Escolar Documentos
Profissional Documentos
Cultura Documentos
I
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111'
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II
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If you have bought from us before, you will recognize the above points, but if you haven't
tried us then we're all losing out. Our past customers make our best references!
EXPECT EXCELLENCEI
Diamond Hones
by SamAllen
by Tom Crabb
R. Webster
Wood Types
Teak by S. Reed Poverny
A Popular Woodworking Project
A Handsome Mirror Frame
31
26
31
by Alan Marks
22
35
40
38
by Hugh Foster
by Paul Mason
40
42
48
Focus on Carving
Relief Carving-The Final Touches
by William H. McMaster
48
April/May 1988
10
12
15
54
56
62
Book Reviews
Videoscene
Tried and True
Tests & Comments
The Business End
Out of the Woodwork
6
58
59
60
Letters
Calendar
Index to Advert isers
Classified
The
Diamond
Edge
Editorial
David M. Camp Editor
Wien Chod Managin g Editor
Paul R. Mason Associate Editor
Debra Nowak Associate Editor
J. A. Newell Editorial Assistant
THE SHARPENER PEOPl.
The exclusive and highly patented Eze-Lap manufacturing process embeds polycrystalline industrial diamonds in a stainless matrix on a steel
base. A heat treated process prod uces the ideal hardness in the matrix
for surface durability and diamond retention.
This process pract ically assures that no individual is likely to wear his
sharpener out in a lifetime of use. No competitive diamond product can
withstand a face to face rubdown with Eze-Lap.
Eze-Lap uses polycrystalline diamonds manufactured by DuPont. Each
diamond particle contains app roximately 18,000 individual micro -crystals .
Instead of wearing Into dull rounded particles, ultra mlcro-crystals fracture off expos ing fresh cutting edges . These sharp edges cut the metal
off with 1/600 the force needed on conventional hones . Low cutting pressure generates little heat and doesn't draw the temper from fine edges .
Dealer Inquires InvitedI Mall requests to the address below.
Contributing Editors:
William H. McMaster
S. Reed Poverny
Hugh Foster
Alan Marks
Art Department
Leslie Nau Ass istan t Art Director
HBK Graphics Typesetting
Advertising
Wayne Lin Advertising Director
Gertrude Berkowitz
Circulation
Suzanne Eriksen
EGW Pub lishing Co. Publisher
Stones
For sharpen ing chise ls, planes
and other flat surface tools
Available In fine, medium and
coarse grits
Sizes 1" x 3" up to 2-1/2" x 11-3/8"
Supplied as stone only , In a leather case or mounted on a paddle
or pedestal
Hones
For deburring and othe r metal
removing needs
Available in three grits - fine,
medium and coa rse
All models 6" in length - one
style with metal hand les, another
with plastic handles
Rounds
Ideal for sharpen ing knives even ones with serrated blades and scissors
Used by sportsmen, fishermen ,
householders and RVers
Available in a pocket model , a
leather sheathed brass body type
and butcher's steels
Needle Flies
Available in 12 different shapes
and two grits - fine(600) grit and
coarse(200) grit
Sold individually or In six piece
sets
Yale Sales
9400 Bellanca Avenue
Los Angeles, California 90045
Popul ar Woodworking
n:T:n
WCALlBIJRJ
A Cut Above
Lesser Saw Fences.
The
Excali
T-Slot
Saw Fence
When choosing
investments,
cheaper isn't better.
better
is
etter!
EXCALIBUR
MACHINE & TOOL
COMPANY
U.S.A.
CANADA
3241 Kennedy Rd ., #7
Scarborough, Ont oM1V 2J9
(416) 291-8190
and there's a
good reason why
Like any other precision tool ,
a saw fence is an investment. And when it
comes to choosing investments , cheaper
isn't better. Better is better. So T-Slo t
owners rightfully count themselves amon g
the ranks of perfectionists who have high
standards and are willing to pay a bit more
to maintain them. A better saw fence...a n d
a more accurate one. The Excalibur T-Slot
saw fence will convert your table saw
into a precison wood-cutting machine.
~OSitive
April/May 1988
EMiit
urn
Ij
jJ
June 3 - July 1
July 5 - 29
August 1 - 12
MAKES
BEAUTIFUL
LARGE AND
SMALL
MOLDINGS
1/2 "
Shan k
We pay shippi ng
Popular Woodworking
"LUMBER"
KILN DRIED. SURFACED TO 3/4" . 1" .
}3/4"
WITH 2
MAHOGANY.
WALNUT .
CHERRY.
MAPLE.
PI NE
Q U EEN A N N C H AI R
"FUTURE ITEMS"
COUNTRY STYLE AND CLAW/BALL TABLE LEGS.
ALL ITEMS AVAILABLE IN QUANTITIES OF ONE OR MORE.
IN CLU DI NG
"FR EE BROCHURE"
DEP T . "L"
DAVID J. ADAMS
President
._--
VISA
TABLE BA S E
C..__'l~~.c
~
...
~,
MODEL
G1243
G1244
G1245
G1246
G1247
G1248
G1249
G1250
G1251
G1252
G1253
....
BLADE SIZE
9"
9"
9"
9"
10"
10"
10"
10"
10"
12"
12"
HOLE SIZE
** OF TEETH
5fe"
5/a"
5fe"
5/a"
5fe"
5/a"
5fe"
5fe"
5fe"
5fe"
5fe"
24
40
60
80
30
40
60
80
100
40
60
SUGGESTED USE
Ripping
General Purpose
Fine Finishing /Cabinet Work
Super Fine Work/Trimming
Ripping
General Purpose
Fine Finishing, Cabinet Work
Cabinet Work, Trimming
Super Fine Work/Trimming
Ripping
General Purpose
PRICE
$27.95 PREPAID.
$33.95 PREPAID.
$40.95 PREPAID.
$45.95 PREPAID.
$29.95 PREPAID.
$34 .95 PREPAID.
$41.95 PREPAID.
$49.95 PREPAID.
$57.95 PREPAID.
$41.95 PREPAID.
$49.95 PREPAID.
April/May 1988
GRIZZLY'S WINNERS!
20" PLANER
15"
PLANER
[-
THE
BEST 15"
PLANER
ON THE
MARKET !
DUST COLLECTORS
ONLY $295.00
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MODEL G1033
ONLY $1295.00!
ONLY $525.00
MODEL G1021
ONLY $695.00!
FOB WILLIAMSPORT, PA
or BELLINGHAM. WA
FOB WILLIAMSPORT, PA
or BELLINGHAM, WA
WOODWORKER I (For the Radial Saw ) This is my original Woodworker blade-most desired by the Ame rican
craftsman. Kerf %,', 60 teeth . Mod ified triple-chip with micro-fin ish grind. Carbide C4 hard and 40 % stronger. Perfect.
polished cuts in every direction. The one blade that does it all-for as long as you'lI cut wood or plastics. Designed for
use primarily on your radial saw. thin kerf gives better oull-control and less bottom splinter on both CROSSCUT and
RIPPING. Available in 8" . 9" and 10 " diameters . Recommended to use with dampener. See below .
WOODWORKER II
(For the Table Saw) My new ALL PURPOSE blade-primarily for your table-saw 10" kerf. 30
to 40 teeth (see below). Mod ified altemat e-bevel with micro-finish grind. Exclusive Forrest 400 carbide. Designed for
super-fast and super-smooth CROSSCUnlNG and RIPPING in heavy. solid stock w ith a smooth-as-sanded surface. We
rip 2" Red Oak with 1 HP at the shows leaving surface smoother than a jointer. then speed-miter and crosscut soft
and hardwoods and PLY-VENEERS w ith NO BOnOM SPUNTERING. Generally I recommend 40 teeth . However, if your
ripping includes a lot of heavy 1Y," to 2" hardwoods. specify 30 teeth . See dampener information . STOP CHANGING
BLADESI (wastes 2-5 minutes) Just ~ for thick woods. ~ for thin woods and perfect cut everythingl
AVOID cheap imports! WOODWORKER I and /I eliminate scratchy saw cuts for the rest of your life!!
LI TOOTH DADO SET cuts all 1/4 " 13/1 6" flat bottom grooves WITH ex CROSSGRAIN all woods and VENEER PLYS.
.~
No splintering due to unique 4T and 8T fillers and 24T outside saws. NOTHING LIKE IT IN THEU.S.A.I
Testimonial " I finally bought one and found all your outrageous claims to be true!"
DAMPENERSTIFFENER One Side Aids A Smoother, Quieter Cut !!
