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NUMBERFIFTEEN

NOTESFROM THE SHOP

TWO DOLLARS

CONTEMPORARY
OAK FURNITURE

WOODSMlTH

Wl)(~llllth
Number FIfteen

May. 1981

Talking Shop-_
ABOUT THIS ISSUE

The two major projects in thi~ issue - the


oak table and chair - have oppcsite problems, The table is quite easy to build. but
ArtOtrectOl
requires. lot of wood. The chair on the
Ted KreUeek
other hand doesn't require much wood, but
does involve some rather preeise joinc.y.
Subscnplion Manager
These are the two 'not enough' problems
LindaHl!!
we all face in woodworking: not enough
money to buy the wood. and nut enough
Administrative Asslstant
time LOrio the joinery. But in the case of
Conn~ L. Lowe
these two projects, neither of these probConlnbultog EdiiOr
lems is 8S big as it seems,
AdOlph E. Peschke
The total
for the oak we used to
build the tablewasS70. This figure is based
en 8 eest of $2AOper board foot for FAS
ISSN 01644114
red oak - the price we paid at a local
hardwood lumber yard.
WOODSMITH Is published blmonlhly (Janua<y,
Ma,ch. May. July, Seplember. _bet) by
Just fo. comparison. clear Ponderosa
Pine
costs about S2.80 per board foot.
WOOdsmllhPublishing Company 1912 Gland
bringing the total cost of the table to about
Ave, Des Moines, Iowa 50309,
$80.
(Of course, these prices will "ary
WOODSMTTHI. a I(~(fematkof the WoodsJT\llh
acress the country. but some hardwoods
Publishing Company
Copyrlghl 1981 by WOOdsmlth Pubhshmg lU'I!actually cheaper than clear pine.)
)'low we get to the mauer of'joinery. \Ve
Company, All Rights Reserved,
SUbse:lplions: On. yea, (6 Issues) S10, Two chose mortise and tenon joiner), for both of
thebe projects, The beauty of .his joint is
years (12 issues) S18. Single copy ~.
52
obvious on the chair, and this is one of the
(Caneda and Fo'8lgn: add S2 pe1' yea,,)
Change 01 Address: Please be sure 101nclude reasons we chose it.
Apart ll'Om be.ut~. it does take quite a
both yQutold and ne ... address lor change 01
address. MatllO: WOOdsmllh. 1912 Grand Ave.. bit of time to CUtall of these M & T joint'
(especially on the chair). And, it's quite a
Des Motnes. IOwa 50309
Second class postage patd al Des Moon.. , challenge to get them to Ilt properly. But
that, LOme, is the best part of woodworkIowa
ing- taking the time to meet a challenge.
Postmaster: Send change of address notICe.
Form 3579, 10WOOdsml1hPubliShing Co .. 1912 And in this case, it's really; worth it.
Editor
Donald 8. Pesej>ke

co."

(hi. time. TIw most obvious reason I. that


the through mortise on the chair would
simply not look right if the end. were
rounded as with a slot mortise.
But, the Ol her reason is that, we were
working with oak. And this ii' a case of
allowing' the wood to tell you what tvpe of
joint i~
best. Il'hell wO"kingwilh oak, I lind
it'. a I'('al hassle trying te> round over the
tenons to iit a 810t mortise. Oak tend. tn
splinter and chip otTtoo easily. So. in thi>
case it's really much easier to ch(li> the
mortise square and leave the corners of the
tenon square,
CU"tNG

DIAGRAMS

~!uch of woodworking involve. ",,,king the


most of what you've got, This was the guiding principle for building the ,toralre box
shown on page 14 of this issue.
Right from the beginn;n!! 1 kne\\ that
the cutting diagram for this project \\'3<;
going to be the toughest Jllll't to work nut.
In fact, I spent hours trying to gel all ofth.
pieces dimensioned and laid out so there
would be a minimum or" aste. The result is
a cutting diagram that is my pride and joy
Ithink working eut a cutting diagram for
each project is important. Whenever I
st.art to build something. one of the flrst
considerations is the cutting diagram.
Very often I fOldthat a few lillie changes in
the design make big changes in the amount
of mat .. ;.1 needed, and especially in th.
amount or waste.
\VI' try to show cutting diRll'rams for
almost every project. However. I must
admit that th~y a.'(' .-eally jlh't guideline,
Grand Ave" Des MOInes, IOwa 50309
SLOT VS. SQUARE MORTISE
(or the amount of material you'lI pl'Uoobl>'
BACK ISSUES
Those of you who have been reading
need. We show the board. that are needed
based on the sizes of dimension oftwoodl
A list of eonrents 01all back rssues appears on \I'oods",ith for awhile. hal'. probably
page 16, If yQuwould like (0 orde, back Issues. noticed that we've given quite a bit of lumber
This might be a lillie misleading when
USBlhereply envelope bound in Ille cenlerof this coverage to the mortise and tenon. This .11
hardwood is used for the project. ~It)..t
Issue II that envelope IS misSIng,JUS! send us a started in lI'ood8milh Number Eight when
note saYIngwhallssues yQuwant and enclose We presented a fairly wide overview of the hardwood is sold 'random width and
length.' (The exception iN hardwood sold
paymenl wllh your order Back Issuos are S2 mortise and tenon joint and how it's CUt.
Since then we've tried to show a. number through mail-order catalogs. wh ieh is
BaCh, (Iowa residents add ~. sales tax.l
of variations of the mortise and tenon and almost alway, cut to specified widths and
SAMPLE COPIES
their applications, In almost every in lengths.) Although you may not be able to
00 you havo rnends who ate InI8(GS1edInwood- stance. we've shown this joint with a slot buy boards at the exact dimenions shown,
worlong? Maybe (hey would uketo .... a sample mortise. (A .Iot mortise has rounded ends. the cutting diagram should still be helpful
copy of WOOdsm"h. Just send (yOu can or lhey and the tenon is rounded to fit the mnrtise.) - and at the Ic3Sl, a good starting point.
In mo<>tcases I think this npproaeh is
can) lhe name and address Of your '"end 10:
DAMAGED COPIES
easier than making a square ..cornered mar ..
WOOdsmlth, Sample Copy, 1912 G,and Ave.
tise. H(l\\'e\'er, there are exceptions. In Ahno!'t e\Tel')" \,eek \\fe get letters from
Des Moones. Iowa 50309,
We'll send a sample copy alOng w,1J'I a S\rb- this isi'tuc\\'e"'e gi\'cn lhe sLep b)t ~lep (or readel''' ",ying that their issu!! of Wood
scnpllon lorm, Thefe's no obNgabon10bUy
cutting a squarecornered
mortise by $mitll wa" damaged in the mail. If you r~
hand. (Although we do cheat a Htlll.'bit by ceive a t,()P)'that was damaged (or if SAlme
DAMAGED COPIES
sh'l\\ing the use of a drill prcS$ (0 get rid of thing i< wrong with the printingl. just let
IIyQurcopy of Woodsmlth IS damaged ,n !he m():;! of the waste before the cheeks of the US know and wc'lI ;;end out a new copy
ma,l.yQucan get. replammonlcopy Just
morti"" are pared squarf1 \\;th a chi",,!.)
(!ncJC)<;(:d
in an en,'elope to prowet it. Ko
There
are
really
t,,o
reasons
\vc"'c
IG us.ex~n the probJem. and we:Q send out a
charlte.
$\\'jtched to the =-quare-conlcred mOl1.isc NEXT MAII.INC' July 6, 1981.
new CIJOY 81 no charge

w_

"

WOODSMlTH

__

(NGINI

T_~s &.Technigu_e_s__
VALV( SANDING PAD

KE':your upon rnaklnga small sanding disk


fnr :-an(Jlnll lh~ bottom of routed lra)':-

CI\',,,.I.,/I,'/' No, 13),


1'11'("olfi('nginl' valves (from ears. lawn
mowers, 4,.'lC:,) 1\.... a ~all(lin)!' 1>3CI
... \(t.er extracung thl' valve fr orn an old .nl.~ne, I
wind it tn the di"mN~r I nt'("', Then I cut.
,.rnall circle of ,,,"d,l<lP"" ~nd II'luo it to th('
!>r,ttComof tbe valve. (J I)refer emery cloth
b<o<-.u,, ,t I""" muth IOlljI'Pr.)
All \'00 han' to rio I- chuck the valve in a
JX,l'UIblr d<'<tn<' drill or a drill press "nd
~'OUesn "kllli an.) sma11flat itrea.

D Fox
Rtr('rStdr. {'t"n
VERY SMALL SANDING O~UM

Re: ~our I 'P on small "",ding drums

III-e eotu-r 1"0- a.' "nail ""ndinjt' drums.


I <imply nulIt'n the 1""1,,<1"nrl and slip a
,uip of ",rndpal)('r Coremery doth) into the
pin. A, the cotte" I"n 1$ til(htcned in the
drill chuck. th. ,i,I", of the pin. in tum.
ti~hten
t th. sandpaper, holdinp: it
....
l"(un'l~'In I.IMl'(.

.''11"..

Aft..r duCkinll IC""ral nyin~ weIl"". I


ct,:-cill,;(1 th'-lt It \r. a." ll)() dangerous to con-

\\Mon I ha,, I .. IiII nail h"It-s,ll!athtr ,;.vm<'


\~I')'fi"" """,1 ,Iu.,ticft 0\ er from sanding,

tinuo unless Ihe problem was eliminated. ,


P~IC''(' otril' IIf "llI-'lrc dt'Ctrician, tape
O\'('r thl' )'OJ"t. h.-a\ lnK a \'~r)'small openin~
- ju-t PIl''''A'h ltr clearthe blade, It works
tx'allt!fllily
nn more flying wedges,

Thi:-.(Iu~t 1:-. mlxl'cl with a rlrol) or two IIf


"hit< IIlu. unti! I jt'(., a \'~I')'thick paste.
The pa1'lt( j .. forced Inlc, the nail holes,
Slightly overfull, so 'I drtes almost level
wuh th ...1'Iurfucc.' A nt'T" ~')f){1final sanding

A/,r I\, FI;m,rh

lhl' nnil huh', ''UmI'J"tl'I~' ,Ir... ppear,

(iary 1\'(Jb,,~

(;" rj'i( ttl .\' ('II' J r-rsl'!I


("t dnr

\\..;,-.:ro",j"

YOU DON'T NUD FOUR HANDS


NAILING flX1URl

'to prevent 1"'" daml" fN m marnng the

Th< "'Hr t ,...rt about bui hn~ the .1<"""l!'e


'box fho\\ n in thl" .......
ue 113.rel.t'j~nailinz
tOj(ether all of those hul, drawers After'
CUI all III<-P ''<l - for Ih, drawers, I",..,
fumblll1K ."Hlllel '1')1"jl' to ...t~ iftht~
were
th~ .t..mps.
t!'ulnJ.!' to fit
To ",h'. this preblem, l drilled two bnlr>T.-n '_"'t " k,ck out of" Ktchml!Ire tl')in~
in each JU\\ of m~' P'PC clamps Then I cut to nailth. fir,1 llra".r IOlCeth"r.and then
"(O\'rralllll"4;ks (I( It'1"R1'wood and screwed a Mid. "What ,VOII
a nailinl! ,"xtUI't',
block to l',wh jaw Thi, keeps m~' hands H. found "i,'<~ or:!, I ,c''''p ;rnrl mad. the
f,,\~v to do thl' n,'c(>...!'ar,Y a(Uu~ting ..
fixtU"l' :.hu\\ n h(h.,\'.
"hi!' flxtUl'l' it' :l4i1.4,:(1
It' ;\\'('('111 th~ ~mall
w'lhout hll"inl( tn w"r,'y about 'he block.'
falling nfr.
rirawlr . h"I,'!n~ .11 tho pi \\hil~
l-d~,-~
(If b.arwl ... or a J'roj\-c r, we all u...c
bI"",,", i........
1bN .. (-eli til<- clampjaws and
tht \\On,lJ1(."('l Hl)....ever, \\hen I'm workmil' b) mr",lf' """', (,.... hands to .h<r,rlthe
proji'rt.l'ut 'h,' blocko tn place, and tighten

'w,'" "

_c....,.,

DF"

Ih~~'r, h~ing laok,," tOl!cther. for the


lllr':('r Ilra\\fr~. !\.m'll~ril' thi::- fi:\tur~
dll"'l1 Ih, <I"trr .Iltl .rld a filler block to
"1d.." It

R ....~,rl'l.J't.i"
(

DtN1AL SANDING DISKS

R," > our IIJl ~n .mall ""nrbn~ dk~


....\'t;.lt (0) our local d~ntal .u"ply hou.~
,hQuld ...... al a ' ...n~t~ of .maIl ",lIdpo!",r
rli,,," 1",,1 by the d.nta! prof.",ion. The""
......n,II1aJl4r (tl~k!" arl' alr~3t1}cut round.
l'Clml~in a "anl't' of "m..1.Jl ~izc.8. and art'
availahlt in 'e,.;"1 gnl~ of garnet popt'r.

