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Contents

Fram-ohd-Panel Doors
Takethis crash courseand make doors like a pro, even if it's your first time.

32
45
=:Tr1'lr

Victorian Trellis
An American beautyyou build in the shop and assemble on site.

.H

?{2 ..,-Page

Rolling Ladder Bookcase 58


Built-in convenience with premade moldings and a design that forgives imperfections.

Three-Year Index
TWenty-oneissuesof AW at your fingertips.

80

ToolTest: Stacking DadoBlades 53


Dont spendtop dollar.Youcan get a first-rate set of bladesfor less than 100bucks.

ToolTest:

DrillPresses 68
Before youbuy,checkout our test andyou'llgetthebest.

American

Woodworker

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Contents
DEPARTMENTS
EDIT0R Ken Collier SENIOR E D I T OT Ro m Caspar ASSOCIATE EDITORS Randy Johnson, Tim Johnson, Dave Munkiftrick C O N T R I B U T IE ND GI T O R S E dK r a u s e , George Vondriska ARTDIRECTORS Patrick Hunter, Vern Johnson, Barbara Pederson COPY EDITOR Mary Flanagan FACT CHECKIN S G PECIALIN ST ina C h i l dJ so h n s o n PRODUCTION TEAM Judy Rodriguez, BillSympson SHOP ASSISTANTS Ben Davis, Jeff Larson, Al McGregor R E A D ES RE R V I C S E PECIALIS RT o x iF eilipkowski ADM I NISTRATIVE ASSI STANTS Lori CaI|ister. Shelly Jacobsen PUBLISHE R M ichae Pl .R e i l l y A D V E R T I S IS NA GL E S DIRECTO RR ick Straface MAR KETING DlRECTOR Robert Galandruccio B U S I N E SM SA N A G E R T om Cassata AMERICA NO O D W O R K W E R S H OW TRADE SHOWEXHIB IT M ANAGE R C i n dH y elmlinger (215) 32I -9662ext46 E X H I B IS TA L E S MANAGE R B ob lePage (215) 321-9662exr42 PROM0TION MANAGER Andrea Vecchio PROMOTIO CN OORDINAT 0a Rn n N lo e o6 ADVERTI SINGCOORDI NATOR Susan Bordonaro A D V E R T I S IS NA GL E S 260 Madison Ave., New York, NY10016; 212-850-7226 (312)540-4804 CHICAGO andWEST COAST JimFord (212)850-7124, NEW Y0RKDavid Clutter Tuck Sifers (212)850-7197, (Sales John Santoro Assistant) CLASSIFIED ADVERTISING The McNeill Gmup, Inc. (215) 321-S62 PUBLISHED BYHOME SERVICE PUBLICATIONS, INC., a subsidiary of theReade/s Digest Association, Inc. EDITOR-l N-CH I EFGary Havens O F F I CA ED M I N I S T R A TM IV E A NAGE R A lice GaTTett TECHNICAL MANAGER Shannon Hooge VICE PRESIDEN ,. UT .S MAGAZIN FE INANCE Joseph Williams VICE PRESIDEN T C I, RCULATIO UN S, MAGAZINE PUBLISH INGCraig Reynolds DIRECTOR OFOPERATIONS Thomas Tzoucalis VICE PRESIDEN GT L O B AA LD V E R T I S I N G RESEARCH Wayne Eadie C0NTROL MANAGER QUALITY Ernie Salto PRESIDEN UT S,M A G A Z I N PE UBLISHING Gregory G.Coleman C H E X E C U T IO VF EF I C E R .CHAIRMA N , IEF Thomas 0. Ryder
(ISSN 1074-9152: USPS0738-710) is American Woodworker@ published seven timesa yearin February, April,June,August,October,November, and December by HomeService Publications, Inc., 2 9 I 5 C o m m e rD s r i v eS , u i t e7 0 0 , E a g a nM , N 5 5 1 2 1 .P e r i o d i c a l s postage paid at NewYork,NY and additional mailingoffices.Postmaster: Sendchange of address noticeto American Woodworker@, P O . B o x2 1 3 4 , H a r l a n l,A 5 1 5 9 3 - 0 3 2 3 S . u b s c r i p t i orn a t e sU i .S. one-year, $23.88; two-year, $43. Single-copy, 93.95. Canada one-year, funds).GST# $23.88; two-year, $43 (Canadian R122988611. Foreign surface one-year, 935; two-year, 965 (U.S funds).Foreign air one-year, $42; two-year, $80 (U.S.funds).U.S. newsstand dishibution.by HearstDistribution Group,NewYork,Ny 10019. In Canada: paid at Gateway, Postage Mississauga, Ontario; CPM# 1447866. Sendreturns and address changes to American . Woodworker@, P.O.Box 2134, Harlan,lA, USA 51593-0323. Printedin USA.@ 2001 HomeService Publications, Inc. All rights reserve0. Reader's Digest mayshareinformation aboutyou with reputable companies in orderfor them to offeryou products and services of interest please to you. lf you wouldratherwe not shareinformation, writeto us at: Reader's Digest Association, American Woodworker, Customer Service Department, PO Box 5073, Harlan,lA 51593. Please includea cbpyof youraddress label.

13 WorkshopTips Reviews 20 Product ShopTips 25 Small 7 6 FinishingTips


Solution 111 Shop Drill Press Table

116

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Howto reach us
We welcome your comments, suggestions,or complaints.Write to us at: American Woodworker, 2915 CommersDr., Suite 700, Eagan, MN 5512I Phone:(65I) 454-9200 Fax: (65I) 994-2250 e-mail: amwood@concentric.net

Back issues
Someare availablefor $5 each.Copies of past articles: photocopiesare availablefor $3 each.For either, write or call: American Woodworker Reprint Center,PO. Box 83695, Stillwater, MN 55083-0695, (7L5) 2464344,8 AM to 5 PM CST,Mon. through Fri.

Subscription inquiries
American Woodworker, SubscriberServiceDept., (800) 666PO. Box 2134, Harlan,IA 51593-0323; 3l I I ; e-mail: AWWcustserv@cdsfulfillment.com
American Wo odworker APR2 TO L Ol

Willis Bowman E d i tu ev d

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StainYourShopFloor
Q. I lust moved into an old houseand will be settingup Etching abradesthe surface of the concrete and allows concretefloor is reallydark and shop in the basement.The in. the stain to deeply penetrate. Use either muriatic acid or I vVould like to lightenit up before I move the machines phosphoric acid (your hardware store should havethese)as What durablefinishcan I use? StewortLelievre directedon the label. Acids must be handled with care.Wear full-wrap gogND Dickinson, concrete gles,rubber glovesand old clotheswhile cleaning and etchA. Youhaveseveraloptions,but we \ke water-based stain the best.Youcan get it in a variety of colors,including ing. Dilute the acid by adding it to the water (not the other way white. It's easierto work with than an oil-basedfloor paint and around!).Make surethe areais well ventilated. Triple-rinsethe floor by sprayingwith a gardenhoseand doesn'tgive offdangerousfumes asdoesepo)rypaint.Conwith a stiff broom; then allow the surface to dry brushing you move your when crete stain won't peel or chip off before applying the stain. completely machines around becauseit penetratesthe surface.Paint Mix all the stain you plan to use in a large bucket and forms a film on top. Cut itwith all4-in.-nap roller in 3 ft.by3-ft. sections. Beforestaining, the concretemust be cleanedthoroughly spread and etched to make it porous. Clean your floor with TSP in around the walls with a synthetic brush. Wait 24 hours (trisodium phosphate).Ifyour statebansTSPaska paint sup- beforeusing the floor or putting on a secondcoat. plier for a substitute. Clean oil or greasestains with a Source (800) | 845-906 Valspar Corp., degreaser. Thoroughly rinse awayall the residue.
Water-basedconcrete stain;about $20 per gallon.

