat- tachingit. ,i: It's not easyto do all thatblade-switching with only onehand while holding up the sawarm with my otherhand. So, with a scrapof aluminumangle, a few pulleys, somescrews. and about 5' of steelcable. I customizedthe sawso I canhold the arm up by pressingon the foot pedal,as shown at right. This leavesboth handsfree for changingblades and has proven to be a hugetime-saver. -SteveManzo, 0kinawa, Japan

en UV WOODmagazine August 2000

,ruw{IItrIEBtlEtF @ Enjoy this 3'7" with your biscuits Buildingwith a biscuitjoiner is sucha pleasure.To makeit evenmore enjoy- able,I fashioneda specialT-square, shownat right, from scrapsof 34" medium-densityfiberboard (MDF). I usethe jig whenbuilding book- casesor shelvedcabinets. I mark thedesired locations of biscuitson m the long leg of the square,and cut rkul a sawkerf at eachmark. Those kerfsserve as registration lines for ,,Nffiffi thejoiner. It's quickwork to cut slotsin the sideof the carcase,then cut match- ing slotsin theends of theshelves. .-{>=- You just may want to makediffer- projects entT-squares for of different sl+x3x lB" stock dimensions. -Glenn Willis, RedondoBeach,

Continuedon page 33 Thebest NoMcrtler How Jpstgets YouGut ll,fhese Ienryu BlclidesAre better 16-32@Pr-us Win-ning Combos Packageincludes: ,. '10 TenryuGold Medal x 40tand Rapid-Cut10" x 50tblades l6-32@Plus Drum Sander giveyou splrnter-freecuts in all woods-even chip-freecuts Save$71.00 in melamine.Both feature extra hard carbide teeth that stay FREE sharplonger, even when cutting abrasive materials, Boxof REnpy-ro-Wnnpabrasives Gold,Medal: "A topperfonner offtring auery smoothcut edgeanl, $ 24.9s glass-smoothfeeding"..."the quietest-cutting blnde in our test" FREE Tnacrcens Rapid-Cut:"The siltoothest cutting of all theATB/R blades tested" 19.95 -W)OD Magaeine,February 2000 $ FREE Forexceptionally clean and accuratecross, rip and miter MernlSrnNo cutsin allwoods, ask for TenryuGold Medal or Tenrvu $ 99.95 your Rapid-Cutblades at favoritedealer. qr l {o() Making quality saw blades since 1910 \y/-lJ TOTALPACKAGE SAVINGS TENRYIJ NOW $849.00x 4301 Woodland ParkDr, Ste. I 04 West Melbourne, FL 32904 Shownwith optional l-80G95l-SAVA . 407-951-?4O0. Fax 407-951-2250. \M ^iv.tenryu.com lrureeo& OurrEEo Taalrs R*9HY,X THE JET FAMILYOF BRANDS Call 800-334-4910for the dealernearest you or visitour websiteat www.PerformaxProducts.com 'i'Manulircturcr's SuggestedRetail Pricc. Oll'cr good throughJuly 3l. 2(XX) CircleNo. 78 -€#rem

Continuedfrom pttge 3l

Automotive paint process inspires HVLP impnovement I love applyingfinish with my HVLP i keep everythingtogether, I mounted pressure-feedingsprayer, but I found it , them on the outsideof a small wooden frustratingalways having to keep the ' Uo* that was largeenough to hold my gun upright.And as the finish got lower i finishpot. in the pot, the lessI couldtip it and still , To usemy modifiedsprayer, I fill the apply an even coat. After studyingthe : pot with finish and adjustthe regulator finish applicatorsat the automotive , to around5 psi. Becausethe pot stays Everythingyou do plant whereI work, I went home and , upright,and only the spraygun tips, I with a drill is now modifiedmy sprayer. , can now spray vertical and horizontal done faster with the I boughtsome V+" plastrc tubing, hose, , surfaces-even the undersidesof pro- Graftsman@Speed-Lok'" fittings, and a regulatorand valve, and , jects-in onesession. drilldriving system assembledthem as shown below. To t. -RobeftWilson,Lawrenceburg, Ky.

Plugsiphon{ube conneclronon gun. // __---J _.-.|.] ill]t-."i i] [) 3/e"coupler

1/+"hose barb

Spraygun

por ] l i

l

r

Airhosefrom aircompressor

Woodenbox to house paintpot and attach pressuregauge

_Qu--\ ick-connectfitti n g I \ Air hoseto g i \ (lengthto fit) Tighten & loosenbolts

Drill a conduitopening

1/q"20 psi pressurerelief valve Continuedon page 34 MAKES ANYTHING PoSsIBLE"- O 2000 Sears.Roebuck and Co. WOODmagazine August 2000 33 tipsixffi H'ilI'*J,"*"*

Continuedfrom page 33

Hand screw holds while drill pness makes holes In my furniture-makingbusiness, I often needto drill holes in the edgeof small, unusually shapedpieces. Rather than makea work-holdingjig for eachshape, I clamp the piece into a handscrewand drill the hole on my drill pressas shown below. The clamp keeps my handsout of dangerand securesthe workpiece for a nice,clean hole. &obJay, Port Orchard, Wash.

THClffiTanffigl,g AAnGCgr$ounGCFon WooDwonwffiG lFOOtIgAflD $upnLtcglt z4-HourShopping Over25,000 Tools & Accessories SpecialSales & Offers ToolComparison Charts FreeSeminars www.woodmatl.Gom 34 WOODmagazine August2000 l^l \-,layton Spindle Sanders are built in the USA with precision balanced spindles, Bandsaw blade storage: oversized bearings, and a premium Zip tem up, clip tem up Baldor Induction Motor. . Benchtop and r Large table surface Insteadof tying up my bandsawblades full.sized, professional r Built.in dust port r with stringor a twist-tie,I placeeach in models Quick.change drums a one-gallonzipper-type freezer bag. Clay ton tackle s the toughest s anding jobs. . . smoothly. Squeezingmost of theair outbefore FREECOLOR CATALOG,call: 1.800-971-5050 sealingthe bag reduces the likelihood of trappingmoisture in thebag. SGtAYT0I{ I thenlabel each bag with thethickness ROYALOAK , MI 48068-0s20 andtooth-count, but you alsocould -ffi includesuch information as the proper tensionsetting for thatblade. To keep my bandsawblades handy, I mounted severalof thosepotato-chip bag clips to thewall right nextto my saw,and hang theblades as shown below. -John Tappan,Chattanooga, Tenn. Drillaccess hole Mountclip with for screwdriver Scfew'f;::,;;'I and washer til, naarlart\ J]jtftP.):ry

One-gallonzippered freezerbag Bladeidentification A fewmore tips from our woodworkingpros wnw .Need round legsfor a project but you don't have a lathe?See our router jig on pages54-55 for the perfect solution. .Wiping on an oil finish can often be the simplestway to complete your project. To avoid the few pit- falls of such a finish, check out our batch of tips at the bottomof pages 64-65.t|

WOODmagazine August 2000 the story of wood ffi rytr* ffiffi m.;:: )::': ca,n \ take \ their ryr Water,fungi, oxidation,enzyme stain, an decay all cause wood to deteriorate. thereare insects,plenty of them. Insectsrecycle dead, down, and wou ed trees into fertilesoil and plant n Unfortunately,these little recyclersdon observe"off limit"signs. They'll eat destinedfor your shop (or the wood alreadythere) as well as what loggers leavebehind. Here's a roundupof those that maketheir mark. Someinsects focus onlv on living trees and green ldgs Horntailsand others do boring work Some insectsbore into trees,logs, and freshly sawn lumber to /nsect species in this category actually number in the simply feast.The most common are the pine sawyersand the thousands. Buf woodworkers usually never see fhese horntails.The -%"to I " grub holes they leavebehind indicate culprits, only the resu/ts of their activity. their pastpresence. You'll find their tracks in hardwoodsand softwoods,and in sapwoodas well as heartwood.Kiln drying kills their larvae.But if their activity was extensive,the Fly larvae create distinctive marks lumber is weakenedand its appearancedowngraded. The dark, thin streaksof varying length running with the grain that you'll often spot on basswood, birch, cherry, maple, and willow boards were made by fly larvae. Termitesand carpenterants These tough guys like wood and damp feet down through the cambium layer of the livins tree toward the sround. The wound heals irfterthe larvaepass. but the tissueturns dark. The pith flecks don't weaken the wood. It only looks bad. Bark beetles engrave as they go Many insects attack the inner bark of trees (mostly conit-ers)and fieshly cut logs. As While common termites and they excavatearound the trunk, they leave a carpenter ants-both social telltale trail. Visible entranceholes with enough to live in colonies-can and expelled frass (fecal matter, bark, and wood will tear through your woodworking stock, it's powder) indicatetheir work. Because unlikely. That's becausethey both prefer moisture. thesebeetles live on fresh logs and So unlessyou storewood where it's damp, or where living trees, they perish with the termites can tunnel their way to it from moist later processingof the wood. ground, you're not likely to encounterthese critters.

Continued

WOOD magazine August 2000 37 the story of wood

Otherbuqs eat seasoned and even-kiln-driedwood Beet/es in this category prove numerous as well as aggressive.They're Enemy Number One for woodworkers. Ambrosiabeetles damage hardwoods and softwoods The pin holes up to %" in diameteroften seenin oak and other woods are signs left by the ambrosiabeetle or other anobiid beetles.No tree speciesis immune to them becausethey primarily attack the sapwood of green wood and that being air-dried. Once the wood dries there's no threat.The holes they've mined usually don't weaken the wood, yet a fungus they carry severely stains it. The holes and the frasscoming from them give away their presence. Powder-postbeetles like hardwood sapwood best With a strongpref-erence for hardwoods.powder-post beetles go after the sapwoodof seasonedand even kiln-dried lumber. Becausethe adultsdeposit their e-e-esin the wood pores.only speciesthat have sufficiently lar-ee pores get their attention.In the United States,you'll find powder-postbeetle dama-ee in ash. hickory,and oak, althoughotlier speciesare susceptible.too, includingblack walnut.When adultselnerge fl'orll the wood, usuallyin splin-uand summer.they leave%:" to t/to"diarneter holes. Fine, powdery tiass nearthe holesmarks their ongoingaction, which can even- tually renderstock useless.

Critter-contai n ment tactics The necessarymeasures to kill insecfsand con- uninfestedwood. The stickersallow air to circr,rlatebetween the trol or contain insecf infestationin wood vary boardsand more quickly dry the exposedsurf'aces. It's alsoa with the type of insect. good idea to remove all bark (wane) fl'orn board edgesbefbre seasoningor storing.And kiln-dryingover l30o nortnallykills For insects that only chew most insectsthat like their wood moist green wood, take away moisture With insectsthat love green wood, the best protectionis get- Insects living 9ff dry hardwoods ting the wood dry as quickly as possiblewithout degrading require special measures powder-post it. Always stack wood for 4y-{ying with stickersof dry, Although the primaryculprit in this categoryis the beetle,there are others.Prevention and eradicationrnethods remain the same.however. Becausepowder-post beetles invade only hardwoodsapwood, buy boardswith the srnallestamount (or rip it off) if you plan to storethe wood fbr zinylength of tirne in a place where the bu-esrnay enter. That coLrldbe a shedor otherbuilding sub- ject to the elements. Pretreatingwood surfaceswith a boratecompound-boron and oxygen-protects againstbeetle inf'estation. Mixed in a l0 percentsolution with water.the borateshould be sprayed or brusheddirectly on and into the holesof unfinishedwood. In inf-estedwood. the lalvae and the adult beetlesdie afier digestingthe treatedboards. (One product.Termite Pruf'e, you'll find at major hardwarestores or call 805/565-1566.) Otherpost-inf'estation treatments include fumigation. heat- in-e.and freezin,e(-40 F for days).But for the niajority of home woodworkers,they're all relativelyinipractical.lP lllustrations:Brian Jensen

WOOD magazine August 2000 l

First, let's fabricate the parts J Cut a mapleblank to l3AxLt/zxl4" QCrosscut the mapleblank to 61/2" squareto its table.On your tablesaw, llenough materialfor two block \,llong. and adherethe FrontCore trim the wedgeblock (C) to l7s" thick. planes,uni long enoughto run through Blank,h.u, Core Blank, and Wedge Setit asidefor now. a thicknessplaner). If you don't have Block full-sizepatterns found in the From t/t" padauk,cut two plane 'tsidesf 1/+"-thickmaple (8/4 stock),laminate WOOD PATTERNSoinsert to the top (D) to 2th.x61/2".Cut the side the blankfrom thinnerpieces of maple. face with spray adhesive or rubber full-sizepattern found in the WOOD Preparean identicalsized scrap blank. cement.Cut the coreblanks (A and B). PATTERNSinsert along its bottomedge f)Plane both blanks to ltVrc" thick, andthe wedge block (C) to shapewith a and adhereit to one of the side pieces, {-keeping all sides of each blank bandsaw,staying just outsidethe lines. beingcareful to preciselyalign the bot- squareto eachother. Set aside the scrap Sandthe partsto shapeusing a station- tom edgeof the patternwith the bottom blank for now. ary sandingbelt or disc set absolutely edgeof the sidepiece' Crntittuetr

WOODmagazine August 2000 41 Time to shape up BODY ASSEMBLY the body J Usingthe Body Assemblydrawing I as a guide,position parts A, B, and D on a flat surfacesuch as the top of your tablesaw.Place waxed paper underneaththe parts. f)Glue and clamp the front and rear Lcore blanks(A andB) to theside (D) with the appliedpattern. Be careful to align the part bottoms,and leave a t/ro" spacebetween the front and rear core blanks.After the glue dries,glue and clampthe other side to the coreblanks. QCut the scrapblank to 5" long and LJinsert this piece(unglued) into the open throat of the plane assembly.It shouldfit snugly,but looselyenough so you can remove it later. The scrap servesas a chip breakerfor the cutting anddrilling thatfollows. Next, cut the assemblyto length, --f,{ using the Side full-sizepattern as a guide.Cut the curvedportions with a bandsaw.Sand the edges,ends, and bot- tom with 1OO-gritabrasive. Take care now to keep the bottom flat and square to the sides. A few final touches and you'll be planing t/+" I Pface a bit in your drill press,and I set its table squareto the bit. Drill the t/q" hole at the location marked on the Side full-size patternthrough the assembly.(See photo at right.) Drill the t]/o+"hole$ where shown on the pattern, routerfence with eitherend againstthe throughthe assembly.Remove the pat- right-sidestopblock. Lower the plane tem andscrap blank. onto the spinningbit, holding it firmly -)Cut five piecesof t/a"-diameterbrass againstthe fenceand table, and slide the 4-rod to 23/re"long. Near the endsof planeto the left until it contactsthe oneof the brassrods, reduce the diame- other stopblock.Lift the plane straight ter just slightly(by about7o+") with up and off the bit. Rotatethe planeend light sanding.Insert this rod into the /+" for end and repeatthis routing proce- hole, withdraw it about t/2",apply epoxy dure to cut a finger recessin the other to both rod ends,and reinsert.Apply sideof the plane. epoxyto the remainingholes and insert / Roundthe edgesof the wedgeblock the other brassrods. The rods should ttCl and the planesides (D) with a protrudeevenly on both sidesof the %" round-overbit, whereindicated on plane.After the epoxy cures,use a sta- the ExplodedView drawing.Sand tionarysander to makeflush the endsof smooththe areasyou just routedin the thebrass rods with theplane sides. lasttwo steps. lh" Q Set up a core-boxbit in a router fiFinal-sand the entireplane with a as shownin the Router-Table r.-lsuccessionof 150-and 220-grit L,ltable, The scrap blank prevents the side stock SetupFor FingerRecess drawing. Place abrasives.We appliedtwo coatsof from tearing out when you drill the lq" the bottom of the plane againstthe OlympicInterior Antique Oil Finish.JF hole for the brass rod.