AAndplIl",r, etc.
Alsu. th~ d"k. corn. ,';th a hole punched
in lh"

"""'ra'

=,

:~

J,:

, ha,,
I<t- "f block." nuten"'.
:m~ll'('.('Un, ..) ;tntl :-otr.u,.:::ht - (it!JX!IKlinJ!
on the nallln' (.f th .. dampinll at hand,

J"JI" \\ .110,,1,'0
7"'.I((f"' ... \ ''1:uun

lHAn QUICK l1P5

C(\ntl'r for th(_ 1)ln (,( 3 mandrel.

(1)"nll'lo u.ually
nlaJldn1 'lo'llh a

MorganMaxfieid
!'hMft Thi:o- \'Oork.' b(.st

""I' "

in a hand JlIilltkr.l
iJr ROll"I H /)" ... kFIIw'11
f'rr-uolt ..4. ";-!(JIllr
SlOP flYING

To I'\'mo\'l' ,11'11,"
(..om "trod 'UTfares. I 11".
~E"IO IN YOUIlIOEAS
a darnl' <lnlh ItIl,1cloth,, iron or soldering f------.!.-------------1
iron. 1'111""Ih. ,'"m" cloth over the ct"1ll W. Invle you '0 sha YOU'_or1<rng ups
.nd ""1'1~ thl' hut i",", :;1I'3m (rum lhe and recI1nlQU" "III 01"", ,.aders 01 lVood'
c10th ~ III raUit ... lh4 (il)\'~ llf the'" (100 to
0",.11.bnlll:injllh, rn b""k to I"\el "ith the

uncinal.ureal'<'

ror a ........nl ma.'- "roduttion job I had to


makp nUmefOlJ" 'A ~1~t'-~haPl>d cut-orf!".
A(\~r .lrn,,t "\,ery PO'" on the tahle ""'"
th<<<
cut~.fr.,\(,uld nde aJonp:Ihe
blad,' and thtn tin,!, down into the openinjt'
in lh, I.blt in,,rt (lhe meta1l)iate around
the blud. . The ".'<Il(e." ere caught by Ihe
'I)innlng blad. lind hur'led out al terrifi.

'Ill""

"J~(ci!".
V,'OODSMITH

$f'l"JIlh

W.VIi

_11_

1)1),. nwwnumoc

""".!or.
suC,,.,ue<l_1he
$100<

SS

",_rty

'or a l!P, and


AllmaIena

01W __

I'lAlIrIhong Co Upon DeI"'l'f'1l you ~

WEDGES

Jr1II~,J H('llffr

(; ,'r,,'('.

Lk Ha~.

P"",,,

smoIIIlIle ng!\11O use Ill.. male<la '" any


10< as long .. "0 ...."

Wood-

mame<

your _
inVOlves a dr... "It or _
ro
t do you, bes' and
recessat}' we
l-tan)' J"-"C~Jo!f'tlon't rt"aliz~ that a nail ha..;;,a e_
cuttonl( f~II(".,.1 a 'plittinll e<llle, 'f ~'ou make a new d w'"9 0< build tl>e prOjeCt 0< l'Il
pJllet' th( cutting (...110:4.'
(l('rr),~.~
the grain..It and pIIologt"Pl' " (Any d'.","ItS 0< plio"," oub

"ill h.l" 1""\'1'111 ""littmlC the wood.

m ned can"", be ,.turned.)


&rod your _SIO Woodsmllh TIps& Tech

r,,,'kit A, 1V(!lIrr.<
Blf,~i(t'f'.t''''YOII',I.g

nlques 1912 Greod Ave Des MoIn~ Iowa


!i0309

Contetn~orary Oak Table


A SOLID OAK TABLE THAT'S BUILT TO LAST
tift~
years frcm now if SQmC01\~
find$ this
table colteclin~ctUf.l in an attic, orsitting at
the back or a garage piled with old newspapers and magazines, he'll pl"()b"bly remark, "Bu.l', Lhey sure dQn't build tables
like rhis anvmorv,"
This i. our ecntribution 10 the elIIS>' of
furniture thar. built 1,,13st, It's <olicloak,
h ea"" and sturdv, Bill I think It ha.s a eertain ~'armth ab<;ut it too, It's the kind ef
table you mighl expect to find ill a country
kitchen,
The table's LOp is thick anti solid, We
cI10S(' :;'4 red ook (:; 1. pronounced fivequarter, IS I'. "thick actual). And though

that much wood

;o;4l1nd:, expensive,

t'ed oak

eosts le~~than ('lear pine (at least around


here),
THE TAIILE'S lOP

"'e started construction with the- table's


top, It consists of fourteen pieces of oak
glued up in butcher blllck fashion to form
35- x :15"~Iuare. \\'tt cut lhe!'c pieces 21;~"
wide and about :ll;"long to begin with, (Af,
ter the boards ~Il'C I,llued up the ends are
trimmed to as" with. Skil saw.)
Once the piece. tor the 101'arc cut, we
layed them OUt and arrauged them Cor
grain pattern. Since \,'E' were \\tot-king with

ahtrge number of narrow beards, we chose

cut J!:I'OO"(!j; in th" edges anti join the


beards with splines.
A. shown in I"j!, 1.
wid. by'. deep
gnK'VCl< an, stopped about I' from each
end, When cutting these grooves, we SCI
U,) the table saw as shown in Vig, 2, markin~ lh\' $tan 31\d stop points 011 n piece of
ma.king tape, The t\\'o end boarel. were
cut first. with a groove on one edj!l' only,
Then I(TO"V" Were cut on both edges of'the
other 12 boards.
It's important when cutting thesc
l(l"()\lves to alw ays keep the same side of the
board townrd the fence, (\Ve always placed
th. face, or tup .ide of each board against
tho r.nce.) AII'(I, It's.best to make a trial cut
in a piece of serap just to make SUI'" the
groove i,the correct width for the It," ply,
wood splines,
The end of each groove curves up be
C'dU"",, of the shape of the saw blade, Rather
than cut the end. of .11the splines to match
II)

V.

this curve, we ;.;imp[)'cut the splines n toW I


I short, allowinllZ" at each end where

or

'tWooo SflUNI

II,' ...

lWlDE

'Am

A,\I,$1CING 'Af'\

\h~curve is.
Now the boards for the top are ready to
be glued up, With this lIlany boards, it',
ju.t aOOUl impo.sible to glue up all of lhem
at once, \\'f glued th ese 00"''11. together
progressively, applying glue to the lodg<>b
,I

\m()DSMIT1i

oft wa boards and clamping them together.


then loosening' the clamps, adding another
board, etc. (For all of this gluing we used
Eimer', Carpenter's Glue, the yellow
kind.)
The 'pline< should force the top>,of th"
board. flush. Then irs just a mailer of
making sure Lhe top doesn't cup, To prevent any cuppiJlt( we placed some waxed
paper over the ends of Ihe OO3.. Is and used
Jorgensell hand .CI'e"'S to keep the surface
flat, Fig, 3.

fiGURE It

EO

,'/

"';.

the four corners otthe lcgl' and the bottom


edges are: rounded O\'C.' with a router and a
t',. quarter-round bit,
THE APRONS

Once the mortises art' dune, the tCll011S arc


cut at the end of the aprons, Make sure the
distance bet
the two shoulders of the

WL"'"

tenons is exactlv the same on all four


aprons, Fig. 6. The bottom edj!e of the
apron is rounded with. ,," quarter-round
bit.
Aner the tenons are cut. grooves are cut
in two of the aprons (see fig. i) to accept
the button tasteners, This method of
fastening is very hanIJ)' (UI'removing' and
,,,atLaching the lOp. IThis table is \'0")"
heavy, if it need. to be moved u's much
easier to remove the LOp.)
However. there is another reason (or
u$ing these 'buttons.' A table top this wide
is bound to swell and shrink with changes
in humidity throughout the year, The buttons can slide in the groove as the to!'
moves. thus pl'(:ventinl! an~' pressure that
might cause splitting.
fINISHING

WOODSldlTH

/'

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ho.

r--li

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-c".' '~1ii;jr.~

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l'v'--";-~

f~U'f IOl...-

)]V

ll'>

BUlTON _.

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lV."'J,hSCIt(W

....

MATERIALS LIST

.j(;'"
2'10 - 28
t II'.-!'r.-1M""

8 leg" finish.d ~
logs, two pes.)
I
C

legt, one pc.

v~

Apron, finilhed

'1' 3 ~. 2S~.,I,.'

CUTTING DIAGRAM

to,VttW

'"

THREEao.... 05

AGUt. I.

_'"

1~",.)""
.'6"

TWOIOAltDS

COINER
lOUNO

! ;;;,;;.t, 121

TWOIOAADS

';..0')1

I~Y
.....

~-CO~NU

lOU"O\v.-cORNEatoUNO

.5'....
-72

I"'_,

l':2>,1u::izIZ2;::,J

'S"

1)'

~'4y;,tj

lYI.,,353S
A Top. finished
TOPt i&o(hpie(~ I' J.~ Yi. JC 21/,. 36,.;,

:c
"
In ..

v. COl"..

'/'/
.'" .;

aunON

5'..,",'0.- s:

1,~7

... --1

:::.t. -

I~
#

-'10.--

:.

--I".._ ...;

\0\. PilOT HOU:

,'

,v.......

L.--(:--

~1

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'-c GltOOYl

~.

Ij,j,~11~
.J-";'I.=ota

AGUila

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'OUI.::;;

.~.-

_,..~,

.~

UP

The ends oflhe table tOPtan now be cut off


to the 35lcl1!(th, Then the top and bottom
edges are rounded over with a Y"' quarterround bit.
To finish this table we applied ['roll 8:
Lambert Sanding Sealer H-40 to the le~
and lOp. Then we added twOcoat~of I' 8: L
varnish to the top only. iVal"i$h is nut
really necessary on the legs.)
The entire table was rubbed OUl with
pumice stone and rubbing <Iii 10 a satin
sheen. (This [U\ishing procedure is discussed in detail in lI'oodsr>I;ill No. 1-1.)

.z'~/J.

-<:;.--::;;-.-

:J

-:7
-~

'IGUIU "~i

mortises L-.; de~tribed on page 12.) ~~inaU)',

"'Of<

2',

r"~,
~, /

..

;:J
.....

r;.;';

,.

1 ./..

