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August 2001 Popular Woodworking

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6 SECRETS TO SILKY SMOOTH FINISHES IT’S TRUE –YOU NEED ONLY 5 TURNING TOOLS August 2001 #123 Super Stow-away Assembly Bench The most versatile mobile workbench you can build SPECIAL REPORT: 10 Benchtop Mortisers Forget what you’ve heard. Slow-speed machines don’t cut it Plus • $15 Shop-made Router Plane • Country Dry Sink • Fighting Rooster Whirligig www.popwood.com $4.99US $6.99CAN 08 Bench does double duty as tool stand, outfeed table 0 09281 01355 6 WoodworkingPopular contentsTOOLS & TECHNIQUES 12 Forstner-Fueled Dovetail Pins TRICKS OF THE TRADE Quickly clean out the waste in dovetail pins using your drill press and a Forstner bit. Also, tips on using a strip sander to sharpen; learn the basics to air-drying lumber in your back yard. By Scott Phillips 1 16 Veritas # 4 ⁄2 Smoothing Plane TOOL TEST Veritas’ new smoothing plane ain’t like your grandfather’s Stanley. Here’s the real question: Is 18 this hand plane worth the extra money you’d pay over a vintage smoother from the flea mar- ket? Also: Finally! Someone made a corded drill with a clutch. Thanks Craftsman. 18 Accuset’s Brad Nailer and Micro pinner ENDURANCE TEST Senco’s Accuset tools are the sleekest nailers you’ll ever hold. What’s better, they hold up under years of heavy use. We’ve abused Accuset’s 2" brad nailer and 23-gauge Micro pinner for more than two years and share the results with you. 19 Make Your Own Router Plane and Beader INGENIOUS JIGS A router plane will cut a hinge mortise in the same time it takes to plug in your router and chuck up a straight bit. Nick Engler’s homemade router plane is made from four parts and 19 works better than commercial models. Also, make a hand beader that cuts details on cabi- nets that no router would dare. By Nick Engler 28 Mortiser Slug-fest Caution: Buying a mortiser can be tricky. You’ve got to know which features are critical on these machines or the only holes you’ll make will be in your wallet. We made hundreds of mortises with all the machines on the market, and our test results surprised even us. 36 A New Manual for Mortisers Even if you buy the perfect mortiser, you’ve got to set it up correctly and use it properly. Learn the all-important tricks that are the difference between making slick-fitting mortises and scorched, ragged holes. 52 Turning’s Fab Five 30 Most turning can be accomplished with just five basic tools. Learn the tricks behind these five tools as you make a candle holder in just an afternoon. Plus we offer a great deal on turning tools from Woodcraft, a special offer for Popular Woodworking readers. By Scott Phillips 74 Rubbing for a ‘Perfect’ Finish FLEXNER ON FINISHING Achieving a high-style finish is within the grasp of home woodworkers. Bob Flexner shows you two ways to transform a cobby finish into one that’s beautifully smooth. By Bob Flexner 52 continued on page 4 www.popwood.com 3 46 On the Cover If you’ve got a small shop and big dreams, take a close look at this rolling, knock-down assembly bench. Store your tools, build big projects, and push it against the wall when you’re done for the day. Cover photo by Al Parrish 24 IN EVERY ISSUE PROJECTS 24 Country Dry Sink 6 Out on a Limb After you milked the cows, the jugs of fresh milk would go into the trough of your family’s Eatin’ Biscuits dry sink. Since the advent of the refrigerator, dry sinks such as this one have changed jobs Letters and now serve as excellent small buffets or kitchen cabinets. 8 By Troy Sexton Mail from readers 71 Caption the 40 Tsunami: Band-Sawn Box Cartoon Put that ruler away; it’s time to trust your instincts and build this ingenious two-drawer box using your band saw, clamps and sander. You’ll be shocked at what you can achieve with Win a Freud router bit set those sappy chunks of scraps in your burn pile. By Lois Keener Ventura 22 Projects from the Past 46 Storage and Assembly Bench Fighting Roosters If you work in a garage, a warehouse or somewhere in between, you’re going to find this rolling assembly bench a handy companion. You can store tools in the cabinets, build 80 Out of the almost anything on the benchtop and stow it all away when you’re done. When flying Woodwork solo, the individual cabinets are rolling workstations for benchtop tools. Junior’s New Tools By Michael J. Dykes 58 Box Turtle True to his name, this little guy can hold jewelry, candy or other essential items beneath his faceted shell. The trick to building