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Work? Actually Gontrols DoRouter Speed


router and want to use a large Q. I havea single-speed panel-raising bit in it. I know that I needto slow down the rpm.Will a router speedcontrol workl John Koczrowski Brockport, NY A. Yes.Arouter speedcontrol will certainly slowyour router to a safespeed.Andyou're right to be concernedabout doing so.Your router wasrt'tdesignedto handle a largebit spinning at its singlehigh speed.Inaddition, you may burn your panelsbecause the tips of the bit are turning tdo fast.When you feed the wood by hand, it's impossibleto keep . up with the bit. A speedcontrol is a reason, able solution for occasionaluse, but you may run into a problem with your router'swarranty if you usethe control frequently.The cooling fans in singlespeedrouters aregenerallydesignedto cool only at maximum speed. Slowing the routerwith a speedcontrol alsoslowsthe fan. There'sa possibility that the router could overheatand become damaged.Most router manufacturers will not warrantee their tools when usedwith a speedcontrol. For heavy-duty and frequent use, replace your largediameterbit with a ver. tical panel-raising bit (which can be run safelyat full speed;seeAW #73,Iune'99, page39) or buy a big, 3-hp variable-speed router and run your large diameter bit at a slowerspeed. Source
MLCSLtd.,(800)533-9298 | 5;$30. Routerspeed control,# RCS-

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American Woodworker

& Answer Question

Aluminum Sawing
Q. Can I cut aluminumwith my chop saw? PoulHemming Londsdole,PA cutting Most carbidebladeswork fine for occasionally A. Yes. aluminum, but we recommend using a special,non-ferrous metal-cuttingblade (about$70) if you cut a lot of aluminum or the geombrass.It'ssaferto usethan a standardbladebecause etry of the teeth makesit lesslikely to kick back when cutting a soft metal.And it will lastlongerthan a standardbladebecause the teeth are made of a softer carbide. No matter which bladeyou use,feedthe sawabout one-third slowerthan you do when cutting wood. Coating the blade with not running) prevents a regular doseofWD-4O (when the saw's the.gullets from clogging.

froma Gontamination TackGloth?


Q. Are oil-basedtack cloths compatiblewith waterfinishes? borne polyurethane Todd D'Allesondro Wobosh, lN A. Yes.You can wipe off dust with a standardtack cloth without fear of contaminatingthe surfaceif you follow two simple directions.One,open up the tack cloth beforeyou wipe verygenuseit and form it into a loosebunch. TWo, tly.lf youpresshard you might transfersomeof the oil from the the tack cloth to the finish. That would be bad, because area. next coatof finish may not adhereto the contaminated

Tools Rxfor Rusty


Q. How do I preventmy edgetools from rusting? Amy Bollenstod Shomokin,PA A. Rust is the curseof all woodworkers,but you'vegot three weaponsat your disposal.First, lower the amount of water isolate vapor in your shop'sair with a dehumidifier.Second, packetsof silyour tools in small drawerscontaining reusable ica gel.Thesepacketsabsorbmoisture in the air and can be renewed by heatingin a microwaveoven.Third, coatyour tools with oil,wax orvolatile corrosioninhibitors(VCIs) emittedby strips you can stick in a drawer.You must renew oil and wax coatingsoften,but the VCI strips do the work for you for up to two years. M Sources
(877) 374-2247 or www.dribags.com Dri Bags, silicagel bags; l0 pack of 3.S-gram $4.50. Bull Frog,(800) 854-3146or www.bullfroginc.com 6VCl emittingstrips,#9 l0 | 6; $7.

10

American Woodworker

APRtL2ool

From Our Readers


I

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Tp
Easy-to-Adiust Backer Board
Nothing is more frustratingthan splinteringout the bottom of a drilled hole.To avoidthat blemish,I move the backerboard on my drill presstablearound a lot so I'll alwayshavea cleanspot under the hole.Tired of clamping and re-clampingmy backer board to the cast-irontableof the drill press,Ireplaced thoseclampswith strongmagnets! I glued the magnetsto the backerboard with epoxy. My new drill press tablehastwo parts.l hangon to the bottom board (with the magnets in it) and tossawaythe top board onceit lookslike Swiss cheese. BruceAnderson Source Alo*ogordo, NM Lee Valley, (800)87| -8 | 58,www.leevalley.com -_. 314"-dia. rare-earth magnets, l; for 5. #99K32.1
95.75

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SaferProfile Shaping
Shaping small parts with a template on .,. a router table alwaysspooks me, so I use ,' a sanding disc instead.Now my fingerr i. t' aren't closeto awhizzing router bit and I don t haveto worry abouttear-outon the .,--' end grain. ,/ I makemy template a bit undersized ji to allow for the thickness of the aluminum guide and its distancefrom ,/t' the sanding disc. Then I attach my template to mybandsawn wood parts with double-faced tape. ElizabethGarvey GardenCity,ID

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If you havean originalVorkshop Tip, sendit to us with a f"r.".h or,. we print. Sendto: lk.r.h or photo.Ve pay $ZOO Workshoir Tips, American'Woodworker, 29 lb Commers Drive, Suite 700, Eagan, MN 55f 21. Submissions cant be returnedand becomeour properryupon acceptance and payment.

Tips Workshop

lnsertDriver Threaded
I never had any luck installing threaded inserts with a screwdriver. I couldnt get them to go in straight! My solution?I made a driver from hardware in my junk drawer.It's more versatilethan the T-handled commercial drivers and didn't cost me a penny! I usea handled version on big pieceqof furniture, but if I m installing threaded inserts on smaller piecesI remove the handle, install the threaded rod itt -y drill pressand turn the chuck byhand. that the insert will go in straight. This guarantees IamesA. Sfssorz Waukesha,WI

THREADED_. >I INSERT

Finder Bandsaw Genter


There'sa dozen ways to find the center of a turning squarebut this bandsawjig hasgot them all beat. It automatically cuts slotsfor the spurs of the drive center and locates the exact center.Good for squaresof alL sizes,this foolproof jig is ready to go wheneverthe turning bug hits me. Roy Noyes Chester,NH

Lube TheBestScrew
I've tried everything to lubricate long screws; the way soap,paraffin,you name it. Nothing eases for a screwbetter than the wax ring used for seating toilet bowls.Youll find theserings with the plumbing supplies at any hardware store. They're cheap-about a buck-and one ring will lubricate hundreds of screws.To make the wax easierto store,I drilled a hole into a wooden holder, scoopedin some wax, and added a swinging cover to

keepout dust. JudWappne ReddingCA


l4
American Woodworker APRI 2L ool

Tips Workshop

Knobs Secure
I'll never forget the time I tried to yank open a stuck and endedup holding draweron myhomemade dresser knob! I pulled knob right off the screw. only the d the Determinedto solvethis problern,l went to mylathe and designed a knob that'll nevercomeoff.As a bonusfor the extra work, my two-part knob combinesthe easeof turning an end-grain knob and the beautifully knob. grainedtop of a face-grain ,-1l4" T-NUT I removed the spurs from a standard T-nut with a pair of pliers and epoxied it into the baseof the knob.I made afacegrain cap for the knob with a plug cutter installedin my drill press,epoxied it into a recess DIRECTION above the T-nut, and turned it smooth.When the cap is madefrom a highly figured contrastingwood, youve got a beautiful knob that'll alwaysremain firmly attachedto your drawer. /W Alf Sharp Woodbury,TN

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American Woodworker

APRtL2ool

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#outtDTtSztP

PBICE!l IFtfR *0fr-6-wcegr


#Dtf746-5200lX Wll(lDIYllBKEB'S IAB1E SAIY PACKAGE
lncludes 10" TableSawwith 52" fencerails,table slidingtable miterattachment.

#ol|tDTt708 12'IIEAUY DUTY DOUBI.E BEUEI. coilPou]tD suDHc ]IIITEB SAW

5" IIEAUY I|UIY B/(|PAI.III SAIIDEB UTHETECTRIIIIIG UARIABTE SPTED

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2 HP HEAUY
US EI.EGIR(IIIIC PTU]IGE B(IUTEB
Bonus:lncludesFine Depth Adjuster & Edge Guide (a $72

#tfwilfw788 SCR(III. SAIV;

stand t5upEn Yi[ flIF varue) slrE-l (a $138.00 qi|i.Eb" I |

0w82sP #lllfL HP HEAUY DUTY usELEclB0lilc RIIUIER PIU]IGE


Bonus:lncludes Fine Depth Adjuster& Edge Guide (a $72 Value)

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Includes: Recip.Saw, 5" Cordless PLUS $50lrlAlt-lllREBAIE Gircular Saw,Drill/Driver/Hammeq 2 batteries, & case charger HURBY! EXPIBES 2I28IOO Flashlight,

HURBY! OUAIIIIIIES ABE tllrllIEIl.