42 WOOD magazine August 2000 -1

ROUTER.TABLESETUP SIDE VIEW FORFINGER RECESS

3/q"core-box bit set Fingerrecess, t/e"above routertable routedwith a 7+"core-box bit 1/8"deep

\)x--3'zo" Y""n?t - I ;f,--\ --t'' stopoloJt

EXPLODED VIEW round-overs A* rearcore blank 11%0"11/z' 37/a' M B- front core blank 111/16tt17A6" 21/16t1 C- wedgeblock 1Ve' 1%0"315/ro" M @ D sides 1/4' 21/a' 6u WEDGEBLOCK -Cut - partsmarked wilh an oversized.Trim to finished- sizeaccording tothe instruclions. MaterialsKey: M-maple, P-padauk. Supplies:/+" brass rod 12" long, epoxy, oil finish. round-over BuyingGuide: Planebfade. Hockls/ex4t/z" blade, item 04835, BLADE $26.99 plusshipping. Woodcraft, 560 Airport Industrial Park, N P.0.Box 1686. Parkersburo. WV 26102-1686. Orcall 800/225-1153 to order. t/+" brassrods 2sl0" long Woodand brass rod. Enough 1/4" padauk,111A6' maple,%" brass rod, and scrap to makeone plane, 17oa"holes, drilled item130981 , $9.99 plus shipping, from Woodcraft at afterassembly addressabove. @ r /)- REAR CORE BLANK

t/q"hole, drilled after assembly Seethe WOOD PATTERNSoinsert for full-sizepatterns. @ Fingerrecess FRONTCORE BLANK

No round-over t/e"round-overs, t/a"brass rod outsideedge only 2sAa"long Writtenby Bill Krier withJames Downing ProjectDesign: Paul Hamler 170+"holes, drilled after assembly Photographs:Baldwin Photography lllustrations:Kim Downing;Lorna Johnson

wwrrv.wood ma g azi n e. c o m 43 ,t 1 F s I ') V(i

t--. U t,,#J*-***qrallu" ..: A 26.HOURFLIGHT I Keith'strip covered 7,586 air I miles,from home base in I Rtroenixto Dallas,Texas, SaoPaolo, Brazil, and, final- - .,!\it- i ly,Asuncion, Paraguay. I

eithStephens lives a woodworker's dream.First of all,as presidentof WoodworkersSource, in Phoenix, Arizona,he presidesover a candystore of tools, \ \ .."L accessories,finishes, and more than 100 exotic Asun*ion ** € woods,ranging from andiroba to zebrawood. Andif that isn't fun enough, he also travels a coupleof timesa yearto remoteforests through- out SouthAmerica in searchof prizelumber to addto his200,000-board-foot stock.

When Keith told us he was planninga trip to the YaguareteForesr ru easternParaguay last fall, we were intriguedut the prospectof learningmore aboutthe exotic wuod business.And to give you (and us) a flavor .,'t what things look like down in tropicalParaguay, we dispatchedphotographer Marcial Barni to documentKeith's trek. As you'll see,getting exoric woods from South American foreststo your wurkshopis a complex undertaking thatrequires ? glcardeal of dedicationand stamina.

It's a long way from day care to Paraguay Until 1984, Keittr headed a chain of child day-care centers ln YES.I'LL TAKE THAT ONE! the Southwest. But when Gerber bought out his operation, Abovenghf: Each tree is numbered,then he capitalized on .r long-standing interest in woodworking enteredinto a "log"book, along with its by developing a haldwood lumber and woodworking supply dimensionsand the number of cubic business.It didn r raKeKeith long to fall in love with exotic metersof lumberit willvield. wood species (thu'c harvested outside the United States). And today, Wouuworkers Source features the broadest NOTEXACTLY INTERSTATE 80 selection of exoLrc" in the United States. Keith stresses, Above:Tractors skid out logs along small though, that seltrrrg these woods from far-away places is roadscut into the jungle. After an area is "fun but not very profitable." He told us that in 1999, logged,these roads grow over in six exotics accountecifur only about 97o of sales. monthsto a year. Cortinuetl

WOODmagazine August 2000 45 the adventures of an

HOW'STHIS FOR A WHOPPEROF A LOG? Above:Keith takes a closelook at a pero- ba rosalog, which is rosered when freshly cut,sometimes streaked with purple,yel- low,or orange.

ALLIN A DAY'SWORK Right:After a treeis felled,workers removeits limbsand clear vines and debris.The trunk of thislapacho measured 18feet long.

ttHey Keith, Itve always wondered...tt Whenyou deal in unfamiliarwoods and take mysterious journeys, too,you attract all kindsof attentionfrom other woodworkers. Keithtells us that people seem fascinated by exoticwoods, and they'reforever asking him about his travels. Here are some of the mostfrequently asked questions, along with Keith's answers:

Q. How much do you pay for a board foot of lumber? Keith:I havepaid anywhere from $.50 to $20.00for kiln-dried, rough-surfaced,usually 414 stock. (l oncepaid $50.00 for some pinkivory, one of therarest woods in theworld.) Freight, unload- ing,and surfacing can add up to anotherdollar per board foot. We sellexotics for double our cost, with 20% discounts for 20 or moreboard feet.

46 WOOD magazine August 2000 '* r "i'(f .4"

HOTWHEELS Localloggers have hauled withoxcarts like this one,left for manycenturies. Keith sus- pectsthat these logs will serveas firewood,

WOODWORKING, PARAGUAYAN.STYLE Theback-to-basics open-air workshop,below, features a bandsaw,the wheels of which arewooden discs, and a jury- riggedlathe with an adjustabletailstock that accommodateswork up to about10 feet.

Q. How much wood do you buy at a time? Keith: Typicallya container load at a time,which figures out to about8,000 board feet.

Q. How do you get the wood back to the States? Keith: Thecontainers are trucked to the nearestseaport, then loadedon shipstraveling up the east or westcoasts of Southand NorthAmerica. lt costsabout $2,500 to shipa containerfrom Argentinaor Chilito theU.S., plus $1,000 per container for han- dlingfees. Inland freight is additional.

Q. How long doesit take a containerto get to Phoenix? Keith: I'vewaited as longas 2 yearsfor someof it, At best,it takes about1 20 days. Continued www.woodmagazine.com 47 the adventures of an

Q. Why use exotic woods? Keith: Becauseof theircolor and figure, they add flair and excitementto projects when used with more common woods.

Q. Can the vivid colots of exotic woods be maintained? Keith: Ina word,"N0." But you can lessen the damage caused bylight rays by using exterior finishes with UV blockers.

Q. How many hardwood species are there? Keith: About10,000. 0f these,3,000-4,000 provide usable lumber.And about 300 different hardwoods are in commonuse somewhereinthe world.

Q. Why are exotic woods so expensive? Keith:Several reasons. For example, they cost more to bringto market,they're scarce, some governments control pricing, and there'sa demandfor premium stock.

Q. Doesn't using exotic woods contribute to rainfor- est desfruction? Keith: That'sa complicatedquestion, but if thelumber is har- vestedusing sound forestry practices, there is negligibleeffect onthe rainforest..l

I'M SUHEGLAD WE TRADED IN THE OXENFOR THIS FORKLIFT Above:Once logs reach the main road,a forkliftscoops them up and loadsthem on a flatbedtruck. Cancharana Goncaio Alves Deepred to maroonwith Lightgolden brown to ICAN'TBELIEVE I BOUGHT purplishmarkings. reddishbrown with dark Lightweight,very easy to producing THEWHOLE LOAD streaks a work,finishes smoothly, beautifulstriped or mot- Abovebottam: Here, Keith takes a very stable. tledfigure. Hard and hands-onapproach to inspectinga heavy.Fine texture takes loadof exotic-woodtimber that has a glass-likefinish. justbeen harvested. "At theseprices, youwant to makesure you're getting thebest possible wood," Keith says. Guatamba Also knownas ivory- Olivebrown to blackish wood.Cream to lemon withexposure to sun, yellow.Generally straight oftenwith lighteror dark- grainwith fine, uniform er striping.Usually texture.An excellent straightgrained. Great turningwood. strengthand durability. Excellentfor decking and othertypes of out- door projects.

48 WOOD magazine August 2000 leff: lpelogs move throughthe Yaguarete sawmill.An operator in lhe boothcontrols the headrig.

Below:Keith checks the tallyon a bundleof ipe lumberthat's kiln'dried andready for shipping.

Do you want to talk exotic woods with Keith? If this article has gotten you excited about trying some exotic woods in your projects, here'show you can get in touchwith Keith. If you live in or nearPhoenix, first call, then drop by 5402 South 40th Street,Phoenix, Arizona 85040. Or call him at 8001423-2450. He's got a website,too: www.woodworkerssource.com

Two excellent sources of information about the characteristics of exotic-woodspecies Woodsof the WorldCD Rom WorldWoods ln Color Forordering information, byWilliam A.Lincoln. ISBN: 0941936201 Availablethrough Woodworkers Source or at Writtenby Larry Clayton and contactWoodworkers Source, orkey in Jim Hufnagalwith Keith Stephens www.forestworld.com bookstores. Photographs:Marcial Barni www.woodmagazine.com 49

ffi,fl1; tffiffiffi*i**,oo*., n*,,*,-

ffiffffi{,

Start with two edge-joinedlaminations It/q"-thick maple (commonly ZVz" strip (12 total), where dimen- how to feed called 8/4 stock), cut the lamination sionedon the Assemblingthe Top and care for strips (A, B, C) to the sizeslisted in the drawing. Note that for the end grain to BUTCHER. Bill of Materials and as shown on the face up, you'll need to cut these BLOCK Laminationsdrawing. grooves in the face grain. PROJECTS /') Position the strips for Panels 1 and J Cut the same-sizedgrooves on the {- 2 in the confisurationshown on the I mating surfaceof eachof the three Youcan apply the finish Laminations dr"awing.Number the 9" aprons and the 51/re"apron, where weused, or for a more pieces to keep them in the correct order dimensionedon the drawing. t/qxttAaxl93A" (we traditionalsealing of the when edge-joiningthem. Q Cut 16 splines Q Edge-join the piecesto form the LJ usedmasonite). unfinishedbutcher block, U two panels.Use a damp cloth to remove the excessglue. (To keep the Assemblethe liberallyapply several coats laminationsmanageable, we glued and laminated maple top ofwarmed mineral oil. just clamped half the piecesof each { Positionthe 2Vz"-wtdestrips in the Alloweach coat to soakin panel to start. Then, we glued the two I confisuration shown on the halves together to form each panel.) Assemblfng the Top drawing. Take forabout five minutes and Leave eachpanel clamped up overnight your time, as the pattern is crucial to wipeoff the excess. Repeat before machining. the good looks of the top. With the cor- theprocess until the A Scrapethe excessglue off both sur- rect layout determined,glue, spline, q''r- r,, ,,n., and clamp the piecesback together,as projectwill not absorb any * *,fril#tTl,,".trlli.trr"il.l;l"li,ffi:shown in Photo A. Use a framing morefinish. After that, a avoid creating high or low spots. squareto keep the endsperfectly flush; reoilingevery month or so You'11need a pair of flat laminations there's no extra to trim-off later. Wipe for a gap-freebutcher-block top. Mark off the excessglue without forcing it isnecessary to keep the the panels 1 and 2 for easein referring into the end grain. Also, remove any surfacessealed. to the drawings. glue from the groovethat wraps around It'sbest to docleanup f, Crosscutthe two panelsinto the the lamination. t ,l leneths dimensioned on the f) Dry-clamp the apronsto the center witha dampcloth and Laminitions drawing. You'll need L lamination to check the fit. Cut the warmwater immediately three apronsat 9" long each,one apron cornerpieces (D) to size. afteruse. 57/rc"long, and one piece 3tAo"longfor Q Glue, spline,and clamp the aprons the drawer front. (We used a cutoff u,l to the top center lamination, as Toreplenish a board with join shown in the April 1999 shown tn Photo B. Be careful to lotsof cutmarks, sand the to reducechip-out.) the aprons so the corners are just grooves 3/t" deep,centered touching at the inside corners for a surfacesmooth and re-oil g each face and end of each tight fit of the cornerpieces (D). asindicated above. Continued

Spread an even coat of glue on all mating surfaces, then glue and Using splines and glue, clamp the aprons to the clamp the top strips together, keeping the ends flush. top center lamination.

