ISSUENO. 120 WINTER1999 Tltis issue's coaer utood grain: cottonutood
CONTENTS
41 Backyardbowyer Meet an archer who fashions traditional bows. Page 56 56 The latestportable planers Find out which of ten models got high marks Page50 during our no-holds-barred tool tests. 74 12 woodworkers'vacation stops Journey to one of these fascinating destinations the next time you hit the road. Woodworkingprojects 37 Quailcountry Scrollsawour sportsman'snatufe scene. 46 Whimsicalcutting boards Take your pick from three outstanding Page46 designs-quilt block, ladybug, and domino. Page 37 50 Theapothecary's friend Build this beautiful. multi-drawered cabinet to remedy any number of special storageneeds. 62 Drop-frontwriting desk Need a special place where you can jot a note of pay a bill? Try this handsome country design. 68 Arts and Craftsphoto stand With just a little oak, you can make a shelf-top picture frame that will last as long as a big oak. 70 Whole-shopair-cleaning system Create a healthy shop environment with this ceiling-mounted blower and ductwork combo.
SHORT.SUBJ ECT FEATUR ES 2 TheEditor's Angle 20 HotOff The Internet 4 TalkingBack 24 InsideInfo: Jet Acquires Powermatic 8 TwoFinishes For Small Turnings 26 TipsFrom Your Shop (And Ours) 10 Ask WOOD 33 ProductsThat Perform 16 Greatldeas: Texas-Size Tablesaw 90 WoodOnline 18 Business:Let The Media Tell Your Story 94 DealingWith Planer Snipe 96 FinishingTouches
Cover photograph: Baldwin Photography
WOOD Magazlne rVinter 1999 -'l
Better Ilomes and Gardenso
WbrkineHard [J7IDTHE WORLD'SLEADING WOODWORKING MAGAZINE ForWobdworkers Everywhere WINTER1999 . Vol.16,No.9 0 lssueNo.120 EditorLARRY CLAYT0N A Saluteto GalleryOwners! ManagingEditor JIM HARR()ID AssistantManaging Editor/Products BILL KRIER SeniorEditor/Features PETER J. STEPHAN0 SeniorEditor/Soecial-lnterest LARRY J0HNSTON SeniorHow-To Editor WILLIAM LAHAY General-lnterestEditor DAVE CAMPBEIL SeniorDesign Editor JAMES R. D0WNING AssistantDesign Editor/Project Builder JAN HALE SVEC ShopManager/Project Designer CHARLES l. HEDTUND seniorAssociate Art Director PERRY A. MGFARLIN AssistantArt Director CHERYL A. CIBULA Production/0fficeManager MARGARET CI0SNER AdministrativeAssistant SHERYL MUNY()N ArtBusiness 0ffice Secretary BARBABA HELPS Reader-ContactSoecialist BEN V()N RUDEN ContributingEditors KIM D()WNING, DAVE HENDERS0N, L()RNAJOHNSON, ROXANNE I.EMOINE, B()BMcFARLIN. CARS()N ODE
@CopyrightMeredith Corporation 1999 All rights reserved.Printed in the U.S.A. Better Hornes and Gardenfi WOOD@ magazine (ISSN- 0743-894X) is published nine times a year in January, February, March, April, June, August, October, November, and December by Meredith Corporation, 1716 Locust St., Des Moines, lA 50309-3023.Periodicals postage paid at Des Moines, Iowa, and additional mailing offices. Better Homes Recently, I visited with a couple of we're compiling a list of them with and Gardens trademark registered in Canada and Australia. Marca Registradaen M6xico. ONE-YEAR SUBSCRIPTION really nice guys who have dedicated help from the Rosen Group, publish- PRICES:U.S. and its possessions,$27; Canada,$39; other themselves to showcasing the efforts ers of Nicbe magazine, and the folks countries, $47. CanadaPost Publications Mail SalesProduct Agreement No. 1369350. CanadianBN 12348 2887RT. of woodworkers. I'm talking about at Tbe Crafts Report, a crafts-indus- CANADIAN RETURN ADDRESS: Better Homes and Gardens WOOD magazine, 2744 Edna Street, Windsor, Andreas Strieve, the proprietor of try publication. As soon as we have Ontario, N8Y lV2. POSTMASTER: Send address changes Gallery M in Half Moon Bay, all the information together, we'll to Better Homes and Gardens WOOD magrzine, P.O. Box 37439, Boone, tA 50037-0439. California, and Bruce Abbott, who publish the results. So when you're you some CUSTOMER SERVICE 800/374-9663: Use this number operates One of A Kind Gifts in out and about, can factor for subscription services, changes of address, billing Ghirardelli Square in San Francisco. of these galleriesinto your itinerary. questions, questions for our editorial staff, questions about how to reach an advertiser, or to place an adver- That's Andreas in the photo aboue. I know they'll appreciate having tisement in our magazine. To order back issues In talking with both of these vou come in. take a look 800/346-9663. Subscription mailing addtessz Better Hornes and Gardens WOOD magazine, P.O. Box 37439, people, it became obvious n around, and perhaps purchase Boone, lA 50037-0439. Please enclose your address label that they believe deeply in one or more of their offerings. from a recent issue. Editorial mailing address: The Editor, WOOD magazine, l716 Locust Street, GA3 10, Des what they're doing. When By doing this, you'Il be helping Moines, lA 50309-3023.Reprints are $5 per article. either of them talk about one of support the efforts of those who ^lP^l the pieces they have on display, are working to showcase fine they inevitably tell a story about the handmade items from some of North woodworker who made the item and America's best artisans.tl talk about what kinds of woods were Attention gallery owners, wood- used. You can sense their enthusi- working professionals. and readers: 'W'e www.woodmagazine.com asm and pride. need your help in compiling our Downloadplans for this rVhether we realize it or not, list of woodworking galleries. If you Andreas and Bruce are an important know about one or more establish- VintageFarm T?uck part of a small network of galleries ments you think we should include, Our l8"-long vintage stake truck makes around the country that represent drop me a letter or send me an a gte t desk or den decoration, and it's woodworkers everywhere to the e-mail. Please send your recommen- sturdy enough for kids to play with. general public. There is a tremen- dations to: Download the plans, with complete dous amount of top-quality wood- My Gallery Suggestions instructions and ful-size patterns, from working being done these days in c/o WOODo Magazine \$(/OODONLINE for just $5.95. Click on this country and elsewhere, and L7l6 Locust Street, GA310 the \$flOODSTORE, then Down most of it doesn't get the exposure it Des Moines, IA 5O3O9-3O23 Loadable Plans, next deserves. Thanks, guys, for what you or e-maift [email protected] Kids Furniture and so lovingly do. Toys, finally go to To help give woodworking gal- the Farm Truck, leries nationwide a higher profile, plan DP-00039. A coupleof Getright to the point cuppingcorrections withblade angle On page 6 of issue 115, you have the This is the first time that I have felt wrong explanation for why wood obliged to write concerning one of cups. Lumber always cups to the your plans. The Bandsaw Multi-Jig bark side, so your illustration is cor- Circle-Cutting guide in issue *ll3 rect. But you should have said, "...the leaves out a critical bit of information face of the board that was closer to regarding positioning the trammel the center of the tree has more rudial point. The trammel point must be grain and less movement, whereas exactly perpendicular to the bandsaw the other face that was toward the blade's tooth tips or the circles outside of the tree has more tangen- attempted won't be perfectly sized. I tial grain, which moves more." learned this the hard way with a tem- -Eugene M.Wengert, Madisory Wis. porary jig. -Verne Gid.dings, Botbell, Wasb. One small correction to the "Talking Back" entry about cupping in issue You haue a point, Verne, and ute 115: The tangential surface shrinks apologize for your inconuenience. It about twice as much as the radial is important that tbe angle of tbe surface. Otherwise, I have been a trammel be 90' from tbe front edge subscriber since 1991, and your pro- of tbe blade. Houteuer, if you follotu jects have given me many ideas. The tbe instructions giuen in tbe article articles are very informative, too. on page 63 under tbe beading Keep up the good work. "Here's ltow to set tbe blade guides," -Keain Cox. Rltod.es, Iouta tbat utill bappen automatically.
Beveledbackward In the Arts-and-Crafts Bookcase pro- edges of each door." Change that to ject, issue #1L6, reverse the bevel "2o bevel on inside edge of each location called for in the drawing on door," as shown below. Also, the Better Ilomes snd Gardenso \-1f7 n-ltn] nI Advertising page 69.In the exploded view of the dadoes in parts U and V should be Yz" L -/ \g1l.Jll3lo &Marketing door, it reads "2o bevel on outside by Vr" deep, not Yq"dadoes V<"deep. THE WORLD'SLEADING WOODWORKING MAGAZINE PublisherWILLIAM R, REED AssociatePublisher MARK HAGEN AncillarySales and Internet Manager MARLEN KEMMET AdverlisingServices Manager PAT HENDERSHOTT DisplayAdveilising: 333 N. Michigan Ave., Suite 1101, Chicago, lL 60601Phone: 3128532890 FM: 31 258G7906 AdvertisingManagers JAMES N, FORD, WILL MURPHY DirectResponse Advertising CAROLYN DAKIS MarketingSpecialist GERALLIE LEGASPI SalesAssistant MARGARET TRAVIS DirectResponse Advertising: 1716 Locust St., GM04, Des Moines, lA50309-3023 Phone: 51 5/284-3575 FAX: 51 5/284-3343 SeniorSalesperson RICH RAINF0RTH DirectResponse Advertising NATASHA KUCHERENK0 AdministraliveAssistantKRISTI HASEK Classified Advertising: Phone: 800/424-3090 FM: 312464{51 2 PublishingDirector JERRY WARD CirculationDirector LIZ BREDESON AssociateCirculation Director K'ATHI PRIEN BusinessManager JANET DONNELLY SeniorProduct Manager RICK GBOW MEREDITHPUBUSHING GROUP Wewould like to hearfrom you CHBISTOPHERM.LITTLE, President BILLMURPHY, Srategic Marketirg; MAX RUNCIMAN, Finance; We welcome your comments, criticisms, suggestions, and yes, even com- JERRYKAPI-AN, Grurp Sales; HAL ORINGER, Consumer pliments. sfle'll publish letters of the greatest benefit to our readers. Marketing;ELLEN de LATHOUDER, Creative Services; tilflrite to: Talking Back, WOOD Magazine, 1716 Locust St., GA3l0, Des DEANPIETERS, Operations; BRUCE HESTON, Mandac'turing; THOMASL. SLAUGHTER, Licensing and New Media; Moines, IA 50309-3023 KARLAJEFFRIES, Controller; BOB MATE, Integrated Marketing tlg"""S^,,t|: Continued on page 6
WILLIAMT. KEBR,President and Chief Executive Officer E.T. MEREDITHlll, Chairmanof theExecutive Committee $ WOOD Magazine Winter 1999 Continuedfrorn page 4 Gainstatic pressure Rockwellhardness tester withreducer provesto be family Congratulations on your Cyclone Imagine how surprised I was when I Dust Collector design in issue#100. I turned to page 4 of issue *116 and built the collector and was impressed saw a Rockwell Hardness tester. with the clear instructions. As a Stanley P. Rockwell, my father, retired mechanical engineer, I do invented the tool. And I spent 22 have one suggestion. I calculated the years of my business life selling, ser- static pressure (S.P.) in order to size vicing, and improving it. I am now the ductwork, and discovered a drop 86 years old and still get a kick out of .85" S.P.at the abrupt exit from the of talking to people familiar with the collector to the fan inlet. By installing hardnesstester. a 5x4" reducer fitting before exiting SinceI retired in 1974,I have been the dust collector, I saved approxi- active making furniture and other mately.72"S.P. items. Except for WOODo magazine, -Albert J. Cappelloni, Scrantory Pa. I have given up all my other wood- working magazinesubscriptions. -Iludley W. Rockutell, Cusbtng, Maine QUICKFIX INCREASESSUCTION
Cut holesin top of Back-flushCyclone, too (A)and (D)4" in diameterinstead Thanks for the great Cyclone Dust that I can connect inlet and outlet of 6" as show Collector project. Your choice of a hoses of my on plan. shop vacuum. The Silicone NAPA air filter was excellent. I have closed-loop system effectively cleans sealant been using this set-up to back-flush it the filter without disassemblyand a and its reducer extend life: I disconnectedthe dusty mess. here. filter and installed several adapters so -Ken Gossage, Belleaue, Wasb,
CYCLONEDUST FILTER together. CLEANER Makeexisting 6" duct8" Cyclonedust filter shorterfor disconnectedfrom cyclone new reducer. Cylinder Wrap self-adhesivefoam weather..\ strip around duct to seal SECTIONVIEW OF CYCLONE
Holein end of filteris 6" Lookingfor a wood- workerwho can write WOODo magazine is seeking an Notch both sides of enthusiastic woodworking editor with adapterto fit into end of air filter. three or more yeafs of technical writ- ing experience. This person will be responsible for producing step-by-step copy for a variety of woodworking project articles. An eye for effective photography and graphics is impor- tant. Location: Des Moines. Iowa. Send cover letter, resume, and writ- ing samples to: D. Neumann, Meredith Corp., Staffing Services, 1715 Locust St., Des Moines, IA 5O3O9-3O23.Fax: 515/284-2958. Equal Opportunity Employer.i
WOOD Magazine Winter 1999 A Pairof FastFinishes For Small Tbrnings When it comes to finishing pens, bowls, and many other small turnings, you won't find arly easier way than applying the finish while the proiect spins on the lathe. Here are two finishes made just for that.
Finishwith a Frenchaccent Dampen the pad with the finish. A liquid finish variously referred to as Then, with the lathe running at about French finish, turner's finish, or 2000 rpm, press the dampened pad padding lacquer gives turned work a against the bottom of the workpiece, rich, satin luster. A variation on the as shown belout. Lay the pad on your true French polish process, this tech- fingertips and grip it with your nique dates far back into history. thumb, keeping your fingers and You can buy a ready-to-use finish thumb pointing in the direction of such as French Polish (available from lathe rotation. You want the pad to Shellac, denatured alcohol, and boiled Craft Supplies USA, 800/551-8875) or be able to pull free from your hand if linseed oil make an easy-to-apply finish turnings. Hut make your own. For a home-brew fin- it catches on the turning. for bowls and other small Wood Finish sticks, left front, are ideal ish, mix equal parts of shellac, dena- Pressthe pad against the work with for small spindle turnings and pens. tured alcohol, and boiled linseed oil. moderate pressure, and move it from If you make your own shellac from side to side for even coverage. Heat 8OO/547-546T, or Craft Supplies flakes (shown in front in the photo at generated by friction dries the finish USA). This proprietary blend of top right), flk 2 pounds of flakes into almost instantly, so you can assess waxes and polishing compounds a gallon of denatured alcohol for a your results as you go. Build up sever- comes in stick form, making applica- fwo-pound cut. (Or mix lzapound into al light applications to achieve the tion neat and virtually foolproof. a pint for a smaller quantity.) Shellac best results. Hut offers three varieties-HUT and turner's finish work best when Wood Finish, a satin finish for gener- fresh, so mix small amounts. A quick,solid finish al lathe work; Perfect Pen Polish, a 'Whichever formulation you use, We like tumer's finish for decorative satin finish formulated for pens; and application is straightforward. After bowls, plates, vases,and other ves- high-gloss Perfect Pen Polish. You sanding the turning to x least 22O- sels. For small turnings, like pens, apply all three the same way. grit, clean off all dust. Then fold clean, pencils, and similar projects, though, Run the lathe at 25OO rpm or faster soft cotton fabric into a pad several we prefer HUT !flood Finish (avail- (or the highest speed that's safe for layers thick and about 3x5". able from HUT Products for Wood, the size of your workpiece). Then,
HUT finish polishes out sanding scratch- es, making it a particularly effective fin- ish for acrylic-stabilized burl like these turnings. Compare the polished and Apply liquid polish with the lathe running, but keep your fingers pointed in the direc- buffed part at far left with the unfinished tion of rotation, and don't wrap the cloth around your hand. end at far right.