While the top wa> d~;ng,we \\ ent ahead


and worked on the legs, Each lel1is glued
up from thr-ee pieces of stock. (!;ee Fig. ,I)
to form a 21'," square leg. There's no special
approach to doing this. ju;t apply the glue
and clamp up the pieces with a> mall), (;damps as you can find.
After the glue i; dry, scrape off any excess, and run the edges over 8 jointer or
through the table saw to square them up.
Then the mortises canbe ehcpped out, fig.
5. (The mer.hod we used for cutting the

ltG

..

THE lEGS

l.,.

'....
.-a3i,' ,60'

La. ,~~,....l;:
TWOIOAROS

l.

C:::~=.J
1

twoaGAtos
1

tl

8, ,:

,fa

3',..-.60

;p

e3

~' 31')' .60'

t'(/1

-/~.'
-z

TECHNIQUES WE USE TO BUILD A TABLETOP


Tht.'n al, 1))11>'
l ,,"'f. \\'al~ to f!t'l U Lat,lt, top

;11Jsolutf"I~'...mooth and fini ..hed tu II('r(l"f~


'Ion'

ou (1In bu)- a 141l (If

\'('1")'

lHr'Jll. \('1")'

.'IK 1151,
... equipmem lhal \\ in do the Job
nlc"'~ . Or. you ran >pend ),"'''' d"~loptng
Ih, ,kill. "",I craftsman-hip neee 01:11') 10
(1(1It t,) hand. There really l.,;n'l a'l,) 143)'
th,- a\t:ra~\' J{U~'in the a\'l'rd~t"..hf'l' can
I(,'t ~(""I lV.ull- nn a labl,' 1<11'
HIII"'II'~!All you have 10do i."'1,1".... nil
lhut t'XIH'IlSI\'(' equipment nnfl )'l'U~ .,( exlH.'ri4.'Ilft' with one simple t(w,l: 1l.<t.lil'Jlt,,\,~

I'm 11(,l s.:cung to :-ta," t11:\l ....mtKJlhln" and


ftlu",hulf ~ tahle top i~
Pa....) It':!> n<lt Hut u
can 1'1(" (IIInt' wuh just a (4:" tOCII.~
it

\\ holt.

I()l

.,f pauenee.

