#10I,July2003 BasicHVLP SprayTechniqu l"jfil,'H:T:fjji" sprayingfinishes. 28
TVCabinet 40 Cleverdesign details in a cabinetthat can showcase(or hide!)your 36-in.TV.
StainingPine 52 Work magic on economicalpine with this step-by-stepmethod.
HVLPTurbineSprayers 56 We chosethe best sprayersfor less than $600.See what featuresmatter.
3-YearIndex 69 Threeyears of. American Woodworker, sortedand groupedfor your reference.
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(J Contents DEPARTMENTS
10 Question&Answer 's # 6# 16 WorkshopTips :"1i 22 TheWell.Equipped Shop I 64 91 92 94 e6w! page 10
Subscriptions: American Woodworker SubscriberService Dept., PO Box 8148, Red Oak, IA 51591-tl4g, (900) 666-31lf e-mail: [email protected] Artide Index A complete index is available online at wwwamericanwoodworker.com photocopies Copies of Past Aftides: are availablefor $3 each.Write or call: American Woodworker Reprint Center, pO Box g3695, Stillwater,MN 55083-0695,(715) 246-4344,8 AM to 5 PM CST,Mon. through Fri. Visa, MasterCari and f)iscover accepted. Bad Arn crican \\/o oclw EDITORKen Collier SENIOREDITOR Tom Caspar ASSOCIATEEDITORS Randy Johnson, Iim Johnson, cp DaveMunkittrick Works Vondriska C0NTRIBUTINGEDITOR George ARTDIRECTORS Patrick Hunter, VeIn Johnson COPYEDITOR Mary Flanagan oilgh FACTCHECKING SPECIALIST Nina Childs Johnson Brsakthr PRODUCTIONMANAGER Judy Rodriguez InEnclnn$ablewonHol desi$n le$ y0u cu$0miru youn VICEPRESIDENT AND GENERAL MANAGER, you'll[e U.S.PUBLISHING GROUP Bonnie Bachar shollon fie type ol ulonl d0in0. PUBLISH ER JimSchiekofer ASSOCIATEPUBLISHER Rick Stralace . Mounttools onto quick-change inserts. When you're BUSINESSMANAGER MiKC FIANIiNO readyto work,place the mountedtool you need in the PROM0TI0NMANAGER Andrea Vecchio workstationtop and lock it down. PROMOTIONCOORDINATOR JOANNC NO6 MARKETINGCOORDINATOR Derrick Phillip o Accessoriesare within easy reach with built-in ADVERTISING COORDINAT0R Susan Bordonaro drawers,shelves, blade and bit holdersand more. ADVERTISINGSALES 260 MadisonAve., NewYork, NY 10016; 212-850-7226 o Addon Tool Dock units as your workshop grows. CHICAGOCarl Benson (312) 540-4802, Jim Ford(312) 540-4804, TomVorel (312) 540-4805 Forcomplete delails and an outlet near you: SherryMallit (salesassistan0 (312) 540-4824 WESTCOAST Bonnie Oda (€06) 282-4OO2 NEW YORK DavidClutter (212) 850-7124, www.tooldock.com John0'Donnell (21 2) 850-701I, Il0Ett 0r calltoll{ree: 1-866-866-5362 TuckSifers (212) 850-7197, Ed Silhan (212) 850-7041 The Modular Workshop CLASSIFIEDADVERTISING The McNeill Group, lnc. ClassifiedManager, Jason Mailliard, @2003Waterloo Industries, Inc. Tool DockrMis a trademarkof Waterloolndustries, Inc. Toolsnot included. (215)32t-9652, ext.21 PUBLISHEDBY HOME SERVICE PUBLICATIONS, INC., a subsidiaryof the Reade/sDigest Association, Inc. EDITORIN CHIEFKCN COIIiCT OFFICEADMINISTRATIVE MANAGER AIiCE GATTETI TECHNICALMANAGER Shannon Hooge PRODUCTIONARTIST Lisa Pahl Knecht READERSERVICE SPECIALIST Roxie Filipkowski The ADMI N ISTRATIVE ASS ISTANTS LOri CAIIiStET, ShellyJacobsen CHAIRMAN,CHIEF EXECUTIVE OFFICER Thomas0. Rydel WORLDWIDECI RCULATION DI RECTOR Cutting JohnKlingel VICEPRESIDENT, EXECUTIVE PUBLISHER DomRossi VICEPRESIDENT/CFO NORTH AMERICAN MAGAZINESAND BOOKS& HOMEENTERTAINMENT Stephen Simon DIRECTOR,U.S. ADVERTISING RESEARCH tdge BrittaWare VICEPRESIDENT AND CIRCULATION DIRECTOR U.S. MAGAZINEGROUP Dawn Zier VICEPRESI DENT, CI RCULATION/OPERATIONS inally,a saw you can dependon with a name ReneeJordan f MAGAZIN E OPERATIONSDIRECTOR I vou can trust.Our new MM seriesbandsaws CathelineMerolle featurehuge resawcapacities, loads of cast iron, CIRCULATIONMARKETING DIRECTOR Lou Sassano and perhapsmost importantly...a company that lssue#101. American Woodworker@, ISSN1074-9152, USPS738-7 10 Published bimonthly, except monthly October and will standbehind it! Call one of our customer NovemberbyHome Service Publications, Inc., 260 Madison representativestoday and discover how our cutting Avenue,5th Floor, New York, NY 10016. Periodicals postage paid at NewYork, NY and additional mailing offices. Postmaster: Send edgebandsaws can improveyour woodworking. changeof address notice to American Woodworker@, P0Box 8148, RedOak, lA 51 591-1 148. Subscription rates: U.S. one-year, $24.98.Single-copy, $4.99. Canada one-year, $29.98 (U.S. Funds). GST# R122988611.Foreign surface one-year, $29.98 (U.S. Funds).U.S. newsstand distribution byHearst Distribution Group, ?%i,4i2//er76,4 NewYork, NY 10019. ln Canada:Postage paid at Gateway,Missis- sauga,Ontario; CPM# 1447856. Send returns and address changes Yio"o- to AmericanWoodworker@, POBox 8148, Red Oak, lA, USA 2012 CentimeterCircle Austin. TX 78758 51591-1148.Printed in USA.O 2003Home Service Publications, o,lln,W Inc.All rights reserued. 866-WRK-WOOD Reader'sDigest may share information about you with reputable (toll free 866-975-9663) companiesin orderfor them to offeryou productsand servicesof www.minimax-usa.com interestto you. lf you wouldrather we not shareinformataon, please writeto us at: Reader'sDigest Association, American Woodworker, CustomerService Department, P0 Box8i48, RedOak, lA 51591. Pleaseinclude a copyof youraddress label. EditeduyJan Carf Oue$lon& Anwer Stripping0ptions favoritetable, but its top is a mess'ls there an Q. My grandmothergave me her easierway to strip off the old finishthan usinga messypaint remover? A. For surefiresuccess, go straightto aliquid stripper.It will quickly cut through any clearfinish and take lesstime and createless mess than semi-pastestrippers. Look for one with methylene chloride, the active ingredient in the fastest working removers. If you want to do some exPeri- menting, stripPermay not be Your only answer.Many old finishes will literally melt awaywith alcohol or lacquer thinner. Alcohol dissolves shellac,and lacquerthinner removesmost old lacquer.Furniture refinishersmight also be effective.The problem is that one might be more effectivethan another on a given finish, sincetheir chemicalcompo- srtlon varles. Pour some of the solvent or stripper into a dish.Wipe it over small sec- tions of your piecewith steel wool (0 or 00 works well) or z U if E a synthetic abrasivePad = you will be finishing the z table with a waterborne = product. Scrub away, o @- keeping your work I area wet by redip- F o 5 ping the pad.A gar- a z dener'sspraybottle o a z is a handy applicator, I - especiallyfor vertical z surfaces. lrJ After the finish beginsto break down, wipe away the slurrY with paper towelsor a rag. Repeatthis (L process until your a piecehas an even,consis- Caution: Work in a well-ventilated = tent appearance.DamP rags area.Outdoors is bestWear gloves, E tossedin a pile area fire hazard,sohang them goggles and a respirator with an organic vapor cartridge. o outsideto drybefore you throw them away. trJ 10 American Woodworker JULY2oo3 Question& Answer BetterBrush Gleaning Along with mineral spirits or paint thinner, you ll usea Q. I bought an expensivenatural-bristle brush for var- nishing,but I cant seemto get it completelyclean.The bris- solventcalled "brush cleaner"($8 per qt.) or lacquerthin- tles are stiff after the brush dries.Whatcan I do? ner ($4per qt.).You ll alsouse "brush conditioner"($7 per A. Pros cleantheir brushesin stages,often with special 6-oz.tube).Ordinary mineral oil works aswell ($+ for t0 solventsand conditioners.This techniquewill keep your oz.).Finally, you ll needa specialbrush comb ($8).All are brush soft for years. availableat paint stores,or seeSources, page92. Rinseyour brushin mineralspirits until most tracesof varnishare Repeatthe sameprocess with brush cleaneror lacquer gone.Pour the mineralspirits back into the originalcontainer.You thinner.Comb the brushto straightenthe bristlesand remove can reuseit severaltimes, because the varnishsolids will sinkto all varnishresidue. Let the brush soakfor l5 to 20 minutes,if the bottom. Dry the bristlesthoroughly with a rag. time permits. Vigorouslyclean the brushwith dishwashingliquid and hot Wipe the brush dry with a lint-free rag and applya smalldab of water. Go through at leastfour to five wash cycles.Turnthe brushconditioner or mineraloil.Work it in,thenstraighten the brush upward eachtime so water runs directly into the bristlesonce more with the comb.Wrapthe brush in its original ,bristles.Comb the brushwhen you're done. containerand hangit to dry. t2 American Wo odwo rker .tuLv2oo3 swer StickyDrawer Slides Q. t built a set of kitchen drawers with ball bearingslides l0 years ago.Today, some of the drawers are sticking.Can I relubricatethe slidesl A. Yesyou can, with white lithium greasefrom an auto parts store. ' Assuming you haveruled out mechanicalproblems (loose screws,overloading, etc.), first clean the slide'sball bearings with a cotton-tryp.d swab. Use a plain household cleaner,such as 409 or Fantastik. Scrub the bearings clean with an old toothbrush. When you're done, wipe the slide with a dry rag. White lithium greasecomes in truo convenient forms at auto supply stores.Youcan buy a small tube (about $2) or an aerosolcan with an applicator (about $4.50).If you use the tube, dab a little greaseon the bearings with a clean cotton-tipped swab and rub it in with your finger. Work the slide back and forth a few times to distribute the grease. Wipe off any excessgrease, and your slide should be good as new. WhenShould I SharpenMy Blade? Q. How canI tell whenmy carbide tablesaw blade needs to be sharpened? A. Thereare three signs that a bladeis gettingdull burning on both sidesof the cut, more resistancewhen ripping a board,and worn teeth. Burning. If your bladeconsistentlyleaves burn markson only oneside of a cut,your fenceor splifferis probablyout of alignment.If you seeburning on both sidesof the cut, the bladeis gettingdull. Feed resistance. If it takesa lot of pressureto push a board througha rip cut,either the wood or bladeis to blame.Boards may spreador closeup whencut, binding against the fenceor spliuer.Try testingthe feedresistance with plywood instead.Is it the sameas whenthe bladewas new? 'Worn teeth. Rer4ovepitch buildup with a blade cleaner (see Sources,page92) and examine the teethwith a magnify- ing glass.A 10X works best,but any magnifier will do. If any of the corners of the blade have started to wear away,or if you seeany rounding over of the tops and sides,the blade slrouldbe sharpened.Cleaningthe blade can also improve its performance.Pitch build-up wont dull the blade,but it can affect the quality of your cut. SOUTeS seehsee2 American Woodworker JULv2oo3 13 Question& Answer DoesPolyurethane Need Sanding? years, have Q. I've usedsolvent-based polyurethane for and ,,,i,111',, alwaysbeen carefulto sandbetween coats. I havebeen told .{S sandingisnt necessary.ls that true? A. lolyurethanes for floors orwoodwork are often Lt*urn ptasTF formulated so they dont have to be sanded,but i,,ih,ffi,f polyurethanesfor furniture generallyshould be sanded. Sandingremoves unevenness and dust in a brushed surface.If you want a silky, smooth feelto your finish, you must sand between coats no matter what kind of poly you use. By abrading the surface,sanding also improvesthe mechanicalbond betweencoats. Sanding scratches effec- tively increasethe surfacearea, so one coat adheresbetter to another.Some kinds of polyurethanedon't needto be sandedto bond well,but only if you re-coatbefore the finish hardenstoo much. The window is usually about 12hours. If you wait longer,you should alwayssand. IW t4 American Woodworker JULY2oo3 ",.#B' t\ "f-' I ders l ndy t fohnson t I tE L L F a u; E lrJ F ff- a :h\ J-' fil J ft cr z lrJ E AluminumAngle Sled Runners z If you've had a problem with the wood runners on your spacer.Youmayhave to adjustthe thicknessof this spacer.You o F swelling,make new runners from want the angleto ride abovethe T-slot in the miter gauge.If o tablesawsled shrinking or T 1/8 in. x3l4-n.aluminum angle.These runners will fit most your miter gaugeslot does not have a T-slot, use a thicker lrl miter slots and will not shrink or swell like wood. wood spacer.lustleave a little clearancebetween the bottom J O Here'show I built mine: First I fit the angle to the miter of the miter slot and the bottom of the angle. z 'a gaugeslot in my tablesaw.Youmay need to file the angle a lir Now I set the sled on the tablesawwith the first runner in z.- sledback a bit and put anotherpiece -o tle to get a good fit. The angle should glide smoothly in the a miter slot.t pulled the z E mitergaugeslotwithoutbinding,with minimum sideto side of anglein the secondmiter slot, carefully marking the loca- lrl Pray. tion for the sawkerf. I cut the kerf and attachedthe second 2 F (J Next I cut a sawkerf in the bottom of the sled base.The runner.IVe used my sled for yearswith perfect alignment and U E kerf makesrunner alignment automatic.Turn the sled over smooth action yearround. F and fasten the first angle to the base with a 1/4-in.-thick IohnRhodes E, 16 American Woodworker JULY2oo3 WorkshopTips DrawerSlide Tracing fig I recentlyneeded a jig to tracelathe turnings. I tried a variety of designsbut none producedthe accuracyor easeof operationthat I wanted. While rummaging around my shop, I discoveredan extra setof 10-in.ball bearingdrawer slides (see Sources, page 92) Ieft MobileMagnetic Light over from anotherproject.I attacheda singleslide to a bracket My shop has poor light. I've found a magnetic-base and attacheda pencil to the slidewith a notchedwood block and work light (seeSources, page92) to be a realgodsend on Wing Nut. The bracketfits in a dado in the jig's base.The lathe my bandsawand drill press.I liked the light so much I turning is held betweena coupleof sharpenedmachine screws. figured out how to useit an1.r,''rherein my shop.I brought The right holder is attachedto a T-track with a T-bolt and knob homea handfulof metalelectrical box covers(about 50 so I can move it for differentpart lengths.To usethe jig I move centsapiece) from my local hardwarestore. I fastened the slidein and out againstthe turning while I slidethe bracket one whereverI neededadditional lighting, over my left or right. The pencil doesthe drawing and I end up with avery workbench,sharpening station, /ou name it. Now I accuratetracing of the part. can grab my light and stick it any,nrhereI need it. Don Posto SteveJones LongTenoning Sled Here'sa tablesaw-tenoningjig that combinesthe light weight of a miter gaugewith the support of a wide tablesawsled.I madethis sledfor use on the right sideof my bladeso my saw'sright-side table supports the sled.I alsoadded an auxiliarywood fenceto my rip fenceto act asa stop guide and to protect the fencefrom beingcut by the dadoblade. The tog- gleclamp (see Sources, page 92) holds the work flat when cutting the facesof my workpiece.When I cut the sidesof the tenon,l just hold the part up againstthe sled'srear fence. JoyceHanna 18 American Woodworker JULY2oo3 WorkshopTips HandyDandy Graft Sticks A $3box of 1,000craft sticks is thebest wooden sticksfor everythingfrom stainand dabbing putty. bargainI've found in a long time (see spreadingglue to shimming cabinet If you wantto usea craftstick to stir Sources,page 92). I use thesesmall doors.They also work greatfor mixing your coffee,iust be sureit'.s a fieshone! ShannortHooge rW Just0ilf ToolFor AII YourRab[eting Needs! INsEnr SUPERABBET,JR.* +nc-4e3ss . 4-sidedreplaceable carbide knives. t 13diflerent deptfswilh one lool using optional collars. e Maintainexact lolerances. -BASIC . Chooselrom 4 differentcarbide grade knives for TOOL dilferentapplications: o,4tquru, ffi AMA-12(wood, plywood) HMA-12 (solid surlace/SSV'/MDF) llY-llSmn-tz (soft and hard woort) MFA-12(all purpose) '**'*:."