Hold s blade rigid and true for better cuts on your ma chine . Dampens out
motor and belt vib rations from being transmitted up to the rim of the tee th
. ca using scra tchy cuts . Greatly redu ce s cutt ing no ise. Helps kill saw
7 W ' 30T
outs ide leave s blad e centered in slot of steel table insert. 6" dampener o n
10" blad e give s 2" cutde pth. Use 5" dampener if always in 1 1 12~ 2 " deep cuts .
Remove or use 4" for 3" cuts . For 8" and 9" blades . figur e dampener size
accordingly.
6" Dampener S23 5" Dampener $22 4" Dampener S20
._III!!!!!!IIII!!!!!!11
49
49
Can be removed instantly it need requires for deep cuts. One against the
WE RECOMMEND OUR FACTORY SHARPENING. . . 2-3OAYSONTHESE ANOALLMAKES OFCARBIOE TIP SAWS. SHIPINUPS
NOW .. . ORDER the one blade that win outlast you! (1Q.20 sharpenings possble).
SATISFACTION GUARANTEED OR FUll CASH REFUND
112
7" 30T
112
8' Da:lo 24T 13/16"set 29ll
ADO $2
SHIP.
MonV;~ =s~~~~~~~:s~~~8[,.s.
To order BY MAIL clip ad. circle choices and
enclose payment. Specify Dept. PW when ordering.
Popular Woodworking
~
!
The Edllor
The Woodwo rker 's Journa l
" Kudos f or the f olks at Penn State Industries fo r value and customer service]
When I contacted them concerning a minor
problem, replacements were rushed out to
me the same day.
As an amateur ....-oodwo rker, I was please d
to find that lower pri ced . well made
equipment is available f rom people who
are willing to stand behind their
products.
A. Mortenson
New Milford , CT
Add $15.00 for Blower Option. Visa, MasterCard, Check or Money Order Accepted
Add $10.00 for shipping in Continental U.S. Pennsylvania residents add 6% sales tax
r------,
ABO ER
SCREW.
Square dr i ve
won't cam out.
Indu str ial
qual ity,
hardened
against
breaking .
Less slippage
eli min ates
Chewed-up
heads.
Double thread
for fast
insert ion.
Assortment or
bulk.
~TE
5900
M
LJ
L -----VISA
April/May J988
City
State
_
Zip
d,S
Toolboox
The Complete Book of Portable
Power Tools by R. J. De Cristoforo (Sterling Publishing Co ., Inc., Two Park
Ave nue, New York, NY 1001 6, copyright
1987) 258 pages, paperback , $ 14.95
The author knows as we ll as you and I
do that this book is far fro m the "Complete" of his title, but nov ice woodworkers will appreciate this co llec tion of ea syto-read, well-illustrated material. De
Cristoforo covers safe use of the common
tools: the circular saw, saber saw, reci pro cating saw, electr ic drill , router, belt
sander, pad sander, disc sander/polisher,
power planes, flexible shaft tools and
other grinders , various battery powered
tools, and some unusual tools as well. He
also tells how to fabricate stationary work
stations for poitable tool s. For those with
access to a fully set-up sho p (whatever
that is), this won 't make much difference,
but then, neither will the rest of the book.
For the novi ce, how ever , these set ups will
help ease the transit ion from novice to
expert tool own er.
The book also discusses lumb er, panel
materials, other wood produ cts, abrasives, hardw are, and shop math . These
appendices consum e nearl y the last third
of the book. Whil e some of the cove rage
may seem superficial, the sections on
hardware and shop math fascinated this
reviewe r who found him self saying, " I
didn 't know that" so often that "De
Cris toforo's Book of Shop Math" might
be a good idea .
Shaper Handbook b y Eri c
Stephenson (Linde n Publi sh ing Co.,
3845 N. Blackstone, Fresno , CA 93726,
1986) 192 pp., paperb ack , $ 15.95
I' ve always been deathl y afraid of
shapers. In my shop a rout er table doe s
what it can, and I send out the res t. Part of
the reason is eco nomic and part is a matter
of room, but f ear is the dom inant feat ure.
It's important to understand this fear as a
co m p o ne nt o f my readi ng of
Steph enson 's book. The cover ca lls this
" Essential reading for all those concerned
with work on this machin e." I've got to
agree. Stephenson 's balanced approac h
Hugh Foster is an English-teaching woodworker in Manitowoc. Wisconsin .
10
lll~
W<!~~8t
\'8Q8Sr
t;!.
otors
RETAIL VENEER
Clipping & Jointing
s 2.50 sample kit available
(refun ded with first order)
Send for free price list.
Freud C5-100
$29.95
Woodworker's
Supply
( O F N EW MEXICO )
HOW TO M AKE
ANIMATE D TOYS
David Wakefield
HOW TO BUILD
OUTDOOR
STRUCTURES
Deborah Morgan
& Nick Engler
Enhance yourlandscape and increase
the value of your property with a
garage, deck, playhouse, gazebo or
greenhouse. Includes fabulous exploded "put-it-together" diagrams and
blueprints for 40 permanent structures-the priceof the book is less than
just one set of blueprints. Here are
designs for each structure, with instructions for mixing and matching
elements. For both designand instruction,thisis thehandyman's dream. 416
pages (2-color throughout) $14.95
(EVaff
~
BOOKSELLER
See the Yellow Pages for the
B. Dalton location nearest you
or call 1-800-367-9692.
II
by Alan Marks
Dovetails with Kenneth E. Bowers,
from the Punkin Hollow Video Library,
Woodworking Series, 1984 by Anderson Video Communications, P.O. Box
09465, Milwaukee, WI 53209, 80 minute s, $39.95
Kenneth Bowers is a native of North
Yorkshire, England. Granted, I don 't
know a whole lot about them, and it may
not be a universal trait of the English, but
to me the y project a dogged confidence
about being able to cope with reality.
There' s something very reassuring to me
in these troubled times about the quaintly
complacent, faintly opinionated tone of a
solid English accent.
Now certainly I realize he is just being
himself, a woodworker, yet Bowers' very
Briti shness blows him up bigger than life
for me. I judge him to be in hi s eighties,
and he speaks with the authority old ag e
bestows upon us whether we de serve it or
not.
This video on dovetail s has no remarkable graphics. No dis solves, fades,
or mu sic . Close-ups and lighting could
have been better. Bowers ' hand tool techniques - how can I say thi s without so unding pre sumptuous? - did not impress me.
Some are time-eonsuming and ineffi cient. I don 't know if that reall y matters;
it depends upon whether one is trying to
make a living at the craft or not. I used to
be smug about my own dovetail technique, and I felt critical of the way others
did theirs. I know now that there is room
for improvement in my technique, and I
believe the craftsman with the edge is the
one who is flexible enough to recognize
and adopt a better method when sho wn
one .
Bowers' description and demonstration of the dovetail ' s strength impressed
me , but I co uld not accept that the
"proper" slope for a dovetail wa s one in
seven . This seemed too dogmatic to me . I
like to gauge things by eye. I immediately
reached in my cabinet for the dovetail
template I designed long ago according to
what looked best to me and measured it:
preci sely one in seven. What can I tell
you?
Alan Marks is a cabinetmaker in Carmel
Valley , California. and a contributing
editor to pw.
12
+f-f&,
W&
BE A PRO FESSIO N A L
LOCKSMITH
r LOCKSMITttINGINn-n-UTE- -
I
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1,:n~~.c.i -1
I
I
I
I
0 Culm TV EIt'('lrunics O
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~It'~~~(~i:slal
~~~h~~f:~r-
~1:~~S;~I~~~r-
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NAME
ADDRESS
crrr
ZIP
All"
...J
STATE
~PH<
~ E~ I
Now you can improve your woodwo rk ing skills for professional resul ts ... at hom e and
at your own pace .
This two-hourvideo is presented byJohn Parko, a woodworking expe rt and an experienced high school and
adult edu cation shop teacher. He will teach you the tech niques that are used most often to build furniture.
cabinets, chests and many other popular wood projects - using frame and panel construction. John will
guide you through basic Cabinetrysuch as blade selection, gluing and clamping, and then on to advanced
techn iques of cove and tenon cuts and cutting raised panels, using the table saw as the major power tool.
Unlike other video programs that are available on the market today, this woodworking videocovers a project
from start to finish (inclUding staining). Not only will you learn the proper techniq ues of frame and panel
construction (by watching John build the Blanket Ch est shown), but alsoall thecritical woodworking knowhow of assembly for professional results. With what you 'll learn, you will be able to apply that knowledge to
build the chest and many other wood projects of your choice.
Best indication of the production quality of this tape is the fact thai hundreds of high schools, vo-tech s and
universities are now using it in instructional setting s.
VISA
Sig na t ure
Name
Add ress
Ci ty
April/May 1988
C HECK
Exp.