WOODmagazine August2000 51 Add a drawer LAMINATIONS to store your cutlery -,1Cut the drawer front and back (E), I sides(F), and bottom (G) to the sizeslisted in the Bill of Materialsand shown on the Drawer drawing. You'll use the 374e"-wide piece cut earlier from Panel2 for the drawer front. f) Using the drawing for reference, L cu a I " groove 3/e"deep along the outsidelength of the sides(F). Then,cut a 3/q"rabbet 3/s" deep acrossthe inside front andback endsof eachdrawer side. Q Dry-clamp the drawer together, t-l check for square,and drill the countersunkmounting holes. Don't forget to mark and drill the pair of PANEL1 mountingholes on the inside face of the drawer front (E) for attaching the drawer front laminationlater. Remove the clamps, glue the mating edges, then glue and screw the drawer back together,checking for square. PANEL2 A Cut the drawer guides(H) to size. T They should slide easilv in the groovesin the drawer sideswithtut slop. Laminatinq the leg blairks J Cut eight pieces of maple to I l%x3t/2x32" for the legs (I). Glue, face-to-face,two pieces to form the 1e/c'--i/ blanksfor eachof the four legs. ASSEMBLINGTHE TOP 1 f) Joint one laminatededge flush on I eachleg blank, and trim the oppo- 1/q"groove s/e"deep Endgrain site edge for a 3/s" finished width. on all four aprons, facingup 11/4"trom top edge 1/q"gloove Apron Then,joint or plane equal amountsof 7e"deep, panel the face-grainportion of each blank to Apron centered Apronfrom keep the joint line centeredon the panel panel blank. Next, crosscutthe endsof each t/+"grooves 7 blankfor a 31:/a"finished length. e/a"deep, centered Q Carefully draw diagonalson the L,l ends of each leg to locate the cen- terpoints.You'll need accuratecenter- points later when machiningthe legs round. Drill a tk+" pilot hole I r/q" deep L._,-11/a" ll at eachmarked centerpoint. Using a dado blade mountedto -T,{ ) your tablesaw.cut a 63/s"rabbet Vz" deep on two adjacentsides of each 3/s"-squareleg blank, where dimen- sionedon the Legs drawing. (We ?o+"pilot hole attacheda long piece of stock to our 1r/q"deep miter gauge for support when cutting Cutlinefor drawer Apronfrom fl s/q" t/2" the large rabbetsfrom the long leg ---=\21". panel o hole deep blanks, making sure the miter gauge e/q"hole /2" deep with a was squareto the blade.) Tez"shank hole Continued centeredinside #B x 3" F.H.wood screw

52 WOODmagazine August 2000 A- strips 1{c' 25/a' 36' B- strips lVq' 33/e' 36' EXPLODEDVIEW C- strips lVt' 21/au 36' Note: Towel bar can be mountedon eitherside. D corners llqo 13/q' 9', I r/q" ' ) lz" hole deeo 2" with a 7sz"shank hole E front& back Vt' 21/z' 14lqo M No round-over centeredinside F sides {t' 21/z' 20V+' M G bottom t2 15' 2Wq' P H guides l/2o 15/16" 21' -o 1" hole t/2" deep l- legs 3%" 33/eu 3174" LM /4" round-oversalong all outsideedges -1/2" dowel IOIIUELBAR T"- yq" lono J supports l;i sr/t" 6' lrli 2 #8 x 1tA"F.H. wood screw 7o+'pilot hole 11/2"deep \ K hanger 1"dia. 15' MD 1 #8 x 2" F.H. Note:Cut oarts labeled wilh an 'oversize. 7gz"shank hole. countersunk MaterialsKey: M-maple, P-plywood, LM-laminatedmaple, MD-maple dowel 1" hole%" deepwith a Supplies:%" lag screws 4" longwith Te" flat wash- %" holecentered inside Matingpilot hole in end ers(14), #8x1" flathead wood screws (12),#8x1th panelt/a" hole 17a"deep llatheadwood screws (16), #8x2" llathead wood screws(6), #8x3' flathead wood screws (14), 7e"washer 1/2"and3/c" birch dowel stock for plugs,clear finish. 7e"lag screw 4" long

No round-over

BACK RIGHT LEG

FRONT RIGHT LEG tZ" round-overalong bottomedge Seethe WOAD PATTERNSc;insert for full-sizepatterns. CUTTING DIAGRAM

\_>- \_>.

13/qx 51/zx 96" Maple 3/+x 51/zx 60" Maple

'ls/qx51/z x 96" Maple 13/ax71/qx 72" Maple (2 needed)

.Planeor resawto thickness listedin the BillofMaterials. 1s/ax71/a x 96" Maple

13/qx 51/zx 96" Maple 1/zx 24 x 24" plywood

www.woodmagazine.com 53 -? 1."i l=q_:$ ii,.i'"'*

Machiningthe four DRAWER legs to shape 7sz"shank hole, J Note: To shapethe legs,you can either countersunk turn themto shapeon a lathe or rout 2t/z themto shapeas describedbelow. 3/q"tabbel J Build the routingjig as shownon 7e" deep I the Routing Jig drawing. Clamp the groove jig to the router table as shown in Photo 1" ZOs/+"3/a" deep C. Fit your router with a 3/q"bowl bit with at least an overall bit length of lraoolr - #8 x11/q"F.H. 2s/s".(We usedan Amana #45984.) wood screw z/qxl" 7ee"shank hole. countersunk ) Cut two discs to shape, C- and screw to both ends of one of #8x 1"F.H. the legs (I). woodscrew Q Raisethe bit 1" abovethe surfaceof U,l the jig to make the first cut, as shown in the ShoulderRadius Routing Final assembling mating shank holes in the aprons. detail on the oppositepage. and,finishing Mount the legs to the top with :2" To start the routing process,place Using the dimensions on the lag screws4" long. -TA I the bottom end of the leg/disc I Assembling the Top drawing, care- Drill four countersunkmounting -tA against the right stopblock of the jig. fully mark the hole centerpointson holes through each drawer guide Rout the shoulder.which will be 103/s" each corner piece (D). Then, drill the (H), where shown on the Exploded from the top of the leg, as shown in the 32" holes Vz"deep where marked.Next, View drawing. Attach eachguide to the ShoulderRadius Routing detail. drill a sAz"shank hole through the inside face of the legs with screws. Lower the router bit so it rs 3A" center 3/q" t/q" fi of each hole. fi Rout round-overson all outside l-/ above the surfaceof the jig table, f) One at a time, dry-clamp the t ,/ edgesof the butcher block top, where shown on the Leg Routing detail. 1- corners(D) in place, and use the where shown on the Exploded View ft Clamp a V4"spacer to the right existing shank holes just drilled to drawing.Finish-sand the butcherblock L,/ stopblockas shown in Photo C and drill mating pilot holes in the aprons. table and drawer. the End of Leg detail. The spacerkeeps Now, glue pieces and screw the corner GScrew the laminateddrawer front to the bit from roughing up the shoulder in place. L,lthe drawerbox front (E). formed by the first cut in Step3. Q With the top upsidedown, use the J Using the full-size pattern on the J Remove stock from the shoulderto \,/ holes in the legs as guides to drill I WOOD PATTERNSoinsert, trans- I the bottom of the leg by sliding the leg from the right stopblock to the left stopblock,as shown rn Photo C. When doing this, the router bit will cut 3/e" into the bottom leg end disc. Continue moving the leg from right to left, removinga small amountof stock with each pass.Rotate the top of the leg toward you for each successivepass. After you have gone all the way around the leg, raise the bit Vq"and repeatthe processfor anotherseries ofcuts. Q Raise the bit to its final curting L/ depth of ltAo". The last cut should be very shallow (about rAe")to make the 2t/e"-diameterleg as smooth as pos- sible. Repeatthe processfor all four legs.Finish-sand all four legssmooth. (l Move to your drill press,and drill V tn. .ount..runk bolt holes in the top, flat surfacesof the legs. Note that the legs are mirrored right and Position the leg on the routing jig left and that there are no with the bottom end of the leg/disc against the lower holes right-hand stopblock. Then, rout the first past. in the front legs.

54 WOOD magazine August 2000 , 7e" holes ) fer the pattern,and bandsawthe towel ,+fN 2" bar supports(J) to shape.Drill a pair of mountingholes in eachsupport. (K) Q Cut the hangerrod to length L/ from 1" dowel stock.Glue and clamp the hangerrod betweenthe sup- ports.Finish-sand the hangerassembly. Next, dry-clampthe hangerassembly againstthe top, wheredimensioned on the ExplodedView drawing.Use the holes in the supports(J) as guidesto drill mating holes into one of the Note that there are aprons.Attach the towel bar assembly no lower7a" holes BACK in the front face of RIGHT to an apron. Crosscut Vz" dowel stock the front legs. to length,and plug the screwholes. LEG /1 Crosscut 7+"dowel stockto the \.,1 {/ appropriatelengths, and plug the lag bolt holesin the cornerpieces (D). Be careful when cutting the dowel plugs to length. You don't want them 313/e" FRONT too standto proud,as the end graincan RIGHT burn easily when you sandthe plugs LEG flush with the surfacesof the corner piecesand aprons.Repeat the process with /2" dowel stock to plug the holes in the supports(J). ROUTINGTHE LEGS -lAApply a clear finish. See the f L,/tint block on page 5l or apply SHOULDERRADIUS several coats of Behlens Salad ROUTINGDETAIL Bowl Finish.tF t/a"round-over - i'o;z';lo - Writtenby Marlen Kemmet top_oJ_feg. ProjectDesign: Dave Ashe Photographs:Hetherington Photography lllustrations:Roxanne LeMoine: Lorna Johnson z\ / 1 IIn ROUTINGJIG gl+x 5" disc T '/+"bowl bii E# Markcenterpoint before cutting shoulders- LEG ROUTING 7o+"pilot hole DETAIL 1th" deep 7+x 5" disc 7ez"shank hole, ---"o- countersunk -J -- r ,/ 3/q' #8x2" F.H.wood screw 7+'bowlbii ffi 3/qxG x 5T" plywood

Rightstopblock 1x6x6"stock

s/q"bowl bit raised 1" from surfaceof the jig

l/q x 6s/qx 57" plywood

(\ 3/q" Left stopblock1 x 6 x 6" stock

www.woodmagazine.com 55 mlII nlaturcs Sincetaking early retirement in 1995, PaulHamler has done a lot of downsizing of his own, turninghis handmadescale modelsof rareand antiquehand tools intoa smallfortune.

ust down the road from Georgia's monolithic Stone Mountain. the world's largestexposed piece of gran- ite, Paul Hamler removestiny, perfectly proportionedhand tools from a display case in his home. His Alabama-born drawl quickens,and he peppersthe con- versation with such phrases as: "There's an interestingstory behindthis onehere..." But Hamler's remarkablereproduc- tions are more than mere eye-candy. Each tool functions in every way like its full-size counterpart.To demon- strate,he draws an inch-long plane acrossthe edgeof a Popsiclestick, cre- ating a Tom Thumb-sizepile of long, curly shavings. There's money in them thar miniatures "That's the first miniature I made," he says of the Sanduskycoffin plane, shownon the oppositepage."I carveda tenon into a piece of boxwood, melted down a few silver coins, and poured them into the tenon to make an ingot." Using a drill and needlefiles, the neo- phyte toolmakershaped the body. After making and displaying his first miniaturesat an antique tool collectors show, word about the Lilliputian planes Toolmaker Paul Hamler casts brass for another miniature in his Sneltville,Georgia, spreadlike kudzu in the rainy season. shop. Shown in the foreground are his full-size and 7g-scalereproductions of a Stanley The first day of the show, he sold his #81 scraper. entire stock of 20 (at $450 apiece)and

56 WOODmagazine August 2000 ?-,Fawloadof linyJoglp l. Bailey#11 spokeshave,2. English-style slotting gauge,3. Sargent "Lady Bug"plane, 4. Stanley#35 transitional plane, 5. CharlesMiller 1872 Mod 50 plane,6. Tideybevel plane, 7. Sanduskycenter-wheel plough plane, 8. Wescott monkeywrench, 9. MarplesUltimatum brace, 10. Strattonbrothers level.

took ordersfor 20 more. "I kind of got the idea there might be a market out therefor this kind of thing," he grins. Indeedthere is. Last summer,Paul decidedto craft full-size and miniature reproductions,shown on page 59, of a one-of-a-kindMoseley plough plane. "This was a specialivory edition of John Moseley'swooden plough plane, hand-madefor the 1855World's Fair in Paris."The original was discovered in 1980 tucked away in the drawer of an abandonedworkbench at Record- Ridgewayin London, the ends of its arms sawedoff, apparentlyso it would fit in the drawer.The tool was put on To make the blade of his tiny Sandusky coffin plane, shown here on a Popsicle stick, displayat the company'smain office. Hamlercut and honed a small section of a hobby-knife blade. "This one employeegot fired from the companyand as he left, he stolethe The tool-nut doesn't cinatedwith spokeshaves,scrapers, and planefrom the display case,"the tool- fall far from the tree all." Then, Paul confesses,his fascina- makerintimates. "He took a coupleof The son of a carpenterand cabinetmak- tion with hand tools turned a corner. photosof it andwas negotiating to sell it er, Paul himself took a shining to the "It's like anythingyou collect. It to a collectorin America,but didn't trade,and as a teenbegan building bil- becomesa disease,"he chuckles. know what it was worth. So this fella liard tablesin the family garage."I "After I got all the comrnon stuff, I sentthe photosto a friend of mine for an didn't have much of a shop at the startedcollecting the exotics.And I appraisal.He told my friend, 'I pinched time," he confides."I'd build a table, couldn't afford $300 or $400 for a gen- thisplane, and it's hiddenin my attic.' then sell it and use the money to buy uinecollectible plow plane." "When my friend calledhim a couple more tools. It got to where the shop One day, while thumbingthrough a weekslater, he found out the guy had was so full of tools, I had to start set- book aboutreproduction tools. he stum- died. So to this day, the originaltool is ting up the pool tablesout there in the bledupon a sideprofile illustration of an probablystill in that attic."Today, Paul living room." Ultimatum brace,drawn in t/zscale. estimatesthat planewould sell for The tools he gatheredat that point "And I thought,well heck,I'll just make $80,000-$100,000.His five full-size were mostly out of necessity.While me one. So I usedthe drawing in the reproductionsfetched $ 12,000each; the building furniture for the home he book as a referenceand mademy first miniatures,$3,000. shareswith his wife Gloria, "I got fas- %-scalemodel." Continued