..,,e*# '--'" "dr\ tr'# ? :* I .",** re INSEnT -BASICTOOL SUpEnaBBET* #RC-49360 o2-sided replaceable caftideknives. If you have an original'Workshop t 18ditlercntdepttrswith onelool Tio, send it to us with a sketch or usingoplional collars. photo. If we print it, you'll get r Maintainexacl tolerances. $ 100. Send to: W'orkshop Tips, . Choosefrom American Woodworker, 3 differentearbide 2915 gnde Commers Drive, Suite 700, kniveslor dilferent E"g*, MN 55121 or e-mail to applications: SSV@is a reqistered [email protected]. m RCK-30(wood/plywood) trademak of Submissionscan't be returned and ll" I SRK-30{soft and hard wood) nI_ become our property upon accep- WILSONART" \We llo fl HnK-30(solid tance and payment. may edit [---ll surface/SSV;7M0F) submissions,and use them in all print and electronic media. *ensrctoor, 6b-+seoo, Rc-49355) includes bit and one set of RCK-30 Amanafool' or AMA-12 kniv'es." Helaiio FOR,OUN, NEW CAIALOG OR,A DEALEN, ouq'nevraaialog AM-r-02 : {6 &'47 for more details ' NEARESTYOU CALL t-800-tw5-(n7z FF$es !rvi"i, ou, web sia ot www.amqnalool.com The Price-GuttingSaw Got $100?That's about all it takesto buy Delta'sMS250 compound miter saw-a sawthat recentlysold for ashigh as$170. Miter sawsare greatfor the shop and asfix-stuff-around-the-house tools, and com- pound miter sawsprovide evenmore versatility.On a compound saw you can angle and bevel the blade. This is especiallyuseful when installing crown molding. With its 10-in.blade, the MS250will cut through2x6 and 4x4 (nominal) lumber at 90 E degreesand at only 28 lb., this o E UJ l F machine is a breezeto move a tr = o z around. z U L A 13-amp motor powersthe U' o}!, = U MS250.This will getyou through UJ E I :) hardwood,but more expensive F machineshave more powerful 15-ampmotors. a trJ ?r ( J The tableangles 47 degreesleft and right with z l positivestops at0,22-ll2 and 45 degrees.The blade E trJ E tilts from -3 to 48 degrees.This is an areawhere the l F MS250falls short.Many miter sawsoffer a greater span of angles,up to 60 degrees,as well as more z. positivestops, though not at this low price. Lr a t! F E. l t I o- l$nk-Free,Lightweight Air Hose t Do you ever feel like the conven- It's amazinghow easyit is to work - L ienceof usingair tools is ounveighed your way around a cabinetwith the a E u by the rubber air hose python you Flexeelhose, and evenmore amazrng F z haveto drag around?Let that snake that it doesn'tcost much more than -f :< hibernateand havea look at the new a good-qualityrubber hose.A Flex- E. F Flexeelpolyurethane hoses from eel hose weighs lessthan half of a o_ Coilhose.They're lightweight, flexi- rubberhose and it doesntmar like a 2 F (J ble and easyto coil, but resistkink- rubber hoseif you happento dragit U E ing. They comein cool colors,too. acrossyour work. o F Coilhosemakes Flexeel hoses in a All the Flexeelhoses are trans- E '.4 rangeof diametersand lengths.The parent,so you canwatch for problem E. L ll4n.x21-ft.coil hosecosts a $18;the moisture or oil migrating from the (J straighthose is $l9,without fittings. compressorto the tool. c; o o U Sourc€S forall producs Seepage 92 22 American Woodworker JULY2oo3 Dp$d,,$hpp?.gv-dk TOGGLE Rock-Solid CLAMP GopingSled When you make doors on the router table,the tricky part is cop- ingthe end grain of the rails.You need a darn good grip on the material and a backerboard to prevent blowout. Eagle America has you cov- ered on both counts with their new coping sleds. Choosefrom the Original, $40 or the Pro model,$60. The toggle clamp grips your material, and a replaceableguide block of high-density poly- ethylene (HDPE) plastic backs up the cut to eliminatetear-out. With tr,vostout handles,hold- ing the sled and feeding across the cutter is a breeze.Sure, you could build one of these,but when you roll in the price of the toggle clamp and time spent to do it, thesesleds are a great value. The Pro model has a slightlywider basethan the Original, and includesa"keeper"on the front to help hold material against the guide block. Maximum width between the keeper and the guide block is 3-314in. Both models use a self- adhesiveabrasive tape to help keep your work- piece from slipping. With adequatepressure from the toggle clamp, a sharp bit, and smooth feed rate, the Original sled works fine, but if you're brand new to door making and want a little extra insuranceagainst rail slippage,you'll get it from the Pro model. After using the sled once,yott've got a set-up gaugefor your next door. fust use the cope pro- file that'sbeen cut into the guide block to set the height of the bit. American Woodworker JULY2oo3 23 TheWell-Equipped Shop Space-SavingGyclone System Dust collectorswith balloon-like filter cartridge filters instead of bags. bagshave away of eating up precious Cartridges take up lessspace and filter r shop space.A new 2-hp cyclonic col- better than bags.Oneida filters are tr z. lector from Oneida Air Svstemsoffers made of high-quality filter material = a U o - and capture over 99.9 percent of test material between0.2 and 2 microns. This new collector comes in two versions.The one with an internal fil- ter, $882,has a footprint of 24 in. x 24 in. The other version, with an external filter,$977,hasa footprint of 24n.x46 in. A 35-gallon drum for collecting chips makes the system 86-in. tall; with a 55-gallon drum, it's 99-in. tall. The external cartridge is a lot easier to clean than the internal cartridge, which mustbe removedto be cleaned. The efiernal cartridge can be blown from the outside.The dust falls into a plastic-bag-lined dust pan, and the bag can be easily removed and f waitingfor a finishto dry dumped. Connected to a typical ductwork won'tfly - wehave theright product for iust iust pull - system,these units 900 cubic feet you ZAR'UIIRA Oil-Based Interior Polyurethane. per minute, great for a small to ZARIIITRA provides a beautiful,smooth finish in just medium sizeshop. The new2-hp unit 2 hours.ZAR's exffemely durable formula makes it can run on 120or 240volts,but draws idealfor highusage areas, such as floors, cabinets, 20 ampson 120volts. furnitureand doors 7ARUnP.i', he way fastest toa beaunfulfinkh! Sqff[g seepagee2 Foro freebrochure ond deolerneoresl you, coll |.9A0.272.3235 or visitwww.ugl.com 24 American Woodworker JULY2oo3 TheWell-Equipped Shop OnlineGaruing Glasses There'snothing like hands-oncarving instruction with an expertteacher looking overyour shoulder.But if you want to hone your carving skills using cutting edgetechnology, and do it for free,check out www.2carve.com. This Web siteoffers four freetutorials in chip carving at the beginnerlevel and I I free tutorials in relief carving at the beginnerand intermediatelevels. The tutorials can be downloadedfrom the Website and printed.The instructions #tilHKb areclear and includegood photos,not sketches.However, AE ,"t rtotto it maytakeyour computera while to digestthe photos.The ' National Woodcarving School files,although compressed, are big, so it'll takesome time with dial-up connections. A paid membership($ZS per year)gets you accessto a greatervariety of techniqueslike sharpeningand finishing, aswell asmany additional carving projects.The member- ship also includesa CD with the free tutorials, so you wouldnt haveto download them. The free tutorials are a greatway to seeif this is a learning style that works for you. If you like them,you cango on to the paid membership.IW tsE h8.t6ot3d Top to bottom,side to side,the JET SuperSawhas all the speciticationsand featuresyou are looking for in a ***'** Every part is of excellentquality and set-upinstructions are i -An Amazon.com i customerfrom * JacKsonvrre,Fr Movable power switch lets you change switch placement to suit your needs Allcast-irontable, sliding table, and extensionwing Slidingtable with large miter gauge with cam:lockclamp down and comfortable hand grips Micro adjustablefence with magnifiedcursor for preciseripping *IVe will rnatch our competitorsprice pl*s beat it by 10% of the diference. Find out moreat wuu.ArnAmn,com/price-rnatch. BasicHVLPSPRN TECHNIOUES How to succeedat sprrying owaterbornefinish hen it comesto finishing, we're all looking for easyanswers that give pro- fessional results.Years ago, I switched from brushed and wiped-on fin- t ishes to shooting waterborne finishes with a high volume, low pressure m - (HVLP) turbine sprayer,and I've never looked back. Now my finishes are quick, safeand :< durable, and they look like a thousand bucks. z B I made a lot of mistakesalong the way,however. Spraying is a whole craft in itself, and z I had to learn on my own, the hard way.If you'venever sprayed before, or arejust learn- E a J inghowthis step-by-stepguidewill helpyou avoidthe most common pitfalls.Wdll cover -J a how to set up your shop,how to adjust gun how lrJ the spray and to go about spraying a Y -t I basic cabinet.Obviously there are a lot of fine points that we wont cover,but this is really lrJ )N all you need to get going. J 6 A good HVLP systemcan cost $600or more (seeour tool test on HVLP sprayerson page 56), but if you want to take a test drive before buying, or simply want to get one E o F big project done quickly,you can rent an HVLP systemat a paint store. T a E lrJ F Waterborne Flnishes Are User-Friendly z. ? :< Waterbornefinishes are clearlythe best choice for sprayingin a home shop.Youget most C) E of the benefits of sprayed lacquer or polyurethane without needing an explosion- trF ; o proof exhaustfan or explosion-proof lights. Warcrborne finishes generally dry to the tr UJ touch in 3 to 10 minutes, and you can re-coat in lessthan an hour, building up 3 or 4 o coatsin a day.The quicker a finish dries, the lesslikely dust will contaminate the sur- s o face.Clean-up simply requireswarm water. q a Be sure to buy a waterborne finish that is labeled for spraying.Waterborne finishes = for brushing are too thick to successfullyspray, and generally can't be thinned. See o SprayableWaterborne Finishes,page 38, for a representativelist of manufacturers. = lrl American Woodworker JULY2oo3 29 ;,,:l: "-: iJ, Before You Staft Beforespraying, do somehousekeeping in your shop and practice how to hold '$ the spray gun. € :# PrepareYour Shop Sprayingin a smallshop is a constantbaale with dust and overspray.(Overspray is the fine mist that bouncesoff or missesyour project.) Outfit your shop with plastic sheetingon the walls,a canvastarp on the floor,a halogenlight and a Wndow fan (about $ 150total). Dust kicked up by the'gun can ruin a finish.Thetarp and sheetingeliminate the dust hazard and keep overspray from settlingon your tools,floor and wallsVacuum AT-e50 your project before you spray. P Ventilateyour shop with a window fan behindthe project,blowing to the outside. Crack open a door or window on the other side of the shop to supplyfresh air.Weara Caution:This workhop setup is designed onlyfor spraying waterbohefinishes, not solvent-basedfinishes, such as lacquer and polyurethane. respirator with an organicvapor cartridge when you spraywaterborne finishes. Strainthe Finish Waterborne finishesmay contain solid clumpsthat will clogthe gun or spoil a finish.Solid pieces of finishor dust mayfall into the finish can,too. When you pour finish into the sprayer'scup, strain it through a smallnylon anklet sock.Youcan rinsethe nylon with water and use it over and over. For the steps aheadyou'll need a large disposablesurface to practiceon.We used builder'srosin paper,available at a home center for about $ l4 a roll, but plain brown paper or cardboard would work. PracticeHolding the Gun There'sa right way and a wrong wq, to hold the gun,and)rou must be familiarwith the right way before adjustingthe gun'scontrols. The first step is to turn on the HVLP turbine to pressurizethe cup.Pressure keeps finish from travelingback up the pressuretube and dribblingout of the gun. Pick up the gun and hold it at 90 degreesto the surface.Dont let the gun droop, particularlywhen you adjustthe gun'scontrols in the steps ahead,because that will create an uneven spray pattern. Hold the gun 6 to 8 in. awayfrom the surface. Lock your wrist and move the gun back and forth with your arm. The speedof your arm movementdetermines how much finish you apply.Move too slow and the finish will pool. Move too fast and the coat will be too thin.You'llfigure out the right speedafter you set the gun'scontrols. 30 American Woodworker JULY2oo3 FAN PATTERN Adjust the Gun CONTROL Settingthe controlson the gun can be a complicatedprocess of trial and error, but there is an easierway.We'll take you through an orderly processthat will work each time you readjust the gun for different situations. Know the Gun's Controls Every HVLP system has three basiccontrols: the volume of air flow the volume of fluid flow and the type and size of the fan pattern.Thesecontrols may be located in different placesthan on the gun shown at right. lf you're in doubt, check the owner's manual. An HVLP gun uses air to break up a fluid finish into tiny droplea. lt's called"atomization." Once atomized,the droplets are formed into an adjustablespray pattern, called the "fan."Thetrick to adjustingthe gun is to get the right atomization,or balanceof air and fluid volume, acrossthe entire width of the fan pattern. But before you tackle that problem,the first controlto adfustis the fan pattern itself. Setthe Air C"p for FanSize A small detour here. lf you have the type of gun that has an adjustableair cap,set it now.Turn the cap so the nozzle is flush with the face of the air cap.Asyou become better at sprayingyou can readjustthe air cap to changethe sizeofthe fan pattern.For now,leavethe nozzleflush with the air cap. AIR CAP FLUSH WITH Selectthe Fan Pattern NOZZLE All air caps can be set in three positions. Each position these settings. creates a different fan pattern. For learning how to set the air and A vertical fan is good for tops, or any time you move the gun side fluid volume controls in the steps ahead,set the air cap to make to side.A horizontal hn is good for sides,or any time you move a vertical pattern.Air and fluid volume settingsare about the same the gun in and out, directly awayfrom you.A round fan is used in for vertical and horizontal hns. Round fans require readjusting specialsituations to concentrate the finish in a small area. American Woodworker JULY2oo3' 31 Adjust the AirVolume l Regulate the air flow from the turbine too little just right too much by'turning the knob on the air hose. Makethis adjustment beforetackling the To start out, turn down the Slowly increasethe air lf you turn up the air fluid volume, below. Increasingthe air air control most of the volume until the fan is volume too much,you'll get flow creates tinier droplets of finish,or way. Pull the trigger and evenlyatomized and has spraythat looks like a fine more atomization.Thick finishes need make a pass.lf finish spits clearly defined edges, mist, plus an excessive more air;thin finishesneed lessair. Hold out of the gun or if you see without splatter. amount of overspray. the gun 6 in.fiom the surfaceand pullthe splatter at the edge ofthe Reducethe air volumeand trigger back only hr enoughto create a hn pattern, turn up the air test again.(lf the air volume 6-in.-wide fan pattern. a little bit. is at the mar Adjust the FluidVolume Regulate the fluid volume by turning too little just right too much the knurled knob at the back ofthe gun. This knob controls how far you can pull Begin by adjusting the lncreasethe fluid volume Back offthe fluid volume the trigger. As you pull the trigger, the trigger for a minimal pull. until the fan is 6-in.wide. if your surhce is flooded volume of finish increasesand so does the As you move the gun,the Tirrn the knob to stop the with finish,or move the size of the hn pattern.Your goal is to set hn should be smallerthan trigger at this point. Now gun at a faster rate.The the trigger so it automatically stops at 6-in.wide. Some spraying you can simply pull the fan will be too large when the ideal size hn for the work you're situations,such as spraying trigger all the way bac( like you pull the trigger back doing.To start out, stop the trigger at a a narrow hce frame, call an on/off switch, to spray too far. 6-in.-widefun. for a small fan in order to the same size fan.As you minimize overspray. move the gun,you should get an even,wet coat of finish,not a mist and not a flooded surf'ace. 32 American Wo odworker JULY2oo3 Spraying Techniques Practice makes perfect. Rather than start right in on an actual project,build a disposablecabinet to try out the following techniques.For construction details,see Practice Cabinet,page 38. SprayingInside a Cabinet Always beginwith the inside of a cabinet.A general rule of thumb of spraying is to start with the least visiblesurface and end with the most visiblesurface. This minimizes overspray from settling on and spoiling a surface that really counts. Overspray on visible areaswill be covered by the final coat. Fill your cup 3/4 full with finish.Thisprevents the fluid nozle insidethe cup from beingstarved of finish whgn you tip the gun to get into corners. Adjust the air cap to make a vertical hn.Increasethe air flow to create a light spray Pattern and minimize overspray. Light coats are fine inside a cabinet. Reducethe fluid volume to make a 6-in.-widefan. Next, follow the steps as shown: Spray under the top, moving from the back to the front.The hn Pattern should just reachthe edge ofthe cabinet back Spray the back, overlapping each pass by 50 Spray the sides, moving from back to fronq away from the overspray. percent. Position the edge of the fan pattern to just reach the inside corners. lf you spraydirectly into the corner,finish will run down the inside edge or overspray will bounce back toward you. On an actual cabinet, remove the back if you can and finish it separately. Spray the botrtom, tipping the gun as close to 90 degrees as )tou can to create an ideal hn pattern.This is the most visible part of the cabinet'sinside. Spraying here last blends . in overspray from previous steps. American Woodworker JULY2oo3 33 Spraying FaceFrames and Small Surfaces Switch the air cap to a horizonal fan pattern. Reduce the size of the fan pattern to about 3-in. across to minimize overspray.You can reduce the fan by reducing fluid volume, reducingthe air and fluid settingstogether, or movingthe gun slightlycloser to the surhce.Alwaystest on paper before sprayingyour cabinet. When you first pull the trigger to sprayany vertical outside surface,such as this face frame, dont aim right at it. Instead,aim the gun at a point above the faceframe,as indicatedby the yellow oval at left.Then pull the trigger and work your way down.'Dont releasethe trigger until you're past the bottom. Do this in one fluid movement,always holding the gun perpendicularto the face frame. Spraying Vertical Surfaces Adjust the air cap for a horizontal fan pattern. Adjust the fluid volume and the air volume to make a 6-in. fan pattern on a piece of paper,as shown on page32. Start spraying at the top.Aim the gun at a point Return at the bottom and work your way up, abovethe cabinet and pull the trigger.Thenmove overlappingthe first passby 50 percent.Once down the cabinet,just as you did with the face again,use the sametechnique of aimingat a point frame above. underneaththe cabinetwhen you first pull the trigger.Repeat an up and down sequenceuntil the side is covered. 