.,xI

SElECTING THE BOARDS

The fi",1 step in buildine:an)lhm.:i.' ""I<'ct


inJ:Ih. "",Jd. \\'hile thls i.-th~ fin-I ,h'P in
mHkmKa labl~ I<lP,it'. abo Ih,' fir-t prob-

~~~~:~~~

I can'l d,'IIY lhal ahemalinl!thebadl.I.\


grain of each board makes sense, (
Problems do ari.", ju.t because of the nature of wcod . . It moves: shrink" . wells,
"m.
Th~ hullding of a tabl ...101linvoll'l'. join warps. IWi!>IA,lInd
cups, Thi~ movement is
caused
by
absorption
or rele ase of moisin): "'\'('ral board . SU( the fini.hl~l IIrn
,11"'1,huu"l negate this p'"<lCe>'... the 101' lure.lnthcoldd8~'~wh
en almost all wood
sh uuld look like it's one homn~.n.nuK
\\'8$ air dried, "o.,d continued to move for
J,j'''<'l". lMlt ju.:-l a bunch of tM..,\m$ -tuek
man~' years, BUI n"" oday" almost "II
lt~tt
h~
-r.
wood i- kiln dnM And Ih... reduce;; many
(){ ('OUt'-(". "-e're dealing with \l(J()(I. not
of these problemI.l....ue IlI'll8JIII Each board i.!lin!: tu be
Also, in IIx- old day. table lOp.; were
cll'n-Ill. btlt matchlo)! tht t.o8n:I'" ft,r made or \.'~I").\\ ide bc~ls. The-wider the
jI1'lllnp;llkmand colur,hould ""dhlle" 'Ih board. the greater chance of cupping.
n CI{')(I"(' of raTe an(1 ~{tn"lti\ il~. Anti (Cupping is" h~n a boanl 'curb', fonning a
Ihough .u Ihe board. can't 1", icl"nlicul Lll!bapedconcaveorconv~.an:h3ero."'it,
IlI'in., Ihey .hnuld at ",." I", ki"JnJr widlb.) M.,.t hRnlwood ~old today is only
(.'(~u$i n l',
"""ilable in ,-cloth'ply nllrl'Owwidths. Thi.
One(' Ih. hO.lI-d, arc ""Ieol<-<l,la)" 1111'111is aotually an advanUl)!c. In facI, even If
uut In 1hI' ordcr lbey will Ix-juinecl. Then. ,,~de board, are pur<h ori. they should IxJU" to "'P lbinJ(>" ....ighl. I dra" u lal'l!c ripped do" n 10 I or S' in width.
In.ngl, alll.tJ a rpenl<r, In.n~lel
JOINING THl BOARDS

.... II.. true thal)OO can't jom the


u,d"f"neboan!C.hurtgrain)\olh,,I'I'
of
anQlh", board (long jI1'llinlwith IIluI' onl).
lIuljoinin): "Igc to edge (lonl( gJ'III1l 10lonj!
J,'min) doe, produce a good glue joint, on,
,hnl'. quit.. strong,
However, whether vou u,,, d<l",b.
,plill~'
or ju,l II bull joinl, Ihere. no point
in even al'I'I)~ng the j!lup un Ie Ih, .~I~I'
of th. boards are square with Ih, thl'
((.cel. IItlV "e Jrel into an 8IVa thaI',
f'rau~hl" llh dchat .
11"w ,I"~yoJI :cqtlart' UJl ,,,. ,.,Igf III
He~'> "hall do. I checkm)' labll' ~,\\.. In
mak, ,un' th, blade is ""'1>"ndicul"r to Ih,
tabh'. Then 1 rip 3 clean l,dg" nn th~
boanl . Ir ,t'. hardwood, I u~ n lOtooth
carbid('lil'l'l-d blade. Ifil'~ ,0f\w(KMI,I u'.
a hollowground planer blade. 'l'h:u'" il.
You can, if you have a jointer. cI.'an Ih,
.." mario<off th. edge<. tr you dun'l h.v,'
a jomler. you've jU>1:;aved you"",lf Ihe
co.-I of anoth~r pit'Ct'of equipm<'nt and 0'1('
To gel the \\;dth I1('(C 1'31')' for. table lOp. ""'I't' .t~l'.
,~,-.ralboard. must be glut'<! logether.
~o" I'm ready to U~up Ih, boanl-.
Mg. to edJr'" SI","dil14la !illi. extra time
\\'en. not quite yet. 'J'Illi;"" here ",""'lice
at th;" .tage will .....,,ho"," of \\Corklater.
III imIM,I1"nl. I pl.ce the board. 011 a nat
"<1'0" all the boarel" AlthouJ:h olher
Su, whoI'. 1/", b".1 ""1110 )0;" III.
"urrac,'(lh., \(I1'0fthetable.awlnntl
I",-h
m"thocl. (If marking Ih~ h""nl. "lin b. boo,.d.llt lViII,
Il'ilil .pli"Cl/I!
th"IlI logelher wilh hand pre.'u~.
u<,'d. Ih., ,'a'llt?lll~r'$ uionll:le i l1mnl),
Many book. de""ribe Ih~ 1I\1eof dowel.
If Ihe joinl between the two boanl, i.
t)n(' nrthtt ~hnl)I~:\t. M ~ho\\'n in tht clrtt\\
or splines whon joinill): boanl odge \0 tight. I'm halfway the' .... Next. I Rip thl'
ln~ nbo\'t'. '"en through tht '']Il(u..iun
OOIW for a I"bl" lup, 1\', usually Mid that
boan!. o"crand cheek tho joinl on Ih(I~'I
C'Uttlng nnel Jvlning. th( bllaJ,I~ c.1l11t'a"'II~' now.l. or .plinl I~,,~'\hcn Ibe joint. 110m .idt,. If thi&joint is lighl, I'm all Ih~
l~'
n:lunl~"C1to their propt'r ~Ut-'n('C
Ihink that'. a linl,' mi.leadinlt. Th. real
"lty Ih,'I'\'. If not, it probably rn"a... Ihal
IJu 1ft> t Or'1'f1.tl!(f: tll( iJlflftrtU." 'hi' 9"lt"
puf'J"N' 0[ do" ~18or ~I'li~,
i.- 10 gel tJko th,' I'll" blade i. nOI really ""I al !It.1.
UJlII,,..,, (II Illr ("lid (J(tl r /x)(Jn!tl""n.'i"$ "P
boal"li> nu.b across 11M>
t"p. If you're nol
I\'B nc,tl>ec<,"''1' 10""",1 tIM>blade and
ON ,1, ",.., bottnl Ie}.c" u, ,It~
6tn,mf NI'. enremelr .a....,J'uI"hen a1illTlinglhedo,,"_1
np N'" edl!:c-. Ju>t take one boanI and
dfJtrH. tt~,
hoi"". or the i!l'1O'C. for tm, .pli""". you're place it on Ihe """" with th<.>'8C'e
dOlln
I Ill'...... yuU,..,.Uppo>M to. HUI Ih,...., jusl defeaung the "hole pUI']J<""'.
IhlS orne. No" rip a new t'<!I1:P.WhAI thIS
:&1\\n~'"
~mti lo be $Orne tlercet thill ,l(O\lr:So knIt' (/0 r/f'" jOlJt tit, ~HlnL'f~
d~,in efi'l"Ct. is produce a bc\(l)rirJ Jflint,
to\'fl'l1th,nJC up. So 1 jwt rh(){Jl'it>thl' ht'l'It
I just pUI ,orne ~luc on the edges and OneboanligbeveledlOtheright.lh,oll",r
.. d" of cnch board, and mnk~ Ihlll ,,,I,'lh,
clamp Ihem tOI:,lh., - " 1l00d old bun
i. bcvek-d the ,"mc amounl to Ih" lun .
(al'''' (t.r [C)) ::.ide.
joinl. Thi" simple joilll h", ""'ec:iVl.tJ
a lot of Thu the IWOe<lge<will be nu.h.

"""",.t

.,r

.,d.

ti

~DSMITH

GLUING AND CLAMPING

The hoanl. hav(' been rh"""n for w..m and


eelor, the Mg.- an. cut -'lu,,",. anti I'm
re"lIy to Illu~ them. lu)(.th~r. Again

but nett So much that it'~Slollllmj{ all over


the pIat.
Should !/fltl ~r'fNo1ltlr,~r:rr"s gl"r.ll1th
n tin'Jfp ("11,,1 I

Tho in.-truclions on Ih,' glue ooltiP' rv


commend
lhut you do. 1 dOli'\, I think thlll
pauenee, I !."'tI'\'erything ready. ju.t "' ir
I were go"'g to apply lho IIlue and clamp \\;ping at Ihi. point dilute th~ 111u<'and
them up. Th.:n I ",,( tho glue .. ide. Rut I ~o ft)~ it int(, th( wood - making it \'('1")'
ah""d and t'blmp the 00anI, tOJl"th~r - It difficult 10 ,and out later,
(1'1' run l(, (ht"('k thin~ out
1 lean' Ih" boards claml..~l up jU.'1 th.
\\'ben clamping. I us. 1"1'" clamp> (hal' way lh~y an' ror at le t an hour. but usualclamps 11'"d to bend too mueh), You n(~d Iy overnigfn. Then I use (I r~lint scraper
enough damp" so they're 'I .. ced no mon- !lh" kind u'I.,1 for scrap ill): I'inl orr thl'
than Ii to " apart. AI,.... lhoy should t.:
..id(! of 3 hf,u!'o"} to SO"aIl(' K\\3)o' the (In",1
glue. Then you're ready to "m()()th tb"
alternated, OtIC' on top,
on the bouom,
ete, Thi" \("00" to t!'CiUall~"the \\""3.rrtlng
boards, mak,"~ them a I"hlt top.
(cupping) .IIu,en b) I hi' clamp; them
SMOOTHING THt TOP
selves,
:0:., thel'" Ih.,y sit. A hunch of h oards glul'(l
Til(hlcn Ih. damp, until the gal' "',.
tween tht boards di:-.al'lK'ar:o-. :\()\ l'''. IO!!'lth.,, challen!l:inll you tu lran,r"rm
tight. nc,t too Ioo...:e~
la~a Ir)nc- :o-t,'(' Ihem inlo a tahl. top. Roll up your ,Jee' (.
ru1er nr a rraming ~uart (1\ l'r the \\;.Ith elf anti H100d(' ~'our \\-eapctns.
the tOIJ. '\'(.u rna~'find thl' tC),. i...
<:\IJ'J,,'(I.
The tOf,l:"!)'OU choo.."\ "tin
..' he po\\'e-rt.-fl h.\
Thi.<problem .hould I", ",I\'ed Ix>f"... th. eleclricit~' or muscle, Thi! IXJ\\'er sour"-,,,"
glue 1(..... Ull.
do n'l r"ally make much dirre,...nl'e. B',lh
If )'OU'I\.' ~\lrE' the ('(JI.:'s.",,:;.quart:'. th.'n ....'lluirt> a cK,ntlclooch.
:d "ith th, ta,k o( ,moothin~
Ihe prubl.m ,- u.<u"l1~ '\llh th. I"l'"
clamp- l.oo.n anclli~"'It'fl them tr;illg 10 out a labl,lup. mo.t PI~,lp ( think) \\'oold
gel thE' h.1:\nJ~ le"el. If lhl!ll (lfJt:~n'l\\llrk t
.h""", .k~trictool-. II look, like a lot or
us.uall~ f":-olton JOr(1t"IIf'" h:lncl $(,It\\~ work HI i.l. and IhoS<'link l'Iecu'ic mOll"'"
I\CTo......
' lht ('n(l~ftCthe bejar,I:-1. 'rhis \'.;11 j!'t)l
\\'hizz.illg a\\'3)' \\ill ~oml'\\'R)o' "lake thjnp
much I... difficulL But. Ih., difficult,' h,n
rid of Ih~ \\ 1lI'P. 3-< well ., I,ullthe oo.nl,
i. not Ih, amount of phy.ical labor in{J~h (in linl' &Ct"'Q:S."; tht t('I)',
\\'b"n Ih. ooan!' are finall, fiu,;h and Ih.
vohed. Ralh.r. it'; a malter of control.
lop i- f.......of warp. ( I,..",.n .lIlhe dam!"
The po.,.."... of both ell",lnc and hand tool
aud I'm rtlldyto glue. F~I'.hno.t aUJl;luing ll!'oLo rem()\'C \\'ood. Ho\\ nluch \\'ood th,','
I U:--f1 F,.if/,A{,l1 Tilt'hun<1 \1l"
remo,'e. unci whelhel'lh~)' remo"e it in Ih,
I)roper pla('(l~.i~
up to ~'Oll
Carpenlt" Glu. (both lIr Ih""" RI... "y.l
I,,","~u...). I -prelld Ihlltlul on on. ',I~.
SMOOTHING WITH IUeTRle TOOLS
of ,,~h boanl \\itha .mall ( ,.., pamt bru-h.
If \'00 ch(lO..t ('ll"Clnc tf)11s \(,u need t""
The glu .. ..hlluld go on in al' ("\'eJl coat. It
should look kind (If glo,-y all alung Ih, pi....., of "qUlpmenl: a b<.!t .ander and ..
"dge. If Ih, 1(1". appeal'l' rlull in a spot 01' fini.h band~r.The choic~ of a Ix>lt"",nnN'I,
I wo. il 1I11'.n$ it ha. ""ak,d in. Apply a
Ilrett)' \\itt, 0l'(~n. ("'{' I,J~{.(1 St'CJ~"R
moch,:1. 1
Rut Ih,' filll..h ~ntl(!r i!"- a mo~ rliffi("ult
btlk- bit m",.".
.-\"I'm putting the pill<'cl:<mp,back" I cholt'\:, I "t.ulcl ret"Ornrn('rwi a R(~t rvll
~/W{J BI'k' ()rhitaJ Sandtr It....e'\~wn.
...i\t
plal,(~ :;t"I':o>u(,\'a,.'(e<l p;tJl"r f,\,er the jUlnl
to makp 'SUr'\' the pipe (I')\'~n't touch an)' (If