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IEEE

New and lnteresting

Shop Stuff

Edited byGeorgeVondriska

roduct leviws
DrillPress HoldDown
Yes, we all know you should clamp the wood down when using a drill press. you skip it, But it'sa pain, so sometimes only to have wood spinning like a wacky propeller while you flail at the off switch.For 90 bucks the Drill Sargent will take control. It automatically clampsyour work down asyou drill. It's easyto attach,unlike many clamps,and fits most floor-model drill presses. is simplya cylinder The Drill Sargent foot. The pressure to a pressure attached foot contactsyour materialjust before the drill bit, and can exert from 30 to 180 pounds of pressure.Even at 30 pounds I found it did a greatjob of holding my material steady while I bored a2-in. hole with a Forstnerbit. The pressurefoot has two positions, one for big bits and another for small. I found myself leaving the foot in the big-bit setting for all my drilling, and it worked fine. The bottom of the foot left no marks,evenon soft wood, like pine. TWoinchesis the largestbit sizethe Drill Sargentaccepts. I d like to seea greaterdiametercapacity. On somedrill presses you ll haveto remove the depth-stop assemblyto install the Drill Sargent. A depth stop is built into the Drill Sargentand limits your drilling depth to 2-l12 'in. A little more capacityhere would

The pressure foot contacts the board before the drill bit, holdingit securelyin place.

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be an improvement,also. For production work, where even the time it takes to work a toggle clamp is precious,this devicecould be a godsend.

Drill Sargent Woodcraft Supply

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(800) 22s-r rs3


www.woodcraft.com $90.

2
F O U E o F E

American Woodworker

APRtL2ool

Product Reviews

Brads andStaples from OneGun


bestfor shootingthrough solid wood Bradsaregenerally for shootingthrough sheetstock.Accuset's and staples Switchingfrom bradsto both needs. gun, $129,satisfies And staplesis easy-all you changeis the fasteners.

Accusetevenbuilt in a fine safetyfeature-the gun'snosemustbe depressed in order for the gun to shoot. This nailer is easyto handle and works greatwith 5/8-in.to 1-ll4-in., 1S -gauge brads and 1 l 2-i n. t o 1 - in. is The downside ll -in.crownstaples. the mark left by the plunger when you' re shooti ng brads (see pho t o, below). Accusetsaysthis problem is because the plunger is unavoidable so it'sa wide enoughto handlestaples, canreduce little too wide for brads.You the mark by holding the gun at a bit of an anglewhen you shootbrads.
2-in-| Tool Accuset

mLlt,r"'.i.
$129.

The Worldts Best Rorrter loinery ligs


Thinking Jig?Think Leigh. 'Whether you'rea hobbyistor a

professional, the Leigh Jig will help you create your best work. Versatiliry with precision make the Leigh Dovetail Jig better than the rest. Rout through and halfblind dovetails, with variable spacing of pins and tails, on one jig. Create decorativeIsoloc joints, finger joints, and multiple

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a largerdimple The 2-in-| Tool can leave nailerbecause the than a dedicated driver is wide enoughfor staples.

American

Woodworkcr

APRIL2OOl

ProductReviews

BiSPackage, SmallPrice
Grizz$ Industrial has long been known for its stationary tools. They've recently enteredthe portable tool market aswell Here'san example:an l8-volt cordless drill and circular sawpackagefor only $ 140.You get a drill with five clutch settings and a 3/8-in.keyless chuck.The sawtakesa5-ll2-in blade (a24Jacobs tooth carbide is included), and cuts up to 1-5l8 in. thick. The battery is a Panasonic NiCd and the chargerhas a one-hour quick charge. Grizzly's new line o f c o rd l e s s tool s i n c l u d e s 12-, 1 4 - a n d 1 8 volt drills, reciprocating saws,circular saws,jig saws and a u n i q u e 5-in-1 tool set(see below). Grizly (800)s23-4777
www.grizzly.com.

:[H.flT*;f::l?ni: fii; Pe rformanceYffi

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state-of-the-art routeroperates at a consistent torqueandspeed for extreme[y smooth operation anda cleaner edge.

Router
With Grizzly'snew S-in-One Quick ChangeSet yoy get a drill/driver,detail sandenreciprocating saw power carver and 4-in. anglegrinder.A locking lever makesall five heads interchangeablewith one base.Theentire kit sellsfor g 150.

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port, andQC start,dustcotlection spindLe. ThenewFEIN RT-1800 is designed for the cabinetmaker, solidsurface fabricator andserious hobbyist. Catt 1-800 441-9878for more information anda dealer nearyou, or visit us on

fro m Fei n ffiil'#'J:iffixH il:,il:, ix'J


FeinPowe'r Tools, Inc. 1030AtconStreet Pittsburgh, PA75220 1-800447-9878

the webat www.feinus.com. Finishing is just the beginning

American

Woodworker

A p R t2 Lo o 1

ProductReviews

Bandsaw Tension Grank


It's not on par with world hunger, I'll is grant you, but one of my pet peeves the tensioningknob on my old 14-in. Delta bandsaw.It's hard for me to get my big mitts around it, so it takesforeverfor me to re-tensiona blade,especially abig I I 2-in. or 3| 4-in. blade. The $25 Quick Crank solves the problem neatly. It consists of the (long) speedycrank and a replacement threaded rod, which take about 15 minutes to install. It fits most 14-in. lW bahdsaws.
Quik-Crank

rNl (877) 64t-s2s2


www.i-n-i.net

$2s.

American

Woodworker

APRT 2o Lo1

MADE WERE RECORDS TOBEBROKEN.

THIS EXCEPT ONE.


Youcan counton our rccod of making yourplanes tools.Because dependable
and vises need to be reliable and strong, RECORD'tools are created from the finest steel and crafted in our foundry in Sheffield, England. We've been making woodworking tools for over 100 years, which is why we can promise you such high quality. RECORD tools-planes, vises and clamps you can

Hold lt! Roll lt! Hanglt! Store lt!

Edited uyDave Munkittrick

Tps
ToolTrolley with Brakes
Mobile tool basesare a must in my small shop.Here'show I built one for my drill press: I screwed togethera shallowbox (3/4-in. plywood bottom and2x2 sides),added heavy-duty casters($3 each at a hardware store or home center) and two adjustable vertical-style toggle clamps ($17 eachfrom Woodcraft Supply,800-225-1153). For easysteering, useswiveling casterson one end and rigid casterson the other. Now I roll my drill pressinto position and push down the clamp leversto lock it in place. ]ean Bartholome Sax,MN
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Sheet-Stock Dolly
Moving sheetsof plywood around in my cramped shop was a real hassleuntil I made this little sheet-stockdolly. The weight of the plywood makesthe basesag, which in turn makesthe vertical supportspinch the plywood, securingit to the dolly. A little self-stick felt on the inside of the supports protects the veneer.Buy inexpensivecasters, two swiveland two fixed, to attachto the bottom. Once the sheet stock is in place, you can roll it to where you SELF.STICK need it. You can even FELT let go of it becausethe dolly offers plenty of support and itwort't tip over.Try this and your backwill thankyou!
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Rudy Giadrosich Stockbridge, GA


1/8'X 114" DEEP SAWKERFS
RIGID CASTER IN FRONT

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Weaken the base by cutting a few l/4-in.-deep saw kerfs acrossthe bottom. This makesit flexible enough to bend under the weight of a sheet of plywood.

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American

Woodworker

APRIL2ool

S m a l l S h o pT i p s

Roller 0utfeed lacked-Up


Youcan adjustthis outfeedroller in seconds to supportboardscomingoff your powertoolsof anyheight.If you stationary it won t bolt the roller to a sturdysawhorse, tip over. Here's what you needto build it: . A sawhorse. . A heavy-duty jack ($12plus scissors from Northern,800-533-5545, shipping or an autopartsstore). . A bracketed roller ($t+ from Toolson 800-3 28-0457 Sale, ). Buy the longest if you want to support roller available wide boardsand ply,arood. It'seasy to crank the jack up and down with the jack'sstandard handle, but to do it in portable faster, a screw hook a chuck drill, put the hook in the jack'sdrive hole, and run the drill to raiseor lower thejack. ParkisKennedy Bristol.VA
28 Ame rican Woocl lr'orker APRIL2001

F t U Y

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Hand Yourcelf tbal atVinning


A Full House of Precision 0uality Products Designs & Proven 0utstanding Durability
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For Call Nearest You TheDealer

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Bedem tNab*rn*|

. Website: . Phone:724-ffi3-9072. . E-mall; wwwfisch-wmdworking.mm F?I,;:724-663-9065 fisdlusa@pulsenet.com Fsch Precision l00ls lnc., Claysville, PA 15323

Tips S m a l lS h o p

Knock-Apart UtilityTable
Your proiects aren't
all flat, s(Dwhy use

a flat sander?

