Escolar Documentos
Profissional Documentos
Cultura Documentos
easy-to-build
Platform Bed
completes our 5-piece suite
shop
solutions
• Workbenches
PERFECT PLACEMENT
• Table Saw Sleds
CLEAN, PRECISE CUTS
Table of Contents
departments tips from our shop
Shop Notebook. . . . . . . . . . . . . . . . 30
from our readers
Tips & Techniques . . . . . . . . . . . . . . . 4 working with tools
Countersink Bits . . . . . . . . . . . . . . . 40
all about Not all countersink bits are the same. Here’s what
you need to know before you buy one.
Bargain Router Bits. . . . . . . . . . . . . . 8
Are low-cost router bit sets worth the money?
You’ll be surprised at what we found out. small shop solutions
Workbench Location . . . . . . . . . . . . 42
tools of the trade Where you put your workbench is the key to
Miter Saw Blades . . . . . . . . . . . . . . 10 getting the most out of your shop.
Getting the best results with a miter saw starts
with choosing and using the right blade. finishing room
Getting a High-Gloss Finish . . . . . . 44
techniques from our shop A classic, high-gloss finish is easier than you
may think. We’ll show you how.
15 Tips & Tricks for Assembly. . . . . 12
Learn the tips and tricks for gluing up a drawer.
in the mailbox
jigs and fixtures Q & A. . . . . . . . . . . . . . . . . . . . . . . . 48
Table Saw Miter Sleds . . . . . . . . . . 14
Take your table saw to the next level by adding hardware and supplies
a precision miter sled. Sources . . . . . . . . . . . . . . . . . . . . . . 49
weekend project
DVD Storage Case . . . . . . . . . . . . . . 16
Organize your growing collection of DVDs with editor’s note
one (or more) of these versatile storage cases.
A
simple joinery, it yields rock-solid results.
few years back (October of 2002 to be exact) we featured a cherry
armoire in Woodsmith. The idea back then was to take a large
heirloom project
project and make it as easy to build as possible. So we streamlined
Inlay Mirror Frame . . . . . . . . . . . . . 32
Show off your skills with this mirror frame that the construction by using plywood panels and straightforward join-
features stylish inlays and miter-free corners. ery. Plus, we updated the traditional armoire by setting it on an
open base and using contrasting stains to give it a two-tone look.
details of craftsmanship The project turned out so well it was quickly followed by a
Coped Joints . . . . . . . . . . . . . . . . . 50 matching nine-drawer dresser, a mirror, and a night stand. Only
Installing molding with a good fit is a challenge. one piece was missing. Which, of course, brings me to the
Learn how to cut a tight-fitting coped joint.
designer series project in this issue — a matching bed.
The bed features a platform-style design, which means you
don’t need to spend money on a box spring. But more impor-
tantly, it gives the bed an updated, contemporary look. Now, we
These two symbols let you know there’s more infor- built ours out of cherry and stained it to match the other pieces in
mation online at www.Woodsmith.com. There you’ll
see step-by-step videos, technique and project ani- the set. But this project would look great built out of just about any
mation, bonus cutting diagrams, and a lot more. wood. Note: If you would like to build the other pieces in the
suite, plans are still available at www.Woodsmith.com.
NEW FACE. Designing projects like the platform bed is the
responsibility of our design group — they’re the key to the great
woodworking projects we feature in every issue of Woodsmith. To
give us a hand in this area, John Doyle recently joined our staff as
a project designer and builder. John brings a lot of experience to
the group, and I’m looking forward to working with him.
www.Woodsmith.com Woodsmith 3
from our readers
Squaring Drawers
Assembling square drawers has diagonal to push the drawer square prevent them from loosening while
always been a challenge for me. I’ve from the inside. I use turnbuckles I’m twisting the coupling nuts. The
never had much luck trying to clamp and threaded rods for larger draw- rubber caps protect the wood from
across the long outside corners to ers. The round eyebolts wedge into the threads on the end of the rod.
square up the drawer. the corners as I tighten the rod and I keep several different lengths of
What I came up with is the won’t twist or mar the wood. threaded rod on hand for different
“squaring rods” you see in the pho- For smaller drawers, I use the rod size drawers. With these two types
tos above. Basically, these rods configuration you see in the inset of “squaring rods,” I can now
apply pressure across the “short” photo. The ends of the smaller rods assemble perfectly square drawers
are epoxied 1/2 " every time I build them.
into the cou- Bryan Rogers
pling nuts to St. Petersburg, Florida
maintain control of the bow while you’re into to help SENIOR PROJECT DESIGNERS Ken Munkel,
working with it, yet allow the bow to flex keep the bow Kent Welsh, Chris Fitch
to whatever size arc you need. The caps steady. I then PROJECT DESIGNERS/BUILDERS Mike Donovan,
John Doyle
are screwed to the base, so you can placed a small
SHOP CRAFTSMEN Steve Curtis, Steve Johnson
remove them if you need to replace the washer into the hole to prevent the bolt SR. PHOTOGRAPHERS Crayola England, Dennis Kennedy
bow. The feet are glued into place. from damaging the hole. Adjusting the ASSOCIATE STYLE DIRECTOR Rebecca Cunningham
Next, I cut a bow to overhang each end bow to the desired curve is simply a mat- ELECTRONIC IMAGE SPECIALIST Allan Ruhnke
of the base by about 41/2 ", with dowels ter of tightening or loosing the stove bolt. VIDEOGRAPHERS Craig Ruegsegger, Mark Hayes
holding the bow in place. In the center of Jim Buske Woodsmith® (ISSN 0164-4114) is published bimonthly (Feb., Apr., June, Aug.,
the bow, I drilled a shallow hole for the Rockton, Illinois Oct., Dec.) by August Home Publishing Company, 2200 Grand Ave, Des Moines,
IA 50312.
Woodsmith® is a registered trademark of August Home Publishing.
Copyright© 2005 August Home Publishing Company. All rights reserved.
Subscriptions: Single copy: $4.95. One year subscription (6 issues), $24.95.
(Canada/International add $10 per year, U.S. funds.)
Canadian Subscriptions: Canada Post Agreement No. 40038201. Send change of
address information to PO Box 881, Station Main, Markham, ON L3P 8M6.
Canada BN 84597 5473 RT
Periodicals Postage Paid at Des Moines, IA and at additional offices.
USPS/Perry-Judd’s Heartland Division Automatable Poly.
Postmaster: Send change of address to Woodsmith, Box 37112,
Boone, IA 50037-2112.
Subscription Questions? Write to Woodsmith, P.O. Box 842, Des Moines, IA
50304 or call 1-800-333-5075, 8:00 am to 5:00 pm, Central Time, weekdays. Or send an
email to: orders@woodsmith.com
Email: woodsmith@woodsmith.com
World Wide Web: http://www.Woodsmith.com
www.Woodsmith.com
a. ONLINE SUBSCRIBER SERVICES
• ACCESS your account
• CHECK on a subscription payment
• TELL US if you’ve missed an issue
• CHANGE your mailing or e-mail address
• RENEW your subscription
• PAY your bill
Click on “Subscriber Services” in the list on the left side of our
home page. Menus and forms will take you through any of the
account-maintenance services you need.