WOOD M;agazine Winter 1999 Tcncoprovldee a full llne of machlneTerrco, Inc. carvlngand slgn carvlng equlpment, 222 1st Ave. NW Beglnnlngmodels are the T.110 slnglo Watertown,SD 57201 splndlebench carver and our CM614 USA alnglesplndle elgn carver, (60s)882-3888 IntermEdiatemodels Include the K.Star, Fa< (605) 882-0778 ModclT.1 I 0 DuplhCarvcr a two-eplndleheavy duty bench model, andthe Northstar, a heavy duty floor modelavailable Inone to elght spindlee, Ouradvanced model isour Master Carverseriee, whlch ls anextremely heavyduty floor model with from eight tolorty splndlee, Website:www,terrco,com E-mall: info@terrco,com ModclCM6l4Slgn Crrvu Multl.SplndlcCrrvlng Mechlno ClrclENo. 2175
starting at one end of the turning, press the stick of finish againstthe surface,as shown in the photo at bot- tom rlght on page 8. Move it slowly towarcl the other end, covering the surface evenly, Apply the stick to the lower portion (l:r ": ol. 8 "ttr '.$,,1 ,{#i.# #,rfr, ,d Runthe lathefart to pollahthe HUTfln. lrh; hcatgencrated by frlctlonhelpr ahlnclt up. Holdthe pad loorelyeo lt wlllpullfree of yourhand lf lt catcheg, Photogrirphs: Hetherlnllton Phtlt WOOD Magazlne Winter 1999 AreYou Stumped? Duelingcrosscuts: Radial-arm saws versus ll you'vegot a questlon slidingcompound mitersaws arm sawsare highly thatyou thlnk would IntEr- I'm ln the market for a slldlng coftrpound mltersaw, but wondered about the aduan' accurate,but thelr eet other readerE,we tages and dlsaduantages of tbese cotnpared to larger bulk and wouldllke to hearfrom a radlal-arn saw, If I do buy a sllder, ls lt heftier price tags you. Wrlte to: Ask wortb golng to a 12" blade slze? ($1,t00and uP) WOODa,1716Locuet St., Byron Trdntbar4 Frederlchsburg, Va, can't compete GA310,Dee Molnee, lA with today's llght- 50309-3023.For an Byron, we took an ln-depth look at sliding weight and precise sliders, which lmmedlateanswer to your compound mitersaws in issue *87 of WOODa for $400-650. Radial-armsaws do have the questlon,try postlnglt on magazlne (seepboto at rlght), but don't mind edge in versatility-they can make rlp cuts, for for you, The basics example, and accept dado blades-though a oneof our10 Internet dls- at all offering an update haven't changed much-portablllty, accuracy, tablesawtypically does these jobs better. cusslon groups atl and reasonable cost stlll rank as key virtues of For most crosscutting and miter work, a 10" www.woodmagazlne.comsliding mitersaws, combined in a package no sliding mitersaw offers plenty of capaclty for radial-arm saw can qulte match. The cutting both wtdth and depth of cut, You can go to a method-pushing the blade into the stock 12" saw if you want, but the extra capability rather than pulltng it through-also offers a wlll come at a price-mofe weight and bulk, slight safety advantage. Industrial-duty radlal' and an additionaldollar cost of $100-250. Resawingwith the bandsaw: ls a widerblade always better? I need, help sortlng out confltctl,ng adulce Better still, our preference (for the Vz"blade) about resawlng wttb my bandsAut, a 14" was conflrmedwhen we posedthe questionto Delta, I planned, to use a i/c"-wl,deblade to woodworker and author Mark Duginske, an resAu some lumber I baue, Thesaut's manual expert on bandsaw setup and use. Here is says lt wlll accept tbat slze, and I'ue always Mark's take on it, tbougbt the wlder tbe better, but a local deal- First concern-the .t/a"blade isn't just wider, er told me I'd do as well or better utltb a t/2,, it's also thicker (.035", versus .02r, for a typi- btade,Any adulce? cal Vz"blade). On larger bandsaws, the bend RonBowllng, Itldtdnapolls around the wheel is more gradual, so the thick' er metal can handle it. But wrapping that same Your question almost always starts an opinion blade around a t4" wheel creates a tighter stampede among woodworkers, Ron, but our bend that stressesthe metal, causing prema' staff actually reached a consensuson thls issue, ture fatigue and cracking. So you'll pay more for a blade that's likely to fall sooner. Second, most medlum-duty saw frames llke yours have trouble generating and holding the lncreased tension necessarywtth thicker blades. Any accuracy you mtght have gained wilt be lost if lnsufficient tenslon allows the blade to drift within the cut. Duginske's recommendation?Stick with a Vz"-wlde, 3-tpi, hook-tooth blade, Hook-tooth blades feature large cuwed gullets that clear chips quickly. Any more teeth than three wlll only result in a slower, hotter cut. Finally, make sure the upper and lower thrust bearings (directly behind the rear edge of the blade) support the blade firmly without allowing it to deflect backward. If the blade "gives" under pressure,it will start wandering from a straight cut, ContlnuedonPage12 WOOD Magazlne Winter 1999 Crmtlnuerl.fretmlnge I o Howto sharpenyour own hand saws I haue some hancl crosscutsaws that need sharpenlng. other half to the left. N (,ltntlnuecl ort ltutrgc'I4 L2 WOOD Magazlne Winter 1999 Continued.from page 12 Tablesaws-howdo I knowwhat type is bestfor me? Wbat's the scoop on tablesaws?I see "professionAl" s*tus cost you more in dollars and floor space, but they're selling for $1,4OOand bencbtop models for $195, but designed to run for longer periods, handle larger stock, botb are 10" snrus and haue tbe same borsepouer rat- and withstand heavier use.These factors-and the type of ing, I can seepaying more money for tbe larger cast woodworking you want to do-should top the list of con- iron table, but a $400 contractor's saw llas tbat feature. siderationswhen you go shopping.i Also, bow do belt-driue and direct-driue sau)s compare? Phihp Mort'ls, Katy, Texas You're not alone, Philip, in your confusion about machin- ery features and specifications.Those numbers don't tell the whole story. Undercarriage mountingbrackets Maximum blade size determines a tablesaw's primary specification(10" being the most common), so many Tilt crank saws will share that trait. Horsepower ratings, however, get a little trickier becausebenchtop and stationary machinesdon't use the same kind of motor. Portable Elevation saws feature a "universal" motor, the type found in most other portable power tools. These motors are compact and lightweight, but perform best at shorter run times, Note:For sake of clarity, more like a sprinter than a distance runner. Their rating some mechanismsart not drawnto exactscale. usually reflects a "maximum developed horsepower," a burst the motor can't sustain for long periods without DIRECT-DRIVESAW damagingitself. Front Elevationcrank Nearly all stationarymachines use induction motors, trunnionbracket Tilt which can run longer under a load without overheating. crank They're also much quieter, producing a barely audible Arborbracket hum rather than the high-pitched whine of a universal Bladebracket motor. An induction motor's rating more likely reflects its Reartrunnion bracket "continuous" horsepower.Not only can it sustainthis output, it will respond to an increaseclload (for example, Fronttrunnion a heavy cut in hard maple) by drawing additional current Reartrunnion (amperage)and producing more than twice its rated horsepower. The catch? Cost, weight, and size make Drivebelt induction motors impractical for portable tablesaws. Your question about direct- and belt-drive saws enters the picture here. Universalmotors are small enough to Motor use in a direct-drive mount and still allow a sizabledepth- of-cut from a 10" blade. On a benchtop saw, this CONTRACTOR'SSTYLE motoilarbor/blacle assemblymounts under the table with one or more stamped steel brackets or "trunnions." With Arborbracket Fronttrunnion bracket its larger diameter, an induction motor with a similar rat- Fronttrunnion ing would limit cutting depth too severely,so the Tilt crank Elevationcrank motor/blade connection is made via a separatearbor assemblyand a drive belt. On a contractor's saw, a lVz-ltp Motorbracket motor hangsfrom the back of the saw and drives a single belt. On a professional(cabinet-style) saw, a 3-hp, 22O- volt motor hangs below the table and features multiple drive belts. Both machinesfeature trunnions made of cast Reartrunnion bracket (though iron the cabinet saw's are much heavier), so they Reartrunnion dampen vibration and resist deflection much more than stamped-steelbrackets. Bladearbor Aside from having more of the right kind of horsepow- Drivebelts er, it's this combination of rigidity and mass that really makes the ditference. Benchtop tablesawsoffer portabili- CABINETSTYLE ty and lower cost, with some tradeoffs. Stationary saws WOOD Magazlne tWinter 1999 A realstand-up fixture Texag;Size j TablesawFence ow \'ou can stanclworkpieces, extcnsi I 3lqx163/ax31" GLIDEMOUNTING DETAIL t Hook-and-looofastener 3/+"continuous z', (hookside) hinge9" long 131q" CROSSMEMBER slqx 13/ax 28" f- stock l 41lz"4 l 81lq" 11lz I .-1la" T-nut slqxlslqx81lq" I stock Levelingglide 131a" 1"hole Frontor (forhanging) rearweb 1/4"wing nut , ;,.\_ \ ) 1/q"washer 1/+"T-nut REMOVABLE 11/q SPREADER L. 1lqx 3lq"x 261/2"stoor ''':','- 1 3/+"holel/o" deep ' witha 5/ro"hole I 1"deep centered inside Lengthof screw= ..1531+" widthof tablesawfence + 112" I'rojcct l)csign:.foe Xitvcr'.Atrbtrrtr 3/a"groove l/ a./ I||ttsttittiort : lio,titntrrLe\loittt 1/a"deep, centered r 4g\-/ I)hotoglitph:.f 16 WOOD Magazine Virrtcr 199!) Let the mediatell you woodworkingstory : When you want the public to know about your work, take a page from the pros. f you're looking for ways to pro ance than generate a story. Do, how- might be your situation. Some recent mote your woodworking, don't ever, call to ask who should receive feature stories in metro dailies includ- be too quick to reach for your your release. ed a husband-and-wife woodworking wallet. The best advertising is publici- The press releaseshould include: team in St. Louis, a Long Island peri- ty, and like some of the other best o Your phone number(s) and when odontist with a woodworking hobby, things in life, it can be free. you can be reached. and a semi-retired Tampa man who Getting publicity, particulady from . A photo of you and what you make, teacheswoodworking in Belize. local media, can be easier than you particulady for a community news- Linking your work with a trend also think. A review of the top 50 United paper, which may actually run the generates interest. If you sell your States' newspapers in a given month photo you submit. Larger publica- woodworking as a post-retirement will show three to five of them run a tions will send a professional out to career, you might bill that as part of a feature story about a woodworker. take photographs. lifestyle trend. Or, if you make fancy So, your chances aren't that bad. o A on€-paragraph suflrmary of your birdhouses and know of several cus. People find woodworking innately background, including such details as tomers using them to decorate their interesting, ffid to reporters, it's high- past or culrent employment, charity gardens, pitch birdhouses as a trend ly photogenic. work you've done, and any other story for a newspaper's garden sec- note of special interest related to tion. This angle presents a seasonal Get rollingwith a pressrelease your woodworking. hook, too. You'll find it easiestto get your news . Some compelling news, with the into community and neighborhood first paragraph containing these Get to know the media publications, although metropolitan essential elements: Who (you), What For an effective press release,do your daily newspapers, city magazines, (your woodworking specialty), homework and familiuize yourself weekly entertainment tabloids, and Where (shop location), When (when with the publication or station to local TV stations are also good bets. you did it or how long you've been at which you're sending it. Know what The best way to approach any of it), and Why (the "hook," see the fol- kind of stories they run and who these news media is with a press lowing section). writes them. Direct your release to release. Don't call reporters and edi- those people and relate your story to tors to pitch stories about yourself. Makeyourself interesting something else they may have writ- It's far mofe likelv to cause annov- The "Vhy" of your release can be the ten. Be aware, though, that if a publi- hardest. To get the attention of the cation has just done a story on a editor or repofter, you'll need a news woodworker, it's unlikely to want hook. Some are simple, such as another for a while. awards you won, classesyou teach, Don't boast or exaggerate in your or the opening of a new business. release. But don't be afraid to honest- In other cases, the hook becomes ly tell your story, either. Editors and something unusual you make, such as news directors always are looking for a working wooden lock, tall clock, news and feature items, and you're colorftrl carousel horses, or spoons. It actually doing them a service. You may not get coverage the first '*F.. time around, but chances are, you eventually will. @specially if you fol- low up with a phone call to check that your release was received.) And you'll get far more public attention than any ad you could afford to buy.i rJfritten by Jack Neff, a Batavia, Ohio, business writer and author of Make Your Woodworking Pay For ltself. Illustrations: Jim Stevenson *-Yse*f" *-',* WOOD Mragazine Winter 1999 Note: if you would like more informationon the woodworking- refated subjects featured here, visit our WOOD ONIINE@dis- cussiongroups at www.woodmagazine.corn' WOODWORKERSTO THERESCUE We haved editied all entries in the interest of brevity and clar- Comments,answers, and ideasfrom our ity while preservingthe message.In addition,we have includ- WOODONLINEu discussion groups ed more specific information to some messages in brackets, and/or have provideda complete responseto some questions. Looking for the wheel deal Does anyone know O Meisel Hardware Specialties at http ://www.meiselwoodhobby. com/wood- where I might find plans hobby has three plans for waterwheels. Two are grist flour mill plans. The for a wood waterwheel? smaller of these, no.W1853, measures 35"-tall and features an l8"-diameter -:Tene lfooks, Fort wheel. It's priced at $8.99. The larger grist mill, no.'$72183,measrres 50" tall Payne, Ala. and has a3O diameterwheel. It's priced at $14.99. A third plan model is for a basic waterwheel [no.rUfl1852lthat measures48" tall and costs $9.99.I used the big basic waterwheel and it came out great. Call Meisel Hardware Specialties at 8OO/441-987O;outside the U.S., call 612/471-8550' 4la.rence Bryant,streaton ilr. Roll call for rolltop desks : Wherecan I geta reallygood plan for O Rockler has a rolltop desk plan and a couple of others are advertisedin the a rolltop desk? Also, is back of most woodworking magazines.I have the Rockler plan no. 19126, tambour very hard $29.99, and it is very detailed with four or five large plan sheets. However, I to make? haven't started my desk yer. call 800/403-9736. -Jobn S.Jobnso4 -Tom llolfmaq Ced.ar Fa.Ik, Iouta Crossaille, Tenn. Ot$[e ran a six-page tambour technique article along with a modified oak roll- top desk in the December 1989 issue of WOODa magazine.To order the back issue,call800/572-9350. We charge $6.95 per issue. -WOOD magazine Continued on page 22 WealherFlectoril FronlS€t $41.S FrontFloor du's$8 shippin0 Mat Set 2nds€t shiDs fR[g ${4.S CargoLiners TancGry,dd$.O SladingFrom WeatherFlectorn plus$8 shipping Front& RearSet 2nds€tshipsffi w.95 Taro|Gnt, add fl0.m $79.95 plus$9 shipping plu'sS ship0ing WeatlrerTech' WeatherTech FlScaruoliner WeatlrerTech' BearsetshiDs fnF FloorMats Cargo Lin ers shippingwhen you W e a t h e r F I e c t o rrM o[rchaselloor mats' Intedorpdeclion for all lypes of uehicles. Cu$omfit caqoliners lor your vehicle. Uenlilalionmade easy! WeatherTech@FloorMats ofler carpet protection WeafierTech@CargoLiners protect the rear cargo area carpeting from all OurWeatherFlectorn isprecision cnfied inGermany exclusivety forl\,lac Neil thatis botheye-catching andeffeciive.effective. 0nly t--lmrs$ipsffi typesof wear and tear. Our cargo liners are designed wifrr up to a 3' lip AutomoliveProducts byClimAh. AnOEM approvd supplier tonearly 20ol WeatherTech@givesyou all season protection you can rely on. Our whichhelps to containspills from leaky groceries or wetsnow boob. fie world'sfinest vehicle manutacturers assuresyou he highwt inquality Weafieilecfr@FloorMab are made ofup to 16 lbs. of pliable Mrgin rub- Iheyare perfect for hauling gardening supplies, fishing gear, construc- engineedng,ufetyand function. Intact fiey are fie only manuhcturer infn berwih deeply sculpted channels and an outer rim tnt tnpswater, road tionmaterials, golf clubs, or the lamily pet. 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Our WeatherTecho FloorMats are designed to hold up lo 1ll vehicle.WeatherTech@ CargoLiners meet FMVSS302 and are IUV ofboth worlds with WeatnrFlectoril! Ile WeafierFlectorft isclearll vour quartsof waterwitrout spilling. A protective,non-slick finish makes approved. finestchoim! Anilable forfirtally all SUVb, Pifirp Truds, Miniya'mind cleanupquick and easy. Automobiles. WeafierTech@FloorMab meet FMVSS302 andare IUV approved. SPOFTUTN,IW TJ.|S APN.EATIOR AyailableinBla*, Tan or Gruy. Awilable toft mostdomestic and .Bnm&.0tum.Clrde.Counly.CR-V.DdBI.ils0vriy.Dlango.Enwy.b€he.Enllrson ORDER TODAY! E@ilinpdilin . EdoalEryloar. 6rud Clnm|(ft . Gnrd yrhra . JimmyJimrry . lardoruiss . U{50 . U470. i,|U}20 (8001 impodedCars, Pickup Trucks, Minivans and SUVs. ML4S.li,|[email protected]$v|i).Pltrtuder.Pa$pn.d1 I 441-6287 BangeEo/s4.05843l|St.MV4. R0de0.RBm.Siddd*.SU [email protected] Bepresentatives are available: - Imgef.Mhn.l,llrutler.Yuitm.Xbm.4Runner Monday through Friday 7AM-11PM Yil / mwff{ u{ERtpf{.rcffiof& Saturday - 8AM -1 1PM & Sunday - 8AM -10PM (CentralTime) br{En).4f0(E4.Carardn.Clubt'llagofl&unlineW@||.i,lffbm.MF/.06b.qFsey.Prwh 0jeS.Stui(bd).$llnurte.Sbnm.T& C.InnsSpoi.Vof|[email protected]$hr AIJIOflffi I 1.IB APPIIGAIFN: 44.16.Acmd.Alltma.Avafil.hete.Bl,fiV3, 5,7Sdies.Camry.Civic.CL.Cflmd0.CfitirEflt- 0onfttb.CrcvinVfrorh.thvitt.ffim.Uorm.Acort.eOmoiU. eSm. egm.nO.nHn Maior credit cards accepted. InBqi,..hta/Jdhm. lqry lvgrvL0FcyOiSd(Wgn..Bm. MafnE.lrtrDd€s "C","P,'S'frs ,UhFyr4|kdfiitgrilhtr4S mnliilq$Sffi, wtH|stindbtEsam drr$ m ddhmlS0ltofi We normally within Ptsd. S70. Sabh. Seville . SC/SCI/XI2 . $iSLlAU . SlVlrSl{Z. Iaunr . TomCar . W0 . l,S . Vsixr ship 48 hours. flEEfiatrIW[Hwfun rud6d hcofitidil|rihaSdfiofltfuff [6 0rddlhrBlS0lWafHff6tilsil rlH| pudnqlh dltiElimrdhasdfutuhdlcfftrbGil. [tflIRmEmn $tEflgnlt. ilyoiare 74Mflt4)40w.