(about $7bl lind bUill f",' rommel"<'ial \I
Hut il'~ ".,11 wOl~hth~ I'ri('" - ~"p.:eially
lhe !l:lu~. Iflh" Ilil)(.>dne. \(I"eh ""m,'
t.herc ,,;11 1>< hemical """'lion fOmlinl( " on 3 pl'<ljl't:l like a tabl, top.
If th4! t.,bl," tllp k \'f:I1' n;.\a)!h ~'(1Umol)'
black !'o)))"l('h fln the Yo '" .. I.
\tant lu rooj:h I,lane it IMrore.t:utin"" lth
WAXlO,,.,.-t
Ih~ belt F.",I~r. I\-e fourKI thaI one ..( the
be~ttool~ [(Ir "nl(Klthin~ 11l1'",t'r:o-urface:o' 1$.1

"""t

~I)".

\\n,'!! r...

EI,,,.',,',,

g""',

1I'0gll'I'

S.~(rr.I'la"'r.

'rhe S(I'" r/)!a,rri'

'\M~ t1i!'-cu.s~l(1

In

'\"()(J(ixIJ"tlt Xumber Tln. 'l'ool~ of tht

Cl,AMl'$6 to. "'All

A.... th4' "'lamllS an' tlcl\t"OC"f1, an "'tn


line of glu. lIhouId _I' UI' bet"' ....n lh.
oo.nl-. (Thi. may Ix> ,. hne of bead, IIf
glue.) Th"l'. good. You kllu\I lh~r~.
~n"uj(h gluc in thejoinl '" il, nul ,lnrvltI.
'WOODS1UTH

Trade. \\bt'n Ihi> pla""r IS mounted un ~


raclial ann N\\'. it \\il) du ;tn t..\C'\Itt>ntji)l)flf
taking orr tho high '1101' on a I:.rg< nat
~urfa('(' like u labl~ top.
The bell .:tndfr i.,u,...d 1ll',I, ThouJth Ihe
.)urpo:;( or a btlt f'.aI1der i~
to tak(. oiT '\'(JOeI.
it.$ool the"Inotor that fit"":"the- ,,'ork, It',.
the gnl on Ih,' b..lt. Your hall,1 i.:, not \1,,,1
to p~ oQ\\n on thl' ~"\n('er (that jU:"!l
m~ke~ tho mlltor tl'elh~atl. I t', jU~1I h,I,
to guidl' Ih~ 1>1'11in the ril(ht direction.

"'/IUI

grtt

tt,) 'I'lll st(lrl. "'Itl,}

I would r(t"flmmtnri all "(.'grit bt'lt


Coarser gril- would remove mon- ,,00<1
but they \\ euld create l.l'1(l' MratC'ht- .. 10
Ihe ",lOll An NJ-jmt belt loki' morE"tim,
(lind )'ou'll hll'' to chang. Ih, b..Its monoften) btlt \'llu"re Jess. lik.ll\, to run intI'

serious trUlit,le.

Al Ii....i, hold the ",n.I,ral a -light angl..


10 the l(I'8in "r IhI.' "'lIUIl.abool3l If;ou
hold the ~nll(.-'r at 90 t() tht ).'nlin (ar ....~:-..;
the width). il will take hl1' more woorl.
ra~ter. hut Yf)U may \\'iflll UI' with Inr.r,>
ripples or \\'.\'f>"; on the :o.UrfH"! Holding it
.t aboul 3<1 take. orr "nou~h w ..od wuh
Ie", chance IIr ......
u,ing ril>pl"
Hold th~ ",.nder liJthll) . Rndkt't'r.it movIng. Th~ billJ.!"'~t(Ianger is pu ..hlnj.! the sander SOit til)')\ up ()IIone r(IJ,!l und f!0ugt'~ (lUl
JI (Jeep scratch
After tht' te'I' i~
It.'\'t"lt'fl,turn thesl.'Kl\:r
to 1114)\'e
,,,th th(_'nain. ~l"l.lrl \\'Ith an ~)..
~'"tIx>lt. )10,." It up anti b..rk. from Ollt
edg!! to th ... othlr (a~ if ~'I'U\\ l're JrQninK)
Slop e"~I'y "" oflen and ch~"k the SUrf.CI
\\;th a ton.'! rult.'r or frnminJ.t M\Uart' If
Ih~,...arp an)' hilth ,put, Im:lrk Ihtm , h
.n "X'"arul"lc)\\ tht r1)f)\'('nlt'nt orth~ --an..
Cll~rO\'t"rthl....arl"~ to ta~,I'(Irf more \\ oocl
\\'h~n )ou,< Kot th, lahl. tol' Oat.
change to n HI(Igrit or u 1:!1.~"itbelt lu
,1II.d out Ih,' marl<$left b)' th, r'>aI'l'er ~'1il.
finally. u,, Ihe Rl)I"k" 1/
810(" 10
and out uU .. Ttllch"" lell b, Ihe bcl1 ...an.
d~r I 11* ,,"cjlTit Canrct I"ptr ror
o~l'lllion. I r the '<;1',,1HI, .... ha; I.fl an)
>\1;1'1mark, IiI probably \l'111tu " han,1
'anding black \\ ilh 12()~""1l;"n101 P"~~'I'
to I!~t th~m u.Jt

.'1'''''

I'"

SMOOTHING WITH HAND TOOLS


It _la\ ~""t'ln like- .. C(nltnl,h~,ti(lll. 1,ut I
lhflik \\'orkif'~ \\'ilh hut,,1 tlHll~i~nlUL'h
t.."Ul"icrthall \\'ol'kin,r \\'ith l)(I\\l')" tool!-, ,-\~

mcntion(."(1 carlit>r. it'~ 11(111I1u:-<le PO\\l'"


thal mak"" Ihln~~ diffirull It'- ,"01111'01I
r....,11ha'. bett,r conI !'> ,1 '\llh h.,,)ojtool.A labl .. till' ran tK> :olnlltllth"",l to nt'a.'
perree!iQn wilh I1IW pl"m'. ".I.I.k 1.lalw. Th.
on~ I u..~.j", a II"c."4)rJ"a~11tt,IIl4:)tl4)lnRI'(,I"'I1

,0,,,

ja.k plan.,. It
ahom ~I;''>.\\'hen th.
I,lane iroJI b f'harp and lt~s~~'1JU"I n~ht.
th('re'~ 11(1 bttttr it>'elin\!In tlw \\(.Itlrl Illr
"tJOd\\

I)rkJn~),

\'ou cotn 1,1AOC'3 tahll) tup in Ie::-$ llrn,


Ihan it wkl" with. Ix>It,.,u.d,,. Alln. ,ou
\\on't ha\', rltlUll...of l'\a"du ..t all f'\"t_'r 'rh,'
,hoI' (and hOll"").
After plamnlt th~ 101' '''Ih Ih.. ja,k
platl{>'. J :-flml'\lnll':- Jt00\ ,,rIt '\-Ith a ~m(,.It h

"Inne (~lIrIn 10111(1.


bUI I u'"ally lin,llhiunnt'Ce<';Kr)'if the jack ph"lL' IIInd the jlll"k
plane ofl\'ralclr) ....\\'o-rkin.: I'nl)\'rl,\'.
The final 'ttl' IS~n.M)thltlt tht' ...ur(aCt
"'Ih a hand II<'ral",rblI., (".... IIwd .. "'1I
~u I~l. Th" httl. pi"". oi .1,'(,'1"ill work
""OIK\Cl't'OJl t h'l t~lbletO~l, 1"~t\,lllJt'the ,,111n
{'lean allcl ('I~'nl' I"t'ad~'r,u' the finh.h.

A Chair Built Of tlak

A CONTEMPORARY CHAIR WITH FLASHY JOINTS


nu:n:'~ no way that building a chair en" be
considered easy, Sturdy eonsuuetion and
proper joinery Are certainly required.
Beyond tbat, II chair must IX' designed to
oomrOl'labl:;accept the human anatomy.
'Ihe chair shown here was designed as a
companion to the table shown earlier in
this issue. We tried to ne..ign chair that
was sturdy and sturdy looking, comfort
able for dining, and most, important, 3 chair
that \\'8.$ made of ,,'Wd,
Before jtetling into the actual construetion orlhis chair, Ithink it'. appropriatelo
mention that the dimensions of this chair
can (and probably should be) altered,
For dining chairs two criteria are important. The first consideration is the height
of the scat from the floor. This distance is
usually somewhere around 16- to 17", but
can be altered (01' II 'tailored' fit, In fact,

this measurement can be taken directlv


from the person who'. going w IX' doing the
sitting, To do this, bend your knee slightly
and feel the crease on the back of the knee,
)!CllSure fl'1l111
the floor to this crease. This
then is the heil1:hlof the chair's seat from
Ih~ floor (not includinl( any roam or "pad.
ding on the seat).
The second consideration Is the relalionship between the seat and the chair
back, Th. seat of tho ehair u~uall~'slopes
down toward the back of the chair anywhere in the range of 0" to about 5', The
back is also angled. usually somewhere IX'.
Iwe~ 5' and 20',
Since both Ihe seat and th. back are
angled, the relationship between these
two (the net angle) determines the comfort
of the chair, This angle (for a dining chair)
should be between 9,';' and 100', The smaller angle (95 ) will feel comfcrtabte if you
~it up strwllht, The larll:er angle (10(1') will
reel comfortable if you tend to slouch 8
liUle, It's reaU~'sort of a personal deeision,
PRELIMINARY

WORK

All of what's been said above is just so


much theory When it gels down 10 actually building a chair, lhin~ can change, In
ract, during' the process of building this
chair we I1:OOfed.
The chair that's shown here has lh. seat
angled down 3t4' ann tbe back rest angled
8t6". Thi, yields a net angle of9'Z' bel ween
the s t and back, This means YUII have to
.11 well back in the chair, nnd sit up
5tl".lijtht. I lind this. little uncomfortable,
However. We d"dded to perform a 'test
sit' to s,!E'l some other opinions, The results:
Two people like it (Connie and Linda), One
liked il with reservations (Ted, because he

MATIRIAlS LIST
A Front L&gs(2)

l'/,.:It 2Y l:&
-1IYo.x2V 321/
C Sid. Roil. (2)
1'/,.xl Y,- 19
D frontlBockRoils(21 - '11 2'10 19
8 8ockl.eg.(2)

E Sid,Stretme.rs(2)
F C..... Str.tch.t(11
G Chair8ock(8)
H Plywood Slot
I Uphoistoyfobric

.. tY..x 1~.14.
Y.xl'lolO
y IY.. x 1'1'.lO
1,4. 1S'/. - 18

22 x 25

CUTTING DIAGRAM

I't.. )I: lV,- '2

LZIIZ~<?ut~;J;~
~2zr;;)~2~ZZf)29Z2~
V,".3~-.17'

WOODSMITH

built It and d.1nt want to start, all over

OIGutt 1

al<3lnl. ~nel I thoujZht til;: eeat should be


~ng,-"(I to. 0 an~k Ilhu....maltinJtthe net

an~I.96'>.

to

'''~

I "\1,,,,,1 1M results, and in fair and


impartial eI.'C inn ded"nod me th .. ";"l1('r.
So, all o( the lira" 1J1~'"and m_urempnL<
(or a.<.~mbhnl! Ih' -eat are h....
~ on a ()
anglr, II' hich 81"" make construction a

I'

IIUOd deal ~.'wr).


STARTING CONSTRUCTION

'H'OUOH
MOt"S'i

The 1i"'1 '11'1' " to nl' all the pieces to


width alld approximate IcnJtlh. Then lhe
(un begin s, The"".'" I~
m~rti ....and tenon
joint' in thi. chair. indueling three diff.
rent \3rif1,li(Jr1.~
on lhi!'! joint.
The ol"laill'hr,to .ho,," the beauty oftbi'
joint. lIut 1:... 1look, .... nt everythmz. A
\\l-cil"C:lm(lr1I~ t("non JOint i:- one of [ht"
.lronlCl'Sl j01ll1< In ...-oo,lI.orking
Con.'lnlctlOn Ix')nll> by <uIUnI' tbe (ronl
and hack I"I!" 10 I,",,'lh.
THF.LH.- The (r"nl I.I!" art' I' Ionl(on
the ,,hi.ilrshown. However. ir~touwant to
alter Ih ""1 height twhich is 16'/.. , you
must .. lju.t the 1""!lIh o( 1M (runt leg. If
you "hanl" Ih, (mnl leW', the back leg.
must 1>1' changed by the earne amoum
AI,,", when cUlling Ih. back leJ!11to lenj!th,
mhor lh. top, HI I)' , "" shown in fig. 3.
~1{'RTI~l'"IS I.~:{;l"l-'ir~lcut a notch in
both the front and back leg, 10 accept
the Jo;irtp rail. ";l't,.' "iJt. 1. Then. inside
this nOlth, lhrouJlh mortises are laid
oUI, drilled and chopped squa re. finally,
~I{lPI){
..t nwn,,.,,:- cut rK'ar the bottom o(
Ihe Ie" fur lit" ,t ....
fig.
"orr. St"l,by'lep instructions for
thoPI.in~out l~
moruse-,are given on
fo:tJ:l.' 12

"h.,.,..

6'

",
I
i
II,
I

._.., I
II
17'

2.

'''''Lt.ll J(ORTIS[S SACK LEe La~'nj(