Ac co unt No .
_
_
_
Stat e
ZIP _
13
ITEM
NO.
DESCRIPTION
RADIUS
LARG E
DlAM.
CUTTING
LENGTH
PRICE
COVE
#0 1 1/4" R
#02 3/8" R
#03 1/2" R
1/4"
3/8"
1/2"
1'1'"
1'/2 '
114"
318"
112"
5/32"
1/4"
1/2"
9/16 "
5/8"
$13 .00
14.00
15.00
1'/'"
1'12"
1/2"
5/8"
3/4"
15.00
16.00
19.00
1 'I."
1'12"
15/32 "
314"
18.00
20 .00
1"
ROUND OVER
1/4" R
#05 318" R
#OS 112" R
#Q4
1"
ROMAN OGEt
#07 5/32" R
#08 114" R
# 11 318"
Deep
1/2"
14.00
1 'I'"
1 'I. "
1/8"
1/4"
14.00
14.00
1'12"
5/8"
15.00
curraa
#Q9
#10
CHAMFER
45
1-5/8"
1/2"
25 .00
Angle
#15
RAIseD PANEL
20
Our nationwide
dealer network
serves you . To
order, call Toll-Free
1-800 -521-2318 for
your nearest dealer
or a Free brochure .
II
Angle
318"
RABBETING
#12 45
1'1'"
Sand irr eg ul ar
su rfa ces without loss
of shape or detail.
1/4"
318"
112"
114"
318"
112"
8.00
9.00
11.00
318"
1/2 "
314"
318"
1/2"
7/8"
7.50
8.50
10.50
318"
112"
3/4 "
318"
11132"
5/8"
11.00
14.00
18.00
#19 318"
'"20 1/2"
#21 314"
Core Bo.
Core Box
Core Box
311 6"
114"
318"
CLAMP 'N
TOOL GUIDE
GROOVE FORMING OGEE
#24
#25
#26
#27
#28
1/4 "
5/ 16"
318"
112"
314"
Straight
Straight
Stra ight
Stra ight
Stra ight
Bit
Bit
Bit
Bit
Bit
112"
314"
318"
7/16"
16.50
21 .00
1/4"
5/16 "
3/8 "
1/2"
3/4 "
314"
1"
1"
1"
7.00
7.00
7.00
7.00
10.50
112"
1"
8.50
1"
ALL-IN-ONE.. .
Bar Clamp
Fence
Straight Edge
Power Tool Guide
8.50
MLCS,
Box 4053P
Rydal, PA 19046
RODMAN &COMPANY.,INC.
,lhl@@liJd1!li.iliti1!M&h_
til j j &\'iiiilitWtit
Gauges
other rigid stemlike object) and mark s a
line parallel to the edge of a board as the
rule is drawn alon g it. By varying the
point at which the rule is held again st the
board , differently spaced lines may be
drawn. A closel y related technique is
available to man y user s of the contemporary metal tape mea sure , since many
tape s are furnished with small apertures
formed in the hook at the end of the tape
for the same purpo se as the pencil at the
end of the rule. However, the simplest and
most basic marking gauge con stitutes a
quantum leap forward from eith er ofthe se
techniques in terms of ease and exactness.
For one thing, the required measurement
Woo dwo rking gauges ex ist in a surprising number of types and varieties.
Wh ile every woodworker is surely fami liar with the basic marking gauge, there are
probabl y few today who have more than
two different types in their tool boxes.
This is a pity since some of the less wellknown type s can pro ve extremely useful
and convenient once you are awa re of
their ex istence .
There are man y tools used in woodworking that might be ca lled gauges, but
convention and usage have decreed that
the term be reserved for those measuring
and markin g tool s which conform to a
particular cons truc tion, nam el y the
stoc k-a nd-beam co ns truc tio n. Th e
stock, or head as it is also called, is no
more than a fen ce or guiding block that
moves along a rod- shaped part (known as
the beam or the stem) that contains some
form of markin g or cutting device such as
a pin, pencil, or sma ll cutting edge.
As I menti oned before, there are
numerou s woodworkin g tools which
might qualify as ga uges in the broad est
sense, and indeed many are, in fact,
known as gau ges. The gauges that will be
considered here may be divided into three
main groups: Marking Gau ges; Cutting
Gauges; and Panel and Slitting Gauges.
April/May 1988
Stock... or
head.-
Gauging Basics
Most carpenters are probably aware of
the technique of drawin g a line parallel to
the edge of a board with a pencil while
holdin g a couple of fingers between the
pencil and the edge of the board. Thi s is
surely the simplest form of marking
gauge, and for rough carpentry, usually
more than adequate. A step up from this is
the rule-and-pencil gauge - whereby a
pencil is held at the end of a rule (or any
iiii&%4&k
. EM_1 14mBVN
l;owoYk.
- t"jpe
Ga~e
T~l1beV\s .steW!
iM SC6Ck.
sterrett
C8wl-.s~pe
vY't'vhse ~ st:lJck...
L 005eVl$
Marking Gauges
There was a time when it was common
practice for most woodworkers to make
their own gauge s. But as a man' s business
thrived and he began to take pride in his
tool s beyond what his own toolmaking
ability could provide, and as the nineteenth century saw the appearance of
specialized toolmakers, more elaborate
and sophisticated forms than the simple
homemade gauge became common. A
few homemade gauges still survive, especially tho se made for specific purposes in
the more specialized woodworking trade s
16
stBvvl
IVI
swck.
K~w"!.'f fz>v
lceepi"".1 .sbJde,
alf.gVl ed. (l'l1 sreWl
..-e
Note p-rcfile oT skavpeVid
pWt. sL1ewl":1 (;gYYeG-t
pv-llfil.e 31d. d10VlW1e~
wW1 coLibYated. scale
oYl
steYVI- .
Fine Tuning
Although the marking gauge appears
to be a relatively sim ple instrument, there
are one or two things that can be done to
ensure its efficiency and accuracy. The
April/May 1988
ALL
Pi""
a/;-
-metaL
eN1t! of stocR..
Cutting Gauges
Gal/ged" LiVie
G/JlJ,5e
::........
rate; too shallow and the pressure necessary to bri ng the blade into co ntact with
the work wiIl end up go uging the wheel
into the wo rk.
As a matter of incidental interest it
should be no ted that man y "universal" or
"combination" plane s are provided wi th
the mea ns for being used as slitting tool s;
yet being so much heavier they are less
wieldy, and it is easier to hurt yo urself
with the pointed blade.
Asid e from slitting thin panels accu ratel y, the slitting gauge is a handy tool for
cutting veneer, slicing off battens or lath ing strips , and separating beading when it
is being made into dow eling. As with
many other tool s, it is not until they are incorporated into one' s arsenal that it is
realized how indis pensable they are. So
keep an eye out for unu sual gau ges - they
are not always what they ma y appear at
first glance. ~
19
DIAMOND
GIVES
THE
EDGE
The Diamond Whetstone! knife and
tool sharpener by DMT will hone your
knife blade in minutes. A sprinkle ofwater
and easy strokes quickly hones tools and
knives. Super on carbides. steel. ceramics
etc. 6' and 8 ' models include cedar box
with non-skid feet. 8' has mounting tabs
for secure bench installation. X-coarse
dresses Japanese water stones.
Specify fine. coarse or X-coarse
20
Popular Woodworking
$69 95
----
RAIL
'.
PANEL
REVERSIBLE
COMBINATION
RAIL and STILE BIT
-;J ~j/:
L/
~I(/
CARBIDE TIPPED
1/4" Shank
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$300
ProjectBooil.I'JI 'J200
13.00 1
. Decorative
Storage Planter
by
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April/May 1988
-----1
I
Popular Woodwor king
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1300 Galaxy Wa y Suite #8 ' I
I
Concord, CA 94520
I
I 0 #3 100 Potato and Onion Bin
$3.00 I
o #3200 Decorative Storage Pla nte r $3.00
I Please mak e check or mon ey orde r payable I
I to: Popular Woodworki ng. (Ca liforn ia
I
resid ent s please add 6.5 % sa les tax.)
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by Sa m Allen
The living quality of wood that make s it such a beautiful material to look
at and work with can also create probl em s if it is not properl y dealt with in the
design of a piece. Variations in humidity will cau se the wood to shrink or swell
no matter how thoroughl y dried. Th is is a fact that eve ry woodworker using
solid lumber mu st design for. If dimensional chan ge is not taken into account ,
cracks, loose joints, and ill-fitting doors and drawers will result .
Hundreds of years of trial and error have produc ed many time-tested
techniques for accommodating wood movement. As modern woodworkers
get used to dimensionally stable materials like plywo od and particle board, we
may forget to use the se techniques. If we do, the results can be disastrou s.