www.woodmagazine.com 57 miniatures

Today'stechnology; "Anything you can do to wood or posessome logisticalproblems. For yesterday's tools metal, you can do with this stuff," the example,for Paul's miniature levels To make the metal parts for his minia- toolmakermarvels. "You can mill it, (including a Davis inclinometercom- tures,Paul learnedthe art of investment sand it, saw it, drill it, tap it, carve it, plete with its 360o-rotatingvial), he (or "lost wax") casting,described in the and the detail is just phenomenal." couldn't just order the spirit vials from box below. He first tracesaround all of When he's satisfiedwith the function the manufacturer'sparts department. the individual parts of a full-size tool, and appearanceof the prototype,he "That was a hard one," he saysof his then scansthe tracingsinto his comput- disassemblesit andcasts the pieces. researchto make the vials, "because er, where he can quickly reduce them nobody would shareany information to 33Voof originalsize. A little help with me. Finally I found an older fella Using those scaled-downdrawings, from his friends who'd worked in a factory that made he builds a fully functional prototype As you might imagine,producing tools them." The trick, he learned,was to from a lightweight, high-tech plastic. much smallerthan their intendedsize heat a glass tube to just the right tem- peratureto draw the alcohol up into it, leavinga smallbubble. If the glasswas too hot. it would shatter."Then I had to figure how to seal the other end of the ca$t creations tube without it becominga blowtorch," he laughs. While thinking through the unique three-leafhinge of a Tidey bevel plane, Paul was stumpedas how to roll each barrel of each leaf consistently:They all had to align perfectly to acceptthe hinge pin. "Believe it or not, one night, we were watching 'Schindler'sList' on video, and there's a scenein a factory where they're making hinges." That scene showed one of the characters using a jig to curl the barrels,and with- in hours. Paul had made a miniature versionof thejig. Problemsolved. He likes playing with big tools, too A living room that once sportedPaul's handmadefurniture now overflows with full-size treadle scrollsaws,some of which he already has reproducedin Everymetal part in PaulHamler's a sprue,on the baseof a flask(shown miniature. His "power" tool collection reproductiontools beginsits lifeas a lowerright in the photo).Next, he spills over into the family's two-car blockof space-agepale yellow plastic placesthe cylindricalflaskonto its garage(which sheltersjust one vehicle: shown at upper left. After carvingthe baseand fills it with investment-a his Gold Wing motorcycle, still warm prototypepart (paint6dgrey in this materialsimilar to plasterof paris. from the 3,000-mile road trip he took photo),Hamler molds it usinghigh- Oncethe plasterhas cured,Paul with his son,Jesse). tech room-temperaturevulcanizing bakesit in an oven,melting and He points to a dusty lathe in the cor- "That (RTV)rubber. drainingthe wax part and sprue,and ner. one there's a movie star," he glows. In the opening sceneof the After carefullyseparating the rubber leavinga pedect,part-shaped void, 1999 TV movie "The Simple Life of moldfrom the prototypepaft, he intowhich he'll pour molten metalto Noah Dearborn," Sidney Poitier is pink makethe finishedpart (shown injectsit with modelingwax. in shown turning at the tool. Paul provid- Whenthe wax coolsand hardens,he hand).ls thereany lossof detail?"l've ed technical advice and more old tools hasa disposablepart (shownin the sprued-upa bumblebee,burned him to the film's producers. mold)identical to the original. out and cast him in gold.You can see Next to the lathe standsan 1890s- He then "spruesup", or suspends the veinsin his wings,so it's pretty vintage Barnes#4 treadle-powered the wax part with a stem of wax, called darnedgood," he grins. tablesaw."There's only four of these left in the countrv. The Smithsonian

58 WOODmagazine August2000 Museum'sgot one of them, I've got Toolsmade of two, and the fourth one is somewhere in Kansas,"he saysmatter-of-factly. Althoughevery tool Hamlerbuys, he Forthe Moseleyplanes, doesso with the intentionof making it Paulourchased certified in miniature,the questionbegs to be asked:What will he do with his grow- pre-banivory from ing collection?"l'd like to build me a museums,so no animals place up in the North Georgia moun- wereharmed in the tains,and make it into a museumfor old tools." It had betterbe be a pretty makingof thesetools big place.Or a very smallone. 'f& Gotta have one of Paul'stools? Because each reproduction tool he makesis a limited edi- tion, most of the tools shown in this story have alreadysold out. But you can get on Paul Hamler's mailing list of upcomingofferings by sendinga business-sizeself-addressed, stamped envelopeto Hamler Tools, 2632 Club Drive, Snellville,GA, 30078.Or, you can build a block planeof Hamler's design,starting on page41.lF Writtenby DaveCampbell Photographs:Emily Minton rc||ilrr Full-size c,7 reproduction"J,15:l *l' f&t*rrrilfre Paul's reproductions of the Moseley plough plane are made of solid ivory hmoks with sterling-silverinlay. for antiquetool collectors

f PatentedTransitional and Metallic Planes in I America1827-1927, byRoger K. Smith, 336 pages,North Village Publishing, 1981. $75, hardcover. 6 PatentedTransitional and Metallic Planes in l America-Vol.ll,byRoger K. Smith,400 pages,North Village Publishing, 1982. $90, hardcover.

QThe Aftof Finelools, by Sandor tJ Nagyszalanczy,240pages, TauntonPress, 1998. $37, hardcover.

1l A Guideto the Makersof AmericanWooden 't P/anes.3rd Edition. byEmil& Martyl Pollak,462 pages, AstragalPress, 1994. $35, softcover.

lAntique & CollectibleStanley Tools: Guide r,f to ldentity& Value,2ndEdition, by John Walter,885 pages, Tool Merchant, 1996, $45, hardcover.

www.woodmagazine.com 59 howstands I sffiil srufr Furnitureand other big projectshave a large enoughpresence to standon theirown, but how can you showoff smalleritems that tendto get lostvisually on a shelfor table- top?We've come up withfour easy-to-build answersyou can scaleto suityour handiwork.You needn't spend a bundleon materials,either. In fact, you probablycan make each from scrapslaying around your shop.

put it on a pedestal This one is simplicity itself. In fact, you'll likely spend more time waiting for the paint to dry than you will constructingthe pedestal. ProjectDesign: Robert Wineland

60 one curvaceous croorct7 Give a lift to long, thin objects,like this spoon madeby Frank Wright, with this cradlestand. To make it, all you need is a few minuteswith a scrollsawand router. ProjectDesign: Erv Roberts

fuFl-dangle You'll be a big hit with friendsand relatives when you presentone of thesecleverly designed,easy-to-build C-shaped stands to them. As you can see,the shapeof the standnot only is intriguing,it allowsyou to showcaseornaments to greatadvantage. ProjectDesign: Erv Roberts

i tlt

starcwaya 0tspL0))lo I Want to amazeeveryone with your creativi- ty and your woodworkingskills? Then stagea seriesof small projectson this five- tier stand.It's one of the niftiestscrapwood projectswe've seenin a long while. ProjectDesign: Eru Roberts Corttitruecl

61 -t Showstands.for

'p€rtestCIl7ttt f t frott ct a

1. Cut the top and feetlrom 3/q" stock. EXPLOD""I4 2. Rout dadoesfor the feet, and glue themin place.

3. Sand,prime, and paint. (We sprayedon severalcoats of blackenamel.) After the finish dries, .TV glue four 7e"-diameterfelt discsto the bottomof the feet.

0I'l€ {'tfi-tYlce0Lts crfidle

EXPLODEDVIEW

1. Scrollsawthe cradletrom 3/q"stock, usingthe full-sizepattern to lay it outand guide your cutting. 2. Scrollsawnotches at both ends of the stock, as shown in the ExplodedView drawing. 3. For the base,cut a 2x3" oval, and routa covearound its top edge. 4. Sand the pieces,glue the cradleto the base,and finishwith paintor clearsealer.

62 WOODmagazine August 2000 fun-dangle- 1. Ripthree 1Aax3/q" strips.(We used maplefor the outer laminatesand wal- nutfor the center.) 2. Bendthe stripsand clampthem together usingwhite glue. 3. Cut a 1/'ra"nolch l/2" long in one end of the laminatedarch. Cuta 4. Make the feet trom 3/+"dowels, and 3/q" dado dadothem as dimensionedon the Side s/0"deep Viewdrawing. in each foot. 5. Sand and finishthe parts,then glue on the feet.

Staffwfi, -y^' affipray,. I

1. Transferthe full-sizepattern at leftto the end of a piece of 2x2x20" stock. (We usedbirch). 2. Bevel-ripthe blank. 3. Crosscutthe blankto the lengthsshown EXPLODEDVIEW in the ExplodedView drawing. 4. Glue the "steps"together, and sand them into a smootharc. 5. We paintedthe steps blackand protect- ed the restwith clearfinish. Jl

NOTE:Turnings and carvings are not availableas projects www.woodmagazine.com 63 e lecently went shopping with one rnissionin rnind: Buv everv clear finish with the word "oil" in its title. Our buying spree netted the l3 prod- r-rctssl-rown here. But as we discovered. these "oil" finishes were actually four dil'l'erenttypes of coatings. It turns out thattsome of the finishes are pLlreoils. one is modified oil, some are oil/varnish blends, and some are wipin-uvarnishes. And as you'll see,we fbund a lot of diffbrencein how they per- fbnn. Here'sa quick look at each: ycu oPure What r-reedtc krrow oil-strictlv "wefor the patient woodfinishen fbund two pllre tun-eoils: Hope's l00o/c Tuns Oil and Behlen Master Pure Tung Oil. True to their names. theseproducts contain only raw oil from the nLlts of tun-q trees. These oils take many Pure days to dry cornpletely, oil finishes so we rarelyuse them. . Modified oil-added metals Speed drying. The only producrwe uncoveredin this categorywzrs Klean- Strip BoiledLinseed Oil. Despiteits

How we tell one type of oil finish from another Here'sa simpleway to tell onetype of To identify each of 13 "oil" finishfrom another.In a 60-80"F different oil finishes by room,place a smallpuddle of finishon type, we poured a pud- dle of each one onto a a nonporoussurface, such as glass. sheetof glass. Wait two days. #do As shownbelow, a wiping varnish will be dry, smooth.and hard.An oil/varnishblend will be wrinkly and dried, but soft enou_ehto scratchwith your fingernail.Modified oils will be

-{ _"__< ./

{1 On this sheet of glass we applied small puddles of (from left): wiping varnish, oil/varnish blend, modified oil, and pure oil. (We turned the pane upright to show that the pure oil runs.)

64 WOOD magazine August 2000 name,this product is not (usea damptowel or a mild soapif the heatedto the point of boil- dirt provesstubborn) and wipe on some ing. Instead,the word new oil. Justkeep in mind that oil/var- Modified "boiled" meansthat the lin- nish finishesrequire a porous surface, oilfinish seedoil, which comesfrom so don't applythem over film-forming the seedsof the flax plant, is modified finishes. with the additionof drying metals. Oil/Varnishblends Without thesemetals, raw linseedoil oWiping varnishes-for proj- takesweeks or monthsto dry. atenessfor exterior surfaces,such as ectsthat needprotectior. These Although a thin applicationof boiled teak boat decks.The two Watco prod- productsmay have "oil" in their titles, linseedoil will dry in abouta day, the ucts are similar in composition,but the but they are mostly varnish,and they resultingfinish is quite soft, so we "teak" versioncontains a fungicide.) perform like varnish.Included in this don't recommendit. You can add Becausewe find much more use in categoryare Formby's Traditional boiledlinseed oil to oil-basedpaints to the WOODo magazineshop for this Tung Oil Finish,Hope's Tung Oil improveflow andlessen brush drag. type of oil finish thanany of the others, Varnish,and McCloskeyTung Oil. we'll devotethe lion's shareof this They are thinnedto the point that you oOillVarnish blends-iust articleto oil/varnishblends. These can wipe them on, but they dry faster right for a natursl-wood[ook. productsgive a rich, natural,and than an oil/varnishblend. Unlike oil By far the largestgroup of oil finishes "uncoated" look and feel to wood finishes,with which you must wipe availabletoday, these products contain becausethey penetratethe surface.But away all excessfinish, you don't mostly linseedand tung oils modified they provide little in the way of a pro- needto wipe away excessvarnish with drying metals,some solvents, and tective film, so we reservethem for unlessit runs. varnish.Products in this category lightly handledprojects, such as clocks, You can build a protective include Deft Danish Oil Finish, nonfunctionalturned vessels, models, finish with theseproducts, but GeneralFinishes Danish Oil, Minwax and light-usefurniture. We don't apply it will requiremore applica- Antique Oil Finish, Minwax Tung Oil them to tabletops,chairs, shelves, tions than if you used a Finish,Olympic Antique Oil Finish, floors,and other hard-use surfaces. brushed-onvarnish. These Watco Danish Oil Finish, and Watco Comparedto film-forming finishes, productsprovide an easy,but Teak Oil Finish.(So called"teak" oils such as shellac,polyurethane, varnish- time-consuming,way to build do not come from teak trees.This title es,or lacquer,oils areeasy to renewor a protectivecoating, so we Wiping only refers to the products' appropri- repair. You simply clean the surface rarelyuse them in our shop. varnishes

wrinkly and extremely soft. Pure oils application,and wipe,away the bleed- .Apply two or three coats,depending will still be liquid. backuntil it stops. on whether the wood continuesto . Allow the oil to dry overnight. Some absorb the oil. Applying more coats is Some tips for using dust may have floated out of the pores counterproductivebecause none of it oil/varnish blends or settled on the surface.Knock down will soak in, and you will wipe off Although oil/varnish blends are a thesedust nibs with 320-grit sandpaper everythingyou've applied. breezeto apply, they can create prob- or an ultra-fine woven-plasticpad. lems for the unsuspectingfinisher. If, despite your best efforts, you get A few words about using Here's how we successfullyuse them bleed-backscabs, you usually can oil finishes safely in the WOOD magazineshop. eliminate them by "wet-sanding" the One of the beautiesof oil finishes is 'Oil finishes do not hide sanding surfacewith more oil and an ultra-fine that you only needa clean rag to apply scratcheswell. So sandthe project sur- woven-plasticpad. If the scabsharden them. But be warned that you must face to 320-grit before applying oil. to the point where that doesn't work, handle those rags with care after use. 'Flood the first coat onto the project so you'll haveto strip the finish. To prevent spontaneouscombustion as much of it soaksin as possible. (oils create lots of heat when exposed Check the surface after a few minutes to oxygen),you needto sealthe rags in and reapplythe oil to end grain or other a water-filled metal can, or dry them areasthat have soakedup all of the oil. properly. You can hang them on a line Wipe off all excessoil. or lay them out on concrete;just make .Oil finishes tend to bleed back out of sure their surfacesdon't overlap. porouswoods, such as red oak (seethe That's wherethe heatbuilds up.al photo at right). This bleedbackforms Oil/varnish blends bleed back out of the little puddlesthat you wipe away before pores of such woods as red oak. You Writtenby Bill Krier with Jan Hale Svec they harden and form scabs.Check an need to wipe away these tiny puddles Photographs:Baldwin Photography oiled surfaceeverv 15 minutes after before they dry.

www.wogdmagazine.com 65 of thiscanteen-style vase. And turning it's easy, evenwith that terrific mock-inldd face.