&50.944 (IAltAl{D GREY CARGo IjNEF AVAX.A8]€FoR SEI.ECI ApruCAItOf{S} mlffidr{ilryotrords,ntmyorunsdF0fuduilnSersfo acdr@d'xf, h$$ippirgA@Jrg. MacNeil Automotive Products Limited.2435 Wisconsin Street. Downers Grove. lL 60515.630-769-1500. FAX 630-769-0300 Continuedfrom page 2O Can't put my fingeron remoteswitch details l Somewhere in the past few months I've seen an electrical device that O Penn State Industries has such a gizmo, something they call a Long Ranger automatically turns on your dust col- II. It's a hand-held remote switch that lets you turn on your dust collector lector when you start your tablesaw. from anyplace in your shop. [This includes the LR110 (1L0 volts system) Does anyone know about this device? priced at 659.95, and the LR220 (22O volts system), priced ^t $69.95. Call -Keitlt lanbam" Ilartford City, Ind. Penn StateIndustries at 8OO/377 -7297 .l -Paul Jones, Louisaille, Ky. O Keith, we have a product review coming up in tl:'e magazineon a Crafstman Automatic Power Switch, model 24031. This device plugs into a wall outlet and lets you plug one tool and two accessoriesinto it at one time. For instance, you can plug a bandsaw into the outlet marked "too[," and a light and shop vacuum into the outlets marked "accessory." Then, when you turn the bandsaw on or off, the acces- sories switch goes on or off as well. Look for the item at your local Searsstore. Also, we reviewed a slightly different product on page 110 of the March 1999 issue, + ll3 of WOOD magazine.The Automatic Switch shown at left from Dan Trimble and Company consists of a sensor ring through which shop outlet circuit wiring passesinside a junction box. When, for instance, a tablesaw plugged into the circuit is switched on, the ring sensesthe current and tums on selected accessorieshard- wired in the wall-mounted switch box. Call724/357-8555 for more information on this product. It costs $249 and may require that you hire an electrician to instatl it.al -WOOD tnagazine hen you buy a machine you also buy the company selling the machine. Torben Helshoj, President of Laguna Tools understands the American Woodworker. because he is one. Torben knows firsthand the hard work that goes into every piece of ' furniture. Having the best tools makes a difference. TAKE FOR EXAMPLE the Robland X3I combination machine, the #1 selling machine of its kind in the world! Powered by three separate 3HP German motors, the Robland X31 gives you a 10" table saw, 50" of cross cut capacity, a 38" rip capacity, 12" jointer,12 x 9" thickness planer, reversible shaper and a horizontal mortiser. OR, IF YOU WANT TO cut wood like butter, our line of Bandsaws will make it that easy. Awarded Jr,rstLtheYou, "Editors Choice Award" by American Wo o dworker mag azirl.e, our LT16HD is designed like a We&illdtoLast tank and perforrns on the toughest wood like a Ferrari on a mountain road. CALL TODAY to order your FREE demonstration video or brochure and see how much YOU and Laguna Tools have in common - 800 234-1976. UqI=U\llA TCIGIT.S You Build With Wood, We Build With Trust. (800) 234-1e76 (800) 234-L976 22651-aguna Canyon Road. 100 Central Avenue, #40E, laguna Beach, CA 92651 South Kearny, NJ 07032 (gflq $4-7006 . FAX (g4g) 497-1346 (973) 4gL-0102 . FAX (gtt) +gt-OSgt E-Mail: [email protected] . Web: www.lagunatools.com Jet Purchases Powermatic No majorchanges expected in the nearfuture If you own one or more pieces of running at full steam after its recent but one affiliated with Jet. Current Powermatic equipment, of wefe con- purchasebyJet Equipment & Tools. Powermatic management will remain sidering a purchase of its machinery, Jet, an importer of woodworking, in place and be responsible for all you may have been concerned by metalworking, and material handling decisions in such afeas as manufactur- rumors circulating this past summer equipment based in Auburn, ing, purchasing, and marketing. As about the company's precarious finan- Washington, purchased the assetsof Bob Skummer, president of Jet told cial condition. Although the Powermatic at auction in late us, "Our first objective is to revitalize Powermatic division has long been September. Powermatic has manufac- Powermatic by infusing the financial profitable, its parent company, tured a well-respected line of heavy- wherewithal that will help it regain its DeMieg-Bu1[ard,had filed for Chapter duty woodworking and metalworking premier position in the market. We'll 11 bankruptcy in JuIy 1999. W'ell, as equipment in McMinnville, Tennessee, provide the funds necessaryto build far as we can tell, you can now rest since 1921. up production and to make improve- easy because Powermatic is up and Jet, which is a subsidiary of Walter ments in areas such as product devel- Meier Holdings of Zutich, opment and marketing." Switzedand, has been on a buying Skummer assured us that the spree lately. In January 1999 it Powermatic factory and foundry will acquired Performax, a drum-sander continue to operate, and that JET manufacturer based in Shakopee, Powermatic's imported line of Artisan EQUTPMENT& TOOLS Minnesota. equipment will be maintained. He As they have done with Performax, said that product support, such as Jet officials expect to maintain providing replacement parts, will be Powermatic as its own corporation, stressed.jl PreferredBy Professionals 3Ib1 firc leastexpensive item in your workshop iust might be the mostimportant Wiffrall dre time andmoney you've invested in your prciect,wlry h$t anyftingelse? TrustedBy Prcfwionals For (hs 45 Yans. TechnicalService I -Sm-347-GtUE urururfranklini.com Magneticswitches make G z an attractiveaddition to 4 blastgates I recently purchased a central dust- collection system for my shop, and liked your idea of using remote low- voltage switches (from the June 1991 issue of WOOD magazine) to turn the collector on and off. I wired the sys- tem as shown in the article, but Bob DiTucci'sdust collectorturns on instead of a tiny toggle switch at each automaticallywhen he opensa blast blast glte, I used a magnetic gate,thanks to his Top ShopTip. door/window switch (the kind used The seed was planted 25 or so years in home security systems) at each ago when Bob DiTucci was a Webelo blast gate, as shown below. The scout: At the weekly troop meetings, switches, which are closed when the he and the other scouts would make magnet is engaged, cost about $5 projects in the woodshop of den- each at an electronics chain store. leader Mr. Massaro,who had set up a The beauty of this setup is fwofold. small workbench for each of them. First, the collector turns on automati- Ten years later, Bob says, "I started cally whenever I open a blast gate. Top Shop Tip winner Bob DiTucci buying inexpensive tools and build- And I can't forget and leave n gate adds a Ridgid Oscillating Edge Belt- ing the small projects I found in open because the dust collector Spindle Sander and shop vacuum to WOODa magazine." doesn't shut off until all the blast his tool collection. Nice going, Bob! Since that time, the woodworker gates are closed. has greatly improved both the quality -Bob DiTucci" Wayne, N.J. uiring diagranl Bob refers to, send of his tools and the size of his pro- $5 to wooD Reprints, 1716 Locust jects, having recently built from (Editor's note: For a copy of tbe cen' St., GA-310, Des Moines, IA 50309- scratch a set of kitchen cabinets for tral dust collection article and tbe 302 3. Ask for "Dust Collection *43. ") his home. Meanwhile, out in the shop, his new dustcollection system inspired the Top Shop Tip at rigltt. Mr. Massarowould be proud. If you take pride in the way you work, would you take money for it? We pay $75 for each tip we publish. And in each issue, one is chosen as our Top Shop Tip, eaming its creator a tool pize worth at least $ZlO. Send us your idea, along with a photo or sketch and your name, address,and daytime telephone number, to: Tips From Your Shop (and Ours) WOOD Magazine 17'1,6Locust St., GA-3L0 Des Moines, IA 5O3O9-3O23 We only use original shop tips, so please send your ideas only to WOOD magazine. Sorry, but we can't return submissions.Thanks! ^,2 W,Jryfu( GENERAL-INTEREST EDITOR Continued on page 29 26 WOOD Magazine Winter 1999 Continuedfrompage 26 Bucketof PVCpipe keeps clampsstanding handy Becausemy shop has limited wall space for clamp storage, I made a rolling rack to keep my clamps within reach wherever I work. I mounted swivel casters to a plywood base and attached a 5-gallonbucket to the base. Then. I filled the bucket with various lengths of lYz" PVC pipe-the longest pieces in the center, the shortest around the outside. My pipe clamps and bar clamps slide right into the PVC, standingready for their next task. 1tl2"PVC pipe 22" long 11/2"PVG pipe 13" long S-gallonplastic bucket screwed to base '/t / Swivel casters Continued on page 30 WOOD }'[.agazine Sflinter 1999 29 Continued.from page 28 Nomiter slot in your router table? Tryan auxiliary tabletop SPEEDPLAilER Sometimes you need to rout across the end of a narrow workpiece. If you have a miter slot in your router table, PtAfEStOP &Boft0il you'd simply use a miter gauge. But what if you don't have a slot? You could index off the router table itself. . Canalso be used as a singlesided planer Build an auxiliary tabletop to straddle the router table and attach a fence to it as shown belout. To rout acfoss [W the end of a piece of stock, slide the table to the right, HotidaguE$849 ttottdlarsile$1 995 put the stock against the fence, and slide both the auxil- gl" Sunhill15" Productlon Sunhifl 25" , , 4" | 32" Single & iary top and the stock acrossthe router bit. Wlde Belt Sander Double Belt lUide Belt Sanders -Cltuck r Pneumaticbelttension for quick &easy bett chan$ng lfed,lun4 WOOD@ magazine sbop rnanager HolidalSALE HolidrySFILE $5395 $3095 r 6" x 30' Capacity . 5HP,1Ph or 7.5H83Ph . Callfor tull specs A FEWMORE TIPS FROM OUR WOODWORKINGPROS .Sheet metal comes in handy when building shop fix- Quickly sharpen router bib and shaperc on tures, and on page 73 lean a simple J-step method DMT Diamond Vllhetstones". Gomparcd to for making tidy bends in sheet metal. It's in the air fil- standard sharpeners, DMT Diamond tration system project. .'W'ondering what kind of finish you can put on cut- Vllhetstones: ting boards and other kitchen items to make them t Eliminate Grinding Seruice Cosf both food-safe and durable?We have some advice you and ExcessiveCarbide Removal can use in the cutting board project onpage 49. .If you're frustrated by planer snipe, take heart. Tool t Extend ToolLife 5-7 Times tester Dave Henderson found end-of-board dishing a planers, - problem with even the best portable and 0 Make Clean Cufs No Burn Marks! offers a smattering of snipe solutions onpage 94. Diamond Machining Technology,Inc. l-NA A;]? Marrboroush'm"'#::ff6'4DMr lll A\|- 30 WOOD Magazine Winter 1999 CircleNo. 112 Double-bevelingisjust the icingon thismitersaw's cake Until recently, the ability to cut left- scale under a fixed cursor which and right-bevels was limited to more- makes setting accurate angles easier. expensive sliding compound miter- And, because the cursor is well to the saws. So when the folks at Hitachi right of the blade instead of directly said that their C10FCD nonsliding beneath it, you avoid the constant mitersaw could cut up to 45" bevels head-jockeying to see the miter angle on either side, I knew I had to get my that other saws require. hands on one. Now that I have, I'm The ClOFCD features a generous impressed. But the dual-beveling 13-amp. soft-start motor that didn't try capacity is only one of many things I to torque the handle out of my hand like about this saw. when I pulled the trigger. Electronic For instance, just as on their 12" speed control senses when the tool is sliding compound-miter saw, Hitachi under load and automatically compen- engineers placed the Cl0FCD's sates by pumping more power to the motor above and behind the belt- motor to maintain blade speed. driven blade. Besides providing the Although I can count on one hand necessary clearance to make 45"-ight the number of times I've needed to bevels possible, the move also result- cut a right-beve1 compound-miter, this HitachiC10FCD compound mitersaw ed in a quiet, well-balanced machine; saw does make the process much I didn't have to wrestle against a stiff more intuitive than a regular miter- spring to lower the blade into my saw. But right-bevel capacity or not, workpiece. you'll be pleased with the perfor- ***** I also like the innovative miter scale; mance-and price-of this light- For the location of a Hitachi dealer instead of moving the cursor over a weight, feature-packed mitersaw. near you, call 800/5461666. fixed scale, the C1OFCD moves the -Tested by Daue llenderson Continued on page J4 THcftffirrcnffigtr'{ $ounGCFon WOOoWonNfrTG INOO$RilD $upputcil a z4-HourShopping I Over25,000 Tools & Accessories I SpecialSales & Offers I Tool ComparisonCharts I FreeSeminars www.woodmall.Gom -1 sfiilrt Continuedfrom page JJ Dremelgoes digital for itstu rn-of-the-centu ry rotarytool Dremel has been making high-speed rotary tools for so long, its name has become practically synonymous with the category. The company's latest entry into the field-the Professional model-builds on that reputation in fine fashion. Unlike other variable-speed tools, the Professional shows the rotational speed on a large liquid-crystal display. Each push of a speed-control button raises or lowers the speed by 1,000 The Professional has a couple of life- revolutions per minute, from 5,000 to lengthening features it would be eas1, 30,000 rpm, giving you precise to overlook, such as user-replaceable DremelProfessional High Speed RotaryTool Kit 3981 adiustments for iust about any task. motor brushes that don't demand dis- I like the tool's "soft start" feature, section of the tool, and a cooling fan ?erformana"fr **** which brings the tool up to speed that exhausts out the front and keeps gradually instead of practically yank- debris out of the motor. The model ing it out of your hand on a high- we tested came with a plastic storage xxxxx speed start. And electronic feedback case and 25 accessories, model 3983 For more information, call Dremel control senses when the tool is under sports 40 accessories and a larger case at 8OO/437-3635,or visit online at load and compensates by automatical- and sells for $ 1 19..F www.dremel.com. ly adjusting the speed. -Tested bv Daue llenderson Let'sClearthe Air., InnoducingThe New Model 750 Si*ply TheBest! . VoriobleSpeed Control . 95%ASHRAE (200CFM to 750CFM TestedMoin Fiher FiheredAirl . LifetimeWononty . Two SpeedOn/Off Pull . 30 Doy Choin MoneyBock . UJtroQuiet Guoronty' ,T,h. NationalInstitute for OccupationalSafetyandHealth (NIOSH) I recommendslimiting wood dust exposures. TheJDS Air-Tech 2000 r.,,,1,. will dramaticallyimprove the quality ofthe airyou breathe. Our new model750 variable speed allows you to dialin yourdesired air flow froma whisperquiet 200 cfm to anultra performance 750 cfm. This will cleanthe airin a 30'x30'x8'shop ten times per hour. For larger areas our models 8-12 and10-16 are available. TheJDS systems willremove 9970 of particlesas smallas five microns and 800/o ofparticles ^ r.Tfl^:^,, Qt KO 00 onemicron. For the removalof odors,fi11gg 2'" sm{rkp | ' 1 ouroptionalcharcoalfilter isavailable. ro prrJ"l,i'l'rt'l Vfl"trtr; or for thedealer nearest you call us toll-free. *BetterHomes and Gdnhnf Anotherqualit', product from JIllSi ,,1 WOODolHs8rrfue (t'loo'95) USA ,, , C()MPANY ATR-IEGI] AOIN'- ru tDs 1-800-382-2637 ring country charm detail lines, such as the birds's wings, To saw the lines, thread the blade indoors with this quaint drill one hole for entry into the entire through the start hole for the first lines. line. (Start you quail cutout. With win- series of wherever want.) Scrollsaw master Rick Hutcheson, "You'll probably have to hammer the dow light streaming who cut out our quail picture, drilled blade ends flat to fit your saw's from behind, this lovelv starting holes for the detail lines with clamps," Rick counsels. "And remem- scene takes on nature's glow. a *58 twist drill. (See the Buying ber." he adds. "these blades have a Guide for a source.) A larger hole, say top and bottom just like regular ones. First,scrollsaw the quail picture %r,",works fine for the cutout areas. The teeth must point down when you 1 Photocopythe full-sizequail pattern 3 Saw the detail lines first, using a install the blade." in the V/OODPATTERNSo insert. thick blade so they'll show up with Unlike ordinary scrollsaw blades, Stick the pattern to a V+x6y'sx8i/s" backlighting. To cllt a wide kerf and spiral blades cut in any direction. piece of Baltic birch plywood using still be able to make the sharp turns, "Spiral blades are hard to control; just spray adhesive. project designer Steve Grimes recom- try to stay on the line as much as pos- 2 Drill blade start holes inside the larg- mends cutting these lines with a sible," Rick advises. "If you do stray er clltollt afeas and near one end of #0 spiral blade (.011x.028" with off a line, steer back to it gradually; each stopped detail line. For joined 41 teeth per inch). don't jog back suddenly." Continued WOOD Magazine Winter 1999 37 UAIL r 11/z' COUNTRY 170q"rabbets 7ee"deep 1s/aq"rabbels i e/sz"deep @ '/rz" grooG 4 After sawing the 7ez"deeP .= detail lines, cut out the openings, including the eyes. Rick recom- 67ex 8zla"glass mends switching to a 63/e x 87/e" *2R blade (.014x.032"wirh ricepaper 20 teeth per inch, reversed teeth at the bottom) for smoother cuts here. 5 Remove the pattern. Sand the faces 87/B' as necessary to femove any fuzz. EXPLODED Now, build a frame for it VIEW 1 Cut two 3/ 38 WOOD rnagazine Winter 1999 r This Mahaska longbow has a honey-locust riser. The arrow quiver is made from the skin of a javelina shot in Texas. owa boyer Kent Ostrem knows all about Robin Hood. But he'd rather talk about men such as Fred Bear, Howard Hill, Ben Pearson, and other renowned archers of tlre 1950s and I96Os. They were "traditional" bowmen who used fiberglass-backed longbows and recurves to hunt game world-wide. Their exploits were celebrated and greatly contributed to archery's growth into a popular pastime. "Today, you'll fincl three types of archery: primitive, using all-wood self- bows like the American Indians did; traditional, with glass-backed, laminat- ed-wood longbows and recurves; and mechanical, with compound bows," explains the 4Z-year-old bow maker. "Myself, I was a traditional archer before there was a name for it. I start- ed bow hunting in 1968 with a Bear recurve that my dad bought me. In 1973 I finally shot a deer, and did it pretty consistently after that. About L976, compound bows became popu- lar. The first one I saw was in Mecbanics lllustrated, which was where it belonged with all its pullies and other components! I thought that was the most ridiculous thing I ever saw. It could never catch on." Young Kent made a wrong call back then. Compound bows became the rage, mainly because their system of pullies enables an archer to draw the bow with some 60 percent less effort than a traditional bow. But with some, Kent Ostrem assumes the traditional archer's shooting stance with one of his handcraftedrecurves. Continued Wood Magazine Wintcr 1999 4r BackyordBowyer bows and keep the price reasonable. My most expensive bow would be the premier recurve ^t $42O. My long- bows are relatively basic, but good looking, and cost around $lOO. Yet, if somebocly wanted a $6OOto $700 bow, I'll build it!" The first three years, Kent was travel- ing to traditional archery meets all \ acfoss the nation to show his bows \ and take orders. "No'w that I'm fairly well established, I depend on word of Limb laminations of walnut, Osage mouth, advertisements in archery fiberglass sit atop the work- orange, and magazines, and a couple of tradi- bench with a riser blank. iust tional shoots [meets] a year," he says, a romance with longbows and almost sighing in relief. "I've also Fadeouts recurves lingered. "Today, there's an developed pockets of customers anti-high-tech attitude. People want to around the country-I sell a bow to get back to the basics," Kent one archer and others see it and order observes. "Yet, many don't want to theirs. And I operate another business get quite as basic as primitive archery. arranging and guiding bow hunts that That's where I come in. I fill the niche keeps me busy in the spring ancl fall." with custom-made, traditional bows." The woods behindthe 'glass The birth of a bowyer Kent made his first bow from a kit Kent's one-man bow-making business because the bowyer he called for a thrives from his Oskaloosa, Iowa, custom bow clidn't work in the woods home. His fiberglass-backed longbows he wanted. Due to that experience, and recurves find their way around he now offers his bows in a wicle Arrowshelf the world. But it took a lot of new range of woods for risers and limb- skills and bad bows to reach the high core laminations (see Anatomy of a Riser--___* level of customer satisfaction his longbow drawing, left, ancl "The Mahaska Custom Bows have attained. bowyer's top woods," on page 45) (Mashaska is the name of an Ioway "For limb cores, I primarily use red Indian chief of the mid-1800s.) elm-it's the most popular-Osage "I started making traditional bows in orange, cherry, walnut, and, as an the late eighties as a hobby," says accent lamination, sugar maple," Kent Kent as he