Sands all sftapee and contouts Threerotatingsandingdiscs wrap flat and concave and hug convex, surfaceslike no flat sandercan.

I couldnt do without this knock-down standfor mybenchtop tools and made from314-in.plywood (tr,vo 36-in.high x 48-in.-wide accessories.It's into baseboardsand a 48-in.x 48-in. tabletop).Cut 3i4-in.-wide slotshalfi,vay the parts together and eachbasepieceusing a bandsawor sabersaw.Slide checkthat the bottom sits level on the floor.Add leveling feet,if necessary. the top Add blocks of wood to the top cornersof eachbasepiece.Secure with screwsrun through pocket holes in eachblock. Youcan designa table to suit your just be surethe needs; baseis wide enough to be stable. fW Curran Jerome Brookfield,IL

tat fte 3'D sander do the work very little pressure Requires to removerust, paint and stain from a varietyof materialsand surfacecontours.

Precise finglertip oontrol The 3D sander'scompact in your designfits comfortably palmfor one-hand operation. Turnthe dial to adjustsanding speedsof 800 to 2600 rpm.

SEARS

THE GOOD LIFE PRICE ATA GREAT GUARANTEED'"

30

American

Woodworker

APRIL2ool

By GeorgeVondriska
his storyis a compilation of the techniquesI've taughtfor I've tried plenty of years itt -y cabinetmaking classes. other techniquesfor making frame-and-panel doors, andmanyof themwork just fine,but the onespresented here are surefire.I guaranteethat evenif you've never made a door before,you can follow thesestepsand get perfect results. Wdll cover router bit selection,jigs to make machining easier, start-to-finish setup stepsand sometips to help you avoid the most common mistakes. Parts of a Door The frame of a door is made up of the rails and the stiles (see Anatomyof a Doot atleft).The frame surroundsthe panel.In its simplestform, a door panel canbe madefrom 1/4-in.plp wood. A panel made from thicker solid wood with an edge shapedto fit into the rails and stiles is called a raised panel. Router Bit Selection I recommend two-piecematchedbit setsfor machining the rails and stiles,andback cuttingbits for making the panel.In Comparedto addition,I only usecutterswith 1/2-in.shanks. those with 1/4-in. shanks, 1/2-in.-shankedbits chatter less resulting in a smoother finish. under cutting pressure, Two-piecematched setsconsistof one cutter that'sused to machine the end grain of the rails (Photo A, page 3a) and another cutter that'sused to machine the long grain of all the parts (Photo B;paSe3a).This contrastswith reversiblecutters, which have one arbor and removable cutters. Muny people of the functions chll thesebits rail-and-stile cutters,butbecause theyper{orm,I preferto caltthe routerbits end-graincuttersand long-grain cutters.

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Anatomy of a Door
A door frame is made of rails 4nd stiles.Railsare horizontal,stiles are vertical (like stila). Railstypically butt into stiles. The frame surrounds a wood piece with its edgesshaped to fit into the rails and stiles.Thispiece is the raised panel.

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American

Woodworker

A P R I2 Lo o l

American

Woodworker

A p R I2 Lo o 1

33

fl. The end-grain cutter is used F on the railsto produce a tongue. Use a permanent marker to label you'll this bit with a " 1,"because use it first.

The big advantagewith matched sets is that all the frame parts are machined face down on the router table.With reversible bits, on the other hand,onepartis machinedfacedown and the other faceup.This canleadto rails and stilesnotlining upverywell, due to inconsistentmaterial thickness. When it comes to panel raising, I swearbyback-cutting panel raisers. Thesebits shapethg panel front and back at the same time, giving you a perfectly fitting tongue every ttne (Photo C, below left). When using panel raiserswithout a back cutter, it's possibleto end up with a tongue that's too thick or too thin for the groove.That cannot happenwith the back cutters. The router bits used in this story, designed for 314-in material, cost $200for all threecutters(seeSources, page43).

Routers and Tables A L-ll2 hp or larger router is sufficient for the end-grain and long-grain cutters.Typically, thesebits are about 1-318 in.diameter,and canberun at up to 24,000 rpm. The panel-raiser bit is anotherstory. You need a largerouter, at least2hp, and you must slow down the rpm. Thesebigboys shouldrlt exceed 10,000 rpm.All of thesebits require a router with a ll2-in. collet. If youle router shopping,checkout two recentAmerican Woodworker Tool Tests:3-hp page Routers, AW #78,February2000, 75, andMid-SizeFixed-Base Routers, 2001, page70. AW #85,February A router tablewith a rigid fenceis a must for frame-and-paneldoors.You'll appreciatea fencethat offers dust collection,because these bits makea mess! And dont forgetto wearhearingprotectionwheneveryou'reusing a router.

A Sled for Safety


p The long-grain cutter is used on Y all the part5 to make the groove that receivesthe rail tongue and the panel.Labelthis bit"Zl' because it's the second cut. cuts.lt Build this simple sled for machining the end-grain makesit easier and safer to cut the rails and at the same time supports the back edge of the rails to prevent blowout.

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34

Panel raisers with back cutters produce a tongue that fits perfectly on the panel every time.

American

Woodworker

APRT 2o Lo1

Begin by routing the end grain of the rails. Here'sa trick to help you rememberto make the raits beforethe stiles:"R" comes before "S" in the alphabet!Only the rails get the end-graincut.

Set the height of the end-grain cutter with a test piece in the sled.Set it by eye, shooting for the profile shown in PhotoA, page 34. Note that the top of the cutter is even with the top of the wood.This is a good starting point.You can fine-tune the height after makint your test cuts.

Position the fence so it is flush with the ball bearingon the bit. Bridge a straightedge across the fence opening so the straightedgetouches both the ball bearingand the fence face.

Cut a test piece. Dont cut all the way through the test piece and into the sled backer until the bit height is correct (see Photo 4).When you ser the bit height for the next project use the profile cut into the backer as a gaugefor the bit.

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Thanks to the pil.es of findling I've produced,I can passalong these tips. I Make your first frame-and-panel door from inexpensive, easy-to-handle wood like poplar.Savethe correctly,machinedparts as set-up reminders and gaugeblocks for your next door. I Make some iust-in-casepiecesas you make your frame parts.l most often goof up the rails,so I like to have one or two extra. I Check the door for squarewhile the glue is wet.lt's easyto assumethe frame automaticallycomes together square. lt doesnt! I Prefinishthe panel before assembling the door.

Tested Tips

American

Woodworker

ApRtL2ool

LIP APPROX.3132"

Check your work.The heightof the router bit determinesthe depth of the shoulderand the thickness of the lip.The lip should be about half as thick as the depth of the shoulder. Dont move on to cuttingyour frame piecesuntil this setting is correct.

Rout all the rails, alwayskeepingthe back of the boardsup.A mark on the back of the frame parts will help you keep track. Rotate the rail to machine the oppositeend.Use consistent pressureon the sled so the end-grain cuts are uniform.

Well, here's a good-for-nothing rail! | managedto flip it over between cuts, so the end-grain cuts dont line up. You can avoid this mistake by taking the time to mark the bocksof all your parts before heading to the router table.All the routing is done with the back sidesup, so you should alwaysbe able to see your marks.

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Woodworker

American

APRT 2L ool

A f t e r a l l t h e r a i l s a r e d o n e , y o u ' r e r e a d y t o m a k e t h e l o n g - g r a i nc u t . The insideedges of the rails and stiles receivethis profile.


Set the height of the long-graincutter using one of your correctly machinedrails.Thetop of the troove cutter should line up with the (op of the tongue. Be sure your router is unpluggedfor setup operations.

Cut a test piece. Use featherboardson the fence to help hold your piece down, and a push stick to move it through.Again,machinethe parts with the back side facing up.

Check your work by fiaing a rail to the test piece.Thefacesof the two should be flush,or nearly so. Evenwith the most careful setup, there may be a slight differencein the faces from piece to piece;just enough to catch on your fingernail.Thiscomes from inconsistent hold-down pressureon the rail cut. lf the differenceis close,let it fly.A little work with a finish sander after assembly will smooth out the imperfection.lf there's more than a slight difference, however,adjust the long-grain cutter up or down and make anothdr test cut.When the fit is good, machineall the frame parts with their backs up.

American

Woodworker

A P R I2 Lo o 1

With the frame partscomplete, then set up the panel cutter.

paneltime. Cut the panelsto size(seepages 42 and 43),

Align the tongue of a correctly machinedrail with the gap in the panelraisingbit. Line up the tongue with the bottom of the back cutter and the top of the panelraiser.