Select striking Q Cut the veneer to a squareabout stock to start \) V4" smaller all around than the { Plane or sand the front blank. If you have a wavy piece of I face of a 2x10x10" turn- veneer, flatten it, following the stepsin ing block flat and smooth. the sidebar "Don't Let a Few Wrinkles Ensure that the back face is Worry You", below. flat and parallel to the front. Wood grain gives this vasevisual Glue veneer to the blank impact, so highly figured stock or a { Sand some scrapsof veneerto dust, burl would be a good choice. I catchingthe dust on a clean sheetof ! Select a piece of figured or burl paper. A sanding block with 80- or d- veneer for the circular highlight on 100-grit paper will do the trick. front. (The vase shown in the photo /-) Mix enough epoxy to cover the below combinesbuckeye burl veneer (- back of the veneer. Slow-setting and a big leaf mapleblank.) adhesive.often labeled as two-ton

aoolvinq ueneer don't let a few wrinklesworry you Highlyfigured and burlveneers-the mostdesirable choices for accenting yourvase blank-rarely come to you flat.The unruly grain that givessuch woodits beaugalso leads to internal stressesthat cause wrinkling and warpingas the veneerdries. Before youcan glue one of theseveneers to a flat surface;you must press out the wrinkleswithout crumbling the veneer.Here's how.

WOODmagazine August2000 epoxy, works better in this application 3-4" lathe faceplateand anotherthat's into the existing surfaces at the guide- than the five-minute variety; it will the largestyou can fit on the blank. lines. The thin veneer doesn't allow allow you longer working time. {) Bandsaw around the largest circle, much leeway for cutting into the front (- Q Stir enough veneer sanding dust protecting the veneered face with of the vase. U into the epoxy give to it the masking tape. Q Carefully trim the veneer to a veneer'scolor. Spreadthe rnix on back Q Bandsaw a wasteblockthe same l) 6%"-diametercircle. The point of a of the veneer. \J diameter as your lathe faceplate skew makes the cut neatly, asihown in A Center the veneer on the front sur- from 1" scrapwood. Glue it to the back Photo 2. Cut in deeply enough to create a face of the turning blank. Cover it of the blank, inside the small circle. a shallow V-groove around the veneer. with waxed paper; then lay a scrap- Screw the faceplate to the waste- Move outward about 3/ra",and cut -TA wood caul on top, and clamp. Allow the block. Mount the faceplate and another V-groove. epoxy to cure overnight. blank on the lathe. fl Sand the curved edge with progres- After unclamping, you'll fi find that fi True the edge of the blank with a V sively finer grits from 100'-220.At r*,/ epoxy has squeezedthrough holes t,l bowl gouge, and turn the diameter this point, you can finish the front and and cracks in the veneer. If any spots down to slightly over the finished diam- edge with commercial French polish remain open, mix some more epoxy and eterof \Vq". or homemade shellac/oil polish. (See sandingdust, and fill them. ft Draw a referenceline centeredon WOOD@magazine, issue 120, page 8, ft Scrape off the excess epoxy and \J the edge. You can do this by hold- for details on thesefinishes.) \J smooth the veneer with a cabinet ing a pencil against the blank as it If you finish the front and edge now, scraper, as shown in Photo 1 on the spins. Also draw a referenceline 1" in you'll have to touch up the finish next page. Then lightly block-sandthe from the edge on each face. later, after you bore the vial hole and veneer with 220-grit sandpaper,taking 7 With a gouge, round the edge flatten part of the edge to form the carenot to cut throughit. I between the centerline and both base. If you prefer, you can wait and faces. (You can photocopy the Radius finish the completed vase later. Shape the edge Guide on page 69, glue the copy to and the front light cardboard, and cut it out to gauge Turn it around { Mark the center on back of the the curves.) Form a symmetrical curve to turn the back I veneeredblank. At the center, draw from the back face around the edge J Dismount the turning, and remove one circle the same diameter as vour onto the front face, blending smoothly I the faceplatefrom the wasteblock. Continued

J Cut a pair of platens-pieces of glued immediately onto a | flat, smooth tA" -thick scrapwood flat surface.) slightly larger than the veneer. Q Stack severallayers of Plywood, particleboard, or MDF \J clean, absorbentpaper would work well. on one platen. You could t^) Soak the veneer (more than one use kraft paper, paper tow- {- piece, if you wish) in hot water els, or unprinted newsprint. until it's pliable. You could batheit in Don't put printed newspaper a commercial veneer-flattening solu- pages in contact with the tion, too, or add some glycerine to the wet veneer,however. water if you wish. (Hot water worked A Lay the wet veneer on fine for our small piece,destined to be a the paper stack, and cover it with more layers of paper, as shown in the photo at left. If you're flattening several pieces of veneer, build a ft Unclamp the stack four hours Dagwood sandwich of alternating \J later, and replace the paper with paper and veneer layers, finishing up dry sheets.Reclamp. Changethe paper with a paper layer. at four-hour intervals until the veneer fi Place the other platen atop the dries. Leave the stack clamped \,1 stack, and clamp the two platens overnight with dry paper. Store the together to flatten the sandwich, as veneer clamped between the platens shown in the photo above right. with dry paper.

www.woodmagazine.com 67 fipl

Scrape the veneer smooth after Define the veneer panel on front as Insertthe turning into a shop-made allowingthe glue to dry. That's olive you shapethe edge.This turning jam chuck for parting off the waste ash burl veneer on this Honduras features beautiful redwood burl block and completingthe back of the mahoganyblank. veneeron a big leaf mapleburl blank. flask.

jam ! Construct a chuck, like the one other, 180o away, in the area that will To bore the hole straight and true, 4. shown in the Jam Chuck drawing. be cut away to form the flat base.Drive chuck a 1" Forstner bit in your drill To build the chuck, bandsaw three the screws only Va"or less into the press.Position a fence on the drill- l0Vz" -diameter discs from z/+"-thick turning itself. press table to center the edge of the particleboard or plywood. On one disc, ,rl Install a rotating cone center in the turning under the bit. Then move the draw a centered circle the diameter of A tailstock, and slide it up against turning along the fence to aim the cen- the lathe faceplate; on the other two, the wasteblock for support. Then, part ter point of the bit at the center of the lay out centered73/c" circles. off the wasteblock.. vase. Clamp the vase to the fence, and Cut out the large center circles to ( Take a light clean-up cut acrossthe bore the hole. make two rings. It's okay to bandsaw t .l back of the vase, as needed.Finish- / Sand a chamfer around the hole, into the rings from the edge. Stack and sandthe back ofthe vase.Ifyou put on al and sand the flat bottom as neces- glue the two rings to the solid disc, the a lathe-applied finish earlier, finish the sary. If you've been finishing the vase faceplate outline on the opposite face. back the sameway. as you go, finish the bottom and the Offset the bandsawentry cuts. Bore the chamfered opening on top. Otherwise, finger holes where shown. Flatten the base; apply a clear finish, such as spray lac- Attach the faceplate to the back, and bore a hole quer, overall. After the finish dries, mount the assembly on the lathe. True { Build a scrapwoodcutoff jig, shown slide a vase vial into the hole to com- the outside edge. With the bowt gouge, I in the drawing on the oppositepage. plete the vase.i turn the inside to accept the vase turn- f) Place the jig against your table- ing snugly {- saw's fence: then slide the fence Buying guide jam 3/s" Q Place the turning in the chuck, over so the blaie will cut off the Vase vials, burl blanks. Glass vial, t-.J as shown in Photo 3. Ensure that edge of the turning where shown. t/ax33/q",with lipped rim, set of three, the face of the turning lies flat against Elevate the blade to saw through the jig $9.25ppd. in U.S. Additional vials, the back face inside the chuck. and the vase. Then, with the vase on $1.50each. Send check or money order To secure the turning to the chuck, the jig, make the cut. payable to: drive two screws into the edge of the Q Bore a l" hole 4" deep,centered on Warren Vienneau to Turned Works. chuck as setscrews,locating them so u) the edge opposite the flat. The vial Warren Vienneau, 146 Ridge Ave., they'll contact the turning at the center fits into this hole; the completed vase Pittsfield,MA 01201. 'of the edge. Position one screw where looks best when the hole's centerline is Call Warren at 4131443-2907 it will contact the turning at the point perpendicularto the base and runs right for price and availability of where the vial hole will be bored: the through the vase center. burl blanks and veneers.

68 WOOD magazine August 2000 lcx/+xBth'

1/tx9 x 9" base

Tablesaw

EXPLODEDVIEW

7/a'-dia. glass vial

Figuredturning bl 17a"thick

RADIUSGUIDE

ProjectDesign: Turned Works, Warren Vienneau lllustrations:Roxanne LeMoine; Loma Johnson Photographs:Hetherington fhotography

www.woodmagazine.com 69

L*

First, bring up the rear (legsl { Start by making photocopiesof the metal or hardboardto trace the arc I patternsfor the rearlegs (A) andthe along its face,Photo C on puge XX. A terrificwood for cs4ter supports(B). You',ll find the Bandsaw and sand to the line. outdoor-proiects originals in the WOOD PATTERNS' Finally, drill countersunkholes for Builderts rt. Use spray adhesiveto attach the eightmounting screws. Tips to appropriate lengths of lt,/2"- Q Again usingthe PartsView draw- cedar. \,t ing as a guide,lay out the contours Fora strongerfinished proj- Parts A and B both sharethe same for the rear crossmember(F) and the ect,choose wider and longer curved top profile and nose shape. seatback support(G) on 2x6 stock. boardsthan you need so Make the cuts for the front seat slat Then cut and sandthe curves.Drill 1:.;*,;r r you can workaraund the notch before you saw the curved con- holes for the carriagebolts and wood knotsthat are typicalof tours on thesepieces. To do this, stand screwsin the rear crossmember,but lhis specr'es. eachpiece on end, and use a miter leavethe seat back support intact. gauge and backing board to make the Next. you'll needa pair of end -tA 4/4cedar usually comes initial cut,Photo A. Use the rip fenceto wedges(H) and one centerwedge 7/o'thick, whictt gives you a (I) help guide this cut. Move the rip fence that mount on the seatback support chanceto cleanup the for the secondcut and adjust the (seethe Partsdrawing). Use a bandsaw boardsto 3/qo and remave blade to 90o,Photo B. to cut the wedgesto shape,then glue Next, use a bandsawor jigsaw to themin place. surfacemars. li,{:., \ Q 4..t... U cut the curvedcontours in partsA To locateand drill the bolt holesin w" E Becausethis weather-tough +;4/. ,"'a&' and B. Cut in the wastearea, then sand r-,/ the seatback support,we used a to the outline on eachpiece. Finally, simpleguide block that hooksover the woodis fairtytightweight as drill the 3/s"holes for the carriasebolts. end wedges.(See the Drilling the softwaadsgo, usingit results Armrest Hole detail and Guide Block in a projectthat is easyto drawingin the insert.) movearound. (J) ft Cut the tableframe uprights and L,l table frame cross rails (K) for Andbecause it is soft,be the centertable, and drill the bolt carefulthatyou don't over- and screwholes. (See the Center tightenscrews, you can bury Table Exploded View and Parts theheads in thewaod easily. View drawings.) Cut the two cleats(L), drill the Cltuck lfedlund. J WOODmagazine's I screwholes, and screwthem to the Project Builder front rail inside face of the front rail. (Seethe piece of SectionView drawing.)

Continuecl

the pattern adhered to the leg blanks, cut the To make the second cut, push the workpiece through the ends first. Note support fence and clamp used. set up as shown. Stop the saw and remove the waste.

magazine August2000 71 settee ARMREST ASSEMBLY DETAIL Spacesplats s/ro" apart. Gluewedqe 5/gz"shank holes. utoct< SETTEE FRAME countersunk @li EXPLODEDVIEW placebefore 3/a"hole. #8 x 1t/2"deck screws drilling

1tle"counterbore

3/ex 31/2"carriage bolt

7/at" pilol hole s/a"deep

#B x 3" deck 541/z' \ #8x 2" deck screw t\ Dll 3/ax 4" tl carriage bolts lca\*s\, 7e" holes

s/a"tlal washer 7e"nut #8x 3" deck screws I I \

7e"nuts and flat washers -\ \ i/." hole l #8x11/2" \ deckscrew 3/ax 31/2"carriaoe bolt s/sz"hole, countersunk on backside

A- rearlegs 1t/z' sqd' o- tableframe nontor " 1Y2' 23/q' B* centersupports 1Y2' 51/a' 23' C 2 crossrails " seatslals 7/su 7/a' C. frontlegs 11/z' 31/z' 19Vt' C L cleats 19' C V rearseat slats Vt' 51/t' 22' C guc D* armrestsupports l\z' 3' M armrests 11/te" 51/2' 28' C W loonblank t/z' E- frontrail 1Y2' 5' 55" C N tablefront slat Ttu 35/e' 9Y4' C Note:Parts labeled with an - getpainted, le€lf O tabletopslat 11/ta" 35/a' 27" C '5* 1Y2' SVz' C crossmember 55' P tabletooslats 11/ta" 35/a' 267/a' C MaterialKey: C-cedar. n* Sg?tback Q seatback solats Vqu 47Aa"261/q" C Suppfies:1t/q" deck screws (2),11/!' deck screws (62), u 1lz' 51/zu611/z' C 2" deckscrews (32), 3" deckscrews (24), V8x31/2" cafiiage support R seatback solats {c' 4sha"2511Aau C H- endwedges 1Y2^ 31/z' 3V2" C boltswith nuts and flat washers (6), %x4' caniage bolts with S seatback solats Vcu 4u 24Ys" C nutsand flat washers (2), paint, water repellent finish. l- centerwedge 1Y2' 31/2' 11a/e' C T frontseat slat 1r/z' 31/z' 55" C ,- tableframe " upriqhts 11/z' 31/2' 121/2' C

72 WOODmagazine August 2000 -l

EXPLODEDVIEW #8 x 11/q"deck screw (2 requiredto attachloon)

#8 x 1't/z"deck screws

7sz"shank hole, countersunk

t/a"round-over alongtop and sides

No round-overon bottomedge

Seethe WOOD PATTERNSToinsert for parts view and full-sizepatterns.

CUTTING DIAGRAM .Planeor resawto thicknesslisted in the Billof Materials.

