Page i Woodworking by Reed Karen Macmillan USA, Inc. 201West 103rd Street Indianapolis, IN 46290 A Pearson Education Company Page aa DEAR READER Page ab THE COMPLETE IDOIT'S REFERENCE CARD Page ac Page ii Copyright ã 2000 by Reed Karen All rights reserved. No part of this book shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission from the publisher. No patent liability is assumed with respect to the use of the information contained herein. Although every precaution has been taken in the preparation of this book, the publisher and author assume no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of information contained herein. For information, address Alpha Books, 201 West 103rd Street, Indianapolis, IN 46290. THE COMPLETE IDIOT'S GUIDE TO and Design are registered trademarks of Macmillan USA, Inc. International Standard Book Number: 0­02­863237­0 Library of Congress Catalog Card Number: Available upon request. 02 01 00 8 7 6 5 4 3 2 1 Interpretation of the printing code: The rightmost number of the first series of numbers is the year of the book's printing; the rightmost number of the second series of numbers is the number of the book's printing. For example, a printing code of 00­1 shows that the first printing occurred in 2000. Printed in the United States of America Note: This publication contains the opinions and ideas of its author. It is intended to provide helpful and informative material on the subject matter covered. It is sold with the understanding that the author and publisher are not engaged in rendering professional services in the book. If the reader requires personal assistance or advice, a competent professional should be consulted. The author and publisher specifically disclaim any responsibility for any liability, loss, or risk, personal or otherwise, which is incurred as a consequence, directly or indirectly, of the use and application of any of the contents of this book. Safety disclaimer: Woodworking is an intrinsically dangerous craft. It requires the use of hand and machine tools that can cause grave or even fatal damage. No book alone can replace actual shop instruction with a qualified teacher; they can only supplement it. This book is intended as a companion to hands­on training by a knowledgeable craftsman, and before using any tool or power machine you must get face­to­face guidance on its operation. Always follow safety instructions that accompany tools, machinery, or supplies. If you don't feel comfortable performing an operation, stop immediately and get guidance. Woodworking can be a rewarding, lifelong pastime, but only if you concentrate on safety at all times. Page iii Publisher Marie Butler­Knight Product Manager Phil Kitchel Managing Editor Cari Luna Acquisitions Editor Randy Ladenheim­Gil Development Editor Doris Cross Production Editor Christy Wagner Copy Editor Heather Stith Illustrator Jody P. Schaeffer Cover Designers Mike Freeland Kevin Spear Book Designers Scott Cook and Amy Adams of DesignLab Indexer Lisa Wilson Layout/Proofreading Angela Calvert Mary Hunt Paula Lowell Jeannette McKay Page iv CONTENTS AT A GLANCE Part 1: Getting Real About Woodworking 1 1 3 Basics: The Shop, the Shopping, and the Skills Figure out your goals, priorities, budget, and where to set up shop. Here's what you need and what you can live without. 2 11 I Need My Space: Setting Up Shop We'd all like more space; here's how to make the most of what you have, including three strategies for organizing your work area. 3 21 A Workshop That Works Before the machines arrive, you need to furnish your shop by picking out a workbench, sorting out a tool cabinet, and stabling the sawhorses. Part 2: The Tools: The Work They Do and How to Work Them 33 4 35 Your Hand Tool Arsenal: The Cutters This guide to chisels, planes, rasps, and files explains how to tell them apart, use them, and care for them. 5 47 Hand Tools for Measuring, Marking, and Other Basics Carrying on where Chapter 4 left off, this chapter explains the other tools in your kit. 6 59 Feel the Power: Portable Power Tools This introduction to the wonderful world of drills, circular saws, sanders, and routers explains how to handle the power safely. 7 73 The Big Machines: Stationary Power Tools Graduate to the big leagues with this guide to the tools that really make a shop a shop. These machines turn rough lumber into finely milled legs and stretchers. 8 87 Keeping Your Edge Get your tools razor sharp and keep them that way. Part 3: The Word on Wood 99 9 101 Wood's Wild Ways Wood is a natural material and must be treated accordingly. Learn how its natural origins affect you in the workshop. 