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Woodworker’s Journal August 2015 WorldMags.net 3 Woodworker’s Journal WorldMags.netContents August 2015 Volume 39, Number 4 Projects
Picnic Table Page 54 By A.J. Hamler Translucent-Screen Shutters A stylish backyard dinner is in your future with our By Larry Okrend Mission-style picnic table. Simple construction, elegant eating! Page 28 Let the light shine in, but keep your privacy secure, with these opaque shutters.
Page 34 Easy-to-Build Benches By Simon Watts This bench is appropriate for indoor or outdoor use, and you can easily adapt it to a size suitable for adults or children.
Greene & Greene-Inspired Nightstand By Chris Marshall Page 38 Sleep blissfully with a classic mahogany nightstand beside your bed. Lovely lines and beautiful lumber combine to make a family heirloom.
4 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
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8 Letters 22 Woodturning 64 What’s in Store A reader applies a formula to Some spindles have fl at spots: Tool innovations and adapations. calculate a radius. fl at/round turning. 70 Finishing Thoughts 12 Tricks of the Trade 26 Techniques Water-based fi nishes and stains: Snug up sloppy miter bars with Use triangles as a tool for accurate better than before. metal HVAC tape. angle cuts on the table saw. 74 Hey … Did You Know? 14 Questions & Answers/Stumpers 44 Today’s Shop Old bodgers, wood for wet Why do band saws have two Sandor Nagyszalanczy takes you bearings and more. speeds? What’s the best shop on a tour of updates in wood screw fl ooring? technology.
18 Shop Talk 52 Tool Preview Veterans group discovers a Leigh’s new RTJ400 has turned Civil War era fl ag and elaborately routing dovetails and box joints carved frame. upside down. woodworkersjournal.com he fact that you’re reading this tells me that you love learning about woodworking. I’m T guessing you may even get a little impatient waiting for the next issue of Woodworker’s Journal to arrive. I get it. I’m a woodworker, too, and I’m always interested in hearing about the latest tools or looking for a new project to tackle. One of the best ways I’ve found to scratch that itch is by opening my weekly issue of the Woodworker’s Journal eZine. It’s fi lled with the latest tool updates, woodworker interviews, expert advice and project plans. And, it shows up in my email inbox every week for FREE! The eZine is no secret if you’re one of the over 270,000 woodworkers who already subscribes and get your update every week. But if you’re not getting the Woodworker’s Journal eZine, then fi nd out what you’re missing. It’s easy (and free): just go to woodworkersjournal.com/ezine/subscribe and sign up now. — Dan Cary P.S. Know what else is online? Great deals like cool T-shirts!
Check out the new Woodworker’s Journal T-shirts: three versions in two color choices — all with fun woodworking sayings. They are $14.99 at woodworkersjournal.com/store
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Woodworker’s Journal August 2015 WorldMags.net 7 LettersWorldMags.net ROCKLER PRESS THE VOICE OF THE WOODWORKING COMMUNITY AUGUST 2015 Styling in the Shop! Volume 39, Number 4
IT’S T-SHIRT WEATHER! ROB JOHNSTONE Publisher Not everybody likes T-shirts, but most woodworkers I know JOANNA WERCH TAKES Editor wear them all the time. So, a while ago, in our eZine CHRIS MARSHALL Senior Editor (www.woodworkersjournal.com/ezine) we hosted a contest JEFF JACOBSON Senior Art Director JOE FAHEY Associate Art Director asking for great woodworking sayings that would look good DAN CARY Senior Web Producer on a T-shirt. Now, I am pleased to announce, we have put MATTHEW HOCKING Internet Production Coordinator those slogans on T-shirts with groovy-looking graphics and MARY TZIMOKAS Circulation Director have them for sale on our website store. The slogans are: KELLY ROSAAEN Circulation Manager LAURA WHITE Fulfi llment Manager “I came, I sawed, I conquered!” “In this world, nothing is certain but death, taxes and wood movement” Founder and CEO ANN ROCKLER JACKSON And my personal favorite: Publisher Emeritus “Woodworker’s Journal: Based in Minnesota for your protection.” LARRY N. STOIAKEN For me, looking good while letting folks know that I am a woodworker: that’s as good Contributing Editors as it gets. And even though my signifi cant other has given me a list of where I can NORTON ROCKLER wear (grocery store, out for a walk, yes) and where I can’t wear (church, business SANDOR NAGYSZALANCZY ERNIE CONOVER meetings, fancy restaurants, no) my new duds, I can’t wait until I see all the jealous looks as I walk through the lumberyard. If you are looking for a bit of sartorial splendor, Advertising Sales ALYSSA TAUER Advertising Director see page 6 for more info. And if not, you’ll just have to make up your own slogans! [email protected] — Rob Johnstone DAVID BECKLER National Sales Representative [email protected] Disapproves of Design (469) 766-8842 Fax (763) 478-8396 In Ernie Conover’s article, “Carving Editorial Inquiries Linenfold Panels” [April 2015], JOANNA WERCH TAKES he commits two cardinal sins. [email protected] The cabinet is built with fl atsawn rails and stiles, and he carved the Subscription Inquiries linenfold panels out of the same (800) 765-4119 or fl atsawn lumber. The fi gure on the www.woodworkersjournal.com Write Woodworker’s Journal, P.O. Box 6211, wood fi ghts with the design, such Harlan, IA 51593-1711 that it’s hard to read the design email: WWJcustserv@cdsfulfi llment.com. Include mailing of the cabinet. There’s a reason label for renewals and address changes. For gift that rails and stiles are made with subscriptions, include your name and address and straight grain lumber, which is your gift recipient’s. the same reason that carvers Book Sales and Back Issues use wood with the least apparent Call: (800) 610-0883 grain: so you can read the design. www.woodworkersjournal.com Ernie’s cabinet has a visual battle royal going on. Woodworker’s Journal (ISSN: 0199-1892), is published in February, 1 Barry Saltsberg handle frame sizes up to 8 ⁄2" x 15". April, June, August, October and December by Rockler Press Inc., Plainview, New York I recently had the need to build 4365 Willow Dr., Medina, MN 55340. Periodical postage paid at a larger size frame and found the Medina, Minnesota and additional mailing offi ces. Postmaster: Send all address changes to Woodworker’s Journal, P.O. Box 6211, Harlan, Framing Jig Upgrade large adjustments using the star IA 51593-1711. Subscription Rates: One-year, $19.95 (U.S.); $28.95 Although I originally built the knob to be tedious. My solution U.S. funds (Canada and other countries). Single copy price, $5.99. “Framing Jig” which appeared in was to turn the star knobs into Reproduction without permission prohibited. Publications Mail Agreement the April issue to handle mostly Number 0861065. Canadian Publication Agreement #40009401. smaller frames, it will, as built, Continues on page 10 ... ©2015 Rockler Press Inc. Printed in USA.
8 WorldMags.net August 2015 Woodworker’s Journal
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Woodworker’s Journal August 2015 WorldMags.net 9 LettersWorldMags.net continued
Raymond LaRochelle upgraded the adjustment system of his Framing Jig by adding a crank.
cranks using a dowel, a piece A reader’s reaction to two of HDPE plastic and a few articles in the April issue added bolts. To provide clearance up to a mathematical formula for calculating a radius. 1 for the crank, I added 1 ⁄2"- high feet to the base. Large adjustments are now much faster than before. Raymond LaRochelle Livermore, California
Dead Nails a Clincher I smiled when I read your trivia topic about deadening nails [Did You Know, April 2015]. My family was in the salvage business. Wood we salvaged had the dead nails In Mike Loveland’s equation, C = the chord, R = the radius and h = the removed. Dead nails really height distance between the chord and the radius. There’s more online at work: I have doors on my woodworkersjournal.com outbuildings that have nails followed by a refinement to Lock Miter Bit Routing
www.woodworkersjournal.com that are bent dead. They are the design. Then I read about I enjoyed reading Michael MORE ON THE WEB still solid with well over 100 Sandor Nagyszalanczy’s Crow’s “L. & J.G. Stickley- Check online for more content years of use. “Mid-Century Coffee Table” Inspired Settle” article [April]. covering the articles below: Dan Debenedetto, project. I was impressed It had some great tips on build- Woodturning (page 22): Halfmoon, New York with his circle jig on the ing in the Arts and Crafts style. Shoulder transition cuts on back patio. We woodworkers However, when routing with a spindles with square spots (video) If you were a carpenter in the always have jigs, shop aids lock miter bit, Crow states that Picnic Table (page 28): Midwest where the majority and template-making on the cut must be completed Using a circular saw to cut a slot of them were of German the brain. in one pass. While it is true normally done on a table saw descent, the “dead nail” bent Later, I read about Larry that you must not change the (video) over was called “clinching.” Okrend’s “Bowfront Hall Ta- bit height between passes, Greene and Greene Don Elenz ble.” In looking at his curved you can certainly change the Nightstand (page 38): Using a Sun City, Arizona layout using three nails and a fence settings. I like to dial in vacuum bag system for laying up metal straightedge, I then re- my fence setting for a perfect thick veneer (video) Article Solves Another called Sandor’s patio setup. I lock miter. Then I add a 1/4" Today’s Shop (page 44): I just finished reading the thought there must be a way spacer to make the first pass. Improvements in wood screw April issue. The first thing to mathematically calculate After that, I remove the spacer technology (video) that grabbed me was a letter any radius and then use the and complete the second pass. Tool Preview (page 52): from Paul Johnson and I three-nail system for layout. It makes much cleaner cuts, Overview of the Leigh RTJ400 quote, “One of the easiest Out came an old engineering and it is perhaps easier on the Router Table Dovetail Jig (video) things to do is find fault with book, and there are some router as well. Small Shop Journal (page 54): someone else’s design.” relatively simple equations. Willie Sandry Using a routing jig to form lattices That gave me a chuckle. Mike Loveland Camas, Washington (video) But, in reality, it’s usually Edmond, Oklahoma
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SIX ISSUES ON ONE CD! 2014 Complete Collection Save 58% he year 2014 might be past, but it’s not Tforgotten: all of the year’s great projects live on inside the Woodworker’s Journal Annual Collection 2014 CD. Everything from every issue of the year is on the CD, from a Limbert Bookcase to a Desk/Bed Combo; a 19th Century Shaving Box to a Toy Train. Don’t let an entire year’s worth of great woodworking information fade into history: find projects for Gorilla Wood Glue’s your home, your shop and your family, premium formula plus more, on the 2014 Annual creates a cross-linking Collection CD! bond to provide superior strength with a Type II water resistance, Item 59231 ($35.94 value) .... $14.99! indoors and out. For the Toughest Jobs Order now! 1-800-610-0883 on Planet Earth® (mention code WJ1546) Order online at www.gorillatough.com www.woodworkersjournal.com/wj1546 ©2015 The Gorilla Glue Company
Woodworker’s Journal August 2015 WorldMags.net 11 TricksWorldMags.net of the Trade Clever Tweaks to Improve Tools Tested and photographed by Chris Marshall
Simple Scribes are in the Cards When I need to scribe an inside corner, two playing cards make it easy. I match the shape by overlapping the cards and fi tting them around it, then holding them together Cardboard Stands Save Effort with a few paper clips. It’s tough to hold long pieces of quarter Now I’ve got an exact round molding for priming and painting, but recently I template for scribing had 300 ft. of it to prepare for our new home. So, I used the mating workpiece. cardboard from our moving boxes to make four of these Serge Duclos triangular stands, taped together, with V-notches cut Delson, Quebec along the top. The notches were shallow enough to hold the molding’s curved edge “proud” for easy fi nishing. Tom Kaye Louisville, Kentucky
Two Rules Tackle Fractions Here’s an old carpenter’s trick for solving fractions that works either with two tape measures or steel rules. If you need to add or subtract two fractional measurements, place the two side by side and align them according to the lengths that need Bull’s-eye Level Keeps Drilling on Target to be added or subtracted. It doesn’t matter if the denomina- Even though a drill press is best for drilling holes perpendicu- tors of the fractions match, because you’re simply comparing lar to a workpiece, sometimes your only option is a hand drill. two distances, not computing two fractions. For instance, in 1 5 11 To help me drill more squarely, I attached an inexpensive the photo here, 3 ⁄16" (top rule) + 1 ⁄8" (bottom rule) = 4 ⁄16". bull’s-eye level to the back of my drill with hook-and-loop tape. The ends of their overlaps tell you the sum. Subtract the same Thanks to this fi x, I can get very close to drill press accuracy way: the end of the overlap minus one rule’s length shows you by keeping the bubble centered as I drill. the answer. No complicated math required. Bill Wells Charles Mak Olympia, Washington Calgary, Alberta
12 WorldMags.net August 2015 Woodworker’s Journal PICK OF THE WorldMags.netTRICKS
In addition to our standard payment (below), Peter Moore of Oakland, California, will also receive a RIDGID 10” Dual Bevel Miter Saw (R4112) for being selected as the “Pick of the Tricks” winner. We pay from $100 to $200 for all tricks used. To join in the fun, send us your original, unpublished trick. Foil Tape Snugs Up Sloppy Miter Bar Please include a photo or drawing My portable table saw suffered from a loose-fi tting miter bar in the table slots, which made if necessary. Submit your Tricks to it inaccurate. So, I applied a couple of layers of metal foil HVAC tape along the edge of the miter bar to serve as shims. I was able to widen the bar just enough to allow for smooth, Woodworker’s Journal, Dept. T/T, “slop” free action. If you try this trick, apply full-length strips and not short pieces, and use P.O. Box 261, Medina, MN 55340. a utility knife rather than your best scissors to cut it. The metal tape will dull them. Or send us an email: Peter Moore [email protected] Oakland, California
Safety First Learning how to operate power and hand tools is essential for developing safe woodworking practices. For purposes of clarity, necessary guards have been removed from equipment shown in our magazine. We in no way recommend using this equipment without safety guards and urge readers to strictly follow manufacturers’ instructions and safety precautions.
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Woodworker’s Journal August 2015 WorldMags.net 13 QuestionsWorldMags.net & Answers Plane ening process. The goal is to Answers create a curve that will make a shaving that is about 90% of the width of the blade. THIS ISSUE’S EXPERTS Rounding the corners of the blade does not accom- Ian Kirby is plish what the curved edge the author of Sharpening with will give. The plane marks Waterstones and the DVD are still there, just a little Sharpening Planes and Chisels. Our expert less pronounced. Whether Sandor Nagyszalanczy is a explains that to the plane is a low angle or a writer/photographer of several avoid plane marks normal bench plane makes woodworking books and a in your work- no difference — the blade piece, you need frequent contributor to is sharpened with a curve in Woodworker’s Journal. to sharpen your plane irons with a the same way. Rod Burrow is quality assurance/ subtle curve. — Ian Kirby customer service manager at RIKON Tools. I’m getting ready to I have run across the If you sharpen a blade Q retire in the coming Q statement several times so that the sharp edge is months and am in a position Contact us that the corner on bevel-up absolutely straight and then to build an actual workshop by writing to “Q&A,” plane blades (irons) must be use it to plane a piece of for my woodworking toys Woodworker’s Journal, more pronounced than on wood that is wider than the instead of sharing with the 4365 Willow Drive, bevel-down blades. What is plane — say, a tabletop — garage. I know my wife Medina, MN 55340, the reasoning behind this? you will take off a shaving would be happy to have a R.E. Jones that is the full width of the place to park her car out of by faxing us at (763) 478-8396 Saginaw, Michigan blade. This shaving will leave the elements. My question: if or by emailing us at: behind two steps on the I build a two-car garage, what [email protected] The bodies of early surface, one at each side of should I use for fl ooring? Please include your home A planes were made of the shallow groove you just I know standing all the address, phone number and wood. The only metal in- cut. The height of the step is time on concrete is tiresome email address (if you have one) volved was the blade assem- the thickness of the shaving and can cause problems bly. It consisted of the iron — it’s called a “plane mark.” with leg issues that I would with your question. and the cap iron. The cap To avoid this, the blade is not like to avoid, but are rubber iron has kept its name. Now sharpened straight but with mats the answer or should I Flooring tiles like Dri-Dek allow most woodworkers refer to a slight curve. The curve is consider something else? you to customize the areas you and the “iron” as the blade. visible if you hold the blade Lee Nalley your tools stand on in the shop. to the light and gently place a Ellerslie, Georgia rule or a straightedge on it. The amount of the curve While you might want is related to the thickness of A to discuss the relative the shavings you are going merits — and costs — of to remove. “Hogging” off installing a wood fl oor the wood with thick shav- in your shop instead of a ings requires more curve concrete one, you’re correct than “cleaning up” when the in saying that rubber mats shavings will be one or two are the cheapest way to thousandths of an inch thick. make concrete fl oors more Making the curve is a matter comfortable to stand on. I of practice, and it’s done with fi nd the 24" by 36" anti-fa- a few strokes on the fi ne stone at the end of the sharp- Continues on page 16 ...