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Make a shallow first cut on a test piece. for The panelsmust be cut in two passes the safestand smoothest cut. For this first pass, positionthe fenceso the bit bearing is l/4-in.behindit (seebelow).

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Make the second and final cut on your test piecewith the bit bearingset flushwith the fence.

38

American Woodworker

A P R2 To Lo 1

Check your test piece by placing a straightedgeacross it and a correctly machinedstile.Thestraightedge should touch both pieces. lf there'sa gap,asshown here,adjustthe heightof the panelraiser. In this case, the panelraiser is too high above the router table. Make adjustments and test cuts as needed, alwayscutting in two Passes. This is a fussyadjustment, but you'll find it much easierto sandthe doors if the frame and panelsare even.

Now raise the panels. Cut them all in two just as you did passes, the test piece.Cut the end grainfirst,then the longgrain.This helps eliminatetear-out at the corners.

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"Back-cutting" panelbitsare theway to go. They guarantee that thepanel tongue is exactlythe right thickness.
American Woodworker ApRtL2ool

t h e d o o r ,s a n d a n d f i n i s ht h e B e f o r ea s s e m b l i n g p a n e l ,i n c l u d i n g a l l t h e e d g e s .A s t h e p a n e lc o n tracts,it will shrinkaway from the stiles.lf you finish it beforeyou [nstallit, you won't haveunsightly

s t r i p e s o f u n f i n i s h e dp a n e l s h o w i n g w h e n t h e panelshrinks. that the lf dry fittingthe door reveals p a n e l i s a l i t t l e s m a l l a n d r a t t l e si n t h e f r a m e , m a k et h e a n t i - r a t t l e s n a k e ss h o w n o n p a g e4 1 .

Assemble the door in this sequence. l. Place the first stileon the clamps. 2. Brushglueon one rail and slip it into the stile,beingcarefulto keep the outside edgesflush. 3. Slipthe panelinto the groove.Do not glue in the ponel.lt needsto float independently of the frame. the secondrail. 4. Glue and install 5. Brushglueon the rail endsand install the secondstile.

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Carefully brush glue onto the rail ends. Keepingglue awayfrom the groove and panel prevents it from squeezing out all over.

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Tighten the clamps gently, holding the frame down to the clamp bar.lf your glue-uptable is flat,then your door shouldend up flat.I dont useclamppads, which remindsme not to over-tighten the clamps(whichwill bow the door). Stop tighteningas soon as you see the joiht squeeze shut.lt takesvery little Pressure.
Woodworker A P R I2 Lo o i

Clean out any glue in the corners using the tip of a pencilinsidea damp rag.Dry glue insidethesetight corners is veryhard to cleanup.

Arnerican

Measure each diagonal.When the measurements are the same, the door is square.You can draw an out-of-whackdoor squareby angling the clampsslightlyso they're not quite parallel to the railsand retightening them. Measureagain after adjusting the clamps.

Check for flatness by setting a straightedge acrossthe frame and panel. lf the door isn't flat,loosen the clamps and pushthe frame down to the clamps as in Photo 15.Remember: Don't usetoo much clamppressure.

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Make Anti-Rattle Snakes
lf your door is slightly undersize, it can rattle in the frame.Youcan prevent this with anti-rattle snakes. Make them by squeezing a fine beadof siliconecaulk, l/8-in. diameter,onto waxed paper.Let the caulk dry, peel it off and cut it into I in. lengths.Put the snakesegmentsinto the grooves as you assemble the door.The silicone prevents rattling and provides a cushion, allowingthe panelto expandwhen it needsto.

American

Woodworke

r npRtL 2001

The foundation of a perfectdoor is calculatingthe sizesof your rails, stiles and panels correctly before you do any cutting. Here'show to figure them out. As you're cutting out the stock,choose materialwith straight grain for the frame parts.When routed they'll chip lessthan wild-grainedparts (and look better,too!).

STILELENGTH

Stile length is easy:it equalsthe height of the door. I cut stiles first, just because they're easy.

Rail length is the door width minus two times the stile width plus two times the tontue length.

Measure the tongue after you've done a test cut, dnd use this number to calculaterail lengths.Once you figure it out for your cutters, it's alwaysthe same.

American

Woodworker

APRT 2L ool

PANELSIZt

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Shoulder and grooveare aligned with most cutters.

SHOULDER

Dry fit the frame to measure for its panel. On most end-grain cuttersand long-grain cutters, the groovefor the panellinesup with a shoulderon the front of the door,so you can simply measure betweenthe shoulders (seephoto).Subtractl/8 in.from both heightand width to allow the frame and panelto expand. (lf your cutter makes a shoulderand groovethat don't line up,you'll haveto poke a ruler into the groovesto measure.)

R I P T OF I N A L WIDTHAFTER ROUTING

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lUarrow Frame Pieces
Make narrow rails and stiles (anything lessthan 2-in.wide), by cuttingthem to finishedlengthfrom a board wide enough to make both parts.Do all the routing;then rip to finishedwidth. lW

Sourees Matched Set Rail-and-Stile Cutters AmanaTool,(800) 445-0077 CMI USA,(888) CMT BITS Eagle America,(800) 872-251| Freud,(800\ 472-7307 (800) 53 | -5559 Jesada, (800) 533-9298 Katana/MLCS, The Woodworker's Choice,(800) 892-4866 Whiteside( , 8 0 0 )2 2 5 - 3 9 8 2 . Back-Cutting Panel Raisers AmanaTools,(800) 445-0077 CMI (888) CMT BITS Eagle America,(800) 872-251| Freud,(800) 472-7307 (800) 533-9298 Katana/MLCS, Woodline Arizona,(800) 472-5950 Woodtek, (800\ 645-9292 Woodworker's Choice,(800) 892-4856. Toggle clamp; $ l4 3-in. peg; $2/bag of l0 Push block;$ l6 Woodworker's Supply (800\ 64s-9292.

Arrrc ri ( a n \\'()oclu'o rkc r ApRtL 2ool

43

Assemble the side lattice panels from cedar boards and clampthem to the legs.Drill pilot holes through the side panel, then fasten with 3-in. stainless steel decking screws.

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Use stainless steel screws in cedan Coated and galvanized scretvs may leave black stains.

Build the seat units from 2x4s and lx6s. Use spacersto maintain an even I l4-in.gap between the seat boards. Leave the front apron off for now.

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FRONT APRON

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Bolt the seat units to the trellis sides.You can easily get a socket wrench on the lag bolts with the front apron out of the way.

American

Woodworker

APRT 2L 0Ol

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Cut saw kerfs in all the side railsthat curve abovethe seats. Save straight-grained, knotfree wood for these piecesso they won't breakwhen they'rebent. CAUTION: The saw guard and splitter must be removed for this operation.

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Add the top plate, cleatsand lattice.Rout an ogeeshape on the ends of the top plate before you attach it (see page 50,Fig.A, Detail4).

MARK LATTICE TO BE CUT OFF

Tips for Building


the Tl'ellis
lf you plan to put your trellis on a patio that isnt lwel, add an inch or two to the legs.Then trim them to fit the terrain, just as you would trim the legs of a wobbly chain Drill pilot holes to avoid splittingthe wood.lt's possible to run scnewsinto a soft wood like cedar without predrilling, but cracks often form later. Assemblethe larger pieces on a flag level surface.This helps ensure that the assembledpieces end up square and accurately aligned.
48
American Woodworker APR2 rL ool

Fill the saw kerfs with a two-part epoxy page5 l).Then wood filler (seeSources, bendthe side railswhile the epoxy is flexible and insertthem into the seatunits. Let the epoxy dry with the rail in place.

Mark the lattice for cutting and removethe hardened side rail.Cut the the latticewith a handsaw and reinstall side rail.Nail the siderail in placeand filler removethe easily sanded excess with 80-grit sandpaper. Lay out the arches with a homemade compass. Cut them from two sheetsof exterior plywood (see Fig.B, page5 l). Then glueand screwthe pieces together to make three sets of double-layer arches. Smooth the edgeswith a belt sander.Then gangthe three archestogether and mark the locationsof the arch bars (see Fig.Aand Photo l0).

We built our prototype trellis a few years ago.The roses look terrific but paint is peeling aroundthe baseof the legs and black spots ar e aP P ear ing around many screw heads. Rats!