Printed in U.S.A.
www.Woodsmith.com Woodsmith 5
more tips from
our readers
Steep Angle
Miter Gauge Jig
Recently I needed to cut some mold- I set the miter gauge to 75° and
ing at a steeper angle than my table trimmed the bottom of the triangle
saw’s miter gauge would allow. I so the sides would be even.
solved this by making the simple 30°). Then I set a rectangular piece Next, I added the fence and side
jig you see pictured above. of plywood against the miter gauge as you see in the main drawing on
To make this jig, I first turned my and ripped it to the bottom corner, the left. I cut the fence to cover the
miter gauge clockwise as far as resulting in a triangular base (see entire length of one side of the tri-
it would go (mine stopped at detail ‘a’). After that cut was made, angular base. That way, the side
closest to the blade will stay fully
supported. The miter gauge side
was trimmed to fit. Finally, I applied
adhesive-backed sandpaper to keep
my workpieces from slipping.
Ted Ralston
Des Moines, Iowa
a.
www.Woodsmith.com Woodsmith 7
all about
Contractor-Grade Bits
Falling somewhere between industrial- Several high-end bit manufacturers
quality router bits and the bargain bits like Amana and MLCS have answered
talked about above are “contractor-grade” the competition from inexpensive bits by
bits. These bits have some of the same launching new lines of bits, like you see
qualities as higher-priced in Amana’s Timberline series shown at left
bits, like better qual- (see sources on page 49).
ity carbide and Even well-known tool makers are get-
steel. These bits ting into the game with their own lines of
will last longer bits as well. These bits are often found in
and will cut home improvement centers individually { Contractor-grade bits can come individually
Thicker carbide smoother than or in sets, like you see in the photo at or in sets. Built with higher-quality materials
Higher-quality and precision the less expen- right. For bits that you use more often, and cutting edges, these bits are designed to
bearings grinding sive bits. these mid-range bits are a good value. last longer than bargain bits.
www.Woodsmith.com Woodsmith 9
tools of the trade
Clean, splinter-free cuts. That’s all I designed specifically for miter saws. ically have lots of teeth. For a 10"-
More teeth mean ask from my miter saw. And yet, as So the question is, “What makes a dia. miter saw blade, 60 teeth are
smoother cuts. The simple as that sounds, sometimes it miter saw blade different than other standard, while 12"-dia. blades usu-
60-tooth, 10" blade seems like an impossible request. types of blades?” ally have 80 teeth.
and 80-tooth, 12" But I’ve learned that the secret to WHAT TO LOOK FOR. Essentially, there More teeth mean a smoother cut.
blade below are typ- getting great cuts with a miter saw are three things that a miter saw But there’s a downside to having all
ical examples of doesn’t have as much to do blade needs to do. First and fore- those teeth. The more teeth on a
miter saw blades. } with the saw as it does most, it needs to make clean, smooth blade, the more friction is created.
with the blade. crosscuts. Second, it shouldn’t And this translates to greater heat
Nearly every “grab” the wood as it cuts. And buildup. This not only leads to
saw blade third, it must be able to power burning on the workpiece, but it can
manufacturer through the cut, without bogging cause the plate of the blade to
offers at least down or stalling the motor. expand and distort, which can pro-
a couple of Miter saw blade manufacturers duce a rough cut.
blades that meet these challenges in a number of To help combat this, most manu-
have been ways. To begin with, since miter facturers add expansion slots to their
saws are used blades (see inset photo at left). As
exclusively for their name implies, these slots are
crosscuts and designed to allow the outer edge of
miter cuts, miter the blade to expand slightly as fric-
saw blades typ- tion causes the blade to heat up.
< Laser cut expansion slots at the edge of the blade allow
it to expand without deforming as the plate of the blade
heats up. The “squiggly” slots closer to the center of the
blade are to help deaden vibration.
www.Woodsmith.com Woodsmith 11
techniques from our shop
2. Mark all drawer parts 1. Dry assemble all parts before 3. Be sure top and bottom
to avoid confusion gluing to check for problems edges are flush before
cutting grooves for
drawer bottom
5. Locate
groove so it's
hidden by
joinery
7. Chamfer edges of drawer
bottom for ease of assembly
15. Prefinish
inside faces to pre-
vent glue squeeze
out from sticking
9. Skew clamp
slightly to square
up drawer
are made from 1/4" plywood or hard- across the diagonals, like Tip #8 front and back to the sides, you have
board. The problem is these materi- shows. Equal measurements are to deal with all the long grooves that
als are often slightly less than 1/4" what you’re looking for here. hold the drawer bottom in place.
thick. So using a 1/4" dado blade to cut So what do you do if the meas- There are a couple things I like to
the grooves results in a loose fit. urements differ? The easiest thing do here that minimize the hassle
To custom fit the groove to the to do here is to adjust the position of and mess. First, I like to use a slow-
thickness of the bottom, I use my the clamps and angle them slightly set glue (Tip #13). It gives me
combination blade and cut the groove in the same direction as the long enough time to apply glue where it
in a couple passes, as in Tip #4. diagonal, as illustrated in Tip #9. needs to be without having to worry
There’s one last thing to consider This will “pull” the drawer square. about a joint “seizing” up before
about cutting a groove for a drawer If I have a number of drawers to everything comes together.
bottom. If you’re using dovetails (or make, I use a handy assembly jig, And instead of applying glue the
box joints) to assemble the drawers, like you see in Tip #10 above. The jig entire length of the groove, I simply
be sure to locate the groove where it is nothing more than a pair of cleats drop in a dab of glue right in the
won’t be seen, as shown in Tip #5. screwed to a base at a 90° angle. center of each groove, like you see in
Once you have the groove cut, Making the base out of a piece of Tip #14. It’s more than enough to
there are a couple more tips that can melamine-covered particleboard lock the bottom in place and still
make assembly easier. For starters, to (Tip #11) serves a couple purposes. help strengthen the drawer.
allow the drawer bottom to slip into First, it provides a very flat surface Cleaning up excess glue on the
place easily, I like to cut the drawer that virtually eliminates any twist. inside of the drawer is a pain.
bottom a 1/16" less in width and And second, any glue that squeezes Wiping or scraping it out without
length (Tip #6). This way, the corner out easily pops right off. marring the inside faces or simply
joints will pull together tightly. Regardless of whether you use a making a mess is almost impossible.
Finally, a slight chamfer around the jig or not to square up the drawer, be To avoid this problem, you can
edges of the bottom makes it easy sure you don’t overtighten the pre-finish the inside face of all the
to slip into the groove, as in Tip #7. clamps (Tip #12). It’s all too easy to drawer parts (Tip #15). I like to use
pull the drawer back out of square a couple coats of shellac for this. Any
FLAT & SQUARE and even bow the sides in. glue squeezeout will peel right off.
For a drawer to fit and work well, it’s As you can see, assembling a
important that it’s flat and square. DEALING WITH GLUE drawer doesn’t have to be a chal-
So as soon as I’ve clamped the Despite its small size, gluing up a lenge. Even if you only use a few of
drawer together, I make sure to drawer can be a challenge. Besides the tips and tricks shown here, the
check for square by measuring gluing the joints used to connect the process will be a whole lot easier. W
www.Woodsmith.com Woodsmith 13
jigs & fixtures
table saw
Miter Sleds
After trying one of these miter sleds, the
miter gauge that came with your table saw
may end up just gathering dust.