14 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
WorldMags.net Questions & Answers StumpersWorldMags.netcontinued ”No More Free Milk” tigue mats made for use in Or, “tough love, Old McDonald style” commercial kitchens and fac- tories are just right for use in front of benches, stationary machines and workstations. photo courtesy of SteerPlanet.com For more complete fl oor Lavern Zimmerman of coverage, you might consider Shiloh, Ohio, commented installing interlocking rubber about the April issue mys- or plastic fl oor tiles typically tery tool (from Rick Kerns sold as garage fl ooring. You of St. Joseph, Missouri): “I Joe Price of Clinton, can customize tile layout to Mississippi, noted that modern am very curious to know cover all the areas of your versions of the April mystery tool how many other people are less aggressive. shop where you walk and know what it is!” stand, yet save money by Answer? 974. There’s purpose as “tough love, Old leaving the areas under a lot of readers out there McDonald style.” “When machines, benches, cabinets, with a farm background the calf tries to nurse, the etc., uncovered. Tiles are (no word on whether prongs prick the cow,” said reconfi gurable, should your they’ve seen Par-ee), plus Byron DeLong of Ocqueoc, shop layout change in the a few “bovine veterinari- Michigan. Keith Hodgin of future. There are two basic ans” like Todd Plocher of Coleridge, North Carolina, types of interlocking tiles: Salem, Ohio. said the cow’s reaction textured solid surface tiles Grant Coffi n of Black would be “evasive action,” (e.g., ModuTile workshop Hawk, South Dakota, said, while Larry Darrow of tiles) and mesh-style “open “This device is called, lo- Salina, Kansas, noted, “A few weave” tiles (e.g., Dri-Dek®). What’s This? cally, a blab.” Other names, kicks from Mom, and the Solid surface tiles provide from Syp Vander Dussen youngster learns that there a continuous, nonslip surface This mystery tool belongs to Mark of Chowchilla, California, is no more free milk.” that’s easier to clean but Patrick of Ionia, Michigan. Do you include “a calf trainer, or a It’s not always “Mom”: don’t typically provide the know what it is? nose spider.” “It is a wean- “Sometimes, you have a same amount of cushioning Send your answer to ing device for cattle,” said calf who thinks every cow that thicker mesh-style tiles Carla Meyers of Curtis, around is a free meal,” said do. Open mesh tiles allow [email protected] Nebraska. David Miller of Mercer, spilled liquids or moisture or write to “Stumpers,” “The round balls go into Pennsylvania. Or, as Dick seeping through the concrete Woodworker’s Journal, 4365 the calf’s nostrils,” explained Smith of Leawood, Kansas, to readily evaporate, but they Willow Drive, Medina, MN 55340 Jim Pease of Waterville, said, “Occasionally a cow also trap sawdust as well as for a chance to win a prize! Ohio. “You would tighten would get the habit of drink- accidentally dropped small down the bolt to hold it ing her own milk, straight parts and screws. However, snugly in place,” added Joe from the source.” you can usually vacuum the Robertson of Chickasha, By the time the calf weaner sawdust out — and recover Oklahoma. “Additionally, a is removed, said Dean lost parts — without having strap is attached to the eye- Budde of Avon, Minnesota, to disassemble the tiles. lets,” said J.M. Ferguson of the calf has “transformed its — Sandor Nagyszalanczy Sweet Home, Oregon. nourishment source to the Pat McDonnell of green pastures surrounding Like most band saws, Homer, Alaska, described its him/her.” Q mine has two speeds: 1,445 and 2,950. I’ve always Woodworker’s Journal editor Winner! Ricky Schlatter of Cochran, been curious as to when Joanna Werch Takes compiles Georgia, wins a Hitachi 23-Ga. Pin Nailer it is most benefi cial to use each issue’s Stumpers responses (NP35A). We toss all the Stumpers letters the slow speed. Is this a — and reads every one. softwood/hardwood issue? into a hat to select a winner. I’ve always left my saw set
16 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
at the higher speed because power the blade through Winner! I’ve never had the need to rough cutting, such as For simply sending in his change it. I’m sure that there resawing, without stalling. question on band saw speeds, is a good reason for more The usefulness of a two- Edward Burns of Mount Holly, than one speed or it wouldn’t speed band saw is most North Carolina, wins a be there. Would you be so prevalent at low speed. kind as to shed some light on With proper blade selection, General International 7-piece this subject for me? one can cut plastic, foam, Deluxe 8" Dado Blade Set Edward Burns composite and nonferrous (item 55-185). Mount Holly, North Carolina materials. The best example Each issue we toss new is the ability to cut a Lexan questions into a hat and Band saws with a sheet down to size to use as draw a winner. A two-speed option give a window for a picture frame workers and artisans alike without melting or curling the ability to introduce the edges. Another example different types of material cially if your saw is equipped is to cut brass strips to use as into their workpieces. It is with cast-iron wheels. The inlay in a coffee table. suggested to use high speed theory is to use the mass of — Rod Burrow for all wood cutting, espe- the wheels to help the motor
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Woodworker’s Journal August 2015 WorldMags.net 17 ShopWorldMags.net Talk Restoring Civil War Flag Frame
Below: Veterans Council Commander Bob Page posed, the week it was found, with the fl ag and frame meant to honor Solon A. Perkins (shown above).
photo courtesy of Richard P. Howe, Jr. n January 2014, Steve Lowell Veterans Council, then Solon A. Perkins joined a Purtell and Gus Kanakis under Commander Bob Page, cavalry unit, the Independent Imade a discovery at which jumped into action to Battalion of Massachusetts, the Veterans Memorial restore the fl ag and 73" wide later becoming part of the Auditorium in Lowell, x 54" high frame, bringing it Third Massachusetts Cavalry. Massachusetts: a Civil War to Camille Breeze of Museum Perkins was commissioned fl ag and carved frame. Textile Services in Andover on February 20, 1862 and was Steve Purtell said, “We for the restoration of the fl ag killed in a skirmish on June found the fl ag leaning behind itself and to Melissa Carr of 3, 1863 in Clinton, Louisiana. a piano one day in basement Masterwork Conservation in After his death, the fl ag was storage and knew there was Arlington for the restoration sent to his mother. much more history behind of the frame. Lowell historian Richard this unique piece. I have Howe says, “We can’t know never seen anything like it.” for sure, but I believe he was This rifl e detail from the frame’s left Whose Flag? side is shown how it now looks They brought it to the The story behind this fl ag so highly regarded by his after conservation treatment. attention of the Greater began when 24-year-old men that they sent the guidon
18 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
The sword hilt is shown at left before undergoing Paint restorer Adeline Myers worked to clean and restore the inscription at the bottom rail of the restoration and, above, inner frame: “Under this fl ag at Clinton, La., June 3, 1863, Solon A. Perkins was killed.” after treatment.
restoration photos courtesy of Melissa Carr to his mother as a special other. There were three city of Lowell. I honor for her.” Mrs. Perkins phases: cleaning, stabiliza- regard it as a way kept it for many years, later tion and loss replacement. to communicate giving it to Charles Knapp, a She also had to analyze the with the past.” banker at Lowell’s Middlesex carvings. Were the carvings National Bank, who commis- of the military equipment Legacy sioned the elegant frame. replicas of actual weapons Conservator The main purpose of a or simply approximations of Melissa Carr says, “guidon” fl ag is to literally carbines, sabers, etc.? The “What struck me “guide on” the troops. Sol- carbine, for example, was from the begin- diers would know where and missing the trigger, trigger ning and all along when they were to move by guard, sight and hammer the project is the watching their fl ag. Histo- assembly. caring attached to rian and consultant Steve The Internet was a this fl ag and frame. The eagle is one of the three- Hill, of the Dupage Military valuable resource, yielding The men originally with dimensional carvings on the frame. Flag Company, said of the photographs in enough Perkins cared enough to save The carving style is similar to that piece, “Clearly this particular angles to be able to repro- this fl ag. How did his mother of John Haley Bellamy. guidon, judging by the mag- duce the missing parts and feel when she received the nifi cent job of framing, was identify it as a Joslyn .52 fl ag? What were the circum- very important to those who caliber carbine, model 1862 stances that she gave the originally carried it.” or 1863. Whoever carved it fl ag to Charles Knapp? Was He also clarifi ed that this had also carved the backs of she dying? There was a huge particular type of guidon was the attachments as well as amount of care initially, then www.woodworkersjournal.com common after 1862. “At the the front. They were in 3D, 120 years later, the Veterans MORE ON THE WEB beginning of the Civil War, even though those sections Council’s care. The veterans guidons were simple swallow- would not be seen. group came into my studio as For a video on the Greater tailed fl ags of two colors: the The quality of the frame if they were carrying a new- VIDEO Lowell Veterans Council’s upper half red, and the lower has led to speculation that it born baby. The word legacy efforts to restore the fl ag and half white. The Union guidons might be the work of master is overused, but people have frame, please visit our website were redesigned as small, nineteenth century carver kept caring about this fl ag woodworkersjournal.com and click swallowtailed versions of the John Haley Bellamy, who was and frame.” on “More on the Web” under the Stars and Stripes.” in the area at the time — but At presstime, the Greater that might never be known Lowell Veterans Council had Magazine tab. Preserving It for sure. raised $9,400 toward the When conservator Melissa Historian Richard Howe $15,000 restoration costs. Carr started the project, she says, “The guidon is a Further information can be did a thorough evaluation of tangible object that was with found in their video or at the frame, which was actually these men in Mississippi, www.lowellvets.org. two frames, one inside the many of them from my home — Helen Hannon
Woodworker’s Journal August 2015 WorldMags.net 19 Shop TalkWorldMags.net continued
Colin McGuckin John Gable
Christy Kobasa Cool Kids’ Stuff From time to time, Springfield High School instructor George Trout sends Woodworker’s Journal updates on the work his 14- to 18-year-old students have been doing in the Industrial Materials pro- gram at the Pennsylvania, school. After purchasing their own lumber, in the rough, from Delaware County Supply Company, the students put problem-solving, critical thinking and creative expression skills together into their choice of project, which must be completed within one school year. See more at ssdcougars.org/webpages/gtrout. Brooke Shea
Kayla Howard
Karlene Raines
WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
Woodworker’s Journal August 2015 WorldMags.net 21 WoodturningWorldMags.net Who Says a Spindle Has to Be Round? By Ernie Conover
Our author describes how to use fl at segments as an element of design and utility.
square section into which the rails are mortised or bolted. On wingnuts, ratchet paws and other mechanical parts; wooden forks and spoons; and tool handles, you will often fi nd two sides fl at. One side may be fl at on a chair stretcher, to serve as a footrest, or on the plug for the mouthpiece of whistles and recorder fl utes. These variations on the theme are what I call “fl at/ round” work.
Work Sharp In turning spindles that have portions left square or fl at, the importance of sharp tools cannot be overempha- sized! Spindle tools, like the roughing-out gouge, spindle gouge, skew chisel and beading and parting tools, have to be just as sharp as e tend to think of to accept a rail into which bench tools, with long bevels spindles as round, the balusters are mortised. in severe 25° to 30° angles. but it is often nec- Turned bedposts need a Tools that are less than keen www.woodworkersjournal.com W MORE ON THE WEB essary to leave fl at spots. For a video on making In some cases, a spindle VIDEO various shoulder may have four sides left square. Most table legs have transition cuts, please visit a section at the top called woodworkersjournal.com and the “pommel,” left square click on “More on the Web” to accept the aprons. Some under the Magazine tab. table and chair legs also have square sections near the bottom to accept stretchers. Most newel posts have a square section at the top to accept the railing, and These chairs in the Yale University Furniture Collection are prime exam- also a section at the bottom ples of legs with square sections near the bottom to accept stretchers.
22 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
The handles on these antique screwdrivers were made with flat spots, which tell the user the alignment of the top and provide more purchase to torque screws home. After first turning a handle with flat spots, it’s easy to Most newel posts have a square section at the top to accept the railing, make it into an oval handle (see inset) by rolling the flats against a belt or and a section at the bottom to accept a rail for the balusters. disc sander. and/or have short bevels will that is cut to uniform squares For things like screwdriver make leaving flat or square or rectangles is imperative. handles or forks and spoons, portions much more difficult For spindles with areas left using a marking gauge and by causing ragged and square, it is just a matter of dividers is the surest way to chipped edges. accurate centering on each find center on both ends. In flat/round work, precise end when mounting the layout saves time and mate- blank. The easiest way to Lathe Speed rial. It is the key to getting accomplish this is by scribing Enough, but not too much, everything right the first diagonal lines between the speed on the lathe helps time around. Jointed stock corners. This method works greatly in making the transi- equally well with slightly tions from square to round. rectangular stock. For 2" square and smaller
These ratchet pawls are on a Swedish band loom. The tall column to which the pawls are attached is square with the top section turned: it is flat/round.
The fipple plug for the mouth- piece of whistles and recorder flutes (seen above) has to have an exactly sized flat spot so the right For relatively flat boards that are going to be turned into things like salad forks, dividers and a marking gauge volume of air hits the sharp edge (seen in the tool well in the photo above) give speed and accuracy to finding the center and the layout. of the bore.
Woodworker’s Journal August 2015 WorldMags.net 23 WoodturningWorldMags.net continued
Shouldering the Burden: The Most Difficult Area
It only stands to reason that if you have a flat area on a round spin- dle, there is an area where the round changes to flat (or vice versa). This is called a transition, and there are three basic ways to form the transition — each can be modified to suit the turner’s aesthetic. A hard square shoulder transition The author turned the stretcher on this three-legged stool in two axes, is most commonly with an intentional flat spot meant to serve as a footrest. encountered in table spindles, 1,000 to 1,800 rpm also presents some pinch and chair legs. The is appropriate; however, the potentials in areas where the best tool for this is higher end of this spectrum flat parts are spinning near the skew, presented is for the experienced turner the tool-rest. The novice is with a heavy lathe. The be- with the toe down and Hard Square Shoulder ginner, using a lighter lathe, the edge absolutely is well advised to stay closer vertical. The handle must be angled such that the appropriate bevel is to the 1,000 rpm speeds. 90˚ to the work, making it kiss the shoulder throughout the cut. For 4" square and larger spindles, speeds between For a half bead 500 and 800 rpm are better, shoulder, the cut is depending on lathe and made with a spindle experience. gouge after first The Transition making a square The difficult part of leaving face with a skew. It an area square focuses on is a half bead, rolled the shoulders, where the transition occurs. This transi- mostly on air. It makes tion can take three different Half Bead Shoulder an elegant transition basic forms, as shown in and is used mostly on table legs, bedposts, new posts and balusters. the photos in the sidebar at left. (You can also watch me It is helpful to draw a pencil line a set distance from the square face When he turned six replacement make these three cuts in my balusters with tapered octagonal to give yourself a starting point. More on the Web video.) sections, the author found the The cut for a half As with learning any new turning easy. The difficult part was technique, practice makes tapering the octagon, which he did cove shoulder is done at the bench with a #97 plane. perfect, and testing these entirely with a sharp various forms is best done on well advised to stop the lathe spindle gouge. It dif- scrap lumber rather than on when moving the tool-rest or fers from a half bead your prized stock intended the banjo. And for the same for project use. reasons, it is a good idea to cut only in that it is a completely remove the tool- cove instead of a bead. Safety Consideration rest during sanding. Either is cut mostly on For some flat work, such as salad forks, it is often Ernie Conover is the author of air. The trick is to start Half Cove Shoulder easier and safer to use the The Lathe Book, Turn a Bowl with with the handle low and touch the bevel of the gouge to the work. band saw to remove excess Ernie Conover and The Frugal Slowly bring the handle up until the edge just cuts. Now, roll the bead. material. Square and flat work Woodturner.
