Festool When to Use ‘Water-Based’ Lacquers Sander April 2016 ■ #224 Roubo Moulding Planes Easy-to-Make Traditional Tools popularwoodworking.com Guerrilla Guide to HVLP Spray Finishing The Core Hand Tools – a ‘Must-Have’ List FnL1 04 0120 01 JUYrVyBQdWJsaWNhdGlvbnMsIEluYyAo 02 SW9sYSBkaXZpc2lvbikPR3JlZ29yeSBL 03 cnVlZ2VyAFaLnXQEMTAuNAI4MAExBVVQ Qy1BDDA3NDgwODAxMzU1NQA= Build a Baille Scott Arts & Crafts Side Table c1_1604_PWM_Cover.indd c1 1/20/16 10:57 AM QUALITY WOODWORKING TOOLS • SUPPLIES • ADVICE® Spray Finishing the Wagner Way – Quick and Easy! Wagner’s new Home Décor Paint Sprayer makes it easy for Features: everyone to paint or finish like a professional, even someone new • Sprays Chalk-Style/ Milk And Other Decorative to HVLP spraying. Lightweight and compact, this tool sprays pretty Paints, Stains, Sealers And Lacquers much any type of finish – chalk paint, milk paint, water-based fin- • Easy To Maneuver For Small Projects • Powerful Enough For Medium Projects ishes and stains, and more. Sprayer setup is simple, and features • Powerful Enough For Medium Projects • 6' Air Hose For Added Manueverability include paint-saving control and pattern options. Gun and cup are easy to clean, so changing color is a snap. 161374 Try this sprayer with NEW Black Dog Salvage Furniture Paint! Available Soon In 15 Colors plus Satin and Matte Topcoats! For A Free Catalog Or To Find Your Local Woodcraft Store, Visit woodcraft.com Or Call 800-225-1153. 16PW04P For Information On Woodcraft Retail Franchise Opportunities, Visit woodcraftfranchise.com CARD #49 or go to PWFREEINFO.COM c2_1604_PWM_FPAds.indd c2 1/20/16 10:45 AM CONTENTS APRIL 2016 30 36 50 FEATURES 22 Roubo Hollows 36 Arts & Crafts 48 ‘Melencolia’ & Rounds Occasional Try Square Use tools you likely already own to make three Table This nearly lost layout tool from Dürer’s 1514 matched pairs (Nos. 4, 6 & 8) of traditional This geometric Baille Scott project offers a “Melencolia I” engraving is fun to make, French-style hollow and round planes. fun joinery challenge with tapered legs, plus accurate and useful in the modern shop. BY CALEB JAMES curved and angled stretchers. BY CHRISTOPHER SCHWARZ BY MITCH ROBERSON ONLINE u Mouldings by Hand ONLINE u Ancient Layout Watch this video to see just how quickly you Get free plans for some early layout tools that ONLINE u 3 Ways to Finish can cut a moulding profi le by hand. Discover three ways to create an authentic- you can make from shop scraps. popularwoodworking.com/apr16 looking Arts & Crafts fi nish. popularwoodworking.com/apr16 popularwoodworking.com/apr16 30 Guerrilla Guide to 50 King of Spray Finishing 43 The Core Windsors Harness the speed and quality of a Hand Tools After 35 years of teaching, Mike Dunbar is professional spray fi nish with this guide to For the cost of one quality piece of large closing the doors of The Windsor Institute using an inexpensive system at home. machinery, you can set up a complete hand and opening the doors to a one-man shop. BY CHRISTOPHER SCHWARZ tool shop – here’s the tools to get you started. BY