examines the wood-and- comments. "There are so many native fiberglass laminations for a new bow. woods that I could use because it's a "A friend and I ordered bow kits. But matter of fact, yon conld probably 'glass-backed as I read the instructions, the methods make a bow out of a seemed like they weren't effective. So pine block. You see, unlike a self-bow I began doing some reading and built made from one piece cf wood, in a it following my intuition. After that Limb laminated bow it's the fiberglass back- first one, I got so hooked that my ing that's doing the work. The wood 'Bow friends started calling me the of in the core people pick for its appear- the Month Club.' I spent all my spare ance. For instance, there's hackber- time making bows to sell. ry-real pretty stuff. I'd use that for a "Finally, in 1992, I thonght I had bow up to around 5o-pounds pull. enough business to do it ftllltime," he And even catalpa, though it's weak, continlles. "Luckily, my decision tied doesn't easily split and looks great. in with the resurgence in traditional Bnt I'd only recommend it for a low- Anatomy of archery. It's still a relatively small mar- poundage kid's bow." a longbow ket, bnt there's enough to make a liv- For bow hanclles, called risers among ing. And I'm not building real elabo- bowyers, he needs strong wood rate bows. I make quality custom because that section bears the brunt Nock ,/ 42 Wood Magazine Vinter 1999 of the pull when the bow is drawn. error. But if they slip, they've wasted ally 3O-6) required to bring it to full And he frequently turns to exotics, a bow." draw with a 28" arrow. The higher the such as shedua, zebrawood, and bub- Kent tries for even pressure."I don't draw weight, the more muscle it takes inga. "There are a lot of people in tra- want to crush the bow, just get good to pull and hold the arrow on target. ditional archery who really know their glue lines." After all the clamps are in Seems simple enough, but getting woods, and when they call to order a place-a C-clamp about every 2" from there from a laminated blank is really bow, they want something specific," tip to tip with protectors on the the hardest plrt of building notes Kent. pads-the glue-up goes into the heat- a bow, according to Kent. box. That's an insulated, bench-high Of course, it's not a guessinggame. Tipson layingup a bow unit built of plywood and wired with After a decade of bow making, Kent Building a bow requires precise align- six 100-watt incandescent bulbs on a has accumulated fastidious notes ment for complete adhesion of its timer as a heat source. as shown in describing what went into each cus- fiberglass and wood laminations, plus the photo belout. tom bow that came from his shop. the riser. Otherwise-at the least- "I could leave the clamp-up to dry on That way, when someone orders one the bow won't shoot straight. At the the bench. But I'm going to cook it at similar to any he's made, he has refer- very worst, it could break when 170' for six or seven hours," he says. ence to materials, type of laminations, strung and drawn. "That way, it can withstand being etc. to use again. "Most of my longbows are 'three- locked up in a car on a hot summer "'What determines a bow's draw lam,' that is, two laminations of the day without delaminating." weight is the thickness of the fiber- same limb-core wood with an accent glassand the wooden limb cores," he lamination sandwiched between," Gettinga bow to weight points out. "I state my bows to be explains Kent. "Then, there's a one- A bow's draw weight, or pull, means plus or minus two pounds from piece fiberglass lamination over the the number of pounds of energy (usu- Continued. wood on the back and a two-piece At his workbench, Kent cleans laminations with denatured alcohol before gluing one on the belly above and below the them up. In the heatbox below, a glued-up bow clamped to its form awaits removal. riser." Extra-long longbows get four laminations and recurve bows two. Kent buys and uses sanded and tapered wood laminations that are thicker at the butt end near the han- dle and taper at a. ra,teof .002" per inch to the tip. So, a lamination of red elm might be nearly Vs"thick at the butt and paper thin at the tip. The fiberglassdoesn't taper. Taper in the limbs gives a bow a bull- whip effect that snaps taut the bow- string with great efficiency. Some bowyers like taper; others don't. And some combine parallel (untapered) and tapered laminations. To lay up and glue the laminations requires a reusable jig called a bow form. Most bowyers make two-piece forms that clamp together-one for each side of the bow with the void between in the desired bow shape. Kent, however, prefers a one-piece form on which he lays the epoxied laminations,.then clamps them snugly in place. "My laminations are always 2" wide, so if they slide a bit under pressure I'll still have a bow blank after I trim them off to 1" or so," says Kent. "Many bowyers use narfowef laminations that don't have leewav for http ://www.woodmagazine. com BackyurdBowyer ordered weight. And that's pretty pencil to lay out the bow's shape on get it down to draw weight. At the much understood in this business- the blank. Then, he moves outside sanding drum on my drill press, I'll it's not rocket science. Still, I'm not where he'll saw out the blank free- further refine the shape of the limbs going to sell something that some- hand on his portable benchtop table- and the riser." one's not going to be happy with. saw. "That fiberglass dust is really too Following the drum sanding comes a That's why when I build a new bow nasty for the shop," he says about the thorough smoothing by hand with 80- design, it takes me a dozen or so of outdoor operation. "Lots of bowyers through 22O-gnt abrasives. Should he them to get it down to draw weight in rough-out with a bandsaw, but the find any detracting checks or open the various lengths flongbows from fiberglass eats up those blades. On the grain in the riser, he'll rub in a little 62-68", recurves from 52-62"1." other hand, my little carbide tablesaw Super Glue, then sand the spot Kent continues the work of getting a blade has lasted over seven years." smooth. To finish, Kent sprays on bow to weight after it comes out of \fith the bow now sawn to rough eight coats of Defthane (a the heatbox and he unclamps it. He outline, Kent hauls out the stationary poll.urethane; lacquer would crack) in runs a strip of masking tape down the belt sander and begins to take off either gloss or satin. For an archer bow's back, then clamps a mason's more of its limb core and to rough- desiring a flat finish, he knocks down string from tip to tip, centering it over shape the riser. It's an attentative the satin with extra-fine steel wool. the riser. "Centering the string has a process as he pauses frequently to Finally, Kent wraps the riser in leather major bearing on how the bow will string the bow and take measure- and glues the leather pad on the shelf eventually shoot. The string has to ments between string and limbs iust (arrow rest). track straight in relation to the riser," below the fadeouts (where the riser To a novice, the bow-making 'Just he says. a teeny bit off and you'd feathers into the limb-core lamina- process might seem tedious and error- 'glass never get the bow tuned properly for tions). "To be absolutely true, the pfone, and it really is. "The can good arfow flight". bow must bend in the same plane- splinter if hit the wrong way with the Once the bowyer has marked the the string has to run right down the blade or sander and you'll ruin a bow center line, he uses a specific tem- middle of the riser," he notes. "By tak- just like that. Making one from scratch plate for that weight of bow and a ing off a little here and a little there, I is not for a beginner because you can To avold lllllng his shop with fins and smelly tlberglass Sandlngnot only smoothsthe bow; lt'a necessaryin order to shape duat, Kentsaws lhe bow blankto lough ahapeoutside. the llmbslo arriveat the desircddraw weight. During sanding, constant measurements between the strung bow's At his drill press, the bowyer further refines the shape of the limbs and string tell Kent how close he's coming to the draw weight. bow's risers and limbs with a drum sander. invest $50 in materials and with one stroke turn it into junk," Kent com- Wantto see morecustom bows,even makeyour own? ments. Then, he cautions. "And if not For a color brochure of Mahaska Kent can't answer personal questions made right, a bow can be dangerous Custom Bows and information on regarding bow making or materials. when you go to string it- somebody guided bow hunts for iavelinr, black He suggests contacting the following could get hurt if the limbs break. For a bear, whitetail deer, and buffalo, write resoufce for videos, bow kits, and beginner, a kit is the way to go." (See MahaskaCustom Bows, P.O. Box 452, materials: Traditional Bowyers Supply, box at rigltt, top.) Oskaloosa,lA 52577.,or call 515/673- 445 N. Stine Rd., Charlotte, MI 48813. After many hundreds of bows over 5501. Sorry, due to time constraints, 5r7/543-8167 the years, though, Kent has the bow- making process down pat. He can complete a bow in about five hours A BOWYER'STOP WOODS (not including its curing time in the Nothing can stir up a more heated discussion among bowyers than the topic of heatbox). "I could build a ton of bows the best woods to use. Many bowyers favor the following. (Note: Under limb- in a week if I wasn't on the phone core woods, the modulus of elasticity (ME) indicates how easily it bends or half the time," Kent says,feigning flexes. The higher the number the greater the resistanceto bending.) exaspefation. "Potential customefs call with questions about bows and Limb-core woods my hunts. Sometimes I talk to a per- Black locust. Not especially pretty, but available and inexpensive. ME=2.O5 son for a half an hour making a sale. Sugar maple. Preferred for limb core accent, widely available. ME=1.83 But that's how it is when you run a Black utalnut. Dark, good shooting wood, relatively expensive but readily avarl- one-man business. Over the phone, able.ME=l.68 people will often ask,'Are you the Red elm. Readily avaldrableand inexpensive; attractive when flat sawn. ME=1.54 boss man?,' thinking that I've got a Black cberry. Not as stiff as some choices, but attractive and durable. ME=1.49 manufacturing facility here. I reply 'I Osage orange. A favorite for self-bows, fine-grained, orange color darkens with am the only man.' And that's what age. No stated ME, but approximates black cherry. archers really want, to talk with the person who is actually going to build Riser (handle) woods their bow." i Straight grain, strength, and attractiveness are desired for this part of a bow. Natiue bardutoods: ash, black walnut, butternut, glm, hackberry, locust, Osage orange, and red gum. Written by PeterJ. Stephano Photographs: Marty Baldwin Exotic ltard.utoods.'bocote, blackbean, bubinga, cardinal wood, cocobolo, Drawing: Brian Jensen ebony, granadillio, koa, paduak, purpleheart, rosewood, shedua, tulipwood, and zebrawood to name the most popular. Wood Magazime Winter 1999 45 Quilt Block For Startwork in the middle 1 Photocopy the Full-Size Star Pattern in the WOOD PATTERNSa insert in the middle of the magazine. Carefully separate the pattern seg- ments, keeping all of the pattern lines intact. 2 Using spray adhesive, adhere the pattefns for parts A and C to l"-thick Honduras mahogany stock. Stick the patterns for parts B and D onto 1" walnut stock. Atign the arrows with the wood grain. 3 Bandsaw parts A, B, C, and D, stay- ing slightly outside the lines. Sand the edges marked I and 2 to the pat- tern lines. These will be gluing sur- faces, so sand them straight and smooth on a disc sander or wide belt sander, using a l2O- or 15O-gritdisc or belt. 4 Referring to the Quilt- Block Cutting Board draw- ing in the pattern insert, lay out the parts in A,/B and C/D pairs. Ensure that the mat- ing edges between each pair fit well; then glue each pair together. Align lnstructiOnsat'rtght the V tails, as shown opposite Page, :l i top left, and keep the faces flush. 5 Sand each assembly to the outside lines (marked 3 on the patterns). Each A,/B assembly should measure Ladybug 2" from edge to edge, with the edges Seruing Board joint See page 49 straight and parallel and the Notjust one, centered. Similarly, the C/D assem- blies should measure2" long. 6 Glue these four sections into two butthree assemblies,joining them along the B- C line (marked 4 on the patterns). sharp... **- To do this, sand the mating surfaces to the pattem line as before. Test-fit the parts before gluing to ensure that B and C form a 90" angle, as shown opposite page, rigbt. 7 Sand each A/B/C/D assembly to ...cuttingand the line marked 5 on the patterns. Holding the two AB|C/D assemblies ervingboards together, check the angles between A and D; they should be 90'. 8 Glue the two A/B/C/D assemblies together. Align the points so they meet at the center. WOOD J0'|.agazine rVinter 1999 Canapes EXPLODEDVIEW 1lexllz x 8" spline 7116" 1"f-- /,tla' 1le llz x spline 171.,o" x 8" t"" 1/s"dadoes Align the V-tailsof the star arms as you 1/+"deep glue the pieces together; you can adjust the points later, if necessary. SEETHE WOODPATTERNSa 9 Adhere the patterns for parts E to INSERTFOR 1"-thick maple stock. Bandsaw them, Bill of Materials FULL-SIZEPATTERNS and sand to the line where they fit into the star. Leave the parts slightly Finished Size Part $ overwidth until they're glued in. Then T w L = a sand them flush with the C/D tail A- point 1 HM z points. Remove the patterns. B- point 1 W 2 C. sidepoint 1 HM 2 Builda squarearound the star D. sidepoint 1 W I 1 Cut parts F, G, and H to the thick- E-side filler 1 Z M 2 ness and width shown in the Bill of F- boardmiddle 1 MB Materials, but make F and G /2" longer G-end filler 1 z M 4 and H 1" longer than specified. H. boardedge 1 I M z 2 Clamp, but do not glue, parts F to 1 W I the A./B/C/D/E assembly (the star). l- frameend 8', Ensure that the two parts F fully span J* frameedge 1 10" W z the distance from A or B to the point -Cutparts oversize initially; then cut to finished on C or D, as applicable. sizein accordance with how-to instructions, 3 Lay out and saw the mitered end of MaterialsKey: each part G. Slide the pieces into HM-hondurasmahogany; M-maple; W-walnut place between parts F, and check Keep the star arms at 90'to each other. Supplies:polyurethane glue, finish. their fit at the end against parts A and Accuracy here ensures success later. B. Adjust the end fit by sanding. 4 Glue parts F and G to the star. Keep Framethe blockwith walnut 3 Cut tsvo YexVzx8"splines from hard- the surfaces flush by clamping the 1 Cut the board ends (I) to the dimen- board. Glue on the walnut ends (I), glueup between platens covered with sions shown. (Verlfy the width of I by inserting the splines in the joints. waxed paper. measuring the lamination's width.) 4 Verify the overall length of the 5 Glue parts H to the assembly. 2 Form a Vs" dado V+" deep, centered board; then cut the board edges (D to 6 Measure the width of the board, on each end of the board, where size. Glue the edges to the board. from the outside edge of one part H shown in the Exploded View drawing. 5 Sand the board smooth and flush. to the outside of the other. Trim the Cut a mating dado on one end of each Sand a round-over along all edges. board's length to the same dimension, part I. (Because of the grain direction 6 Finish, referring to Tips on finisbing centering the star on the board. on parts I, the ends are long faces.) your cutting board on page 49. Continued /- lr t tp ://www. woodmaguzi nc. conr +/ Cutting Boards Oh, Domino Laminatethe basic board 1 Cut eight t/+xLYzxlJ" pieces of maple, and joint both edges to a fin- ished width of 7/s". (These edges will become the faces of the ly's"- thick laminated cutting board.) 2 Laminate the boarcl blank, using poll'urethane glue for moisture resis- tance. The open time-the time allowable for assembling and clamp- ing parts-varies among brands of polyurethane glue. Check the open time for the brand you're using; then 3 Mark the centers for seven 1" holes laminate only the number of pieces on the top face, where shown on the you feel confident you can glue up in the glue-up and the platens. Similarly, full-size pattern in the WOOD PAT- that time. You can laminate several line up the subassemblies when you ZERNSo insert. CYou can photocopy subassemblies, then glue those togeth- glue them together. the pattern and adhere it to the board er to build the board. CVe glued up 3 Sand both surfaces smooth. Sanding to mark the holes, if you like.) two four-part laminations for the to about 120 grit will be adequate at 4 Bore a 1" hole Vt" deep at each cen- domino board.) this point. ter mark, using a Forstner bit chucked When working with polyurethane 4 Crosscut the board at both ends, in a drill press. glue, WOODa magazine pro je ct trimming it to finished length. 5 Slice seven t/+"-thick discs from a 1" builder Chuck Hedlund keeps a 5 Sand the edges and ends to 120 grit. walnut dowel rod. (To do this, we sponge paintbrush and a cup of water first sanded one end of the dowel rod handy. Because moisture helps cure Decorateit likea domino true, using the miter gauge on the the adhesive, he applies glue to one 1 Saw a Va"-wide kerf Vs" deep across disc sander. Then we clamped the rod side of the joint and bmshes the other the middle of the board on the top to the bandsaw's miter gauge, and cut part with the dampened brush. face. (An outside blade from a stack- off the V<"piece. Next, we took the Line up each lamination's faces flush able dado set does the job nicely.) rod back to the disc sander, sanded during gluing; this will make the next 2 Resaw and plane a piece of walnut the sawn end smooth, and sliced off step easier. To align the faces, sand- scrapwood that's about 1" wide and at the next piece, continuing this wich each glue-up between two least 6yz" long to a thickness that fits process to make all seven markers.) scrapwood platens, as shown belotu. snugly into the board's kerf. Cut a 6 Glue the walnut discs into the holes. (Pllqrood or particleboard pieces a lit- piece of the thin stock to about %r," 7 Sand the top face of the board flush. tle smaller than the glue-up would be wide, and glue it into the kerf. After Then rout a /s" round-over all around fine for the platens; we made them the glue dries, plane or sand it flush the edge on both sides. approximately tAx/Vzxl2" for this with the surface, and trim it flush 8 Apply a clear finish, referring to the board.) Place waxed paper between with the edges of the board. tips on the opposite page. EXPLODED VIEW I V, x 1/ax 6" walnut stock---l 1" walnutdowel 1/q" 13/e' lhick 13/+" \ l- ) 1" hole t/a" deep t/a"round-overs Sandwich the lamination between scrap- wood platens to keep the surfaces flush. 3/qx13/a x 12" maple (8 needed) 48 WOOD Magazine Winter 1999 Ladybug, Tipson finishing Ladybu0 yourcutting board 1 Finish-sand the board, using progres- sively finer grits from l2O to 22O. 2 Raise the grain. It's inevitable that a cutting board will get wet, so to mini- mize accidental grain-raising later, raise it now on purpose; then sand it off. To do this, wet the board thoroughly. Let it dry overnight; then sand the fuzzy-Iooking swollen fibers smooth, using sandpaper one grit finer than the finest one you sanded the board with. Build up the body first Don't sand down into the wood under 1 Cut 11 pieces of cardinalwood or 7 Bandsaw the body to shape. Saw the swollen fibers. another reddish-colored hardwood slightly outside the pattern line, and 3 Apply polyurethane or an oil finish. 3/r'xlx9./<", and laminate them into a sand to it. Polyurethane is a good choice for lx8%x9./4" blank. 