24 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
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Woodworker’s Journal August 2015 WorldMags.net 25 TechniquesWorldMags.net Dead-on Angles in the Woodshop By Al Goldstein
Here’s an inexpensive, easy and super-accurate way to align your crosscut sled and miter gauge.
triangle to the saw kerf in the sled base and the other 90˚ side to the front fence. This is accomplished by placing a flat reference surface in the saw kerf to contact the triangle. For standard saw blades, I find aluminum bar stock 1/8" thick works well. Thinner blades will require a thinner reference surface. The reference surface must be at least 1/8" proud of the sled base to contact the plastic triangle. The second step is to use Hold the triangle so that plastic drafting triangles to one 90˚ side is always in con- set accurate angles. They tact with the aluminum bar are inexpensive and highly and slide the triangle toward accurate. the front fence. Take care that the fence does not con- Table Saw Sleds tact the aluminum bar. When Plastic drafting triangles (or those When it comes to crosscut the other 90˚ edge of the specifically made for woodworking) sled construction, the crucial triangle is in full contact with can be used to verify that a crosscut element is setting the front the fence, it will be exactly sled is cutting true 90˚ angles. fence exactly perpendicu- perpendicular to the saw lar to the saw kerf in the kerf. (See top photo, above aking accurate sled’s base. After mounting left.) With a bit of practice, angle cuts on the the unfinished sled on the you can align the front fence M table saw can be a table saw miter slot(s) and with your eyes closed. challenge. This technique is partially cutting through its The triangle can also be a great way to be sure that base, one end of the front used to verify that an existing your setups are dead-on accu- fence is attached to the sled fence is properly aligned. rate. It is easy to implement base and then rotated to be Place one 90˚ side against the and does not depend on exactly perpendicular to the aluminum bar in the saw kerf aging eyes or shaky hands. saw kerf. and then slide it toward the Al Goldstein The first step is to verify The key to this technique index fence and verify that that the table saw blade is is to use mechanical contact the other 90˚ side makes full parallel to its miter slots. of one 90˚ side of a plastic contact with the fence. The
26 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
An accurate woodworking version of the drafting triangle is available for purchase on our website: #31545 ...... $15.99 woodworkersjournal.com/store bottom photo, opposite page, shows this verifi cation, with After placing a miter bar into the right-hand miter slot and raising it up with pennies placed the triangle in contact with underneath, the author uses a drafting triangle to set the miter gauge for a perfect 90˚ cut. both the 1/8" aluminum bar and the front fence of this sled.
Miter Gauge The alignment of miter gauges is accomplished in much the same manner, making use of both miter slots: the miter gauge in one and a refer- ence surface in the other. Of course, this technique relies on the fact that the two miter slots are parallel. The most convenient ref- erence surface is a commer- cially available — or shop- made — miter bar placed in one miter slot and elevated higher than the table saw surface by placing pennies In a method similar to that for setting a 90˚ angle, the author can also set up his miter gauge underneath as spacers. to cut a perfectly accurate 45˚ angle — a common-sense solution to a tricky setup. Slide the miter gauge in the other miter slot with its the miter gauge, and it will This method has the ben- fence free to rotate. Position be dead-on perpendicular to efi t of being highly accurate the plastic triangle between the miter slots — and, hence, and easily repeatable. And, of the two miter slots with one the saw blade. (See the top course, if you have other tri- 90˚ side held against the photo, above.) angles with other angles, you elevated miter bar. Slide In a similar fashion, a 45˚ can also convert those into the miter gauge toward the miter gauge angle may be dead-on angles for creating triangle, allowing its fence to achieved accurately using great woodworking joinery! rotate until it makes full con- a 45˚ triangle with its long tact with the other 90˚ side side placed in contact with Al Goldstein is a retired medical of the triangle. Make certain the elevated miter bar. The physicist, using his experience in that the end of the elevated bottom photo, above, shows making accurate measurements miter bar does not contact a 45˚ angle being aligned on to advance his woodworking to the miter gauge fence. Lock a miter gauge. a higher level.
Woodworker’s Journal August 2015 WorldMags.net 27 WorldMags.net
MISSION PICNIC TABLE
By A.J. Hamler With a slight twist on the usual flavor of picnic table design, you can dine al fresco in style.
f Yogi Bear had spent more time would have been the typical attached why a picnic table couldn’t be just as building picnic tables instead of bench, A-frame style picnic table found sturdy and serviceable with a Mission Irobbing from them, I suspect Ranger in every park. Yawn. flavor. (Who doesn’t love Arts & Crafts?) Smith’s job would have been less stress- When I thought about the design for With its complementary horizontal and ful. Not sure what Yogi’s furniture tastes this picnic table, it occurred to me that vertical lines along with the side slats, were (he was probably more concerned most are boringly utilitarian. You rarely typical of the Mission style, you can with what was in the pic-a-nic baskets), see one in a distinct furniture style. With bring flavor to your outdoor dining in but chances are good that his table that in mind, I couldn’t see any reason more ways than one.
28 WorldMags.net August 2015 Woodworker’s Journal Cut table components to size per the Material Lists, but keep WorldMags.netin mind the variances common in cedar’s width and thickness.
Wood Considerations all four sides) measure 1 1 The first thought for any outdoor 1 ⁄2" x 3 ⁄2", but a cedar 2x4 furniture is making it to withstand the (rough on all four sides) 3 3 elements. Regular pine dimensional measures 1 ⁄4" x 3 ⁄4". The lumber is inexpensive but should be Material Lists on pages painted or stained regularly if you want 31 and 33 list the actual it to last. Treated construction lumber is sizes of the cedar used for also commonly used, although it’s very this project. heavy and sometimes oddly colored. If you’ve never worked Although more expensive, the best with cedar before, take a choices are woods that naturally resist look at the sidebar “Rough, both weather extremes and insect but Ready” for some handy damage. Almost any lumber suitable tips and advice. for decks works great, with redwood, Western red cedar and even white oak Getting Started being favorites. For the perfect balance Cut your workpieces to size per the between durability and weight, I’ve Material Lists. Keep in mind the chosen Western red cedar. actual dimensions of the cedar you Keep in mind that cedar typically get when cutting. comes with one or more sides left Rough cedar has a surface that can be rough, which can slightly alter the quite splintery, especially on the corners dimensions from what you’re used to of all straight edges. To make the stock working with. It’s important when using easier to work with — and lower your cedar dimensional lumber to carefully chances of getting splinters — chamfer measure your workpieces, and adjust or bevel the edges a bit. A small block The author chamfers the corners of his cedar component sizes accordingly. For plane does great, as seen in the photo components. It not only helps to prevent slivers, example, typical pine 2x4s (smooth on at right, but a sanding block with coarse but it looks great, too.
Rough, but Ready: Working with Cedar
Western red cedar is a delightful wood. It’s great for outdoor products, it takes screws and nails readily, and your shop smells wonderful when cutting it. (And for days afterward!) But there are a couple of odd things about it you should know. s Cedar typically comes with rough, unplaned faces; 1x dimensional cedar lumber usu- ally has one rough face, while 2x stock is rough on all four faces. This roughness adds
1 both thickness and width wherever it occurs. A dimensional pine 2x4 measures 1 ⁄2” x
1 3 3 3 ⁄2”, but a cedar 2x4 is 1 ⁄4” x 3 ⁄4”. This extra thickness may vary from board to board — or even within the same board — but count on an additional 1/8” for each rough face. Always measure your stock, and adjust workpiece size and nail/screw length to account for any variance. Cedar width and thickness is typically a bit larger than When working cedar comparable dimensional lumber. The rough cedar 2x4 with a dado cutter, 3 shown here measures 1 ⁄4” thick. watch out for flying splinters. s Cedar is splintery, really splintery, so handle it with care. Knock splinters off edges and corners with a plane or sanding block whenever possible. Take extra precautions when cutting cedar, particularly with a router or a dado cutter on the table saw, as splinters and knots — some of them surprisingly large — can fly in all directions even when using dust collection.
Woodworker’s Journal August 2015 WorldMags.net 29 Mark the notches for WorldMags.net the vertical slats on the table and bench end assemblies. A square is a must for this task.
With all the notches marked, start each with a pass over the dado cutter on your marks to define the width of the notch, and then just remove the waste in the center. Between the table and the two benches, you’ll have a total of 36 of these notches to cut, so pace yourself accordingly. Finish the preparation of the end piec- es by mitering the corners for both the top and bottom, and cutting the relief on paper also works fine. If the underside of the bottom pieces. The you’re feeling ambitious, a band saw is perfect for this, but a jigsaw small roundover bit in your or handsaw works just fine, too. router is another option. I started the construction Assembling the Ends process with the benches, Line up the top and bottom end pieces, so that’s what you’ll see in making sure to orient the corner most of the photos, but the notches toward the middle. Be aware procedure for building the that 1x dimensional cedar is typically ends of the main table and rough only on one side, so orient the the benches is nearly iden- slats with the smooth side facing inside tical: your construction can the benches and table to give a uniform go in pretty much any order. appearance on the outside. However, you might find it Apply weatherproof glue into each more efficient to cut all your notch and bridge the top and bottom mortises for the side slats pieces by dropping the slats into place. on both table and benches Drill countersunk pilot holes, then drive Cut each notch by first defining the ends, then plow out the at the same time. For this four exterior screws into each joint. waste between them. Be sure to set the cutter height to task, I’ve installed a 3/4" With regular pine dimensional lumber accommodate your stock’s actual thickness. 1 dado set in my table saw, 1 ⁄4" screws are best to avoid piercing but you could also make the the other side, but with the typically notches with a circular saw thicker cedar, you should be able to use 1 and bench chisels, as seen screws a full 1 ⁄2" in length. Be sure to in my video. measure first. Lay out the notches by Speaking of screws, you’re going to first measuring the thick- need a bunch: With 36 of these joints to ness of the 1x4 side slats secure, you’ll need 144 of them. and setting the height of The boards for the tabletop and bench the dado cutter to match. seats are secured via cleats from the (Remember, it’s probably underside. However, before attaching slightly more than the the cleats, give the inner top of each typical 3/4".) Starting in the end piece a quick sanding to ensure that center, carefully measure it’s flush across the slats. Due to the the spacing of each notch nature of cedar lumber, there may be a using a rule and square for slight variance in thickness at the end accuracy. Since some of from one slat to another. The difference your marks are pretty close probably won’t be much, if any, but you Cut the profiles of the top and bottom components of the bench and table end assemblies on the band saw as seen here, or together, it’s a good idea to want to be sure it’s flush for the cleat to with a jigsaw or handsaw. mark the waste areas. attach securely.
30 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net 5 6
2
3 4 5 1 Exploded View 4
MATERIAL LIST (Bench) 2 T x W x L 3 3 1 Bench End Bottoms (4) 1 ⁄4" x 3 ⁄4" x 16" 3 3 1 2 Bench End Tops (4) 1 ⁄4" x 3 ⁄4" x 10 ⁄2" Bench Assembly 1 1 (End View) 3 Bench Slats (8) 7/8" x 3 ⁄2" x 15 ⁄4" 3 3 3 4 Bench Stretchers (4) 1 ⁄4" x 3 ⁄4" x 52" 3 3 1 5 Bench Cleats (4) 1 ⁄4" x 1 ⁄4" x 4 ⁄2" 3 3 6 Bench Seat Boards (4) 1 ⁄4" x 5 ⁄4" x 72"
3 3 The cleats themselves are 1 ⁄4" x 1 ⁄4" 1 strips that I ripped from a 2x4. After making the cut, one side will be smooth from the saw blade, so use this side for the mating surface, and attach with glue and screws. For the thicker cedar, use 3" screws, but slightly shorter screws if using regular dimensional lumber.
Making the Frames For rigidity, the bench and table frames are joined with 2x4 stretchers under- neath the top boards, while the table gets some additional bracing. Cut the stretchers to length — the making sure that everything is flush Topping it Off bench stretchers are sized smaller to along the top. Now, drill 1/4" pilot holes Lay the top boards on your workbench 1 allow the bottoms of the benches to fit for four evenly spaced 5/16" x 4 ⁄2" lag or assembly table, orienting the boards between the ends of the table for com- bolts through the bench and table ends, so their presentation sides are face fortable seating. Clamp the stretchers then drive the bolts in with washers as down, and then upend and center the to the ends of the mounting cleats, in the photo at left on the top of page 32. frames on your boards. The benches are
Set the vertical slats securely into their notches Before attaching the mounting cleats, sand Center the mounting cleats on the inside tops of with weatherproof glue and exterior-grade the cleat location flush, if needed, to ensure a the table and bench end assemblies, and secure screws for outdoor durability. secure attachment. with weatherproof glue and exterior screws.
Woodworker’s Journal August 2015 WorldMags.net 31 WorldMags.net www.woodworkersjournal.com MORE ON THE WEB For a video on cutting VIDEO notches with a circular saw and bench chisels, please visit woodworkersjournal.com and click on “More on the Web” under the Magazine tab.
of both the tabletop and bench seat boards, as well. Another benefi t of sand- ing the top of the table is that removing the roughness makes it easier to clean Drill a pair of 1/4” pilot holes for each stretcher Upend the bench and table frames onto the 2x6 after your picnic. through the bench and table ends, then drive top boards, and drive 3” screws through the 1 home 4 ⁄2”-long lag bolts for a solid frame. cleats to hold them in place.
pretty easy to handle, but you may want screws, countersink a diagonal pilot hole to enlist a helper for the table frame. through each of the end pieces. Drive in 1 With the frame in place, drive a pair a 3 ⁄2" screw at each point to secure the of exterior screws through the cleat edges of the outer boards. and up into the undersides of each Construction of the benches is board. Note in the photo at right (above) complete, but the table needs one last that I’m using some small pieces of component. Because of their low height, 1/4"-thick scrap to act as spacers to get the stretchers in the benches are suffi - the boards uniformly spaced along their cient to make them solid, but the table length. As before, 3" screws work well requires a bit more bracing. Accomplish 1 with thicker 2x cedar, but adjust screw this with a pair of 36 ⁄2" braces, mitered length accordingly for regular dimen- 45 degrees on each end. Locate the sional 2x lumber. lower ends at the center of the table The cleats don’t extend past the bottoms, allowing the tops to rest nat- stretchers, so, for the last attachment urally where they fall on the underside of the table’s center board. Attach the Finish up the table assembly with a pair of diagonal braces. Attach these underneath the lower ends to the table sides with a table with 3” exterior-grade screws. pair of countersunk 3" screws driven from the inside. Check the table ends for square, then anchor the upper ends on the underside of the table the same way, as seen in the top photo at right.
Finishing Up By now you’ve certainly realized that ce- dar can be splinter-prone. (You probably got several while building; I know I did.) To keep from getting small splinters while dining at your new table, give the tabletop and the tops of the benches a good sanding to remove the roughness. A fi rst pass with 100-grit paper knocks down the roughness quickly, while a followup with 150-grit gives a nice, For the outer edges of the last boards, counter- To avoid getting splinters during use and to help sink diagonal pilot holes through the bench and smooth surface. While you’re at it, it’s make the table and bench tops easier to clean, table end pieces, and secure with screws. a good idea to lightly sand the edges sand the rough surface smooth.