out lite antd<-cImoru-e-, for tM back rest
,t'ig 3J1,en''''rthan
it 1001<.,.Since the top

"fth~ bark Ipl( ha. beenmitered at 6'. it',


~imply a matte r of plodnl!' a I,), square on
Ihe IOJlof Ihl' leg ano ",arlring a line dow n
the .ide oflhp leg. Then the through mertises arl' laid OUIand cut as shown.
"IU~ RAIL Thor., art' actually two joints
th.l hold the .irle rail 10 the from and back
llJ,rs. Rt.ft.rto "'ig. -t. "'ir>l. a notch iSC'Ulin
the ,id~
rail to m.trh Ill;: notrh on the from
and b k Ie" . This 111 elfee!. creates a
holf,13jljoint. However. before thb notch
i,rut, it's ""'1 10 rout tM edge. to thoir
half roo...1.hal""" hleh we diel nn a rout e r
",hIe "lilt a~ quartprroondb,LI
Aii.r tM notch'. cut, tho front k'J: i~I
In the notch and1M throuj!"h moruse (" hi.h h... a1",ady been rut in the t~1
i,used .. (I gu,de to mark out the stopped
mortise in th" >id~ rail, fig. ~.
STHt:r<'HI;K The final step ,at least at
this point) b tu rut the tenens at the end of
the side ,tretchel'll to lit their rellpectivc
mort I",,". All\O.n through mortise must IxCIll fo.. (h('
Mln-teh.r.

\\'OODS14ITli

'IOU.tS

Irq'
'tOutle

It=
o '

14....
12"'.

--i

C6t

,,0

..~

MOCTI5.eCfNTtIID

'.

c...,...

CUnlNG
~If'l'~'
such

THE TENONS

precise f'ill~ required fur the

len"n" .1 may be hdpful tueut the-m .Iijlhl.


Iy larl(.'r than needed and parethem 10 SI7."
with R chisel. 'l'hi1> i:; a lilllf' (.lxt,,. hl\nlt
'<f.rk, but will probably ray ..ff
A. mentioned before, the h'non~ al lh~
l.ntJ~o( th,' "'1(1('stretcher al"\' cut fil"1Lt
Th"!Ie &llfl !tntr~l""
.,Jon~\\Ilh thl

I(_~

11'".,

and Ih,' ,,,Il' raib- o;mpk'l('

the 1ra"",,'
lhal mak" up tbe lell and riKhl."I, .. O(I~
chair The "" (r.une> should be ,I.... a.~.
b'l~ttu Inakt~re the)' match. .
WIl,'n tvcrylhinjr check- out, Ih.,.

rr.lm,', ran b,..partially as-embl .. I, lIu" ."


or, I)nly Ih,' (nmt and back leg>.and Ih,' 1"0"
oln'leh,'r 31"1'glued up at lhi, lim.', The
'Siftt' rail i~
1)10('(,'<1in posiuon (but not tcllll'tl)
'" II", rrill11<'rail be "'Iu8 re,,1 UI' rlunn~
r1'lmpi"~.AIl('r the glue i,dry, 1111,'<IJ:"" or
Ihi' (ran" hndudinJr the .,~1, or th., I.~"')
~re ntUf)lltodover \\-ith a
qllart'r-rowkl

HOull,

v..-

bit

un a rutlt4,."r.

It... ~impl~ a mauer or hookant::


th('....
4 \\\0 frames t~thcr
with th.. ti\C
~I',"

pit-e..,.;

',UI'I.,rt'

the Cront and back rails,

tht back r"')'It!'.,ano Lht' C'J"Q:-.:-. ~trt'l,,'ht'r.


\,'tll'll cutlin)! lh(._, 1\'n"I1:-, t,n tht')'oj' Ii"t
pi"'l'l'" n,.l(' that the lli"tan('t' 1"'1\\('('11
:-.houl{I\I~()rlh(' tenons i~cxltl'll)'tlu- ...arl1f.'
on ~tll
Ilit,,(,(,:o., that i~
17*

Ii",

JU"Sl
111

\SI'

U\("

l(.\11

Th, tlimt'll.'I,IOU'"

the tto'UULIi.are shown in ~'1~ 6. 1<n

.o\,,(Orthe t".")r~:-.are eut, th(.bottom ,..tilt


of th('N. ,lIt't:"" ..houlct tM4 nlUrKkod 1)\( r

oe....

OfT ....

ClHTEIIlMft.A tt

ON_

,,'th a ,. 'IWlrt\'rround hit


t ItfJSS ~"i:.:1'("LR Llimt:Il ....
](J,1..... for th(
u-n..1I1 on the cross ~tntt'llt'r an' JOohcl" n In
fl).:. tl, n}tht The-e It'n~ln:-;arv \',Il " liltll'
1fln),!'

~.

thv Ii"
('1':-0.

,'f

t 11(.1)' I,mlnld(l ~t"'Jlll I - l)to)'untl


lh(' mortises In tho :oidC'!-tl'lt'h

Aft. r the tenons an?"cut

ttl

",izl", 1)4,\h

,,11.'1'" "r thi ... J1il'tt,,


are roulK1l'cI (,\',,1',
It \c h It. sn-- The back lt.'~\" ,1)',-' }t('nll~'

comfortable fit. In mof....l ch.urs


thl." eurv L4 ,i"Jle b)- ...team }'I('1l411'K th,'
I t"t"'t
\nolhl'r \\ 3)" of fttqn~ It 'll' tf' t.. ,}Ct"'a" lh\ ("UMt". \\'eo (ho.;;t lhL' :to"rond
m..\ ,,"lifl(or t hl ...c.-haJr. Hv\\ tv,r. In unter If.
,t'-"\'t.,nllt,,.Iatt thi .. CUI"\~. tht' O;)"k J't t~
ml1.~t 1.,.tn:ul\, ll~ lt1ujnj! up (CKlf I,itt'\.... IIf
,j , J'i,l.",k.c":l('h I)iece at IloU:--l I .- \\ltt ..
nll"\

rhl"l

4"C1fIll

t hi' t t'J1Cln::o. au'" ('Ul. H:-o:-ih"" rlUI 'i)t, j.

TI ~II'I..\TI. f'''1< ('l'I<\'I .. Til .Im.,hf)'

thlnJ,:':oo.tht

toU,'\.'("

for tht

rrflllt

.tlut '~ll'k

,O'_it

81\f'ltJll)'l alKI lh~ hack re:-l.!'>,...


It) thl'
t-;f,ll1t,\ 'In,.d~a lcml\)....
tt(ur lhliltun .. a"
h,,\\ ,lIn I>(."tail .0\ b." ll~nj:' a ,nl: :IItt.), 1)(
\\ IMN' .\t Of"" ,'IllI \\"t_' rlriJl("Ct a ....
m:t 1h"rl to

fit 0\' r a bract. ,.\t the l,ther t"l<I v. t' ("lItt" It


Unt' 1~ from lh.., hl,;,{1 anti the
.,th('r I' I fJlJm th..o hmo, 'rhf'll anot'
IlCJt~~

41111"n

(In

\\t'''

,'Il'Cl'

f,f 1-")!'otl'r boanl .In(1 th,'

Itn\I,I;ttt '''' ctll out.


I \\ISI,ct\ T('l'R\''''

To nlark th,'

C\lI'...

III tl,,- i'.,111t:unl b(i\:k r-diL-;.th('IU'~t"'Ilx';l)'rl


1,'J'II1)IIII' j~I)(,;.;;-ition(.-dun tIlt' ruil ~) Ihr'
III

C\lr\"e start~ fj.


ICI'IlJUO.,Uctu..il

rnlm lh(' t'hc.ulcler of the

ri. (Th,' ,.,{Itrail \\;11 r~l

OfT.lle

I.

on

lhi..... v~...\\ iele nUL :-1)(,\,1

Th~ $SImp t('ml)liltt' i~


th"'I1I)().:o:iliOOE'<l (In
lhe I!lued Ull block (ur Ih,' bark l'e.l.l>a.
o;h(.\\'fl in lklHill, TII(' rUr'\c.oi..
barnba\\'l-d
tIl rough ~h:tJk.-."r~t m(lOtht.'(1c.lU\\"'tl with a

(O'H(I 0' ',MlI'lAtl!


M(I'SCOIN'.
OI'StOCC

,.".k,.,.h3\( and ha.. 1 ,..,roper blade to

.-\l~I.
the COJ"l'lCrs or
lbe baci;n"t'Br\' rouM,.1 "rrloa I' radill.-.
final t.bickne!'o'"

.,i ,

\\ IJ<;j'n ~,",

,,<'<I,,e<!

Tht'"

art' .lotal o(t~n

t~Mn, on th .. "hair, Six of Ibem


I,.. real but ruur ur th.'m lire fake I.e. Fig,

x). 1'he (OUI' Cllkt'(1Ilt'k hultl the '!'ide rnil~ to


tho Ie!:". Th~.(, "rt' mll.tly (or d('('()ralion
but they abo >lIJlI,I.'m('nt th~ hftlf-Iapjoinl.
\\ooOSN.ITH

1I~~'".- r,

Figure U shows how the wedges force


the outside sections of the tenona~in~t
the angled eheeksof'the mortise. The trick
I> to cut slots in the tenon so the wedges

"GURE.

force the outside S>P.t:.i()nsout fat' enough to


fill the mortise, but without splitting. To

'V.

do lhi" flrst drill. Y,' diameter hole about


y;' fI'Omthe .houlder of the tenon, Then
use 3 back saw to saw down to the edges of
the hole.
The \\'edge~ we used COl'this: chair were
cut from some ","rap walnut (ju,'l for contrast in <'0101'), To make them, rip a piece or
scrap v....thick, Ya' wide, ::In(1 SC\'(,'I-a.1 inches
Ion)!,.Then sand one side of each end of this
~l1ill on a stationary belt sander to get a
taper as shown in rig. ~. Finally. cut 1I I
length off the end of this strip. Thi. i. the
\\ed(l:e. One note of caution: once lh~
wedges are in place. it is extremely (iiI1i
cult, if not im~sible tu (l:etthem out.
Now the chair can be assembled. The
side rail, are mounted tu the pa..tjall~'
assembled frames with the fake tenons,
fKlUlil D. Then the two frames are joinc..-i
together with the back rests, front and
back rails, and the cross st1'etch~,. Glue
everything up, drive in the wedge>. and
clamp it with pipe clamp'.
Wnen the glue i~dry. U$(;.belt sander to
!':lntl the protruding tenons tlush with the
(act' of the I~.

.,J.
"Ott-

1..-

'!I

I--

\::

,-

,R::8~

{~\~~
~

,.

IOPYffW

G~

l:.:..

/7?
V OfiTA.'
~y"

.~

/'

:~

r"

96..

/ ,.

iii""

not require an)' sewing. Basically, it'~


j\l~t

WOODS141TH

fl-rl'"

AGUlllO

'I'hp seal is a very simple process, that does

~. -,--

"1 ..

w.

V,---

~_)

THE SEAT

a pieee oi 0/"' pl~'w()()d\\ith a bUllchof .hal


low kerfs cut in it so it bends C:l$il~'to
match the curve 011 the front and back nUL<.
Belote the Iabrie and padding are added
to the plywood. Lvbrackets are mounted to
hold the seat to the chairrails. Fjrst fasten
L,b''ll.kcts to the r,.ont and back rails, l"ig.
Il. Then put the plywood in po~iti"n and
mark the hole tor the tOI) part of 1he 1.bracket. This end "fthe bracket is fastened
to the seat with ~ machine screw aile! deuble nut .~bly
shewn in Fil!. l:!.
:-10\\ a layer of I' foam i. place" on the
plywood. Oil top of the foam are layers of
cotton balling. A. shown in Fig. II there
are two extra IaY~l">of bau~ in the center of the $<>31.This. is ~.IU'" \\ hell the
seat is placed on the rails it will curve and
th<: Cabric wlll buckle slightly. The "xtrd
Illy.,.. make the top of the scat look nat.
Finnlly, the fabric is added. (The fabric,
foam padding and cotton ballin!?:should all
be available at most fabric stores.) \Ve
used a chocolate brown velour to COVerthe
seat. The fabric is cut to approximate slze
and wraped tightly around Ihe plywood
seat. and stapIL'(1in plaee with a sraple gun.
To lini.h this chair. we applied three
coats o( \I'atro Danish oil. The oil was
allowed to dry thoroughly Cabout two
weeks) and then we put on 3 wash coat of I
Ih.-cut white ,hell ae 10 add a liule luster,

-~.::r

"7

SAHOFlUSH

WIT)1ItAll

'.

~= ?

0?
/>

l_t

DRill "I.

RGUU.

wtOG1,

:'1

:'

','

" ..

.. <.

SlOEVlfW

AGUI'E 11

FIONTvtlW

~. -

,-

- """

',-PlYWOOD

-- ~

nGU.' l'

/'U""\

!MA~'
-\;;)"

11,.. ~
101ltAtKfT
FIGUlt 13

..-,.

.~

COUNTER'ORE
I~ DEfP

I ~ "MACHINE
SC.EW

,.
;oJ

--

,.> HtXNUT

~ CEHftl

RAll

{'"OtUt.L I. MOO

~- -- ~- .. - --i '"'11-"-

~
\;:_

?/
ST'IPtt.

,~!F':
n
~

IA",c,22-~

'""'_,.\_r "
II

Wedged Mortise and Tenon

STRONG, HANDSOME, AND A BIT OF A SHOW-OFF


-----A "l'flW:tfJ rn(lrli~('anfl tenon joinl u. one or