him is just one router bit. By John W.Hutchinson 66 Shaker Trestle Desk An icon of Shaker furniture craft, this small-size desk was built in a Harvard, Mass., com- munity and is a fixture in the many books on Shaker life and craftsmanship. By Glen Huey Popular Woodworking (ISSN 0884-8823, USPS 752-250) is published six times a year in February, April, June, August, October and December by F&W Publications, Inc. Editorial and advertising offices are located at 1507 Dana Ave., Cincinnati, OH 45207; tel.: (513) 531-2222. Unsolicited manuscripts, photographs and artwork should include ample postage on a self-addressed, stamped envelope (SASE); otherwise they will not be returned. Subscription rates: A year’s subscription (6 issues) is $24.96; outside of U.S add $7/year ■ Canada Publications Mail Agreement No. 0546232. Canadian return address: 2744 Edna St.,Windsor, ON N8Y 1V2 ■ Copyright ©2001 by Popular Woodworking. Periodicals postage paid at Cincinnati, Ohio, and additional mailing offices. Postmaster: Send all address changes to Popular Woodworking, P.O. Box 5369, Harlan, IA 51593 Canada GST Reg. # R122594716 ■ Produced and printed in the U.S.A. 4 POPULAR WOODWORKING August 2001 OUT ON A LIMB Contact Information Steve Shanesy Editor & Publisher Eatin’ Biscuits Specialties: Projects, techniques, article and We did our own research, and the results are . project selection 513-531-2690 ext. 238 here’s a legend about the early wood- through the eye bolt and then attached it [email protected] Tworking days of Sam Maloof. Seems to the anvil. On top of the cubes we set a that one day Sam wanted to test the joint 2"-thick, 16"-wide piece of birch. David Thiel Senior Editor strength of a table or chair leg. It was amazing. In truth, we all thought Specialties: Projects, Sam’s test didn’t involve rigorous sci- the first drop at just over 4' would barely new products and tools, entific methods. Being a practical guy, he cause any damage.Were we wrong. On the tricks of the trade took the mocked-up joint to the second first drop, the cube with biscuit joints was 513-531-2690 ext. 255 [email protected] floor of his house and chucked the thing destroyed. The sides that took the brunt on the driveway. The joint didn’t break of the impact had their joints completely Christopher Schwarz and Sam was satisfied. sheared off. Senior Editor In that same spirit, we decided to get to The mortise-and-tenon cube fared bet- Specialties: Author the bottom of the debate over which is ter. It survived enough of the first drop to liaison, website, projects, stronger: biscuits or mortise-and-tenon warrant a second whack. photography 513-531-2690 ext. 407 joints. We were ready to fling two open- We examined the joints, and here’s [email protected] sided cubes off a water tower. But then I what we concluded. First, take care not to Tricia Barlow Art Director Specialties: Magazine and cover design, photo direction 513-531-2690 ext. 599 [email protected] Got Questions or Problems With Your Subscription? To report problems with your subscription The anvil about to hit the The cube made from The mortise-and-tenon The mortise-and-tenon visit our website at popwood.com, call our cube made from biscuits. biscuits after impact. cube after the first hit. cube after the second hit. subscription offices at 515-280-1721, or write to Popular Woodworking,P.O.Box realized a flaw in Sam’s test. Furniture is drop 100-pound anvils on your furniture, 5369, Harlan, IA 51593. rarely thrown to the ground. In reality, all no matter what joints you use. Next, as we sorts of objects land on them, be it an abun- have concluded before, the wood always Our Privacy Promise to You dant backside on a chair or a heavy object gives out before the glued joint does, We make portions of our customer list available to carefully screened companies on a table. whether it’s a biscuit joint or a mortise and that offer products and services we believe So there was only one real test, and all tenon. Last, the length of the tenon rela- you may enjoy.If you do not want to re- the staff here knew it. Hey, we all watched tive to the biscuit, along with the rounded ceive those offers and/or information, poor old Wile E. Coyote try to drop that shape of the biscuit, gives the mortise and please let us know by contacting us at: List anvil on Roadrunner hundreds of times, tenon greater mechanical strength, glue or Manager,F & W Publications,1507 Dana only to become the victim of his own mak- not, than biscuits.
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