32 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
12
8 11
13 10 13 9 11 10
7 Exploded View 8
MATERIAL LIST (Table) T x W x L 3 3 7 Table End Bottoms (2) 1 ⁄4" x 5 ⁄4" x 35" 9 3 3 8 Table End Tops (2) 1 ⁄4" x 3 ⁄4" x 29" 1 1 9 Table Slats (10) 7/8" x 3 ⁄2" x 27 ⁄4" 3 3 1 10 Table Stretchers (2) 1 ⁄4" x 3 ⁄4" x 56 ⁄2" 3 3 1 11 Table Cleats (2) 1 ⁄4" x 1 ⁄4" x 21 ⁄2" 7 3 3 12 Table Top Boards (5) 1 ⁄4" x 5 ⁄4" x 72" 3 3 1 13 Table Braces (2) 1 ⁄4" x 3 ⁄4" x 36 ⁄2"
Test fit your Top Boards (pieces 12) so they fit flush to Table Assembly the edge of the Table End Tops (pieces 8). (End View) Because cedar is naturally resistant to both weather and insects, no finish is really necessary. The table will last for many years as the color of the wood darkens to a silver-gray patina. If you’d like, however, an application of a sealer can extend the natural color a bit longer, and make it even easier to clean after picnicking. And if you like a darker appearance, you’re in luck: almost any sealer for outdoor wood darkens it. Any product for decks or other outside wood furniture, such as Thompson’s® Water- Seal®, does a good job. The unique styling of this Mission- influenced picnic table will make your
backyard the envy of the neighborhood. Ranger Smith would certainly approve.
A.J. Hamler is the former editor of Woodshop
News and the author of Civil War Woodworking, Volumes I and II.
Woodworker’s Journal August 2015 WorldMags.net 33 Easy-to-BuildWorldMags.net Benches By Simon Watts
These easy-to-make benches are attractive and practical. Our author suggests you size them to fi t your needs.
made the fi rst of these benches any size, but I think the one at the top I used local white ash (I’d just bought a from a large piece of driftwood that of the opposite page looks about right. butt log from our local sawyer), but any Ihad washed up on the beach of my With a 44"-long top, 11" wide, it seats reasonably hard wood such as maple, island home in Nova Scotia. The sand, two comfortably. The overhang is only oak, walnut, cherry or even fi r would do 1 of course, ruined the saw, and the gritty 8 ⁄2" long, so there is little chance of equally well. wood was impossible to plane. I still fl ipping it by sitting on the end. have that bench, it still smells of the sea, The only “tricky” joint is a sliding slip Bench and I keep it as a reminder that drift- joint between the apron and the two For children, you could very well wood is better left on the beach. supports. You can make this on the ta- reduce the overall size of this bench You can adapt the basic structure of ble saw or cut it by hand — if you trust 80%, 75% or even 50%. It’s best not to this bench to make one of practically yourself to hand saw to a line accurately. reduce the thickness of the supports by
34 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
The technical drawings and the Material List on page 37 represent the “adult-sized” bench in the photo above.
makes excellent pattern stock (photo at right). Use the pattern to mark out the two end supports, but leave these as rectan- gular blanks until after sawing the slip joints. That way, you can use the table saw fence to make accurate, identical cuts. Clamp a stop Use the gridded drawing block to it, as shown below, so you don’t on page 37 to guide you as you oversaw. Complete the cut by chiseling lay out the hourglass-shaped leg template. out the waste or using a coping saw. Cut the template and fair the curve, then use it to transfer the leg shape to your Finish cutting out the supports by band working stock. sawing just clear of the curved lines, then clean up the sawn edges with an inside spokeshave that has a convex sole. Finish with a 2" drum sander mount- ed either in a drill press or a handheld the same amount, or it will begin to look electric drill. frail. The bench in the photo above is Cut out the reduced 50% from the adult version, so stretcher, then notch it is only 22" long and 8" high. Instead it on the table saw to of reducing the width of the top in pro- fi t the slots already portion, I left it a little wider for stability cut in the verticals. 1 1 — 7 ⁄2" instead of 5 ⁄2". These must be a The fi rst step is to make an accurate, close, sliding fi t: too full-size, half-pattern of the hour- snug and you are The notched joinery on the legs and upper stretcher can be formed using glass-shaped vertical supports. I use the likely to split the a table saw (as shown above), or cut by hand. The lower stretcher is held 1/8" plywood known as doorskin, which ends of the stretch- in place with dowels.
Woodworker’s Journal August 2015 WorldMags.net 35 Test the sliding slip joint and adjust WorldMags.netit until the pieces slide together with a smooth friction fit. Once those pieces fit together, use a jig to bore holes for the dowels, chamfer the edges, and do your final sanding.
Then you’re ready to get out your clamps and glue the pieces together, as shown in the photo at right.
er; too loose, and you’ll end up with a toe out slightly — not more than 1/8" the blunted look of a soft, rounded edge. bench that wobbles (see photo above). or 3/16". This helps compensate for the Chamfer the inside curves — both A Japanese Shinto saw file, which has optical illusion of parallel lines appear- sides, inside and out — and be consis- both a coarse and a medium side, is the ing to converge when seen from above. tent: make a uniform 1/8" or 3/32" flat. best tool for fitting end grain joints such The top of this bench is best attached The child’s bench is made in exactly as these. to the base with 1/2" dowels. To facili- the same way, but you may need to use Now cut the stretcher to length and, tate dismantling for moving or storage, smaller dowel pins. with the aid of a doweling jig, drill two glue the dowels into the base only, not holes in each end for 3/8" dowels (see the top. Finishing photos below). Use doweling points to Instead of rounding the sharp edges If you plan on using the bench indoors, transfer the hole centers to the two sup- with a wood file or sandpaper, I think it you can finish with Watco® oil: two appli- ports. Glue the stretcher in place and looks better to plane a neat 45˚ chamfer. cations, with a light sanding in between, adjust the clamps so the two supports This makes a crisper impression than using #600-grit wet/dry abrasive paper and oil as the lubricant. Be sure to wipe off the surplus within 30 minutes, or you’ll be contending with a nasty, yellow, wrinkled finish. Remember to treat the oily rags as incendiary bombs — douse them in water or put them outside on a safe surface to dry. If the bench is going to live outdoors, consider using a wood that weathers well: teak would be my first choice, The author used a mahogany second and any of the cedars drilling jig to ac- third. If you use a wood such as red curately locate the oak, which is prone to check severely in dowel holes in the ® ends of the lower rain and sun, treat it with Epifanes , a stretcher and the penetrating outdoor sealer widely used legs. Then he used on boats. Of course, the lowest mainte- dowel points to nance finish of all is a couple of coats of transfer the dowel good paint — you might even acquire locations to the inside face of the the almost forgotten skills of painting legs and the lower and graining it to look like teak! face of the seat. Simon Watts is a boatbuilder, teacher and writer. He lives in San Francisco during the winter months and on an island home in Nova Scotia during summers.
36 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net1
5 2 Upper Stretcher (Front View)
5 Exploded View 5 Seat (Top View)
3 4
4
Leg Pattern (Each square = 1”)
MATERIAL LIST T x W x L 1 Seat (1) 1" x 11" x 44" 2 Upper Stretcher (1) 1" x 4" x 33" 1 3 Lower Stretcher (1) 1" x 2 ⁄2" x 25" 1 4 Legs (2) 1" x 10 ⁄2" x 17" 1 5 Dowels (8) 3/8" Dia. x 1 ⁄2"
Assembled Bench (Front View)
Use the red lines as a guide for laying out the angles at the bottom of the legs.
Woodworker’s Journal August 2015 WorldMags.net 37 Greene & Greene- InspiredWorldMags.net Nightstand
By Chris Marshall Here’s a tailored complement to our Greene & Greene Bed project featured in the February 2015 issue.
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A clamp-on routing jig, with a slot sized to match the fixed shelf and bottom panel plywood thickness, ensures accurately made dadoes in the legs. The author used a piloted hinge-mortising bit (see inset) to mill these 1/4"-deep, 1"-long cuts. A back stop on the jig limited the cutting length.
hen I delivered my client Jo and the fixed shelf and bottom panel for your plywood thickness (I used a Ellen her Greene & Greene slip into shallow dadoes that intersect 23/32"-diameter undersized plywood W bed (February 2015 issue), those grooves. So, start with those pairs bit) and mill the back panel grooves she soon asked about other pieces that of short dadoes. I routed mine using 1/4" deep. Set your router table fence so could fill out her bedroom suite. So, this a simple shop-made, slotted jig (see these grooves are located 1/4" in from custom nightstand is the second install- photos, above). Mill these 1/4" deep. Be the outside faces of the back legs. Stop 3 ment. I used quartersawn mahogany to sure to mirror the dado orientations on them 1 ⁄4" up from the leg bottoms. capitalize on its handsome ribbon-stripe the front and back leg pairs. Then, head With the leg joinery now tackled, you grain pattern, which also gave me the to the router table to rout the 1/4"-deep can chisel all the groove and mortise chance to try my hand at vacuum- side panel grooves with a 1/2" bit. Stop ends square. Then, make a short 1 bagging the side panels’ special quarter- them 2 ⁄4" up from the leg bottoms. template of the legs’ cloudlift shape sawn veneer. In all, it’s an ambitious and While you’re still at the router table, from scrap, and use it both to trace leg fun project that’s well worth your effort. and with the same bit, you can cut 1/4"- profiles for initial rough-cutting at the deep mortises on the inside edges of the band saw, then to template-rout the Making the Legs front legs for the top, middle and bottom cloudlifts to final form. Drill some shelf The Material List on page 41 lists quan- rails. The 3/4"-long top rail mortise is pin holes in the legs now, too — those tities for one nightstand, and that’s how open at the tops of the legs, while the will be much tougher to do later. 1 I’ll describe the building process here. middle rail’s 1"- and bottom rail’s 1 ⁄2"- Double the part list if you build two. long mortises are closed on the ends, as Building the Side Assemblies Round up some 6/4 stock for four legs, usual. Position them all 3/8" back from The side rails are your next order of and mill them to final-sized blanks, then the front faces of the legs. business. Cut four blanks to size, and study the Drawings carefully. You’ll see This project’s back panel is 3/4" thick, head back to the router table to mill that the side panels fit into long grooves, so switch to a router bit appropriate their side-panel grooves. Notice that,
Mill the front legs’ rail mortises at the router ta- The cloudlift leg profiles are best made against The side panels require two different groove ble with a 1/2" straight bit. Mark the bit location a template secured with double-sided tape. Use depths in the side rail blanks (shown): 1/2” deep on the table to guide these “drop” style cuts. a piloted flush-trim bit to follow the template. for the bottom rails; 3/4" deep for the top rails.
Woodworker’s Journal August 2015 WorldMags.net 39 WorldMags.net
Roll wood glue onto the side panel veneer and its substrate, then assemble the lamination and tack near one edge to keep the panels aligned.
Form two side assemblies by gluing the legs, side rails and panels together. Glue the side panels into their grooves — their veneer/plywood construction makes wood movement a nonissue here.
plate so you can mill these shapes onto of clamps to glue and press the veneer the bottoms of the rail edges, too. and substrates together, but when I laid Given the striking pattern of the door up these two panels, I tried a 26" x 28" roarockit.com A heavy-duty vacuum bag, one-way valve and and top’s ribbon-stripe figure, it would Thin Air Press™ Kit from hand pump made easy work of pressing the side have been a shame for the side panels (see center photo, left) instead. Vacuum panel veneers flat against their substrates. to be made from mediocre-veneered pressure alone does the clamping work plywood stock. Why not make these beautifully. Once my two custom- while these centered grooves are all side panels showstoppers, too?! So, I veneered panels were out of the bag, I 1/2" wide, the bottom side rail grooves resawed and glued up some 3/8"-thick trimmed them to final size. happen on top and are 1/2" deep, while panels of quartersawn mahogany for Final-sand and glue up the legs, rails the top side rail grooves are situated on the side panel veneer, then planed those and side panels into two side assem- their bottom edges at 3/4" deep; label down to 1/4" thick. I cut backer panels blies. Set them aside for now. your rails and work carefully. Once the for these veneers from 1/4" mahogany grooves are cut, raise 1/4" tenons on plywood, which fattened the overall side Assembling the Carcass the rail ends at the router table or table panel thickness to 1/2". You could use a There’s plenty left to do while the side saw. Then, make a double cloudlift tem- conventional veneer press and armloads assemblies dry. Continue on by follow-
Chop 1/2" x 1/2" mortises 1/4" deep into the top The back panel and rails form a third major subassembly, while the top and middle front rails and full and middle front rails for the full slats. The half slats make a fourth subassembly. Gluing these parts together now reduces the total number of wet slats have no tenons that would need mortises. glue joints in the final big carcass glue-up — and that makes the whole assembly process easier.
40 WorldMags.net August 2015 Woodworker’s Journal 19 Nightstand Cloudlift Layout Hard-to-Find Hardware (Front View) WorldMags.net1 Ball Tip Hinges 2’’ x 1 ⁄2’’ (1 pr.) 18 #56930 ...... $25.99 pr. 20 21 19 1/4” Shelf Pin Supports (1 pk.) #22765 ...... $4.99 pk. 11 Brass Ball Catch 1 ⁄16" x 5/16" (1) 8 #28613 ...... $6.99 ea. 5 To purchase these and other 9 products online, 21 visit www.woodworkersjournal.com/ 2 hardware 10 Or, call 800-610-0883 (code WJ1577). 24 12 13
Full Slat Mortise 1 6 Location 4 3 (Top View) 14 1
16 15 8 23 11 25 22 17 7 1 16 Exploded View 2 Front Leg Rear Leg 15 22 Mortise Groove Locations Locations MATERIAL LIST (Inside View) (Inside View)
T x W x L 3 3 1 1 Legs (4) 1 ⁄8" x 2 ⁄8" x 24 ⁄8" Front and Back 3 Leg Groove 2 Side Rails (4) 1" x 2" x 13 ⁄4" 3 5 Locations 3 Side Panel Veneer (2) 1/4" x 13 ⁄4" x 19 ⁄8" (Inside View) 3 5 4 Side Panel Substrates (2) 1/4" x 13 ⁄4" x 19 ⁄8" Note: Mill the same 5 Front Rail, Top (1) 1" x 1" x 16" grooves in all four legs for 1 6 Front Rail, Middle (1) 1" x 1 ⁄2" x 16" the side panels. Then, the front legs receive mortises 7 Front Rail, Bottom (1) 1" x 2" x 16" for the front rails, while the 8 Back Rails (2) 1" x 2" x 16" back legs require a wider 7 groove for the back panel. 9 Back Panel (1) 3/4" x 16" x 18 ⁄8" 3 1 10 Fixed Shelf (1) 3/4" x 13 ⁄4" x 17 ⁄2" 3 Plug Locations 11 Bottom (1) 3/4" x 13 ⁄4" x 17"
(Top View) 12 Full Slats (2) 3/4" x 3/4" x 6" 1 13 Half Slats (2) 3/8" x 3/4" x 5 ⁄2" 1 14 Adjustable Shelf (1) 3/4" x 13" x 17 ⁄4" 1 3 4 4 15 Door Rails (2) 3/4" x 1 ⁄ " x 13 ⁄ " 1 3 16 Door Stiles (2) 3/4" x 1 ⁄4" x 12 ⁄8" 11 5 16 8 17 Door Panel (1) 1/2" x 13 ⁄ " x 10 ⁄ " 1 3 18 Top (1) 3/4" x 16 ⁄4" x 21 ⁄4" 1 19 Breadboard Ends (2) 1" x 2" x 16 ⁄2" 20 Pegs (6) 1/4" x 1/4" x 15/16" 1 21 Cleats (2) 3/4" x 3/4" x 13 ⁄4" 22 Hinges (2) 2" Butt 1 23 Door Pull (1) 7/16" x 1" x 4 ⁄2" 24 Catch (1) Brass, ball-type
25 Shelf Pins (4) 1/4" Antique brass
Woodworker’s Journal August 2015 WorldMags.net WorldMags.net
Pocket screws driven from the bottom panel and fixed shelf A large raised-panel cutter with a cove shape reduced the door’s 1/2"-thick panel to fit into the front bottom and center rails strengthen these joints the frame grooves while also adding a decorative profile around its face. Take several and ensure that the visible seams are tight from above. rounds of deepening passes for safety and to help minimize burn marks.