11/2x71/qx72"Cedar 11Aax71/q x72" Cedar

1t/zxSt/zx 96" Cedar 11Aax51/2x96"Cedar

3/qx91/qx 96" Cedar 11/zx 91/qx72" Cedar

3/qx 91/+x 96" Cedar 11/zx71/e x72" Cedar

1t/zx7thx72" Cedar 3/qx91/+ x 96" Cedar www.woodmagazine.com 73 settee

Note: Before proceeding any further, apply whateverpaint, stain, or finish you've chosenfor theframe components. (See the Bill of Materials for information on which parts get painted.) For our project we used a solid-color latex stain from Olympic. It's designedfor use on decks,so it will be plenty durablefor this furniture project. (We chose a color called Faulkland,and applied two coats.) Slats and splats-easier to make than to say I While the finish on the frame compo- I nents is drying, start cutting the other parts-armrests (M); table front slats(N); the tabletopslats (O, P); the seatback splats(Q, R, S); and the front, center,and rear seat slats (T, U, V). (See the Parts View drawingas well as the dimensionsin the Bill of Materials.) /-) The profile of the front seat slat (T) I requires some creative work on the tablesaw.(See the Front SeatSlat Profile- Cutting Sequencebelow.) Then, use a With end and center blocks temporarily Clamp temporary support legs at block plane to round over the ridges,fol- fastened to the front rail with screws, each end of the frame to position the lowed by sandpaperto smooth the final bend a thin metal or hardboard strip to seat back support and connecting surfaceto shape. trace the arc. chair parts.

FRONTSEAT SLAT PROFILE. CUTTINGSEQUENCE

74 WOODmagazine August 2000 Apply finish to all of the unpainted Q ft Cut a pair of temporary support centerout. Place%0" shimsin between r-/ parts after they are cut to size, L,l legs (each I93A" long) from a 2x6, the splats,and fasten the splatswith sanded,and drilled for screws. and two short spacerblocks each3Vq" #8x1Vz"deck screws.When they're Note: We used Wolman Raincoat@ wide. Clamp the spacerblocks and sup- secured,you can remove the clamps Water Repellent (in Cedartone)for port legs to the rear legs; then clamp and support boards,including the tem- added protection for theseparts. It the seat back support to the temporary porary supportlegs. mimics a clear finish, but actually adds supportlegs, flush at the top, photo D. Fastenthe front (full-lengrh) seat a more unifurm color. 1\ This will position the rail correctly T slat (T), driving 2" screwsup while you install the armrests,the table throughthe cleats(L). Assemble a solid slats,and the seatsplats. Next, lower fi arrangethe center seat slats frame U (U) and the rear seatslats (V) on Start the frame J assemblyby bolting Installthe the rear legs and center supports.After I the rearlegs (A) to rhefront legs(C). seat components positioningthe slatsfor uniform spac- f) Use #8x3" deck screwsto fasten J Then, working from the bottom side ing betweenthem (about 3/a"),fasten L the front rail (E) and the rear cross- I of the seatback support,drill up them with #8xl Vz" deck screws.Now, member(F) to the leg 3/s" assemblies. through the holes you drilled earlier do one final check to make sure all the Bolt and screw the Q centersupports and on through the armrests.Secure bolts are tight, and the setteewill be (B) place \,, in as shown in the Settee each armrest with a t/sx3Vz"carriage readyfor your patio or deck. FrameExploded View. bolt. (See the SetteeFrame Exploded If you'd like to add the loon to the Attach the cleats (L) to the inside View -tA drawing.)Fasten the armreststo front face of the center table, see the face of the front rail, flush with the the front legs with 2" deck screws. notes on the full-size patternin the top edge.(See Section View drawing.) p) Q Attach the tableropslats (O, with WOOD PATTERNS@insert. Cenrerand Assemble f, the centertable frame E- 2" deck screws.Use r/+"shims to fastenthe loon to the center table front \,/ (J, K;, and make sure it fits in spacethese boards. Vz" above (T) with #8xlVq" deck betweenthe center supports(B). Then, Q Next. clamp a scrapboard to the screwsdriven from behind.JF fastenthe table front slats (N), and bolt \,1 undersideof the rear crossmember the unit in place. We used 3/sx3Vz"car- (F), and arrangethe seatback splats Projectdesign: James Downing riagebolts. Photographs:Baldwin Photography (Q, R, S) in place, working from the lllustrations:Kim Downing;Lorna Johnson

CENTER TABLE EXPLODEDVIEW #8 x2"deckscrew ------I 9lge wedgeblock ( I )to seat back 7se"shank hole, sU'pport@before countersunk screwtngcenter Space.boards1/a" apart. tabletopboards in place.

7/aq"pilol hole 1 " deep

#8 x 2" deck screws V; Spaceboards t/q" apafl.

3/8"nut and d{td flat washer 3/ex 31/2"carriage bolt

Centersupports@are screwedinto frame at this point. vvww.woodma gazi ne. co m 75

/-1ver the years, many WOODA magazine readers have told us that U they'd like to saw their own stock. So we rounded up five sawmills from their manufacturers and ran them through their pacesto learn firsthand just what's all involved in operating one.

Gan a sawmill pay ott? What to consider A quick look at the Buying a transportablesawmill before buying less-expensivesawmills requiresa sizablefinancial investment Becausesawmills cost a bunch,you'll Of the five sawmills that we tested, and time commitment.Three of the need to dispensewith a few major three were bandsawmills (Norwood machineswe testedcarried price tags issuesbefore you startshopping. LumbermateMark 4, TimberKing around$5.000: the othertwo weredou- o Do you haveenough access to trees? 1200, and Wood-Mizer LTl5) and ble that. If you don't have a woodlot to supply carried prices in the $5,000 range. By Despitethese prices, we believethat a you with logs, can you find enough the time those three units were sawmill can be a profitabletool. Our sources?Check tree servicesand con- blocked and leveled,the working quick calculationsuggests that two structioncompanies that clear land. height from ground to bed averaged modestdays of customsawing per r Fortunately,these sawmills are about 9". We quickly found that the month(1,600 board feet x .20 per transportable.You can take them to lower a mill sits to the ground,the bet- board foot = $320) shouldcover the the logging site. But do you have a ter, especiallyif you're loading logs averagemonthly paymentsover the enough spaceto do sawing on your without help from other equipment. length of a loan on one of the lower- property if need be? And what about With the above three sawmills (all pricedmachines. noiseordinances and neighbors? bandsawmills), we loaded and turned Beingable to obtainwood speciesnot o Do you have secureindoor storage the logs manually using cant hooks. commonly availabledraws many availablefor the machine?You'll need Loading ramps come standardon the woodworkersinto the sawyerrole. to protect it from foul weather, theft, TimberKing, optional on the Wood- Ownin-sa mill also can help you get andvandalism. Mizer, and aren't availableat all for consistentlybetter grades of wood for o Where will you stack and storethe the Norwood. furnitureand other projects. And with a wood? You can air-dry your green If you plan to move your mill from mill, you'll find yourselfcutting logs boardsoutside, but after that the mate- site to site, you'll want a transport for quartersawnand riftsawn boards rial must be storedproperly-pre- package.TimberKing and Norwood that you can't get elsewhereexcept at ferrably indoors-to keep it in top offer optional trailer packages.All high cost.Besides all thoserewards, condition.And thatbecomes more of a three of the less-costlybandsaw mills it's flat-outfun! factorif you havewood kiln-dried. offer optional bed extensionsthat add additionallength for sawinglong logs. The mills differ in the size of logs bandsaw AnatOmV Of a typical bandsaw mill they can saw. The specificationschart I for With the horizontalbandsaw at on page 82 shows thesevalues one end of the frame, the standardconfigurations. In some sawyerrolls the log up the load- instancesyou can saw a log larger ing rampsand onto the deck than the stateddiameter by repeatedly usinga cant hook or winch.He sawingand turningit. We successfully then centersthe log in the saw's worked a 40"-diameteroak log on a placing throatwidth while it firm- machinewith a 32" statedcapacity. th.roat ly againstthe log rest. Finally,he width uojuit. the heighiof the bladeand makesthe first cut. movinothe Two pricey machines saw alongthe lengthof the log. We alsotested two mills in the $10.000 price range-the Wood-Mrzer LT25 and the LucasModel 6. While four of our test units were bandsawmills, the Lucasmill employeda circularsaw blade.And with its circularblade, the Lucascan startcutting dimensioned boardsout of a log in just two passes. With a bandsawmill, you can only do this after you have squaredthe log into a cantby slabbingoff the bark or wane, as the operatoris doing in the photo oppositepage.

Continued

WOOD magazine August 200tl 77 -l

A closerlook-the sawnnills'pros and cons NorwoodLumbermate Mark 4 This bandsawmill has featuresthe other two mills don't that really made it fun to operate.We liked the torsion spring/cablesystem for lowering and raising the saw head.It was faster and easierto operatethan the winch- es used on the other machines.(See inset left.) You've probablyheard pros and cons about having to push and pull the blade through the log. Basedon our experiencewith the Norwood, we found this fasterthan the winch sys- tems employedby the other bandsaw mills. On the Norwood, all the necessary controls are located on the same side, making them easy to reach and operate. We also appreciatedthat the sawdustand the engineexhaust exits the sideopposite the operatorand is directedaway. lnsef. A torsion spring/cable system low- ers and raises the saw head on the Norwood, making it faster and easier to operate than the winches on the others. And all of the necessary controls are The Norwood Lumbermate must be pushed and pulled manually through the log dur- located on the same side, making them ing the sawing operation.The sawmill ships unassembled. easy to reach and operate.

TimberKing1200 The welded bed on this mill proved to be very strong and rigid. Loading ramps and a cant hook come standard,and handledmost log loading. We got along pretty well with the transport package,too. To remove the axles, y6u lift and support the bed with the four screw jacks. We also liked the idea that the leveling screws were stan- dard equipmenton the TimberKing. TimberKing's basic 12'-longlog capacity should be adequatefor anyone wanting to cut cabinet-gradematerial or trim stock. lts 28V2"throat also enables it to cut a wider slab than the Norwood. We downgraded the TimberKing, though, becauseits feed winch operates full time, making for slow carriage return. And the depth scale on this saw doesn't warn you when the blade may Manuallyloading logs and turning cants was part of the experiencewith the TimberKing contact the log rest or log dogs. The 1200and the othertwo lesser-pricedbandsaw mills.

78 WOOD magazine August 2000 shorrvdown

Wood-MizerLT15 The Norwooduses a centrifugalclutch We liked the LT15's strong,one-piece nient. However, there's no way to start so the blade only runs when the engine welded log deck and log rests.The the engine should the battery or starter has beenpowered up. This setupdoes closer center bolster and log rest spac- fail. We also liked the combined throt- take longerto stop the bladethan on the ing also allow logs shorterthan 4' to be tle/clutch control. An integratedbrake othermills. worked safely. quickly stopsthe blade. Of the three lesser-pricedmills, the The winch-feed system functioned Raising and lowering the head on the Norwood has the smallestthroat open- smoothly, and it disengagesfor a much LT15 mill was much slowerthan on the ing. This limits the size of the quarter faster head return. The combined head- Norwood. Becauseof this factor, quar- that canbe quartersawnto 19". raising/loweringand feed-winch handle ter-sawingwas slow, too. We weredisappointed that the bed-lev- also simplifies machine control. The You can't buy a trailer packagefor the eling gear on the Norwood was not large throat allows cuts on cants up to LTl5. To transportthis 826-poundunit includedas standardequipment as with 23" wide. meansloading it onto a pickup or trailer. the other bandsawmills. We also think The LT15 usesthe samesaw blades as The log ramps, although effective, are loadingramps should be available; its bigger brothers,so they're readily optional. We felt the short log dogs were they're not evenan option. available. Blade changing was fast and harderto use than thoseon the two other The Norwood arrived on a pallet, simple, and the blade-tensionindicator mills we tried. unassembled.It took about 20 hours to performedadmirably. The sawdustexits at the operator'sfeet, assemblethe machine.However, once An electric starter comes as standard and forces you to constantly walk in it. you've assembledit, you'll know exact- equipmenton this model This becamemore than a bit annoying ly whereevery piecegoes, what it does, and proved to be conve- after a few hours of sawing. andhow to later adjustit. The Norwood usesa lVq"-wide.148"- long blade.It costs$26.50 (OEM) com- paredto $18.50for the bladesused on the otherbandsaw mills.

sheet-metaldepth indicator was harder to read than the plastic hairline indica- tors of the other mills, and we missed not having a blade-tensionindicator. While operatingthe saw, we discov- ered the separatethrottle and clutch controls were more troublesometo use than the integratedsystem on the Wood- Mizer. We also found the guide adjust- ment more difficult to reach and operate comparedto the others. The one-pieceblade guards, attached with threadedknobs, were a bit time- consuming to remove when changing blades. The small water tank also required more frequentfilling than those on the other machines. Blade-guide bearings are sealedbut not enclosedlike those on the Wood- Mizer. The infeed-sidebearings did With the Wood-Mizer LTl5, as with all bandsaw mills, you must first square the log lock up from sawdustand debris. into a cant before you can saw boards.

Continued

www.woodmagazine.com 79 Theexpensive nnachines in cur roundup

r*.ltth* LucasMill Model 6 We doubt you'll find a more trans- portable sawmill than this one. Its alu- minum frame breaks down into I I pieces, with the heaviestweighing less than 100 pounds.You can carry it to the log, even in heavy timber and under- brush, or to difficult terrain where other mills cannot be hauled or towed. The power head/carriageunit rolls on two wheels, much like a -tarden-varietytwo- wheel wheelbarrow. One man easily can set up the mill and startsawing in lessthan 30 minutes.The log does not have to be moved-just wedged or blocked to keep it from rolling over. The saw's unique desi-gnallows the "ilo blade to operate both horizontally and @ vertically. To saw. you push the head carriagealong the guide rails parallel to the log. At the end, swin-ethe blade 90o, then pull the saw back alon-ethe log to l?- cornplete the cr"rtand free the board, as shown in the photo-uraphsbelow'le.fi. The Model 6 has a 6t,/t" cutting width limit. However. by manually turning the saw head 180'. it can rnake a double- width cut about 12" wide ( 17" on Model 8). The manufacturer does offer an optional slabbingattachment for cutting boards up to 7x50" boards. Quarter-sawingwith the Lucas was a breeze.With a little practice,you can produce close to 1007aqLlartersawn material fiorn aln-rostany log. The 17"-diameter.five-tooth carbide- tipped blade stays sharp longer than bandsaw blades,especially if sawing densewoods or dirty logs. A new blade currently costs $95. Blade repair, includin,s replacement of the five tips, cost us $20, about the price of a new bandsawblade. Sawing through-and-throughon a Above: The Lucas Mill can be carried and bandsaw rnill inevitably yields more set up almost anywhere by one man in less lumber becauseit cuts a narrower kerf than 30 minutes. The log does not have to (%" compared to )lo" with the circular be moved-just wedged or blocked. blade). For example, flat-sawing l"- Left: The unique head design of the Lucas Mill enablesthe circular blade to cut in hori- thick slabsfiom a 16" cant with a band zontal and vertical position. The head floats blade should yield one more slab than on an aluminumframe. will the circular blade. A band blade also leaves a bit smoother surface.