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Peeling Paint
The problem: Paintdoesnt stick to d a mp w o od. The ends of our l egs soakedup rainwater like sponges, so the paint eventually peeledoff. The fix: We raisedour trellis off the paversand let the legsdry out. Then we filledthe crackswith epoxywood filler (seeSources, p a g e5 l ) . W e t h i n n e d s o m e epoxy glue with acetone and brushedit on the bottom of the legsto sealthem.Polyurethane gluethinnedwith mineral spirits would work as well.

Paint Bleed-Through
The problem: The coated screws we used haven't rusted, but a chemical reactionhasdiscoloredthe wood around them. Coated screwsare fine for pressure-treated lumber, but they canstain cedarand redwood. The fix:We replacedthe coated screw s w i th stai nl e ss s t eel screws.Then we repainted the trellis with Kilz stain-killing primer and appliedtwo top coats of white paint.

Place the arches on the arch bases, set on sawhorses. Hold the archesupright and accurately spacedusinga clamped-in-place C).Then drive 3-in.screwsthrough fig (Fig. the arch bases and into the arch ends.

Mount the arch bars with 3-in.screws. Keepthe archesaccurately spacedand the overhangof the arch bars uniform by using jig.Now you'vegone as far as the spacing you can in the shop.lt'stime to take the trellisoutside.

Set the assembled arch in placeout in your yard,centered on the top plates. Shiftthe seat units until the arch bases line up with the top plates, then screw them together.

American Woodworker

ApRt 2L oot

DOUBLE.LAYER PLYWOODARCHES DETAIL 1

R O U N DO F F

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1/4" SPACE TYP.

84" (ARCHWIDTH)

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10" (rYP.)

108" TO GROUND

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6-3/4" SPACE

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6-114" SPACE (TYP.

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50

American

Woodworker

There's n o t e n o u g hr o o mo n o n e p i e c eo f p l y w o o d t o m a k et h r e ef u l l - l e n g t h a r c h e ss , o one o f t h e a r c h e sm u s t b e l a i d o u t i n t w o p i e c e s C . ut out the twofull-length arches f i r s t ,t h e n u s eo n e o f t h e m a s a p a t t e r n for drawing the half-length arches. N o t e :T h e e n d so f t h e h a l f - l e n g t h a r c ha r e d i f f e r e n t s h a p e sT ! h e e n d st h a t b u t t t o g e t h e r a r es q u a r e , b u t t h e o t h e re n d sa r e a n g l e d .D r a wa l a y o u tl i n e i n t h e m i d d l eo f a f u l l - l e n g t h a r c hb e f o r e c u t t i n gi t o u t , t h e n t r a n s f e r t h e l i n et o o n e e n d o f t h e h a l f - l e n g t h arch. lW

32-1

32-114"

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2x6 x 2x4 x 2x2 x lx6 x lx4 x

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QUANTITY
8'cedar 8'cedar 8' cedar 8'cedar 8'cedar

3 1 4x " 4'x8' AC exterior plywood


No.6x l-l/4" stainlesssteel screws No.8 x l-5/8" stainlesssteel screws No. l0 x 3" stainless steel decking screws

Epoxywoodfiller

A&Bqrt.

VJctorian TFellis 9' H x T Y x 4 ' l " D a t b a s e


Name Material

83 84

4 32

LatticeUprisht Lattice Crossoiece

lx4 lx4 lx4 lx6

5I 58-l 12 69-112 17 42

R i pt o Rip to R i pt o R i pt o

l- l/2" wide l- l/2" wide l-l/2" wide l- l/2" wide

Rip to 4-ll4n wide

53 4 SideCleat PremadeLattice Side Rail lx4 About 5 | 42 x 54 27 8-ll2

Rio to 4" wide Rip to | - l/2" wide, cut lensrhto

lx4 2x6

Ked-cut and bend SeeFie.A,DetaM 3/8" radiuson

Arnerican

Woodworke

r A p R t2 L0 o l

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Blades
Great resultsfrom a low-pricedset.
By DaveMunkittrick
try to imagine woodworking without dadoes.They're Tust everywhere! And the realbeautyof dadobladesetsis their ver,f satility: rabbets,bridle joints, tenons and box joints are all stock-in-trade.That's why everywoodworkershouldhavea greatdado bladeset. A dado is simply a square-bottomed groove,usuallycut kl across the grain,intowhich aboard is fit to form a strongyet simple joint. A good dado set cuts dadoeswith clean edges, squareshouldersand flat bottoms (Photo l). Cutting these grooves in wood seems like a simplejob,but if its not done (Photo2). well,the resultsaredisastrous

Dado

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THE TEST
We looked at 6-in. and 8-in. stacking carbide-tipped (Fig.A)thatrangedinpricefrom$50to$500. t dadosets Wecut hundredsof dadoes in oak plywood,melamin :and solid maplefor this test.Plowinggooves with the gtuir is a test any dado setcan pass.The acid testis cutting cross-grain dadoesin veneered sheetstock without tear-out,and that'swherewe concentrated our efforts. All the cutsweremadewithout thebenefit of a zero-clearance throat plate. Wobble-typedadoblades werenot includedin this test because we found their performanceto be far inferior to thestackingtypeswithlittle orno costbenefit.Wob- | ble dado bladeshaveadjustablehubs that increase or decrease the amount of runout or "wobble" in the bladeto varythewidth of the dado.Includedin the wobble-type group are the hybrids that combine the adjustability of a wobble bladewith tr,vooutside cirttersand a singlechipper.

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SHIMS 1/8'OUTSTDE

1/16'CHIPPER 1/8" CHIPPERS

HOOK ANGLE:THE KEY FEATURE Wefound the singlemost important factor in the qualityof cutwasthe hook producesmuch angleon the outsidecutters(Fig.B).A negative-hookblade requires more feedpressure.The lesstear-outthan a positive-hookblade,but when cutting 3/8-in.-deepdadoesin plywood is differencein feedpressure negligible,but much more noticeablewhen cutting them in solid maple.The a slighdyslowerfeedrate.Unlessyou work increased feedpressure necessitates exclusivelyinhardwood or run a production shopwherespeedreallycounts, dado set. you'll getbetter all-around resultswith a zero-or negative-hook

CUTTER TABLESAW
ARBOR

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A ANATOMY OF FIG. DADO SETS STACKING
of two dadosetsconsist Stacking withthree to six 1/8-in.-thick outside blades in Theoutside blades arebeveled chippers. of the onedirection to score the woodahead (or for a clean cut andareresponsible An occasional ragged) edgeon the dado. a beveled tooth raker toothis placed behind cut. to create a flat-bottomed shoulder andare Thechippers varyin thickness width.Shims to create the desired stacked between the chippers to finecanbe added tu net hewidt h .
POSTT|VE-

A well-cut dado has two essential qualities: l. Squareshoulderswith flat bottoms for strong,tight-fiaing joints. 2. Little or no tear-out along the good-lookingjoint. edgesfor a clean,

Uneven bottoms and severe tean out are the hallmarksof reallycheap stackingsets (they retail for around $50) and the wobble-type dado lf you valueyour sheet stock, blades. sta),awayfrom these blades.

AMANA656030 & 658030 AMANA 658()3()AK AMANA 658040 Precision Daoo CMT DELTA 35-535 t

6&8
8. 8 8

130 & 160


175

225
190

6&8
8

80&90
215

DML 73000
EVERLAST DS6& DS8 EVERLAST DS84() F0RREST DadoKinq Feed F0RREST Easy

6&8
8

155 &r65
215

6&8
I

FREUD SD2O6&SD2O8 G FREUD SD3O6 & SD3O8


FREUD SD5O6 & SD5O8 JESADA JointMaster LEE VAI-LEY Dimar 8-46TN LEE VALLEY Dimar618C1 & 824C1

6&8 6&8 6&8 6&8


8

250 & 260 200 & 220 75&90 110 &120 r60&180 r40 &180
160 130 &150

#3 NoBDTC
#3DS NORDIC N 0 R D IC - M e l a m i n e

6&8 6&8 6&8


8 8 8 I

220
230

FIG . B HO O K A NGL E hookproduces a cleaner cut but A zeroto negative feedratewith a little morefeed requires a slower pressure. 'A positive and requires hookcuts moreaggressively youto Thistoothdesign allows lessfeedpressure. in cut dadoes faster andwith lesseffort,especially is a slightly rougher.cut. hardwoods..The downside

OLDHAM #5818 #5824 OLDHAM PROMAX R I D GC EA R B I D D ado Master E Fine SYSTIMATIC SYSTIMATIC Super-Fine

530 r00&r15
170

50
160 & 170 150 & 155

6&8 6&8
I I

260
260

TENRYU 20340 GMD

54

American

Woodworker

APRIL2ool

Deep scoring cuts madeby the outside cuttersare undesirable joinery(boxjoints, whenusedfor exposed bridlejoints, etc.).