While a tree is alive, the cell walls of the wood are saturated with fluid. The
fluid level stays fairly con stant and the cell s remain dimensionall y stable.
Once a tree is cut, the cell s begin to dry and shrink. From this point on , wood
is dimen sionally unstable.
As long as the humidity is constant, the wood will be dim ensionall y stable.
If a piece of furniture is built in a climate that has a relati vely con stant
humidity, design fau lts may not show up until the piece is mo ved to a different
environment. A modern home with cent ral heat and air-conditioning ca n
prove to be a more hostile environment for furniture than a drafty old cabin
ever was. So even if you are making a direct co py of an old piec e of furniture,
you may need to pay more attention to dimensional change than the original
builder did .
Dimen sional change beg ins at the ce llular level. The longitudinal grain is
the most stable dimen sion of a board ; the ce lls stay almo st constant in length ,
varying less than 0.3% no matter what the moi sture content. Notice in Figure
I that the total shrinkage from green to dry is almos t imperceptible in the
longitudinal grain sec tion. It' s the diameter of the cells that increase or
decrease with fluctuating moi stur e. The actual change in size of each cell is
minute, but the cumulative effect of thou sand s of ce lls add s up to a substantial
change in dimension. The more cell s that are involved , the gre ater the change.
Thi s mean s that the wider a board is, the larger the possible amount of change
can be. For example, a 6" wide board may be stable to plu s or minu s
1/16" while a similar board that is 12" wide will only be stable to plus or minu s
1/8 ". In other word s, the actual size of the 12" board may vary by as much as
Sam Allen is the author of the book Making Cabinets & Built-In s: Techniques and
Plans fro m Sterling Publishing Co.
22
Popular Woodworking
A
B
size of
drawer opening
remains stab le
drawer sticks
as opening shrinks
Figure 3. Grain should be oriented so that dimensional change will not affect the
size of critical openings.
Figure 4. Frame and panel construction uses stable longitudinal grain in the stiles and rails to fIX the outside dimensions. The large panelfloats in theframe,allowing it to
shrink and expand without affecting the overall size.
panel
stile
2
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23
panel con struction that is commonly used in ply wood carcases. If this type of frame is rigidly
sides may crack as they
attac hed to a solid wood side , the result may be a
shrink because of
cracked side . To use this type of dust panel concross grain
struction and still alig n the grain properly, the
drawer runner
drawer runners must be cut from boards that
have been glued up to width with the grain
running as shown in Fig ure 58. If you use this
technique, substitute dowels for morti se and tenon
joints on the frame because a tenon that has the
grain in this orientation is not very strong. You
can keep the long itudinal grain alignm ent of
the drawer runners and still accommodate the
dimensional changes of the sides by usin g the
design shown in Figure 6. The rails are firml y
A
attached to the sides with double morti se and
tenon joints.
Fig ure 5. Cross grain construction can lead to splits as sho.....n in A. The
The run ners are attac hed to the rails with morgrain orientation in B eliminates these problems.
tise and tenon joints, but the joints are not glued; a
is cross grain to the sides. no
Figure 6. Even though the dra wer runner
single screw in the ce nter of the runner attaches it
alia..... movement.
problems will result if the jo ints
to the side . The runner is shorter than the distance
between the rails, leaving a gap for movement in
doub le mortise and tenon
the
joi nts. The size of the gap depends on the width
attaches rails to sides
of the side. For sides up to 12", a gap of 1/16" will
usually be sufficient; sides that are 24" wide need
a 1/8" gap in the joint, and wider sides a proportion ally wider gap . This assumes that the side is at
about the midpoint of its possible shrinkage and
expansion. If you know that the humidity has been
gap between
especially low or high, adju st the size of the gap acend of tenon
cordingly. When solid wood is used for the dust
and bottom
panel, the design shown in Figure 7 can be used.
of mort ise
The front rail is dovetailed into the side to tie the
do not glue
carcase together. The dust panel is thinner than the
rail, and it rests in a rabbet in the front rail and a
dado in the sides. Align the grain of the dust panel
with the side s. A strip of wood (a kicker) fills in the
space between the bottom of the dust panel and the
bottom of the dado . The kicker keeps the drawer
below from tipping as it's pulled out. With this type
Figure 7. This traditional typ e of dust
pan el .....on't create
prohlems as long as the kicker isfree
to move in the dado.
of construction, you mus t take care to avoid cro ss
grain prob lems caused by the kicker. Leave a 3/8"
gap
between the end of the kicker and the back of
kicker is shorter
the
carcase.
If the kicker is butted against the back ,
than dust panel
it may push the back out of its joint as the sides
shrink. The kicker must also be left free to move in
rail
the dado for most of its length . Attach it firmly only
doveta iled
at the front end.
to side
Prob lems caus ed by movement of the sides can
be totally eliminated by using framed panel s forthe
sides. Fig ure 8 illustrates a type of con struction
only glue
called post and panel. Posts at each comer form the
kicker at
legs and side rails. The panel fits into a groove in
this end
~ the post. Drawer guides are attached to the posts
~ with mort ise and tenon joints, but the y are not
attached to the panel s in any way, so the panels are
~o free to float in the frame. The front drawer rail s are
~ joined with double morti se and tenon joints to the
'--- - - - - - - - - ~~~i!I---------...J ~ posts. The drawer runners are attached to the rails
24
PopularWoodworking
25
by Tom Crabb
The idea behind thi s garden cart is to
tran sport gardening tool s and supplies all
at once to the spot where they are needed.
As it turns out, it is also a perfect place to
set a drink, the cordless phone and the
portable radio for listening to the ball
game while you work in the garden.
Piece
1'/2"
2"
11/ 2"
2"
Qty Part
D 11/ 2"
3'/2"
17" axletree
41/ 2" handle hasp
38" handle'
3/4" dowel
4"
axletree pivot
1" dowel
4"
axles
11/ 2"
11/ 2"
6'/4"diameter frontwheels
'/2"
'/4" dowel
23/8" linchpins
3/4" dowel
c:
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The Chassis
The " I" chassis con sists of three parts:
the front and back frame pieces (A ) and
the center beam (B) made from yellow
pine 2 X 4' s ripped to 1-1/2 " X 2". Cut a
3" long, rounded notch in the end s of the
front frame piece (see Figure 1) to allow
clearance for the front wheels. Assemble
the three members with glued half-lapped
joints.
Make the ax letree (C) from 2 X 4 stock
as well, and shape it for ground and wheel
clearance (see Figure 1). Cut a 2 X 4- sized
notch in the underside of the axletree to
Tom Crabb learned woodworking as a
boatbuilder. He is the author of Maki ng
Wood boxe s with a Band Saw , and his new
book , Band Saw Projects is due out this
spring from Sterlin g Publishing Co.
Figure 1
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April/M ay 1988
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27
Figure 2
2 1/2" R.
,e,,1
4"
R. "
Make a plywood trammel jig to rout the circle detail in the wheels.
Chamfer the edges of the wheels using a f ence and a tilted table on the band saw .
1!
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-a.
The Body
The next step is to build the bed onto
the chassis. Position the five bed boards
(M) flush with the front frame piece (A)
and spaced 5/16" apart . Thi s leaves room
for the 1(2" plywood sides to land on the
chassis with a spare 1/8" for wheel clear28
Popular Woodworking
30"-- ----"1
~---=
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Finished Size
Qty Part T
Piece
3/
4"
3/
4"
\"
'/2" 21"
3/
3/
3/ "
4
3/ "
4
4"
4"
3'/2"
3,,"
3/ "
4
3/
4"
\"
183/ 4"
3/ "
4
3\ "
3/
8"
1"
3"
latch
3/ "
4
1"
4"
keeper
\" dowel
\ " 9\ "
AA
' /4"
10"
BB
' /4"
9'/2"
CC
3/ "
4
DO
3/ "
4
23/ 4"
EE
3/
23/ 4"
4"
13/8"
latch handle
1l"
bin back
To cut the door and the bin f ront out of the side. make plung e cuts with a
portab le circular saw .
1--------
38"
- -------:r
1 114" D.
--- ---
Figure4
April/M ay 1988
"
17"
--2"
111"~38"
29
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- 4 3 /4 ..
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112"
3/8"
1/ 2"
Figure 6
II
II
30
III
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III
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III
III
III
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1 114"
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cutout
from side
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-t==:=-~
Popular Woodworking
Diamond Hones
Clockwise fr om upper left: Yamaguchi's 3 " X 8 ", l500-grit hone mounted in a rubber stand ; the Tsuboman 2-1/2" X 8", l200-grit with
stand ; TBW's 2" X 6 " grid and magnets mounted on a wood block; DMT's 2" X 6", 600-grit; Eze- Lap's 2" X 6", 600- grit , the Yamaguchi
2" X 6 ", l200-grit ; and center: DMT's 2-5/8" X 8" , 325-grit.
by Alan Mar ks
Like many woodworkers, I spent
years accumulating what I thought was
the finest possible collection of stones for
sharpening my chisel s and plane blades.