manship, while at tht' same time adding a

thf' :-.lr(Jn~,..t joint .. in woodworking,

fact. (,nft' thiN jtunt

~(.I(~

In

together.

it'to

nearly Iml"):-..iblto to J.t,-~tit apart, even if it's


nut ~luI(1.
Rut I\lrl\nJ..rth nJolt( i~
not what makes
lhi~ je,iJll NJ :tlllk'alillL!_ It':-oquite a hand ..
sorno joint - ;llm1)!".l to tIl,", }JlJilll of being a
bit f'(:l "hn\\ -(Iff. '1(.n.' alKi mflr(> furniture
if' ft'Ct'nt )'('~l",i...
bc>iJl,t.!' buill \\itb exposed
jojf1(r). TIlt 'A (-d~"(t mornse and tenon
offl'n- an {\l'(IJl'l1t o,lportunit)' to demnn'tllll, I!o"d J0ln('l'Y and ........,ful craft~

mort,,,,, aro ho\\ n In t"il,'llJ""' I throuJ1:bI;

cla,h o(

below, Though I'm su .... there are purists


or
does carry a price. who would ,",i_t that the moruse be chopIn this ease. the prlet' i, time. A good deal ped 0111with morti,inJl ch;"'I~. I.l', (ace h,
o( tim" i~
""Iuh"d because the mortise (or mOl1jl'ing ('hiMI~are tXlxn~j\eaO(J lhp
thi. joint must have "'Iunr"d comers, an,1 whole profl." of choppinll mortises by
the two end ch~I'1u<must be cut at a slight
hand i..."C~' liln(' consuming
angle. AI~u, tJlt' u-non must be cut to fit
I much prvfer to drill out most of the
prl"('i~(_'k'in the mClrtil"(_'. Then slots must W8.<t" in thl' nI<'rti",' first. Then u's just a
be cut 10ae""pt th~ ""1)10,, and finally lhe matter of "'!uaring the COn1(''''' and cleanwed!!., mu.t bo rut That's a lot of work
in", up t be <~ks. Tn do thi,. We use regu , , but I think It', worth it.
Iar old bull ,hisels - th.y..., cheap. and
TI\I' .tt-I ....((Or1a~;nJl out and rut~inJ1:the th.~' j!t't the Job done,
dl"<"MItIOIl.
C(IIIN', all o( this

SlUt.1T

1 I"k~

/~a!J,uq tll,f
11"11 (tl'

('f.~,

II t', Ilff

tIlt

11'/"" ""

III"rl,1t1

rllft'J.,;S

!I"" "~('.\Iark

de-

ball,

Ita f'"NI", r 1,,1tiC II)lIC/ \I(,ri' filII"


r I,,,r 'f (I 'I,,,r ',1113 "!ltd.

---

..
\
;,0(
"8r
Mark
'''/91'' (flld <Ileeks)
2
l'~u II,~
Tnt'" u" o,'/~idrfac ot 3 df'tll tJ",
tl,r roll (1"1,,. ,,,ark
of'i,;e~ ~.. t"hrrk "ff,. .. (,, ali!I" tl'f I,i' ffo
1", L"
I//~

Q{ the

""/11;11('.

(lit

all(Jthl-'rft.f't
10 tJ~ (",t~,df.
f)1 th( ,.tld r"~J,.-.8.

Furst tlf" bit


tltf IH"ftt I,it to
t"
out
I'HlrlilCf.
t"lfSid.
.",/,Uf

I,M-td. (11'9"

(I"

tt

1I(t'r

1",#

SMCMADUi Of tlNOH

__

,..a::><;;:;;1

~
,

Ih(1 ,,,o)1i.>f(,Of' th
flit' Nidr Ilt(,/
"';/1 l}l U9fl' 'tsf fhf ItJllltllt/f'r,If of till! (tll(lll.)

4 ,"M III, 1(1f" 111'~',17'lIi" i~


:;I"rt3Y/fUt-Jugllll

1)."" d,u, " Ii,

tr

,If ",/; ,,;

(Jilt)", ~.

(I,'/~,

5 ~'/ifllhrj',r. mil

"u'

lite
sid,
SInrt 1/11."IIar;"1I "I' Iht
flld. Ihe IIwrti.r. rhoppillq 10/11/1 depU,.
1'1,," I"'" Iii., "d~<lltek.III /ul/ deplh.
f)'~"'ltJ """,/( 01/

or

Cui tht t('null I() (IJ)/)~'O.r;'J/al(' siu,


(J b,1()'!('ntizt Refil"t'r"ttiug
(e1l0t1(III 1)lllrr
l PIIAt 81~rt RllOltlder- tu

6 It',t; "!l il ,url

~hlllltdr,.diAtlJUrtt r~r(I';"'rel

,
'AftIHD

OIIUHCIU

CHIIIt ..,
RJOHTAHGU

.,I, up
In'J,1,sr by
w Ilf
e,,1 ('
.Irip "' 11.>1)(/ fit "f.lgt
7 J",iV'
8
9
tJ" ,I/uri ix,. Till " d"ll IIoleg about "'....
"11,1<IIuk. at a "'ghl allglt.
elll
sla',,_ TOI1t'f
belt
uud
r,
lH,t'k
abolll ~ }"Olll .. ",1 r/ ...~k. elli ...1 ,,ill rill ofI Itllll,h. fur II'N.I{/<~.AjI,.,. Joint i.
f"rt.

"""11 '(1fit pl'Cristly III

~/I",,/(/;
CJllfl ,,~"
$01(' 10 r"t
s/lJt~ 1<1.,,;i(1111
((tll"II ttl Illf d,.,'frd

/."tlll/

J,m,s_

f;1,;.

(Ill

al."i),'fl (l1I1(1,""li('ullll

tttfti1tg the
SIar(

IlfaA-(

OJlgltd tOut.

Ilm{/

l "~/,,(III

I()
tj(lt,drr,

IIl,ud lip, . ,,,"1 on flld JIII,'/' ",il" Mil.


'M:>ODSMlTH

End-Grain Box To_p__ -

END GRAIN: IFYOU CAN'T FIGHT IT,JOIN IT


We all spend a lot or lime fighting end
grain. whether in joinery or finishing. end
grain presents obstacles that must be confronted, I finally gave up ... and decided if
I can't fij!'htit. 111join it. The result i~
thi.
end-grain box top,
It may be of some consolation til know
that (hi> i" one project where j(O<l(lold
white pine yields better results than
almost ally hardwood. The box top shown
her" was made from a piece of plain-cut
white pine 2x4. T~ get tbe best ring pattern, select a 2,4 cut [rom, or near. the
center of the tl'e". (Fortunately, the- is

very common,

"GUlf 1

.8

"

iv.

The box top consist" of 32 blocks, each


lV"square.ln order 10get these blocks cut
and arranged In the bull's e~'e patten . I
follo\\'l'(l thls cUlting sequence.
STEl't. l started with a piece of2x~ about
IS" long (for easier handling) WIth a 12'"
clear section at one end. Since 2x"~ come
\\;th rounded edges. it must be squared up
first. I wound up with 8 piece 21.~"
wide and
about 1 " thick,
It's important to choose a blade thAL\\;11
gi\'e a nice smoot h cut because it's not wise
to do any sanding' after cutting. I chose a
Sers hollow-ground planer blade.
ST.~12.Set the tip fence exactJ~f1\,~,from
the inside of the blade. and lip off t wu
pieces
"ide as shown in Fig, I. Then
turn each piece on edge and make a second
cut $0 it', IV, thick, :-low mark off 3\
lengths on each piece and number each seclion to keep them in order.
STt:r 3, Cut fOUT a-long sections f.'om
eaeb piece (~i.lding eight section> in all).
These seeriens are 'opened' as shown in
Fig, z to produce 'book matched' pair".
STEP' These eight sections are then
glued up, paying close attention to the end
~n
pauern, Looking' at the end of this
block. the ring patterns should form a
series of four half-cil"I es. Fig. 3. If. during'
gluinl\', the bloeks have slipped. you must
carefully plane the surface. flat.
STEP6 NvI'. four strip, can be rip(lt'<1 off
the end of this block. Fig. ~. Eath .nip
should be about
'Ion)::.'These strips 81'(t
then matched to form the bull'< eye pattern
and glued up in t\\'(, rows.
Since I wanted to preserve the bull's e)'.
pattern all the way 0111to the edl\'e~. I built
the lid first and then built the box to fil .0
no trimming would be necessary The box
shown here is made of red gum and joined
with locked rabbet joints.
The lid and 00" were finu-heo with I' ~
Ib.-CUlwhile shellac. and then given a 003t
of earnaubn furnitu .... wax.

)b~~~~E&i-~~~~~~~~~~
,
A~L---~2----4---~'----_f----.----~~

~.
I-

..oUU,

11'

l~'"

>I,

"GUI'"

WOODSMlTH

__

S_h_op Storage_B_ox

A
PLACE FOR EVERYTHING
-----------------------Ican't

"'IV

thaI bUIi<lmg IhlS"'ora". box I,


CUllin!! alllh, ... little ple'5 is not
tno bad, But a,,"'mblin~ Ih" .....bul~ piect',
into" 1(1\ of little dr~\\ I''''' I~nd, 10 get a bit
t""')

u-diou.
\\','\'e hada lot of "'I"",t. ror 8 made,f\,(OO "lora~e 1,.,:\ likc> lhi.....The mt'taJ
allfl pla.lo,tX-~lordJ.:eunns ) ou -ee e\ ery"hen: are niee, 00\ lhe>,re ,lill pIa'llC
..\mllt seems m<t'ot \l,OI_I",tlrkpr.-. dL'"'(.iain
Ihml!'- made of pla'lir
II t lried 10d",ijll1lh .. b", to make .fIi,
t'u'nt u-e of materials, RI14lll\ the same time
(.'1.tnt,'UI) with n modular fl"'l'lJ(Tl so the box
('flulelbe built to ~uit it "urit:ty of n~~.
I\'hil..... ,,.., 011 Iht ~Uhjl-c:1 of d.,ijll1.
II("rnl1t me a few eommtn~. I) As you can
......from the Cutung l) .~
lhie eIora~c
bo~ m",ke~ ""'r)' ,rr,C'u.nt u ...(I' of readil~'
.'ailat,l .. material ... Thl.... I" nice the finot
timt' around. a.... \\1.'1114.~In the future

m('1"(' boxes

art'

a.....

built.

~) The", are Iwo .i1A" of drawers, The


."'011 one is quill' 8d'~IU"h' for brads, small

"'rt'" s, etc, The Iltl)wl' <Ira" ers will hold,


(IIr lxllmr1
....J( ) N'n'" ,f.r twe dozen
l.alL"i. tlr laJr serew-, etc
31 ~In<e lhe Iarj:,' lira" rs Ill\! e""''ll)
,loul>I,' thi>width o.lhe ~m"lIer ones, lhi'
""~ I"," lIP buill ",lh "II -rnall drawers all
htrKI' ones or an~' combinauon with ont~
minor changes in thl' (\Ittinl< lJiap;ram and
ntl need (or extra malt.'t;nl"
II The dr.\\l''''' ,,'" 11.'i~ned so lb. bottom al..~ serves a... It h_tlMllc a.... well 8Ji
PlY,' wlin),!'space for a lahPllfl Idpntif~ lh(>
rrmtt nts of thl draw (>T

, ;
1

to

a (anc~ 1ll\t~)
('"n.""tructlon C-If th :"lo I>t I fair" unit L.. l"\.'all)
militi

ttlllll' .....
iml'le.

:-.ltlrt((1 h)'

ouilttin~ th~

11.1:-'ll':ourroWltl.' A ,.lm"It rnbbt>t juint i:u:-.,'(I Lo jOin thE' fOllr lttt'I".r~.


f"..,.l. I, deep by .. \I ide rabbet-, ar~
II

'

11:. ~",,;(..:'.:l

I:

i'

-\I;.

Y.

t,'-r~ .t f-=

~t 1

.,I

BUILDING THE lOX

J\U duru-n-iens $,ho\\ nit' tht ~1(,terial!o Li:-.t


~'rl' lla."e(l on using "J" J,l)'\\'(Wld f01"the
c-Iril\\','r bot turns nnd :oicll'!'I,nnc-I t he shelves.
Th(, ('Ultm!! Diagram ,hnw> tbe layout for
hUI""n!!"the ba-ic "1111 with IS smal! draw,
\'N klltt fl double-w itle tin" f"'r-. It ,IOt..n,
andud~ the opuon ,,( Il<loIanl!lb, lon~r
:r'i"f~ (or the tool txtr~,""~htl\'\n 1n t~ vrult'~.
~lItf.111
....00\ :-.ho\rn In thl' ("regn)und
flf thl'I,holu i:- a (anJitr \"'r",ion mad@of
..
ilia pl., fur Ihe box, h' birch Illy ..."OO for Ih~
,.h(Jl\(_,fo. I .... ~1ru;oJlilt.'fUI' tht CII"!4,\'er hc,t
lon\~ :llld :,l(les-, ann rloc}~\lIn ((lr the drs\\ l'r
(nonl < and back.,. '11lo1ll~hIh.. wlil is a liltk
nltf'r. it ub\'iou.,;;,l,. clO<'ilin'\ makej.!ooc.J u* of
n'll(hl~ a\ailabl., =1('1;,,1 .., (I JU'I WaIlleO