Shallow scoring dado sets with negative-hookteeth are best becauseof their versarility.They do a grear job cuaing dadoesand wont spoil the look of exposedjoinery.

PRODUGTION VS. SMAIbSHOP BLADES There's areal price difference betweenblades designed forheavyduty usein a production shop and thosemade for occasionaluse in aone-person shop.Blades thatcostmorethan $100tendto have a higher tooth count. The benefit is increaseddurability and cleanercutsathigher feedrates. Productionshopsneedbladesthat lastlong and cut fast.But,ifyorlre not running dadoesall daylong fivedaysaweek,thisworftbe important.Most of uswill getalifetime of usefrom a good dado setwith only one or two sharpenings,and a slower feed rate is really of little consequence. Someof the more expensive setsalsoinclude an extra ll32-n. chipper that can be stacked with three 1/8-in. chippersto create dadoesfor undersizedplywood.Other extrasthat come in handy arewell-made storagecases and shim sets.

Chip-limiting fingers in front of each tooth limit blade bite to about | 132-in., reducingthe chanceof a kickback causedby overfeedingstock.

N
N

Y
Y N N N

Y Y Y Y
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Excellent instructions. Excellent instructions.

Y
N N

(8001 445-0077 (8001 445-0077

Y Y
Y

Y Y
Y

(800) Excellent instructions. 445-0077 (8881 Teflon coatinq; color-coded shims, 268-2487 Thin-kerf outside cutters; cardboard shims. (8001 438-2486 Minimal instructions. No instructions. Noinstructions. Excellent instructions; color-coded shims. Excellent instructions; color-coded shims. Instructions; metal shims. Instructions; metal shims. Instructions; metal shims. Instructions; color-coded shims. No instructions. No instructions. Noinstructions. No instructioni. Deep scorinq cuts. Magnetic shims; uneven bottoms. Free sharpeninq coupon. Ragged cutswithveryuneven bottoms. plastic Instructions; shims. Maqnetic shims. Maqnetic shims. Instructions.

(8001 242-7003
(800) 387-5278 (800) 387-5278 (8001 733-71 11 (8001 733-71 11

Y
N
N

Y Y Y Y Y Y
N N N N N N

Y Y
N

N N N N N N

Y Y Y
Y Y

(8001 334-4107 (8001 334-4107 (800) 334-4107 (800) 531-5559 (800) 871-8r58
(800) 871-8158

Y Y Y
N

Y Y Y
N Y

Y Y Y Y
Y N

Y
N

(8001 345-3535 (800) 345-3535 (8001 345-3s35 (800) 828-9000 (800) 828-9000
288-2487 {8881

Y
N

Y Y Y Y

Y
N N

(800) 443-0992 (8001 426-0035 (8001 426-0035


-7297 (8001 951

American

Woodworker

ApRtL2ool

55

OTHER FEATURES TO CONSTDER What's best, a 5-in. or 8-in. dado set? An 8-in. setis no problemfor a 3-hp cabinetsawbut aI-ll2-hp contractorsaw cuttinga2-in.-deepdadoin solidwood.Certainlyanyonewith usuallystruggles a portable tablesawshould only look at the 6-in. dado sets.If there'sany some doubt,gowiththe 6 in.Yotilllosean inch of depthcapacity,butyorfllsave when you. This is one case motor will thank money up front and your saw's smallermay be better.After all, how often do you cut 2-in. deepdadoes? Scoring cuts when the joinDeepscoringcutsleft by the outsidecutterscanbe a realeyesore ' (box and bridle joints,for example). Look for a dado setwith shalery is exposed low scoringcuts (seethe chart and Photos3 and 4). Anti-kickback bladeswith this featurewonl preAnti-kickback is a bit of a misnomer because ventalltypa of kickbacklltechip-limitingfingers found on anti-kickbackdado the stock (Photo 5). by overfeeding seisdo help preventkickbackscaused

OUR RECOMMENDATIONS When it comes to cutting high-quality dadoes,speedkills. Simply slowing down your feedratemakesa tremendousdifference in the amount of tear-out.The dado setswith negative-hook teeth performed especially well when crosscutting dadoes in oakveneered plywood and melamine.The only real drawback to this type of blade is an more in feedpressure that becomes increase noticeablewhen cutting solid wood. If you cut that a feel you need the more aggressive positive-rake angle offers,we recommend the ForrestEasyFeed s Super-Fine, SystiMatic DS6 and DS8. Everlast and the f udged by the quality of cut, there was a large group of top performers: Amana 658030and 8040 CMT PrecisionDado EverlastDS840 Forrest Dado King FreudSD508 FreudSD208 Jesada Joint Master Dimar 8-46TN LeeValley Blade Nordic Melamine Northwoods Dado Master The pricesof thesebladesrangefrom $90 to $500 and all performed beautifully. The more expensivesetshave more teeth so the blades stay sharp longer while giving you greatcutsat a fasterfeedrate. BEST BUY I wish all our choicesfor shop gearwere this crystal clear.For greatperformanceat a great SD208. price no bladecomescloseto Freud's lke chipper Youdont getthe extras a3132-in. or a well-made carrying case,but for the money,you simply cant go wrong with this set. With a slowfeedrate,the FreudSD 208cut cross-grain dadoesin veneeredplywood blades. almost aswellas the most expensive EDITORS' CHOICES With suchalargegroupof top performerswe looked to other features,likean anti-kickback design, shallow scoring cuts, an efira 3132-in.chipper and shim setsto arrive at our Editors'Choices.Three blade setswere firsts among equals: the CMT, the Freud /W SD508and the Jesada.

The FreudSD 208 hasallthe important features: hook angle / minusS-degree / steel shims (4-ll8 in.andl-l/16 in.) / 5 chippers / anti-kickbackfeature / samequalitycarbideused in models Freud'smore expensive / shallow scoring cuts / a greatprice;$90.

even with faster feed rates,and include: All of these bladescut beautifully, design' / anti-kickback chipper / an extra 3/32-in. / 24-tooth outside cutters / shim sets / shallowscoringcuts.

JOINTMASTER CMTPRECISION DADO JESADA

55

Ameri.can Woodworker

APRT 2o Lol

ru;;;;;;
kb

By DavidRadtke

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Floor, torcellln
you'rebursting at the seams with books and collectibles 1f Ito display, here's a bookcase that maximizesspace, fits any room, and useslumberyard moldings. A Flexible Design We designedthis bookshelfwithout a back or baseunit to make it easierto fit into any room. You can build around ventsand outletsby simply shifting a standard(the upright piecesupporting a shelf).This only affectsthe length of the shelves,whichis not difficult to changein the Cutting List, p ag e 61. Without a baseor back, will the bookshelf be sturdy? Sure,becausehidden steelpins made from lag bolts go

Createa classic look with ready-made moldings.

oo ase
right into the floor and hold the standardsrigid (Photo 8). Are your floors and walls out of square? Not a problem. We'veengineeredthis project to work even if your room is a bit out of kilter. The moldings areapplied individually to eachstandardand coveranygapsresultingfrom uneven floors or walls. Easy Molding A largebuilt-in requiresa lot of molding, so we'vechosen a mixture of classic shapes that you can buy through a lumberyard or home center.We special-orderedthe maple moldingsfor ourbookcase,butif you buildyours from oak or pine, molding to match is readily available. We'll show
text continuedon page 62

Measure the height and width of your wall. Note the locations of all receptacles, switchesand vents.lf they're in the way,modifr our designby relocatinga standardand changing the lengthof rhe shelves.

Rip the plywood into strips for the standards.Although you can use a tablesawto make these cuts,you wont have to strugglewith a bulky sheet of plywood if you use a circularsaw and a simplecuttingjig.

American

Woodworker

ApRtL2oot

59

45-DEGREE MITER

O FB O O K C A S E IEW D F I G .A E X P L O D EV

DsDr
Dz De t ail 1
1/2"S|DE SPACER ANGLE BRACKET(TYP.)