Open any woodworking catalog and wide panel. In order to get a better pivots to allow you to cut any angle
you’ll find all sorts of gadgets and sense of whether or not a miter sled of miter. Depending on the brand of
devices that promise to improve the might be valuable in your shop, let’s sled, you set the fence by lining it
accuracy of your table saw — as well take a closer look at what they do. up with an angle scale on the base of
as your woodworking. One of these COMMON FEATURES. I took a look at the jig or by using one of several pre-
accessories is a miter sled. three different miter sleds — the set stops. In all cases, a simple knob
A miter sled is kind of a cross Dubby sled by In-Line Industries, the or clamp locks the fence in place.
between a miter gauge and a sliding Woodhaven Deluxe Sled, and the Delta
cutoff table. It can do just about Sliding Miter Jig. (See page 49 for DEAD-ON MITERS
everything that most of the fancy, sources.) All three have some basic Although these sleds can do many
aftermarket miter gauges can do. features in common. things, frankly, cutting miters is
But it can also do some things that a To start with, they all have an MDF where they really shine. Once you
miter gauge can’t. Like crosscut a base. And attached to that base, is a have the fence squared up with the
miter bar that allows the sled to blade, it’s a simple matter to set the
travel in the miter gauge slot. This fence to the angle you want and cut
isn’t much different than a crosscut perfect miters every time.
sled you could make in your own I think the thing that makes these
shop. But what really makes a miter sleds work so well is the fact that
sled useful is the fence. the workpiece rides on top of the
The sleds I looked at all feature sled, rather than on top of the saw
an extruded aluminum fence that table. With an ordinary miter gauge,
it’s too easy for the workpiece to shift
Aluminum along the face of the miter gauge as
fence you push the workpiece forward,
throwing off the accuracy of the cut.
But with a sled, the workpiece and
fence remain fixed while the sled
Steel base slides across the top of the saw.
pin The only thing you have to worry
about is holding the workpiece
against the fence during the cut. And
{ A steel pin serves as a stop for the all of these sleds have a T-slot along
{ Two sets of holes on this miter sled allow you to posi- fence. By moving the pin to differ- the top of the fence. So you can add
tion the miter bar to use the sled on either side of the ent hole locations, you can set the a hold-down clamp to eliminate any
blade. The aluminum fence can also be repositioned. fence to commonly-used angles. concerns of the workpiece moving.
between the saw blade and the fences on all the sleds Stop
edge of the sled. So the bottom are moveable, so no
of the workpiece is supported by matter what angle you
the sled all the way up to the are cutting, you can slide
blade. This prevents splintering the fence right up to the
and tearout in your workpiece. blade to back up your
There is one downside to this, workpiece.
however. With most of these miter One of the sleds even
sleds, once you trim the sled to fit features a replaceable
your saw, you can’t use it on a dif- wood extension on the end of the < To position the fence
ferent saw (unless the distance fence to give your workpiece sup- on this sled, simply
between the blade and the miter port on both sides of the blade. loosen the knob and
gauge slot is the same). (It would be pretty simple to add line up the cursor
Some of the sleds allow you to an auxiliary wood face to the with the desired
reposition the miter bar on the fences of the other sleds.) angle on the scale.
base of the sled to use it in either PANELS. One thing that a miter
the left-hand or right-hand miter sled will allow you to do that a miter Fortunately, all these sleds allow
gauge slot of the saw. But with gauge won’t is crosscut panels. On you to adjust the scales and stops
at least one brand of sled, you a typical table saw, your crosscut for the fence. Some of them even let
have to specify which side of the capacity with a miter gauge is lim- you adjust the fit of the miter bar.
blade you’ll be using the sled ited to around 12" in width. With a OTHER FEATURES. Of course, there are
when you place your order. miter sled, you can cut about double also other features that you’d expect
that. That’s because to find on a crosscut sled — things
the sled supports like hold-down clamps, flip-up
the workpiece even stops, and fence extensions. You can
if it’s pulled back see some of these in the box below.
partially out of the PRICE. The price of these sleds may
miter gauge slot. seem steep at first — they range
ADJUSTABILITY. As from about $135 to $170. But when
with any jig that has you consider all they can do, and if
moving parts, being you cut a lot of miters, a miter sled
able to periodically is definitely worth the money. And
{ Before using the sled for the first time, you’ll need re-calibrate the jig what about the miter gauge that
to trim the edge. This creates a zero-clearance fit for accuracy is came with your table saw? Well, it
between the blade and sled to prevent chipout. important. makes a great paperweight. W
Adjustable Backer Board. A replaceable Positive 90° Setting. An adjustable stop Adjustable Stop. An adjustable stop on
wood extension on the end of the fence of makes it easy to quickly return the fence to the fence allows you to cut multiple pieces
this miter sled allows you to back up your a 90° setting for right angle crosscuts. You’ll to the same length. This stop is reversible,
workpiece completely when making a cut. find this feature on all the miter sleds. giving you two settings.
www.Woodsmith.com Woodsmith 15
Weekend Project
dvd
Storage Case
Organize your collection of DVDs in style with
this easy-to-build, versatile storage case.
It doesn’t take long to build up a rather You can set the case horizontally
sizable collection of DVDs. But the (photo above) and stack a couple
challenge is keeping them all organ- together so they’ll look like an old
ized and neatly stored. That’s just one library card catalog. Or stand a single
of the reasons I like the DVD storage case on end (photo at left) where it
case you see in the photo above. resembles a miniature filing cabinet.
Another is that it’s easy to build.The Regardless of its position, the
few simple joints you need to make drawers slip in place smoothly. And
{ The storage case works just as well vertically. can all be done at the router table. your collection stays organized so
After standing it on end, just give the drawers a The final thing that makes this you’ll always be able to find the DVD
quarter turn, and then slide them back in place. project unique is the design of the case. you’re looking for.
www.Woodsmith.com Woodsmith 17
a.
b.
d.
c.
making the Since you’ll see the dado at the a rabbet along the back edge to hold
CASE
front of the case, a straight bit will the back of the case (detail ‘a’). And
cut a smooth, clean bottom and both the sides and dividers are sized
create a tight-fitting joint. The next to project slightly (1/8") past the front
page shows you how this is done. edge of the top and bottom.
As you can see in the drawing above, STOPPED RABBETS . While you’re at You’re just about ready to assemble
the storage case is nothing more than the router table, you’ll want to rout the case. But first you’ll need to ease
a box with a couple of dividers. The a rabbet along the back edge of both the sharp edges by routing or sanding
key to making the box is creating the top and bottom. It’s sized to a small roundover on the front edges
perfectly square openings so that the accept the back of the case (detail of the sides and dividers, as well as the
drawers will fit the case whether it’s ‘b’). Just be sure to start and stop the ends of the top and bottom, as shown
sitting horizontally or vertically. rabbet without routing through the in detail ‘c’ and on the opposite page.
To do this, I started by cutting the ends of the top and bottom. Finally, if you’re building more
top and bottom to final size and then At this point, you can set the top than one case, detail ‘d’ and page 31
headed to the router table. The router and bottom aside and work on the show you the steps to take to join
is the best choice for making the case sides and dividers. What’s them together. Once that’s complete,
dadoes that the sides and dividers important to note here is that the you can glue up the case and install
of the case will fit into. sides are a 1/4" wider. This allows for the hardboard back.
www.Woodsmith.com Woodsmith 19
a.
b.
c.
two-way DRAWERS
With the case complete, you’re ready without the drawer falling out of the top edge of each side, as in the
to turn your attention to the drawers. case. Finally, to “dress up” the fronts drawing above and pattern below.