KlwtS

-?

~.

HIIMI(!:S INDiCATI
SlOUlNCI: Of CUTS

lOX SURROUND
A Top & 80110"'
"'... 51/ 14

I Sid..
\- 5'9~.

C Plywood Sock
1 .-14
SMALLDRAWER
D Front & Bode:
'J,.1.2V.
E Sid
'I.X 14'/,
F tollom
'1...

2' ... S~.

lARGE DRAWER

4 l~ ....

G ' ...n' & Socia


111.1.4V,

.s ....-...

H Sid
'1 14Y,
Bottom

I I
L_~~==~===~===========~::'
eo,..

tu\ allhi> ends oftht, I""

(our

\1....

,.:It \ ,. wwoc!'Ooart'

"tI.for PK-._
Th~n
the ".he1,.e....

CUl

there L' e""-'Lh 1 "be",,,,,n


th..e dad_, Thonrut R VI" b) VI" rablk-t
on the back edge o(.U (our pi.''~ ror lbe
pi) \\ ttod back,
No" for lh~ dr:lw'..... I ",m<'" by rip
pil1l(I",\\;de <trip. (rom n I)il~c of 1x~ pine.
,UI'\'

1/....

", __S:...c..:....._J

I" Ion~, AJlA!rlbe* .lril" an' cUi 10the I"

\\ltllh.1 n.-<Elthe (encel" "I.C ....""wlthi>m


~" lhiclme$.<_Th"n, a1lhoolllllt's not
r\("('1l' .. ~
, it'":, be~tto rounrl o\,t.r one ed~
of ..a<h slrip, Til;' roundl'fi over edj!e \\ill
he 81 Ih. top of lhe dra" ,'r and make~ il a
link' eMirr to slide lhl' dnlw".' back intn
Ih. box,
\n.

\roOOSMJTH

Table Sa\VTechnigu_e_s _

CUTIING AND RABBETING SMALL PIECES


SI"'<1(IIJ>n'Cauti'm, .hould be
taken when "orkinll with "'I')"
small pi'!(.'c:l on H table ~a\\.
I~tln'an' twu M1l'UI':-\\ l~w....to
kcepfinl(.'''I'''''tl'''I('(I. yet still
make aceurateeuu-.
Whenever wr- hu\,t to cut a
Yo hull' b\1nrh
,.0Ut11 Illf>C{"~to
the sam Il'llj(\h. we u"'" th('
... -t -u p,h,," nin F'j!. I.There ,'
a rule when U~ln~at table Ni\\
that ~'OU"huJ.Jnever U~ the
m.t,r~'1Iu\!l.ntlnp(t:IM.'Cat tM
..amt tlmt'
If th~y ,. crv UM'<! t01:ltber.
tht' eut-eff I'iecp would be
trapped be'''.....n the blad~ and
Ihe nl'
\c.; qUickly tbe
hlarl~\\ DuMcatch th"'''''''' and
lh1"n" it bafk at )'UU - not
~","I
III "nll'r tu solve Ihi. probk-m WI' clamp ";('[" uf 2,4
-cral' 10Ih,rip f'lIce. The from
,'Illlc of rh.. bleck .. placed in
line With the fnllllll!e of the
hl,,~,. Thl'n the CUl,of(I.nlllh
i", ml'1l"'\lr(-<I (rom thl.' blads to
lh,' block, 'I h. workpiece is

or

f."""

pushed o~in, h, bl'ICk and


guirled through thl' hl",I<',
With thi-, :o.PtU)),Ih~1 tUlrJt(

F'lGUQI

piece,; have ernluuh "'f);tl't' ht


tween lh. bladc und ,h~ 1"1'
fence1<0 they "011" g( tn'I'I>l,1
and thrown back.
The rule mfnliQnl'tl ..,~)\ l~ 1$
intended for thruujl'h (or cut,
oro ""win)!, In the e..... nf cutune a rabbet at thr lnlJ or a
pieee. both the miter ~~\llo!'tand
rip fenee can be ll~ In CInjunction.
Tbe """ul'
in f"11." ~
,bow, thi> uperauon, Ho"
ever, smce "P ,. .re cutting a
rabbet un Ih. ,,"01v(\ cry small
pieee-. we ad,I.,1 an "X!PlIo!"n
renee to th~ mi ..r ).'n\l':'~tIl t'up
port the piece aUlhe way tu Ih,
blade.
Also. \\'~ clamped a .trill flf
1)lywood10 Ih,' nil ("I\e\' t<>
halo down 110.elld "flhe workpiece, Since the pl~ wourl i8
pesirioned dirtcII~ over thv
blade. it ~f:r\ ('~ 8:-. .t blade
I guani a.' \t.II,

.ho,,"

It"'Er<!

_.

1',

B.,rore CI.. tIDI( .n~ pi",,; to length.

I
".nt ahe.. lanol npped lh.... plywood ior
the ''''''''l'r bull"m.' and .,,1.,. And CUIthe
-hcl ve, .,.1 boIckto ..." The l'uuinj! Dia1(1'1U11 doe'n't .Ilow mU"h"a.'t., The layout
alto"'~Ih(t,r klrfs. hut r.he~~almv~tnfl

T
!
I~.

room (or ~.'rrur.


Onc(' aU01the .tril'" have been cu. you
11111,( cut orrllu th,' Jli~~
to length, lSome
~JK)Clnl~t'I"UI~ for ("utting small piC-l'e"al~
dc.cribt-d1l1 the "rticl, abo'.,)
To a,'mlol"lhe d,"UwcrsI found it much
~3,"'r tu U'C tht 113ilinl(fixlure described
t,n )la)!1,.13. ThnuJth It takf."8 tJme to make'
thi' fixture. It
IIllIk~~naililll( the;('
bttl~ rlra\\C"l"2Ia \\oolt" lot t>a....ier.
.-\J\O.,. nailing lbe draw.", together, I
:'!oilJM1l-d do" n lhl
SJ41( ... on a di:,k sander
mounted on the table "",.. 'f'hk.littl. bit or
s:..ntlmg 1\(.'" onl) ..mc""theo.. out. ttwo ~id..- tJ(
the .1",,. r. hut .I~ ( ....~Ies the minimum
cll'3l1UK't' ll(oa"""U') btt "l'<.'n the draw""",
tTht: nIRl(l'n.'ii14)1L8 of the 4ira\\"t?'N and the
~urroun41.1I(1\~ 110 ('I\'araru:~.hcllL.....tht'"
nding takt1' c... " Iof thi'.l
On\~ final JIIul[J:tstiun. I u.... '~l anel
~tl~k' 8dlll, lab.I, tn mark lb~ contcnt ..
o(tht' dn.wtr, Thl"e la"'1>,hould be 3vall,
ahl<- ,..t uhn4"'it an~' ~{.ati()n(.\I'".\'
store.

'''1'<'

V.'OODSliITH

*'

, ,.

,
.. ;

1. "

"u

...

'..

"--_

---,.

H.

". .,
,

..

'

1\,

!
1

J'.

"2 01..

~
~

Radial SaW"Technigues
CUTIING

AND RABBETING SMALL PIECES

Cuttingsmall pieces on a radial


arm saw reuuires n ,lIghlly
diff('r~nt approach than was
used on the table saw tprevious
T"ge'.
Allhaugh a stop bl(l(lklorelld
block) can be us('d on a table
saw for oeuing the length (or
culting
<JIIlI1i pieces, this is
not a I!OO'Ipractice on a radial

extra pr...caution we take i$ to


use a hollow-ground planer
blade for these small cut-oITs.
The Leeth of this blade arc no!
'set' so lh")' don't project OUL
from the bl.de and there's less
chance o(the blade catching tbe
cutoff piece,
When cULting rabbets 011the

arm AAW. A. shown ill lei!:. 1.

sal')' to provide a method of


holding the workpiece in place
while the cut j, made.

orr

we UW I)Illy a pencil line on the


fence to g1luge thel(!njrth ufthe

cutolT.
Ifa stop block wen? clamped
to the fence. the small piece
could ~asil~' he cnught by th..
blade. especially when the
blade carnage is moved back
after the cui.
However, .' en if the block i.
not present. the cut ..off piece
could still be caught and
thrown across Ih. room, One

l>nctor small pieces. itls neces-

W~ use tbe holding' fixture

flOUR!2

shown in Fig. 2. A small notch


is "ut (Jut of Que corner of a
piece of scrap that matches the
size of ~heworkpiece. The
workpiece j. placed in the fixture and pushed against a stop
block. This procedure keeps
your finl!ers well away from
the blade. yet .1I0ws complete
control during the cut,

BACK ISSUES
f"otl(J\\'ln~i..u li.':;;l of the ctln\t'nt6 of i>3ck Issues
(1f "'000",,,,,1,, B1tt:k 1~"U('1iart' a\'llilable- for
$2 each
Number Ono: Tfi'!o!tle 'fabh-. (_"l;nt(,lnpont!")'
I)l)uhl~"Outs Tables. TIl' Rack. ('0t,.Ik.ie ('f~linJ!'
Rack. (~utling IJ0:8nl. fo-inJt~rt Ilun..,~. Drill
Press t.iuirl,,>;oi., Tnpt'" .fig, (._'arpeuter's "j'rUtng14.'
Number Two! ('ont~mr~"lrary
Chairs, Table
Saw Teehniques: Box JoinL arul Stoppt.'<I Dado,
Hanging t,nmp. Nru."i.'tIP'Ull'l Ouor" Technique;
~ht.rffi H,d(I .ap. l\hakcr "OK RlIc~.
Humber

ThrM:

('&n\'A3 and Reci\\-(I(HI D,-t'k

Chair. ftt.-d\,v~JOtI
(~ard('n Beneh, Deek Squ~.
Kl':!i\\'ood Plant Tub, (ed.r Plant Pilhll"l'. llilnj:"
mK Planter, TiPEo f'ur OUldoor Fumaure. Nine
\",uiatitlos

On j'\Ltrnter llOXt>!O.

Numb.,. fou,: Rilll-Tnl) Bread Box, Thrt>("


A<Ij!I. l)niJinl' Jig>. Shol' &",,1. 1-.)' S;II" Tool
~tllm~(.I.
nux OiDrn\\cl'1., R('j~RuiklinJr Ra,;c.'I'I.
,\ ('.'L.,p "''''or ~torln$l Rouler Anll L~i~.
Number fivo! I';xcl\k'ive r1an~""or .~ Ruult'J'
Table.
Your Own Tool' W....lg. CiJuul'-,

~h""

W IX: ~",ith
PI.

'tT J '"

IS~N:

'-"5I~.!!o

om 1-111-1

P~lmastcr:
Addl'o..s Con'Ccl ion Requested

Taper,Ii!!" Bow Saw. D... ,,'!nl' An Ellip"~. Oval

Frame. Toy Trnin and

R.'1C1' (..~.

Knirv Holders, Letter Opc.tlcr. Recipe Box.


JQlneT~/ Techniquex: Rabbt't ll{tdlJo Jeint ,

Numbor 51.: )lu!ollc130". Cookbook R(!~ipt-'


Shelf. Candle Sconce. Spice Box. Joinery
Tcehmque..:- fUboot and Groove Joint. Three
ltet'a""inJ{ Ji~.\\'ooden Chrisltna:s Ornomenl.&.
(.'hrit-tlltag Oi~]}tay Tree,
Number S."en: J3ook'~lagazin~Case. "'ill'
Cabinet. Miter and Spline Joinery. Router
Table Technique . Book Rack, L I.af
Binder. \Va.-c;lc 8a..,k~l. Tips, &: Techniques,
NUMber light: Joinery: ?tfortise & Tenon.
Frome and Panel Constructton. \\'all~Hung

Cluinglip I..amilllllioll>:Tool,<of tho

(.Willet, frame and P.",nel Cuntemporar)' Cabin!". Panel Cullin)! Tethniqt1l-o:\.

C.bint:t

Tra,r..

(Iovon: Shake)' OE>Jtign: ~I("Tnbw,


ClUlillt Stand, f)rOI)-l.enr T3ble: Technique:
Number

Drop Leaf Joint, l\lountinjZ. Hmges. llathcma.ties (if Taperinrc a Leg; ("ir't'l~Sandin", Jj~.

Slam-Top \Vritin~ Desk.


Oc'.~"'n.1 Clock Frame. RoundMirror, Cullin!!
Th in T."."" By Hruvi. Horizolltal Boring .Iig.
~Iathematjcs of Jll1ll..'l"'S.I\dju,,;,tabll' )lit('1" Jig,
Co,'. CultiD)l On A Tabl. Sow
Number

Twelve:

Thirteen.
C'ont-empQrarr Ilulch
Step B:;.' $lt:,) Tu auildjn~ Gl:t.ZNt
Deors. llorUse 001,1Tl:l1on \\'ith Conecaled Hu.bNumber NinO! Project, .. \Vith \\'nodel' Hin~ be" RolIAroundShop Cart. Rout"" ,l.".lry
Box. 01... CUtling T<'cltniquI!>.
Adjustable '"ht BIlIckel. Jewolry Box. Lap
lJe3k. S\\'eater Chest. Di::play Ca.~:.1(1iJlt'1,)': Number Fourteen: Peml)roke Tablt, nutlE-'r'~
l.o<kod MIl"r, Joinory. End Iloards, JoiJwry: Tray Tab1e. Dr;t\\'inR' An Eli~c, ~lountinj.!
Drop-Le.f Hillll'''''' How T. Sharpen A SeI1lfl'"
PvalIel Spline, Ti~&: Tt"C"hniques.
al..-h"" Tunll"Ci C:mi:otel", rlniAAing TeMniqu("",
NumberTon: Ptc>jec~ """romSenl' \\'ood: ~k
How To ~!<"'nl Butl"r', Tabl. HinRt",
('ltK'k, \tWlit) ltirror. Coin Tra~.Belt Buekle.
Numbor

Second Cia&; Postuge Paid


At De. Moine$, IA

1A!Ol:JQ

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