34 American Woodworker JULy2oo3 Spraying Tiops Set up your light at a low angletothe toP so you can clearly see your spray patterns. The edge of a top deservesspecial attention. lt gets three coats for even/ one coat that goes on the top itsell in part because edges inevitably get extra wear.In addition, it's easyto sand too deep between coats on a narrow edge.Extra coats will help prevent accidentallycutting into a stain layer under the finish. Set the air cap for a vertical 6-in. fan pattern for bottr the edgesand the top surhce.lt's not necessary to reset the air caP to a small fan for the edges, becausethat will slow you down. Waterborne finishesdry very fast.Your goal is to keep the gun moving at all times. Eachpass should blend into a previous passwhile it's stillwet. Spray all four edges, all the way around the top. Hold the gun at 90 degrees.Some oversPra),will land on the toP, but that's okay.You'llcover it up later. Spray the top edges. Hold the gun at 45 Spray the top. Hold the gun at 90 degrees,and sprayacross the front. Use degrees.Again,dont worry about oversPray onto the sametechnique of handlingthe gun'strigger as you did with vertical the top. surhces on page34.As you move the gun from side to side,pull the trigger before you reach the top and release the triSSer only after you've passed beyond the top. Overlap each pass by 50 percent.Alternate direction back and forth to keep the gun moving quicker than the finish can dry. Sprayingfrom front to back directs overspray toward the window hn. . Stop sprayingwhen you reach the back. American Woodworker JULY2oo3 35 Runs,Drips and Errors Missed Overlaps Mistakesare inevitableas you learnto spray.I've madesome whoppers,butI've come to con- NOT ENOUGH siderthem as opportunities,not 1 '\ FINISH failures!With eachopportunity' I you'll becomemore familiar with fine-tuningthe gun's adjustmentsand holding the gun whilespraying. - r.t;l: ', :1"+i Fortunately,most mistakes Yucl<.Tryingto be careful,I movedthe gun are easyto fix by sanditg. Cheapskate!What was I thinking?That I'd too slow while sprayingthe side of a savefinish by hardlyoverlapping at all?lt's cabinet.Or maybemy fluid volume was Waterbornefinish dries very not worth it, becausehere I'vegot a rough looking texture between the spray coats. too high,ldon't know.ln anycase, I let the fast.Whenyou mess up,wait an messdry, shaved off the excesswith a utility Actually,I just couldn'tsee where the fan knifeand then sanded.Next time l'll check hour,sand and sprayit over. patternhit the surface,so I couldn'tiudge my adjustmentsby sprayingon a pieceof the overlapsproperly. What I reallyneed paperfirst and makesure I l Bubblesin the Finish Pools of Finish at the Ends Clogged Needle TOO MUCH t-rurrr. FINISH I told everyoneI reallywanted the finishto There'sa wadingpool-size puddle at the Now what?My gun quit on me after I tool< lool 36 SprayingRaised-Panel Doors Edgesare everywhereon a raised-paneldoor!The secret to successis to follow a systematicplan. To set up the gun,turn the air caPto a vertical fan pattern. Then increase the air flow a bit beyond where you set it in "Adiust theAir and FluidVolume," page32.This increases the atomizationof the finish, producing a finer spray and lighter coat. Finally, reducethe fluid volume (the trigger setting)to make a 4-in.-wide fan pattern. Now you're set to 8o. Placethe door on some 2x4s to elevateit abovethe table.The best setup,though, is to make a turntable to support the door.Then you can rotate the door as you go, alwaysspraying towards the window fan. Spray alt four edges, all the way around the door. Hold the gun about 6 in. away. hold the gun at 45 Spray the outside top edges. Hold the gun at 45 degrees Spray the inside top edges. Again, finish from buildingup and make a second passall the way around. degrees.Keep the gun moving to Prevent in the corners. Spray all the top surfaces. Hold the gun at 90 degrees.Spray Spray the bevels of the panels. Continue to hold the gun at two continuous coats for full and even coverage.Spray from 45 degrees.lf your panel is prefinished,naturally you'd skip this side to side,then rotate the gun and sprayfrom top to bottom. steP. American Woodworker JULY2oo3 37 Cleaning the Gun Practice Cabinet At the end of a day of spraying,take 15 minutes to cleanthe Build this partial cabinetto practice spraying.lt's better to make gun. If you skip this step,the gun may not spray properly. mistakeson a throwawaypiece than on your pride and joy! Make Empty the cup and fill it with warm water.Adjust the air the cabinetfrom a half sheet of 314-in.MDF (medium density cap to make a round fan pattern, reducethe air volume and fiberboard) and assemblewith a brad nailer or drywall screws. increasethe fluid volume. Then follow thesesteps: Spray warm A water into a bucket until the water is clear.This cleansthe internal fluid passagesinside the gun.Empty the cup. Disassemble the gun, removing eveD/ Part )rou can. Clean off dried D 1-114'x 16' finish with warm water and a brass brush.Make sure the holesin the air cap are cleanand free of finish.Poke them with a dull sewingneedle or toothpick. Lubricate the gun. Wipe petroleumjelly on all threadedor movable parts. Reassemblethe gun.IW Sprayable Weterborne Flnlshes EF Pro-series These waterborne finishesare specifi- www.ge neralfi n ishes.com callyformulated for sprayingwith an (800) 783-60s0 HVLP system.Thisis just a sampling; EnduroWat-R-Base there are many others on the market. www. compl iantsprq/syste m s. com. (800) 696-06ts ApollocoatAquaClear www.advmachinery.com Hydrocote (800)727-6ss3 www.hydrocote.com (800) 22e-4937 Crystalac www.crystalac.com PianoLac (63r) 207-0328 www.pianolac.com (84s)8ss-0ee6 38 American Woodworker JULy2oo3 lovemy new36-in. TV The double-hinged doors fold expect to pay about $600 in but my wife hateswhat flat against the sides to open up materials for this project. the glassand plastic the cabinet for unobstructed Ventilation and monolith doesto the viewing. Plus, they're a whole lot Wire Management cheaperand easierto install than look and feel of our family Big TVs kick out a lot of heat, so pocket doors. The adjustable,no- room. To avoidmarital strife adequateventilation is a must. The mortise,partial-wrap hinges(see we went looking for some- cabinet is designedto let the heat Sources,page 92) make these thing to housethe behemoth. escapethrough a series of vent doors a snapto hang. No luck.Sounds like ajob for holes(Fig.A). the familywoodworker!I love Cost and Materials it when I get a chanceto jus- I chosepine for its tify my sometimes-contro- rustic feel.Plus,I love versialinvestment in the shop. the smell of fresh-cut A cabinetlarge enoughto pine in myshop. accommodatea 36-in.TV Pine plywood is a could look like an oversized special-orderitem shippingcrate. But I used a and comes with designwith angledcorners to either knotty or clear easethe big-box look. veneers(see Sources, Note:There are afew extra- page 92). You can deep36-in. TVs that may requireyou to cut a hole in the back for the TV to poke through. You could make a deepercabinet but youd have to buy an additionalsheet of plywood.Play it safe;buyyour TV first,then adjustthe depth if necessary. Television American Woodworker JULY2oo3 4l Holesat the bottom of the uppercrosspiece and at the You'll Need aWell-Equipped Shop backof the TV shelfallow both wiresand heatto pass To build this projectyou ll needa tablesaw,a stackingdado set, through.All thewires funnel out of an 8-in.-dia.hole in bandsaw,biscuit joiner, screw gun, router table, router, the back (Fig.A). The removableback allows easy access pneumaticbrad and finish nailer,planer, miter saw and at to the snake'sden of wires behind the TV and its leastsix 6-ft. pipe clamps. components. Checkyour router bit collectionfor a ll2-in.Roman ogee,a ll2-in. cove,a ll2-in.round over,a flushtrim (top or bottom bearing),and a chamferbit. If you want to makeyour own bun feet,you ll alsoneed a 1-in.round-over bit (seeSources, page e2). Build some knee-high sawhorsesto support an oversized assemblytable. All set?Let's start building. AA /.\ 45 DEGREES Double-hinged doors fold flat against the sides, leavingthe screenwide open for optimalviewing. Becausethe doors are doublejointed, they can be operatedwith as little as l4 in.of sideclearance. * uoRuAttyAPPLIED TO RIGHT-HANDDOOR A conveniently located drawer with full-extension slidesallows easy access to a treasuretrove of movies. DOOR DOOR DOORPANEL COLUMN TRrM(X) ASTRAGAL(Y) rRtM (z) TR|M (AA) Detail I n 7112" , \ Door Moldings r-2.. l3.r \rtaf Roundover top of \ -'L.' f. tVl- * door trim (X) with :aF*")'.)lJl-L---i r/16"r'.,{------l 1t4" 114,,/ sandpaper l-t"--*l lgtl,.l I f 1"+l t l<-3l4"+l ;-- Ameri can Woodworker JULy2003 Fig.A ExplodedView #8x2" l"- The "double-jointed"doors are much cheaperand easierto installthan pocket doors. American Woodworker JULY2oo3 43 ll Make all the Buildthe Cabinet I shelves 1.Cut the 3/4-in.plywood partsA through J identical by using (seeCutting List and Cutting Diagram,Page one shelf as a sl). template. Cut the angledcorners on the 2.Cutthe shelfblanks (B, C and D) to size.Lay other shelvesa bit out the angledcorners on one shelfblank by oversize.Clamp the making marks 4-in. from the corner along rough-cutshelves to the side and front edges.Connect the marks the template,and trim and rough-cut the corner on the bandsaw. flush with a router. 3. Clamp a straightedgealong your layoutline and usea flush-trim bit to finish the corners. Usethe finished shelfas a templatefor making the othershelves (Photo l). 4. Glue up the double-thickTV shelf (C) and r) Glue edging the centerdivider (F).A coupleof brad nails 3 to the cabinet will keepthe halvesfrom shifting under clamp parts. The angled corner edgingon Pressure. the shelvesis done 5.Add the 1/4-in.edging (QQ and RR) to all first. Use a notched the angledcorners (Photo 2). Then add the block to apply front edgingpieces (NN and RR) to all but the pressure. clamping bottom shelf(it'llbe addedlater). Let the edging hole in the back of the overhangalong the 6. Cut the semicircular front.Thentrim it TV shelf.Add 1/4-in. edgingto the drawer flushto the plpvood openingdividers (l) and the centerdivider. Cut on the tablesaw. the notch at the top of the drawer opening dividers(Fig.A). 7. Cut through dadoesand rabbetson the sides (A) accordingto Fig. D. Glue on the solid-woodedging (PP) and sandflush. GlueUp Gluing up this cabinetis a big job. Dry clamp the cabinetas a dressrehearsal for the real thing. Measurethe exact distancebetween the TV shelf and the componentshelf and cut the centerdivider (F) to fit. ScrewtheTV and component shelvesto the center divider and disassemble. cabinet Q Assemble the tJ with cauls and shims. The shimshelp put pressure in the center of the cabinet sides.Fasten the center dividerto the two center shelvesbefore assembly. Use screws for the bottom shelf: moldingwill cover them later. 44 American Woodworker JULY2oo3 l. Assemblethe cabinetwith glue (Photo 3). Create a ledge -Ji Make sureit's square! below the doors with solid wood 2. Cut the upper (G) and lower (H) fastened to the crosspiecesto width. Cut the wire and vent underside of the archesin the upper crosspiece.Add the screw component shelf. flanges(GG) to both. Use a 7|8-in.spacer 3. T\rrn the cabineton its side and reachin block to keep an even reveal. from the back to screwin the uPPerand lower crosspieces(Figs. C and D). Apply the CabinetTrim The cabinettrim is applied to nailer boards fastenedto the subtop and the comPonent and bottom shelves. of Beforeyou cut your trim stock,select the E Add a row t nailers below best-looking,straight-grained pine for the the ledge to create a (P), column doors (N), column bases door surfaceto nail moldings frames(R, S and T) and drawerfront (Q). to.The naileris flush 1.Rip the nailerstock (DD).Cut and fit nailer with the ledge in front boards under the componentshelf (Photo 4 but is recessedat the angledcorner where and Fig.F). The tops of theseboards create the the column basefits. ledge under the doors, so use defect-free Determinethe stock. setbackfor the Note: Beforeyou add the nailer to the recessednailer by front of the component shelf, slip the two holdingthe column placeand drawer opening dividers into the opening. basein tracing the back edge t be able to get them in once the You won onto the ledgeabove. nailer is in place.Dont screwthem in place Justyet. 2. Double up the nailer board along the front edge of the component shelf.The nailer board at the angledcorners is set back to accommodate the column base(Photo 5 and Fig.F). 3. Cut, glue and nail the column basesin place. I Screw dividers 4. Attach the drawer opening lJ into the case to dividers (Photo 6 and Figs.A create the drawer andC). opening. A 35-in.long s. Add shelf edging (MM) and spacerboard keeps dividersparallel as nailers to the bottom shelf (see the they are screwed into Fig.F). position.Tip:Mount 6. Machine the ogee(KK) and the drawer slidesto round over moldings (LL). Glue the dividers before them together to make a single they're fastenedto the molding. Note: Removethe cabinet. bearingfrom the round-overbit to createthe double fillet (Fig. D).Cut and fit the two bands of molding around the lower portion of the cabinet(Photo 7). American Woodworker JULY2oo3 45 I Attach the T.Addnailersto the top of the cabinet(Photo , moldings 8 and Fig.E). with nails and 8. The angledcorners of the top (E) are cut glue.We used specialmolding in the sameway asthe templateshelf except glue insteadof you measureback 4-314in. from the corners traditionalyellow insteadof 4 in. Glueon the top edging(HH). glue.Thethick- Then rout the ogeeedge (Photo 9). bodied molding 9. Attach the top, keepingabout a 1-in. gluewont drip Apply the or run while margin on the front and sides. positioningthe covemolding (Photo10). molding. Doors and Drawer The double-hingeddoors may look like a nightmare to hang,but theyte really a snap. Adjustable,partial-wrap, no -mortise hinges are the key. Be carefulwhen screwingthe hingesonto the bevelededge of the column door (N). Q Fasten nailer I boards on top The hingescome with li2-in. and 5/8-in.- of the cabinet. These long screws.Play it safeand nip 1/16-in.off nailerboards create an the ends of the Ll2-in. screwswith a side overhangabove the cutter so they won't poke through. doors and providea 1.Make the column trim (AA) (Fig.A, Detail surfacefor applying the cove molding.Start 1). Glue and clamp it flush to the outside with the angledcorner edgesof the columns(no nails,please).Then naifer.Use a l-l l4-in. cut the bevelededges (Photo 11). spacerblock to set the 2. Attach hinges to the cabinet side of the overhang.Attachthe columns. The point of the bevelededge remainingnailers and screw them down should butt right up againstthe barrel of securely. the hinge.Attachthe columnson the cabinet (Photo12). 3. Assemblethe door frameswith biscuits. Removethe column doors and attachthem to the door frames(Photo l3). Putthe door A Rout the I ogee edge on the top.Just glue on the edging,sand flushand rout.Then screwthe finished toP onto the cabinet. 10*"?i1"'r""" under the top and against the edge of the nailers. Hold the moldingin place with springclamps as you go. Fastenthe moldingwith glue and pin nails. 46 American Woodworker JULY2oo3 :W qA Attach the door to the column. Make Itf surethe columnand door frameare even at the top by butting both piecesagainst a board clampedto your bench.Put someshort 2x4s underthe hingedjoint so you canget to the screw holes. Rip the 45-degree 44 bevels on the columns. To avoidkickback, make I I sure the bladetilts awayfrom the fence.That'seasy on a left-tilt saw;on a right-tilt,move the fenceto the left sideof the blade. 4A Nail panel molding to the back of It the door frame to hold the l/4-in. panelin place.Miter the cornersof the molding to giveyour door a finishedlook insideand our. Cut the door qt Hang the column on the cabinet. First,fasten the hingesto the al tr trim on the bandsaw. lG column.Thenuse shims to positionthe columndoor on the cabinet.The lrJ Tilt the tableto 20 degreesand secure a half-wrap,no-mortise hinges wrap aroundthe insidesur{ace of the cabinet;all guidefence. Use a sharp,high-tooth-count blade you haveto do is screwthem in place.Remove the columnsafter you're (6 to 8 teeth per inch)for a cleanercut that satisfiedwith the fit. won't requirea lot of sanding. Arnerican Woodworker JULy2oo3 47 16il;lJi;in"' drawer box. Shimthe drawer front so the gaps will be even.Apiece of duct tape stuck to the insideof the drawer acts as a temporary pull. Open the drawer and screw on the drawer front from insidethe box. The holes left by brad nailsare tiny and easyto disguisewith filler. +': J,a Cut the bun feet Fig. B Circle-CuttingJig a f on a bandsaw using Machinethe solid-wood strip to fit a circle-cutting jig. Set the the miter slot of your bandsaw.Screw blank onto the pivot point of the strip to a piece of plywood and the jig.Thenslide the jig onto slide the jig onto your bandsaw, the bandsawand cut halfway cutting a slot to about the halfway through the blank.Clamp the mark.Make a line perpendicularto the jig in placeand spinthe blank end of the cut.To set the pivot point, to cut the bun foot. mark the radius of your circle from the saw kerf to a point on the line and pound in a finishnail so the head protrudes I in. or so. Nip off the head and your jig is ready to go. 48 American Woodworker JULY2oo3 assembliesback on the cabinet. Apply the astragal(Y) to the right-hand door. 18;l;?:in"" 4. Drill ll2-in. holes in the edging of the router table with a l -in. round-over bit. subtop and component shelf for the four With the subfences rare earth magnet cups (seeSources, page wide open,set the 92) that keep the doors closed (Fig. A). fence over the bit so Removethe door assembliesand hinges for the blankjust makes sanding and finishing. contact with the bearingand the 5. Make the panel trim (Z) (Fig.A, Detail 1) subfencesare just shy (L) (Photo and add the panels 14). Make of the blank.Thiswill the door trim (X) (Photo 15) and fasten minimizebit exposure. with glue and nails inside the door frame opening(Fig.A). 6. Build the drawer box (Fig. C), add the full aA Measure extensiondrawer slidesand install the drawer lY how much in the cabinet.Attach the pine drawer front your floor dips (Q) (Photo 16).Add the iron pulls (see away from the Sources,page92). wall. This cabinet must be level so the doors will stay open. The Bun Feet Simplysubtract an 1. Make the four 7-in. blanks (BB). Run amount equalto the diagonal marks from corner to corner to dip in your floor establisha centerpoint and drill a 1/16-in. from the thicknessof hole at the center of eachblank. the foot blocks for the back feet. Now 2. Cut the bun foot blanks into 6-in. dia. there'll be no circles(Photo 17).Round over the edgesto unsightlyshims finish the bun feet (Photo 18).