ing the Drawings to make top, middle with 180-grit paper, bore pocket screw one front leg, depending on which way and bottom front rails with 1/2"-thick, holes into the bottom faces of the fixed you want the door to swing. You can 1/4"-long tenons on their ends to match shelf and bottom panels along their front rout or chisel these shallow mortises; I the front leg mortises. The bottom front edges: they’ll connect to the rails, later. made a simple clamp-on routing jig for rail receives a cloudlifted bottom profile. Create blanks for the two 3/4" x 3/4" this job and routed the hinge mortises The middle and top rails will also need a x 6" full slats next, then form 1/4"-long with my piloted hinge-mortising bit. pair of 1/2" x 1/2"-square mortises, cut tenons on their ends to fit the top and You’re finally ready to glue and clamp 1/4" deep, along their inside edges to middle front rail mortises. the carcass together, with all the parts house the full slats, yet to come. It’s time to dry-assemble the rails, you’ve made so far. While you’re at it, 1 Make two back rails now, as well. slats, back, fixed shelf and bottom on drive 1 ⁄4" pocket screws through the These receive centered, 1/4"-deep the side assemblies to check the fit of all fixed shelf and bottom panel to draw grooves along their inside edges to the carcass parts. If everything regis- these panels tight to the front rails. house the plywood back panel. Cut the ters well, glue the back panel into the Glue up a panel of solid wood for the grooves carefully: their width needs back rails to create a third subassembly. adjustable shelf next, and trim it to final to match your plywood thickness, and Form a fourth glue-up of the top and size. Check its fit inside the carcass the walls of the grooves are just 1/8" middle front rails and slats. before you sand, stain and apply finish. thick. When the grooves are done, mill Bring the four subassemblies together 1/4"-long tenons on the back rails; their again in another dry fit. Rip and cross- Making the Door thickness must match the groove width cut two half slats to fit against the legs The door’s construction is stone-simple on the inside faces of the back legs. between the top and middle front rails. cabinetry work: stub tenons on the ends Then template-rout a cloudlift profile Glue them to the legs to wrap up the last of the rails fit into the grooves in the along the bottom edge of the bottom of the carcass parts you’ll need. At this stiles that also house the center panel. back rail to match the front bottom rail. point, stain and topcoat these big com- Start by milling stock for the door rails You’re ready to cut plywood blanks to ponents while you can still lay them flat. and stiles. At your router table or table size for the back panel, fixed shelf and When the finish cures, cut the two saw, plow 1/4"-wide, 3/8"-deep contin- carcass bottom. After a light sanding hinge mortises on the inside edge of uous grooves along the inside edges of
Continous tenons on the ends of the top panel fit into matching mortises in Square pins driven into the breadboard ends and through the panel tenons the breadboard ends. Aim for a snug friction fit of these joints. fasten the parts together. The outer pegs fit into slotted tenon holes.
42 WorldMags.net August 2015 Woodworker’s Journal www.woodworkersjournal.com MORE ON THE WEB WorldMags.netA simple shop-made jig For a video showing the side makes quick, precise VIDEO panel vacuum-bagging process, work of cutting the hinge-leaf mortises. please visit woodworkersjournal.com and Its opening matches click on “More on the Web” under the the exact hinge-leaf proportions. Magazine tab.
all four door frame parts for the center short of each end and panel. Then machine 3/8"-long stub centering them on the tenons on the ends of the rails using a part thicknesses. The dado blade in your table saw or at the panel received matching router table. Lastly, glue up a 1/2"-thick tenons at the table saw, panel of solid wood for the door panel, followed by a quick trip to and trim it to fi nal width and length. the band saw to trim their I used a cove-shaped, raised-panel end shoulders 5/8" shy cutter in the router table to add curved of the panel edges. After profi les around the front face of the rounding their corners, I door panel, and to reduce its edges to installed the breadboard slip into the frame grooves. (It’s the ends with a bead of glue same bit I chose for the bed’s two center along just the middle panels.) Shape the panel in several 6" of tenon length, and rounds of passes, raising the bit about three 1/4" x 1/4"-square Rout the cloudlifted door pull’s fi nger slot fi rst, “drop-cut” style, at your router table. Then cut out the shaped profi le and round over 1/16" each time, to minimize burning. pegs driven into mortised the edges before rip-cutting the pull free at your band saw. Sand the door frame parts and panel, holes through the tenons. then go ahead and stain and fi nish The center peg fi ts tight in the tenon, After hanging the door on its hinges, I the door panel now. When that cures, but the two outer pegs are nested into made a cloudlifted pull for the door and glue up the door frame with the panel 1/2"-long slotted holes in the tenons mounted it with a pair of countersunk 1 installed: this enables you to trim the that run cross-grain. This enables the #8 x 1 ⁄8" wood screws. A ball catch “raw” frame to fi t its opening, scrape or panel to expand and contract while still came last to hold the door closed. Rest sand the corner joints fl at, if needed, staying centered on breadboard ends. I the adjustable shelf inside on its shelf and cut the door hinge mortises. Once gently sanded the top ends of the pins, and your graceful nightstand is these tasks are done, stain and fi nish pegs to “pillow” them before ready for bedside sentry duty. Jo the door frame to complete it. tapping them home. Their Ellen’s are next to hers now. tops protrude 1/16" above Forming the Top the faces of the breadboard Chris Marshall is senior editor of Breadboard tops with thicker ends are ends — a nice tactile detail. Woodworker’s Journal. quite common on Greene & Greene furniture, and the ends of this top pro- Finishing Up vide 1/8" “step-ups” that add attractive Once you’ve shadow lines where they meet the thin- applied fi nish to ner center panel. Glue up the top’s 3/4" your top, install center panel, and cut a pair of 1"-thick it with a pair of blanks for the two end pieces. cleats screwed Since my panel is made from quar- to the top tersawn mahogany, its cross-grain insides of the wood movement will be minimal. So, side rails. I I resolved that its tenons could be used four attach- continuous, rather than divided up ment screws for — an otherwise typical necessity for the top: the front wide breadboard panels made of more two are driven reactive, fl atsawn stock. into round pilot I started by routing 3/8"-wide, holes in the cleats 1 1 ⁄4"-deep continuous mortises in the and the back two breadboard ends, stopping them 1/2" fi t in slotted holes.
Woodworker’s Journal August 2015 WorldMags.net 43 Today’sWorldMags.net Shop Today’s Wood Screw Technology By Sandor Nagyszalanczy
From heads to drives, points to threads, platings to coatings, our author gives you a thorough education in the options available in the world of modern screws.
technological developments in construction and wood products manufacturing have spawned an extensive range of new screws in recent decades. There are so many choices, it’ll positively make your head spin! I’ve written this article to serve as a short primer on wood screws. Close exam- ination of the various parts of a screw — the material it’s made from, the design of its head, drive style, point and threads, the platings and coatings that protect it from corrosion — will give you a better understanding of all the design and technology that goes into the manufac- ture of every single screw. Hopefully, this exploration will better empower you the next time you need to choose the right screws for the proj- ect at hand. crews are undoubtedly or adhesives (and unlike the most versatile fas- glued joints, screws are Screw Types & Materials Steners used in wood- removable, so you can take Among the many materials working. Wood screws are apart whatever you’ve built). wood screws are made from handy for quickly building Screws are also good for — brass, bronze, aluminum, jigs and clamping forms, reinforcing parts assembled etc. — steel screws are the joining cabinet and furniture with traditional joinery — for most useful for woodworking parts, mounting hardware example, pinning tenons in and interior DIY projects. and trim, and much more. their mortises. They’re strong, affordable Screws form strong connec- Choosing the right wood and readily available in a vast tions between parts made screw used to be simple: range of sizes. But old-fash- from solid wood, plywood pick a zinc or brass screw ioned tapered steel wood and other sheet goods with- with the right size and length screws can be a pain to use. out the need for cut joinery for the job at hand. But Many woodworkers switched
44 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
Old-fashioned tapered steel wood screws are made from relatively weak Originally developed for the building and wood products industries, production steel, so their slot recesses tend to deform and cam out. The shanks of screws, as well as construction and deck screws, are made from carbon steel drywall screws often snap when driven with ambitious force. heat treated to provide a good balance of hardness and toughness. to inexpensive drywall use, hardened steel screws trim head screws and bugle screws when they became aren’t especially weather head screws have heads readily available a few de- resistant, and they are best designed to automatically cades ago. Made from harder reserved for indoor projects. sink fl ush in all but the www.woodworkersjournal.com MORE ON THE WEB steel that can penetrate Deck screws are basically hardest materials (e.g., wallboard and studs, drywall production screws that have rosewood, ebony). Bugle For a video on advances screws drive in quickly and been plated and/or coated head screws drive in quickly VIDEO and advantages of modern without the need for pre- to increase their corrosion and have good holding power screw technology, please visit drilled pilot holes. However, resistance. They’re great in most materials. Trim head woodworkersjournal.com and click they’re relatively brittle and for outdoor projects, like screws are a good choice on “More on the Web” under the will snap when subjected to playhouses or decks. For when you only need modest high drive forces or stress, even greater resistance to holding power and don’t want Magazine tab. making them a poor choice rust and corrosion, the two the head of the fastener to for projects requiring strong best screw materials are show too prominently. When construction. silicon bronze and stainless driven into pre-drilled holes, Fortunately, a different steel. Weaker than regular they are a better choice than kind of screw has largely steel screws, chromium fi nish nails for setting door replaced traditional tapered alloy stainless steel screws jambs or mounting trim and and drywall screws. “Pro- come in two popular grades: moldings: trim head screws duction screws” have points Grade 305 stainless is good are less likely to split thin or and threads sharp and strong for applications where coated delicate wood parts. enough to penetrate the deck screws don’t have suf- Traditional fl at and oval hardest woods and man- fi cient corrosion resistance, head screws lend a nice clean The best screw materials for re- made materials — even some while grade 316 (sometimes look to projects but require a sistance to rust and corrosion are metals. Their heads and referred to as marine-grade conical recess for their heads silicon bronze and stainless steel. shanks are durable enough stainless) are best for proj- drilled with a countersink. In (Brass screws, shown second to withstand high torque ects that are exposed to salt contrast, most fl at head pro- from left, also work outdoors, but delivered during driving with air or in areas where severe duction screws are self-coun- will tarnish and aren’t as strong as silicon bronze.) a power drill or impact driver, corrosion is likely to occur. and can withstand the pun- ishing stresses that screw- Head Type joined furniture or cabinet Regardless of a screw’s mate- parts may be subjected to. rial, size or length, the shape Hardened-steel screws with of its head has a signifi cant brands including GRK Fas- impact in how well it works teners™, SPAX®, PowerPro™ in any particular application. and Saber Drive™ are often Head designs can be divided sold as “construction screws” into two groups: those that or “multipurpose screws.” sink fl ush with the work Unless they’re specifi cally surface and those that stand plated/coated for exterior proud of it. In the fi rst group,
Woodworker’s Journal August 2015 WorldMags.net 45 Today’sWorldMags.net Shop continued This offers a reasonable Drive Type amount of hold in hard- Unless they are building woods, but in softer species, period-style furniture, few the smaller heads tend to woodworkers still use tradi- crush the wood at the sur- tional tapered wood screws face. When the joined pieces with slotted heads, as they are stressed, the screw’s tend to slip off the screw- effective hold is reduced. driver or driver bit and “cam Screws with larger heads out” easily, especially when offer more contact area with driven with a cordless drill or the work surface and a great- impact driver. er resistance to penetration However, many wood- and pull-through. workers still do use Phillips Truss head screws (aka head screws, which came “mushroom head” screws) into production in the 1930s have a head much like a and became popular be- metalworker’s pan head cause their cross-slot recess screw, only the overall head automatically centers on is flatter and larger in diame- the tip of the screwdriver. ter. These are a great choice They do have a tendency to for mounting hardware such cam out, especially when Screws with heads that sink flush tersinking: they create their as drawer slides, where used with power drivers. (or near flush) with the work sur- own recess that allows the you want good contact with But a little-known fact is that face are, left to right: bugle head, trim head, flat head and oval head. head to sit flush (see photo, the hardware but need the Henry Phillips designed his above). Quickscrews’ unique screw head to not stick up screws to do this on purpose! “Funnel Head” screws, de- too far. Washer head screws To help speed up automo- signed for use with veneered look like regular round head bile production, the cam plywoods and coated sheet screws with small wash- out helped prevent workers materials like melamine, ers set under their heads. from over-tightening Phillips have double serrations, with The added surface area on head screws with early very fine teeth that cut into the underside of the head power drivers, which lacked delicate surfaces without prevents them from sinking torque-limiting adjustability. tearing them up. too deeply, especially when Today’s woodworkers reduce Among the screw head driven with power drivers. the tendency to cam out by types that sit proud of the Appropriately named “super carefully setting the clutch- work surface are traditional washer head” screws have es on their power drivers. round head, pan head and even larger diameter washer POZIDRIV®, a modern vari- The underside of the heads of (left cheese head (aka fillister heads. They excel wherever ant of the Phillips drive, was to right) the SPAX MULTI Head, Quickscrews’ Funnel Head and head) screws. Each has a two parts are joined but must developed to retain centering GRK’s R4 has nibs or serrations relatively small head with a remain adjustable, such as while reducing caming out. It that slice into the surface to create flat bottom that bears against attaching a drawer front to a is a good choice for larger/ their own recess. the surface of the workpiece. drawer box. Wafer head (and longer screws that require flanged head) screws have lots of torque when driven large, flat coin-like heads. into hard materials. Most wafer heads, including Although there are dozens FastCap®’s “PowerHead” of modern drive styles found screws, are not only large, on screw fasteners (hex, but are also very thin, giving polydrive, spanner head, them great retaining power etc.), two have become and a low profile. particularly popular in recent Screw heads that stand proud of decades: Robertson square ® the surface include: (front) round and TORX star drives. The head; (left to right, middle row) square “Robertson” drive pan, fillister, truss; and (back was developed in Canada in row) washer, super washer, the early 1900s, but Peter flange and wafer.
46 WorldMags.net August 2015 Woodworker’s Journal Wood screw drive and driver styles include (left to right): Outlaw, Posisquare (combo), WorldMags.netTORX (star), Robertson (square), Phillips and traditional slotted (which are most prone to caming out: the driver slips out of the screw head, distorting the slot).
L. Roberston’s reluctance electronics. The majority of Both Robertson and TORX to license his screws to TORX-drive woodworking drives have two qualities that industrial users (like Henry fasteners are deck screws, make them a great choice Ford) kept it from becoming but the drive style is gaining for woodworkers who use popular in the United States. popularity for general-pur- power drivers: stick fit and Only in recent decades have pose construction and cab- resistance to cam out. Stick companies like online fasten- inet screws, too. Robertson fit is the ability of the driver er retailer McFeely’s started drivers come in six sizes, but bit and drive recess to form a marketing them to wood- #1 (green), #2 (red) and #3 temporary connection. Once workers. TORX drive screws, (black) drivers are used for you set a square or star drive with a distinctive six-point wood screws from size #3 to screw on the tip of a drive star pattern, came out in the size #14. TORX drivers come bit, you can drive it without late ’60s and quickly became in two dozen different sizes having to hold onto the a popular production fastener (T1 to T100), but T15, T20 screw. This not only frees up used on everything from cars and T25 drivers cover most your extra hand, but it allows to motorcycles to consumer common wood screws. you to drive screws into all
Hiding or Covering up Screw Heads Screws can provide a nice decorative detail on a project: imagine a If you’d rather enhance the presence of fasteners instead of entire- row of shiny brass screws punctuating the edge of a walnut cabinet ly hiding them, decorative domed or button plugs or screw covers are or a mahogany the way to go. You can see a variety in the photo below. Decorative jewelry box. But wood plugs glue into counterbored holes and can lend a nice detail when you don’t while keeping screws hidden. Craftsman-style hole plugs (available want screw heads to from www.rockler.com) are sized to fit into 3/8" holes, but they have show, hiding them square heads with pyramid-shaped tops that resemble the chiseled or covering them ends of small through tenons traditionally used in Mission style are both options. furniture. For modern style woodwork, try metal hole caps, available The simplest way in various metallic finishes. I really like the look of black anodized to make flat head aluminum plugs on a blond wood surface. Inexpensive and quick to in- screws disappear stall, FastCap plastic screw cap covers have small tabs that snap into is to set them into counterbored holes topped with flush-trimmed the head recesses of square drive, flat head screws. White caps are wood plugs that match the workpiece. You can drill pilot holes and perfect for camouflaging screws in melamine cabinets, and you can counterbores in separate steps, or use a special bit that performs both remove the caps if you need to disassemble the piece in the future. tasks at once. Starborn Industries’ Pro Plug® system is a very nice kit designed to make the entire process quick and easy. It includes a spe- cial countersink/counterbore bit, a glue bottle tip (as shown in photo above) designed for applying glue into the holes, screws and tapered wood plugs (available in a dozen different wood species).