10 111 The Subtle Art of Buying Solid Wood Learn what it takes to navigate the lumberyard with confidence in this guide to picking boards. 11 121 The Sawmill: Where Trees Become Lumber The sawmill determines what your lumber will look like, and the drying process can make or ruin your day. Page v 12 129 Plywood: The Engineered Natural Material Plywood can make your life a lot easier. Here's why. 13 139 Words to the Wise About Storing Wood You can easily ruin good lumber and plywood by storing it badly. Here's a guide to keeping your wood high and dry. Part 4: Putting It All Together: Means and Methods 147 14 149 All About Adhesives Get your parts together and keep them that way. 15 157 Frame Joints: The Skeleton as a Model Nothing defines woodworking like a well­cut joint. This chapter looks at mortise­and­tenon joints, spline joints, dowel joints, and other frame joints. 16 167 Carcass Joinery: The Box as a Model This chapter picks up joinery where the last left off and explains the other category of joinery: box joints. 17 181 Nails, Screws, and Bolts: When It's Okay to Use Fasteners So many screws, so little time. This chapter looks at the myriad types of screws, nails, and bolts and explains how to choose and use them. 18 191 Doors and More Doors Doors and drawers are the trickiest characters in woodworking because they work mechanically. This chapter shows you the ropes. 19 203 The Ins and Outs of Drawer­Making This chapter explains how to make drawers that close as effortlessly as they open. 20 213 Edgings and Moldings: The Last Details These simple details can make your project come alive. Here's how they work, how to buy them, and how to make your own. Part 5: From Principles to Practice 223 21 225 Plan It on Paper: Drawings, Cut­Lists, and Procedure Lists These simple organizational tools keep your head above the maze and prevent problems and mistakes before they materialize. 22 235 Milling: How to Make Parts That Fit This step­by­step guide to the parts­making process explains how to cut out your parts so they resemble the ones on the drawing. 23 245 How the Parts Become a Carcass Now it's time to round up those parts, get them ready, and glue them together. This chapter will help you keep your glue­up from becoming a fiasco. Page vi 24 257 Woodworking Art: Tabletops and Other Flat Surfaces Grain patterns can make or break a tabletop or panel. This chapter walks you through the aesthetic and technical steps to making a tabletop. 25 267 The Well­Hung Frame­and­Panel Door A detailed guide to every stage of making and hanging a frame­and­panel door. You learn about hinges, panel profiles, and how to use grain patterns to give your door a sense of unity. Part 6: The Finishing Touch 277 26 279 A Fill­In on Finishing This short history of finishing introduces the cast of players and explains their characteristics. 27 289 Choosing Finishes: Knowing Fact from Fiction This in­depth look at the pros and cons of the various finishes explains how to choose the right one for the job at hand. It also looks at stains and fillers. 28 303 Surface Prep: Groundwork for a Great Finish If the surface isn't right, the finish won't be. Learn about the different sandpapers and other abrasives and how to get this onerous task over and done with quickly. 29 313 Let's Get It On!: Applying Finish Step by Step There are different strokes for different folks. Each finish is applied differently; here's a guide to all of them. Appendixes A 323 Glossary of Woodworking Terms B 335 Resources C 343 Organizing Your Project Index 349 Page vii CONTENTS Part 1: 1 Getting Real About Woodworking 1 3 Basics: The Shop, the Shopping, and the Skills What Do You Want from Woodworking? 4 Inch by Inch 5 Basic Buys and Budget­Busters 5 Space—the Final Frontier 6 The Tools of the Trade 7 Tool Lust: The Woodworker's Waterloo 9 Tools on the Cheap: Flea Markets, Auctions, and Want Ads 10 2 11 I Need My Space: Setting Up Shop Apartment Woodworking: The Big Squeeze 12 Think Small 12 The Stowed­Away Shop 13 Stretching Out: The Garage or Basement Shop 15 Enter the Machine Age 15 Freedom of Storage 15 Flexing Your Space 16 Movin' Up and Out: The Rented Shop 17 Scouting a Space 17 Setting Up Housekeeping 18 3 21 A Workshop That Works The Supporting Cast: Workbenches, Sawhorses, and Other Shop 22 Fixtures Home Base: The Workbench 22 Working Your Workbench 23 Trust Me 24 Horsing Around 25 Beam Me Up 26 The Tool Cabinet 27 On a Roll 28 Push It with Push Sticks 29 Tooling Around 29 The Jig's Up 30 Storage Savvy 30 Part 2: 33 The Tools: The Work They Do and How to Work Them 4 35 Your Hand Tool Arsenal: The Cutters Who's a Chiseler? 36 Butt Chisels: The Cabinetmaker's Workhorse 36 Paring Down: Paring Chisels 38 Choosing Your Chisels Wisely 39 Grasping