8 Remove the pattern, and sand the boards on which you'll build sand- 2 Photocopy the Ladybug Body Full- top surface flush. Then rout a wiches, slice cheese with a wire cut- Size Pattern, found in the WOOD PAT- V<"round-over along the top edge. ter, or serve hors d'oeuvres, for exam- ZERNSo insert, and adhere it to the ple. This durable finish resists abra- top of the blank. Center the body Add the headand tail sion, wipes clean, and stands up to from side-to-side on the blank. 1 Adhere a copy of the Head Full-Size washing (and wet food) better than oil. 3 Rout of saw a Vt(,"groove V<" deep Pattern to a t/ http ://www. woodmagazine. com 49 -1 ATI In the days before pharmacy chains and mail-order pre- scription services, there was 4$thecaryb the local apothecary or phar- macist. This individual pre- pared all manner of remedies Fiiend for ailments ranging from An Up-To-Date Version gout to mysterious fevers. And more often than not, he of an American,Glassic stored his antidotes in a cabi- net very much like the one we've designed for you. Ours is great for storing all sorts of things. And it holds its own as a home accent piece, too. Start with the birch plywood carcase 1 Cut the sides (A), top, bottom, and shelves (B), and dividers (C) to the sizes listed in the Bill of Materials. (We used birch plywood.) Note that all these pieces are the same width. For flush front and back edges later, set your tablesaw fence, and rip all pieces to width at the same setting. 2 Mark the screw-hole centerpoints and slots on the sides (A) where shown on the Parts View drawing and accompanying Slot detail on the WOOD PATTERNSo insert in the mid- dle of the magazine. 3 Mark the divider location center- lines across the bottom surface of shelves 81-85 and the /op surface or shelf 86 where shown on the Parts View and the Divider detail accompa- nying the Carcase Exploded View. Measure carefully to ensure tbe cen- terlines are Accurately located for consistent-size openings later. 4 For securing the dividers (C) later, mark the screw-hole centerpoints on the marked centerlines on 82-86, where shown on the Parts View draw- ing on the insert. Note that 82 has two extra sets of holes for the two additional dividers (C) at the top of the cabinet. Drill the countersunk mounting holes where marked. 5 Build the gauge shown in Step I of the Marking Gauge drawing. Align the gauge with the marked centerlines on 81-86 as shown in Step 2 of the draw- ing. Mark a pair of reference lines on front edges and surfaces of the Bs for WOOD Magazine tVinter 1999 Ss** locating the dividers (C) later. MARKINGGAUGE 6 Locate and form the slots in the top (Bl) (H) for securing the top later. Aligncenterline on gauge 7 Mark the locations, and use a with centerlinesmarkel,,on (9.. pocket-hole jig to drill the pocket holes in the dividers (C) and bottom surface of the ends of all the Bs. See the Parts View and Carcase Exploded View and accompanying Pocket-Hole and Divider details for reference. I Screw (no glue) the sides (A) to 81, keeping the top end of the sides (A) flush with the top surface of B1. 9 Construct a simple right-angle clamping support as shown on locationon (81-86).Use a Installing the Dividers and Shelves square to extend lines to opposite drawing. Use the support to hold the edge and also on the frontedge. dividers (C) in place and square to 81. Then, screw the four dividers in place. INSTALLINGTHE DIVIDERS Use the reference lines marked earlier AND SHELVES to accurately locate the dividers. RIGHT-ANGLE 10 Position, clamp, and screw the CLAMPING second-to-the-top pllurood shelf (82) SUPPORT in place as shown at rigbt. 11 Repeat the procedure in the pre- ceding two steps to secure the remaining dividers (C) and shelves and bottom (83-86) in place. Create a finished look with banding 1 Rip at least 30' of V+"-thickstrips from the edge of 3/<"solid stock. OVe found it easier to rip plenty of edging to start, and then cut the individual '.-,4 / pieces to length from the long strips.) \_ 1rl2,'poCket_hole 'pocket 2 Measure the lengths to fit your cabi- Top of cdbinet holes screw net (these may vary from ours due to thickness of plywood), and miter-cut the banding (D, E) to length. Glue and clamp them in place, with the inside spacersfor the installationand levelingof the next edges flush with the plywood carcase. Sand the outside edge of the banding ATTACHINGTHE BANDING flush with the outside of the carcase. 3 Cut banding (F, G) to length. 4 Cut a Vt6"rabbet Vte" deep across the ends of the front face of banding strips F and G where shown on the Attaching the Banding drawing. Outsidecase parts provideclass 1 Edge-join enough ll/rci' (fwe-quarter) cherry to form the top (H). Later, femove the clamps and trim H to the size listed in the Bill of Materials. 2 Referring to the Top Section View detail accompanying the Exploded Continued http://www.woodmagazine. com 5r 4.EEtheca.ry's Fiiend View clrawing and the four-step ROUTINGTHE TOP Bill of Materials Routing the Top drawing, rout the FinishedSize side and front edges of the top (H). STEP1 Part o > 3 Edge-join enough .:/i" cherry to make Place(Dfacedown T W L = a on tabitssaw.and the sides (I). Trim them to final size. cut a saw kerf along CARCASE Transfer only the bottom slot and hole frontand ends. 3/e,,_ A sides 3h' 101/q' 35V4" BP z locations from the sides (A) onto the B top,bottom solid-wood sides (I). Drill the holes &'shelves 3/q' 101/q' BP h and form the slots. You'll need these C dividers 3/^' 101/i' 5' BP 12 later to attach the base sides (L). 4 Cut the base rail (D to size, being BANDING careftil to keep its length the same as D banding vi' 3/A' J+f2 z the width of the assembled pll.rnrood E banding 1/q' 3/4' 291/z' 2 3/,i" cafcase. Cut a rabbet V,i" deep Sawblade Tablesaw I l\_ 1/a' 3h' across the back side of each end F banding 33 4 where shown on the Carcase STEP 2 G banding 1/r' 3/a' 5', t/ 12 Exploded View drawing. Drill the 10 Place@face down TOP.SIDES, AND BASE mounting holes, and then glue and on routertable. and cul a s/'ra"cove along H. top 1t/rc" 12" ?q" tl./ 1 screw the base rail in place. front and ends. 5 rVorking from the inside of the cabi- l. sides 3h' 11 35vi' EC 2 net, screw the top (H) to the cabinet 3/t' J baserail JJ/4 341/z' 1 top (81), keeping an even overhang at the ends, and a t/i" overhlng across K. basefront V4" JI f2 c 1 the back to hide the plywood back L. basesides 34', cf4 113/4" c (X) later. Center the screws in the DRAWERS slots, allowing the solid-stock top (H) to expand and contract freely. M fronts 3h' 47/s' 57/a' U 25 6 Screw (no glue) the sides (I) in N spacers 3h' 3h' 4?/Ei' (/ d place, using the previously drilled 1/z' holes and slots in the sides (A). 0 fronts 47/a' 1z', B d PlaceO face down.and rout a bead 7 Cut the base trim pieces K and L to P fronts 1/z' 4?/d' 53/e' B o alongfr-ont and ends. l-l size plus 1" in length. Referring to the STEP4 Q sides Vz' 4?/d' 91/z' B 34 Base Side Section View detail accom- Lowerbit, flipQf ovet 1/z' panying the Exploded View drawing, (faceup), and rout R backs 4Va' 1z'. B d 7e"round-over along fout a t/2"foLlnd-over t/s" deep along 1/z' bottomedge of fronl S backs 41/e' 53/a" B I the top edge of each piece. Then, cut and ends. T bottoms vi' BV4" 1z', BP o a Ve"decofative gfoove Vre"deep. 8 Miter-cut the base trim pieces (K, L) U bottoms vi' 83h', svd' BP I to length. Screw the side trim pieces DRAWERGUIDE/STOPS (L) in place flush with the bottom 3J-9 V guide Vi 117/rc" 9" a ends of the sides (I). Screw the front BP trim piece (K) in place flush with the W guide V4" 413/16t' 9" BP I bottom edges of the side trim pieces. X back V4" J.+f2 291/z' BP .Cut * Builda multitude of drawer fronts.) Cut the individual partswith an oversize.Trim to finished size accordingtothe how{o instructions. of matchingdrawers false fronts (M) from each strip. Note: You'll be making parts to cre- Number each front for ease in re-laying MaterialsKey: BP-birch plywood, C-cherry, EC-edge-joinedcherry, B-birch. ate single and double-uide dratuers, out the fronts later so the grain flows Suppfies:#Bx1t/2" pocket screws; #8x11/4", 11/2", using the sarne-sized false ft"onts. It is across each row of drawers. and2" flatheadwood screws, #6x%" flathead important to maintain consistenqt 2 Cut the spacers (N) to size. woodscrews, #17x3/+" wire brad, #17x1" wire when macbining the parts. 3 Measure the double-wide drawcr brad,clear finish. opening. Two Ms and an N should BuyingGuide t/i" 1 From cherty, rip enough material measure /s" less than the opening. Porcelainknobs, 25 %"-diameteroorcelain cabi- to make the false drawer fronts (M). 4 From Vz"birch stock, cut the dou- netknobs, catalog no. 130173. Woodcraft, 560 flVe wanted the the grain to continue ble-wide drawer fronts (O), single- AiroortIndustrial Park. P.O. Box 1686. horizontally across all the fronts, so wide fronts (P), sides (Q), and Parkersburg,WV 26102-1686, or call 8001225- 1153 to order. we cut one long piece for each row backs (R, S) to size. Cotttinuecl 52 WOOD Magazine Winter 1999 Attachtop, shelves,and *Not_e: bottom(81-86) to sides Mountingslots and mountingholes with pocket-holescrews. in @ andQ niustbe drilledbeforS assembly. *s/sz"hole, countersunkon bottom surface *s/sz"mounting slot Ta" long Pockethole -/ #8 x 11/2" pocket-holescrew POCKET.HOLE CARCASE #8 x 11/2" EXPLODED F.H.wood VIEW SCTEW o'u'o=*| #8 x 11/2", 351/q' pocket-hole v\ ,,,lffirzscrew s/sz"hole, countersunk on bottom *Tez"mounting slot7e" long "s/sz" hole, countersun k 13/q'---,-..{ 7/aq"pilol hole e/+"deep 21/q' 3/e" *7s2"mounting slot7e" long Note: Carcaseis madefrom ( 7+"plywood, which does not 25/a" measureexactly 3/q". All 141/+" dimensionsfor the spacing */sz" hole, of the dividers(C) are from countersunk centerlines.Use the marking on inside gaugeto locatedividers. Cut 7ez"holes, countersunk surface bandingto fit cabinet. on insidesurface s/q" labbel t/q" 'ltl2" deep #B x pocket-holescrew s/ez"hole, countersunk #8 x 11/z' F.H. wood screws 3/qx 51/zx 96" Cherry 1/zx 51/zx 96" Birch s/qx 48 x 96" BirchPlvwood 11A6x x O,@,@, 9tA 96" Cherrv "rlo@ t/zxSt/zx 96" Birch 3/qx 91/qx 96" Cherry 1/2x51/zx 96" Birch 3/qx91/q x 96" Cherry 1/zx 51/zx 96" Birch 3/ax 71/qx 96" Cherry 1/2x51/zx 96" Birch (3 needed) t/qx 48 x 96" Birchplywood http ://www. woodmagazine.com 53 ^ The 4ij6thecaq/'s Fiiend -POSITIONINGTHE Drawerset back is the same as the 5 Drill /-2"holes in the clrawer fronts DRAWERS thicknessof drawerfronts (O, P) where climensiclnecl on the Drawer clrawing. 6 Cut it 7''' groove t/.r"cleep in the clrawer flonts (O, P), ancl sides (Q) to house the b Installingthe drawer guide/stops 1 Builcl the spacer block shown on Positioning the Drawers clrawing ancl accompanf ing cletail. The spacer ensrlres that the false clrawer fronts will be flush with the case fiont later. 2 From %" birch plywoocl, cut the guicle/stops (V, W) to size. Flip the clrawers upsicle clown, ancl check that the guicles/stops slide easily between the bottom eclges of the clrawer sides (Q). Sancl if necessary'. QVe kept the front, ancl then from the back to fur- came from. Drill a hole in each false guicles rz'rr,"nitffower than the clistance ther secnre the guides in place. fiont where markecl for the screw-. between the clrawer sicles.) 4 Working fiom the front of the cabi 7 Rout A ru'i"cove along the outside 3 Referring to Inst:rlling the Drawer net, use clouble-facetape to temp >+ WOOD Magazine Wintcr 1999 -.,. ad." BASESl IDE ,/o SECTIOIN VIEWDETAIL /o 0=.----r /l@ R,A L- TOP SECTION %" round-over V:/ Donot rout back edge. with a t/e" VIEW DETAIL shoulder /a'$roove o - %0"deep .'- 5/a' #B x 11/q" r/ll '/a - F.H. wood { SCfeW / 4ffi #B x 11/z'F.H. 7sz"mounting slot woodWC screws s/e" @ long #B x 11/q'F.H. 1/q" wooo screw Singledrawer #6 x5/a"F.H. wood screws Double drawer #17 x 3/q" wirebrad l %0"gaps oh ootnsides of @ Top edqe otCD) 35I tirlr'r*ilr'.r toffurt"." of @ EXPLODED Transferlower screw VIEW holeand slot ontoO. 1\ Miter(Apply glue on )< miterededges only.) #8x11/q'F.H. wooo screw SEETHE #B x2" F.H.wood screw WOOD PATTERNSa INSERTFOR Routtop edge RTSVIEW DRAWING -rl t/2"holes centered Miteredcorner 91/2" over 1/a"holes in drawerfronts t/q" rabbet t/a" deep *Note: Drawersshould be 1/a"narrower thandrawer opening. t/+"groove t/q" deep '+" deep #17x i,, wirebrad DOUBLE SINGLE t/e"hole, centered DRAWER DRAWER %o"gaps on bothsides of @ between@s http ://wrvrv.rvooclmagazine.cour )) (left) and photo tachometer wene able to measure draw and cutterhead speed during various cutting tasks, The Latest PdrtableGeneration Fast Facts r All of the portable planers cut a high-quality surface finish that is comparable to that produced Planers by stationary planers. We test 10 machinespriced under $+SO r The amount of snipe cut on the ends of a board by these t's been more than a decadesince the first portable planer (the Ryobi machines has been reduced AP-10)was introduced. Before that, we had to rely on heavy, costly, with new models, but not totally tough-to-adjust, and even tougher-to-maintain stationary planers. But eliminated. Ryobi's little dynamo, with its die-cast aluminum body, integral universal r Quick-change knife systems on motor, and stamped-steel shroud, brought to our shops a down-sized thick- some of these portable planers ness planer we could afford. considerablyreduce the time Once the AP-10 caught on, other tool manufacturers quickly joined the and skill required to install fray, offering their own portable planers. And, as often happens, competi- knives accurately. tion brought improvements to the machines and, at the same time, kept o Portable planers are great for prices in line. small jobs and finish planing. lf To find out how the latest generation of portable planers perform, we you need to quickly hog off brought 10 of them into our shop and ran them through a battery of material on lots of rough-sawn detailed observations and tests. All of the planers have a maximum width stock, opt for a stationary plan- capacity of lZ-IZVz", except for the Ridgid with its 13" of width capacity. er instead. Whatwe learned A few wordsabout our set-upand testingprocedures from our test readings Once unpacked, the planers change the knives. (See the section In the chart at the end of this arti- required little assembly-mostly "'We like quick-change knives.") cle, we note how the amperage attaching the handles. Next, to Before starting the test, we ran draw and cutterhead speed changed ensure that the machines would each planer for 15 minutes with no for each machine as it encountefed produce flat cuts, we checked that load to ensure that the motor the cutting load. A powerful and each cutterhead was aligned paral- brushes were well seated. Then, efficient motor will draw fewer lel to the planer's bed and that the using an ampefage gauge, we mea- additional amps, and have a lower knives laid parallel on the heads. sured the power draw of each drop in cutterhead speed, than a For this we mounted a dial indica- under no load. At the same time we lesser motor. Although it was a tight tor upside down, then measured in took cutterhead RPM readings with race for the most part, the Delta 22- the middle and at both ends of a photo tachometer. 560, De\X/alt, Makita 2012, and each head. A wooden block and an For the surfacing tests, we select- Ridgid planers did slightly better inexpensive feeler gauge would ed 6"-wide pine and red oak than their peers in this test. work just as well for doing this. boards that were relatively uniform You'll note in the cutterhead- Four of our ten tested portable and consistent. These boards wefe speed columns of the chart that the planers-the Craftsman, Grizzly, crosscut into 16" lengths, then Makita 2OL2 is geared lower than Powermatic, and Ryobi-did jointed flat on one face. We also the other planers. Its no-load require some adjusting to bring used l2"-wide cherry boards to test speed-7,678 rpm-was the only their cutterheads to within .002" of how well the planers handle full- no-load speed under 9,000 rpm. In a panllel with the bed. But none of width cutting loads. Vre"-deepcut, it runs about 1,300 to the machines were perfect, so A test consisted of three passesof 2,4OO rpm slower than its competi- spending some time (about l0 min- each board through the planers at a tors. Although a higher cutting rate 'We utes) on this during set-up will pay }zre"cutting depth. took addi generally equates to a higher-quality dividends for a long time. tional power draw and cutterhead planed surface, the Makita pro- As part of each machine set-up, RPM readings under this [oad, aver- duced surfaces as good as any we timed how long it took to aging the three readings. machine in the test. Continued WOOD Magazine Winter 1999 >/ 11 ffi*rtmbilePlaners Recentinnovations help preventsnipe We likequick-change knives Portable planers have tra- fixed head assembly and If you dislike changing knives, you'll ditionally had one vexing elevates the bed instead. appreciate the nifty quick-change sys- problem-snipe-the It incorporates ball bear- tems used on the Makita 2Ot2. shallow divots that form ings where the elevation Powermatic, Delta 22-560,Ridgid, and on both ends of a planed screws go through the Ryobi AP12. All have knives that self- board. (See photo ^t table to stabilize the sys- align-you simply place them on the rigbt.) Some woodwork- tem. The Ryobi AP12, cutterhead and lock them down with- ers work around the although it still relies on out making tedious adjustments. Time problem by simply allow- twin centered elevation required: about five minutes. ing extra length and then screws, interlocks the The Makita knives have a full-length trimming away the snipe head assembly with the channel along the top face that aligns when they cut the work- case to give it greater with a ridge in the lock bar that holds pieces to final length. We rigidity. (Like the Makita the knife. Put them together and the prefer to eliminate or at 2OL2, the Ryobi AP12 will knives automatically fall into position We passed test pieces least minimize snipe to a soon be replaced by a under a stand-mounted on the cutterhead. Ridgid knives have point that we can lightly dial indicator to measure new model. See the side- a notch at each end that align with sand or scrape it away snipe depth. bar "Two planers too new nibs on the cutterhead. The Delta and rather than cutting it off. to test" onpage 60.) Ryobi planers use small oval-shaped (See the article on page 94 for tips on To further ensure that the cutter- holes in each knife that fit onto pins reducing snipe.) head remains stable during operation, on their cutterheads to simpliff index- Not surprisingly, the manufacturers Ridgid, Powermatic, De'Walt, and ing, as shown at rigltt. Powermatic have worked to overcome the prob- Delta (on the 22-550) added locking has a similar system, but its knives lem. Some, such as Craftsman, mechanisms that clamp the cutter- Dewalt, Grizzly, Jet, Powermatic, and head in place. See photo belou left. Ridgid, now have four corner posts The Ridgid, Powermatic, and DetValt holding the motorized cutterhead also have extra-long infeed and out- rigidly to the base. Many of the earlier feed extension tables for better mater- Thingsto keepin mind machines had just two centered posts. ial support. about cutting capacity All of the tested machines, except So, have these design changes elimi- All of the tested planers accept stock the Makita 2012, have tables at a fixed nated snipe? Yes and no. In our tests, up to 6" thick, except the Grizzly, height; you adjust their cutrerheads seven of the ten planers produced which goes 5" thick (which still up and down to change the planing snipe measuring..002" or less when strikes us as more than enough thick- thickness. The Makita 2012 has a taking a Vre"-deep cut. This represents ness capacity for these machines). an improvement over the results we And most of them have cutterheads A quick twist of a side-mounted handle reported from our November 1995 that can be lowered to within Ve"of locks the cutterhead of the Delta 22-560. test. At that time, snipe measurements their tables. If you want to plane ranged from .0005" to .006". stock thinner than Va",for safety and But let's put this problem into per- best results we suggestyou attach spective. Snipe that's .001" deep will the thin stock to a 3/<"-thickcarrier be barely discernible to the eye and board with double-faced tape. you can sand it away easily by hand or Although about half of rhe tested with a palm sander. Snipe that's .OO2 machines advertise a rnaximum cut- deep calls for a more aggressive ting depth of Vs",we recommend touch-we use a random-orbit sander you make cuts this deep only when to eliminate it. Snipe deeper than planing narrow (less than 3" wide) .003" gets cut off in our shop. 