(For ready- under the feet after madefeet, see Sources, page92.) your cabinet's 3. Machinethe foot support blocks (CC) so installed. they compensatefor any sag in your floor (Photo 19). Screw them to the bottom of the cabinet. Screw the bun feet to the foot blocks(Photo 20). lln Screw the 4V bun feet to The Finish the foot blocks. I have to confess,even after 20 years of The thinner foot block in backallows professional my woodworking experience, the cabinetto sit kneesshake when it comesto finishing pine. level on a sagging Blotching is so hard to control if you want to floor. add any color. For this project, I kept the blotch monster at bayby sprayingthe whole piecewith a shellacsealer (see Sources, page 92). Then I sprayeda color layer of toned shellac.Imade the toned shellacby adding Il2 tsp. of Trans Tint Golden Brown Dye (see Sources,page 92) to 1 qt. of shellac sealer.Itopped it all offwith a couplecoats of satin,waterborne poly. For more on finishing pine from someone who knows what he's doing, see"Staining Pinei' page52,by the incomparablefinishing wizard,Tim Johnson. American Woodworker JULY2oo3 49 Fig.C Fig.D HorizontalCross Section VerticalCross Section Through Drawer and Dado Placement 114"X 112"RABBET 1 D 8-1/9" trGG I fi *--*-L; rl le 1.r U I J I ooj t. I \\. ) ,r(Z- PP //r \ P Fig. E TopNaiter Positionthe angledcorner pieces(EE) so that one 22-112 mitered end runs directlyover DEGREE the corner of the subtopand ANGLE the other mitered end runs over the outside corner of the cabinetside. LL #8 x 1-114" (rYP.) Fig.G ClampingJig 45 DEGREES 50 American Woodworker JULy2oo3 Cutting List overafl dimensions 60" x 47-112"x30-718" Paft Name otv. Dimensions Notes Sides 2 23-3/4^x56-1/2" add 1/2 edqe a b Subtoo/ComoonentShelf L 26-7/8" x 43" add 3/4 oineedoe to front C W Shelf 2 26-7/8" x 43" add 1/4" pine edqe D BottomShelf 1 26-7/8" x 43" pineis added to the cut corners,then add 1-1/2" edqeto front E Top 1 29-1/2"x44-3/4" measureback 4-518' from the corneralonq both edqesto createanqled corner a F CenterDivider Z 11-1/2"x18" qluetoqether and add 114"edoe', don't cut to finalwidth before the dadoesare cut Upper Crosspiece 1 11-1/2"x42-1/2" add screwflanqes; cut a littleoversize, then trim to fit aftercabinet is assembled H LOWerLTOSSOTeCe 1 9" x42-1/2" add screwflanqes; cut a littleoversize then trim to fit aftercabinet is assembled a J DrawerOoenino Dividers Z 9"x 18" add 1/4" edqe;cut a littleoversize then trim to fit aftercabinet is assembled K Back 1 43-1/2"x55" screwback to cabinetto provideaccess for wirinq s5 a >o- L Door Panels L 13-1/4'x 40-3/4" M DrawerBottom 1 4-t/-J/+ atA il x5z a^tl N ColumnDoor Z 6-1/4'x45-3/4" add column trim before cuttinq anqled edqes P ColumnBase z 6-1/4'x9-3/4" o DrawerFront 1 7-1/4'x35-1/4" trim to fit R Stiles +A 2-1/2'x 45-3/4" S LowerRails 2 3" x 12-1/2" T UooerRails 2 2-1/2'x 12-1/2" a U DrawerBox Sides L 1/2"x6-3/4" x 18" DrawerBox Front 1 1/2"x6-3/4" x32" DrawerBox Back 1 1/2"x6-1/4" x32" X DoorTrim Moldinq Z+ 1/2"x7 /8" miterto fit insideof door frame Astraqal 1 5/16"x1" x46" trim lenqthto fit asrequired Z Door PanelTrim 20' 1/2"x3/4" add1/4" x 1/4' rabbet;bevel inside and outside edqes; miter around door panel AA ColumnTrim 4 1/4"x1"x48' bevel inside edqe BB Bun FeetBlanks A 2"x7" x7" glueup 2layersof 3/4" stockplus one 1/2'-thicklayer; finished foot is6-in. dia FootSuooort Blocks +A 6 x6 varythickness to levelcabinet on floor DD Nailers/LedqeBoards 26' Z-I/Z keepthe clearnailer stock to makethe ledoeunder the doors EE TopAnqled Corner Nailer 2 2-1/2'x 6-314" measure6-3/4" lrom lonq pointto lonqpoint;22-1/2-deq. miter on bothends FF Angled CornerLedge Board L 2-1/2'x 6-1/4" measures6-1/4" fromlong point to longpoint; 45-degree miter at cabinetside, 22-1/2-deq.miter on the otherend GG ScrewFlanqe 4' 3/4"x1-112' qlueor screwflanqes 'r0' to backof crosspieces HH Too Edqinq 3/4"x 1-3l8" rout oqee edqe after edqinq is qlued on and sanded flush '10' JJ Cove 3/4"x5/8" rout cove on wide piece of wood, then rip on tablesaw KK Ogee 1B' 3/4"x 1-3/8" tL Round-OverMoldinq td 3/4"x3/4" routprofile on two edqesof a wide board,then rip on the tablesaw N/MBottomShelf Edoino 1 1-1/2"x36" cut to fit betweencolumn bases NN OtherShelf Edqinq 6' 3/4"x3/4" trimlenqth to fit asreouired PP SideEdqinq 2 1/2"x3/4" x56-1/2" trim lenqthto fit asrequired Edqino 4', 1/4"x3/4" trim lenothto fit asreouired RR Wide Edorno o 1/4"x1-1/2" trim lenqthto fit asrequ red /w Fig. H ety*oodCutting Diagram I I I tc I i I I i :i,"..___. i ! i I I lD ci i t i i i-"-""---- l 3/4" PINE PLYWOOD 3/4'' PINE PLYWOOD 3/4" BIRCHPLYWOOD 3/4" BIRCHPLYWOOD 1/4''PINE PLYWOOD AmericanWoodworker JULy2oo3 5l ffil /l)'",, z z &B E Lrl co - t! :< = I o F T I z a z I - z. U ; tr U E o S'{E :\ir. tl j j j :l n! iix ntique pine often has a dark, mellow color. BEF()RE Y()U STAIN Unfortunately,when woodworkers try to duplicate that color on new pine by using stain,the resultsare usuallydisappointing. It's easyto end up with mega- blotchesand it's hard to avoid"grain reversall'a peculiareffect that makesstained pine look unnatural(photo below).lt doesnthave to be that way,though. If you follow the processpresented here, you can give pine deep,rich-looking color without losing it's natural aPPearance. Pine is hard to stain for a couple of reasons.First, its grain is unevenlydense. Typical wood stainscause grain reversalbecause they color only the porous earlywood;they can't penetratethe dense latewood.Second, pine's surface is usually loaded with randomly occurringfigure and super-absorbentpockets that suckup stainand look blotchy. Ai FILLGAPS and stabilizeloose Our stainingprocess includes four ingredients,water-based wood &*-\l knots with epoxy.Tapethe back conditioner,water-solublewood dye,dewaxed shellac and oil-based ofthe knot so the epoxy cant leakout. glaze(see Sources, page 92). Our processisrit fast,because there are severalsteps. But it isn'thard, and it'shome-shop friendly.You don t needany specialfinishing equipment,just brushesand rags. In a nutshell,the conditionerpartially sealsthe wood'ssurface to controlblotching. Dyes penetrate both the earlywoodand latewood, so theyminimize grain reversal.Shellac andglaze add color in layers, creatingdepth and richness.This coloringprocess works on all types of pine,although the end resultvaries from one speciesto another. [i:! SAND WITH A BLOCK angled LP-) acrossthe growth rings.Because of the differencein hardnessbetween the earlywood and latewood,bridging as many rings as possiblehelps to keep the surfacelevel. EARLYWOOD 'r'1.' -r'' , j' '" 1-"'u Staining usually (;':, PREEMPTIVEGRAIN-RAISING iS A ,'i causesblotches and \:) alwaysmakes pine's porous must-do for all water-basedfinishes. earlywood darker than its After you've finishedsanding, dampen the denselatewood, just the opposite surface,to raisethe grain.Thensand it of unstainedpine (inset).This again,with 400-grit sandpaper. transformationis called"grain reversal." American Woodworker JULY2oo3 53 Look Before You Leap Beforeyou touch your projectwith a brush or rag, getfamiliar with the materialsand the processby practicingon good-sizedpieces of scrap.Experiment on end grain, facegrain and veneeredstock. Practiceuntil you're comfortablewith the processand know what to expect. Fix Loose Knots Beforeyou sand,stabilize any looseknots by dribblingepo)ry into the gaps(Photo A, page 53). To make cleanupeasier, keep it off the surrounding wood surfaces.After the epoxy has set,sand it flush with the surface.Clear BRUSHON two generouscoats of water-basedconditioner. epo)rytransmits the dark STEP 1 With eachapplication, keep the surfacewet for three to five colorof the knot.If minutes,then wipe off the excess.Let the conditionerdry thoroughly,then sandit with your epoxy curesmilky-white, touch it up 400-grit paper.Go lighdyon contours and edges,so you don't cur through. later,after you've dyed the wood and sealedit with shellac. Sand Thoroughly A good-looking finish alwaysstarts with a thorough sandingjob, especiallywith a soft wood like pine.Here are some guidelines: Sandwith a block. Orbital sandersleave swirl marksthat makethe stainedsurface look muddy.After power sanding,always sand by hand,using a block,before you go on to the next grit (Photo B). Sandingwith finger pressurealone wears away the soft earlywood, creatingan unevensurface. Changepaper often. Pine gums up ordinary sandpaperwith pitch-ladendust that quickly rendersit useless.Dull papermashes the wood sr EP 2 lin::Y: ::#, .[:,HTJ.Ym:::fibers insteadof cutting them, which also container and let it cool. "?:ill?'""til createsa muddy appearancewhen you stain. Stearatedsandpaper lasts longer (see Sources, page92). Sandup to 220grit. First,level the surface with 100-gritpaper. Then work through the grits to createfiner and finer scratchpatterns. 220-gritscratches are fine enoughto disappear when you stain,as long asthey don t go across the grain. Raise the Grain Invariably,sanding leaves some fibers bent over.Water-based finishes swell thesefibers so theystand up,leaving a rough surface.For smoothresults with thesefinishes, raising the grainprior to finishingis essential(Photo C). Two Goats of Conditioner BRUSH ON a liberalcoat of dye and keepthe surfacewet. Water-basedwood conditioner (seeSources, STEP 3 Wipe the end grain occasionallyto checkits appearance. page92) makesthe water-baseddye easyto After'the surfaceis uniformlycolored,wipe offrhe excessdye and let the wood dry.Thenrepeat the process. apply.Itlimits the dye'spenetration bypartially 54 American Woodworker JULy2oo3 sealingthewood,like a thin coatof finish. Two coatsare necessaryto control blorching (Step1). It's important to keep the surface wet until youwipe it, and then to wipe thoroughly.Any conditioner that'sallowed to dry on the surface will seal so well the dye won't penetrate. Two Goats of Dye We used Transfast"antique cherry brown" water-solubledye powder (seeSources, page 92). Water-soluble dy. from other manufacturers will work just aswell, although the color will be different. Dissolvethe dye at the label-recommendedratio of 1-oz.powder to 2-qts.hot water (Step2).Be sureto let the SEALTHE SURFACEwith two coats of 2-lb.-cut dewaxed shellac solution cool to room temperaturebefore use. STEP 4 (see Sources,page 92). Sandafter each coat with 400-grit paper. . On the conditioned surface, the dye acts like a liquid oil stain (Step3).Let it penetratefor a couple minutes before wiping. The second coat of dye imparts a deepercolor and a more uniform appearance. It's tough to get uniform penetration on end grain. Fortunately,youcan minimize any unevenappearance laterwith the colored $azn. When you have a large surface to cover,use a spraybottle to apply the dye and a brush to spreadit. Simply re-spray previously worked areasto keep the entire surfacewet until you're readyto wipe it dry. Sprayingandbrushing also works great on vertical surfaces.Start at the bottom and work your way up. MAKEYOUROWN GLAZEby dissolving artist's oil into TVvo Coats of Shellac STEP 5 glazemedium (see Sources,page 92).You dont haveto be Shellac prepares the dyed surface for glazng scientificabout the ratio as long as you use only one color. Dont go overboard (Step4).It alsokeeps pitch sealedin the wood. with the amount you mix-a liale glazetoes a long way. Without shellac,pine'spitch can bleed into oil- basedfinishes,leaving fissures or shiny spots that remain tacky, especiallyaround knots. Apply Glaze Glazeis nothing more than paint formulated for wiping. It's easyto make your own pro- quality glaze(Step 5). Artist's oils contain high- quality pigments for pure, clear color. Glaze medium makesthe artist's oil easyto spread and quick to dry (within 24 hours). Glazingadds a second,separatelayerof color that reallymakesthe pine come alive (Step6). Topcoats Youneed to protect this layeredfinish with clear topcoats.Anytopcoatwill work aslong asyou wait until the glaze has completely dried. To GLAZEACTSASATONER on the sealedsurface, resulting in a check, wipe the surface gently with a cotton STEP 6 deep,rich color and a uniform appearance.Justbrush it on and rag. If it picks up any color, wait another day. wipe it off. Blend unevenareas by varyingthe amount of glazeyou leaveon the surface. ,vv American Woodworker JULY2oo3 TOOLTEST \ High /I Volume Low Pressure TurblneSprayers ou've probably brushed and wiped called HVLP becauseit produces high on gallonsof finish over the years. volumesof air (50 to 100cfm) at a low pressure Advantagesof But have you ever dreamed of the (4 to 8 psi). For comparison,a conventional HVLPSprayers luxury of spraying on a fast, silky- high-pressurespray gun runs on 6 to 12 cfm of - smooth finish? If you're readyto wake up and air at 50 to 70 psi, which is supplied by an air E I Less Overspray start spraying, read on and we'll help you comPressor. :< Lessoverspray make the best choice of HVLP sprayersfor z meansmore finish d your shop. Three Basic Models |! goes on your project ; HVLP turbinescome eitheras 2-,3- or 4- and lessis wasted E going into the air. How an HVLP Turbine Works stageunits and range in price from $1OOto E a f Some manufacturers An HVLP sprayeruses high-speed turbine $1,000or more. For your money you get a J : claim a transfer rate (spiral-finned) fans to compressand blow air turbine unit, a hoseand a gun (Photo1). For a that's double conven- UJ (Photo3). Each fan is calleda"stage" and rotates this tool testwe looked at 22 svstemsfor $600 F tional high-pressure up to 20,000rpm. That'sas fast asa router! It's or less. o sPrayertuns. z U U'' Dry, Clean Air A Big Word of Caution = TURBINE E Moistureand in U oil Sprayingcan be dangerous.The overspray T the air supply,which 56 American Woodworker JULy2oo3 Features thatAdd Convenience The up-front switch and hose connection ONBOARD TOOL KIT makethem easily accessible.The power cord should be mounted out of the way of the switch and hose.The gun holster is a handy placeto store the gun between usesand the onboard tool kii holds spare parts. GracoHVLP 2500, two-stage;$525. REAR. MOUNTED POWER CORD How aThree-Stage HVLP TurbineWorks Air travelsthrough the inlet into the first fan and then down the first finnedbaffle to the center ofthe secondfan.The second fan then forcesthe air down into the second finnedbaffle, which directsthe air to the center of the third fan where the air is finallyforced out through the outlet. 58 American Woodworker JULY2oo3 Anatomy of an HVLP Spray Gun The spraygun, with controls for fluid and air flow, is the working end of an HVLP spray system.Thegun shown here is from the CapsprayCS5 100 system and has a FLUID built-in air control valve.Some guns use an CONTROL air control valve on the hose instead.The Capspraygun also has an external lever that is used to rotate the position of the fluid pickuptube. LEVER FOR We Used Waterborrne Finishes . ROTATING It's important to FLUID use a waterborne finish that is PICKUP formulated specifically for spraying (see Basic TUBE HVLP SprayTechniques, page 28). Manywater- borne finishesare formulated for brushing and are too thick to spray with an HVLP turbine sys- tem. This is particularly true with the two-stage sprayers.Some brushable finishes can be thinned, but ybu must be careful not to thin them too much becausethis can adverselyaffectthe finistfs performance. 3-Stage Turbines Haye Plenty of power A three-stageturbine producesabout 50 percent more pressurethan a two-stageturbine. This efira pressureatomizes finish better. The extra airpres- sure also allows a wider range of adjustments for the fluid and air settings.This in return provides better control over the shapeand size of the spray patterns.The most e4pensivetwo-stage systems do an acceptablejob of atomizing sprayablewater- borne finishes,but apply them at a slowerrate. A four-stageunit provides 25 percent more air pres- sure than a three-stageunit but this additional pressure is not needed for applying sprayable waterbornefinishes. Fig.A Howan HVLPSpray Gun Works An HVLPgun has large internal airways. They allow easy passagefor the highvolume of airthat is usedfor atom- ization.Some of the airtravels down a pressuretube andpressurizes the materialcup. When you pull the trigger,finishing material ii pushedup the pickuptube andout the nozzle.As the fluid leavesthe nozzleit is atomizedby air coming from openings in theair cap. lan ffiFLuD American Woo dworker JULv2oo3 59 OutstandingFeatures We found severalfeatures that make pattern size and overspray. an HVLP turbine systemeasier to Metalguns with insulatedhandles how useand adjust.Some can affect Some metal guns have a plastic (Photos well your finish turns out 2 cover over the metal handle,others through 6). use a plastic tube inside the han- Easy-to-changeair filters dle.This is a particularly good fea- AII machineshave air filters that need ture to look for in a gun that has a to be cleanedregularly for peakper- bottom air hose connection.The formance. Machines with easyto hot air producedby the turbine can remove and replacefilters scored make an all-metal handle uncom- pointswith us. fortably warm. Easilyaccessible controls Topand bottom hoseconnections We alsoliked units that haveswitches We prefer guns that have air hose and hose outlets that are conve- connection points at both the top niently positioned and power cords andbottom of the gun.Connecting that aremounted out of the way. the air hose at the bottom givesthe gun a balancedfeel and works great Gun holster for most spraying.Connecting the A few units havea gun holster for air hoseat the top of the gun allows storing the gun betweenuses and you to run the hose up your arm, during transportation. Sprayguns over your shoulder and out of the areeasilytipped over and dam- way. This is useful when spraying aged,so a holster is a valuable inside cabinets or a wide flat area The flexible self-adjusting pickup accessory. tube on theTitan spraygun such as a tabletop. automaticallyswings to any angleyou Non-bleederguns Easy-to-adjustfluid pickup tube tip the gun.lt's a greatfeature, but When you let go of the trigger, air This featurereally caughtour atten- cleaningthe ribbed tube is a pain.Titan