Ultimately, I settled on my present collection of three. The first is a coarse carborundum, the second is an unidentifiable
mineral stone similar to Arkansas stone
(something I picked up in a secondhand
shop) and the third is a hard white Arkansas stone for the final edge . I tried and put
aside many stones during this process of
selection, but still was never entirely satisfied. Sharpening got to be a drudgery I
approached with distaste.
During this period of time I saw more
and more of my fellow craftsmen switching over to Japanese water stones. They
claimed they were quick-cutting and a
joy to use. But I noted how rapidly they
lost their flatness and (even more troublesome to me) the coarser grit stones had to
be kept soaked or in water. I had developed an early philosophy that the fewer
pieces of equipment I needed for my work
- in this case , flattening plates, carbide
Alan Marks is a cabinetmaker in Carmel
Valley, California , and a contributing
editor to PW.
April/M ay 1988
Popular Woodworking
Choosing a Gem
li~ L--
~_~__""""__'_~
......
__
~~
___l
Diamond hones are also effective for sharpening carbide tools such as this spokeshave blade
which is being honed on a Yamaguchi stone.
April/May 1988
Since diamonds are the harde st substance known, there is little wear on them
even when they are used to abrade or
shape tungsten carbide. Con sequently
they can be used for honing tungsten
carbide tools. Diamond stones cost two to
three times what their counterparts
would. Considering that diamonds are
"forever," and that they cut about twice as
fast as conventional stones, this does not
seem exorbitant to me. For the sizes and
grits that are available, and also their
prices, see the chart on page 57.
As I have said, the diamonds themselves are embedded in a metal matri x,
usually nickel. If the substrate consists of
a sheet of thin metal with holes in it, you
33
Manufacturers' Addresses
DMT
85 Hayes Memorial Drive
Marlborough, MA 01752-1892
(6 17) 481-5944
Tsuboman Co.
2-22-11 Taito
Taito-cho, Tok yo 110
Japan
-or-
Yamaguchi Co.
Box 165
Osaka, Nishi , 9-18
Shinmachi, 3-chomei,
Nishi-ku , Osaka 550
Yale Sales
9400 Bellanca Ave
Los Angeles, CA 90045
(2 13) 215-3007
5Grizzly Imports
P.O. Box 2069
Bellingham, WA 98227
(206) 647 -0801
3Brookstone Company
127 Vose Farm Road
Peterborough, New Hampshire 03458
(603) 924-9541
'Constantine's
2050 Eastche ster Road
Bronx, N.Y. 10461
(2 12) 792-1600
2Leichtung
4944 Commerce Pkwy
Cleveland, OH 44128
(800) 321-6840
IParker's
Box 24WD46
Welle sley Hills, MA 02181
(6 17) 481 -5944
2Eze- Lap
3TBM
"Tsuboman
"Yamaguchi
B
... . UILDING
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BOOKC.ASE
by Mark R. Webster
Okay, there aren 't any dovetails, steam- bent curve s, or
inlay , but let me explain. My son came to me one morning and
asked ifI would build a bookcase for his room (a que stion I think
originated from his mother). I am sorry to say that I'm a lot like
the shoemaker who se family goes around with holes in their
shoes.' In 12 years of avocational woodworking, my quality
woodworking has always been for my waiting customers, and
there has always been someone waiting. There never seemed to
be any time for the family furniture. My first thought was to
throw something together out of particle board, buying time
until my three boy s were older. Later, I would build something
out of "real" wood and use "real" joints when the furniture would
be better cared for. After I thought about it for awhile, I decided
to make something that didn 't look thrown together, would be
relatively strong, and still not take too long to build.
The resulting plan can extract two cases from one sheet of
3/4" plywood, making it fairly cost efficient. After I built a couple
of these bookcases , it occurred to me that someone else might
have a similar need. They might also appreciate a design that
wasn 't ultra-eontemporary or colonial.
The first step in making this bookcase is to cut the basic
carcase part s: the side s (A), shelves (8) , and the top and bottom
(C) to size from good hardwood plywood. I don't have a large
table around my table saw to allow easy management of large
panels. So I usually cut the parts slightly large and finish cut
them with the help of a crosscut ji g when they are a more
manageable size .
Once the panel part s are cut to exact dimension, make the 2
dadoes in the sides to accept the shelves , top , and bottom. Since ~ '------- - - - - - -- - -- - ---J
3/4" plywood is not really 3/4" but rather 47/64" , your 3/4" dado set
will be too wide . A solution is to replace one of the I/S" chippers produce a tear.
with the 1/16" chipper and make spacer rings out of paper (a
To make the insert, take any 3/S" material (my personal
business card works well) or plastic laminate. The se rings are preference is hard maple), and cut it to the same size as your
placed on the table saw arbor between the chippers and saws of existing insert. Drill a 3/4" finger hole so you can remove the
the dado set. Using this technique, you can widen the cut getting insert after it is in place . Add four sheet metal screws to the
underside of the new blank located so the y will land on the
just the fit you want.
Another problem encountered when cutting dadoes in ply- support flanges in the saw table. With the new insert in place,
wood is tear-out on cro ss grain. One solution for this is to use a adjust its height by turning the screws until it is flush with the
router with a straight bit. The cure I use (after some helpful tabletop. I would suggest making two insert s for this project, one
advice from a friend) is a wooden insert for the table saw that's for a 3/4" dado, and one for a 1/4" dado.
used only for cutting dadoes to accept 3/4" plywood. The purpose
Now that "all" the foreseeable dado probl em s are so lved, go
of the homemade insert is to provide support behind the outer ahead and cut the 3/4" wide X 1/4" deep dadoes for the shelves .
veneer fibers so they sever cleanly and do not pull away to When you're finished, reset the table saw to cut a 1/4" X 1/4"
dado, and cut the groove at each end of the sides for the tongue
Mark R. Webster is an avocational woodworker and one
and rabbet that attaches the top and bottom to the carcase. Notice
of the fo unders of the San Joaquin Fine Woodworkers Asthe fence setting is the same for both end s. The last step is to cut
sociation in California.
April/May 1988
35
ze
i1e
1/0"
15/16",
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fl
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lit :...!
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1 ')10"
e4 lie"
1 7/0",1':
the 5/16" wide X 1/2" deep rabbet on the inside back edge of the
sides to accept the back (D) .
After completing the carcase sides, cut the rabbets on the
ends of the top and bottom panel s making sure to leave enough
tongue width to form a tight joint. Be sure you check the joint
before glue-up . If the dado is too shallow or deep , or the tongue
is short or long, you will have problems. When making the cases
for my boys, the tongue s were slightly too long, so I used a hand
router to adjust the depth of the dadoe s.
At this point, cut the back to size and keep it close by; it can
be helpful for squaring the basic carcase when gluing. Finish
sand or scrape all interior surfaces before assembly. Don' t forge t
to assemble the unit and dry clamp to be sure everything is just
right. Assemble the carcase on its back with glue and clamps,
making sure the front surfaces are all flush. With everything
clamped, raise the case on end and clamp on the back (without
glue ). Ifthe back fits properly, it should square the cabinet right
up.
Now tum your attention to the solid wood top (E). Cut
enough pieces (a little long) to make up the needed width. Arrange the boards for the best visual effect and, if possible, keep
the surface grain running the same direction. Mark a big triangle
on the panel so the board s won't get out of order. With this accomplished,j oint the edges to be glued and finish fit with a hand
plane, planing a slight hollow on the edge s to be joined. This
increases the pressure on the ends ofthe joining surfaces, reducing the possibility of joint separation later.
36
4') 5/0
I
I
5/0'
Bookcase
Cutting List
MOWlN0
Finished Size
Qty Part T
Piece
\"
3/ "
4
3/ "
4
\"
24"
3/4"
13"
3/
4"
13/ 6"
393/8" stiles
3/ "
4
3"
3/ 4"
3/
4"
3/
23//
3//
23/ 4"
3/
4"
23/4"
3/4"
2\ "
3//
3/ "
4
4"
strips fit tightly between the stiles; any gap will show up later.
Remove the excess with a hand plane or by scraping or sanding
when the face frame is completely attached.