'When workpieces fed through the planer we cranked down these plan- one at a time. rJ7henutilizing most of ers to make aggressive, 7:2"-deep cllts, the cutting width of the machines, snipe depth increased by .001" or we recommend cuts no deeper than .002". Obviously, to keep snipe at a Vre".If you go much deeper than minimum, you must take light cuts, that, the machines 'We begin to bog especially on the final pass. also down and cut quality suffers found that our snipe measurements immensely. (fhese problems intensi- ran .0005" deeper in soft pine than in fy as knives dull.) Heavy cuts also the harder cherry and oak. will shorten brush and motor life. 58 WOOD Magazine rVinter 1999 ,t'T have round holes that don't allow you to move the knives laterally in case Miniplaner pal you nick them. $fith the other machines in the test, AA pair of magnetic Mini Planer Pals help you set the knife height with a sup- you change knives that don't self-align. plied gauge, then lock the knife in ( A magnetic holder helps you position place by tightening a series of fasten- the oval knife slots over the pins on the cutterhead of the Delta 22-560. lts long ers, hoping the knife doesn't shift as wrench keeps your fingers well away you tighten it down. Setting the from the sharp edges. knives to within .001" of parallel took from 10 to 15 minutes on the Dewalt, cutterhead and blades, you must first The Delta 22-550 and Makit^ 2oI2 and about fwice as long as that on the remove the chip chute. We found have another leg up in knife changing other units in this group. \(rith the them easiest to remove on the Ridgid, because the manufacturers provide Craftsman, Jet, GrizzIy, and Delta 22- Makita 2012, and Delta 22-550. wrenches that you can spin quickly 54O, we reduced the changing time to Knife changing also takes longer on for faster bolt removal. Ryobi and the 10-15 minute range by using a set the DeValt because you must use fwo Powermatic also provide socket head of Mini Planer Pals, a magnetic knife- different wrenches and roll the cutter- wrenches, but unfortunately they only setting jig (shown far rigbt). (Item head while you loosen and remove move the bolts a slow, one-quartef G3541, $29.95 plus shipping, from the knife bar screws. By comparison, turn at a time. The other units use Grizzly Industrial, 8OO/ 523-477 7 .) on rhe Delta 22-560. Makita 2012. and standard open-end wrenches that xe Other factors also affect knife-chang- Ridgid, you do this with the head slow and place your hands closer to ing time. For example, to access the locked in the coffect position. the knives. Knifealternatives affect Otherfeatures to your maintenancecosts considerbefore buying With planer knives, you have two 'Portabilitl'. tveight and handle basic options-those you resharpen type dictate how easily you can tote and those you throw away when dull. these planers. Six of the ten machines The DeIflalt and Grizzly planers have weighed 5O-7O pounds, one weighed knives with one edge that you can less than 60 pounds, and two topped resharpen multiple times. All of the the scales at 80 pounds or more. Beefy side handles on the DeWalt planer other machines have double-edged help you move it about. Most of the machines have side han- disposable knives. \ffhen one edge dles that make them easy to heft dulls you turn the knives around. about with both arms, as shown at The disposable knives make a lot of left, top. The DetValt had the best sense to us. Considering that dispos- handles, but those on the Ridgid, ables cost about $35 per pair, and Powermatic, Grizzly, Makita, Jet, and give you four sharp edges, you're Craftsman also worked well.'We were money ahead compared to paying $10 less enthused about the center handle to $ 12 per edge to have blades on the Delta 22-560. And the strap resharpened (assuming you know a handles on the Ryobi and Delta 22- good sharpener). 540 were uncomfortable to use. All of the tested planers come with ' Storabilitj,. If you plan to stow steel knives except for the Makita awry your portable planer when it's 2012, which comes equipped with not in use, look for one with exten- carbide knives-a big plus in favor of sion tables that conveniently fold up. this machine. We were doubly As shown at left, bottom, planers with impressed by the Makita knives dust chutes tucked within their main because of their keen factory sharp- housing enable you to completely fold The Powermatic has a dust chute con- ness. The Delta and Ryobi blades also tained within the main housing. This up both extension tables regardless of were excellent, but not quite as sharp allows you to fully fold up the outfeed the height of the cutterhead housing. as the Makita edges. extensiontable. You'll find this feature on the DerValt. Continued http://www.woodmagazine. com 59 trmrtmbtePlaners Two planerstoo new to test Makita, Powermatic, and Ridgid plan- ers. With the other planers, you must Just as we wefe wrapping up this arti- head that moves up and down rather crank up the heacl halfway or more to cle, we learned of two new planers than an elevating table. The Makita fold up the outfeed extension table. that will eventually replace moclels we 3OI2 does not have a locking clltter- ' Dttst collection. Planers produce testecl. Both the Makita 3OI2 and head, but its tables are on the long monnds of sawdust in no time, so a Ryobi APl24 should be coming to side at 3Of,' from end _ MAKTTA3012 'Whereas dust-collection port for hookup to a stores sooll, but current stocks of ?u,., -" '.\ ,o encl. the |' shop vacuum or dust collector will tlrerf-- Makita l\,{^t.:r,. 1n2O12 1 1 ^^.rancl Ryobi D-,^r-: APlz Anl1 l']"':U; ,^lLlj 11. 53-potrnd 60 WOOD Magazine Winter 1999 CRAFTSMAN GRIZZLY G1017 1OPORTABLE PLANERS ON PARADE PERFORMANCEEVALUATION (5) I lslI IE ;+-7.I /v/s /= i/*t/ "F I /€Y=s I s- I ss ffi /5/ .** / corvrmrlrs Machineis similarto Jet,but costs s963/ more.Has double-edoed knives, but CRAFTSMAN 23378 I/g" 6" 22.5 DE/# N FSP .004'.005".002".004' 7 8.9 12.8 61 1 yr. T F 8369 G $400 theyare time-consuming to install. Top-siderollers prove handy. Theoredecessor to the 22-560. it lacks someof the 22-560's hioh-end r/s' DE N FSP 7 11.5 9904/ {eatures. was thehigh DELTA 22-540 6" 23.5 F 002"002'.004"005" 8.2 8213 F 62 2yr T 270 Snipe on side of testedplaners. A lowprice makes it a goodvalue. The knife tested 9299t easiest changing0t 118" FSP/HL U.J 11.2 T performance, DELTA 22-560 6" 23.s',DESA .002".001'.002" .003" 7 8082 G 65 2yr. 330 units,solid andmodest pricemakes it ourtop-value buy. A sturdydesign, low snipe, and long 9942t extensionlables make it a solid 1la' 6 SE FSP/HL 6 12.8 75 1 yr. T DeWALT DW733 33', G .001"004".002".002" 10.3 8628 G 430 contender.Lacks quick-setting knives 0n theheavy side. A good-performingmachine with low 9623/ 400+30snipe.But relatively high price, G1017 5ltz" 6 20' N FSP .003".001".00'1".002"I.Z 11.8 yr. l GRIZZLY SE F 9.2 7888 F 80 1 shipping80-poundweight, and slow knife changesreduce its desirability. JET JWP.12-4P1la' 6 22.s', DE N FSP 002".006".003" 005' 7 13.19533/ 61 2yr. T 300 Seecomments for Craftsman23378 F 7535G A favoritemachine because of itslight weight,standard carbide knives, and 7678t fastknife changes. The only machine 20't2 t la" o 23', DESA Y# :SffMB .001'.005'.001".002" 4 I 11.5 53 1 yr. J 450 MAKITA 6248 witha tablethat elevates instead 0f cutterhead.Will be ohased out bv new Makitamodel 3012 in nearfutuie. 9421t 0uickknife changes, long extensi0n 412 6', DESA FSP/HL 7 I Z.Z yr. POWERMATIC 34', .003".001'.001".002" 8.8 8097 G 67 2 T 400 tables,low snipe, and standard dust chutemake it anothero{ our favorites. Knifeand cutterhead paralellism were 1lB" AA' 9940/ Life- T TP1300 o DESA FSP/HL .001" 5.9 10.4 tt I nearlyperfect. A good RIDGID 001" .001" 002' 8748 F 82 time 400 Snipewas low. valueif youdon't mind its weight. A good, machinethat will be 9478t butdated AP12 r/s" 6', 18.25'DESA N ES/CS 7 12.6 yr. RYOBI 004".001".003" .004" 9.,| 7948 G 63 2 T 340 replacedby new Ryobi model AP124. Hasquick-setting, double-edged knives. NOTES: FOBMORE IllF()ffMATION. CAIL; 1. Totaloverall work support length. (FSP)four steel posts 5. Excellent ! [fl r.i' Craftsman Delta DeWalt Grizzly Jet (HL)head lock 2. (DE)double-edge p eoo. 800t377-7414 800/438-2486 800/433-9258 800t523-4777 800t274-6848 (SE)single-edge (TMB)table-mounted bearings @eooo (DESA)double-edge, selt aligning (ES)elevation screws 6. Measuredbefore making Makita Powermatic Ridoid Ryobi (CS)case-sidedsupport anyadjustments. 800t462-5482 800t248-0144 800i474-3443 800t525-2579 3. (-) AIsohas depth-stop turret for 7. (J)Japan (T)Taiwan standardthicknesses. Forspecificalions 0nolher types of tools, click on (#) Lockon elevation handle. 'ToolComparisons" atwww.wo0dmall.com MAKITA POWERMATIC RIDGID RYOBI 20'12 412 TP1300 AP12 ?- http ://www.wooclmagazine. com 6t \ tiniH'D"rk o..y.n *uu lf-lhe best traditional desk designs always have offered a First,make the edge-glued way to organize papeflFrork, and just as important, to panelsfor the largerparts I Ikeep arly cluffer out of sight when you're not working. Note: Tltis project inuolues a number of utide panels and sbelues made This writing desk succeeds on both counts. Our vslsi6n- from solid pine (see tbe Bill of built of pine and finished with a colorful stain-has a decid- Materials). Before machining any edly country flavor, but you can use hardwood and a differ indiuidual parts you'll utant to glue ent finish to create a look all vour own. up boards for tbese panels. If stock already is tbicknessed to 3/<",tbe edge joints must be aligned closely. G;*iltr 1 Glue up the necessary panels and shelves (A,B,C,D,Q). Then scrape off any dried glue squeeze-out, and sand the joints smooth. 2 Cut the desktop (A), the floor- board (B), and the side panels (C) to the sizes shown in the Carcase Parts View on page 64. Mark the "slant front" layout lines at the upper front corners of the side panels, but don't cut them yet. Rout the dadoes and rabbets 1 Rout the /s"-wide stopped dadoes in the underside of the desktop and the upper face of the floorboard (Illus. A). Next, use the same straight bit to rout the rabbets along the rear edges of those same panels (Illus. B). Note that the rabbet on each panel extends only to the dado locations, not all the way to the ends. 62 WOOD Magazine Winter 1999 ToGet Organized 2 Using a Vz"-radiusrouncl- No round-overalongback edge DRAWER UNIT 7e" rabbet t/q" deep J+ MOUNTING DETAIL Partialround-over o Partialround-over 7se"shank hole, Drawercabinet countersunk ill l^ll Magnetic catches \I V Lidhinge /'l \ #6 x3/q"F.H. wood screws 7e"rabbet t/+" deee ./' -" for backto fit into -tt at' @-" No round-over alongback edge Partialround-over *W 2" no-mortisehinge ,l 14. B\ ) EXPLODEDVIEW #10x 11/q"F.H.4-- wood screws fugDesk 6 Making suie you 2 Clamp a straightedge guide and a stop the tongues into their corresponding have them oriented block near one end of the upper shelf, dadoes. Check for equal diagonal mea- correctly, rout (or saw) and use a3/q" straight bit to rout the mor- surements to make sure the assemblyis the full-length rabbet tise for the hinge. (See the Hinge Mortise squaredup; then let the glue dry. along the inside rear edge of detail and Illus. C.) Use a chisel to bevel each side panel (C). the very edge of the mortise, creating Take care of the carcase details clearance for the hinge knuckle. Repeat 1 Cut the filler strip (E), and glue it in Follow up with the shelves the same sequence for the other hinge place on the underside of the upper and carcaseassembly and make sure they both fit propedy, but shelf, offset 7/s"from the front edge. 1 If you haven't done so already, trim don't install them yet. the edge-glued panels for the upper 3 ffier a quick test fit, glue and clamp Bill of Materials and lower shelves (D) to size. These the shelves into the dadoes in the side Frnshed Size Part (5 > two parts measure the same size, but panels. Lay the assembly @ack edges T w L = g you'll mortise down) onto yorr only the Llpper shelf for workbench. A desktop 3h' 12', 34 EP I the drop-leaf hinges. (See the Hinge 4 Next, glue and clamp the desktop and B floorboard 3h" 171/z' 34 EP 1 Mortise detail drawing belout.) the floorboard to the side panels, fining C sidepanels 3h' 17', \tof 4 EP 2 CARCASE PARTS D shelves 3/4' lat/8 JZ EP 2 VIEW E fillerstrip 3h' z', 311/z' P 1 SIDEPANEL (rightpanel F backpanel l/qu 321/q' 361/q' Plv 1 Se/ta" shown,left 3/4"stopped panelis a G foothalves 3h' 4', 4', P 8 dadoes mirrorimage) 1/4" H corner deep blocks 3/q' 23/t' 23/4' P 4 3/t' 3h' g/"n I glueblocks 31/q' P 4 J top/bottom paners vi' 103/q' ,ttv2 P 2 *Length TONGUEDETAIL not 1/z' includingtenons K uprights 103/q' 6" P (shoulderlength) L drawer 3/4' 103/q' 121/z' P 2 **Length shelves M drawer including 3h' 23/rc" 123/a' P 4 tenons fronts (overall N drawer *g1r/"" length) sides 1/z' 23/ta" 107/a' P I O drawer 1/z' *241/q' backs 19/ta" 117/e' P 4 7a"rabbet P drawer 1/t' 9r/d' 117/a'Ply 4 th" deep along bottoms insideedge Q dropleaf of side panels HINGEMORTISE panel vi' 12', 27vd' EP 1 3/a" DETAIL x3/a" z/e"-longnotch R endcaps V4" 21/z' tt P 2 tonguelong I t/16 Routa partialround-over bottom edge 3h' alongfront and side edge. S doorstiles 21/2' 22s/a' P 4 T doorupper 3/r' rails 21/z' 11114aP 2 Frontedge U doorlower shu ?rl TOP PANEL rails 11114a P z (shownupside down) V doorpanels 1/z' 111/z^1B1Aa"EP 2 3/e" rabbel 1/a" , stoppedat dadoes MaterialsKey: EP-edge-gluedpine, P-pine, Routa partialround-over Ply-pine/firplywood. alongfront and side edge. Suppfies:#6x%" flathead wood screws, #8x11/q" 7e" dadoes /a" deep, stopped F.H.wood screws, #8xlt/2" F.H. wood screws, z/a"lrom front edge #1lxIt/c"F,H. wood screws, #17x1" wire brads. 17Yz' Frontedge BuyingGuide In additionto thesupplies shown above, the fol- lowingitems (or appropriate substitutes) are requiredfor this project. All are available from PaxtonHardware, P.O, Box 256, Upper Falls, MD 7e"rabbet 1/4" deep, 21156.Phone 410/592-8505. Brass-plated stoppedat dadoes FLOORBOARD hinge/support(1pr,), no. 5009,1/2'porcelain knob (4),no. 6411,3/q'porcelain knob(3), n0.6412, no- mortisehinge (2 pr.), no. 4167, magnetic catch (2), s/e"dadoes 7/a" 7e"deep, stopped trom front edge no,4401, 7/ac"pilol hole %" deep 45" miter 45' cornerblock @ 2 Ctrt the back panel (F) from V.t"ply- half, for a miter joint. s/0"mounting wood, and drill countersunk holes for 4 Before gluing up the feet, cut the holes,countersunk the mounting screws. Temporarily fas- 15" taper on the nonbeveled edge on bottomside ten the panel with +6x.7,"screws. of each half. We used a simple 3 Cut eight 4"-square blocks of hold-down jig with the miter gauge %" stock for the desk feet (G). These to make these cuts (Illus. D). are actllally halves that get glued up in 5 Cut the corner blocks (H) and pairs. (See the Foot drawing.) Then glue blocks (I) for the foot assem- cut a 45' bevel on one edge of each blies, and drill the countersunk #g x 11/q,F.H. COUnterSUnk screw holes in the corner blocks as shown. Both of these pieces help reinforce the feet. 5 Cut a pair of ZVr,"-wide spacer 6 Glue and screw the parts together blocks, and use them to support the to make up the four foot assemblies. drawer shelves while you fasten each Then fasten them to the underside of one to a pair of uprights (Illus. F). Dry- the floorboard, Vz" irt from each cor- fit the uprights for this step so you ner edge. can remove the subassembly tem- porarily after the drawer shelf (L) is Next step: Building the drawer secured. The reason? The tight spac- unit assembly ing between the uprights at the cen- 1 From 7<" stock, cut the top and bot- ter of the drawer cabinet doesn't tom panels (D for the drawer storage allow enough clearance to fasten the assembly. Cut the drawer shelves (L) second drawer shelf if the other sec- to the same width, but leave them tion is already in place. Vz"longer than the final dimension. 6 Apply glue to the dadoes and rab- 2 Install a Vz" dado blade in your table- bets and put together the drawer stor- saw to cut dadoes in the inside faces age assembly. Secure everything with of the (|) panels. Center the first dado clamps and check for square. After in each; then reset the rip fence as an the glue sets up, drill countersunk end stop for the two outside dadoes screw holes along the front and rear (Illus. E). Finally, shift the fence clos- edges of the top panel (one at the Auxiliarymiter er, and add an auxiliary wood fence to center and one near each end), and gauge fence cut the end rabbets on each panel. fasten the cabinet to the desk carcase. (Setmiter t/2" gaugeto15".) 3 Now mill the stock you'll need (See the Drawer Unit Mounting detail for the five uprights (K), and cut these drawing onpage 61.) parts to size. 4 Trim the drawer shelves (L) so their Now build the drawers to fit length matches the distance between 1 Cut the eight t/2"-thick drawer sides the end rabbets and the "outside" (N) and four drawer backs (O); then dadoes in the (|) panels. Continued. '.,t 1/2"rabbel 'tz -s/a,,deep tZ" dadoess/a" deep #8x11/q'F.H. wood screws 1/2"rabbet s/a" deep 7/aq"pilol hole 7+" deep DRAWERUNIT EXPLODEDVIEW #8x1Y4'F.H. t/2" rabbet 3/e"deep wood screws Desk 1/+" Uiug dado 1/4" you can turn immecli- deep 7a" grooves t/q" deep ately to the drawer s/a"irom Oottom eOgje fronts (M) and also 1/q"rabbel1/4" deep the pl1'wood drawer bottoms (P). 2 Cut the drawer fronts (M) -%" { #17x 1" from solicl stock; then install a wire brad W" dado blade on your tablesaw to cut 23/a" the joinery for the drawer parts. (See h the Drawer drawing and Drawer Lock ,/r,,)dia.JOINT DETAIL ( porcelainknob Joint Detail drawing.) t/q" dado 7a"hole, bentered 3 Mount a tall wood auxiliary fence 1/4"deep on your tablesaw's rip fence, and with a follower block for support, cut the DRAWER ,i"-deep dadoes in the ends of each drawer front, as shown in Illus. G. This cut leaves two /;"-thick tongues, both the same length, at each end. 4 Reset the auxiliary fence directly 3/ax 3/a"tongue against the dado blade, but leave the 7a"groove Hingemortise zAa"deap, blade height setting intact. Then centeredon guide the drawer front (face up) past edge,stopped 1sle"from end the blade to cut away /i" of the inside tr9 tonglle on each end (Illus. H). \fith Routa partialround-over alongfront and sideedge. that done, drill holes for the knobs, (, and set the drawer fronts aside. 1/2"porcelain knob 5 Lower the blade height to V+" and DROPLEAF cut the rabbets at the ends of the (shownupside down) drawer backs (O). (Note that this joint differs slightly from that on the draw- er fronts.) Remove the auxiliary f-ence, adjust the rip fence, and cut the lock The drop leaf wraps up top half tbe center panel, uthich resists cup- joint dadoes in the drawer sides (N). Note: Tbe last component for tbe top ping but can still motte relatiuely 6 Shift the rip fence again to cur rhe section of tbe desk is tbe drop leaf freely in response to seasonal grooves for the drawer bottoms. Yotr (Q). Like the other large cArcase changes in hurnidity. want this detail in the drawer sides pieces, this panel gets glued up from 1 Cut the drop leaf panel (Q) and the (N; and fronts (M), but not the backs nArrozaer boards, but it bas an addi- caps (R) to size; then set up a 7.1" (O). (The backs are cut narrower to tional feature to keep it stable and straight bit in your router table. Adjust sit atop the drawer bottoms.) flat. Ttuo end caps (R) are fitted to tlre fence for a tAr,"offset from the bit. 7 Dry-assemble a drawer to confirm the drop leaf (one at eacb end), a The closer you get to an exact setting, the size of the pll.wood drawer bot- metbod sometimes called "bread- the better, but cutting the groove in toms (P). Cut those parts; then glue boArd" construction. (See the Drop two passes (alternating faces against the drawers together, and fasten the Leaf dratuing.) Grooues in tbe caps the fence) will ensure it ends up dead- drawer bottoms with 1" wire brads. house a tuide tenon or tongue from centef on vouf stock. 