completelystops coming out of the includesan extra flex tube with the gun. tion. The Titan usesa flexible tube nozzleof a non-bleedergun. On a (Photo 5) that is self-adjusting.The bleedergun, air continuesto come usesan externallever that E Capspray U out.We preferthe non-bleederstyle E l rotates a rigid pickup tube that becauseyou don t have to worry tr rotatesforward, backward,and left l about accidentallyblowing dust into z (Photo 4). Being able to keep the you point your gun L the air when bottom of the fluid pickup tube in from your project between U away F the finishing material when tipping = sprayingpasses. the gun at various anglesis a great F Easy-to-adjustair cap I feature.It's especiallyvaluable when L The air cap controlsthe shapeof the the spray cup gets half empty and spraypattern from horizontal to ver- you need to tip the gun to the side tical to round. An air cap should or backward in order to spray that rotateeasilybecause it is common to hard to reachspot. Pickup tubes on readjustit severaltimes while spray- other guns requireyou to open the OUICK-CONNECTCOUPLER ing a project. Someair capsrequire cup and then turn the tube by hand you to loosen and retighten the cap or with a wrench,which is not very A 20 ft. hose is usefulbecause it has ring to make adjustments.Others practicalwhile spraying. length work aroundyour enough to rotate roughly or arehard to turn. project,while keepingthe turbine at a A 20-ft.air hoseprovides distanceso the filter doesnt pick up Finelyadjustable fluid and the best reach excessoverspray. A quick-connect air controls We found thatyou needat leasta 20- coupler is usedto connectthe hoseto Fluid and air controls that can be most hose'sair valveis used ft. hose to provide enough length tuns.The precisely make it easierto for gunsthat don't havea built-invalve. adjusted to work around most projects. control fluid atomization,the spray 60 American Woodworker JULY2oo3 Recommendations zffi If youwant an HVLP turbine sprayer for finishing ffudft ilTjffi*ffi;::1ffiril:'::::,:;:JffH b6g Our Editors'Choice and Best Buy tools are both three-stageunits and havealmost all the features we liked. Other RecommendedTools The Graco HV-2500 and the Capspray CS5l00 havemany of the featureswe liked but they areonly two-stageunits. They areboth however,available as three-stagemodels, but at a pricehigher than $600. In fact,youcan get three-stage models for mostof the two-stageunits representedin our test. Wagner Softspray 2500; $475 3-stagemachine This systemhas everything we likedexcept the power cord is mounted right next to the switch so it gets in the way when turningthe machineon andoff andthe fluidpickup tube cant be adjustedwhile spraying. Conveniently Mounted Switch, Hose and Power Cord (800) 279-4441 (866) 247-6e37 247-6937 (800)328-82s1 FinecoatPlus (8oo)s61-6908 Accuspray (8oo)46s-232s AmericanTurbine (800)443-4s00 Lex-Aire 539-2473 (888)900-48s7 (866) 247-6937 (800)328-82s1 Turbinaire MiniPro1 135 247-6937 Titan - Editors'Choice ) s26-5362 (800)328-82s1 * seeSources. page 92 for street-pricevendor list American Woodworker JULY2oo3 You ShouldAlso Know About There are HVLPspray guns that are desiqned to run off regularcompressed air. k6* They'recalled HVLP con- j; "ffi versionguns and they offer the same low-overspray i-*f high-transferadvantages of a turbine svstem. One ', advantage these guns ,fiJE have over turbine-powered ""elw#-il, ; 'f j1 HVLP guns is that conver- Lynx-3HVLP sionguns hook up to a reg- ConversionGun. ff' ular small-diameterhigh- pressureair hose.This is easierto pull aroundthan the largerhose on a turbine unit. Some of these guns are availablefor lessthan $200 but most cost twice that, or more (seeSources, page 92). Some run on a 1- or 1-1/2-hp compressorbut many Titan TS40;$600 require a 5-hp compressoror bigger ano you 3-stagemachine stillhave to be on guard againstmoisture and oil This systemhas almost everyrhing we liked:anonbleeder gun, in the air supply.lf you have an appropriatecom- self-adjustingfluid pickup tube,fronr-mounted switch and hose pressor,and a way to extract the moisture and oil, connection,rear-mounted power cord and onboard tool then going with a HVLPconversion gun might kit.lt only lacksa gun holster. save you some money. Finely Adjustable Non- Easy-to- Adiustable Metal Insu- FluidPickup Bleeder Adjust Fluidand Air Gun lated TwoAir Hose TubeWhile Gun Air Cap Controls Body Handle Connections Spraying N Y NN n.a. Top onlv N Hasno aircontrol valve N N N N n.a. Too onlv N N N N N n.a. Iop onlv N N N N N n.a. Top onlv N Hassmall built-in spare partVtoolbox N Y N N n.a. Top onlv N Hasno air controlvalve. N N N N n.a. Top onlv N N Y Y N n.a. Top onlv N N N Y Y N Bottom onlv N N Y Y N Y Bottom only N Hasa shorthose because the turbine is desioned - to be hunqfrom operator's shoulder via a strao. Y Y Y Y Y Bottom onlv N Hasburlt-in N Y Y Y Y Bottom onlv N Y Y Y Y Y Y Y Hoseand switch mounted on oooositesides of theturbine N N Y Y N Bottom onlv N N Y Y Y Y Y N N N N N n.a. Top onlv N Y Y Y Y Y Y N Switchand powercord mounted too closetoqether N Y Y Y N Y N N Y Y Y N Bottom onlv N N Y Y Y Y Y N N Y Y Y N Y N Y Y Y YY Y Y Hasbuilt-in spare partVtoolbox Y Y Y Y Y Y N Switchand powercord mounted too closetoqether. lW n.a.: Not applicable becausegun has only a top air connection A rncri can Wooclr.l'orkcr JULy2oo3 63 a a LrJ I z. f Iri :< J T U l N SprayBooth for WaterborneFinishes J o is all it takesto put togetherthis finishingbooth.It keepsover- t Fiftybucksand a fewhours T projects.Since I usewaterborne finishes, I'm ableto sprayoff my tools and dust off my E. usea regularbox fan in the window to vent the fumes.A furnacefilter overthe fan keeps oF I oversprayoffthe fan blades.Before spraying I thoroughly sweepmy shop floor, put down rL a paperand crackopen my garagedoor severalinches to makeup for the air beingblown z a outsideby the fan. -z. I built the booth by first staplingan 8-ft.by 8-ft.piece of plasticto the ceiling.Then I sta- z. t pled the top edgeof the plasticwalls to 2x2s,whichI screwedto the ceilingrafters. Once the t! plasticwalls were hung,I stapled2x2sto the bottom edgeof the plastic.I cut a hole in the 2 backplastic wall for the fan.To storethe plasticwalls I roll them up and hangthem on loops F t! E. of ropethat hook onto screwheads. This booth alsoworks greatfor brushed-onfinishes. NOTE:This setup is for spraying o F waterborne finishes onlY. t Brent Greer American Woodworker JULY2oo3 SmallShop Tips TubularStorage Here'smy solution for storing skinny things like wood trim and edgeband- ing.I boughta 12-in.-dia.by S-ft.-long cardboard concreteform at a home centerfor about $14.I slid plywood dividersinto the tube and addeda few screwsto hold the dividers in place.I hung it from the ceiling in my base- ment with plumber's strap. Get plumber's strap at a home center for about$2 for a lO-ft.roll.It took one roll to hang my storagetube. GeorgeR. Hoffman SprayGan Storage I'm a greatfan of aerosolfinishes, especially now that many of them haveadjustable tips that makemuch lesssplatter. But my shopgot so clutteredwith half- used cans that I had trouble finding the color I wanted,so I built this simplestorage rack for all the cans.Now I can instantly find just the color I'm looking for.The shelvesneed to be 5-in.deep,but the angleisn t critical.Anything between45 to 75 degrees will work. Mine is 70 degrees. Tim ]ohnson TablesawTool Drawer It seemslike I m alwaysmisplacing my push sticks, bladewrench, featherboards and other small table- sawaccessories. To solvemy problem I addeda shal- low drawerunder the sidefeed table.I simplybuilt a wood box that wasopen in the front and screwedit to the bottom of my side table.Then I installeda drawer using a set of 22-in. full-extensionheavy- duty drawerslides (see Sources, page 92). The slides costme $14and I usedleftover plywood.It didnt cost much but it sureprovides a lot of convenience. TbmCaspar /W If yog hlve an originalSmall Shop Tip, sendit to us with a sketchor photo. If we print it, you'll get $100! Sendyour tip to: Small Shop Tips, Arnerican Voodworket,29l1 Commers Drive, Suite 700, Eagan, MN 55f 2f or e-mail to [email protected] be returnedand becomeour property upon acceptanceand payment. \7e may edit submissions,and usethem in all print and electronicmedia. 55 American Woodworker JULY2oo3 I I Thisindex covers American Woodworkerissues #78,Febn rary 2000 3-vear I n q €)K,-I"ftT::i1i.;11[sJ:;h'Hff:;,?lsfl;is3;?:JJr;*"'o'"' guideblocks,88:90 grading,8l:3 | molding,86:59-60, 85:6 I, oscillatingspindle sanders n disposable,88:24 sources,8 l:33 86:65 reviewed and AWrated, Acid-free paper, sources, phenolic,9l:42 working,S l:32-33 from plywood carcase,9 l :86 82:82-85 79:38 guide blocks of Bird's mouth joinery installing,88:82-83 power miter saws Adjustable chucks, shims.85:l8 bits for plywood reviewed by other advantagesof 83:82 ocagons on,88:22 reviewed,92:32 parts,88:8| magazines,S3:58 Air compressors outfeed tables for Biscuit joiners safetychains,9 l:60 slidingcompound-miter saws station for as,88:94 clamping simple plywood, 95:76-86 reviewed and AW rated. portable,9l:ll4 drill-press iig,79:.17 parts sources,9 l:45 mini-biscuits.85:54 toe boards,9| :62,91:65 84:9&-109 buyer'sguide, 83:9 | -94 recommended 200 l, 92:| 04 routers as,85:53 two-part, 82:56-63 routers, 83:85-89 developmentsin,83:93 recommended 2003,97 :26 Biscuit joinery valances,9 I :62,9 | :65,9 | :66 reviewed by other easy-drainadaptation, S0: | 3 resawing for table rails,94:62, 94:63 Bookends magazines,S3:89 featuresand types,83:92 bladeselection. 8l :4748 slots,94:80 lead-filf ed, 87:82,87 :86-57 shop vacuums settingup an air line,83:94 on,88:23 techniques,79:73 Bowl turning reviewed and AW rated. size and capacity,83:93 squaringcuts on,92:27 Bits beautifulbases.79:22 80:69-73 Air fi lters, cleaning,89:20 table for as gauges,94:63 Bowls, turned tablesaws.83:72-76 Air filtration systems temporary,89:25 bird'smouth.92:32 blanksfor reviewed in other capacityguidelines, 80:44 table for brad-point,9l:78 preparing,S5:99 magazines,83:76 filters, source.80:47 auxillary,9l:42 bullnose natural-edge,85:98- | 03 thicknessplaners shop-madefrom kits, small,93:23,93:108 primavera,99:102 benchtop,reviewed and 80:4347 shop-made,8l:103-104 tapers with carbide Boxes AW rated.79:83-87 when to clean,80:46 wide,89:89 sharpening,92:| 7 ABC boxes,84:75 vises reviewed and AW rated. Allergies tensioner for chamfer,93:108 clamping,93:86 82:92 sensitizerspecies, 99: | 8 quick-crank,9l:42 cove dividers.93:90 to wood. 99: | 8 replacement,86:24 source,93:| 08 installinghinges on, 79:20 Aluminum I tires of, cleaning,89:| 6 depth gaugesfor Cabinetmaker's triangle, cutring iewelry,93:8G-90 tool holder for making,92:8 | sources,93:| 08 79:75 with chop saw,86:l0 magnetic,9l:42 dovetail lids.93:88 Cabinets Aluminum tubing, source, 90:23,90:25 care with.85:l4 magic-coi n puzzle,87 :82, assembling,95:7l-72 78:82 typesol upgrading,S l:5 | drawer-lock. 92:60-61 87:8&€9 bathroom Angles zero-clearanceinserts, source, drill Brad nailers, hoseless,95:30 fiom plparood carcase,9| :86 gauge for 83:12 as depth gauges,92:79 Brad setters box frames, 98 :77, 98:8 | 42 making,92:8| Banks for "recoverable"beads for nailremovd, 93:26,93: 108 display shop-madechecker for magic-coin,87:82, 87:88-89 reviewed,87:26 Brass hardware and pulls lighted,98:7647 sharpening,82:79 Barrel bolt connectors, Forstner pullsand handles dividers for stop block,98:56 sources.T9:38 speed,93:| 2 source.82:23 vertical,96:l7 Anti-sag powder for glue, Baseball bats, making,78:l2 hole-saw Brass rod stoch source,80:38 entertainment source,S | :69,81:72 chip clearance,ST: l8 Breadboard ends home theater. S4:4U63 Antique tools Bases concrete weighted, 98:5f59 hollow screw-remover.85: | 0 Greene and Greene sryle, walnut, 78: | 7 correction books about, source,83:50 Batteries lock-miter,source, 79:59 78:26-28 face frame collector and restorer pattern, 93: | 08 Brown, Molly ("Unsinkable"), buifding, 9l:74-86 profiled,83:46-50 disposal,83:69 maintenancetips, 83:69 pfug-cutteri 87 :64, 87 :65 79:56 face frames.89:62 restoring,83:4&-50 nickel-cadmium(NiCad) removing rust from, 82: l0 Brushes fitting, 9 l :80, 9 1:82 Arches compared to (N|MH) (nickel round-over.93:| 08 90", creating,39: | 4 filler strips,88:83 plywood,86:46,86:4&49, 86:5 | meal-hydride),83:59 router brass,sources, 79: | 2 flammables.82 122-124 Arcs rebuilding,93: l0 anti-kickback,90:| 6 Bubinga, qualities of, 9 | :126 for drill press,78:I l9-120 describing,92:80 recycling,87: | 4 core-box,85:85 Builder's paper uses of,99:23 for router table, 99:,4| 42 large,drawing,9l:18 types of,90:17 flushtrim,87:65,87:80 Bulletin boards hanging Armchairs Beadboard, making,95:22 panel raiser,86:34, 86:43 making,95:69, 95:75 solo.92:20 Greene and Greene ioinery, adding,93:23 rail-and-stile,86:8, 86:32-34, Bureaus Hoosier style,79:14 78:3G-32 Beading, Beds 86:43,87:26 restoring, 96:70-78 correction Arts and Crafts style assembling,85:67-69 slot-cutter vs.plate Burgess Edge System installingbuilt-in, 78:56F{ | bookcase.9l:5&-72 basicdesign, 8l:4G-45 joiners,ST:8 router bits kitchen chairin.93:6G-72 hardware,S5:59,85:69 spiralup-cutting, 87:63, 87:65 reviewed,99:29 carving,89:24 hall mirror headboardsfor vertical molding,85:83 Burls lights,98:84 making,85:7&-8 | with insert cutters, 94:34 centering on a lathe faceplate, material,9l:75 plansfor making,85:66 mattresses.85:59 router slot-cutter,99:50 8l:16 over-desk.95:6S-75 book of 94; | 8 rail fasteners,sources, 8 | :45 screw pilot,87:37 mesquite,8T:46 pie safe,79:70-77 Ash, source,82:77 stock, 85:59,85:69 self-centering Butcherblock guick plywood, 96:60-67 Assembly table, 8 l :62-65, source.93: I 08 quartersawn,89:53 rollingshop 84:74-78 turned-post making,85:56-69 spiral-up-cut,85:5| Butterfly inlay from ptywood carcase,9| :86 Auger bits Belt stop collars,9l:78 kit, 99:6 l-63 scribingallowance, 78:59 ship,source,80:76 sanders buyer's guide tongue-and-groove,95:75 Butternut shop,9 l:88-96 Awls, sharpening 80:32 lig, reviewed and AW ratec. adjustable canker of.96:96 making,87:33-43 79:66-69 reviewed.92:3| finishing,96:94-96 sink n shelves,S5:92,85:94 Backsplashes features and types, 79:66-69 undersized qualities of,96:90-96 storage curved,89:60, 89:64, 89:65 Belts, link,9l:39, 9l:4 | for plywood dadoes,85:5| Buyer's Guide l-94 building,87:36 Bamboo skewers, T8:22 Bench dogs, making,89:43 Blade cleaner, air compressors,83:9 planes,83:34-40 wall mounting, 95:72-7 3, 95:75 Bandsaw blades Benches reviewed,34:24 block web frames, 95:62, 95:64-69, sources,T9:56,8l:50 garden Blast gates, modifying,79:l6 cordlessdrills 95:75 storing,34:46 building 8 l :66-72, 86:45-5 | Blemishes reviewed by other wide Bandsaw jigs Bevels touch-up,95:24 magazines,S3:70 building,87:36 duplicator reviewed,82: | 0 I angleblock for grinding,32:80 board feet, how to calculate, dovetail iigs,reviewed and Cabriole legs Bandsaws angle, calculating,82:79 82:12 AW rated.84:66-73 step-by-stepinstructions, | 4-in. heavy-duty throat plates,95:5 l, 95:57 Bocce balls drills,cordless, 83:66-70 80:55-5 | reviewed,9l:24 with tablesaw 94:56 rulesof the game,8l:22 dust collectors Calculators bladesfor Birch turning,Sl:|&-23 reviewed and AW rated. for construction math,98:3| 2001 recommended,92: 104 finishing,89: 120- 122 Bolts 80:8l-85 jointer-planers Calipers center-finder | 4 for other-speciesmatchi ng, locking lig,86: dial,reviewed,83:33 dust collection,88: 16, 90:25, 89:l 17,89:122 making,93:77,93:79 reviewed by other using,82:45 9l:42 gradesof,89:l 16 Bookcases magazines,83:65 jointers, Carcases features of 90:24-25, 97:21 --24 plywood,39:l l8-l l9 Arts and Crafu style, 83:6l-65 , plate-joined,98:5I for resawing sourcesfor Baltic,80:47 88:76€3 lathes,83:7&€3 gauges plywood, 89:56-67, 9 | :74-86 blades,9l:104-105 speciesol 89: | | 5 Arts and Crafts style knock- miter reviewed and Carts recommended, 90:26-27, vs.maple,89:123 down,9l:58-72 AW rated,8l:8l-83 rolling-cabinet , 90:l18 Bird's eye maple floor pins,86:63 mortisers building,87:35 reviewed, S8:84-9 | buying,8l:30 formal built-in,86:58-66 benchtop,reviewed and workshop, 96:52, 9 6:56-57 guide bearings,source, S l:50 characteristicsand uses, materials list.85:5| AW rated,Sl:73-77 8l:2&-32 American Woodworker JULY2oo3 69 I 3-Yearlndex Carving parallel-jaw with router,9l:91 to length recommended 2003. 