The challenge is to build the drawers of the drawers, I added a miniature ROUTING A LOCKING RABBET JOINT . To
to match the openings in the case so hardwood face frame. join the fronts and sides, I used a
they fit well — whether the case is set FRONTS AND SIDES. Since the front of locking rabbet joint, as shown in
horizontally or vertically. the drawer determines the overall fit, detail ‘a.’ The opposite page covers
DRAWER DETAILS . The drawers are I started by cutting the drawer fronts everything you need to know.
built to have a small 1/16" clearance to fit the opening, allowing enough ADDING THE BACK & BOTTOM. Once you
side to side and top to bottom. And for the 1/16" clearance. have the locking rabbet joints cut,
if you take a quick look at the While I was at it, I cut the side you’re ready to add the back and
drawing above, you can see how the pieces to the same width and bottom. The back fits into dadoes
back of the drawer is recessed just a trimmed them to final length. Then, cut in each side piece (detail ‘b’) and
bit. This way you can pull out the to make it easy to reach a DVD inside the bottom fits into grooves cut in
drawer and easily access the DVDs the drawer, I made a cutout along the the front and sides (detail ’c’). After
cutting the drawer bottom and back
to size, you can glue up the drawer.
FINISH IT OFF. To give each drawer a
finished look, I created a face frame
by gluing on thin strips of hardwood
on the drawer fronts (see drawing).
Finally, I added some plastic
bumpers and a brass bin pull.
Now all that’s left to do is round
up your DVD collection, organize
them the way you want, and then
slip them in place.
www.Woodsmith.com Woodsmith 21
Designer Series Project
low-profile
Platform Bed
This project combines the best of both worlds — a modern, elegant
design with basic, traditional joinery. Simple techniques make it easy.
Here’s a project I’ve been looking build a platform-style bed. With joinery. Nothing fancy or tricky
forward to building for some time. this type of design, no box spring is here. All you have to do is chop a
This queen-size bed completes the needed. So you end up with a sleek, few mortises, cut some tenons to
five-piece bedroom suite that low-profile bed. But best of all, the fit, and you’re almost done. And
includes an armoire, dresser, night clean, simple design makes the panels in headboard simply
stand, and wall mirror. (To see all building a large project like this slide into grooves cut into the frame
of these projects together, check out very straightforward. pieces. To complete the job, you just
the photo on the back cover.) For starters, the headboard and cut a couple of rails, install some
To match the contemporary look footboard are both put together simple hardware, and the bed is
of the other pieces, we decided to with basic mortise and tenon ready to assemble.
www.Woodsmith.com Woodsmith 23
a.
c.
b .
building a sturdy
HEADBOARD
On this project, I decided to get the THE LEGS. To get started, you’ll need hold the side panels, connects the
most involved work out of the way to make the two stout, 3"-square legs. two upper mortises.
first. That means I started by put- These will give you a solid founda- KEEPING IT SIMPLE. But before you get
ting together the headboard. tion. As you can see above, the leg started on the layout, let me point
LOOK IT OVER. Take a look at the blanks are glued up from two pieces out a couple things you need to
drawing above and you’ll get a of 11/2"-thick stock. Once that job is know. First, as shown above, you
good idea of how the headboard is completed, you can cut them to want to orient the leg blanks so the
put together. You’ll see that it’s really length, and then turn your attention glue lines are along the sides of the
nothing more than a large, mortise to the mortise and tenon joinery. headboard. They’ll be a lot less
and tenon frame. THE LEG JOINERY. As shown in the left noticeable this way.
You start with two sturdy legs and margin, each leg has three mortises. The second item has to do with
join them with three rails. The space Two long mortises for the lower and the width of the mortises and the
between the upper rails is filled by middle rails, and a narrower, open grooves in the frame. I did things
a pair of vertical stiles and three ply- mortise to capture the upper rail. just a bit differently here.
wood panels set into grooves. I think This open-ended mortise makes the To keep things simple, I wanted
the main challenge you’ll find might assembly go a little easier and it will to set the three plywood panels into
just be the large size of the head- be hidden by a cap piece added later. full-width, centered grooves cut into
board. But it’s not unmanageable. Finally, a shallow groove, sized to the frame parts. But now since 3/4"
www.Woodsmith.com Woodsmith 25
capping the
HEADBOARD
The joinery is complete but don’t get
too anxious and start gluing the
headboard together just yet. There’s
a certain order to things that you’ll
want to know about first.
STAIN NOW . You’ll remember that
the headboard frame and the panels
are stained contrasting colors. This
left me with a decision — should I
stain before or after the assembly.
Prestaining made the most sense. So
at this point, I took the time to sand
and stain all the parts. You’ll find
the two stain colors at our website.
THE ASSEMBLY . After the stain was
dry, I carried all the pieces to the
bench and got out the glue and
clamps. The large size of the head- a. b.
board can make the glueup a little
tricky. So I took it in stages to make
it more manageable. You’ll need six-
You can find infor- foot clamps to reach from side to
mation on the stains side. If you don’t have any long
used on the bed at clamps, the box below gives you
www.Woodsmith.com several good options.
I started the assembly by gluing
the lower and middle rail between
the legs. When this assembly is dry,
you can drop the stiles (with glue)
and panels into place from above.
Finally, the upper rail is glued into fered cap that covers the top rail and dowels between each leg and the
the slot mortises in the legs and the legs. Glue holds the cap to the long headboard cap, as shown in details
clamps can go on. grain of the top rail but the end grain ‘a’ and ‘b.’ If you turn to page 31,
A SIMPLE CAP . The last piece to be on top of the legs is a poor glue sur- you’ll find an easy way to match up
added to the headboard is a cham- face. So here, I added a pair of the holes for the dowels.
{ You can avoid the need for long clamps { A cheap solution is to make two clamps { If one pipe clamp won’t do the job, I’ll
by giving yourself an alternate clamping into one. All it takes is an inexpensive put two to work, back-to-back. The two
surface. Here I tightened my clamps down coupler from the hardware store to make pads are turned 90° so the clamps can
on cleats clamped to the rail. two sections of pipe into one long section. be tightened against one another.
b.
d.
c.
making the
FOOTBOARD & RAILS
With the headboard complete, most to worry about, so I cut mortises that THE SIDE RAILS . The side rails only
of the hard work is out of the way. were a full 3/4"-wide (detail ‘b’). And need a short mention. Just cut them
The next job is to build a footboard since the footboard has no cap piece, to size and they’re ready to go.
and a pair of rails to wrap up the I routed a chamfer on the tops of the THE HARDWARE. Now that you have
frame. Then you’ll add the hardware legs as well as the bottoms. all the frame pieces made, the next
to hold everything together. And The footboard rail is pretty much step is to install the bed hardware
finally, some cleats to support a plat- self explanatory. The only twist here used to fasten everything. For details
form for the mattress. is the gentle curve cut into the lower on this, you can turn to page 28.