MEGAN FITZPATRICK BY DENEB PUCHALSKI ONLINE u Make a Spray Booth ONLINE u Milk Paint Read this free article from Bob Flexner on Read this free article from Mike Dunbar on ONLINE u Sharpening Jig making your own spray booth. how to mix and apply traditional milk paint. Get free plans for the author’s jig that helps popularwoodworking.com/apr16 popularwoodworking.com/apr16 you set the right sharpening angle every time. popularwoodworking.com/apr16 48 COVER PHOTO BY DANIEL DUBOIS PHOTOGRAPHY; SPRAY FINISHING PHOTO BY AL PARRISH; SIDE TABLE PHOTO BY MITCH ROBERSON popularwoodworking.com ■ 1 01_1604_PWM_TOC.indd 1 1/20/16 10:42 AM CONTENTS APRIL 2016 61658 REGULARS 4 Woodwork 12 Festool’s New 58 Give Me a Brake By the Book 5" Sander ARTS & MYSTERIES OUT ON A LIMB TOOL TEST BY PETER FOLLANSBEE BY MEGAN FITZPATRICK BY THE EDITORS 60 ONLINE u Tool Test Archives Water-based 6 Sharpening We have many tool reviews available for free Finish isn’t on our web site. Pond’s Top popularwoodworking.com/tools Lacquer Attachment FLEXNER ON FINISHING LETTERS BY BOB FLEXNER FROM OUR READERS 16 Graduated Drawers 64 Humble Job 10 Dust Collection DESIGN MATTERS Endures For Ports of BY GEORGE R. WALKER 1,000 Years All Sizes 54 END GRAIN TRICKS OF THE TRADE Custom BY JIM BAKER FROM OUR READERS Push Pads JIG JOURNAL u ONLINE More Tricks BY JERRY C. FORSHEE Read some of our favorite vintage tricks. popularwoodworking.com/tricks Number 224, April 2016. Popular Woodworking Magazine (ISSN 0884-8823,USPS 752- 250) is published 7 times a year, February, April, June, August, October, November and December, which may include an occasional special, combined or expanded issue that may count as two issues, by F+W Media. Editorial and advertising offices are located at 8469 Blue Ash Road, Suite #100, Cincinnati, OH 45236. Unsolicited manuscripts, photo- graphs and artwork should include ample postage on a self-addressed, stamped envelope (SASE); otherwise they will not be returned. Subscription rates: A year’s subscription (7 issues) is $24.95; outside of the U.S. add $7/year ■ Canada Publications Mail Agreement No. 40025316. Canadian return address: 2835 Kew Drive, Windsor, ON N8T 3B7 ■ Copyright 2016 by Popular Woodworking Magazine. Periodicals postage paid at Cincinnati, Ohio, and 60 additional mailing offices. Postmaster: Send all address changes to Popular Woodworking Magazine, P.O. B ox 42023 5, Palm C oast, F L 32142- 023 5 Canada G S T Reg. # R13259 4716 ■ Produced and printed in the U.S.A. ILLUSTR ATION BY MARY JANE FAVORITE; CHEST PHOTO BY GEORGE R. WALKER; 2 ■ POPULAR WOODWORKING MAGAZINE April 2016 BRAKE PHOTO BY PETER FOLLANSBEE; FINISHES PHOTO BY BOB FLEXNER 01_1604_PWM_TOC.indd 2 1/20/16 10:43 AM SHOP FOX® machines are SINCE 1989! backed by a 2 Year Warranty! 