Woodworker’s Journal August 2015 WorldMags.net 47 Today’sWorldMags.net Shop continued
Screw Points & Threads fingers, so be careful when A wood screw’s point and handling them! A self-tapping threads have a mighty big flute just behind the point task to accomplish. They cuts a hole through the sur- must pierce the surface of face while channeling debris wood, then pull the screw in, up the shank of the screw. without causing the wood to This helps to pull the screw split or splinter. Once driven, in while reducing outward the threads have to hold the pressure that can cause splits screw firmly in the wood so and bulges. In lieu of a fluted that it doesn’t pull out or al- auger point, some SPAX low the parts it joins to sepa- construction screws feature a rate, even if they’re stressed. 4CUT™ point with a squarish The one-handed operation that’s kinds of hard-to-reach places. An old-school tapered wood end that pushes aside wood possible with square or star drives allows you to drive screws into TORX and Robertson drives screw needs a pilot hole fibers as the screw is driven places that are a stretched-arm’s both feature deep recesses when driven into all but the instead of cleaving them. length away. into which the head of the softest materials: their points driver fits snugly. The recess are relatively dull and their The Threads has near-vertical sidewalls, shallow threads don’t offer Once the point has pulled which means very little need much holding power. a wood screw down into for down pressure on the In contrast, production, the material, it’s up to the driver to keep it engaged. construction and deck threads to continue driving This not only significantly screws have very sharp it the rest of the way in. reduces the chance of cam points and threads that are Conventional wisdom has out, but also reduces driver larger in diameter than the always been that screws wear and damage. shank of the screw itself. with fine threads are best for Two other screw drive This enables them to pene- hardwoods — oak, cherry, styles are worth mentioning: trate most materials without maple, birch, etc. — while Pozisquare® and Outlaw the need for a pilot hole, coarse-threaded screws drive drive. Pozisquare (aka combo which adds up to a huge and hold better in softwoods, drive) is a hybrid that com- time savings when installing plywood and composite bines a #2 Phillips and a #2 them! There’s no area of sheet goods (particleboard, square drive in a single screw wood screw development MDF, etc.). However, newer head recess. You can use that’s seen more innovation thread designs have changed either a Phillips or Robertson in recent years than thread the rules and made many bit to drive them, but a special and point design. Let’s look production/construction Pozisquare (combo) bit gives at both features in depth: screws suitable for use in a you better stick fit and cam wide range of materials and out resistance. The new kid The Point applications. on the block, Outlaw Fasten- A good screw point bites into Some threads, including ers, raised more than $100k non-pilot-drilled surfaces rap- the QuickCutter™, lead via Kickstarter and created idly, pulling the screw down spiral and cross-cut threads, their own line of unique deck quickly and creating an entry are designed to reduce the screws. A three-tiered hex- hole for the screw’s shank torque needed to drive the agonal head recess offers 18 and threads. The majority of screw. In some specialized points of contact for a super production/construction/ screw threads, a section of stick fit with virtually no cam deck screws rely on a Type knurled shoulder thread, out. In lieu of using their 17 auger point to get this job just above the regular thread A traditional tapered screw’s (left) threads and shank are the same special driver, Outlaw screws done. This needle-sharp point of the screw, enlarges the diameter; a production screw’s can be driven with a regular penetrates even the hard- hole slightly as the screw is threads are larger. hex driver. est materials — and your driven, allowing the screw
48 WorldMags.net August 2015 Woodworker’s Journal The sharp Type 17 auger point found on WorldMags.netmost production screws enables the screw to quickly penetrate most woods without the need for a pre-drilled pilot hole.
and RSS™ screws; Outlaw or already-plated screws). deck screws): A knurled Screws are plated and/or shoulder just above the regu- coated for three reasons. lar thread of the screw. 1. Prevent Corrosion Reverse thread sec- Regular steel screws rust tion (Starborn Cap-Tor xd quickly when exposed to deck screws): A section of moisture. Plating not only reversed thread just under helps keep the screw itself the head of the deck screw from rusting, but prevents helps prevent dimpling and rust that forms on the screw mushrooming (raised area from staining the wood around the screw head). A around it. The most common similar reverse thread on plating on wood screws is SPAX stainless steel wood bright zinc, largely a decora- deck screws helps prevent tive finish that provides only the screw from backing out a small amount of corrosion shank to turn more easily as the lumber dries out. resistance. Zinc screws while helping to increase Euro screw thread can develop a dull white the clamping force between Melamine, particleboard, corrosion (“white rust”) joined parts. Here are some and MDF are notorious for unless protected with a clear of the newer thread designs their poor holding power coating or a colored chro- and their intended advan- when joined with regular mate, such as yellow zinc. tages: screws. In the 1970s, Ger- Bright golden yellow zinc QuickCutter thread man hardware manufacturer screws have more corrosion (Quickscrews production Hafele introduced Confirmat resistance than bright zinc, screws): Deep threads and oversized screws specifically so this coating is common on an extra-long flute above the for building ready-to- construction screws. Black point. assemble Euro-style furni- oxide (black phosphorous) Lead spiral thread ture and cabinets. Confirmat plating prevents steel screws (Quickscrews Funnel head (or similar Firmit) fasteners from rust staining wood, but screws): A spiral thread just act like threaded steel dow- offers little protection against above the tip pulls the screw els, forming a strong, stiff serious corrosion. into the wood quickly. butt joint between parts. Galvanizing processes, Cross-cut thread (Power W-Cut™ thread (GRK RSS e.g., electroplating and hot Pro outdoor wood screws): and Cabinet screws) and dipping, have traditionally A dual thread design with a Serrated thread (Saber- provided screws with the best standard outer thread and drive and SPAX screws): A protection against rust, but an inner thread that helps saw-like serrated edge cut reduce friction at the root of into the threads designed to Modern screw thread designs (left the screw. slice through wood like a cir- to right): QuickCutter, lead spiral, Hi-Lo thread (Rockler cular saw blade. (See photo, cross-cut, Hi-Lo, CEE, reverse and Hi-lo screws; Kreg® Hi-lo top of page 50.) Euro screw. pocket-hole screws): A dual- thread screw with a coarser, Plating and Coatings sharper outer thread and a In the final step of manu- finer inner thread. Creates facturing, most steel wood a multipurpose screw that screws receive some kind offers good holding power of plating (a metallurgical and less strip-out in all woods process done to bare metal and sheet goods. screws) or coating (applied CEE™ thread (GRK R4™ to either bare metal screws
Woodworker’s Journal August 2015 WorldMags.net 49 Today’sWorldMags.net Shop continued
resistance and come in four screws’ look works well with colors (gray, green, red and contemporary style projects. tan) to match treated lumber. To help hide fasteners Climatek™: A GRK coating without counterboring and consisting of six layers of plugging, some screws come zinc and polymers; approved with heads coated with epoxy for use with highly corrosive paint. White or sand (tan) pressure-treated lumber. heads match the color of HCR™: SPAX “high corro- white or almond melamine sion resistance” screws have sheet material. Starborn’s a dual barrier coating system HEADCOTE® stainless-steel with an electrically applied screws have heads colored to substrate and a proprietary match commonly used deck- A serrated thread on a screw organic topcoat designed to ing lumber as well as PVC reduces required driving torque modern deck and construc- extend the longevity of the and composite materials. and splitting, and it allows the tion screws are also available screw even when used with 3. Reduce Friction screw to develop and maintain with high-tech coatings or treated lumber. The better the surface high withdrawal strength. plating/coating combinations Weather Maxx™ Bronze lubricity of a screw, the eas- for outdoor environments: Ceramic Coat: Power Pro ier it is to drive and the less Blue-Kote™ (Kreg pock- brand screws with multiple power it takes to drive it in. et-hole screws): Blue screws layers of zinc and polymer- Slippery screws are also less with three anti-corrosion based coatings. Recommend- likely to cam out, break or layers; weather-resistant. ed for use with ACQ, CA and get stuck when they encoun- NoCoRode PLUS Pro- CCA treated lumber, plus ter knots or dense grain. Master wood screws (sold cedar and redwood where You can lubricate screws by McFeely’s): almost 20 they won’t stain the wood. yourself by rubbing them times more corrosion-resis- 2. Enhance Appearance with candle or beeswax tant than standard yellow Other color choices are before driving them, but it’s zinc plating; work well with available besides silvery much easier to buy screws most outdoor woods. bright zinc. Brass-plated already treated with a Epoxy Coated: Starborn’s screws mimic solid brass lubricating coating. Beren- Deckfast® Epoxy Coated screws but are stronger and son coats both their plain screws provide corrosion cost less. Black oxide plated and zinc-plated screws with a thin wax coating, which reduces friction and leaves no residue. Square-X Drive screws and Highpoint screws have specially formulated dry coatings that make them easier to drive while preventing surface corro- sion (they’re recommended for interior applications only). For outdoor projects, FastenMaster TrussLOK® construction screws have an anti-friction topcoat applied over their corrosion-resistant Metallic platings and synthetic coatings provide epoxy coating. wood screws with varying degrees of protection against Sandor Nagyszalanczy is a corrosion and staining the contributing editor to wood they’re driven into. Woodworker’s Journal.
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LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. LIMIT 5 - Good at our stores or HarborFreight.com or by calling 800-423-2567. Cannot be used with other discount Non-transferable. Original coupon must be presented. Valid through 10/22/15. Limit one coupon per customer per day. or coupon or prior purchases after 30 days from original purchase with original receipt. Offer good while supplies last. Non-transferable. Original coupon must be presented. Valid through 10/22/15. Limit one coupon per customer per day. Non-transferable. Original coupon must be presented. Valid through 10/22/15. Limit one coupon per customer per day. • 100% Satisfaction Guaranteed • No Hassle Return Policy • 550 Stores Nationwide • Over 25 Million Satisfi ed Customers • LifetimeWorldMags.net Warranty On All Hand Tools • HarborFreight.com 800-423-2567 ToolWorldMags.net Preview Leigh RTJ400 Router Table Dovetail Jig by Chris Marshall Leigh’s newest dovetailing jig solution produces up to a dozen dovetail and box joint sizes with quick setups, foolproof repeatability and minimal fuss.
The RTJ400 provides an inverted confi guration compared with many typical dovetail jigs: you steer the jig and workpiece over the bit rather than balancing a handheld router on the jig.
ome dovetail jigs are written manual, I milled the Leigh’s refi nements to the
www.woodworkersjournal.com frustrating to learn: six different glue-ready joints template principle include a MORE ON THE WEB Shours upon hours of you see on the facing page. number of standout features For a quick video overview test cuts, multiple adjustment That included jig change- that set it apart from other VIDEO of the Leigh RTJ400 Router variables to resolve and the overs, just two or three test router table-specifi c jigs of this sort, and those are key Table Dovetail Jig, please visit sinking feeling that you’ll cuts per joint and no previous have to repeat the laborious experience. Impressive. to its simple and repeatable woodworkersjournal.com and click setup process for every new The RTJ400’s basic design performance. on “More on the Web” under the project. Ugh. isn’t altogether revolution- For one, Leigh has incorpo- Magazine tab. Thank goodness Leigh is ary: it consists of an aircraft rated its patented cam style making router dovetailing grade aluminum template “eBush” guide bushings into substantially easier with the fashioned to mill pin slots this system. Sized for typical 3 new RTJ400 Jig I tried re- on one side and tails on the 1 ⁄16" router plate openings, cently. In about an afternoon, other. That styling has been they have numeric index and thanks to the clearly around for decades. But, marks that allow you to adjust
52 WorldMags.net August 2015 Woodworker’s Journal a loose- or tight-fittingWorldMags.net joint by simply twisting the base col- lar left or right. Its elliptical bushing widens or narrows in .001" increments to help dial in a perfect cutting width for the template slots. Even better, in most cases you can make the first side of a joint, then refine the fit of just the mating piece by changing the eBush setting, rather than re-routing both parts. Leigh has designed the ver- tical fence portion to unclamp from the template. Then, pin locators under the end han- dles fit into various holes and slots on the template. Those Numeric indexing on Leigh’s “e10” eBush makes adjust- A pin under each handle enables the vertical fence ing the fit of a joint’s mating parts as easy as twisting the are well-marked and automat- to be repositioned in template holes to well-marked, elliptical bushing left or right and re-routing one piece. automatic settings for various joint sizes and styles. ically position the fence for different joint setups. No trial action happens in front of and error process here. This the jig, so you do need to pin-and-slot index enables the lean forward to monitor your jig to cut five sizes of through progress. Luckily, the stance dovetails in two pitches, three doesn’t feel awkward. sizes of half-blind dovetails The RTJ400 comes with and four box/finger joints in four carbide bits, “e10” guide workpieces up to 16" wide. bushing, other necessary Be aware that the pin and supplies and a tutorial DVD tail pattern produced by the for around $359. An accesso- RTJ400 is regular — there’s ry kit ($175) provides nine no variable spacing option. more bits, an “e7” bushing Another handy feature and a 1/2" to 8 mm collet is the side stops: when you reducer, in order to cut the center a board over the jig’s full range of dovetail and template to cut the first half box joint sizes. of a joint and tighten the side stop against it, that sets the Chris Marshall is Woodworker’s Stepped side stops position pin and tail boards accurately — very helpful Journal’s senior editor. for half-blind dovetails where both joint parts are milled simultaneously. mating board’s position, too. It’s particularly useful for half-blind dovetails — proba- bly the trickiest router-made joint to dial in well, because the pins and tails are cut in one operation. Sturdy cam-action clamps lock workpieces securely, and a handle on each end of the fence makes the jig stable to move around your router table top. While a “business- end-down” jig like this has gravity working in your favor — no tippy router to steer and balance — the cutting You can form both dovetails and box joints with this new RTJ400 Jig from Leigh. WorldMags.net 53 SmallWorldMags.net Shop Journal Translucent-Screen Shutters By Larry Okrend These interior shutters let in light but don’t compro- mise privacy. They’re a straightforward millwork project with parts that can be produced in quantity and adjusted to fit various sizes of window casings.
indows are meant to deliver light into your home’s interior, Wbut they can also provide an unwanted view into your home. That’s why almost everyone wants and needs some form of window covering in their home (unless you live in the middle of nowhere or don’t care about privacy). Al- though window treatments vary greatly in style and function, I think the best kind are the ones that ensure privacy while still letting in light — and ones that you can make in your shop. This interior shutter project has a lot going for it, including excellent light transmission that doesn’t compromise privacy and simple modular construc- tion. You can use almost any wood for these shutters, but typically it’s best to either match or complement your exist- ing woodwork. I used vertical-grain pine that has a naturally attractive ribbon pattern and a medium ivory color. It’s also easy to work and relatively inexpen- sive. A translucent shoji-style fiberglass material works well for the screen, but there are a number of other materials you can use (see final caption, page 62) such as rice paper and plastic-coated paper. Keep in mind that this is a mill- work project, so it doesn’t require quite
54 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
the high level of workmanship you might devote to a furniture project. The thickness and width of the parts work for most window sizes, so you only need to adjust the length. For very large windows, you might want to scale up the size of the parts or add more lattice strips to the grid. The variations on A Festool Domino is a quick way to make strong mortise-and- When assembling the frames, spread glue evenly this project are almost infinite, tenon joints for the shutter frames. Dowels, plate-joining inside the mortises and on the tenons. A silicone so you’ll likely want to add your biscuits and pocket-hole screws are good alternative brush works well here and can be easily cleaned own special touches. joining methods. because glue won’t adhere to it.