BO WOODmagazine August 2000 showdown

Wood-MizerLT25 In one glance,you'Il seea rnachinewith taperedlogs also came as part of this sawing,though. Even cranking the head more featuresand strongerconstruction upgrade.The winch makeslog loading back to the top after finishing a log than found on the other transportable and rotating considerablyeasier and becamebothersome. bandsawmills we tested. Dependingon much safer. We really dislike the amountof saw- how the LT25 has beenoutfitted, it will The LT25's standard167/sx32" throat dust the operatorhas to breatheand weigh-in at between2,000 and 2,500 enablescant cuts up to 28" wide. The wade in, too. Most of the time while pounds.So moving it will require the log-clamping systempermits cuts to sawing the dust chute sits betweenthe optional-and complete-trailer pack- within 1" of thebed. operator'shead and waist. This createsa age,which costs about $1,000. Oil-bath drive-wheelbearings and virtual blizzard of sawdust,with no We liked settingup the LT25. The large idle-wheelbearings indicate that option but to walk in it. We alleviated standardleveling legs are easyto use, the mill has been designedfor heavy- the problem somewhatby settingup the and the adjusting bar stows onboard. duty or continuousoperation. We found mill with the wind at our back. The log loading ramps also stow that the hydraulic blade-tensionsystem log rolleron the Wood-Mizer appliesgreater tension easier than the An optional onboardwhen not in use. LT-25makes turning the log a simple, Our test unit came with an optional manual systemsfound on the smaller effortlesstask. deck-upgradepackage that includes a mills. A gaugegives a direct readoutof manual winch for log loading and for bladetension. turning the logs on the bed. Front and Raising and lowering the head was rear screw-typetoe boardsthat level slow and got irritating when quarter-

The manual winch (part of an optional package) on the Wood-Mizer LT25 makes load- onto the saw bed easv and safe.

Continued

www.woodmagazine.com 81 -.,|t

Aftersawingn here LUCAS6 t{0RW00D TIMBERKING WOOD-MIZERWOOD-MIZER areour thoughts 1200 tTl5 tT25 Comparingthe small sawmills,we find WPE Circular Band Band Band Band it tough to choose between the TOWAEtE No Yes(optional) Yes(optional) NO Yes(optional) Norwood and the Wood-Mizer LTl5. Basedon our experiences,we think HEADELEUATIOI'I EndWinches TorsionSpring Winch Winch Winch you'd be happywith eithermachine. HEADLOCK N/A Yes Yes- DiskBrake- YeS- Yes. In choosingbetween the two expen- CARRIAGECO}ISTRUCTIOI{ AluminumTube Four-PostCant FourPosl Two-PostCant Cantilevered sive machines,we feel that it primarily OVERALTWIDTH 84" 68" 80" 6'3" oo dependson what operatingfeatures FRAMEGOIISTRUCTION AluminumBeamsDebossed Beam SteelTube SteelTube SteelTube appealmost to you. AluminumBeams Anglelron BoxTube SteelBar SingleBeam If you need somethinghighly flexible, TRACKWPE JackScrews mobile, and easy to set up, the Lucas LEUETIT{GTYPE PostWinch (0ptional) JackScrews JackScrews StiffLegs wins handsdown. But if you want a NUMBEROF LEVELERS 2 0ptional o 8 4 super-ruggedbandsaw mill the Wood- HEIGHTFROM GROUND N/A 8' 9" 9" 30tlz" Mizer LT25 more than fills the bill for Winch Winch sawinglogs into lumber.l CARRIAGEDRIVE Push/Pull Push/Pull Winch t NUMBEROF tOG DOGS NR I 3 2 1 Sources for mills tested NUMBEROF LOG RESTS NR z 3 4 4 Lucas(Bailey's) TimberKing EI{GIT{EHORSEPOWER 18hp Gas 13hp Gas 15hp Gas 15hp Gas 20hp Gas 800/322-4539 800/942-4406 ETECTRICSTART Yes Yes(0ptional) Yes Yes Yes www,baileys-online.com www.timberking.com Mechanical CLUTCHWPE Centrifugal Centrilugal Electromagnetic Mechanical Norwood Wood-Mizer (Belt) 800/567-0404 800/553-0182 BLAOEBRAKE Yes(Emergency) No Yes Yes Yes www.noruoodindustries.comwww.woodmizer.com BLADETENSION WPE NR Spring Screw PolySpring Hydraulic Other Sawmills Not Tested TENSIONINDICATOR N/A Yes No Yes Yes N/A NO Yes Yes(0ptional) Yes American Linn LOADIIIGRAMPS 888t778-0014 541/367-6900 MAXIMUMtOG DIAMffER 54" 27^ 29', 28', 32" Baker Log-Master MAXIMUMtOG IEI{GTH 20' 13' 12',4' 11 16',8" 573/663-3133 800/820-9515 THROATOPENING N/A 1931t 28112" 26'. 28112" Bizzy Beaver Mighty Mite THROATHEIGHT N/A 7tla'(bolt) 16', 10112^ 15' 405/944-5100 503/288-5923 MAXIMUMDECK TO BLADE N/A 23', 251|q' 27" 35" Cook's RipSaw MAXIMUMSLAB 800/473-4804 978/657-5636 THICKNESSx WIDTH 61lqx121lz' 71lzx193lt' 16x22' 9Uzx22' 15x 26' Cutting Edge T.A. Schmid MAXIMUMSLAB 8/4 WIDTH 12112' 193A" 281/2" 26^ 28112' 888/222-6171 888/858-8589 BLADESIZE 3/ro 1rltx144" rA 158' 1rlax 158" 1lLx 158" WIDTHT LEI{GTH/ DIAMETER x 17" 1 x Enercraft Thomas 877/527-1100 207/722-3505 BTADECOST OEM $ 94.95 $ 26.50 $ 18.50 $ 18.50 $ 18.50 Hud-son Timber Harvester 800/765-7297 800/343-2969 Kasco Timberwolf 800/458-9129 888/419-0558

EASEOF LOG DOGS N/A G EASEOF BLADE TEiISIOI{ NR I G EASEOF BTADE CHANGE G G BLADECHAI{GE TIME 10Minutes 4 Minutes 8 Minutes 4 Minutes 6 Minutes WATERDRIP CONTROT GGG * lrxcettent @eooo lrtit Lockswinch only NiA= Notapplicable NR = Notrequired

Writtenby Charles Sommers with Dave Henderson Photographs:Baldwin Photography lllustration:Bdan Jensen

82 WOOD magazine August 2000 ffiffiM

lf you'relooking for an answerto a ques- Foran immediateanswer to yourques- tionthat you think would interest lots of tion,get helpfrom fellow woodworkers by otherreaders, write to: postingit on oneof ourinternet discussion AskWOODo, 1716 Locust St., GA310, groupsat: DesMoines, lA 50309-3023. www.woodmagazine,com

Kiln- u$, air'drying wood Lastspring I hadsome hickory ffi | : therecommended 60lo. My shop is And yes, you can get plansfor it. Send W I sawedinto 4|Alumber,and last : locatedin northeasternIndiana, and your check or money order for $9.95 fall I didthe same with some cherry, : ourweather is usuallyhumid. Also, ppd. (U.S.) to Kiln Plans,WOOD maga- beech,maple, and ash. How long will , hasanyone tried building a small zine, 7716Locust Street, GA3l0, Des thiswood take to air-dry?The ends i solarkiln and had good results with Moines,IA 50309-3023. arepainted to inhibitchecking. lt is all i it? lf so,where could I getplans? Now back to your first question. stickeredand stacked in a l [email protected] dry barn. : Unlessyou live in a desert,we doubt that Somearticles l've read seem to sayit you can ever air-dry greenwood down to willair-dry in abouta year;others say : ffi | Let's answeryour secondquestion 6-8%omoisture content, the preferred lwill needto kiln-dryit to reducethe : ffi | first. Steve.In issue70 of WOOD drynessfor stock destinedto becomefur- moisturecontent from around 20% to ; magazine,we featured a solar kiln, nitureor other indoor projects.That's shown on pages 44-46, basedon a design becausethe averagehumidity for most of conceptoriginally createdby University the U.S. hoversat about 657o-equiva- of WisconsinExtension forester Eugene lent to l2%omoisture content in a board. Wengert.We loadedit with 614 board But, indoor humidity runs a lot less,so feet of ash, cherry, and walnut, and projectsfor use there should be built from checked back about six weeks later. It kiln-dried stock in the lower moisture- worked like a charm,bringing the contentrange to avoid wood movement. woods' moisturecontent down to a bone- (For outdoor projects,the wood with a dry 67o,as reported in issue 74, page 48. higher moisturecontent is okay.)

What's the best way to figure angles for tenon shoulders? I'm buildinga proiectwith theresult will beall butimpossible to Cut the piece ==M6fl% | : i stretcher longer than | taperedlegs and don't know : calibrateaccurately. Far better,in rq;*. required, clamp it in place on the dry-fit howto computethe angle to which| : ouropinion, is to throwout the I legs, and mark the shouldersdirectly on shouldset my mitergauge to correct- , math and mark your cuts directly. the stretcher,as shown below. ly markthe shoulders for tenonsfor : thebottom rails. The taper is 13" : fong,starls al2x2" andtapers to i Ix1".ls therea formulathat can . determinethis angle? i RobertBroome, Terrace,8.C., Canada :

ffi | fhere is a formula,Bob, and if ffw I we did our mathcorrectly, the answeris 4.3987degrees. The correct answer?Yes. The best solution? We don'tthink so, and here's why: (A) You couldgoof up a complicated geometric/algebraiccalculation, and (B)

Continued on page 86

84 WOOD magazine August 2000 #ffiH€ Cr,tntinued frorn page 84

How to successfully scrollsaw plastic? ffi | I'mtrying to cut acrylicplastic on my scrollsaw, W I withvery disappointing results. At highspeed it just melts;at lowspeed the plasticchips badly. Can you help? Glen Roach (glenr@ nbnet.nb.ca)

scrollsawspecialist Rick Hutchesonrecom- & IWOODo #*& | mendsusing packaging or maskingtape on the top and bottom of the cut or leaving the paper covering on the plastic until you've cut it. Saw at a low speed,using a blade with only a few teeth per inch. Even with theseprecautions, "some types of plastic just won't cut right," Rick says.For more about cut- ting plastic, check out Rick's web site at http://www.scroll- saws.com.

Power-sawing compound miters ffe I Formany years t've cut crown molding using the %d | "upside-down"method in a miterbox with a hand- saw.I feelsure that this could be done with the wood lyingflat on a radial-armor compoundmitersaw. Can you tellme how? | can'tfigure out what angle and bevelto I /r\ D I I rlv^v{r t use. William J. Setzer, Southampton, Pa.

job. ffi | No problem.Bill. Bothmachines can do the Setthe GENUINE OGAITY ffi | miterangle at3l.62'-a positivestop on manycom- (Swtetenia macrophglla) . South Amerlca pound mitersaws-and the bevel at 34".iF Brown to rlch red. Exceptionallystable, works easily.Statns and finisheswell. Greatfurniture wood!Random 4-12" wlde, 6-7'long, surfaced2 sides.Tcrlce aduantoge oJthts spectal purchase and stock up nuo! SctlsJaction0uaranteedl 4t4...saLE ft Reg,7'ee/bdJ, $s.99/bd 20+$3.5glua rt 100+$3.411n0 rt 8t4...SALE $4.991na rt Res$g'ee/bdJt20+ $4.49lnort 100+$4,27nan UP$PACK . 4l4!0mort.,, Dellvered Cont US $99,00

Place the bottom of the molding against the fence to cut the left piece of an outside corner, as shown. Then put the right piece with its top against the fence, again on the right side of the blade, and swing the saw to the opposite 31.62"setting.

lltr o Dl l[r]ll I{{l #tl t4,

86 WOOD magazine August 2000 CircleNo. 598. 2090 anH€fuclte Arnerican Chestnut An ecological disaster wiped out this orrGe-Froudt

ust a century 4go, you could find quite as fast as a forestfire, but equally specimens of the magnificent devastating-throughNew Jerseyand American chestnut ( Castanea into Pennsylvania'sgreat chestnut stands, dentata)practically everywhere in the thenon west.By the late 1930sthe noble easternpart of this nation.It thrivedin Americanchestnut was wiped out. farmyards,town squares,and forests from Although the treecould sendout sprouts southernMaine to northernMississippi, from its stump-and did after fire or log- Alabama,and into Arkansas. ging-they only lived for a shorttime Thesemighty trees stood 60'to 100'tall, beforealso succumbing to the blight. with trunksthat could measure10' and 12' Peoplemight rememberthe chestnutfor in diameter.Because the Americanchest- its tastynuts, but in its day the treehad nut first branchedhorizontally from its lots of commercialuses. Its wood resem- trunk, thenfanned out with ascending bled oak. Thoughcoarser, lighter, and branches,it wasmuch-loved for shade. weaker,chestnut better resisted wood- The beginningof the end for this mag- destroyingfungi, which madeit a natural nificent speciescame in 1904,when trees for fenceposts and railway ties. Chestnut at the New York Zoological Park were alsowas madeinto furniture,interior Afterfelling, the American strickenwith a fungusdisease that origi- trim, packingcases, and crates. Tannic chestnutsprouted fromthe remaining stump. But it tooklitile time natedin Asia. Spreadby wind-borne acid,for tanningleather, was extracted forthe blight to eventuallykill eventhose spores,the blight movedrapidly. Not from the bark andwood.l valiantnew sprouts.