7a"plywood auxiliary fence z attachedto tablesaw--.-- Stopblocksclamped on bothends - t/a"straight bit \_l_-, Lwqrs orvPurvwno 3/e"groove | / 1Q7/ra"from center z/re"deep, stopped' of router bit, 17eofrom both ends 66 WOOD Magazine Winter 1999 V! I/q x 1/zx 2" stock, cut the tenons on the ends of 1 the top and bottom rails. (See the 1111/'ra" -1 Tenon detail drawing.) 4 Plane additional stock to 1/2"thick and edge-glue boards for the door panels (V). After the glue joints are dry and sanded smooth, cut the two panels to finished size. 3/q"-dia. porcelain knob_ ,.[*"J 5 To bevel the door panels, first 1/2" deep ,/ molrnt a tall auxiliary fence and a ll feather-board setup to steady the pan- TENONDETAIL els. Then tilt your sawblade to 7", as 1,,'rshown in the Panel detail drawing. Cut the bevels with the panel on edge, doing the ends first to prevent tearout; then sand off the saw marks. I 6 After a dry run to fit the parts, glue up the door assemblies. Like the drop leaf panels, the raised panels need room to shrink and expand within their frames, so apply glue to only the ll centef of each panel end. Make sure l/ each door is square and flat before 21/2" you set it aside for the glue to dry. 1011/'ra" 7 Install the hardware for the doors. This includes the knobs, no-mortise DOOR hinges, and-after the doors are hung-the magnetic catches. 1/+x 1/zx 21/2"tenon ASSEMBLY To finish, undo hardwarefirst 1 Remove the hardware from the 2 Clamp stopblocks to the fence to to the drop leaf caps (R). Rout and doors and the drop leaf, and also the index the ends of the drop leaf caps, chisel the mortises as before; then screws holding the drawer cabinet and adjust the cutter height to about install the hinges and check the fit. and the carcase back panel in place. half the finished depth. Lower each Vhen closed, the drop leaf should Finish-sand all of these components cap onto the cutter for the first pass iust clear the front edge of the desk and also the desk carcase. (Illus. I). Make another pass with the top (A) and rest against the drawer 2 For the first stage of our finish, we opposite face against the fence; then cabinet. Make any necessary adjust- applied a stain conditioner to prevent adjust the bit to full depth and repeat ments, and install the knob. blotching of the pine. Next came a the process with each cap. waterborne "Antique Red" stain (from 3 Use a dado blade on your tablesaw Doors close up the lower half the Accents line by Minwax) for the to cut the tongues on the ends of the Because a drop leaf design creates leg carcase, drop leaf, and doors. We drop leaf panel (Q). Fine-tune the cut- room while you're working at the opted for no stain on the drawer cabi- ting depth so that two passes (with desk, there's no need for the knee- net and drawers, but you can decide alternating faces down) create a snug hole feature common to fixed-top on the look you want. fit between these tongues and the end desks. Our design uses that valuable The stain required about 4-6 hours cap gfooves. space for enclosed storage , tucked drying time; then we followed up 4 Trim the tongues back 1tl2"from the ^w^y neatly behind a pair of raised- with two coats of satin poly.urethane edge of the panel as shown. Do a dry panel doors. (See the Door Assembly on the entire project. After allowing test fit first; then glue and clamp the and Panel detail drawings.) You can 24 hours drying time for the second end caps to the drop leaf panel. make them easily with just a tablesaw. coat, we reinstalled all the hardware, (Apply glue to only the first 3" of the 1 Cut the stiles (S), top rails (T), and and reassembled the desk. The draw- joint at the hinge edge of the panel, to bottom rails (Ll) to size. ers and pigeonholes aren't crammed allow some "floating" of the wood.) 2 Install a V<" dado blade and cut the full yet, but even when they are the 5 After the glue dries, clamp the drop centered grooves in the inside edges closed desk will still look sharp.tF leaf in place temporarily (in the open of the stiles and rails. position), and transfer the locations of 3 Using the rip fence as an end stop Written by Bill LaHay' Photography: Baldwin Photography the hinge mortises in (D) gauge the top shelf and the miter to guide the Illustrations: Kim Downing; Lorna Johnson http ://www.woodmagazine. com 67 fence. Because the bit cuts into the wood on the side near the fence. feed the workpiece from left to right to prevent climb cutting. flMhen the bit is cutting on the side farthest from the fence, move the workpiece from right to left for the same reason.) 3 Rout the grooves in the uprights (B), where shown in the Exploded View drawing. To do so, position the router-table fence to center the bit on the edge of one upright. Following the procedure above, but without stopblocks, rout a 7/32"groove the futl length of one edge on each upright. 4 Rout the groove in the cap (C). (See the Parts View drawing in the pattern insert.) Rout this groove the way you routed the base, placing stopblocks 5tAe"from each side of the bit. Shapethe baseand uprights 1 Photocopy the base pattern, and adhere the copy to one edge of the base (A). Bandsaw the arch, staying slightly outside the line. Sand to the line with a drum sander. 2 Form the tenon on the bottom of each upright (B), shown in the Tenon detail of the Exploded View drawing. To saw the tenons, install a Va"dado blade on your tablesaw. Attach a scrapwood auxiliary fence to the saw's rip fence, and cut into it with the dado blade. Adjust the blade to cut a r7/eq"rabbet 3/re"deep on each face of the upright. Back each piece with scrapwood to prevent chipout. Reset the fence to saw a Va"ttbbet Frarneafavorite photo irr tAe" deep on the ungrooved edge of oak each upright. Ease the outer corners of the tenons with a chisel to make A prized photo calls for a spe- install a /s" straight bit in your table- them easier to fit into the routed cial frame. ffere's a laand- mounted router. Adjust the cutting groove in the base. depth to 3/16",and position a fence to 3 Cut a piece of scrapwood to size some one of oah that fills the 'What's center the bit on the face of part A. and rabbet the edges as shown in the bilt. more, it's quick Clamp stopblocks to the fence 5/2" Rabbeted Insert drawing in the arrd easy to build. from the right side and left side of the WOOD PATTERNSinsert. bit. Then. with one end of the base 4 Place the rabbeted insert between against the left stopblock, lower the the rwo uprights (B), and clamp the Routgrooves in all the parts workpiece onto the spinning router assemblytogether. 1 Cut the base (A), uprights (B), and bit. Slide the part to the other stop- cap (C) to the dimensions shown in block. Turn the base end for end, and Drill holesfor the dowels the Bill of Materials. repeat the operation. 1 Referring to the Parts View drawing, 2 Rout a centeredT/3z"groove in the To widen the groove, move the mark the dowel hole locations on the base (A), where shown on the Base fence slightly toward the bit. Rout the cap (C). Temporarily fasten it in place Full-Size Pattern in the WOOD PAT- base again, making one pass with with double-faced t^pe atop the ZCRNSoinsert. To rout the groove, each edge of the base against the assembleduprights and insert. 68 WOOD rr.ragazine Winter 1999 2 Position the assembly on your drill- 7 Cut a piece of stock /tx/sx6". Sand 9 Cut two pieces of glazing material press table, centering the bit over the Vre" chlmfers at both ends, and cut a (either single-strength window glass mark at one end. Clamp the assembly 3Ae"length off each end to make the or 0.1"-thick acrylic) to 4Yax6V+". to a fence on your drill-press table, as plugs. Glue them into the square Sandwich your photo between the shown belous. Drill the /s" counter- counterbores in the cap. two sheets, slide them into the bore and t/a"holes as shown. Reclamp, I Finish-sand the cap. Apply a clear grooves, and install the cap to com- and drill the other end. finish to all parts. plete the frame.il 3 Remove the cap, and enlarge the 17/64". 3/e"square counterbore -Sand a 1/ro"chamfer holes in the uprights to 1/e"deep, with a 1/+"hole -4r- { ,,t/a 3/e", 4 Square up the /s" counterbores in centereb'inside x x ,3/e" squareplug the cap. A sharp chisel will do the job. I 5/8" 1/a"dowel 7/sz"groove 1/ro"chamfer 2" long glqed 3/ro"deep 7ro"chamfer into part EXPLODEDVIEW 17lo+"hole 1/tox41/qx61lq" clear acrylic Drill the holes through the cap into the uprights with a drill press. Tape on the twist drill serves as a depth indicator. Now, make it picture-perfect 1 Fasten the uprights together with double-faced tape. Adhere the Upright 1/ro"chamfers Full-Size Pattern to the stack. Bandsaw the tapered edge slightly outside the line, and sand to it with a disc sander. 2 Install a chamfer bit in your table- mounted routef. Rout the Vre" and t/e"chamfers where shown. A miter gauge and extension will help when Bill of Materials routing across the ends of the base Finished Size Part 6 (A) and cap (C). T w L = o 3 Rout the TAcl'chamfer on the under- 1 A base I 2u 71/q" o 1 side of the cap (C). Ctfe cut the deep B upright !"u 11/q' 6%0" o 2 chamfer in Vr(,"increments.) 4 Glue the dowels into the cap holes. C cap Vau 17/B' 6lq' 0 1 7lzz" 5 Finish-sand the base and uprights. groove 3/ro"deep MaterialsKey: Gwhite oak 6 Glue and clamp the uprights into ON DETAI Supplies:t/+' dowel, glazing (either single- the base, placing the rabbeted insert stren$hglass or 0.1" acrylic sheet). between the uprights to square them. Insert the cap dowels into their holes SEETHE Project Design: Schlabaugh and Sons; Jan Svec in the uprights for spacing. (Do not WOOD PATTERNS@INSERT Illustrations: Roxanne Lemoine; Lorna Johnson FORFULL.SIZE PATTERNS Photographs: Steve Struse; glue the dowels into the uprights.) Hetherington Photography www.woodmagazine .com 69 K, rrFnffi "v WHOLE.SHOP grandfather might $our f. have scoffed at the rraea- AIR.CLEANINGsufes we take to curb work- shop dust because in his time, few knew about the health hazards. These days, SYSTEM virtually every power tool Stopfine dust comes equipped with a dust- collection port, but what in its tracks about those pesky airborne particles that make a mess of everythirg, including your lungs? This simple system traps floating debris in a parr of commonly available fur- nace filters to keep dust under control. First, find the best mounting locationsin your shop Ideally, you'll want to locate the filter cabinet over your dustiest work area with the blower cabinet directly opposite it at the other end of the room. This conflgllration circulates shop air, capturing the debris before returning the freshly scmbbed air to your work area. If ceiling-hung obstacles make align- ment impossible or impractical, yotr can add elbows to the duct to get around them. Just remember that every additional bend slightly reduces the airflow, and thus the efficiency of the system. Constructionstarts with buildinga boxfor the blower (Note: Altbottgb ue purchased our blouer/motor neta, you ctn slue monq/ by bt4ting a used unit from a heating and cooling contractor. Make sure to get one tuith a free-air deliuery rate of at least 1,500 cubic feet per minute. And, you may need to resize tbe bloruer cabinet accord- ingly. See tbe Buying Guide in tbe Bill of Materials for tbe blouer/ motctr ute used.) 1 Cut the blower to one side as shown in the Blower stack's size may vary slightly, so cut Finally,hang your unit Cabinet Exploded View drawing on the opening to its actual size.) and run ductwork the preuious page. By orienting the 2 Assemble the parts as shown in the 1 With a helper, lift the blower cabi- louvers this way, you'll get better Filter Cabinet Exploded View. Sand net to its mounting location and total-shop air movement. (Directing and finish the outside of the cabinet. attach it to the joists using 5/tex2"c r- the louvers toward the floor only stirs 3 Cut the filter tracks (1, K) from riage bolts, flat washers, lock washers, up more dust.) sheet metal (we used galvanized-steel and nuts. 7 Mount the power switch in a conve- flashing), and shape them as shown in 2 Wire the blower/motor and switch 'We nient location. cut a hole for the the Filter Cabinet Exploded View. to a shop circuit as described in the switch box in the remaining side (See the photos on the opposite page blower's manual. (For safety sake, if panel and flush-mounted the switch. for a simple method of braking the you're not familiar with wiring, hire a You may want to wire the blower/ tracks.) Attach the tracks to the sides qualified electrician.) Attach the motor to a remote switch near your (I) and back (G) with sheet-metal remaining side (E) to the cabinet. work area. In this case, attach a junc- screws, allowing just enough space 3 Assemble enough lengths of 3V Next,fashion the filter cabinet (Note: We designed tbe filter cabinet to nestle betuteen open ouerhead joists, so tDe ran tbe ductutork out one end. You can easily modifu tbe design to exbaust from tbe side or top if you uisb.) 1 Cut the filter cabinet front (F), back (G), top (H), and sides (I) to the size shown in the Bill of Materials. Using the Part View at rigltt as a guide, cut an opening in the front panel to accept the 3v 7/oa"pilot hole s/a"deep CUTTINGDIAGRAM 31/+x 12" cutout for duct 3V+x 12" wallstack 1 x 14 x 25" allergen-reducingfurnace filter (such as 3M Filtrete) 1 x 14 x 25" fiberglassfurnace filter FILTERCABINET EXPLODEDVIEW Join the segments and attach them to You don't need a box full of special tools to make crisp corners in sheet the ceiling. metal. rVith a few straight scraps of wood, a hammer, and the instructions 4 Mount the filter cabinet to the ceil- belout, you'll be on your way to bending (or "braking") sheet metal with ing, and affix the wall stack to the professional-looking results. opening with +8x5/g" panhead sheet- metal screws. Seal the joint between the wall stack and cabinet with caulk. 5 Stack the allergen and fiberglass fil- ters and install them in the filter tracks as shown in the Filter Cabinet Exploded View. Periodically vacuum dust from the filter. And if you notice a substantial reduction in airflow. replace both filters.? Writtcn b1' Dave (,ampbell Proiect Design: .lames R. Downing Ilhrstrations: Kim Downing; Lorna Johnson Photographs: Balclwin Photographv Bill of Materials Finished Size Part (E > T W L = a BLOWERCABINET 3h' I A bottom to 191/z' BP I Btop 3h' 16" 191/z' BP 1 C front 3/^^ 16" 251/z' BP 1 Dback 3/r' 16 zcf2 BP 1 Esides 3h' 21', 25Vz' BP 2 FILTERCABINET F front 3h' 5 t+ BP 1 G back 3h' 6" 14 BP 1 H top 3h' 12t/z' 231/z BP 1 3/", I sides 5 23Vz' BP I J side standard filtertracks gauge 25', F 2 K back standard 1A\ filtertrack gauge 5', F I Materialskey: BP-B|rch plywood, F-Galvanized metalflashino Supplies:i,hr6*12" rectangular stackhead; 3t/qx12"wall stack; universal tailpipe hangers (4);r/r" flexible electrical conduit; %" flexible conduitconnector; switch box or junction box; switchplate or junctionbox cover; switch; 5/tax11/t"carriage bolts, flat washers, and nuts; 5/16x2"carciage bolts, flat washers,lock wash- ers,and nuts; %ox1%" carriage bolts, flat wash- ers,and nuts; 14x14" air return grille; #8x1t/2" flatheadwood screws; #Bx%" panhead sheet- metalscrews; 1x14x25" allergen-reducing fur- nacefilter; 1x14x25" fiberglass furnace filter; acryliccaulk. Buyingguide Blower/motot.105/s" double-inlet belt-drive blowerwith /+ hp.motor and 1,680 cfm free-air clamp the sheet-metal workpiece between a pair of straight-edged wood delivery,W,W. Grainger stock no. 7C656, about scraps, leaving the portion you want bent hanging out of the "sandwich", and $160,For the location of a Graingerbranch aligning the brake line with the edges of both scraps (Photo A). Using a block near you, call 8471647-8900or visit of flat scrap, first bend the metal gently by hand. Then, tap the block along the www.grarnger.c0m. brake line (Photo B), to get a taut corner like that shown in photo C. WOOD Magazine Winter 1999 TOP VACATIONSTOPS FOR ADVENTUROUS WOODWORKERS Ever consider tying youf vacatTon-of at least pafi of it-to your favorite hobby? We've found a dozen good bets for you. (Even your nonwoodworking spouse and children should enioy them.) { The best of Shaker It was called I Widely considered the greatest Massachusetts, or Spring Hill in FurnitureCity and most complete collection of Kentucky, which are touristy "living At the turn of the century, Grand Shaker artifacts, the Shaker Museum history" facilities, the Shaker Museum Rapids, Michigan, boasted nearly 800 and Library at Old Chatham, New and Library has comprehensive collec- furniture manufacturers. Albert and York, rates as a must see. Unlike the tions representing Shaker life and John George Stickley, two of the five Shaker villages, such as Hancock in industries. These span 200 years of Stickley brothers, produced their history and represent every known "Quaint Mission" furniture line there. Shaker community. As companies merged in the 1950s There you'll nnd all sizes and forms and 1960s, most moved south for of Shaker rocking chairs, plus tables, cheaper labor and a greater wood sup- chests, boxes, and other household ply. Luckily for you, the Public items. A big plus is the woodworking Museum of Grand Rapids has pre- tools and machinery, set up as the served this past in its "Furniture City" g o Shakers would have used them. pefmanent exhibit at the van Andel o= Included is the first circular saw Museum Center. You'll meet the mak- z blade, invented by Sister Tabatha efs, tour a l9th-century factory, and o G Babbit of the Harvard Shakersin 1810. trace 150 years of "product." There's Library, more, as a 1928 Spillman va ShakerMuseum and 88 Shaker such ;s 6X' MuseumRd., Old Chatham,NY 12136. Engineering Company carousel and art =E €4. OpenThurs.-Mon., May-Nov., l0 a.m. to 5 1890s train station. Minutes away is =@' p.m. Adults$8, seniors.$7, children8-17 the museum's victorian Voigt House. Eg $4.Phone 518n94-9100. ThePublic Museum of GrandRapids,272 =L UE Pearl St., GrandRapids, Ml 49504. Open E-b In 1813,the Shakersof Mount Lebanon, 6= New York, used this jigsaw fashioned year round (exceptChristmas and New from a sewingmachine treadle and Years),Mon.-Sat., I a.m. to 5 p.m., Sun., pail frame to make bottoms and other noon to 5 p.m. Adults seniors. chil- round objects.A piston pump even $5, $4, blows sawdustout of the kerf. dren3-17 $2 . Phone616/456-3977. 74 WOOD l.f;agazifle r$flinter 1999 - Ptr l.llrseLrncfGranJ Baprds California'sredwood country You may never have heard of who logged redwood trees and along with the gigantic redwood Scotia, California, but it's one of the worked in the sawmill. The company sawmill that offers self-guided tours. few remaining "company" towns in erected single-family homes, housing There's also a museum that reflects America. Back in the late 1880s, the for singles, a library, a general store- early logging and company history, town was built by the Pacific Lumber just about everything that made up a including an 1882 "steam donkey" Company (PALCO) for its workers small town. And it's still there today, that once pulled logs. You'll also like the fisheries exhibit at the aquarium Besides Pacific Lumber Company's massive redwood mill in Scotia, California, that and a demonstration forest a few miles offers self-guided tours, there's a logging museum featuring this steam engine that south of town. pulled logs in the late 1800s.Scotia is a highlight of a visit to the Redwood Empire. To see some really big redwoods, fol- low the Avenue of the Giants (old U.S. 101) from Stafford (just south of Scotia) to Sylvandale. Along the 31- mile stretch, you'll see a redwood with a road through it, and several named and protected redwood groves, such as Founders, Bolling, and Pioneer. You'll long remember this land of giants, the only place on earth where redwoods grow. Pacific Lumber Co. sawmill, Scotia, California. Open all year; free tours Mon.