Measure, Mill, Join Frames a plate joiner is just as fast and makes You’ll need to start by measuring your acceptably strong joints. You can also window casing and checking it for attain very good results with dowels or square. Measure the exact opening, pocket-hole screws. then subtract about a quarter inch from Once you’ve glued and clamped the the sides and top/bottom to allow a little frames, you can sand them with 150-grit room for swing clearance and space for paper. Be sure to ease the edges enough the hinges. (Most carpentry isn’t as pre- so they won’t splinter, but don’t round cise as your woodworking, so you may them too much. If your shutters are a need to make some adjustments after matching pair like this project, mark you assemble the frames.) For large the top edges with arrows that point to windows or ganged windows, consider the front and inside stile edges. This making bifold or multiple shutters to will serve to keep the shutters paired span the area. and correctly oriented. Check the bare Because this project lends itself to frames in the window casing to be sure mass production, it’s best to mill the they fit with some room to spare and frame parts for all the windows you make necessary adjustments. If the fit is intend to cover before doing any joinery, too tight, trim the inside stile edges that to ensure consistency. (Read on to learn form the closure between the shutters. more about making the lattice strips.) A Now is as good a time as any to cut jointer and planer are almost a necessity the translucent screen material. This to achieve straight, square and uniform should be done before fastening any stock. You might want to sand the parts lattice parts inside the frame because lightly before you start the joinery. the bare frame serves as a pattern. The There’s a lot of flexibility when it easiest way is to lay the frame on top of comes to joinery. I used a Festool the screen material and trace around Clamp the frames with even pressure applied Domino to make floating mortise- the inside with a pencil; then use a metal on the center of the joints. Check for square by and-tenon joints. This tool can quickly straightedge and a utility knife to cut measuring diagonally across the frame from make strong, precise joints. However, the material. corner to corner with a tape measure.
Woodworker’s Journal August 2015 WorldMags.net 55 Small WorldMags.netShop Journal continued
Photo at left: To use a band saw to make the 3/8”-square lattice strips, rip pieces slightly less than 1/2” wide from larger stock. (The piece shown is roughly 2 x 2”.) Photo at right: Next, with the band saw fence at the same setting, make the second cut. Use a planer to clean up the strips and mill them to exactly 3/8” square. You could also make the strips on a table saw, but there would be more waste, due to the wider saw blade kerf.
Make Lattice Strips and Router Jig strips to remove about 1/32" and then or self-adhesive abrasive strips to the If there’s a fussy part of this project, a third and fourth pass on the opposite carriage bottom to prevent stock from it’s making the lattice. The 3/8" x 3/8" sides for the final 3/8" dimension. The shifting. To ensure that the jig makes lattice strips must be uniform, and the strips might not be perfectly square, accurate cuts, all the parts should be half-lap joints that form the grid must be but the deviation with pieces this small square, the carriage bolt holes should precisely made. There are a number of will be insignificant — try making a align perfectly in the base and router ways to make the strips, but I’ve found few practice pieces first. (If your planer carriage, and the fence on the base that using a band saw and a planer is won’t adjust down to 3/8", you can should be perpendicular to the slot in efficient and it keeps waste and dust to make a sub-base out of particleboard or the router carriage. The fence should a minimum. MDF to fit under the planer’s cutter- be the last piece you install because it’s First, rip wide pieces from 3" or 4" head.) Make more pieces than you’ll dependent on how the base and router stock roughly 7/16" thick. Next, rip need because you’ll unavoidably have carriage are aligned. Finally, run the 7/16"-square strips from these pieces. some ruined pieces. router into the fence with a 3/8" bit to Now you need to remove the saw marks You can use a table saw to make the create an alignment mark. and mill the strips to exactly 3/8" half-lap joints, but I think a router jig is square. Run the strips through your more accurate and makes cleaner joints. Cut Half-lap Joints planer making four total passes: the The router jig (see Drawing, page 58) is There are several tips that can increase first two on perpendicular sides of the simple and easy to make with MDF or your success in cutting the half-lap particleboard and a joints. You should cut all the strips few bits of hardware. to the exact length before you cut There are two basic the joints. Use the shutter frames to parts: the base and determine the fit, and you might want the router carriage. to make dedicated sets of strips for each The base has a thin frame in case there are slight dimen- hardboard fence sional differences. attached to it to Once you cut the strips, use masking align to workpieces tape to gang them together with the so they’re perpen- ends perfectly flush. Mark the joint dicular to the router locations in pencil, and then scribe the carriage. The router joint lines with a utility knife. This will carriage is adjust- help prevent any chipping or tearout able for different from the router. When you place the The lap-joint jig (see Drawing, page 58) stock thickness with ganged strips in the jig, be sure they’re allows you to gang-cut the lattice dadoes. the carriage bolts abutting the fence, that the joint lines Tape the strips together and then mark the and should be made correspond with the router alignment joint positions. Place the strips against to fit your router (or mark on the fence and that the carriage the hardboard fence and align the marked at least the guide bolts are securely tightened. Also, place joint with the cutout in the fence from a previous router pass. (The router carriage has been removed for photo clarity. Also, note the self-adhesive rails positioned for an extra piece of lattice to the outside of abrasive strips on the bottom of the router carriage that prevent the your router’s base). workpieces from slipping. Use sandpaper to make your own.) Adhere sandpaper Continues on page 58 ...
56 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
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Woodworker’s Journal August 2015 WorldMags.net 57 Small Shop Journal continued WorldMags.net
MATERIAL LIST (Jig) T x W x L 3 1 Base (1) 3/4" x 20 ⁄4" x 22" 1 2 Fence (1) 1/4" x 2 ⁄2" x 22" 1 3 Frame Sides (2) 3/4" x 2" x 19 ⁄2" 1 4 Frame Ends (2) 3/4" x 2" x 10 ⁄2" 5 Frame Bases (2) 3/4" x 5" x 18" 6 Guide Rails (2) 3/4" x 2" x 18" 1 7 Self-adhesive Abrasive (2) 2 ⁄2" x 19" 8 Carriage Bolts (4) 4" x 1/4"-20 9 Washers (4) 3/8" 10 Wingnuts (4) 1/4"-20
The inward facing lattice grid (the side that faces into the room) is permanently attached to the frame. Establish the grid’s 1/8” setback with a combination square and pencil.
Use a plunge router and 3/8” straight bit to cut the dadoes in the lattice strips. Set the fences in the router carriage to work with your router’s base. In this case, twisting the router between the fences Use a pin nailer to attach the vertical perimeter produced the least amount of friction and the best stability and accuracy. strips fi rst, then the horizontal strips. There’s no need to glue the strips, and it’s unnecessary the ganged pieces to help balance the provides visual balance when the shut- to fill the pin-nail holes because they’re height of the router carriage. ters are open. almost invisible. Rout the joints with a 3/8" straight bit Begin by marking the 1/8" setback and make the cuts in two passes while guidelines for the front lattice inset keeping the router pressed against the with a combination square and pencil. guide rails. Work carefully and don’t Before you start, make a dry run to force the router through the cut. Use ensure the grid strips fi t properly in dust collection if your router has it. It the frame. The strips don’t need to be will enable you to see the start and stop glued; pin nails provide all the needed of the cut much more easily. fastening. The holes made by the nails are so small, they’re almost invisible Assemble the Lattice and don’t need to be fi lled. Attach the Continue the grid assembly with the inside ver- You’ll assemble the front lattice in the vertical lattice strips to the stiles, then tical strips and, fi nally, the two inside horizontal strips. Glue these joints together and use small frame and the rear lattice as a stand- the horizontal ones to the rails. Now clamps if needed. Assemble the rear grids as alone unit. The rear lattice acts as a stand-alone units; just be sure they fi t into the retainer for the screen material and Continues on page 60 ... frames easily.
58 WorldMags.net August 2015 Woodworker’s Journal Longer Battery Life “My friends all hate their SoundBetter and WorldMags.net NEW cell phones… I love mine!” FREE No Car Contract Here’s why. Charger Say good-bye to everything you hate about cell phones. Say hello to Jitterbug.
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® 47625 IMPORTANT CONSUMER INFORMATION: Jitterbug is owned by GreatCall, Inc. Your invoices will come from GreatCall. All rate plans and services require the purchase of a Jitterbug phone and a one-time set up fee of $35. Coverage and service is not available everywhere. Other charges and restrictions may apply. Screen images simulated. There are no additional fees to call Jitterbug’s 24-hour U.S. Based Customer Service. However, for calls to an Operator in which a service is completed, minutes will be deducted from your monthly balance equal to the length of the call and any call connected by the Operator, plus an additional 5 minutes. Monthly minutes carry over and are available for 60 days. If you exceed the minute balance on your account, you will be billed at 35¢ for each minute used over the balance. Monthly rate plans do not include government taxes or assessment surcharges. Prices and fees subject to change. We will refund the full price of the GreatCall phone and the activation fee (or set-up fee) if it is returned within 30 days of purchase in like-new condition. We will also refund your first monthly service charge if you have less than 30 minutes of usage. If you have more than 30 minutes of usage, a per minute charge of 35 cents will be deducted from your refund for each minute over 30 minutes. You will be charged a $10 restocking fee. The shipping charges are not refundable. Jitterbug and GreatCall are registered trademarks of GreatCall, Inc. Samsung is a registered trademark of Samsung Electronics Co., Ltd. ©2015 SamsungWorldMags.net Telecommunications America, LLC. ©2015 GreatCall, Inc. ©2015 firstSTREET for Boomers and Beyond, Inc. www.woodworkersjournal.com Small Shop Journal continued MORE ON THE WEB For a video on using the jig WorldMags.netVIDEO to form the lattices, please visit woodworkersjournal.com and each side. Three or more hinges click on “More on the Web” under can cause binding and complicate installation. It’s important that the the Magazine tab. screw holes are perfectly centered to keep the hinges aligned. I used 6 a self-centering Insty-Drive bit for 1 this purpose. Remove the hinges 4 before fi nishing. 4 Shutter Sceen (Front View) The rear grid serves as a retainer for the trans- lucent screen material and needs to be fastened to the front grid with brass screws. Bore pilot 4 holes and countersinks for the screws in the 9 four intersections inside the grid.
3 7 5
3 5 5
Next, install the brass screws in each hole to set the threads. You might want to use steel screws of the same size because they’re less likely to break. 4 you can add the inside vertical strips with a little glue in the joints followed 9 by the horizontal strips. The rear lattice goes together the same way with glue in all the joints, 2 but it’s not permanently attached to 6 the frame. You just need to check that MATERIAL LIST* it fi ts fl ush over the front grid and isn’t T x W x L 7 too large (or small) for the frame. To 1 Top Rails (2) 1" x 2" x 9 ⁄8" Exploded View 1 7 fasten the front and rear grids together, 2 Bottom Rails (2) 1" x 2 ⁄2" x 9 ⁄8" 3 1 you need to bore screw holes and 3 Stiles (4) 1" x 1 ⁄4" x 43 ⁄4" countersinks for #4 x 5/8" brass screws 7 4 Horizontal Lattice Strips (16) 3/8" x 3/8" x 9 ⁄8" through the rear grid into the four 3 5 Vertical Lattice Strips (16) 3/8" x 3/8" x 38 ⁄4" inside grid intersections. Install the 6 Domino Tenons** (8) 8 x 50 mm screws to cut the threads before you 7 3 7 Translucent Screens (2) 9 ⁄8" x 38 ⁄4" fi nish and assemble the shutters. With the grids completed, now is a 8 Brass Screws (8) #4 x 5/8" good time to set the hinge positions. 9 Shutter Hinges (2 pr.) 3" Non-Mortise Butt Hinges The shutter hinges have removable *The length of all pieces is dependent on the window frame size. **Dominos can be substituted with plate-joining biscuits or 3/8"-dia. dowels. pins so they work on the left or right side. Unless your shutters are very large or heavy, stick with two hinges on Continues on page 62 ...
60 WorldMags.net August 2015 Woodworker’s Journal Introducing the PanelMASTER IV RAISED PANEL DOOR MACHINE
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color of the wood was appealing the opposing shutter and can align the without alteration. For a smooth pair. If the shutters are a little twisted finish, sand lightly with 320-grit in the frame, you can try moving one of The screen hinges don’t require mortising and they have paper between coats to remove the hinges slightly out to compensate. removable pins, so they can be mounted on either the left dust nibs. And if the gap where the shutters meet or right side. Use a self-centering bit to ensure that the screw holes are perfectly centered. Remove the hinges Once the finish has cured, isn’t even, use a shim behind the hinge before applying finish. install the screen material. The leaf. When the shutters seem reason- fiberglass shoji that I used is stiff ably well aligned, install the rest of the Finish, Assemble, Install Shutters enough so that no glue, tape or staples screws. I installed a magnetic touch Sand the assemblies with 150-grit were needed to retain it in the frame. latch to retain the shutters. It elimi- paper and be sure to ease all sharp But you might need to fasten thin paper nates the need for knobs to open and edges. There’s no need to sand too screen to the back of the front grid if close the shutters to maintain a clean much or with a finer grit paper — the it doesn’t stay put. Install the rear grid appearance. finish will hide many imperfections. over the screen and install the brass If you’re like me, once you’ve built a Thoroughly clean off all the dust be- screws; then reinstall the hinges. few of these shutters you’ll want to make fore applying finish. Installing the shutters isn’t difficult, more sets for other rooms in your home. Because the shutters are next to but there a few steps you can take to re- They’ll help keep your rooms light and windows, they’re exposed to more duce any possible frustration. Use a thin airy even on the most dreary days. light and temperature variations than spacer between the window casing and other woodwork in your home. A film the shutter to eliminate the possibility of Larry Okrend is the former editor of HANDY finish will help reduce seasonal wood binding. The hinges also have a slotted magazine. movement and protect the wood from hole to allow for wear and tear. I brushed on two coats vertical adjustment, of a clear waterborne interior finish and so use only this hole opted not to stain because the natural until you’ve installed
The author bought Synskin fiberglass shoji material from tapplastics.com; you can also find paper, vinyl or fiberglass options at Before finishing, check the fit of the screen material and trim if necessary. decorativefilm.com or There’s no need to glue or staple the material to the grid: the rear grid and Water-star Chinese rice screws will retain it securely. paper at amazon.com.
62 WorldMags.net August 2015 Woodworker’s Journal Chicago Doctor Invents Affordable Hearing Aid OutperformsWorldMags.net Many Higher Priced Hearing Aids Reported by J. Page • Designed By A Board-Certified Ear, Nose, and Throat (ENT) Doctor CHICAGO: A local board-certified • Doctor-Recommended, Audiologist-Tested Ear, Nose, andThroat (ENT) physician, • Top rated hearing aid online— Dr. S. Cherukuri, has just shaken up the thousands of satisfied customers hearing aid industry with the invention of • FDA-Registered a medical-grade, affordable hearing aid.