Turning your attention to the base of the bookcase, cut the
parts to the exac t width, but slightly long. Cut a 45" ang le on the
ends of the base front piece (I) and on one end of each base end
piece (J), then cut the end pieces to length. The base back (K) will
be butt joined between the two end pieces. Mark out the
decorative pattern; band saw and sand the curves and plane the
flats . Glue up I, J, and K. Add the corner glue blocks at this
point. Now , cut the apron (L, M, and N) to exact size with
miters. Dowel the apron back (L) and the apron ends (M) and
spline miter the ends to the apron front (N). With this lower
subassembly dry, glue and clamp it to the base subassembly.
Finish plane, scrape or sand all exposed surfaces, and rout the
cove. The base is simply screwed to the carcase through the
apron.
The moulding is the last touch. Make the moulding from
stock that is 5/8" thick by about 2" wide. Rout the cove alo ng one
edge, then rip the moulding to its 1/2" width. Rip it in such a way
that the waste is between the blade and the rip fence and the
finis hed cove is outside of the blade. This gives you a little more
to hold onto during this step. Cut the miters and glue the
moulding to the carcase sides . Do not glue them to the solid top .
Wit h all the construction complete, finish sand the project.
Don ' t forget to soften all edges while sanding. I used three coats
of the new Deft Gloss Clear Wood Finish for a finish. ~
37
Wood Types
Teak
by S. Reed Poverny
Why is teak so precious? You know
teak, certainly, if not from its use in
Danish Modem furniture, then as decking
on ships, veneered wall paneling, or parq et, flooring. Tectona grandis, as it's
scientifically known, is one of the most
important timbers on the planet. There are
numerous less expensive species sold
under the name "teak" - iroko, ~h edua ,
and afrormosia among them - but no
otherwood known possesses the qualities
of true teak.
A Malayan word, tekka, gives teak its
:::,'.::r:~n"a'-m e . Indigenous to India, Burma, Thailand,Ind hina, and Indonesia, teak trees
also grow on plantations in Africa and
parts of South America.
Teak has been widely used in India for
over 2,000 years. As testimony to its
durability, beams of the wood in temples
and palaces in both Burma and India are
claimed to have lasted over 1,000 years.
Depending upon where they grow,
teak trees vary in height from 50' - 150',
with gray bark and straight trunks . Plantation trees are often fluted near the base,
limiting their yield for lumber and veneer.
The huge egg-shaped leaves of the tree,
up to 2' long and 12" across, are so roughtextured the natives use them for sandpaper.
Harvesting teak once involved six
years or more before the wood came to
market. Since the logs had to become
light enough to be floated down river
to the mill, the trees were killed by hackin through the cambium layer all
around the circumference. After several
years of seasoning on a stump, the trees
were felted in the dry season an hauled
out of the thick forest by elephants.
Stacked on the riverbank, the logs would
General Description
The light-colored sapwood of teak is
susceptible to rot and termites. Durable
heartwood is roughly the density and
The sprung deck on the "Nightingale " is unfinished teak. Worn and weathered gray,
it contrasts with the varnished teak and polished bronze hardware.The all-teak "Nightingale, " owned by David Abrahamsen, is one offour ketches designed by Gene Wells and
handbuilt in Hong Kong.
oads:
Popular Woodworking
to
~
"
c
C'
:J
by Hugh Foster
:
I made this attractive mirror to com~ plement the tall pecan chest that was fea{l tured in Popular Woodworking Issue #39
-a (October/November 1987). Making it
requires some extra care and introduces
you to cutting mitered dovetails.
While the first step is to gather your
materials, I wou ld caution you to buy
your mirror after your inner frame is assembled-just to make sure you have a
good fit.
Start by making the inner frame. As
you'll note in the cutting list, the inner
frame top and bottom (A and B) are short
wide pieces with the grain running in the
same direction as the inner frame sides
(C) . Of course, you could glue up a solid
29" X 39" panel and cut out a 23-1/2" X
29-1/2" opening in the middle, but, unless
you can use the piece in another project,
that would waste a lot of wood. Making
pieces A, B, and C separately is more
economical, but then the question is: How
do you glue up wide short pieces and have
them come out flat, smooth and square? I
made mine as extra length on the panels
for a larger project and then cut them off
to the proper length.
I cut the 1/4" X 1/4" rabbet on the back
of these pieces before gluing them between the inner frame sides (C). Make
sure you have a square fit, then glue and
clamp them together (but don't pull the
joints too tight) . After you have cleaned
up the glue, rout in the rest of the mirror
channel and square the comers with a
chisel. Now your 24" X 30" mirror
should fit.
Cut the frame top and bottom (D) and
sides (E) to size. Mark out and cut
dovetails just as you wou ld in any other
project-wi th one slight difference: instead of cutting off the full shoulder next
to the first tail and leaving the whole first
pin, cut hoth at a 45" angle so the front
edge of the frame is mitered (see detail A
Hugh Foste r is a part-time furniture
designerlbuilder in Manitowo c. Wisconsin .
40
Popular Woodworking
Piece
3/
4"
231/ 2"
5"
inner frame
top
3/ "
4
23 1/ 2"
4"
inner frame
bottom
\"
23/ 4"
39"
inner frame
sides
3/ "
4
2"
30"
frame top
& bottom
3/ "
4
2"
\"
291//
39 1/2" back
SuppJies
1
24"
3D" mirror
Detail 8
1/4"
1/8"
1"
E
t:
.s
E
~
Detail A
>-
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on
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April/May 1988
-.1
41
Workshop OrganIzation
Ideas
by Paul Mason
You say your shop is growing ever smaller, and now you
have to go outside to tum around? Or maybe you spend hours
on your hands and knee s looking for ju st the right wood scrap
that' s hiding underneath the workbench with the mice and
sawdust? If the pack rat syndrome has you infected, and your
support, etc. until the last end cap . This rack is to support. Always add a few
Against the Wall
Not only do woodworkers stack and will give you the overall length of the extra supports in hopes of an increasing
store scraps, we also shove and balance project , which is the dimension you need clamp inventory, and hang the extra
our tools in the only available places left. to cut a top and bottom cap, each 3/4" length s of pipe which can be supported
Many times, these aren 't very conven- thick X 2" wide by however long your by their unions.
To use this rack, the pipe clamps
ient or safe spots. Most of the shops I've project is. Glue the supports and separabeen in store their pipe clamps haphaz- tors between the top and bottom caps as must be in the closed position. Note
ardly, standing them on end in acorneror shown, and finish as desired . Mount as that removing the clamp from the
dangling them dangerously from as- high as needed, centered on two wall rack will require a 3/8" lift before
studs. Be sure and use screws that are comin g out ; this keeps them from
sorted hooks.
Jerry Emce from Broken Arrow , long enough screws to carry the load the falling out.
Oklahoma has come up with a safe and ~ . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .
handy rack to store his clamps. Instead of ~
lD
having to wrestle a pipe clamp out from ~
the others each time one is needed , this ~
rack holds the bars separately from one ~
another. And be assured no matter how
often you bang or back into them , they ~
1 114"
will stay put.
The rack can be individually tailored
to suit any shop becau se you make as
many supports and separators as you
have pipes. The supports should be made
from pieces of hardwood 1-1 /2" thick X
2" wide X 3-1/2" long. Cut them to size
and mark a front edge for each support.
From that edge, measure in 1-1/4" on
center, and drill a 1-1/2" hole 3/8" deep.
1 1/ 0"
Finish drilling the rest of the way
through with a 1-1/8" bit. From the front ,
cut into each support to the 1-1/8" hole
leaving a 7/16" thick wall on each side.
Select from your scrap box enough
stock to cut 3/4" thick X l -t /z'wide X
1" long pieces to separate each pipe support. Also cut two end caps 3/4" thick X
1-1/2" wide X 3" long.
t{)f~
Lay all this out starting with an end
)/4"
y..
y.. 1 lie"
cap, then a support, a separator, another
-1
:/AC95 BefWIXN
42
CL.,AJ,f ~fS
WA~~ MOUN,
PiPe C~AMP ~AU\
Popular Woodworking
few spaces were left fornarrow strips up to 5' that are too sma ll
to use and too good to throwaway.
This storage arrangement makes it possible to find a piece
of material just the right size without searching throu gh an unreasonably large pile.
e:
April/M ay 1988
43
44
Apri1/May 1988
WA~~ M
OUN,
(,OMP~eSSO~
S,AND
...J
45
swung down , allows the bin to open about 45, expo sing the
freezer cup s. To operate the tilting bin, simply hold the bin
handle, swing the lock board down, and ease the bin into place
until it rests again st the stop cleats.
Thi s bin will not only hold nails, but any small part as well.