THE FOOTBOARD. First comes the foot- edge of the rail. You’ll want to do THE CLEATS . With the fasteners in
board. You can see in the drawing this after the tenons have been cut, place, the frame can be set up and
above, it’s much simpler than the as shown in detail ‘a.’ the cleats that support the platform
paneled headboard — merely a pair To lay out the curve, I simply used installed. First, I cut the headboard
of legs with a curved rail connecting a flexible strip of wood pulled into and footboard cleats to fit and glued
them. Here again, mortise and tenon a slight bow by a piece of string tied and screwed them to the rails (details
joinery supplies the strength. between the two ends. And once ‘c’ and ‘d’). The side rail cleats need
I’ll only mention a couple things you’ve marked the line of the curve to be set back from the ends of the
about the legs for the footboard. on the rail, you can take it to the rails in order to clear the end cleats,
Here, I didn’t have plywood panels band saw to cut it to shape. as shown in detail ‘c.’
www.Woodsmith.com Woodsmith 27
Bed Rail Fasteners
BED RAIL
mortise
behind slots
provides
clearance
SIDE for hooks
FASTENERS
RAIL
Tapered
hooks lock
When you assemble a bed frame, into slots in
female plate Female
you want to accomplish two things. plate of
First, you want it to be solid as a fastener
mortised
rock. Next, you need to be able to into face
of leg
assemble and disassemble the bed
frame quickly and easily for mov-
Male plate of
ing. Well as you might guess, there’s fastener mortised
hardware available that handles into end of rail
both jobs and it works great.
HOW THEY WORK . The
drawing at upper right
shows how the bed rail 1
fasteners I used (and most a.
{ These bed rail fas- other types) work. The male plate
teners give you the of the fastener (left in drawing) is
best of both mortised into the end of the side rail.
worlds. They make It has a pair of tapered hooks that
setting up the engage two slots in the female plate
frame easy. And of the fastener, mortised into the leg.
once it’s together, As the rail drops into place, the
it’ll stay together. tapered face of the hooks pulls it
tightly against the female plate
locking the leg and rail together. All
it takes to reverse the lock is a solid 2
“thump” on the bottom of the rail. a.
MORTISES. The only catch is, to get
the best result, the fasteners have to
be mortised snugly in place, flush
to the surface. This means cutting
eight mortises, four of these into
tough end grain. So it didn’t take
me long to decide that routing these
mortises was the best way to go. It
was an easy job using a simple jig.
You’ll find the details on page 30.
FINISH UP. Once the shallow plate < Seated in a snug fit-
mortises were routed, I got out a ting mortise on the
hand drill to complete the job. As leg, the slotted plate
you can see in the upper drawing, provides a solid
both parts need a relief area drilled attachment point for
out behind the plate. The side rail the side rails.
mortises simply need a couple of
shallow holes to provide clearance
for the nubs on the back of the plate
(Fig. 1). On the legs, I drilled a
deeper, secondary mortise behind
the slots in the plate to accommo-
date the fastener hooks as in Fig. 2.
A Different Size
Building a wider frame is about the
only change you’ll need to make for
a king-size version. But I do want
to mention a couple minor things.
First, when you build the head-
board, you’ll have more space to
fill with the plywood panels. The
best way to do this is to leave the
two side panels the same size and
make the center panel wider.
And then at the tail end of the
project, you’ll want to add extra
support under the platform. All
this takes is a centered leg
screwed to the platform brace.
A couple final notes. You’ll find
dimensions for a full-size bed on
To find a materials list and cutting
our website. And check your mat- diagram for a king-size or a full-size
tress size before you start work. bed, go to: www.Woodsmith.com
www.Woodsmith.com Woodsmith 29
tips from our shop
Glue up top
of jig around
2 To rout
one of the mortise in
bed rail fasteners legs, move
Size 3 fence to outer
grooves groove
to hold
hardboard
fence
NOTE:
#/4 15 Top of jig is
made of
!/2"-thick stock
1!/2
NOTE: a. FRONT b.
Do not SECTION
glue hardboard VIEW
Setting !/4" fence in place
for bed rail hardboard fence
!/2" dado
1 END VIEW clean-out bit
Place Bed
fence in groove post
closest to slot Clamp jig
to bed rail
a. Countersink b. FRONT
FRONT for !/4" SECTION
SECTION machine !/4" x 1"Fh.
VIEW machine
VIEW screw
screw
Headboard Cap
When it came to installing the cap on a.
Cap
the headboard of the bed, I used
dowels to keep the pieces aligned
and create a stronger joint. I just had
to make sure sure the holes in the
top of the legs lined up with the holes !/2"-dia.
in the bottom of the cap. !/2"-dia. dowel
To do this, I used dowel centers. I dowel
centers
drilled the holes in the legs first. b. Drill holes in
cap for dowels
Then I placed a dowel center in each
hole and centered the cap on the
headboard. By pressing down on Leg
the cap, the dowel centers made
SIDE
“dimples” in the bottom of the cap, SECTION
VIEW
letting me know exactly where to
drill the matching holes. W
www.Woodsmith.com Woodsmith 31
Heirloom Project
elegant
Inlay Mirror Frame
Take a frame from basic to outstanding with a few small pieces of
veneer and pre-made inlays and marquetry patterns.
Icing on the cake — that’s what this it stand out from the crowd. While veneer choices, and marquetry medal-
project is all about. Just take a look at this may sound complicated, it’s not. lions available. For a couple of other
the photo above and the drawing on The inlay and marquetry pieces are ideas, take a look at page 39 or the
the opposite page to see what I mean. pre-made from different species of sources on page 49.
The frame joinery is just butt joints wood that are sliced thin, dyed, and With this frame, I’ll show you the
reinforced with splines. But then, the then glued together. All you have to techniques and give you the infor-
frame is dressed up with figured do is arrange them on the workpiece mation you’ll need to successfully
veneer, marquetry medallions, inlay and then cut them to suit your needs. work with these pieces on this project
strips, and stringing that really make There are dozens of inlay patterns, or any other you’d like to build.
For veneer
and inlay
sources, turn
to page 49
Beveled mirror D-ring
sits in rabbet hangers
routed on
back of frame
Frame pieces
covered with
burl veneer
and pre-made
inlay strips
Rails made
from
inexpensive
hardwood
Hardwood edging
conceals sides of
frame pieces
Hardwood splines
reinforce corner
butt joints
Corner blocks
have roundover
with shoulder
Screws allow
easy removal
of mirror
Inlay stringing
helps square up
marquetry medallion
SIDE SECTION VIEW
www.Woodsmith.com Woodsmith 33
Inlay strips
Burl veneer a.
applied first Cut edging extra
long, then trim
after attaching to
frame pieces
Trim
flush NOTE: Frame pieces
made from
!/2"-thick poplar
Inlay glued in
rabbets routed
on frame pieces
21 SHORT EDGING
C
A
SHORT
FRAME
PIECE
!/2
D
LONG EDGING
NOTE: Edging made Rout profile
from !/2"-thick mahogany 2!/4 on extra-wide
!!/16 Inlay strips blank
mitered with B D
chisel and
LONG FRAME LONG EDGING
dressing up the
miter block
PIECE
(2!/4 x 35)
edge molding are added to complete the same, exact length. A stop block
Cut Rails to Length. To end up with a square assem- Gluing the Veneer. A set of hardwood Trim Veneer Flush. After the glue dries,
bly, the frame pieces need to be cut precisely. A stop cauls and plenty of clamps provides the use a veneer saw to trim the veneer flush
block on the miter gauge makes this a snap. pressure needed for a flat veneer bond. with the edges of the frame pieces.