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he Bandy Clamp Contact Information edge clamp from Affi nity Tool Works T Rockler allows 866-588-0395 quick, one-handed clamping General International of edges, including ornate or 888-949-1161 decorative designs or oddly Kreg Tool Company shaped profi les. “Squeeze 800-447-8638 and push the clamp onto OLFA any piece that fi ts inside the 800-999-3436 jaws, and Bandy Clamp will hold it,” said Steve Krohmer, Rockler 800-279-4441 vice president of product marketing. Each Bandy Clamp features a built-in fl exible rubber band made of tear-resistant rubber, with three extra-strength splines molded into it. The rubber band stretches to conform to the shape of an item. Anti-slip clamp pads on pivoting jaws accommodate different angles with full pad contact. The by American GIs. Among the Kreg’s Precision Router Bandy Clamp opens to 2" OLFA knives are the 25mm Table System combines three 5 and has a jaw depth of 1 ⁄8". Extra Heavy Duty Utility elements: the Precision Bandy Clamps (item 54258) Knives, which offer both Router Table Fence (item are priced at $19.99 a pair. non-slip and cushion grip PRS1015), the Precision handle options, ratchet-lock Router Table Top (PRS1025), The OLFA® line of utility or auto-lock mechanisms, and and the Multi-Purpose Shop knives is manufactured by blade options that include a Stand (item KRS1035) into a family-owned Japanese 25mm saw blade manufac- one system (item PRS1045), company — inspired, in the tured from Japanese carbon sold for $499.99. (The compo- aftermath of World War II, to tool steel with a 59˚ edge an- nents are also available for create snap-off knife blades gle. Seven-segment snap-off individual purchase.) after seeing how pieces of blades are also available. All The self-squaring Fence chocolate broke off of Her- the OLFA knife handles fea- features a T-square style shey’s® bars distributed ture tool-free blade design, ensuring that the replacement. fence remains parallel to the Suggested miter/T-slot. Independent pricing for the sliding fence faces allow it to 25mm Extra be adjusted, or used as a joint- Heavy Duty Utility er. A measuring scale adjusts Knives, depending on to bit sizes, while a micro-ad- handle and locking style, just wheel adds to accuracy. OLFA 25mm ranges from $16.99 to $19.99, The 24" x 32" Table Top Extra Heavy Duty Utility Knife with the HSWB 25mm Saw has an Easy-Slide™ lami- Blade (model #1105914) nate low-friction surface, priced at $14.99. heavy-duty insert plates that
64 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
Kreg Precision Router Table System can be swapped out, and to create a circular saw four Precision Insert Plate guide for precise, consistent Levelers. Three Level-Loc straight-line cuts, without 3 reducing rings, with 1"-, 1 ⁄16"- wander or twist, which 5 and 2 ⁄8"-diameter openings, prevents binding or stalling. twist in and out of the plate to The BORA Saw Plate works adjust for different bit sizes. with any right- or left-handed The Shop Stand is con- circular saw and connects to structed from heavy-gauge the saw at three points for steel, with legs that can added stability. An adjustable be adjusted to any custom channel is designed to work height between 29" and 35". with any straightedge guide 1 Leg levers reduce wobble up to 3 ⁄2" wide. The BORA and adjust to uneven fl oors. Saw Plate will rip material up to 50" long (longer with an BORA Saw Plate The BORA Saw Plate and Rip optional Extension Kit). The Guide Handle from Affi nity Saw Plate is priced at $29 and Tool Works work together the Rip Guide Handle at $20. Continues on page 66 ...
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Woodworker’s Journal August 2015 WorldMags.net 65 What’sWorldMags.net In Store continued
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Woodworker’s Journal August 2015 WorldMags.net 67 WoodworkingWorldMags.net Tools & Supplies Index August 2015
For product information in the blink of an eye, visit www.woodworkersjournal.com and click on “Woodworker’s Marketplace” under the Tools & Supplies tab.
ADVERTISER Page No. Web Address ADVERTISER Page No. Web Address
1-800-BunkBed 9 www.1800bunkbed.com/wj Howard Products, Inc. 17 www.howardproducts.com
3M 7, 9 www.3M.com Jantz Supply 7 www.knifemaking.com
Abrasive Resource 17 www.abrasiveresource.com JDS Company 25 www.jdstools.com
American Fabric Filter Co. 65 www.americanfabricfilter.com Jitterbug 59 www.jitterbugdirect.com
Armor Crafts 9 www.armorplans.com Lignomat 57 www.lignomat.com
Badger Hardwoods of WI, Ltd. 9 www.badgerwood.com www.moistureproblems.info
Briwax 15 www.briwax.com MDHearingAid 7, 63 www.mdhearingaid.com
CMT USA Inc. 67 www.cmtusa.com Next Wave Automation 13 www.nextwaveautomation.com
DR Burn Cage 11 www.burncage.com Osborne Wood Products, Inc. 3, 9, 21 www.woodencomponents.com
DR Trimmer/Mower 65 www.drtrimmers.com Preval 21 www.preval.com
Epilog Laser 3, 67 www.epiloglaser.com/wwj Rockler Woodworking
Fisher Forge LLC 67 www.fisherforge.com and Hardware 57, 75 www.rockler.com
Gorilla Glue 11 www.gorillatough.com SENCO 5 www.senco.com
Granberg International 7 www.granberg.com Titebond 2 www.titebond.com
Grex Power Tools 57 www.grextools.com Triton Precision Power Tools 21 www.tritontools.com
Grizzly Industrial, Inc. 3 www.grizzly.com Varathane 76 www.staining123.com
Harbor Freight Tools 51 www.harborfreight.com West Penn Hardwoods 9 www.westpennhardwoods.com
Hawk Woodworking Tools 61 hawkwoodworkingtools.com Woodworkers Source 9 www.101woods.com
68 WorldMags.net August 2015 Woodworker’s Journal NEW!WorldMags.netpresents The Way To Woodwork: Mastering the Table Saw
Learn to safely and confi dently operate the most important tool in your workshop with the latest installment in The Way To Woodwork series: Mastering the Table Saw. Our experts teach everything, from the basics of ripping and crosscutting, working up to more advanced techniques. You’ll also discover how jigs add versatility, safety and accuracy to your table saw. Expert or rookie, this DVD has something for every woodworker. Our experts put these techniques to work building a classic Arts & Crafts Nightstand made entirely on the table saw — free plan included! FREE White Oak Nightstand plan!
Order Yours The Way to Woodwork: Mastering the Table Saw TODAY! 57292 ...... $29.99
CALL 800-610-0883 (mention code WJ1541) Order online at www.woodworkersjournal.com/wj1541 Sponsors include ... WorldMags.net FinishingWorldMags.net Thoughts
Water-based coatings are becoming more popular, and Water-based there are good reasons why. Coatings Manufacturers have kept By Michael Dresdner what was good but fi xed a host of old problems.
to apply them. and, in some cases, even We’ll also look improved resistance to abra- in on some of the sion. There’s also a wider newer offerings in range of materials available, the fi eld. with new items that make the whole fi nishing expe- What’s Different rience more pleasant and The original water- varied. (More on that later based coatings were in this article.) diffi cult to brush and spray, and did not What’s the Same fl ow out well. They From the beginning, water- were very sensitive based had some advantages, to even the slightest and they’re still there. surface contamination, Water-based coatings are and demanded near ideal nonfl ammable, low odor, temperature and humidity contain fewer hazardous controls during application solvents, dry faster and have and cure. To make matters a higher solids content. Why worse, the fi nal coats were the fi rst three are advanta- lear water-based often less durable than geous is pretty self-evident, fi nishes have been many of their solvent-borne but the other two deserve a Caround since 1980, counterparts. In short, they closer look. but lately they’ve been were harder to work with Faster drying means that gaining converts, with and sometimes left a poorer you may be able to fi nish a some 50% of woodworkers fi nal fi nish. project completely in one saying they now use them. Thanks to some interesting weekend, something that Why the change? additives, the new generation means a lot to those of us To be honest, when of fi nishes go on and fl ow who only have limited wood- water-based clear lacquers out much better. Those same shop time. Pair water-based and polyurethanes fi rst came additives make the coating stains and glazes with water- on the market, they had lots less sensitive to contamina- based topcoats, and drying Michael Dresdner of problems. Many of those tion and give them better and handling times plummet is a nationally known fi nishing issues have now been solved, adhesion when applied over from days to hours. You’ll expert. He shares his expertise on and some new fi nish options oil-based stains and sealers. wait less after staining and the DVD The Way to Woodwork: have been added, making Along with better adhesion between topcoats. Step-by-Step to a Perfect Finish, water-based a much more en- comes better fi lms. Expect Higher solids is a less available through the store at ticing alternative. Let’s look more durability across the obvious advantage. The woodworkersjournal.com. at what’s changed, what’s board, with higher resistance solids content is the amount the same, and the best ways to water, heat and chemicals, of fi nish that remains on
70 WorldMags.net August 2015 Woodworker’s Journal WorldMags.net
On the maple board above, you see the dramatic difference between a fi nish with water-based polyurethane (left side) or oil-based polyurethane product (on the right). the surface, as opposed to Unlike solvent fi nishes, Contact us the amount of solvent that water-based coatings do evaporates off. For instance, not look particularly good with your fi nishing most solvent-based lacquer when wet, but they fl ow out questions by writing to is shot at below 20% solids considerably during drying. Woodworker’s Journal, after thinning. That means That’s especially true when 4365 Willow Drive, for each coat you spray on, spraying. While wet, you’ll Medina, MN 55340, less than one fi fth of it re- see dramatic orange peel, or by emailing us at: mains to form a fi nish, with but don’t try to “fi x” that by all the rest evaporating. Wa- spraying heavier. Stop and fi [email protected]. ter-based coatings typically wait, and it will eventually Please include your have solids contents almost fl ow out far smoother than address, phone number twice as high, so they tend to you expect. and email address (if you build faster. I still prefer using a paint have one) with your thoughts Then there’s the color, pad on large, fl at surfaces, or questions. which can be either a boon either vertical or horizon- or a bust. Most water-based tal. A paint pad has a huge topcoats dry water clear, as application surface compared A paint pad provides a larger surface than opposed to the amber hue of to a brush, and it’s easier a brush for applying water-based fi nish — it’s easier to apply a smooth, thin layer. most solvent- and oil-based to lay down a coatings. That can be an smooth, thin layer advantage when you want to quickly. When you keep light woods from turn- must resort to a ing yellow. Of course, you brush or foam-on- can always tint the coating a-stick applicator, with amber dye, so you can be gentle. Flow get the best of both worlds. rather than scrub to avoid foaming Application Techniques — those tiny air Good application techniques bubbles that get still make a big difference, trapped in the and rule number one is to fi nish. If you work apply it sparingly. Because quickly, you’ll now of how water-based coatings have more work- cure, you’ll get much better results applying a coat that is just barely uniformly wet. The easiest way to apply any stain, including the Don’t pile it on; go for thin water-based variety, is but evenly wet. Once it’s on, to fl ood it on liberally, be patient. and wipe it off evenly.
Woodworker’s Journal August 2015 WorldMags.net 71 FinishingWorldMags.net Thoughts continued
ing time to blend and even up the coat. If you’re curious, my favorite bristle brush options are Purdy’s Chinex® For spraying water-based fi nishes, the Titan Gravity Feed HVLP Spray Gun (above and ™ or Syntox brushes. left) works if you have a compressor that will handle a conversion gun. If you don’t, Spraying or want a freestanding option, you might try When spraying, use a small the Earlex Spray Station 5500 (at far left). fl uid aperature (1 mm or slightly larger) and spray sparingly, until Color Add-ons the entire surface is You’ll see a lot more just barely wet. Use a water-based pigment good quality gun that and combination stains and Pearl Effects lets you control both available than ever be- (pearlescent colors) are the fl uid and air fl ows, fore, and they can be either thicker versions of stain that and hold the gun a tad wiped on and off, or sprayed can be used on raw wood or closer to the wood on. Dye stains, pre-mixed and in between coats of fi nish (6" vs. 8"), especially ready to use, apply the same to create shading, antiquing with HVLP or LVLP way, but without the mess of and special effects. Then guns. With standard mixing and the fear of colors there’s their Enduro-Var compressed-air guns, that don’t match from batch water-based polyurethane dial the pressure to batch. All can be inter- varnish, which is the closest back a bit so the fi nish mixed to create custom col- thing to “old world” oil var- lays out gently rather than ors and can be added in small nish you can fi nd in a faster smacks onto the surface. amounts to clear coatings to drying water-based mode. Oh, and clean the guns (and make tinting lacquers. Bottom line? If you haven’t brushes) immediately and Some of the more entic- already done so, maybe it’s thoroughly with soap and ing new offerings are from time to take another look at water or, better yet, propri- General Finishes. Their water-based coatings. etary cleaning solvents. Glaze Effects (solid color)
Hold an HVLP or LVLP spray gun about 6” from the piece when spraying water-based fi nishes.
Water-based dye stains can be mixed to create custom colors. Here, a 2:1 ratio of General Finishes Orange to Medium Brown creates an appropriate color on mahogany for Greene and Greene style pieces.
72 WorldMags.net August 2015 Woodworker’s Journal WorldMags.netpresents The Way To Woodwork: Getting Started in Woodturning oodturning is growing in popularity as Wpeople discover how inexpensive and easy it is to get started in this practical, fun and creative craft. This full-length DVD teaches everything you’ll need to know to start woodturning safely and with more than enough knowledge to have fun right from the start. And to make this DVD even more useful, we’ve added a bonus sharpening section to get you sharpening those curved tools perfectly!
BONUS SHARPENING SECTION!
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CALL 800-610-0883 (mention code WJ1542) or order online at www.woodworkersjournal.com/wj1542 Sponsors include ... WorldMags.net HEY Did You Know? WoodworkingWorldMags.net trivia: a forest of facts
Bodgers were itinerant woodworkers who set up in forests where they cut, hewed, shaped and turned green wood on-site, making chair PIKWERHWXVIXGLIVWXSFIWSPHMRFYPO8LIMV tools included the shaving horse and drawknife, WE[WE\IWERHTSPIPEXLI%XEPIRXIHFSHKIV could make upwards of 12 dozen (144) legs ERHWXVIXGLIVWMREHE]EPP[MXLSYXTS[IVXSSPW
And the award for most ornate goes to … Coachmaker’s planes, like What Does It All Mean? the one pictured at left, are among A quick guide to terms from the the most unusually shaped hand world of woodworking. TPERIW6EXLIVXLERGYXXMRKÀEXW many were used to shape the complex contours in fancy coaches. Dimensional Lumber: Wood building material cut to standard sizes, both in width and thickness, such as a 2x4, and sold in various Lignum Vitae (Latin for “wood of lengths life”) is extremely hard and so dense Hardwood: Any lumber from a MX[SR·XÀSEX8LI[SSHVIQEMRW deciduous tree self-lubricating both in and out of
Shaving Horse: A combination water, and therefore has been used bench and seat for carving; a as wet bearings (as seen at right) on movable end piece is held with the HEQXYVFMRIWWYFQEVMRIWERHWLMTW-X foot to clamp a workpiece in place, has also been used as belaying pins, freeing both hands British police truncheons, mortars and pestles — even the neck wood of the
PEXI4IXI7IIKIV·WFERNS photos courtesy of Lignum-Vitae-Bearings.com
Submit your Your Trivia Test: own trivia ... Q What wood has been Send in a curious fact about your favorite topic and ours: instrumental in keeping Navy woodworking. If it is selected submarines running silent?
for use, you will win an
awesome prize! quiet very were bearings wood The Father Chrysanthos of Etna, California, will receive a
Submit your Trivia to Woodworker’s substances. space-age by displaced cently SENCO FinishPro 23SXP 23-ga. Headless Pinner,
Journal, Dept. Trivia, 4365 Willow Drive, re- until bearings shaft propeller in used 1 Gallon Finish & Trim Air Compressor (model Medina, MN 55340. Or send us an email: vitae, lignum lubricates naturally Seawater PC1010N) and pack of 23-ga. Pins (item A101009) for
[email protected] Answer having his contribution selected for the Trivia page.
74 WorldMags.net August 2015 Woodworker’s Journal EdgeWorldMags.net clamping is about to get a whole lot easier
Rockler Bandy Clamp™ (54258) $19.99/pair
The new Bandy Clamp™ quickly and easily applies pressure to edge molding without marring the piece or the finish. The built-in rubber band stretches over the molding, while the large clamp pads securely hold everything in place while the glue dries. Your assembly times will be faster than ever before, allowing you to get more done in the shop. Bandy Clamp: the latest Rockler innovation to help you Create with Confidence.
Materials code 642
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