I1\TERNATIONAL Findspecials such PoRItR+tRBlt /\> DA25o \ ^'.,) 15 ga. 2 Vz" Angle FinishNailer l(it $179.00 w CORPORATION ProFinish Kit Hffii;i,!,t[?,li",W$ffi Nailer,9 boxesnail case Glickfor 100ns $199.95 ffi of onlinedeals! EYC003 12V Saw& 15.5V GuaranteedLowest with 3 batteries, Prices! charger& case onmost orGrs orer $50.00 On the tinest quality industrial wlthinthe contlguous {8 statest posrertools & machinery $269.00 ffi the fuqn[tufie repair shop aFFrAlsalthe art of the r Howto makevalue judgments A writtenappraisal offers one of the surestmeans of establish- ingthe value of antiqueor high-qualitycollectible furniture. Here aresome tips on findingand working with an appraiser.

ack in the 1930sand 1940s, How to hire an appraiser RogerEpperly's dad became You'll find appraiserslisted in the interestedin antiques."He wasn't real- Yellow Pages.Look for one associated ly a collector," the Ankeny, Iowa, resi- with a major professionalorganization dent recalls, "but when he saw some- for appraisersof antiques,fine art, and thing he liked, he would buy it." personalproperty, listed below. Or, call Among those purchaseswere several the organizationsfor appraisersnear you. piecesof Eastlake-stylefurniture, y'American Society of Appraisers, including the secretaryat right. (See 80O/ASAVALU or 703 | 47 8-2228 The Eastlake influence on page 92.) y'Appraisers Associationof America, RogerEpperly reviews the appraiser's Roger had always thought his par- 2r2t889-5404 valuationof his Eastlakesecretary, ents' collectionof Eastlake-stylefurni- ( InternationalS ociety of Appraisers, which turned out to be two to three report -0359 times his own estimate.The doc- ture might be valuable.When he inher- 888| 472-47 32 or 2061241 umentsthe item'svalue for insurance. ited the piecesa few yearsago, he fig- When you contactan appraiser,item- ured the secretarymight be worth as ize what you want appraisedand and taking notes, perhaps even mak- muchas $1,500. To find out for sure,he explain the reason-insurance, estate, ing sketches or taking photos. (You turnedto an appraiser.And he found he or sale,for instance.This gives the might take small things to the apprais- hadguessed low. appraiseran idea of how long the job er's office.) You won't be told a value will take, and verifies that the one yet, however. "Market research and Sometimes, price matters you're talking to has knowledgeof and pricing arc always done back at the Putting a value on a family heirloom is experiencewith the artifactsyou want appraiser's office, where reference just onereason you might want an to havevalued. books and catalogsare athand," appraisalon antiqueor high-quality Appraisalsare not inexpensive. Dennis points out. collectible furniture. "Insurancecover- "Expect to pay from $75-250 per hour latet, you'll receive the appraiser's ageis anotherimportant reason," for a qualified appraiser'stime in your report, which should include accordingto Dennis Tesdell, an home," Dennis says.Travel time is y' a cover page, with your name antique-furnitureappraiser and consul- often extra. "Don't deal with appraisers and addressand the date, location, tant in West Des Moines,Iowa. who basetheir fee on a percentageof and purpose of the appraisal, "Without a specific fine-art appraisal the object's value or thosewho offer to y' a statement by the appraiser that on file with your insurancecompany, buy the piece at their appraisedvalue," he or she has no personal or financial your chancesoffair (or, perhaps,any) Denniswarns. interest in the subject items, reimbursementin the event of fire, y' a sufirmary of the appraiser's cre- damage,or theft are slim." An appraisal Herets what to expect dentials and professional affiliations also comesin handy if you donatean The appraiser will spend some time y' atypewitten appraisal report, item to charity. at your location inspecting the items signed and dated by the appraiser.

Continued on page 92

90 WOODmagazine August2000 trffiffiffi$ffimfu*p ContinueelJfunnpuge 90

Some appraiserswill include photosof selecteditems, too. If not, it's a good idea to take your own photos to attach to the appraisalreport.

Carved decorations help identify this secretary as an Eastlake-stylepiece, datingfrom the 1880sor 1890s.

The Eastlake influence EnglishmanCharles Locke Eastlake dis- likedornate Victorian furniture. Even more, he despised"speedy fashion changes," whichseemed to go handin glovewith mechanizedmanufacturing. Around 1 870, in hopeof improvingpublic taste-partic- ularlyamong Americans-he espoused a stylefor machine-madefurniture that was rootedin simpleMedieval English designs.lnstead of elaboratecarving, he favoredincised decoration based on Gothicand Orientalthemes. as shownin the photoabove. ManyAmerican furnituremakers-seek- ingfashionable new temptations for the buyingpublic-brought broad interpreta- tionsof Eastlake'sideas to the market. Often,ornamentation far exceededthe simplicitythe designerenvisioned. Eastlakehimself never manufactured or marketedfurniture, but piecesreflecting his influenceare valued for representinga turningpoint in designphilosophy.lF

Writtenby: Larry Johnston with DenniesTesdell Photographs:Hetherington Photography

CircleNo. 2030 92 WOOD magazine August2000 How to prep a new tutw#k ilmu?s

Okay,you've built a great-lookingblock plane from the instructionson page 41. Now, you need to sharpenand sef fhe blade before putting it to use. Here's how.

Hock-brand bladethat we sourced too-the Hock blade comeswith detailed, : the wedgeblock one good rap with the Jhe : I for usein the plane may feel sharp : illustated sharpeninginsrucdons written : heel of your hand. That shouldbe enough when it arrives,but it requiresfurther : in ptain English. : to make the bladejust barcly stick out of sharpeningbefore you can effectively : To Foperly set the blade in the plane, : the plane's bottom (known as the sole). shavewood with it. To do this, we recom- i withdraw the wedgeblock ard set the : The btadeshould take a light cut of con- mend you use a honing guide (a wheeled : plane on a flat surface.Place the blade in : sistentdepth. Expect to practice this carrierthat holds the bladeat a setangle) : the planeand use the flat surfaceto posi- i blade-settingtechnique some. and a Japanesewater stoneor a diamond : tion the blade edgeflush and pamllel to : The plane should makepaper-thin shav- stonelike the one aboveight.yon cal. i the opening in the boftom of the plane. : ing curls as you push it with moderate buy theseitems through any number of ; Slide the wedgeinto place to lock the : force over a workpiece.You'll find it woodworking catalogs.To our pleasant i blade into position. Then, lift the plane : comesin handyfor generaltdmming and surprise-and you'll appreciaiethis, i off the flat surfaceand give the back of i for planing end grain.i

Buy Our Best Seller Peels Plus 16 oz.can 10" x 40T onrv$107 maybe $l0l purchased o" orr 2ni bhde \MOODWORKER II CHOPMASTER BI-ADE separalely ri EXTRABONUS! 3 AT $5EACH! 5tls" to 14" diameter available 6' 2" to 15" diameter available Vsa+ $6snii All-purpose-tablesaws Buy a blade or dado and get $15 worth of and Specially- designed for sliding compound portable circular saws. mitei mitdr-chop,and ra"dialsdws. sharpening discount coupons from Forrest, Special'I0%- Discount! Take 15% off good on any make blade or dado set you Sale10%off 15%off second blade ofvour choice. Price1st Blade 2nd Blade own.The first 100 customers will receive a Euton's CHorcE.rxo Tor Reuxc 6'/z"x 40T $94 $49 $84 FREE Picnic Table Plan and Router poster! ovEn l8 Colrprlr^*c Saw Bunrs. Delta,Sidekick, & Others 'l (.htia' ht l()" r 10'l nrnul tht lililor': 8'/r"x60T tN 9a 93 ITIEOTIE BIAIIE ,{unrdfor thr lttstftn'lttrnunt n,grrrlh'st Sears,Delta, Ryobi oJprin. SrAnrerican llboduorher, 8'/z"x 60T Yg 1O7 1O1 TITATI"EAI'ES A ,llril l99i:i. 6,\(tQ. ltlr. Hitachi,Dewalt, Ryobi, FreudTRl 25 Select one of these items FREE wher.r placing SMOOTH-AS- Sale l0%Oft 150/oOff 9" x 80T 72Fr 116 11O an order for any sarvblade or dado purchase PricelstBlade 2nd Delta & Others from this ad in WOOD magazine. Choose sAilttEn 14"x 40T x 1" $74s $134 5127 10"x 80T 72s 125 118 from the eight book tides shown, imprinted Twiceoutpedormed 6 other 14"x30Tx1" figt 125 118 Delta,Bosch, Mitachi, Makita, Ryobi, AEG, & All cap, or 16 oz. can ofspray blade cleaner. Hurrv! prcmium blades, both forcign and domestic, 12"x40Tx1" tN 116 11O 12"x80T 7*s 134 127 This special offer is limited, while Dewalt,Hitachi, Makita, B+D, Sears, & All supplies last. WOOD Magazine lest, Sept 198{3, 45; - 12"x30Tx1" .rrbJ 1O7 1C)1 W. 14"x f00T 17O 161 WOODChart Febffi, lssue#121, p9.66. f 10"x40Tx1/a"or3/a"Jl# 1O7 101 7nr 10"x 30T x1ls"or3lp" A9 84 Makita,Ryobi -*lg 179 169 FORREST DADO-KING 9"x407 98 93 15"x100T t*g 7H' Hitachi,Ryobi Unmatched Precision on Every Dado Cut! 9"x 307 -*J a9 a4 The Forrest DadaKing gives you flat-bot- DURALINE HI A/T .811q" 7'/l' to 16" diameter available x40f x3/?" -*J A9 84 tomed grooves and no splintering-everr 8"x40Tx3/se" F A9 84 when crosscutting oak plys and melamine. Cus MELAMINE PERFECTLY. 220 mm & 3/a" WOODWORKER I ,l 8" x 30T x -zf aO 76 This arvard-winning set comes with six 300 mm available.Our bestPLYWOOD 7r .r" to 14" diameter available (inch.rding 71i+"x 30Tx 3/:2" 62 59 tooth chippers 3,/32" chipper), blade.8", 7'/q" & othersavailable ,E Designed for radial arm nvo 2.l-tooth ouLside blades plus shims. -*6" x 40T x 3Az" aO 76 Sale 10%otf 15%otf -. ,J or tablesaws-fine crosscut. Cus l,/8" to 29l32"grooves, t*-5%" x 40T x l0mm-lJ AO 76 Price lst Blade2nd Blade Sale10%Off 1570Oft .ry. Sale 10%0ff 15%0ff 10"x 80T $t'g!t $143 $135 NEW for'Sears & Makita Table Price1st Blade 2nd Blade G Price lstDado 2ndDado (1/s"or 3/32"K) **Saw I I 6" Set$2€!' 5242 5229 Saws Boss "**Dewalt Cordless 8",814",714"x60T$t€9$98 $93 *I 260 245 12"x 80T -#1 163 1 54 f 8 Set 2E!l lie" 10"x60T('/e"hole1.rd 116 11O ( %" or t " hole, K) 12"x60T(5/g"or1")Jgg 125 118 f.'f i, ffi A?et3# 14"x 80T .s2 177 168 BI-ADE (1" hole) o 4"...$21 "i 14"x1007 # 203 192 STIFFENER ..I]ASY-FI],8,D" Make all your CANADASALES: CMR RON COLLIER STANDARD DADO (1" hole) o 5,'...$24 For solid hnrd rnd soli h'oods onlvl (No Dlvs. no blades cut better 3644SCHUMANN RD., BAY CITY, MI 48706 rrclanrircl) a D, \vith D.,srti!(.hool i.t rooth 6li(l(.s & 16"x 100T 219 206 2 touth clriDncrs :uKl shiilrs, (ir6 '/r" ro tri(l( . N and ouieter with a 6,'...$25 "/r, (1" hole) Phone800-229-4814. FM 517-684-0402 l-tsil- SA.LE 100/o 1 5-/o blade stiffener! o $24€r s2i€! $1 96 91 a5 WESTEHil GANADA CALL FREE SFIIPPIn|Ci sl{ARP'rEGH, lNC.: on orrders ov€r t$275 All Major Credit CardsAccepted Tbll-Fr.ee A27 - 22,e -O goa FL, NJ, NY Residents- Pleaseadd SalesTax MANT]EACTTIRINGCOMPAI{Y. INC. Fax 403-223-?767 YOURSATISFACTION GUAMNTEED! oRDEF EY [l|!: 4!r rfir.r rroad, C{tno||' aa, oiTota . EY PHo e 8OO-7aA-7111 0[ r*[ git8..r&q4t3l . !v FAx: gzt-4tt-algt SEE ouR lllTERlrlET STORE AT woodmall.com oR stores.yahoo.com/forreatman -l fi nishin I - , r'' i : tropical-tnee investmentsI EARNas theyGROW

{ As he conductedbusiness in CostaRica for 20 years,Steve Brunnersaw hillsides gradually being strippedof lushrainforest. Then, in 1991he laid out a planto startreplen- ishingthat lossand make a profit, too. woodtruck truck He andhis wife, Sherry,founded A Al Gu.nther.a wOOtr HugeDouglas TropicalAmerican Tree Farms, a magazinereader from Bonita fir logsin Springs,Florida, sent us this convoy CostaRica-based managed forestry old photographicpostcard. througha companythat contractsto grow Takenin westernWashington western selectedspecies of tropicalhardwood in thelate 1930s or early Washington 1940s(based town drew treesfrom seedlings.The payoff for on the approxi- matevintage of thetrucks), it littleapparent clientsbegins at abouteight years graphicallyportrays just how attention60 afterplanting and ends when all the hugeDouglas fir from old- yearsago. contractedtrees are harvested. As the growthforests was back then. Basedon someadmittedly treesgrow, they accruedividends of roughcalculations, Al guesses sizeand quality. According to the thateach log mightcontain Brunners,$3,400 invested in 100 28.000board feet of wood! plantedteak trees yields about We welcomeyour estimates. $100,000over 25 years."The client SteveBrunner canopt for the yieldedlumber and have it shippedafter Canada's standsamong two- eachcutting," says Steve. "Whatever the client wants." year-oldteak trees Besidesproviding investment for profit, the annual on a Tropical CrownLands AmericanTree plantingof tropicaltrees reforests about 4,000 acres. And Canadahas about 1 billionacres of forest- Farms'plantationin the Brunnershave protected nearly 3,000 acres of rainfor- CostaRica. eston their landsand have set aside to naturallyregenerate landcompared t0the 730 million acres in the some1,200 acres. They hopethat their operationserves as UnitedStates. But while private ownership a positiveexample of a for-profit solutionto the disap- dominatesinthe U.S,, it's the other way pearingrainforest. For their efforts,Tropical American aroundnorth of the border. There, B0% is TreeFarms was given the Associationof Woodworking heldby the various Canadian provinces and andFurnishings Suppliers' 1999 environmental achieve- arecalled Crown Lands. The federal govern- mentaward. Call 800/788-4918. Website:http://tropical- mentholds another 11%, while individuals hardwoods.com;e-mail to [email protected]. andcompanies own the rest.l

104 WOOD magazine August 2000