97:38 replacingmissing parts, small.96:29 with tablesaw,89:86, 92:50-5 I, jig,87:84 rims of,86:70,86:73 79:8-10 PiPE 92:53,92:56,92:57 Dowels and cylinders round stock with,98:72 Case construction expandable,S0: | 3 Dents, steamingoug 8l:92 gluing into blind holes,80:24 sandingon large cases,84:55-57 guards,78: | 8 Depth gauges hardwood, sources,78:45, caveats,86:7 | Case-hardening, detecting, Quick-Grip reviewed,83: | 04 bits as,92:79 8l:69 sharpeningsystem with, 79:14 sources.T9:77 for bits storage, T8:20 98:62-74 Cauls, shop-made,79:74 racks,98:44 making,92:8| turning, T9:28 sizesol 86:69 Cedar, working with, 98:54 rubber bandsas,85:26 Design Downdraft dust collector speeds,86:69, 86:70 Center finders small strong proportion calculator;92:83 Delta model reviewed.83:l4 storage,92:98 bandsawlig,86: | 4 making,93:22 Desk accessories shop-made,80:66 switches on, 86:7 l, 86:74 making,87: l6 spring,96:25 file holder,80:36-38 Drawers table for Center finding squaringblocks,89:72 Desks assembly,TS:20 extended-reach,93:94 with squares,92:77 stands,89:72, 89:74 building,95:6G-75 biscuit joinery, 95:62-44, 95:66 tables Chairs toggle cord-hiding backboards, ceilinghung,78:49 auxiliary,94:20 Adirondack source,78:82, 8l:6 l,85:43, 95:73-74 dividers,92:5G-57, 92:59 bottom boards.94:29 all-weather: 87:6G-65 93:|08 Detail sanders, shop-made, quick,89:l0 tables for disassembling,92: l4 Clothespins 80:32 dovetailed.84:9 l-94 making,86:||l-l14 outdoor sling clampsfrom,93:22 Disc sander designdetails,84:92 materialslist,86: I l4 making,93:60-72 Cocobolo Delta reviewed,8l:86 file, 95:60-66, 95:70 taps with,98: | 4,98:72 Rieweld style, 79:60-65 qualities of,94:6G67 Discs, twist-andJock, fit, checking,84:87 typesof,90:3 |,90:32 seats for Collets 98:&4-7 | fronts for variable-speed,98:34 frbric sling,93:.7l-72 removing rust from,82: l0 Door jacks false,9l:7| vibration with Chalk marking pencils, Colors, artists',93:56, 93: 108 roller standas,92:35 ioint construction reducing,9l:39 sources,79:56 Columns Doors Greene and Greene style, Drilling Cherry tapered, 88:76-77, 88:7840 exterior 78:32-34 stop block, 94:7 | figured Commodes wood.88:57 lipped,making with a dove- straight sciurce,88:| 04 quiltedmaple,86:ll6 flip-up,95:60, 95:5 l, 95:69, tail iig,84:9 l-94 jig,89:26 finishing,93:52-58, 93: | 08 Compasses 95:7l-72 lock rabbets,92:60-43 Drilling jigs sapwood ol 93:52,93:57-58, improvised,92:80 flush-fit, 79:7&-81 making, 89:64-65, 9 | :70-72, for centered holes,84:| 4 93:| 08 making,86:48 glasscabinet,98:84€5 92:5l. 92:58 for pocket holes sources, 78:45,79:77 Concrete, stains,86:8 glass,98:87 plate-joined,98:50 Kreg K2000 reviewed, 84:22 Chests Containers glass-panel quick and easy,87:4f43 Drills blanket gaskets for bits,92:32 qu ick pfywood, 96:62, 9 6:65-67 cordless.9T:| 6 frame-and-panel, tape,99:23 glazed restoring, 96:70-78 features of,97:29-31 Mission,99.4L59 Corbels "recoverable"beads, 87:26 runners.S9:62J3 recommended 200 l, 92: | 04 78:,3745 for top overhang,99:56-57, hanging,89:65, 98:85-€6 runners for easy-sliding, 9 | :21 recommended 2003,97 :32 hope chest 99:58 hingesfor smelly,96:77 reviewed,39:92 frame-and-panel, Cordless drills from inside,87:38 spice-rackinsert, 96:26 cordless l8v 78:3745 accessories.83:70 installing,88:62-{3 stops,96:67 reviewed,9l:28 chests of drawers buyer'sguide, 83:66-70 making,89:65 magnet, 92:58,92:59 cordlesscompact, 95:29 Shaker sewing cabinet, developmentsin,83:68 mortises,88:58 tool cordless mid-sized 84:82-89 features and types,83:67--68 plywood flat-panel,9 | :62 dividers,96:68 featuresof,9 |:48-5 l ,9 | :53 Chisels Corner joints plywood shop-cabinet tray-qrPe reviewed, 9l:47-54 angle gauge for sandingtool, shop-made, 82: 17 hanging,9l:94-95 making,85:92,85:95 handlesfor making,92:8| Countertops raised-panel wear away problems,84:l2 interchangeable,98:3 | bevel-angle,8l:14 holesin anti-rattle snakes,86:4 | Drill bits spacerjig,86:62 an$e block for ginding 8280 cutting,85:93 assembling,86:40 sharpeningand grinding Drive belts flatteningthe blade back 82:8 | Cracks designing,86:4243 brad-point,78:65 link type compared toV- hollow- butterfly inlay,99:6 l-63 making,86:32-43, 95:3440 Forstner. T8:67 belts.83:24 for mortises,S5:80 Credit card fraud, buying para o(85:32-39 spade,78:66 sources.33:24 new via the internet and,83:| 8 plywood,9l:67 techniques,78:63 Drum sander dullnessol 85:8 Crosscut sleds and tables screen panels,88:58 twist,78:64 dust collectori shop-made, protectors for for tablesaws storm panels,88:58 sources 80:64 glove-finger;87:20 slidingstop,80:24 storm-screen,88:56-64 | 4 mm brad-point, 79:,34 Drying wood, air-,8 l :50 sharpeninghollow 78: l0 sI idi ng, shop-m ade, 7 8: | 7 twist prevention,98:85 half-inchbrad-poing 79:34 Dust bags Chop saws correction.S2:ll0 Dovetail jigs taper-point,8 I :69 shop-madehangers, 82: I 8 dust collection,92:24 Crosscutting for comfortable work Drill presses Dust collection station for sled,9l:76 position,S0:24 -sandercombo,97:38 books and booklets about" wiring,95:20 crown molding recommended,90: I l9 -sanders 80:67,80:85 Circles cutting reviewed and AW rated, reviewed,39:96 for drill presses,86:| | I describing,92:80 with a compound miter 84:6G73 abrasivedisks, 98:62,98:64-7 | for scroll saws,87:70 router iig,94:72 saw.84:57 setting the bit,84: | 0 as outfeed tables, 88:94 protective clothing, 80:65 without lathe,98:69, 98:7 | Cupboards using with a routenffi:92-94 backer boards for tips for better, 80:62J8 Circular saw blades Amish lelly,89:56-67 for making slidingdovetails, sacrificial,86:l3 Dust collectors teeth, types,78:lGl7 Curves 84:86 basesof, improving,9 l :39 bags thin-kerf.80:68 describing,99:59 Dovetails belts of,86:70,86:72 selectionguidelines, 80:82, Circular saws iig for clamping,TS:20 clamps,89:7 | cabinegshop-made, 80:83 cordless'reviewed.9l:28l8v layingout,8l: l2 jig for 78:ll9-120 sources.S0:85 on router table,99:47 reviewed,35:34 center finding on,94:62 blast gates,modifing, 79: l6 Clamping routing,ST:79 jigs,92:59 chucks of buyer'sguide cauls,93:66-67 s- recommended 2001,92.|U improving,9l:39 reviewed and AW rated, jig,for curves,78:20 describing,92:82 on router tables,87:62, 87:63 chuckson,86:7 |,86:74 80:8l-85 of angles router jig,99:28 circle-sandingjig,98:69, 98:7 | capacity blocks,93:69 D saws.90: l9 depth stops on, 86:72, 86:73 size required,80:84 of boxes,93:86 Dado blades sliding features of, 90:32-34,97:35-38 chip and offcut separation Clamps sizefor contractor saw,8l: l0 easing,92:22 fl oo r, reviewed, 86:68-7 5 accessories,sources, 80:62 3-way dado heads iig,99:29 for wood techniques,80:62-63 edging,87:57 height-setting tool reviewed, router jig,84:86 remodeling,90:32 downdraft table band 8l:86 with router. 85: l4 handlesof Delta model reviewed,83:l4 source,93:| 08 Dadoes with plywood,93: l5 improving,9l:39 shop-made,80:66, 82:54 bar angled,94:76 Dowels hold-downs,86:20 features and types, 80:82 choosing,94:32-33 blow out, preventing,80:77 drilling hole-sawswith filters,80:82-83 caul for 98:57 for plywood iig,87:84 chip clearance,ST: | 8 for routers.80:66 centering,cauls, 89:7 | undersizing,35:5 | hardwood key holder for grounding duca,80:26 corner,for miters, 94:24 on router table.96:83 source.87:89 retractable, 87:20 leaks,sealing, S0:83 making,89:69 on tablesaw,85:94, 85:95, jig for levers,86:70, 86:72 mounting,S2:38 extenders,89:70, 89 :72 88:58,96:62 as saw stop,93:20 lights on,86:75 pipe fittings and connectors for dovetails.89:7 | on tablesaws.9l:76 iigs,94:62,94:63 mortisers, 86:70, 86:74, 97:37 for,80:67 for miters,88:52, 99:55, 99:55 router base plate for notching mortising attachments,90:37 remote control, hand-screw graduated,85:52 jig,87:8'1-85 ' parts sources,9 l:45 80:ll4-ll6 visesfrom.99:27 router jig, 96:22, 99:29 splitting recommended,90:36-37, single-stage,anatomy of, padsfor throat plates,95:5 l, 95:57 for test fits.89:70 90:ll9 80:82 plywood, 78: l8 recommended 200 l. 92: 104 sources,S0:85 70 American Woodworker JULY2oo3 3-YearIndex two-stage cyclonic, anatomy - fumed oak, 85:79-80, 85:8 | Glazes in plywoodend,93:78 of,80:82 colors,93:52, 93:56, 93: | Fabric lacquer 08 stopped,88:58 Dust masks and helmets vs.dyes,93:57 for chair seaa, 93:7 l-72, spray-on,93:55 V- National Institute of Occu- with shellac,93:56, 93:57 93: | 08 mixing at plywood-woodloin, pational Safety and Health Glazing velvet self-adhesive,93: 108 cups,98:22 99:48,99:50, 99:5I, recommended,80:68 muntins with Face frames nontoxic. ST:80 99:53-54,99:54, 99:58 sources,80:68 glued-on,88:83 for cabinets oil Dust, health risks from, Gloves, lint-free, 80: 104 aligning,79:75 applying,93:54 88:53,88:55 I Dust-collection systems Glue blocks, adding, mitered, Sl:7L79 spottint with,90:128 89:62 Handles bags,90:43, 90:47 pipettes,99:27 Glue-up with plate 98:47 crank sealing,9l:43 ioinery, dowels.80:24 Fasteners polyurethane for vises,85:l8 upgrading,9l:43 of mitered joints and sements, tabletop,shop-made, 80:26 rubbing out, 88: | 6 rubberizing,85:20 control for 8l:14 Featherboards spray-on,93:55 Handsaws remote,9l:43 rub-joint gluing,82:8 for router tables,85:82, toxiciry of 94: l5 flush-cutting, sources, 78:45 features of,90:4243, techniques, 85:83,92:26 pre-assembly,99:54 S2:8 Hardware 97:4749,97:50 Glues for tablesaw,92:64, 97: | 4 removing,96:78 brass filters,97:50 and wood-surface making,99:46 screw props,99:56 age,96: | 4 aging,93: | 4, 93: | 08 fine-particle collecting,96:28 plastic shellac bottle,99:32 escutcheon-plate,93: | 08 for bandsaws,SS: 1 6, 90:25, ePoxy reviewed,98:38 spray-on,93:55, 93: | 08 Heating ducts, installing 9l:42 with rabbets.96:83 with glaze,93:56-58 source.87:65 cabinetsaround, 78:61' for lathes,9l:44 excess Feet sources,93: I 08 Hide glue, sources,79:77 for router ables, 88:95,92:66 kerf bracket spray-on,93: | 08 catchment,S9:74 Hinges for routers, 92:.| 0, 9 6:27 removing,89: making,93:86-€7 stripping,78:| 8 l0 bits.93:108 for tablesaws extended-open-time, brass testing,85: | 06 European,characteristics overarm.88:34 sources,7917,82:63 source,87:89 touch-up kit for and uses,82:64-67 impellers of for exterior for furniture portable,86:76 use,88:57,88:6| installing,9 l :67 upgrading,9l:43 gap-filling,9l:l6 sealingend grain for out- varnish installing parts sources,9 l:45 holder,98:22 door use,84:30 drip removal,85:108 bua,79:8G{l portzble,92:24 hot-melt round straining,85: | 06 center punch,sources,8 l:65 recommended,90:41'|'7, heavy-duty,9l:26 installing,89:60, 89:63-64 wire hangers,36:78 European,32:64-67 90:ll9 loosening,92:l4 Fences Finishing su rface-m ou n ted. 79 :20 recommended 200 l, 92: | 04 with heat,86:65 jewelry-box, auxillary dust-collecting,88:95 avoidingdrip shadows,S l:90, 93:108 recommended 2003,97:50 open time of choosing,96:42 82:104 mortises for sizing,90:42 extended,9 l:128 commercial,95:43 end grain,8l:90 with tablesaw 93:84 switches for rubber tips,98:27 easy-adjust,99:40, 99:.4'115 final rubout,82:8 piano tool-actuated.92:24 spreaders for router table.88:95 flooding and wiping technique, instalfing, 89:67, I | :94-95, two-stage can-toP magneticmicro-adjustable, 78:106-ll0 unorthodox, 78:20 93:78 reviewed,9l:30 97:16 levitating your workpiece stains from positioning,with tape, 93:88 types of, 90:39-4 | avoiding,89:70 micro-adjustable,9 | :40 fon 80:100 sources,T8:45 upgrades,96:32 white, extended-time,87:28 on new tablesaws.96:5| pad sponges,8 l:90 bun,79:56,79:77 Dyes yellow,93:86 router,92:65-67 raised grain white vs. continuous with barrel bleaching,82: | 08 Gluing layout,85:54 as a prefinishingstep,78: | 06 up bolt connectors,T9:38 for figured wood,93: | 04 brackets.9 router-table Fire hazards l:93 European,32:67 source,93: | 08 face-to-hce,98: making,92:87-91 flammablescabinet for finish- | 2 wrap-around,99:57, 99:58 vs.glazes,93:57 glue blocks,98:59 router-table 85:38-42 ing supplies,82: | 22- | 24 Hold-downs water-based iointer: jig,96:8G47 sacrificial,9l:78 Flashlights miter for drill presses,86:20 removing,32:108 of carcases,99:54 for miters,93:83 cordless l8v for plate joinery, 98:56 of miters,93:86 spring boards,92:26 reviewed,9l:28 for workbenches,9T:| 6 - with tape,89:7| sub-,92:66, 92: 67, 99:40,99:44 Floors plastic Ear protection of tapers,89:74 T-tracks, 99:40, 99:43 concrete reviewed.98:38 and eye,92:92-95 staining,S6:8 squaringjig,89:59 router-table,86:3 3, 86:37 Ebonizing, tall,99:47 Fiberboard mappinguneven, 78:57 stands,89:73 Holes with Indiaink.86:76 third hand,96:25 cabinetsfrom. 87:33-43 Flush-cutting saws, in end grain Ebony, sources,8l:6| Gouges split, repairing,87:38 sources for,78:45 centering,85:63 Edge banding sharpening widths of Flutes routed shop-madeclamp, 8 l : 12, custom for cabinets,ST:38 with router, 85:82,85:85 strop,82:80 enlarging,85:63 83:9&10| gouge, -23 Fiberboard, Food safe, deailing 80:2 l shelf Edge gluing medium-density for jigs,98:66 portable,82:20-23 spindle-roughinggouge, iig,9l:78 clamp racks,78:5| laminating,98:67-48 Food-safe finishes, 78: | 04 80:20 spacerjig,86:62 Edge marking,92:77 technique,80:7-l ioinery, Fibral, abrasivewool, 98:36 Frame-and-panel | 8, straight Edges 80:22-23 jig,89:26 File cabinets and holders construction roundingwith a router;78:20 jigs,80: desktop, doors,79:76-77 tools and l6 Holes (defects) Edgings 80:36-38 Files for cabinet backs,98:79, sources,80:23 repairing,88:82 applying,96:62 Grain, auger-bit,source, 78:65 98:82-83 sefecti ng, 99:52, 99:54 Hollow-chisel mortising clampsfor,87:57 Greene auger-bit,using, 78:65 for chest,99:50-54 and Greene attachments disguising,87:56 joinery Fillers reversiblestile and rail techniquesof, sharpening,78: | 0 for miters,98:49 78:24-34 ePoxy cutters, 78:72-74 Honing for plywood, ST:54-58 side in source,86:5| Frames table the style of, machinesfor painted filled,87:57 8 l:52-{ | for plywood edges,87:57 mini-biscuia,85:54 reviewed, 39:76-8 I planing Grinders in tubes,98:30 wedges,85:8| process of , 89:76, 89:77 marking,87:56 adjustable-speed Finials, ball, Framing squares with strop,82:80 router bits for source,86:5| Finish markings on reviewed. ST:29 Honing guides, using,82:80 reviewed.99:29 buying,90: in tight spots,89: l4 repainting,85:24 | 2 Hoosier cabinets trimmer for Finishes truing,82:| 0 Grinders building,79: l4 correction router,87:58 adhesion, Furniture shop-made,80:| 3 Hoosiers, plywood, 88:36 with plate joinery, 98:47-48 testing,80:98 applicatorsfor maneuverabilityof swing-up housing,8 | :39 Horizontal boring Electrical outlets lintless,93:24 testing,90:I 28 Grinding drill press vertical support installingcabinets around, period conical stones, cherry-aging,93:58,93: | 08 sources,78: | 0 fon79:17 78:61 gauge for colors,93:55, 93:108 society,8S:8 Horsepower, Electrophysics making,92:8 contaminating rustic,99:6 | peak vs. rated, 78: | 4 moisture meters machinesfor with tack cloths,86: l0 Humidors recommended.94:8&€9 ebonizing U reviewed,89:76{ | wood selection,78:l0 End grain, sanding,79:54 Gaps process stain,86:76 of , 89:7 6, 89:77 Hygrometers and Epoxy disguising Grinding exterior wheels moisture meters specialty,sources, 8 | :69 withV-groove,9l:84 aluminum oxide, water-based, 94:36 character- pin type vs.pinless, 79: | 4 Extension cords Gauges istics,80: flammablescabinet, l6 sources,79: | 4,8 l:50 organizers,98:32 82:122-124 thickness dressing,80:| 7,82:79 Extension-cord holders shop-made,80:30 sources, TS:64 food-safe, 78: I 04, 94:l 5 n shop-made,82:| 8 Glass Grooves for exterior doors. 88:58 lnfeed/outfeed aids Eye protection curved for box bottoms,93:83 for figured wood,93: I 04 swivelingrollerl 80: | | and ear,92:92-95 cutting,85: | 2 for frame and panel,99:52, for mahogany,93:90,93: | 04, lnlay for 99:57 93:| 08 cabinets,98:87 bunerfly,99:48, 99:5 l, 99:54, Glasses gang-cutting for restorations. 96:78 99:63 prescription safety,94:| 2 on tablesaw.9l:93 Internet, buyingtools on the web. 83: | 6- | 8 72 American Woodworker JULy2oo3 3-YearIndex r Knobs and pulls marking system, 92:78, 94:75 quilted big-leaf,86:I l6 miscut chucks, shop-made, drawerand door, source for, rounding oven94:64 Marking fixing,87:57 Jam props,99:56 8l:19 79277 screw lines for perfect Shakerstyle, source, 84:89 tapered darkening,92:80-8| testint,88:49 Japanese planes Knots, removalof , 89:22-23 making,92:5G-5 l, 92:53 symbols,92:76-83 splined,99:7F75 pull rype, reviewed,S l:89 Koa,curly,89:124 uneven Marking tablesawsled,96:8F85 ligs tautes centering,for drilling or fixing,94:65 beveled-edge wheel testing,93:83, 93:86 marking,34: l4 r Levels, accuracy as a straight- reviewed,93:37, 93: | 08 Moisture meters Lacewood, qualities of dowel-drilling ,94:96 edge,83:| 28 knife choosing,94:87-88 Ladders source,82:77 Lid supports sharpening,92:79 recommended,94:8&€9 rolling for clampingcurves, 78:20 sources.T8:45 making,88:54 types of,94:86-87 source,86:66 -pla tenoning, on router, 84: | 6 Lighting using,92:79 Molders, ners, 97:7 2 Lamination for displaycabinea, 98:79, Mat Moldings Jigsaws bent base plates for 98:84 board "recoverable" beads,87:26 process of,86:49 zero-clearance,89:20 for shops cutting,88:5f55 assembled,86:59, 86:60, for veneer,87:86 tool-free blade changing designing,87:l2 cutters 86:65-66 gang,95:78 reviewed,93:34, 93: | 08 under-cabinet,95:6 l, 95:69 using,88:5f55 cove press,89:73 Locks, cam,sources, 8l :65 Materials list small,86:66 Joinery Lap joints edge-to-edge,87:| 0 Logs care with.89:l5 with router table. 93:8648 test cuts.85:79 plate-joined,98:48 cuttint and drying, 8 | :49-50 MDF curved with tablesaw 92:56, 92:57 knockdown.9l:63 Louisville Slugger bats, for machinery tables,92:67, making,99:7{78 Lapping stamps,92:82 dimensions,TS: l2 92:88,92:90 dentil machinesfor with drywall screws,87:37 Lumber Measuring making,86:65 reviewed. 39:76€ | amounts of systems,92:7643 fluted,85:85 fointers process of 89 :76, 89:77 -planers,90:52, 90:7 6, 97:55, , aflowances, 89 :48, 89:49 Measuring tapes for picture frames, 96:82-83 Laser guides, 97:72 83:26 board-foot formula, 89:47 board-foot computing, 95:29 making,89:63 Lathe chucks 8-in. bowed,89:5 | stick-on,93:20,93: | 08 with routen 85:82-85 rim chucks,78:102-104 reviewed.99:35 calculatingboard feet,82: | 2 Mesquite reed,78:8f82 Lathe tools features of,90:52-53, case hardening of , 94:54, 94:55 about,87:4f53 routing, 95:7 l, 95:73-7 4 gouge 97:53-56 certified source,95:32 barbecuingwith,87:53 sandingblock,85:84 using,85:62, 85:64, 85:65, long-bed checkingin,84:32 dimensions of.87:48 small 85:100-103 reviewed. 