C D
Waste
Aux.
fence
C D
A B a. #/8"
!!/16 roundover
6 bit
Veneer Waste
a. Width of A B
inlay strip a. C D
Thickness
of inlay
Spacer piece
helps to align
miter at corners C D
Straight bit
Routing for Inlay. A straight bit Applying Inlay. A mitered spacer makes it easy to posi- Shaping the Edgings. Rout the profile
in the router table makes a flat- tion the first strip of inlay. On the long edges, apply of the edge molding on an extra-wide
bottom rabbet for the inlay. glue to short sections and use finger pressure. blank. Then rip to width.
www.Woodsmith.com Woodsmith 35
Cross banding
Cross banding
Inlay
stringing
Use mitered Cut second
spacer to fit miter on end
first piece of first piece
Gap
Straight border
piece is used to
square up sides
Align corners of of medallion
medallion with Spacer
layout lines
E
Placing Medallion. Use diagonal layout Apply Inlay Stringing. Black inlay stringing sets off the medallion. Since the medal-
lines to roughly center the marquetry medal- lions may not be square, don’t glue the stringing tight against the medallion. Instead,
lion on the corner block. use the inlay to help square up the pattern. The tiny gaps won’t be visible.
Frame side
rail assembly
CUTTING MITERS. The Frame
miter joints on the inlay rail
Frame rail edge Chisel or sand
strip are cut with a chisel like and corner block extra-wide splines
the inlay on the frame pieces. edges are flush flush with frame edge
But instead of using a miter block,
I used the layout lines on the corner
block to line up the chisel. Then it’s SPLINES
!/8 #/16 (!/8 x 2#/4)
just a matter of cutting and fitting F
each piece as you work your way the frame.
around the marquetry medallion. To keep things
CROSS BANDING. The final piece you’ll simple, I used
add to each corner block is a strip spline joinery. The !/2 Frame bottom
of cross banding. The narrow drawing above shows rail assembly
banding is crosscut from a larger how it works. A groove in the #/16 1
sheet of straight-grained veneer. Just end of each piece creates a pocket !/8
note that the grain runs across the for a thin spline. !/2
width of the strips. These pieces are But there’s one thing to watch out Corner block
then mitered and fit to the block the for. When cutting grooves on the assembly
same way as the thin inlay stringing ends of the frame pieces and the end
that was just applied. grain of the corner blocks, it’s a good
There’s just one last thing to do idea to back up the workpiece to ASSEMBLING THE FRAME. Speaking of
before moving on to the joinery. And prevent tearout (box below). assembling the frame, I found that
that’s to rout a roundover on all four Once the grooves are routed, you one way to make the process a little
edges of the corner block. When set- can make the splines. Note: The less hectic is to do it in two stages.
ting up for this detail, I created a grain direction runs across the joint Start by gluing up the ends of the
slight (3/32") shoulder so the cross line. I cut the splines extra-wide and frame first. In my case, I glued a
banding strip really stands out. trimmed them flush after the glue short frame piece to two corner
SPLINE JOINERY. With all the details of dried. This way I didn’t have to blocks. The second stage of the
the frame taken care of, you’re ready worry about keeping the splines process is to connect these two
to connect the eight parts (four frame aligned while the frame was assem- assemblies together with splines and
pieces and four corner blocks) into bled, as in detail ‘a’ above. the remaining two frame pieces.
Corner block
!/8" slot-
cutter bit a.
END VIEW !/2
!/4"
a.
roundover !/4"
E E bit roundover
CORNER bit
BLOCK #/32"
NOTE: Use step
mitering guide #/16
block to cut cross banding
ends to fit
Add Veneer Cross Banding. Cut cross Rout Roundover. After trimming cross- Cut Grooves for Splines. Rout a groove
banding strips from a sheet of straight- banding, rout a slight, shouldered in two sides of each corner block and the
grained veneer. Note grain direction. roundover on all four edges. ends of the frame pieces to hold a spline.
www.Woodsmith.com Woodsmith 37
a.
9!/4 SIDE
G #/4 SECTION #6 x %/8"
LONG STOP VIEW Fh wood-
D-ring screw
23
SHORT #/8
SHORT
STOP STOP D-ring
H
H hanger
with
screws B
Mirror STOP
Kraft
paper
2
11
LONG STOP
G b. D-ring BACK
with #4 x !/2" #/4 VIEW
Fh woodscrews
#6 x #/4" Fh
brass woodscrew 1
Kraft paper attached
37 to mirror with
spray adhesive
securing the 2
a. b. c. Square up
Rabbet waste #/8 corners with
Skim pass a chisel
Rabbet
%/16
Frame Rout shy of
edging rabbet depth
Bit set to full Rout full
depth of rabbet depth of rabbet
Routing the Rabbet. To prevent tearout, the rabbet that holds the mirror is routed in Squaring Up the Corners. Since the rab-
three steps. The first pass establishes the shoulder of the rabbet at full depth. The second beting bit can’t reach into the corners, you’ll
removes most of the waste. And the final pass cleans up the bottom of the rabbet. need to clean them up with a chisel.
Corner Options
There are literally hundreds of possible
combinations of veneer and inlay strips
to customize your own project. And a
good way to see them is to take a look
at the possibilities available from the
source on page 49.
In the drawings here, you can see how
just a simple change can really trans-
form the look of the frame. In the left
one, I replaced the marquetry medallion
with a piece of the veneer used on the
frame pieces. On the right, I went with
mitered corners.
www.Woodsmith.com Woodsmith 39
working with tools
Countersinks are one of those small details that are manufactured in Europe in which the angle
can really change the look of a project. And it’s around the holes that attach the hinge measure
Screw Head Position. For the screw easy to overlook the importance of doing it right. 90°. So to get the screw to seat properly in
head to seat properly, the angle and There are many types of countersinks that these hinges, you’ll need to redrill the hole
diameter of the countersink must will cut a cone-shaped opening at the top of a with an 82° countersink.
match that of the screw head. screw hole. But when it comes to making coun- PILOTED AND NON-PILOTED. It’s also important to
tersinks that look consistently good and seat determine how you’ll be drilling the counter-
the screw head correctly, using the right bit sink. That’s because some countersink bits
Piloted bits have a makes a big difference. will require drilling a pilot hole first while
center pilot to So, how do you know if you have the right other bits don’t need a pilot hole.
maintain proper bit for the job? Well, several things need to be A lot of countersinks are nothing more than
hole alignment.} considered before answering that question. a large bit with a tapered point at the end, like
COUNTERSINK SIZE. First, you’ll want to make you see in the bottom photo at left. They require
sure the head of the screw fits into the coun- a pilot hole to center the bit so it is able to cut
Pilot aligns tersink so it sits flush with the surface of the equally on all sides of the hole.
countersink wood (or slightly below). That means using a A great advantage to this type of bit is that
countersink that’s at least as large as the head it can be used for a wide range of screw sizes.
diameter of the screw. With some types of By simply increasing or decreasing the drilling
countersinks, you’ll need to adjust the size of depth of the bit, the diameter of the counter-
the opening by setting the drill press depth sink can be made larger or smaller.
or controlling your hand drill. Other types You’ll also find countersink bits available
require you to choose a countersink size that’s with a center pilot at the end, like you see in
Tapered
specific to the size of the screw you’ll be using. the top photo at left. They allow you to quickly
point Another important consideration is the countersink in wood and dress or resize holes
angle of the countersink bit (see illustration in hardware. These bits generally come in
at left). For the screw to seat correctly, the angle diameters that correspond to screw sizes.
of the countersink bit must be the same as the Size and angle are important. But it’s the
{ Non-piloted bits have no angle of the screw head. cutting flutes that really determine the kind of
center pilot and require the An angle of 82° is the one you’ll find most hole you end up with. The type of cutting
drilling of a pilot hole first. often. But I’ve come across some hinges that edge and the number of cutting surfaces on the
www.Woodsmith.com Woodsmith 41
small shop solutions
perfect placement
Workbench
Location Pivot pin
Lock-down
Sturdy plywood
top prevents
racking
The first step to an
efficient shop is choosing
the best location for
your workbench.