Any commercial service shop could use the bin for storage of
repair or sale s parts. Should your workshop not contain wallhung storage cabinets, mount the bin along any wall. In fact, if
you need more storage area, build a series of bins and stack them
over each other on a convenient wall surface. Start the first at eye
level and stack downward, unless you don't mind using a ladder
to retrieve the cups.
The bin can be cut from 3/4" plywood or solid stock. The
(1 Of. CLf)
(BIN tUOS 11 CLfS)
n. flNCJ
46
SfOfZl\CJf BIN
Popular Woodworking
6-
,- - - -,
COl
)14-
)14-
..I
Nail Bin
Cutting List
Finished Size
1
Qty Part
I
I
I
CD \/gJ11 l~
\
6-
)14-
5 1/4-
CD
(J)
~
1 lie-
-1
April/May 1988
1 lie-
CK)
y
-1
1 lie-
-.
1 lie-
r-
Piece
3/
4"
6"
48"
bin front
3/ "
4
4\"
48"
bin bottom
3/ "
4
6"
3/
4"
5\"
1'/2"
3/ "
4
11/ 2"
11/ 2"
3/ "
4
11/ 2"
48"
3/
4"
3"
center brace
10" support
3/ "
4
3"
48"
10 lie-
4 lie-
eM)
stop cleat
bottom back
brace
lock board
Supplies
1 handle
1 pull knob
8 hinges
11 one-quart freezer cups
47
Focus on Carving
--
../
."
_
---------------.. -- 1.
...
~
by William H. McMaster
For the past seve ral issues, I have
been using my carving of the Columbia Panel to illustrate the techniques
for relief carving a nature scene. In the
finished carving here you can see the
overall effect created by the detailing
we shall discuss in this article.
I like to carve the final touches
with a small #3 gouge mounted in a
dowel rod so that it can be handled
like a pencil. You will find that this
style of gouge gives you the most control for carving fine details. I use a full
set of such gouges ranging from Imm
to 6mm in width. Note that the panel is
almost vertical while it is being
carved. This is harder on the arms, but
has the advantage that you can step
back frequently to observe what you ~
have just carved. This helps solve
problem s of perspective and lighting ~
that could not be seen properly if the ~
panel were horizontal. Because of the ~
shadow pattern, you can clearly see
0. . .::...
the convex shape of the ground in front of the building as described in the article on depth perspective ("Relief Carving: The
Illusion of Distance," Popular Woodworking Issue #40 , December/January 1988).
The effectiveness of detailing is extremely dependent upon
the effects of light and shadow. Make a cut and the shadow it
creates reveals its shape. Study the shadow carefully and use it
to determine how the next cuts are made. Thus the carving is
William H. McMaster is Chief of the Education Division of the
California Carvers' Guild. His "Focus on Carving" is a regular
fea ture in PW.
48
....,..;;;...;;;;;;,;;;;;;;;::;;;;...;;;;;;.;;;;;.::::::::::::::::::::::11
....._....,.,.....,.,.................,.,._,;.;;......,.,._ _
iterative since each cut affects the next one. The way the
texturing is done depend s upon the effect created by the previous
cuts. The carver is using his own creative ability to represent a
scene rather than making an attempt to reproduce one.
The article I referred to above discussed the use of perspec tive to provide the illusion of distance in a carved scene. Thi s
carving uses a variation of the laws of perspective known as
universal perspective, which means a representation of a scene
does not necessarily have to use ju st one principal vanishing
point. When actually viewing a scene in nature, such as the one
recreated in the Columbia Panel , your line of sight moves from
Popular Woodwork ing
roundings. The openings between clusters of foliage help explain the growth of the branches that support them . These open ings vary for each type of tree and bush and help us to recognize
the species . Thus you should carefully follow nature's design in
your carving.
The author carves the details with tools mounted in dowel rods so they can he handled like a pencil. The panel is set up vertically so he can
step back and study it as he carves.
"..._J
.
April/May 1988
49
50
April/May 1988
51
"
., -; ." . . '.
"f," - ..,
ttl"':' ','
#'
It '# .
"
t
#
. "",,"',f
"
...
,"" :. -.-. .
"'""
To give the impression of man zanita fo liage . the author carved deep
holes to simulate the light and shadow patt ern of the leaves.
Since shrubbery that is fu rther away would appear less weI/defined . the author used a brass brush to sof ten the texture.
structure of the bush. Study bushes to find these clusters, and put
them into your carving. They will be indicated by the shadows
they cast. These cluster s should be the first form you carve
before doing the detailing to repre sent the leaves. One warning:
make sure your patterns of bran ches do not form a shape that can
be recognized as a familiar object. If the eye- brain combination
can make such an interpretation, it will. Thi s disrupts the
appearance of your carving since the observer will be unable to
shake this unintended figure.
When I studied the manzanita bush on the right side of the
carving near the picnic bench , the leaves suggested deep hole s
to me. I arranged them in clu sters, with open areas in between
where the branches could be seen - especially near the ground.
These holes were carved in the wood using a 2mm U-tool again of Japane se make because of the thin blade s. I held the tool
at a high angle to the wood and rotated it to make a circular hole .
These holes would cast dark shadows which would give the
effect I desired . Thi s is in contrast to the more distant bushes
which were textured with longer and shallower cuts with the Utool. The far bushes near the building were further softened by
again using a brass brush.
The grass on the far shore was carved in short. scoop-like cuts with
a bull-nosed Us-tool and softened with a brass brush.
To carve a stone wall . pencil the shapes of the stones on a smooth surface , outline them with a V-tool. then shape and textur e with the gouge.
rifflers , and brushes in much the same way as the tree bark.
April/May 1988
53
Shop Software
Plywood Planner is a co mputer program created by Roger & Ryan Drummo nd that will help you find the best way
to layout your project on piyw ood, metal,
plastic laminates, or oth er shee t stoc k.
The software is designed for IBM &
compatibles with color gra phics adapter
or Hercules graphics card and 128K
RAM, DOS 2.0 or higher and Commodore 64, Apple $24.95.
Being a typi cal computer operat or, the
first thing I did with this disk was to try to
run it without reading the directions. I was
rewarded with an error messag e. Frustrated becau se most computer instru ctions are simply awful, I sat back , gritted
my teeth , and read the directions. What a
surprise!
There are two sets of directi on s, one in
a dis k file, the other: a 17-page users'
manual. The on- screen do cum ent files
When he's not pursuing freelan ce writing or
teaching English. Hugh Fo ster designs and
builds custom f urniture in Manitowoc.
Wisconsin .
are a model of their kind. Th e Drummond s have refined their program , making it very simple, and unlike many software authors, they have attended to writing clear doc umentatio n. I thought the
manu al might be superfluous, but many
of the niceties of the program are thoroughly ex plained there . Read the manual ;
you'll be glad you did!
The program would be valuable to
people who deal with wood via computer
if only for its on- screen decimal equivalent chart.
To use it, you enter the sizes of the
piece s yo u wish to cut. Be sure to enter
these sizes by length , then width, for the
pro gram will ass ume that that's the way
you want the grain to run; it won't tum
piec es to mak e them fit (but wouldn't a
particl e-board option be nice on a future
version?) . I thought I was "faking out" the
program when I entered 127.224% of a
sheet; one of the pieces I hoped to cut was
IOI" X6". Gleefull y, I watched the program acce pt my input; then I was even
I I
I I I
54
Popular Woodworking
~w&{
#1 0 May '8 1
$1.00
#2 0 July '81
$1.50
Assembly Furniture
Solar-Heated Wood Dryer
#5 0 Feb/Mar '82
$1.50
A Chair Is Born
Rima Fixture
#6 0 Apr/M ay '82
$1.50
#7 0 Jun/Jul '82
$ 1.50
#8 0 Aug/Sep '82
$1.50
#9 0
OctlNov '82
$1.50
Staining Wood
Questfor the Thinnest Blade
Marketing
$1.50
$1.95
$1.95
$2.25
$2.25
$2.25
$2.95
$2.95
$2.95
$2.95
$2.95
$2.95
Martha Thompson's
Magica l Mirrors
Power Carver's Tool Cabinet
Building a Wine Rack
$2.95
$2.95
$2.95
$2.95
$2.95
$2.95
Joiner's Toolbox
Dovetail Joinery
Connecticut River Valley
Desk on Frame
$2.95
Relief Carving
Make Your Own Han dscrew
Clamps
Tall Chest of Dra wers
$2.95
$2 .95
~ - - - - - - - - - - - - - - - - I
I
I
I
I
I
I
I
~
by Peter Good
PLANE- MOLD-SAW-SAND
Power TOOLS
Feed l
in
U
..