5 HP, 26" DUAL DRUM SANDER 1 HP, 14" BANDSAW VARIABLE SPEED PLANER MOULDER • Motor: 5 HP, 220V, 25A, single-phase, • Motor: 1 HP, 110V/220V with Stand 3,450 RPM • Precision-ground cast iron • Motor: 2 HP, 240V, single-phase, 1 1 • Capacity: 4 ⁄4" thick x 26" wide table size: 14" x 14" x1 ⁄2" 10.8A, 3450 RPM 1 1 • Conveyor motor: ⁄3 HP, 2A, universal • Blade size: 93 ⁄2" • Precision-ground cast iron table 1 1 1 3 1 7 • Conveyor table size: 26 ⁄8" x 30 ⁄4" (⁄8" to ⁄4" wide) size: 14 ⁄8" x 10" x ⁄16" 3 3 • Footprint: 36 ⁄4" W x 23 ⁄4" D • Cutting capacity • Max. planing width: 7" 1 • Powder coated paint 13 ⁄2" (throat) • Max. planing 1 • Surface speed of • Cast iron frame and wheels height: 7 ⁄2" drums: 2,300 FPM • Ball bearing blade guides • Cuts per inch: 3 • Two 6" x 27 ⁄4" • Includes fence and 64-300 aluminum drums miter gauge • 2 HSS knives 177335 • Dual 4" dust ports Feature packed, and an incredible value 177335 W1678 5 HP, 26" Dual Drum Sander W1706 14" Bandsaw W1812 Planer Moulder with Stand 3 2 HP, 10" OPEN STAND /4 HP, 13" BENCH-TOP DRILL PRESS POCKET HOLE MACHINE 3 1 HYBRID TABLE SAW • Motor: ⁄4 HP, 110V, • Motor: ⁄2 HP, 120V, single-phase, • Motor: 2 HP, 15A at 120V, 7.5A at 240V, 1725 RPM 3A, 17,500 RPM single-phase, 3450 RPM • Overall height: 38" • Two flip stops for drilling consistency 1 1 • Footprint: 21" L x 19 ⁄2" W • Spindle travel: 3 ⁄4" • Auto start/stop motor actuation with 1 1 1 pull of handle • Max. depth of cut at 90° angle: 3 ⁄4", at 45°: 2 ⁄4" • Swing: 13 ⁄4" 1 5 • Auto-adjust • Precision-ground cast iron table size: 57 ⁄4" W x • Drill chuck: ⁄8" 1 3 clamping foot 37 ⁄2" D x 35 ⁄4" H • Speeds: 12, mechanism for • Built-in mobile base 250–3050 RPM 3 workpiece • 4" dust port • Table: 12 ⁄8" dia. • Table swing: 360° thicknesses 1 1 • Table tilt: 45° left between ⁄2" to 1 ⁄2" • Cuts both diameter & 45° right Made in an holes for pocket screws ISO 9001 at the same time factory • Ideal for face framing 3092372 PATENTED! 3 W1837 2 HP, 10" Open Stand Hybrid Table Saw W1668 ⁄4 HP, 13" Bench-Top Drill Press W1833 Pocket Hole Machine 1 12" X 15" BENCHTOP WOOD LATHE 1 /2 HP DUST COLLECTOR 16" SCROLL SAW 3 1 • Motor: ⁄4 HP, 110V, single-phase, universal motor Improved Filtration • Motor: ⁄8 HP, 120V, single-phase, 1 • Electronic variable-speed spindle control with digital • Motor: 1 ⁄2 HP, 110V, 1.2A, 60 Hz • Variable speed motor RPM readout • 12" swing over bed • 15" between centers single-phase, 3,450 RPM • No load speed: 550–1650 SPM • Two spindle speed ranges: • Motor Amp draw: 110V - 16A • Max. cutting thickness: 2" 1 1 500-1800 RPM & 1000-3800 RPM • Portable base size: 21 ⁄2" x 33 ⁄2" • Max. cutting width: 16" 51 • 1" x 8" TPI RH thread spindle size • Bag volume: 5.4 cubic feet • Blade stroke: ⁄64" • Spindle indexing in 15-degree • Height (with bags inflated): 78" • CSA certified increments • Bag size: 19" x 33" (2) • Heavy-duty cast • Air suction capacity: iron construction Approx. 1,280 CFM • Rubber feet for • Static pressure: 10.1" 226002 increased • Standard bag filtration: stability 2.5 Micron Uses Plain or Pin-Type Blades 1 W1836 Benchtop Wood Lathe W1685 1 ⁄2 HP Dust Collector W1713 16" Scroll Saw WOODSTOCK® INTERNATIONAL, INC. IS ALSO HOME TO ROMAN CARBIDE®, PLANER PAL®, JOINTER PAL®, AND MANY OTHER FINE BRANDS. PLEASE VISIT OUR WEBSITE OR CALL TOLL FREE TO FIND AN AUTHORIZED DEALER NEAR YOU.