Aside from the table saw, I don’t your workbench is something that accessibility to the workbench may
think there’s a more important deserves a little thought, particu- not be as important as having the
“tool” in my shop than my work- larly if you have a small shop. bench close to your major power
bench. Sometimes I use it during tools. If this is the case, you may be
each step of construction on a proj- TWO CHOICES able to locate the bench against a
ect and other times only for layout When you get right down to it, there wall. Take a look at the sample floor
or assembly. But it’s pretty safe to are really only two choices when it plan drawing at left to get an idea of
say that every project that comes comes to locating a workbench — some of the benefits of locating your
out of my shop passes across my either against the wall or out in the workbench against a wall.
workbench at some point. And middle of the shop. Which of these FRONT & CENTER. On the other hand,
that’s why deciding where to put locations you choose has a lot do some woodworkers see their work-
with the way benches as more than just shop fur-
you use your niture. It’s a tool in itself. It can be
workbench. used to hold a workpiece while saw-
AGAINST THE WALL. ing, planing, or working on joinery.
For many wood- If you use hand tools regularly or
workers, a work- do a lot of hand-cut joinery, you may
bench serves as a want to give your workbench a place
“staging area” right in the center of the shop. This
for setting out way, you can have easy access to the
parts while using bench from all four sides, which is
the table saw or great advantage when it comes to
other pieces of assembling a project. The sample
shop equipment. floor plan on the opposite page
For woodwork- shows some of the advantages of
ers like this, this type of layout.
www.Woodsmith.com Woodsmith 43
finishing room
If you read through the box at tent. The Behlen brand shown at right
right, you’ll have a good idea of is my first choice (see sources).
the differences between them. But A THICK FILM. Building the finish is
I want to make special mention of a pretty straightforward process.
one very important difference. Your goal is a film thick enough to
ONE LAYER. When you apply lacquer, sand flat and then polish without
each successive coat “melts” into the fear of rubbing through.
one before it. So in the end, you basi- At this point, I just settle into a
cally have one thick coat of lacquer routine. I carefully brush on a coat Before you choose whether to go with lacquer or
on which to sand and polish. of finish, let it dry completely, sand varnish, it helps to know the pros and cons of each.
MANY COATS. With a varnish, each a bit, and apply the next coat. A I like the fast-drying property of lacquer. This
coat simply lies on top of the pre- good-quality brush and good tech- lets you apply as many as three coats in a day. But
vious coat. So sanding between coats nique will result in a flatter finish since it tacks up and dries quickly, it can be tricky
is a must to get good adhesion. But and save you work later. to apply without leaving brush marks. And it builds
a problem with varnish can lie in the Even with lacquer, I like to sand slowly, so you’ll have to apply more coats.
final sanding and rubbing. If you lightly between coats with 320-grit On the other hand, a slower-drying varnish flows
rub through the final coat to the one sandpaper. This flattens the surface out and leaves a smoother surface. It builds faster,
beneath, you’ll expose a faint joint a bit after each coat allowing you to so fewer coats are necessary. But the slow drying
line (called a witness line). The solu- judge your progress toward a thick, time means one coat a day is the best you can do.
tion is to apply a flat film that won’t relatively flat film. And there’s more time for dust to settle in the finish.
require too much sanding to flatten. As each coat is applied, the finish
And with varnish, this isn’t difficult. will lie smoother and flatter, as Lacquer Varnish
I’ve used both finishes and had shown in the drawing above. But Pros: Pros:
great results. In the end, your choice even after the final coat is applied, • Dries within a few hours • Brushes easily and flows
comes down to which type you feel the finish won’t lie perfectly flat. allowing several coats a day. out smoothly.
more comfortable with. I think lac- The trick is to judge when you’ve • Multiple coats create one • Requires fewer coats to
quer gets the job done a little quicker, built up enough finish. Four or five thick film. build a thick film.
but varnish probably takes a little coats of varnish will usually do the Cons: Cons:
less work. One last thing. If you job. With lacquer, you might need • Can be difficult to apply • Dries slowly, only one
choose varnish, buy a good-quality, seven or eight. After curing for sev- without brush marks. coat a day is possible.
interior type with a high resin con- eral days, the finish is ready to rub. • Thin coats build slowly. • Dust can be a problem.
www.Woodsmith.com Woodsmith 45
sand and
POLISH
At this point, you’ve built up a thick,
shiny film, but it’s not perfect. You’ll
see brush and lap marks and dust
specks. So after allowing the finish
to cure for several days, the next step
is to sand the film until it’s perfectly
flat. And when it’s flat as glass, you
can polish it to a high sheen.
WET SANDING { Once you’ve laid down a thick film of finish, it only takes a small amount of
This sanding process is a little dif- elbow grease to level it. The three ingredients you’ll need are wet-or-dry sand-
ferent. Here, you’ll use very fine-grit paper, a padded sanding block, and plenty of mineral spirits.
“wet-or-dry” sandpaper found at
paint or auto body stores. The sand- Sanding near the edges gets my By now, most of the leveling
paper is wrapped around a padded special attention. It’s often where work is done, so you can get
sanding block and the surface kept the finish is the ”roughest” and through these last stages pretty
well lubricated with mineral spirits needs the most work. But you want quickly. But you don’t want to
(paint thinner) while you sand. The to take care not to sand through the leave any deep scratches that will
mineral spirits float away the sand- finish to bare wood. I try to use a take a lot of time to polish out later.
ing dust to keep the sandpaper clean. light touch and not “drag” the It can be hard to judge when to
I like to start with 800-grit sand- sanding block too far over the edge. quit sanding and move on to the
paper. Just pour a liberal amount of CHECK YOUR PROGRESS . I use both polishing. When you think you’re
thinner on the surface and start sight and feel to check my progress. close, clean the surface with a soft
sanding with a circular motion. When you run your fingers lightly cloth and take a look. It may sound
This “random” motion will get you across the surface, you’ll feel any strange, but what you’re shooting
to a perfectly flat surface quicker. unevenness. Then after sanding for for at this point is a perfectly flat
As you work, the mineral spirits a time, I’ll wipe the surface clean surface with a consistent dull sheen
and the sanding dust will mix to and look closely for shiny areas. and no noticeable scratches.
create a light slurry (photo Spots of shiny finish mean your
above). This shows that surface isn’t quite flat. You want a BRING UP THE GLOSS
you’re making progress. surface that’s completely dull. So now you’ve taken the film of fin-
It’s a messy process, but TIME TO SWITCH. When I think the ish from uneven and shiny down to
even so, you want to keep surface is 99% flat, I switch to 1200- dead flat but completely dull. But
the surface good and wet. grit and finally 1500-grit sandpaper you can bring it back to a high sheen
On the plus side, you’ll be and repeat the process. These two in two quick polishing steps.
surprised at how fast the steps create finer and finer A LITTLE DIFFERENT. This polishing or
fine sandpaper levels the scratches and reduce the amount rubbing process is slightly different
irregular surface. of polishing you’ll need to do. from the wet sanding you just
Dead Flat. The drawing above shows the goal of the wet sanding process.
The built-up finish is now perfectly flat and ready to polish to a high gloss.
www.Woodsmith.com Woodsmith 47
in the mailbox
A MDF , or medium-
density fiberboard,
is a manufactured wood
flat, and uniform surface.