39:94 color of.89:53 dust of,87:52 making,93:82 partint tool planesas,94:26 construction-trade hardnessof,87:50 method,85:83 using,85:62 recommended,90:54-56, preparing, 98: | 0 sapwood ol 87:50 trim skew chisel 90: | 20 crooked,89:5 | sources,ST:53 over gaps,88:83 using,85:62-63 recommended 200 l, 92: | 04 cupped,89:50 stabifity o1,87:49 Morse tapers, fitting, 86:74 Lathes recommended 2003,97 :56 figure in,89:53 Metal Mortise and tenon | 6-in.variable-speed router-table for exterior use,88:57 for machinery tables,92:67 fit ol 88:10 reviewed.9l:32 making,85:38-42 grades of,89:4&49 tapping,98:14,98:72 correcting, 93:67 bed height of straightedgesening aid,85:22 grzding,&4:3*42 Metal detectors for doors, 98:79,98:80,98:85 raising,9l:45 troubleshooting,9 I : | 2 grain direction in, 89:52,98:8 reviewed, SS:30 haunched,88:5&-6 l, 88:64 bowl heavy-duq,96:32 types of,90:5 | marking system,94:75 Methylene chloride lrlortisers buyer's guide,83:7&{3 planed characteristicsand uses,79: | 2 benchtop Jointers mini lathes reviewed, adjusting,maintaining, and hit-and-miss,89:49 Mineral spirits recommended,90: l 2O-12 | 78:68-71 tunint pre-milled,89:52 disposing,84:28 reviewed,8T:24 buyingadvice, 83:78-80 quarter checkingfor square,83:| 30 measurements, 89:47 reusing,84:28 reviewed and AW rated. centers for pulleysand bela,83: I l8 rifuawn,89:52 Mirrors 81273-77 live,9l:44 table alignment, correct- selectingand buying,84:3f assemblyof,85:80 souping up,78:41 chuck for ing,83:l2G-122 84:42 hall oak drill-press,97:37 4-iaw,9l:44 tuning,83:ll8-130 sources,96:92 making,85:7&€ | discussed,90:37 cushions.9l:45 waxing the table, 83: 126 sticker stains on. 94: | 6 Miter gauges features of,90:69-71 developmentsin,83:81 buyer'sguide, 83:6 l-65 twisted,89:5 | accurate,95:31,95:48 hollow chiselsfor direct-drive.95:33 developmentsin,83:63 warped,89:50 features and types,8 l:82-83 reviewed. S9:98 dust collection.9l:44 features and types,83:6 l-63 Lumber racks precise recommended,90:72-73 dust collectors,shop-made, fence alignment methods, shelf shims,87:94 reviewed, SS:32 recommended 200 l, 92 | 04 80:65 83:| 26-l 30 precision,9l:4| Mortises faceplates fence features and size,83:64 U recommended,90: | 08, 90: | 20 cutting,93:62, 93:54 centering on burls,8l : | 6 Machinery settint knives on recommended 200 l, 92: | 04 for pegs features ot, 97:6043, 98:88-94 | 20v x 95: methods, 33: | 22-126 240v | 6 reviewed and AW rated, with hollow-chisel,85:80 height,98:93 American-made.95:l4 8 | :8 l-83 making,88:70 lointing live centers.99:| 2 basesfor on router table.92:89 slots for on legs mini- mobile,88:92,9l:4 on router tables.89:| 3 | tightening,93:24 marking system,92:78 recommended,90:| 20 modular stations for router jig,78:5| stop for plugging reviewed, T3:6&7| wide boards,78:8 reviewed,9l:33 quick-action,87:24 for turning, 35:6 | motors of outfeed rollers for joints with a routeri 8 | :8, 82:70-7 | Miter router jig, 92:50,92:52 by brand,98:90 on jacks,86:28 with router | lock-miter,79:57-59 splines,ST:63 iig,89:58,98:2 pars portable with tablesaws,9T:12 sources,9l:45 Miter saws squaring,85:6| recommended,98:95-97 storage,98:42 laser-guided,96:30 stopped,88:58 foints recommended 200 l. 92: knock-down | 04 tables for recommended,90'61-64,90: I l9 through reviewed,98:88-97 material, 92:,67, 92:68 bolt-and-wingnut, 85:24 slidingcompound squaringup,85:80 sliding-headstock, 97 : | 4 Magazines features of,90:59-62 with plunge router, 87:62, n small filing tips,95:7 Miter saws, compound 87.'63 Kerf bending recommended 2003,97 :64 magnetic switches, as a features of,97:67-49 with routen 87:77 process ol 86:48 speed and poweri 83:80 safetydevice,83:28 fences for bits,85:51 Kerfs, jig, 93:83 stabilizing,98:9| Magnetizer wall-hinged,92: l0 | jigs,85:5G-5| Keyhole hanger steadying,85:| 00 for smallnails, 93:23, 93: 108 recommended 200 l, 92: 104 Mortises and mortise- sources.S0:34 weighg9l:45 Magnets, rare-earth recommended 2003.97 :69 and-tenon joints Keyhole slots Lattice source,86:| 3 reviewed,97:8 routing,Sl:7Hl making,89:84, 89:86, 89:88 building,86:46,86:47 Magnifiers station for techniques,78:37-45 screws for Layout visor-type,97:7 portable, 93:92,93: | 08 Motors installing,89:89 tools for Mahogany Miters brushesof Kilns storing,8S:96 finish,93:90, 93: | 04, 93: | 08 biscuit joinery,94:80 replacing,S5:8 making,94:42-55 Layout tools quilted clamping electric,sources, 8 l :50 operating,94:52-55 TriScribe reviewed. 82:98 features of. 93: | 04 with tape,89:7| power of,96:3&-39 Knives, sharpening,82:80 Lead source,80:54,93:| 08 clampingblock,99:55, spark from Knobs embedding Mantels 99:56.99:58 diagnosing,S5:8 attaching for weight,87:86-87 Arts and Crafu style, clamps,88:52, 89:69, 94:24 understanding horsepower with Tnuts.86: l6 Legs 88:7G43 for little boxes, 93:82-€3 ratings, 78: | 4 drying rack,85: | 08 exterior building,88:7&80, 88:82-€3 gluing-up iig,96:8647 Mulch, from workhop, 92: l2 star water-proofing,86:49 Maple jig,88:5| Musical instruments source,87:94 laminated birdseye,96:98 long turning a whistle,78:l7 T-style making, 94:60-6 l, 94:64 curly plate-joined, 98:49 correction source,93:I 08 leveling,98:57,98:86 bed ol85:56-{9 mini-biscuits,85:54 Myrtlewood lumber:89:52 finish.85:69 quafities of,92:'102 74 American Woodworker JULY2oo3 3-Yearlndex miters of,88:49,88:5 | Plunge routers Powermatic Red oak r Bosch l6l9EVS, review, bandsaws decay resistance compared Nail sets oval revie*ed, 88:88{9,9o.2F27 to white oak,8l:8 magnetizing making,99:72-78 83:|04 painting,96:88 buyer'sguide drill press | 170 Reed moldings, T8:8G€2 for smallnails,93:23 reviewed and AW rated, reviewed,86:68-75 Refinishing rectangular rustic-style,8 l :2f26 78:7G79 drill presses glue-upfor making,9l:20 splines,88:49-50 Fein,review 83: | 04 reviewed.90:36-37 before stri pping, 86:76 Nailers supplies,88:54-55 Plywood jointer PM 54A Repairs, fillers,9 l : 128 brad Planenmolders 90: I 4, 90:76 -wood attachment, 98:48 reviewed,89:94 Resawing cordless-compressor,9 | :29 buying, ApplePly,source, 80:38 avoiding warp after,79: l4 Nails Planers iointers -jointers, 90:52,90:7 6, 97:55, Baltic birch,source of void- recommended,90:56 bandsawsfor and staples free,80:47 planers recommended combo gun,86:22 97:72 ,90:.2F27, -molders,97:72 camouflaging,83:44 reviewed,90:79 90:l l8 brads carrier,39:26 abfesaw 64 4,95:46 for bookmatching 88:78, 89:53 bobby pin holden 84: l6 benchtop reviewed,93:28-29 chip-out protection, 95:8 | tablesaw 64A, 96:38, 96:48, on a bandsaw,S l:45-5 | compared to finish nails, 79:45 dust collection for cutting,9l:76 96:5G-5 | accuracytips,8l:4F50 cautions,9l:77 Primavera trick 88:23 pusheri88:50 built-in.98:30 90:7 :7 | -7 guide,89:38 qualitiesol 99:102 Respirators plier-holding,9l:9| features ot, G77,97 3 Profile shaping organic-vapor cartridge removing knot removal, E9:22-23 tearout Protection, 87:56 portable with a circular saw 78:50 with disc sander,86:l3 storing,8l:90 brad setter,93:26 small recommended,90:122 dimensionsof Proportions Restoration 200 l, 92 | 04 true,85:5| calculating of bureau,96t70-78 magnetized starter, 93:23 recommended Roller stands Noise recommended 2003, 97t7 4 drilling device,92:83 99:25 gang,89:38 gauge, double-duty,95:88 room insulation,99:l4 snipe-preventionsleds, Protractor/depth folding Notches stands,95:88 edge banding,89:58, 95:63, source,78:64 sled,9 l :69,93:68 95:6,{-66,95:82 Pulls supports, 89:22-23 with tablesaw 89:88 taper types of,90275-76 jointing,89:| 3 brass pivoting vs.sanders,90: | 8 edge trimming, 9 | :62,9 | :64 source,87:89 reviewed,94:39 n . Oak Planes edgebanding,96:62 calculator, 92:83 with vise curly red,95:106 block edges of carving, 39:24 reviewed,92:35 finish for buyer's guide,83:39 filling,87:57 from aluminum stock, 96:6 I, Roller supports fumed, 85:79-€0, 85:8 | sources,S3:36 edging 96:67 drawbridge-type, 87 :94 quartersawn "old-growth," types and features, Europly launched,84:26 installing,92:I l6 suppliesfor 85: | 20 83:3,1-36 router bits,99:29 Push blocks, right-angle,85:52 source.87:94 Ocarina, turning an,78: l7 cufting angles,83:40 edgings,87:5f58 Push blocks and pads Rolling pin, turned, correction flatteningthe blade back,82:81 finishing, 88:46, 89: | 2F | 22 from concrete float pads,82: I 6 79:24-34 Octagons, method, 88:22 irons of for dovetails,98:l6 sources,79:59 Rosewood, allergiesto, 99: l8 Oil finishes sharpening,38: | 2 high-density,98:l6 Push sticks Rotary tools jigsawing applying,78:106-107 uPturned fastening with magnets,8 l :37 base for jointers,94:26 sources,78:54,79:62 as sanssplinters,89:20 pictured,85:83 routen94:22 Oscillating spindle Planing laminating,95:78 Puzzles Router bits joint,96:64 sanders figured wood,93: I M notched knog 87:82-€5 bushings,sources, S l:6 l, 8 l:69 buyer'sguide of curly wood,92:44-45 red-oak magic coin, 87:82, 87:8&€9 flush-trimming -saw reviewed and AW rated. wetting before,92:45 choosing,88:3!44 scrol f 87: 66, 87:7 2, 87 :73 withTeflon bearing 82:82-85 without jointing,84:9 ripping,86:59 reviewed, 34:24 Grizzly reviewed, 82:97 Plans rotan/-cut vs. plain-sliced, - reversiblestile and rail cut- for Mission furniture 88:36-44 Rabbeted joints ters, using,78:72-74 Porter Cable hand-held -94 reviewed, S2:96 book ol 94: | 8 sguaringup,89:58 locking ficr draryers,84:9 | sources,7 8:45, 8 | :6 l, 82:77 outfeed rollers period supports for Rabbets lock-miter,79:59 glass,88:8 swiveling,80:| | sources,SS:8 board,99:82 for | point-cutting round-over Ovals, mat cutters, 99:78 Plant stands l-beam,9 l :60,9 l :6 l, 9 l :62 for round frame,99:78 bits,78:82 nine-pot Pneumatic brad and lock radius type,84:89 - making,94:7V72 finish nailers with router,92:6f63 reversiblestile and rail Paint Planters anatomy of,79:44 on tablesaw,89 :58, 96:62 cutters, TS:74 and fasteners patio shingled bfowout, avoiding,79:47 on tablesaws,9 | :77,9 | :9 | Router jigs bleed-throughwith, 86:49 making,94:7840 bfowout, repairing, 7 9 :47 trimming for dado cutting, 78: | 8, 78:48, for exterior doors. 88:58 Plastic laminate features and types, 79:43-49 with router, 9 l :82, 9 l :83 80:28 on damp wood,86:49 applying,99:43 impact mark, avoiding,79:45 with router, 88:6 l, 98:8 | for diagonal routing, over pressure-treated samplesof sources,T9:49 with tablesaw 94:66 78:8G{2 wood.86:48 uses.99:25 Pocket-hole joinery Racks for dovetails removingfrom pores,79: I Plate joiners clamps,97:l6 drawer,96:26 slidingdovetails, 84:86 sPray-on biscuitsfor Pocket-screw ioinery drying for jointing,78:5 | rack,96:88 making,87: l6 without aiig,82:17 for knobs,85:| 08 tenoning,34: | 6 strippint,79:| 2 edge-to-edge alignment Polyurethane finishing,88:52 Router tables Panels with,87: l0 creating a custom sheen,78:8 for damping,9S:42 "recoverable" beadswith, 87:26 assemblyol 85:80 features of,90:82 waterborne for portable tools, 98:42 -router combo bits for recommended,90:83, 90: l 2 l addingcolor,80:102 for tablesaw blades,85:44 reviewed,99:30 reviewed,92:32 recommended 200 l, 92: | 04 best brush,82: | 04 for turning tools, 96:20 adjustments, 92:66, 92:68 Patterns rypes of, 90:81-82 sources.80: | 02 knife bases,92:69 gridded vs. slot cutters, ST:8 Posts making,85:92-93 benchtop vs. fl oor, 92:64-65, enlarging,8T:65 Plate joinery turned two-part lumber 92:66 transferri ng, 82: | 4, 82 | 6 anglejig,99:20 making,85:58-65 with under-slungdrawers, bit storage,85:46 Pegs, decorative, 9 l :65 biscuit exposure in, 99: 104 Power miter saws (conven- 85:44 bit-height adiuster, 85:89 Pencif holder,84:14 biscuit sizing,98:5 l, 98:52 tional and compound) painting,96:88 Boschfolding table Pencils carcaseswith.98:5 | accessories,33:58 Radial-arm saws reviewed, S4:26 carpenter's cut gauging,9S:5| buyer's guide compared to power building 99:39-45 sharpene499:36 drawers with,98150 features and types, miter saws,83:55 cove with,93:8648 chalk marking,sources, 79:56 edge joinery with, 98:48 83:54-56 recalled,8S:32 curve-routint iig, 99:47 multiplying edgingwith,98:47 Ryobi reviewed,83:l4 Rags dadoeson,96:83 quickly,92:80 Paceframes with.98:47 capacity,determining your hazards of oil-soaked, 78: | | 0 dust collection,SS:95 Perf-board hold-down.98:56 needs.83:55 overhead dispenser;82:36 end-grainjig 86:34,86:35, 86:36 extending the hooks on, miters with,98:49 compared to radial-arm what makes a good, featherboards,85:82, 85:83, 8l:38 shelveswith.98:50 saws,83:55 78:| 06-107 85:85 shelving,S0:8 technique,98:52 dust collection Random-orbit sanders features of,99:40 Phenolic top attachments with, 98:48 after-marketsolutions, 83:57 dust collection tips, 80:64 fences,92:65-67 for machinery tables,92:67 with slot-cutter bits, 87:8 laser cutting guide,83:26 Rasps sub-,92:66,92:67 Picture frames Plate turning, 78:9&-l fi Power tools sandpaper for tablesawextensions, 92:73 assembling,88:53 Plugs caddy,79:| 00 making,92:22 gaugesfor fasteners for source,87:80 storage devices,82:34, 82:36 sources, S0:6 | set-up,85:53 quick-change,88:53 tapered,sources, 8 | :69 technologicaladvances in Reclaimed lumber guard for fi4ishingrack,88:52 trimming portable, S3:30 checkingfor embedded meal, freehand.99:47 hangers,38:49 router jig,89:25 understandinghorsepower 84:18 inserts making,96:80-88 ratings of, 78: | 4 Excalibur EXRT2 reviewed, 34:25 76 American Woodworker JULY2oo3 3-YearIndex joint-making,92:73 jointingjig, 89:58, 98:2 | belt Screwdrivers Sheet goods jointer fence,85:3&-42 lever locks,85:75 features ol 90:8&49 right-anglebattery-d riven, crosscutting,ST:37 lointingon,87:54-55 mid-size recommended,90:89-90, 98:32 dolly,86:26 knock-down,89:3| reviewed,85:70-76, 89: 100 90:l18 Screws ripping,87:37 miter mini-biscuitswith, mid-sized random-orbit broken sawingrack,80: | | 85:54 reviewed,90:122 recommended,90:8G{8, removing,35: l0 storage,8T:96 moldingson,96:82-83 moldingswith, 85:82-85 90 122 broken-through Shelf supports moldingswith, 85:82-85 fluted, 85:82.85:85 types of,90:85-86 Fix,88:82 brass,sources. T9:77 on tablesawextensions, 88:95 mortiseswith. 92:50.92:52 Sanders, random-orbit coarse-thread usingbiscuits, 32:59 olatesfor mortisingwith recommended200 l, 92:| 04 loinery with,87:37 Shellac advantagesof,85:86J7 jigs,85:5G-5 l, 85:60,85:6| Sanding drivingin tight spots,78:22 dewaxed angled,85:89 stop blocks,85:60 blocks extractors for applying,78:107 mounting,85:9G-9| new improved,96:30 profiled reviewed.9l:34 instant,80:98 perfect.85:88 noiseol 85:73 making,85:84,95:39 galvanized source,92:34 recommended,g0: | 23 plug-trimmingjig, 89:25 sources.T9:56 source,93:| 08 Shelves reviewed,85:8&{9 plunge end grain,79:54 makinggood joina with,79:62 cleats,87:38 pull-out,79:104 for tables,96:28 hand.78:23 paint bleed-throughwith display,89:84€9 push-blockfor reviewed,92:30 insidecorners, 32: | 7 fixing,86:49 glass,98:79, 98:85, 98:87 right-angle,85:52 power of,85:72-73 Dads pilot holes,86:48 heavy raisedpanel doors on,86:32-43 rabbetswith,88:6 | flexible, sources, 79:56 pocket, 89:59-42,9 l :65, 9 l :66, supports,99:84 recommended,90:| 23 recommended,90:96 scratchesfrom 9l:79,91.81 installing,78:56-61 roundingover with, 93:65, recommended200 l , 92:104 exposing,88: I 4 predrilling,94: l4 metal upside-down,98:40 93:70,93:88 recommended 2003,97:86 smallpieces,80:32 removing,SS: l8 pin hofes,9l:67,91:79 routers. 97:7.99:28 reviewed, 99:64-7 | Sandpaper sheet-metal pin-hole iig,98:80, 98:83, 98:84 safetyfeatures,92:68 roundingwith a,78:20 dispenser,T8:22 lor grip,9l:94 plate-joined,98:50 shaper-like safetywith,90: l6 file storage,32: I 4 stainless sink-cabinet,85:92. 85:94 reviewed,89:92 sizesol 90:92-93 folding,85: 109 source,86:5l,87:65 stiffening sleds.99:47 sparksfrom high-quality,96:29 wax, 86: l4 with edging,87:58 slotson.88:49 diagnosing,S5:8 mounting,93:68,98:70 Scribing support holes,drilling springboards,92:26 speed chart, 92: | 7 overhead dispenser,82:36 adjacentedges,78:60 accurately,T9:74 tablesaw-mount speed controllers, 86:8 reinforcing,9l:20 cabinets between walls.78:60 wall reviewed,35:30 soeeds. of saving,98:I 7 cabinetsto walls,78:59 display,78:52-55 tabletops, 92:67-69 variable,85:7l-72 sources,T9:56 Scrollsaws free-form,80:34 template routing on, 87:6 l, squaringup with,99:l6 for "short" rolls. 78:22 blade changing,87 :68-69 Shims 87:63, 87 :64, 87 :7 8, 87:7 9 table-mounted,vs. shaper; 83:22 unclogging,8 l :92 bladepainting,94:26 aluminumtape, 93:24, 93: | 08 feed direction,8T:79 table platesfor Sawblades blade-threadingslots, 95:26 source,87:94 templates,93:70 recommended 200 1,92:104 bandsaw bladesfor Shingles, laying tested.92:64-73 template guide bushings,85:73 features of, 9 | : | 04-l 08 choosing,ST:74 on box,94:80 Routers Rubbing out, recommended,9| : | 08-l l0 controls, 87:69-70 Shop vacuums basesfor process ol 88: | 6 reviewed,9l:ll0 dust management,87:70 buyer'sguide dust collection,83:89 Rulers, storage,88:96 setting,9S:28 extendingthe useful life of, reviewed and AW rated, removable.83:88 Rust typesof,9l:103-104 79:16 80:69-73 shop-made,8l:37 Preventing combination features oi 90: | 0 l-l 02, features,80:70 "body-grip" with corrosion inhibitors. sources,95:28 97:91-93.97:94 mufflingnoise from, reviewed, 92:28-29 86:10 dado multipleswith,9l: l8 79:ll5-l l6 3-HP with dehumidifiers,86: l0 carrier,93:96, 93: I 08 recommended,90: | 02- | 03, plastic liner,source, 80:64 reviewed,90:123 with silicagel,86: l0 recommended200 | ,92: 104 90:123,92:104.97:94 recommended,90:.124 accessories.85:73. 85:75 dado stacking reviewed,ST:66-74 tool-actuated,97:8 as biscuitjoiners, 85:53 - choosing,S6:56 speeds,87:70 switches.80:7 | baseplates for Safety recommended,90:|'24 tables,87:70 Silicon putty, sources,T9: l0 making,85:20 dust hazards reviewed,86:53-56 types of,90: | 0G-l 0 | SL I E, defined,82:70 basesof health effectsol80:104 for aluminum,86: l0 vibrationwith,87:69 Slats, spacing,ST:80 removable.S5:7 l. 89:1 00 Uniform Mechanical for melamine.9T:l2 Scroll work Sleds bearingsfor Code standards.80:67 jointer-quality,97: | 2 finishingbath,92:27 crosscut,93:66 graduatingwith,85:84 Prevenringstatic electricity stabilizers,95: l0 Sealers gang,93:64 bit acceptanceof , 85:72 sparks,80:26, 80:67 stiffeners,95: | 0 shellacas.92:34 for router tables.99:47 brushesof Sanders tablesaw sources,79: | 0 small-piece,93:82, 93:84 replacing,S5:8 -drill-presscombo, 97:38 setting,9S:28 Sectors, making,92:83 taPer buyer'sguide, 83:85-89 disc tightening,95:l2 Sewing cabinet, for planers,93:68 MakicaRD | 100 reviewed, templatesanding with,86: l3 Sawdust. as mulch.92:l2 Shaker.84:82-89 for tablesaws.93:66 83:12 drum Sawhorses Shafts, mounting,98:7 | slidingcompound-miter saws reviewed and AW rated. discussed,93:39-45 flip-top,93: l8 Shaker style advantagesol 84: | 00- | 04 78:76-79 double, 93:48,97:42 knockdown and folding,79:102 sewing stands,desks, and buyer'sguide circle iig,94:72 features of,97:.4143 making,96:52, 96:54-55 cabinets,84:82-89 reviewed and AW rated. climb-cuttingwith, 99:l0 papersaving with,98: l7 nestin8,8l:38 tools and supplies,84:89 84:9&-109 colletsof,85:72 qualitiesof, 90: l8 stacking,39:30 Shapers features,34:l0l-102 self-releasing,85:75 recommended,93:50-5| making,94:9| compared to table-mounted Slots cordless reviewed,93:38-5| Sawing, of multiples,9l: l8 routers, S3:22 on router table, 99:52,99:55, reviewed,89:90 single-drumclosed-end, 93:47 Saws with router 99:75 crosscuftingwith, 78:48 single-drumopen-end, 93:46 dovetail.90:l9 reviewed.S9:92 on router tables.88:49 dado baseplate,35:52 vs.planers,90: | 8 edge protection,94:29 Sharpening Smoke alarms, dado iig,96:22 drum frugality,39:24 Japanese-sryle,90: l9 edge tools,82:78-8 | dust and,80:| 04 dadoeswith,9l:9 | oscillating-spindlesanders veneer gauge for Snipe, eliminating,79:85 angled,94:76 reviewed,90:l2 | source.87:89 making,92:8| Solvents depth gauges,92:79 random-orbit Saws, compound-miter hollow-chisel mortising choosing,96:| 6 depth-of-cut adjustments features of.97:77-78 aluminumwith,86: l0 attachment.78: l0 Sound Safety Products for,85:73-74 recommended 2003, laser for lappingplates, 98:62, 98:64, Optimuff developmentsin,83:87 97:7&-79 reviewed,SS:30 98:65,98:68 reviewed, 92:92,92:95 dovetailswith spindle stand for machinesfor Spanish cedar sliding,85:14,85:53 and drill press,89:96 building,87:36 recommended200 | . 