-Fri., I a.m. to 2 p.m. Scotia Museum, summer through early fall, Mon.-Fri., I a.m. to 4:30 p.m., free. PALCOdemonstration for- est, open summers only, every day, 8 a.m. to 4:30 p.m., free. Phone 707/764-2222. Continued 75 12rop VACATIONSTOPS A Thev look t lire ihey'd fly There's a hard-to-describe charm about Maryland's Eastern Shore that goes beyond boats, fresh seafood,and views of ChesapeakeBay. But at The Ward Museum of l7ildfowl Art, in Salisbury,it's easy to name: unbeliev- able carving. Decorative wildfowl carving started with Lem and Steve Ward, two Eastern Shore wildfowl hunters turned craftsmen. and the museum carries their name. To do them justice, the \$flardMuseum exhibits a major collection of wodd- class carvings of everything from working decoys to decorative geese and colorful, lifelike songbirds. In the Decoy Study Gallery, you can trace 100 years of decoys from the nation's E flyways. You'll find sculpture, paint- = .p ings, and prints, too, as well as '6= a museum store selling antique decoys E f o and other gifts and collectibiles. f The WardMuseum of WildfowlArt, 909 S. Y =6 SchumakerDr., Salisbury, MD 21804.Open -o F all year,Mon.-9at.,l0 a.m. to 5 p.m.,Sun., The Decoy Study Gallery at the Ward Museum of Wildfowl Art lets visitors explore more noonto 5 p.m. Adults$7, tour ratesavail- than a century of regional decoys from North America's major flyways. able.Phone 41 0/742-4988. A woodcraftcapitol Nestled in the Appalachian and a host of others: Most are situated Mountain foothills, Befea, Kentucky, in Old Town. Stop at the Berea Ihe ShelbumeMuseum has more than a fair share of wood- Welcome Center for directions to workers and other craftspeople for a woodworkers' shops. town of 10,000. Members of The Another Berea highlight is the stu- Studio Craftspeople of Berea publish a dent production of Berea College tour map and welcome visitors to Cra.fts. You'll find retail outlets at the their work places. Working in wood, Log House on campus and at the there are spoon makers (treenware), Boone Tavern gift shop. musical instrument makers. chairmak- Berea Tourist Commission, 201 N. ers, general furniture builders, tumers Broadway, Berea, KY 40403. Phone (Rudy Osolnick calls Berea home), 800/598-5263. Chairmaker Brian Boggs welcomes visitors to his woodworking shop and gallery in Old Town, as do most of the talented craftspeople in Berea, Kentucky. 'a At the Shelburne Museum, you'll see .a E exhibits, such as this wall of early wood- E o working tools, with each tool identified. = ,o 6 o o WOOD Magazine Wint_er 1999 m J America's I classicfurniture You can easily spend a whole day o viewing the foremost collection of llShrine of the Pines &ShelburneMuseum CDShelburne Baldwin,Ml Shelburne,W (l has the tools I l-Nat'|. Museum l€haker Museum of Woodcarving GForestHistory Center Old Ghatham,NY The Shelburne Museum in Guster,SD GrandRapids, MN \ $Esherick Shelburne, Vermont, llias37 fascinat- Museum ing exhibition buildings housing Paoli,PA more than 8O,00O objects of ?Public Museum Americana. And the setting is 45 $Pacific Lumber hilly acres ove rlooking Lake Champlain. In a day or more, you'll want to examine Shelburne's collec- tion of woodworking tools, totaling upward of 1,6O0!Among them are the tools required to build the aver- age home and its furniture of 150 {.Wad Museim years ago. Other collections include decoys, weather vahes, carriages, and circus memorabilia. There's a watef-powered sawmill, too. TheShelburne Museum, U.S. Rt.7, P.O. Box 10, Shelburne,VT 05482.All bldgs. [.i' openlate May throughOct., daily 10 a.m. to 5 p.m. Adults,$17.50, children 6-14, $7. Forfull schedule, call 802/985-3346. Continued http ://www. woodmagazine. com 77 12rop VACATIONSTOPS 1n Coloniallife as it was I rY Sure. vou've heard of Colonial r$Tilliamsburg. That's where the mas" The deanof ter of the old hand ways, Roy AmericanCraftsmen Underhill, hangs out. It's also where Designer and wood craftsman you'll see all the old trades as they Wharton Esherick died in l97O at once were practiced, from cabinet- At Jonathan Haye's cabinet shop in age 83. But his pioneering work of making to coopering, wheelwright- Colonial Williamsburg, craftsmen in period costume build furniture as they the 1930s in contemporary, hand- ing, gunsmithing, and instrument would have in the 1700s. crafted furniture and interiors was making. And these pre-Revolutionary heralded by the national afi and craftsmen work in a realistic. authen- the official hotels in Colonial design community. He was called tic setting that puts Colonial ufilliamsburg, but they book up fast. "dean the of American cfaftsmen," Williamsburg at the top of the Colonial Williamsburg, P.O. Box 1776, and his work led the 1960s' renais- nation's living history attractions. But Williamsburg, VA 23187-1776. Open daily, sance that made hand craftsmanship that's not all. There's collection upon 9:30 a.m. to 5 p.m. (some sites may differ). as valued as it is today. collection (and building after build- Ticket prices start at $31 for adults, chil- Esherick lived on a mountain top ing) of preserved period furniture. dren's tickets, ages 6-17, $18. For details outside Paoli, Pennsylvania, in a Unfortunately, you can't see all that and help in planning your visit, call home and workshop that he Colonial Williamsburg has to offer in 800/Ht sTo RY (800/447-867 9). designed and built. In relative isola- a day. You'll want to stay in one of tion, he pursued working wood dur- ing x time when our culture frowned upon hand-crafted things. In the architecturally unique com- al wood comes A shrineof pine plex, lt you'll see his sculpture and I I alivehere a - Near Baldwin. in weste rn quarters sculptured furniture, living To the west of Custer State Park, in Michigan, there's a special place. and work room, and his carvings. South Dakota's Black Hills, you'll Lake County Park is pleasant, but it's An exhibit traces his work and influ- find a display of woodcarvings the Shrine of the Pines there that ence on American wood craftsmen. unlike anything you've ever seen. As makes it special. It showcases the The Wharton Esherick Museum. P.O. an example, the National Museum of skill of a l920s guide and woodsman Box Paoli, PA 19301. (Near Valley 595, rffoodcarving exhibits thousands of who created a building and filled it Forge National Historic Park.) Open Mar. lifelike wooden scenes created by with rustic furniture without the aid Dec. through Group tours, Mon.-Fri., l0 one of Disneyland's original anima- of power tools, nails, or screws! a.m. to 4 p.m.; Sat., l0 a.m. to p.m.; 5 tors. Beyond that, there's the encom- Ray Overholzer retrieved logging Sun., by reseruationonly, 1 p.m. to p.m. '7O 5 passing work of nationally known leftovers and turned them into such Admission: children under 12, $6, $3. woodcarvers-western figures, buf- things as a perfectly balanced rocker Reseruationrequired. Call 610/644-5822. falo, elk, cartoon caricatures, and and a table crafted from a 700-pound more. And a resident woodcarver The unusual spiral staircase crafted stump. Before his death in 1952, he from oak by Wharton Esherick is one works right before you. Sfith had turned his collection into a muse- of many unique features you'll discov- advance feservation, you can stay a, um, now operated by the county. er at his home and studio near Valley day or two and take a carving class. Shrine of the Pines, Lake County Park, Forge, Pennsylvania. National Museum of Woodcaruing,Hwy Michigan Route 37, two miles south of 16 W, P.O. Box 747, Custer, SD 57730. Baldwin, Michigan. May 1S-Oct. 15, Open June, July, and Aug., I a.m. to 8:30 Mon.-9at.,l0 a.m. to 6 p.m.; Sun.1:30 p.m. p.m. May, Sept.,and Oct., I a.m. to 5 p.m. to 6 p.m. Adults $3.75, seniors$3, children Adults $5.75, chitdren O-14 $3.75. Phone 6-13 $1. Special family rate. For more 605/673-4404. information,phone 231/745-7892. Lifelike scenes, large and small, fillthe Gota trip tip? lf you've had a memorablevacation stop that you feel would interestother woodworkers, '= we'd like to hear about it. Drop a note briefly o o o describingwhat you saw, what it's called, =o E where it is, and other pertinentinformation to: E TravelTips f o f WOODa magazine E c 1716Locust St., GA310 .9 6 Des Moines, lA 50309-3023 z. Written by PeterJ. Stephano Illustration: Brian Jensen 78 WOOD MAGAZIIIE Winter 1999 WOOD@CLASSIFTEDMnnr For rates: 1-800/424-3090 Fax 3L2/464-O512 BUSINESSOPPORTUNITIES $100.00PER HOUB. woodworkinq lrom vouroaraoe. tull or ilreglig. WANTTO CREATE part-time.N0selling! Free brochure: llome Tech 800--456:4987. G HAYE YOU YOUR OSt4\ DIScovERED THE PogKET HOLE HOMEPAGE? ADvANTAGE? WEOFFER R CoIupIETELINE oF tensionSwedish Silicon Steel "TIMBER- W@@wo- 1 1/4".FREE CATALoG 1-800t234-7297. POCKETHOLE SYSTEIvS RnrucIruc )t.atl.netH0ME PAGE-timberuolf 1.com as low as $56.25!Great oift idea!Gift rnou $20-$1685. #}*EIGHtsS,RHSOD rsion.looo. sionalure. VISI/MC/AMEX WWW "(,'uts proje(t linrc in hulf, elimirurtt;s You say you'd like to leam more about the rrced.frtr un e-upe,nsivcursenal of your online woodworking friends? (ldnrps." WOOD nagu:inc Check out our personal home pages by "A ltocket lwle jig tlnt <-lnnged mt logging onto www.woodmagazine.com ROUS$EAUCO}IPAI{Y rnintl aboul Jtocktt lwle joinery,." and clicking on WOODworking f' I N I'. H O M F:B U I LD I N G masa z.irtt Router Accgssories Neighborhood. Here you can get <: -- acquainted with hundreds of other Bnsr ,.,;.i\ Sprrnc woodworkers, find out where they Rorrren Pr-ATE live, meet their families, and learn ON Trm about their woodworking and other Mnrucr! interests, shops, and equipment. And after you've checked out their home pages, we hope you'll be inspired to create your own. Setting up a personal home page is a lot easier than you might think. You don't need aoo-447-a63e to know anything about programming, 800-635-3416 WWW. KREGTOOL.COM web page design, or other techno-gar- Call for FREE Catalog ble. You just fill out an online form and \.!'wwrou s seiluc o. c om CircleNo. 877 let our automated page builder do the CircleNo. 1272 rest. You can even show off your latest projects by adding your own photo images to your home page! Best of all, your personalized home page won't cost you a dime . Simply review the existing pages, read our policies, and complete the forms. Most home pages can be completed in less than 10-15 minutes. Okay, we confess: If you're wonder- ing whether we have an ulterior motive for including personal home pages in WOOD ONLINE's mix of dis- cussion groups, wood profiles, classi- fieds, Idea Shop tours, tool talk, and othef features-well, you're right. Home pages give us an excellent opportunity to learn more about who our readers are and how we can better serve you. And lest you think it's a one-way street, be advised that you can also visit home pages from quite a few WOODo magazine staffers. View their home pages to find out what Senior Editor Larry Johnston means when he says he's doing a restoration on his 1966 Mustang, or see a photo of Design Editor Jim Downing's hand- crafted 30'sailboat.? WOOD ltragazine Winter 1999 CircleNo. 3 ttvT-RoDucttvG- Plarrer r^f o TheCultinE EdtreOf Snipelil:tFf="JHAND Routing! tdcnndrcgr Ls WOODo magazine tool tester Dave Henderson discov- Sabty, perblmance,and durabihty'. NEW Katana'" router ered during his review of portable planers (seepage 56), bitsare manufactured using the highest quality materials it's impossible to totally eliminate snipe on the ends of on precisionmulti-axis grinders.They pre CNC feature: planed boards. (Snipe is the slight planed miummicrograin carbide cutters, high hook and shear dishing of the anglesfor clean cutting, anti-kick- surface at both ends of a board caused by the planer's cut- backrounded shoulders, an anti- terhead taking a too-deep cut.) stickcoating, a diamondhoned The causesof such snipe-some are operator related but grit 600 mirrorfinish, SAE 4140 -can solidsteel bodies, plus our most are mechanical in nature be minimized by SafetyGauge ShanK for properly setting up the machine according to the manufac- easyset up. Katana" tufer's instructions. But even after doing that, Dave found brandbits come with a that some of the tested planers produced in excess of bythe MLCSreputation for cus- .OO4"of snipe-too much for our tastes.To get your machine to produce less than .002" of snipe (at that depth you can easily sand the board so the snipe can't be seen or felt), Dave suggeststhe following strategies: o Dull knives tend to ffi the ends of workpieces (which increases snipe) as the board enters and exits the planer. So keep your knives sharp. 3 rc. ROUNDOVER o The deeper the cut, the worse the snipe. So take light BEADINGBIT SET cuts (%2"or r/64"deep) on your final planing passes. i55;ixs o It helps to raise the outside ends of the extension tables KATANA* An MLCSCompany just 2381Philmont Ave., Huntingdon Valley, PA 19006 WOOD BOX INCTUDED a few thousandths of an inch above the main table. Every planer is different, so do some experimenting with scrap stock. fr \ o If you butt your boards end-to-end as you plane them, the snipe will show up only on the entry end of the first ==t Econ-Abrasives piece and the exit end of the final piece. If those ends are WE MAKE ABRASIW BELTS ANY SIZE ANY GRIT! /) \- checked, you lose no stock due to snipe because you d Sheets ABRASIVEBELTS geteffiitna would have cut them away regardless. CABINETPAPER bi-directional splice, specify grils. o You can take the above tip one step further by butting 50/pk 100/pk 1X3O $.81ea 3X24 $.93 ea scrap stock at least 10" long againstthe entry and exit ends 60D $16,70 $30.00C 1X42 .81ea 3X27 .96 ea of one or more pieces of stock. This will eliminate snipe 80D 15.60 27.80C 4>(213141.06 lX4r'- .81 ea ea on your good pieces altogether, provided the thickness of 100thru 150C 14.50 25.60C 2112X16 .85ea 4YC4 1.1Oea FINISHINGPAPER 3X18 .86ea 4X36 1.35 ea the scrap pieces precisely matches the good stock. .90ea 6X€ 3.5O r Finally, for shorter pieces of highly figured or expensive 80A $ 11.15 $18.s0C3YC1 ea 100thru 2804 10.00 16.70C 3YC33l4 .93ea 6x89 6.24 ea stock, Dave glues a pair of scrap strips to both edges of a oTHER SrZES ON NO LOAD PAPER(white) REQAEST workpiece as illustrated belout. Like the scrap boards in HEAVYDUry SPRINGCLAMPS the previous tips, the strips preload the cutterhead and 100thru 4004 $12.25 $21.25C amps comewiPVC tips and grips. take the snipe instead of the good uC": 100SHEETS workpiecc. The l"-wide Size Price strips should be the same thickness, or slightly thicker, Velcro@Vacuum Discs 4' $lFea 3 Hole pattern for Bosch sanders o', 2.25 and about 8" longer than the workpiece. After completing g' 3.50 the planing, rip away the strips.l JIJMBOROUTER PAD(24'x 36') T tr ffi"@- Stripssame thickness 5' 80 .46 1'.,.;ii: Itwill not allowsmall blocks of wood to slipout underrouter orsanding as workpiece,1" wide., 5' 100thru320.45':.'.:f and 8" longerthan workpiece, applications. ROUTERPAD Jc Anilable in 5 holepaftem 7 ONLY$8.95ea. ofworkpiece 'Wide BeltsiRolls'FlapWheels Z -.4' *Pump I Sleeves*PSADiscs I TUMBO BELT CLUNING STICK *Router& Wood Bits*WoodGlue oNLY $8.80 *Mastercard, VISA,C.O.D. or Gheck E^^^ A l^-^ rsATrsFAc'oNGUARANTEEDII! Econ-Abrasives *oALL Bg FOBFREE CATALOG -G. I .O W1628 - TX& NVadd appropriate sales tax --l Fris^co,.TX75034 - continentdU.5. shippingadd $5.50 I | (972)377-9779 . rou--rREE ORDERTNGLINE (800)367-4101 WOOD Magazlne r$(zinter 1999 CircleNo. 1229 Pointsfor purchases Bosch Power Tools has borrowed a "Woody" Beetlewows the crowd marketing program often used by Steelcase,the world's largestdesigner mahogany against a metallic silver supermarkets and cigarette manufac- and manufacturer of office furnish- body color. In the black leather interi- turers-redeemable points for prod- ings, unveiled a real crowd stopper at or, matching wood surrounds the uct purchases. The Chicago-based the NeoCon furniture and design speedometer and door pulls. The company believes its program to be a trade show in Chicago last June. To gear-shift knob and shift casing also tool-industry first. highlight its new Tableau Collection are made of crotch mahogany. According to Bosch, the Accessory of wood veneer and natural stone "Our goal was to dispel the notion Rewards Program enables profession- wrapped casegoods, the Grand that wood is too traditional or formal al tradesmen and serious woodwork- Rapids, Michigan-based company dis- for work environments,t' said Adolph ers to accumulate points based on the played a 1999 Volkswagen Beetle Bessler,vice president and general purchase of Bosch power tool acces- decked out in wood. manager of wood furniture at sories. They then can redeem them The inspiration of designer Lauren Steelcase."The Volkswagen in partic- for free Bosch-branded merchandise. Rottet, who created Steelca.se'sshow ular, and the showroom overall, really such as jackets, sports bags, coolers, exhibit, the Beetle features'\exterior demonstrate the versatility of our watches, and more. panels of crotch-figured designcapabilities." Program membership applications are available wherever Bosch prod- ucts are sold. You also can enroll by visiting the company's web site: www.boschtools.com. Displayed at a national furniture and design trade show last June in Ghicago, this Volkswagen Beetle sports f igured mahogany "woody" panels. The custom interior In-store displays like this promote also has accents done in mahogany. Bosch Power Tools' new program that bestows redeemable points for purchas* ing power tool accessories. Tomorrow'swoodworkers build today Sometrees In Lewisville, Texas, there's a Every semester, the instructor and may be doomed yearnin' for learnin' woodworkin' senior high school students devote According to the World Conservation among teenagers. And Joe Davis, the two weeks to a production project. In Monitoring Centre and the World mill and cabinetmaking instructor at the fall of 1998, the project was to Wildlife Fund of Vashington, D.C., 10 the Lewisville school district's Dale build four computer desks (shown percent of the world's tree species Jackson Career Center, has the proof. belout). This was accomplished by face extinction. Scientists estimate "Becauseof my students' dedication dividing the 14 students into two that the wodd has between 80.000 to this program, I have one that con- teams, each with a foreman. The and 100,000 tree species,with 8,750 tinues to grow in a time when most teams were responsible for designing, needing significant steps to avoid schools are closing down theirs planning, and constructing the differ- their extinction. [wood shop programs]," Joe wrote ent parts of the project. "Then hope- The United States has 259 of the with evident pride. He has good rea- fully at the end, the different parts fit endangeredspecies, and ranks l2th son, too. into a saleable product," says their of all nations in this category. The instructor. They did-two were threatened speciesin the U.S.include sold and two were retained by the Florida yew and Georgia's stink- the school. ing cedar.O InstructorJoe Davis,far right, Photographs: VW by Lambros Photography; stu- poses with his Dale Jackson dents, courtesy of Lewisville Independent School District; Bosch display courtesy of DeFrancesco- CareerCenter woodworking stu- Goodfriend dents.They built four oak comput- er desks in two weeks. WOOD Magazine Winter 1999