This makes it the perfect
base for wood veneer and
product that’s in the same plastic laminate.
family as particleboard. Third, its higher density
But unlike particleboard, holds an edge better than dull steel cutting tools lector if possible, and
which is a mixture of particleboard (see photo quickly, so carbide cutters always wear a dust mask.
wood chips and shavings at the bottom). And you and blades are recom- FINISH. You can find MDF
held together with resin, won’t have problems with mended. About the only unfinished, or with wood
MDF is much more voids, like in plywood. thing you shouldn’t do is veneer or plastic laminate
refined. The finer the MACHINING . A standard run MDF through a thick- already applied to it.
sheet of MDF is 49" x 97" ness planer or over an You’ll find that MDF
(the extra is for trimming). edge jointer. takes paint well. Unlike
Do you have It’s available as thin as 5/32 "
and as thick as 15/8", as in
Safety Note: Since the
fibers are so fine to begin
particleboard or plywood,
which the surface texture
any questions the photo below. It can be
worked like any other
with, working with MDF
kicks up a lot of fine dust
or grain shows through,
MDF looks smooth after a
for us? wood product, including that can hang in the air for coat of primer and a cou-
traditional joinery like quite a while. When work- ple of coats of paint.
If you have a question dovetails and tongue and ing with MDF, and espe- Note: Whenever I use
related to woodworking groove. Because of the cially during sanding, MDF for shop jigs , I pro-
techniques, tools, finishing, glues used in the manu- proper ventilation is tect it with a couple of
or hardware, we’d like to facturing process, MDF will required. Use a dust col- coats of wiping varnish. W
hear from you.
Just write down your < Available in several thick-
question and mail it to us: nesses, the dense structure
Woodsmith, Q&A, 2200 of MDF means that it cuts
Grand Avenue, Des and routs more like solid
Moines, Iowa 50312. Or wood. Using carbide router
you can email us the ques- bits, you can rout crisp,
tion at: woodsmith@wood- clean profiles in MDF.
smith.com.
Please include your full
name, address, and day-
time telephone number in
case we have questions.
Constantines
WOODSMITH PROJECT SUPPLIES 800-443-9667
constantines.com
We now feature hardware from in many Veneer
of our new project kits. To order, please use our toll-free on the web In-Line Industries
order line, see below. It’s open Monday through Friday, 800-533-6709
from 8 AM to 5 PM Central Time. Before calling, please • “Online Extras” - Plans, Patterns, & More in-lineindustries.com
• Over 100 Woodworking Tips Online Dubby Miter Sled
have your VISA, MasterCard, Discover, or American
Express card ready. • Visit Our Readers’ Project Photo Gallery Woodhaven
• Project Plans You Can Download
If you would prefer to mail in an order, please call the 800-344-6657
• Catalog of Project Kits, Tools, Jigs, & Plans woodhaven.com
toll-free phone number below for more information
• Forums for Woodworking, Tools, & Classifieds Deluxe Miter Sled
concerning shipping charges as well as any applicable • Links to Other Woodworking Sites
sales tax. • Order Woodsmith & ShopNotes Back Issues
Lee Valley
800-871-8158
www.Woodsmith.com Woodsmith 49
details of craftsmanship
4 steps to perfect
Coped Joints
When it comes to getting perfect-looking joints with
molding, nothing beats this traditional woodworking joint.
No gaps. That’s the goal whenever out of square. With a miter joint, you
I’m fitting molding to a project. But have to do a lot of fussing and trim-
this is often easier said than done, ming if the corner you’re fitting the
particularly when it comes to fit- molding to isn’t exactly 90°. But that
ting molding in an inside corner. isn’t the case with a coped joint.
All it takes is for the corner to be The second major benefit is that
slightly out of square to throw off if the molding pieces should happen
the fit of a mitered joint. That’s to shrink over time, the gap between
{ In a coped joint, the end of one
where a coped joint comes in. the two pieces of a coped joint will
piece is cut to fit around the pro-
A coped joint is one where the end be a lot less noticeable than if you
file of the mating piece.
of one piece of molding is cut had used a miter joint.
(coped) to match the profile of the WHEN TO USE. Coped joints are often
mating piece, see photo above and used by carpenters when installing
upper drawing at left. When care- baseboard and crown molding. But
fully done, the pieces fit together so you’ll also occasionally find them on
well that the jointline is nearly invis- furniture projects. Acoped joint can be
ible, see lower drawing. used any place where you’re applying
ADVANTAGES. You might be won- molding to an inside corner.
dering why anyone would go to Making a coped joint really isn’t as
all the trouble of making a coped complicated as it looks. There are
joint when a simple miter joint actually only four steps. The trick is in
would do the job. Actually, there learning to saw to a line accurately
{ The result is a tight-fitting joint are a couple of reasons. with a coping saw. But that’s some-
that looks like it has been First, a coped joint will give you a thing that you’ll pick up quickly with
perfectly mitered. good fit even if your project is a little just a little practice.
2 Highlight Profile
Even though mitering the
end of the workpiece reveals the pro-
file, it can still be difficult to see while
you’re trying to cut it. It’s not easy to
tell just where the edge of the miter cut
meets the face of the molding.
So, to make the profile stand out
more, I highlight the edge of the miter
Use side of pencil by shading it with a soft-lead pencil,
lead to "highlight" see drawing at left. This gives you a
profile on edge of miter
much more visible line to follow.
3
the way along, it’s easier to cut the pro-
Cope the Profile file in sections. By coming in from dif-
With the profile clearly marked ferent angles, you can cut into corners
out, the next step is to cut along the and tight curves that the saw wouldn’t a.
layout line with a coping saw. There otherwise be able to navigate. Start by
are just a few things to point out here. cutting out the larger curves first, then
First, I like to mount the blade in my come back and cut the shoulders and Saw
blade
coping saw so the teeth point away smaller sections of the profile. Cut up
from the handle. This allows you to Finally, I hold the saw at a slight Pencil to pencil
mark line
cut on the downstroke while still angle as I’m cutting the profile to Waste
working from above (see drawing). create a back bevel on the coped piece.
Waste
Not only do I find this more com- (You don’t need much of a back bevel
TOP VIEW
fortable, it allows me to keep my eye — three to five degrees is fine.) This
on the layout line as I’m cutting. way, you’re certain the two pieces of NOTE: Angle saw
Second, instead of starting at one end slightly to create
molding will fit together tightly at the back bevel
of the profile and trying to follow it all front of the joint, where it counts.
4
Scrap piece
Check The Fit
The final step is to “fine tune”
the fit. To do this, hold a scrap piece
of molding against the coped piece
No gaps are to see where you need to make any
File coped
profile as visible with adjustments, see first drawing at left.
needed to get proper fit
snug fit Then using a file, gradually remove
material from the profile a little at a
time until the two pieces fit together
tightly. Acouple different sizes of half-
round files come in handy here. After
END VIEW END VIEW filing, you can lightly sand the profile
to refine the fit even more. W
www.Woodsmith.com Woodsmith 51
looking inside
Final Details
!/2" x 7!/2"- 84" Oak (4.4 Sq. Ft.) !/4" - 24" x 24" Hardboard
A A B B C C G
D
I J
!/2" x 7!/2"- 84" Oak (4.4 Sq. Ft.)
H H
A
B A B B C C G
H
!/2" x 7!/2"- 96" Oak (5 Sq. Ft.)
E E E F F F F F F G