92: I M preferred for cigar dust collection,92: | 0, 96:27 Sanders, belt Scrapers reviewed,89:76-€ I humidors,78: l0 dust collector for -polisher,97:80 burnishing,78:104 of carbidebits,92: l7 Spires reviewed,35:36 detail,97:80 cabinet of marking-gaugeknives, 92:79 pyramidal features of,78:76-77. features of,97:-79 sources,30:6 1,80:68 scrapers,S0: | 07 making,94:76 83:85-86, 90:93-95, finish,97:80 edge protection,94:29 system for Spline joints 97:83-85, 97:88, 99:64-67 recommended200 l, 92:| 04 sharpening,80:| 07 drill-press,98:62-74 for drawer runners.92:58 feed direction,90:l6 recommended 2003,97 :7 9 sources,S0:6 |,80:58 testing for sharpness,S2:8 | making,93:83, 93:84 flush cutting with, 9 l :82,9 l :83 Sanders, drum squaringedge, 82:79, 82:8 | tool holder,98:64-73 on router table, 99:.74-7 5 flush-trimming jig,87:58 cleanerfor storage,33:96 Sharpening machines Splines for router tables.97:7. 97:85 reviewed,94:40 Scratches, minute recommended,90:124 jig,88:50 from roary rcols,94:22 Sanders, oscillating spindle exposing,88: | 4 sharPeningstones Spokeshaves, in end grain recommended2001, 92: 104 Screw extractors waterstones sources,30:6 | centering,85:63 Sanders, portable hollow flattening,82:8| Spray painting and finishing using,85:| 0 holders.82:79 techniquesand equipment for,8l:92 78 American Woodworker tuLv2oo3 3-Yearlndex Spring boards Stools for glue,96: l4 shelves.94:65 storage under as fences,92:26 nested,78:47 for stains,88:46 side trays,87:98 Squareness Queen Anne footstool, Switches Greene and Greene-style, switches,95:48 by feel,92:83 80:4&-54 combining,95:20 8l:52-6 | table insert for by fol fowi ng kerIs, 92:27 Stop blocks magnetic stretchers,9 4:62, 9 4:63, 9 4:64 tape temporary,S5:22 checking,9l:56 workbench safetyo( 96:39,96:40 trestle taper jig,88:78,89:86 drafting triangles,92:78 from old deadbolt 79: l6 Sycamore how to size,82:3G-32 taperson,92:50,92:53 for large pieces,99: 16, Stops qualitiesof, 98: I l4 utility tenon jig,88:6G-69, 88:7 I, 99:4243 doweling jig as,93:20 knock-down.86:30 88:73 Squares for angles,98:56 - Tablesaws throat plates,95:29, 95:50-58 buying,90: | 4 for dadoes,98:69 T-nuts | 20v x 240v 95: | 6 zero-clearance,9 l:4 | storage,88:95 for routers.99:46 for drawer pulls,85:l6 240-volt.96:4 | types of, 90: | 05- | 06 Stains quick-action Tables 120-volt vibration with applyingbright-colored reviewed, ST:24 aprons,92:54-55 reviewed,96:36-5| reducing,9l:4 | stains,82:106 Storage Arts and Crafts style accessory storage, T9: | 00 wrenches,95:46 chemical behindstairs,95:90 small,94:5&{7 arbor-washer fl attening, 96:24 Tabletops for cherry,93:58,93:| 08 drawers for assembly bases for attachment methods,94:64, ebonizing,S6:76 between studs,87:94 folding,85:48 mobile,9l:4| 94:67,98:84 for blemishes,95:24 for lumber,85:44 buifding,87:7640 mobile storage,9l: I l2 fasteners for for concrete.36:8 for small para,98:25 materialslist.87:79 benchtop,95:49 metal,94:64 gel in bottles workstation, 8 | :62-65, blade guards fastening,80:26 corner removal,39: l2 for the shop 84:74-78 sources,83:74 for router abl e, 99:4 l, 99:4243 on plywood,88:46 carts and caddies,79: | 00 coffee bladetilt.83:76 making,92:49-50 over figure, 89: | 20- | 2 I drawers,rolling,80:8 two-d rawe red, 92:48-59 bevel gauge,94:66 slots and buttons, 87:78,87:80 Stamps, source,92:82 lumber racks.84:44 dining blade spacers,88:67, 88:70 slotted, 9S:55,98:57 Stands overhead,34:46 how to size.82:24-32 blade storage, 35:44 squaringup,99: | 6 garden weighted,98:54-59 power tools, 79: 100, 82:34, farm style,82:6&-77 bladesand cutters Tack cloths Staples 82:36 folding shop, 93:74-7 9, 99:80 dust volume and,80:68 finish contamination with. and brads hanging,89:32 kitchen work bladesfor 86:10 combo gun,86:22,80:67 rack-hungdrawers, 85:44 building,87:76-80 dado,86:53-56 Tambours Stave construction shelvesfor materialslist,87:79 bladesof replacing bird's mouth joinery,92:32 upside-down,98:40 legs anglesetter,85:32 tip,93:I l6 Steel, rod stock source, 80:38 tool "book," 79:100 factory-turned, sources, 82-Z squaring,92:78 Tape Steel wool under bench.95:92 mortising tapered,8 l :60 buyer's guide,83:72-76 acid-free,88:55 life of walls for quick utility legs,78:23 cabinet clampingwith, 89:7 l, 89:74 prolonging,88:2| reviewed.9l:35 turned.82:4246 reviewed,SS:28 double-faced steel-free.98:36 Straightedges outfeed cabinet left-tilt for hinges,93:88,93: | 08 Stippling tool, holders,85:22 drill-press,88:94 reviewed,93:30, 93: | 08 source,87:65, 93:88, shop-made,82:16 shop-made,83:128-129 parlor,79:5G-56 choosing, 96.,3642 93:| 08 Stock preparation sources,33: | 29 pedestaf,80:74-78 crosscut sled,87:37, 87 :4243, Tape marking,92:76-83 test,83:| 30 picnic,80:74-78 89:58 double-stickinS,sources, process ol 98:78 Surface preparation rails, crosscuttint 78:54,79:56 curved,87:.78-79 tables,78: | 7 correction Tapering legs dadoes on, 85:94,85:95, 89:86, on a iointer,84:126 9 l :76,92:5G-5 l, 92:53, Tapers 98:6&-69 clamping,89:74 developmentsin,83:75 jig,89:86 dust collection,S0:66 jointer techniques,84:| 26 impact of blade selection, on bandsaw.39:89 ffi 80:68 on planers,93:68 features of,83:72-73, on tablesaw 93:66 A Superiorline of "Pin-Free" Moisture Meters 90:9 l,:90:1 07, 97:98-100 jig,88:78 grooves on planing,9l:69 gangcutting,9 l:93 tablesawjig, 92:50,92:53 stopped,88:58 with circular saw.98:57 guards for Taps, using,98: | 4, 98:72 dust-collecting,88:34 Taps and dies, metal- Ittc 2t0 easy-mounting,95:47 threading, sources,80:38 overarm.9l:4 | Templates hybrid,95:44-45, 97: l 0 tape,87:6l, 87:65 inserts for toggle clamps,93:70 zero-clearance,88:67, 93:84 Tenons kerfingjig,93:83 angled,93:62-65 lapjoina with,92:56 fitring,88:73, 88:74 left-tilt,95:46 haunched,92:50, 92:53, miter gauges,sources, 83 :74 92:54-55 mobile base,87:94 loose,99:5l,99:52-53 fltffi ftiHffitfltg tfitt7 notches with mortising,85:6| safely,87:80 mitered,ST;77 octagonson,88:22 on router.84: | 6 llewFeatures Include. , . parts sources,9 l:45 on tablesaw.8T:77 jig,88:6G-6 * Selectable&clas $atttngs prices of,95:47 | rabbeting iig,94:66 round rabbets on, 89:58,9 l :77,9 1:9 1 cutter.99:6 * Ptass/,loldBeadlngs Functlon raised panelson, 95:34-40 shoulders,88:7 | -72, 88:74 recommended 2003.97: | 0 I tablesawjig, 88:66-69, 88:7 I, * to NanualConectlorc Rcqulrrd resawingsplitteri 96: l0 88:73,92:53 rip fence-mitergauge use,87:77 turned,85:64 Wagner's Proven rippingjig,9l:84 Thickness gauge * Earyto BeadDlglFrl DWef router tables on.85:30 shop-made,80:30 moisture meter router-table extensions,92:73 Thickness planers * Exfr;ndedSpeclas Bange tor Erotlc, technology is virtually SawStop saleq,97:6 benchtop (also called Iletmr lladund $pactas unaffected by wood sledsfor portable) gang-cutting,93:64 reviewed and AW rated, temperature miter.96:84-85 79:83-87 or surface moisture. small-piece,93:82, 93:84 dust collection improvements, splineson 80:62-63 iig,88:50 features and types, 79:83-€6 splitteri97: l2 Thompson'sWater Seal splitters,9l:40 Advanced Wood Protector. squeaking 94:36 silencing,9l:14 Threaded inserts wffin www.moisturemetets.com F storagerack,9l:41 drivers,86: l4 EL.Fr(Jcs roll Frce:l-800-e44-7078 Tcl: Fax:(541) 582-4138 : ffi.tffjl1 M6doin ths USA 82 American Woodworker JULY2oo3 I What's ComlngUpI inAW #l0z,Sept.2003 Artsand Grafts Table Jon Stumbrasis assemblingthe piecesof a small round table, e perfect for putting next to your hvorite big chair.lt'sgot U contemporary lines,but is actuallya scaled-downversion of a hidden gem from the AmericanArts and Crafu movement, f, z made 100years ago by the Limbert Company in Holland, Michigan. L U> u F o BradNailer Tool Test T c What's the reol differencebetween a 950 and a 9300 brad nailer?Tim Johnsonhas vowed to find out in our next tool test. He's poking and prying into virtually every l8-gaugenailer on the market. SimpleKitchen Upgrades Dont you wish you had designedyour own kitchen cabinets? Think of U all the cool ways you could make them more roomy F and useful.MacWentz hasthree simple projects that turn 6- = ordinary kitchen cabinetsinto custom-built problem solvers. U =an E UJ F ,$ U GoAnywhere Drill Gaddy . Bits,drivers, countersinks, extra battery:where is all that s4 stuff when you need itl Jan Carr is putting the final touches o on a small carrying box that organizesall -t the essentialsfor drillingand driving. E o ! L a E U z. FoolproofScraper Sharpening - Does it feel like your card scraper only works half the time, and you E. sF cant figure out why?Tom Caspar is taking the mystery our of how to 2 sharpenthis incredibly usefultool, usingwhat he callsthe worrd's tr simplestjig. He saysthat any U woodworker can make shavingslike those d pictured here the first time out of the gate. E American Woodworker JULy2oo3 91 Sou rces Wheretobuy ar the stuffwe used. www.labsafety.com Dick BlickArt Materials Half-maskrespirator, 3M 6000 series,# | 5255; (800)828-4548, www.d ickblick.com Better Brush Cleaning l2 (availablein small,medium and large) artistl oil Wilson-lmperialCo., (800) 332-6050 $ VanDyke Brown Organic vapors/P| 00 filter cartrid ge,#34770; -83 www.wilsoni mperial.com 0046| | 3 1.25oz. tube; $5 $21 Liquinglazing medium Rapid Brush cleaner;$8 per qt. Northern Tool and Equipment, 00445-1004 250 ml. Bottle;$9 Wooster Brush Co., (800) 392-7246 (800) 556-7885,www.northerntool.com Norton Abrasives www.woosterbrush.com Halogen light,500 watt, with stand,# | 60982- (800)55 l-44 | 5,www.nortonabrasives.com Brushcomb;$8 8226; $20. Stearatedsandpaper Flood Co.,(800) 321-3444 3X HighPerformanceAbrasive Paper www.floodco.com | 00-, | 50-,220-grit 3-packs; $4 ea. Brush Stuff brush conditioner; $7 per qt. LeeValley &Veritas (800) 87 l -8 158, www.leevalley.com When Should I Sharpen My Blade? TWolron PendantPulls, 01A60.30; $6 ea. Accuspray 22SP;$470 Woodworkerl Supply,(800) 645-9292 Two lron Oval Pulls,0lA60.40;$7ea. (800)696-0615, www.woodworker.com Twelve PartWrap lron Hingeswith Minaret www.compliantspraysystems.com per 8 oz, Oxisolve blade cleanen#828-418;$9 Tips,0 | H3 1.50;$4 ea. AmericanTurbine ATI950; $530 One 18" BlackFull-Extension Drawer Slide, (877)434-395 l, wwwmikestools.com 02Kll.l8;$l6ea. Apollo A700;$600 l/10" RareEarth Magnets, Drawer Slide Tracing Jig Four 3/8" x (800)727-6553. www.advmachinery.com Woodworker's Hardware, (800) 383-0| 30 99K32.03;$0.50ea. www.wwhardware.com Four 3/8" Cup for Magnets,99K32.52;$0.50ea. Campbell Hausfeld 10" drawer slides,#KV8400-B l0; $ | 3 pr. Four 3/8" Washers,99K3262;$0.40 ea. HVl000;$172 | HVl500;$215/ HV2000;$221 One l/2"-highRoman Ogee Bit, 16J33.51 HV2500;$32 | / HV3000;$430 / HV3500;$594 Rockler,P00) 279 -444l, www.rockler.com ( for | 14"shank); (4| 0) 692-6300,www.jackssmallengines.com 36".#21746,T-slottrack; $ l0 ea. 16J33.01 $27 Cove Bit, 16J29.58(16J29.08 l8-5/16'x l-l/2"T-slotbolt,#833 | l; $l ea. One l/2" radius CapsprayCS5 | 00;$575 T-knob,#71514;$lea. for l14" shank);$29 (888)385-9969, www.o-geepaint.com One l/2" radiusround-over bit, 16127.58 Mobile Magnetic Light Fuii (16J27.08for | 14"shank); $28 (800) 535-4482 FujiSuper; $500 Woodcraft, One f " radius round-over bit, l6)27.66;$57 www.woodcraft.com (94l) 6 | 3-l0 | 7,www.cheyennesales.com One l/2" flush-trimmingbit, 16J09.58;$ l2 FuiiQ3;$600 Magneticwork light,#09L06; $25 bit, 16J30-58( | 6J3008for One 45-deg.chamfer (800)645-9292, www.woodworker.com LongTenoning Sled l/4" shank);$2| (800) 24l-6748 Graco HVLP2500;$525 HighlandHardware, Public Lumber Company, (3 | 3) 89 | -7125, rki ng.com www.o-geepaint.com www.too Is-fo r-woodwo www.publiclumber.com | 105; (888)38s-ee6e Toggleclamp, # 66 $7 Two 3/4" birch plywood;$50 ea. Handy Dandy Craft Sticks Two 3/4" clear or knotty pine plywood;$70 ea. Lemmer T-55;$425 Gramco SchoolSupplies,Inc., (800) 788-5250 One l/4" clear or knotty pine plywood;$40 ea. www.lemmer.com www.gramcoonline.com 50 bd.ft. pine ;$4 per bd.ft. (800)s6r-6e08 #2499;$3 for 1,000 Adams Wood Products, (423) 587 -2942 Lex-Aire LX-30C;$595 www.adamswood p rod ucts.com, (800)539-2473, www.lexaire.com Four 5" Maple Bun Feet,A0554-DS;$8 ea. Rockler HVLP1000; $ 100 Price-Cutting Saw Woodworker's Supply,(800) 645-9292 (800\27 9 -444l, www.rockler.com Delta MachinerX (800) 438-2486 www.woodworker.com Titan TS40;$600 www. deltawoodwo rki ng.com One pintTitebond wood moldingglue, (800)338- | 042,www.jnequipment.com MS250,10" Compound Miter Saw;$100 921-971;$7 TurbinaireMiniPro | 135; Kink-Free, Lightweight Air Hose $550 One gal.sealcoat (shellac), I l9-459;$23 (800)225- | | 53,www.woodcrafc.com (732) www.coilhose.com Coilhose, 390-8480, (800) Woodcraft, 225-l 153 Wagner |14"x25'coih$|8 www.woodcraft.com Softspray2900, $580 / Softspray2600; $475 l14"x25'straighu$19 OneTransTintGolden Brown Dye, 128482;$l7 Rock-Solid Coping Sled Finecoat2000;366 / FinecoatPlus; $255 (228) www.gleempaint.com EagleAmerica, (800) 872-251| 863-3942, www.eagle-america.com Minwax OriginalCoping Sled;$40 (800) 523-9299,www.Minw.x.com TablesawTool Drawer ReplacementGuide Block;$ l0 -qc; WaterbasedPre-Stai n Wood Conditioner | $8 (800) 383-0I 03, Pro Model CopingSled;$60 Woodworker's Hardware, U Woodworking Shop www.wwhardware.com F ReplacementGuide Block;$ l5 Klingspor's z l2 pr. f (800) 228-0000 22" drawer slides,#KV8400-B22; $ T Space-Saving Cyclone System :< Oneida Air Systems,(800) 732-4065 www.woodwo rki ngshop.com E. www.oneida-air.com Tranfastwater-soluble dye, HS3266, antique k cherry brown;$9 per I oz. bottle GilmerWood Co, (888) 667-3979; $882; $977 I 7/bd.ft.for 2 Online Carving Classes Wood Finishing Supplies.com www.gilmerwood.com,$ Plain up for figured stock; Note: 100 F www.2carve.com (866) s48-1677 stock, $25 and $ ul lumber. www.woodfi ni s h i ngs u p p I i es.co m minimumorder on Zinsser Sealcoatdewaxed shellac (2-lb. cut);$8 Lab Safety Supply,(800) 356-0783 Per qt. 92 American Woodworker JULY2oo3 SpectacularWood andWhere to Get lt by Dave l'1unl Loc-rkbe,vond the striking becsn'ittgftrlLrrc itt (lcvlcltl sirtitl- n ood and xrLr'llflnd scln-rethingelse vcry spccial-the colclr. Cevlon sartinu,ctodhas a beautifirl pale ycllotv to solt'lctlvcllorv color ofien accentedrvith darker strcirlis.Iltrt thc ctltllest thing abor-rtClevlot.t satinrvood is th.rt it tc/rri;t,.its color, charrsinF,\'cr'\' littlc ttvcr tirttc. Tl-rccollrbitlaticltl of stablecolor anclsprgtllcltltlr flgLrre i: u,hittrlade (levlorrsatinwood one of thc "qrcatn,('rodS" ctl-thc I8tl-r-centuryt-t-tilstet's. Earlv cabittetrttaltcrsr-tscd satitltvooci veneersto cretttestr-tttt-tit-tg effects. (,evlorl satillvclod is still largel,vused as it \/crlccr.llLrt solid n'oocl is alstt itt dctrli.tncl,trot onlv for cdging to nratchthe vcttect'[rlrt also for btlx n-raliittq' tr-rrningsancl as t'irredetail in largcr priccc's. Nanred tor its ntrturalsatin-lil e O F r,.-- o Nnow o*;;;;, *;;.'*;'"* abor-rtit. r I & t____vite to us at [email protected] . 94 American Woodworker luLY2oo3 EditedbyTim f ohnson / Hair-Raising Finish r. ]p f\ I had just built a -.-._: ) lazy Susan for my in-laws. It was made from walnut tliat had lots of senti- mental value,hav- ingcomefrom \;r.r) a magnifi- .-:t*- cent tree --4;IiF{F that once stood on their family farm.I wanted the wood to look really special,so I chose an oil finish, the kind you Unfortunately,the oil saton the surface made a perfectbed! My specialfinish brush on generously and allow to so long it gottacky.Panicked,I grabbed wasa tacky,furrymess. soak in. Then you just haveto wipe the nearest rag-from the old laun- Fortunately,more oil, followed by offthe excessoil before it dries. dry basketwhere I store them-and wiping with cleanrags, saved the day. |ust after I'd slatheredon the oil,I began wiping furiously. Only then did My inJaws were thrilled with thelazy got distracted by a lengthy phone call IrealizethatAbby, the family cat,had Susanand Abby has lived to achieve (from a fund-raiser,of course!). discovered that the laundry basket a ripe old age. DavePrasuhn MasterPlanner z = My two boys, Steven and Daniel, and I enjoy doing table.Wealso had a number of oak piecesthat appeared :< E projects together.We're currently making to go to the coffeetable that we were not making. o woodworking (D- oak end tables and a walnut sofa table from a set of Tomorrow I'll to go to the lumberyard for more oak UJ lrl F plans that I bought. The plans are for three tables- and walnut. Next time, we'll highlight the parts we need a 2 we'renot making the coffeetable that completesthe set. on the plans and check all the parts after rough machin- o F ing, to make sure theyte correct, before we spend the As project organizer,I decipheredthe instructions and F a assignedjobs. We labored many hours making legswith time on joinery!. = hand-cut mortises and tenons. Unfortunately, during Gary Arvan a z M o assemblywe noticed that we had two walnut legsfor one a .z- of the oak end tablesand two oak hgs for the walnut sofa - z E t4 2 I If you havea woodworking blunder you'rewilling to share,send it to us.Youll receive$100 for eachone we print. Sendto: F 29li Commers Drive, Suite 7OO, Eagan, MN 55121, br e-mail to lrj AV Oops!, American Voodwo"k"t, 'W'e E [email protected]. Submissionscant be returned and becomeoru properry upon accePtanceand Payment. may 6 edil submissions,and usethem in all print and electronicmedia. E American Woodworker JULY2oo3