4-
,
@
, ";'~,.',
,
Q
','
"
Now you can use this ONE power-feed shop to turn rough
lumber into moldings, trim, flooring, furniture - ALL
popu lar patterns, RIP-PLAN E-MO LD-SAND" , separately
or in combination with a single motor. Low Cost. " You
can own this power tool for onlyS50 DOWN!
30 -Day
F
_R_
EE
_ Trial! EXC~~~r?GF~~C TS
RU.'S.'H COUPON
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6301 Equitable Rd, Dept. 91288
:gg~!!_~_::~-~~ ~~~~~--~
.
'
Foley-B elsaw Co,
iTI!ilili!Jt
630 1 Equitable Rd. Dept. 9 1288
I
I
:
I
I
'
: Name
: Address
: Cit y
~~~---~----~~~---------~
56
1500
NOMINAL G RIT
1000
800
600
DMT
2X6
2-5/8 X 8
2-5/8 X 12
$39.50
$64.00
$95 .00
EZE-LA P (unmounted)
2 X6
2X8
2-1/2 X 11-3/8
$23.45
$3 1.25
$55 .80
T BW
2 X6
400
325
270
220
$39.50
$64.00
$95.00
200
$39.50
$64.00
$95.00
$36.65
$47 .60
$84 .75
$56.55
$75.40
$ 134.20
Ya mag uc hi
12 X 6
12 X 8
23 X 8
$30.00
$40 .00
170
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$30 .00
$40 .00
$49.95
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ALES
eD
'v,l \.c
~
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41 Atl anti c Ave .. Box 4000
Wob u rn, MA 01 888
April/May 1988
AVAILA B L E
w.
WOODWORKING
PATTERNS
:~~u=.~~::::~:rnn:rn':~1
$21.95
AVAILABLEWITH:
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'h 20 RHthread(except 'I.' x3")
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CALL:(919) 852-8581
L:Og~~~!!t1,;:~
FIVE MOOELS
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Products For
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,;
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o
o
o
o
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57
11
April/May, Brookfield, CT
Araised
panel door
in two minutesl~4
f
HAM
D
MAC
ER~
RY C~~
0..
INC.
Popular Woodworking
Wheels. Spindles
Balls. Knobs
Shaker pegs. And more!
Since 19271 Send $1.00 for Catalog.
~ 'f
wwn
Index to Advertisers
7
11
59
6
57
20,64
5
56
8
63
11
2,7,8
58
6
13
20
9
57
14
13
14
57
57
9
9
11
57
57
II
59
TOOLS
CLASSIFIED
.' ~t
J!!>~
~
"
NOW Wl Tlt
HAHD TltREAD5
pertect ll2' , 314', and l 'lhreads. For information: Dept. PW, 541 Swans
lid.,11.., N.w ar~ , OH, 43055. (614)3455045: (800) 331 -4718,
INTRODUCTORY OFFER- SIX 10" HANDSCR EW KITS + catalogue for $36.00, a $54.00
value. Quality clamps, vises, and kiln dried Hardwoods - catalogue$1 .00. Clampelt, 507F Kenmore
SE, Warren, OH 44483.
Nat ionwide CIll!13 Tool Sales
Ca ll (800) 241..ij7 48
Call (404) 872 4466
HIGHLAND HARDWARE
"-
A bi-monthly
magazine with plans
and instructionsfor
metal-working projects
you can build. $19.00
per year (Check/M.O.).
With charge card
-call toll-free.
800-824-7888Operator 660orwrite
The Home Shop Machinist,Box 1810-T
Traverse CityMI 496B5
II 0IfEYIA ClIiUARAltTU
FINANCE PLAN
COMPETInVE PRICES
HELPFUL, KNOWLEDGEABLE STAFF
LARGE STOCK OF TOOLS & ACCESSORIES
PACE 0lJ11'ES
TECHNCAL f.FO
)~--woodworking
~~
Catalog
ELECTRO
BAND SAW BRAZER
#1018
Do inside contour sawing
easier and faster. Mak e yo ur
own band saws from coi l stoc k.
Brazer complete with kit.
Manufacter Direct
Largestand finest selcnon of Oak, Walnut, Hickory, Maple, Cherry,
Mahogany, Teak, even Treated Dowels
._ _ -;".,
QuantityDiscounts
MIDWEST DOWEL WORKS '
4631 Hutchin sonRoad
Cincinnati, OH45248
513 5748488
INC .~
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"
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Catalo onr uest
NATIVE CALIFORNIA
HARDWOODS
Expressiv e California Oak. Exotic Pacific Madron e. Golden
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c atalog or se nd 5 7.99 for a Samp le Pack of all spec ies (add
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WOODS
SAW MILL DIRECT defect-free bowl/spindle turning stock, lumber, logs, cants, cocobolo, lignum,
Parakingwood , bocote , primavera, partridgewood
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CA 92008 or cal l (619) 434-3030.
$75.50
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B ULLDOZER R EPLICA
Any wood craftsman will be pro ud to build and own this oneof-a-kin d wooden bulldoze r repl ica. Its hefty size (l5Lx9.5W
x8.5H) will comp liment any fireplace mantle or office desk.
Looks authc rnic. Can be built with ordinary shoptools from
any kind of wood. Th is unique "dozer" can easily be mass
produced and sold pro fitably. Plan pack includes step-by-step
instructions and full size drawingJ . !ILANS $14 9S
ELCO Products - Box 126-E , Waukom is . OK 73TI3
THIN HARDWOODS: 1/32" to1/4"thick. Oak, butternut, cherry, maple, ash, poplar, walnut. Send
large stamped envelope to: Shaker Miniatures,
Dept. PW, 2913 Huntington Rd., Cleveland, OH
44120.
CLASSIFIED
10
12
EASTERN WHALER...$9.95
INDIAN CHIEF...........S9.95
14
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MISCELLANEO US
eu c orr
RD.
716-6623648
14170
PLANS FURNITURE, TOYS , OUTDOOR furni ture, lamps, gates and trelliswork, and more. Catalog $1.00 Smith Brook Press, R.R.1., Diamond Pt.,
NY 12824.
DOOR HARPS ARE HOT! Our proven fast sellers
mean big bucks for you . Six different 11 X 17 full size plans $6.95 ppd. Arts-Nic (PW) Box 587215,
Alsip, IL 60658.
MAKE YOUR OWN LAWN/PATIO FURNITURE,
kids' rocking toys and furniture, workbench , etc.
Plans catalog $1 .99. LLEPW , Box 908, Cornville,
AZ 86325.
PLANS FOR 250 + TOOLS Catalog $1.00(refundable). Wood-met Services, Dept. PW, 331 4 Shoff
Circle , Peoria, IL 61 604.
PROfESSIONAl.
just $3/co py
SrAINED GLASS
WINDOWSILL CAT PATTERNS for twelve different wooden cats tosit onwindowsill, shelf orledge.
Send $6 .00 to Dakota Wind, Box 866PW,
Jamestown , ND 58402.
200 SCROLLSAW PATTERNS ! Createprofitable
shelves, mirrors, racks, novelties, puzzles,
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36 NEW SHOW TESTED WOODCRAFT designs
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BRANDING
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250 to 800 wa tts
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IN CA NA DA:
4 54 Law rence West
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April/May 1988
FOR SALE
INFORMATIVE 176 PAGE CATALOG for woodworkers, woodcarvers, upholsterers, antique restorers, including many unusual, hard-to-find
items. Send $1.00to Van Dyke's, Dept. 50 , Woonsocket, S.D. 57385.
SERVICES
CU STOM TURNING - HAVETURNINGS madeto
your exact specifications. Furniture reproductions,
porch railings and stairway balusters a specialty.
For Free Brochure send to: River Bend Turnings,
Box 364, Dept. PW, RD#1, River Road , Wellsville,
NY 14895.
CLASSIFIED MARKET INFORMATION:
Classified Display. $40 .00 per inch for 1
issue,$35.00per inchfor 3timerate (3consecutive issues); $30.00 per inch for 6 time
rate (6 consecutive issues) ; Classified
Rate : 75 cents per word ; 15 word minimum.
Payment must accompany all Classified ads
(notcommissionable). Deadl ine forIssue 43
(Jun/Jul '88) is Apr. 10, 1988. Popuisr
Woodworking, 1300 Galaxy Way #8, Concord , CA 94520, (41 5) 671-9852.
61
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Building a Stairway
by Susan E. Shakespeare
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30 Rip
64 TCG
80 TCG G G
96 TCG
108 TCG
40 Comb
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50 Comb E G
60 Comb
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64 ATB
72 ATB
80 ATB NR E
96 ATB
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DS306
DS308
6" set
8" set
5/8"
5/8"
, fence-saw
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guide, and
1 an Auto-Set'
CELTA
Building On Tradition_