Detail5

1t4"DtA.X1t2" D E E PH O L E S F O RS H E L F PINS

SET REAR 2xa (B) lN 1/2" (TYP.) TRIM PLINTH 1 / 4 "O N RIGHT SIDE

7'ROLLING LADDER

60

CROSS SECTIONS Detail6 Detail I


(114"x 3" LAG BOLTS

FIG.B CASINGS AND MOLDINGS

IN FLOOR

Detail2

Detail7

3" DRYWALLSCREW CEILING INTO JOISTS

lI
(wP.)
2-519"

MT. 1|]
SOLID COVE

fq

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FLUTED CASING

SHELF MOLDING

TI*

ANGLE BRACKET

Tx

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s-rry FlT'

v1_''0"

COLONIAL STOP

G Detail3 AA
- / L

SHOPPING LIST

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3 / 8 "x 1 - 1 / 4 ' 3 / 8 "x 1 - 1 / 4 x " B' 1 - 1 / 1 6x ' 4-1/2" x 4" x4" x7' 1 - 3 l 8x " 8'shelf

Detail4 A

CUTTING LIST
OverallDimensions: 8' H x 8' L x'14-3/4" D Part
A

ow. Name
x

Material
Plywood 2x4
Plywood Colonialstop Colonialstop

Dimensions
3/4 x 13-3/4 x96 2x4x96 3/4 x 13-3/4 x96 3 / 8x 1 - 1 / 4 x 7/ 8 3/8x 1-1/4

Comments
Trimlength is 1-in. less thanthe distance fromfloorto ceilino.
Same.as above.

Face

c
D D1 E
F

8 1
a.n. z

Brace Top Dentils Filler strip Backer boards


Moldinq

Trim to fit Rip1O-ft. long,1-1l4-in. widemolding to 1-1l8-in. Then cutdentils to lenqth. piece Cut 10-ft.-lonq to fit
pieceto fit Cut 10-ft.-lonq

D2 2
6 4 4
a.n. z

3/4x3-1/2
Colonial stoo
Flutedcasino Cove moldinq Crown moldinq

Plinth blocks
Casinq Cove Crown

ANGLE BRACKET

\l

1/2" SHIM

H K

Middle shelves Plywood Outershelves


S h e l fm o l d i n q Plywood

3/8x1-1/4 1 - 1 / 1x 64 - 1 / 2 x8 3/4x4 3/4x 1-1/4 2-5/8 tall 3/4x 11-3/8 x32 3/4x 11-3/8 x26 5/8x 1-3/8x32 5/8x1-3/8x26
American

pieces Cut 8-ft.-lonq to fit.


Cut 7-ft. piecesto fit

5-1/2" NO.g SCREWAND COLLAPSIBLE ANCHOR

Cutfrom8-ft.len Cutfrom 1O-ft. Trimlength is3/16-in. less than distance between standa rds.
Sameas above. Sameas above. Sameas above.
Woodworker A p R t2 Lo o l

14 7 M2 1 4 M1

Shelf moldino

Shelf moldino Shelf moldino

51

page 59 textcontinuedfrom you how to modify one molding to make an impressive cornice,completewith dentils (Photo 10). If youte ambitious and want to make your own moldpage82 Molding"AW #85,February'01, ing, see"Router for tips on how to minimize the worst part of the job-sanding the darn stuff. This bookcaseblends right into your room reusing your existing baseboardmolding. Simply cut your molding and reinstall it betweenthe standards. Size and Cost We designedthis bookcaseto fit into a typical room with something like an 8-ft. ceiling and at least8 ft. of wall space, a typical bedroom you maywant to convert to a library or home office. You can enlarge this bookcasesimply by adding standards. We spent about $600 on materials for the bookcase shown here. The optional ladder and hardware cost an additional $700to $1,200,dependingon how fancy it is (seeSources, checkout page66).Beforeyou makesawdust, our advice on Planning Your Bookcase,page 63. Then follow Photos I through 15for the nitty grittyhow-to.

Make a foolproof, durable iig to drill accurate holes pins.Drill l/4-in.-dia. holes into a for the shelf-support | - l/4 in.x l/8 in.x 6-ft. pieceof aluminumor steel bar at hardware stores). stock (available

Nail the jig to the plywood through four smallholes drilled along the jig's length.ldentify the top of the jig with paint or tape,then alignthe top hole with a line 84 in.from the plywood's bottom (see Fig.A).Drill l/4-in. holes ll2-in. deep through each of the lig holes usinga stop collar to dont limit the hole'sdepth.Remember, the end standards require holes.

Selecting Lumber
lf you Lookfor straight 2x4sfor the standards. youcan can'tfind any, cut up the bestones find into2-ft. lengths andsandwich these pieces. pieces the plywood shorter between Youdon'tneed 2x4tor strength. a continuous
Glue 2x4s between the plywood piecesto create the Be sure the front 2x4 is flush with the front standards. edge of the panelsand the rear 2x4 is set in about I 12 in. After assembling, scribe the standardto fit the wall, if l/2-in. overhangon the back makesscribing necessary.The much easier.

62

American

Woodworker

APRIL2ool

Install a pair of pins to hold the bottom of the standard into holesyou'll drill in the floor (Fig.A,Detail 6). Makethe pins from 3-in.lagscrews. Use a wrench to turn them until the threadsare all insidethe bottoms of the 2x4s.Then cut off the headsof the screws with a hacksawand file a slighttaper on the bottom of the protruding pin.

Mark the floor locations for the pins on masking tape (Fig. C). Use a framingsquareas a guideto ensurethat the holes are perpendicular to the wall.Be sure to remove the baseboardbefore you measureand drill the holes.

F I G .C LOCATIONS OF FLOOR PINS (TOPVIEW)

_.r- 'l-+frc- + ?\ \ urrr"DrA. H.LEStryp.) *li \ | I _ +_+_+


12"'l
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66'

Planning Your Bookcase

Thisbuilt-inbookcase'is easy to enlarge, workaroundwindows, or changein anywayto suityourroom.Before you buyyourlumber, carefully measure yourselected site.Take into consideration the height,widthand anyobstructions uniqueto your room. The centersectionof our bookcase is 6 in. wider than the two outer sections. This establishes a focalpoint,and the two sidesections providesymmetry. Keepin mindthat you canmovethe standards closer togetheror add a standard or two to fit a longerwall. lf you movethe standards to accommodate outlets or airvents, notethat the standards should never be fartherthan 36 in. apart.This is the maximumdistance for sag-free shelves and safeinstallation of the rolling-ladder hardware. Usea levelto check for irregularities likea sloping flooror an uneven wall.lf they'renot too far off,the standards won'tneedaltering. Butif yourwallsandfloorarewayout of whack, you'llbe ableto scribe the standards on the backside and bottom,andthencut alongyour scribefor a perfectfit. Our bookcase wasbuilt onto a wood floor.lf you havecarpeting, you'llneedto pull back the carpetand pad and reinstall them lateraround the baseof the bookcase. And yes,the ladder will rollon carpeting.

American

Woodworker

ApRtL2ool

63

Receptacles andfloor vents of most arethebane butnot thisone. built-ins, thestandards so Iustlocate theobstacles, theymiss

top and bottom. Tip the standards into position. Eachstandardshould be plumb and equallyspaced, Start with the standardthat goes in the corner, facingthe wall (see inset).lf the wall isnt plumb,nail Fastenthe standardto the wall shims onto the spacersfastenedto the standard'sside to compensate. with long drywall screws and anchors (Fig.A,Detail 5). Next, tip the second standardinto the holes in the floor. Have an assistanthofd the standard in place while you make sure it's plumb and the top and bottom measlrements are equal.When everything'slined up,lock the standardin place'with a temporary brace.

Slide the cabinet top over tfre standardsand secure it in placewith anglebrackets (Fig.A).Shim the gapsbetween the top and the ceiling.Screw the top to the ceilingjoisa in three . locations usingtwo screws at each location. Note:You may haveto use a stud finder to locate the ceiling joists,or install blocks between joists in the attic.

Prefinish all thepartsin yourshop to keep themess andsmells under control

64

American

Woodworker

APRIL2ool

w!
Make dentil molding from Colonial-style stop molding(Fig. B).You could start from scrarch, but this is much easier. First, glueand naila long pieceof molding (the filler strip) to a bacl<er board.Then cut individual dentilsfrom a long strip of moldingand gluethem onto the backerboardwith a smalldab of glue (Fig.A, Detail l). Use a scrappieceof moldingas a spacer. My dentil molding needs some dental work! | gluedone of the dentilsin crooked, and it spoiled the whole look of the molding. To removethe offending p i e c e , lw a r m e di t u p slightlywith a heat gun to loosenthe glue.(Both white and yellowglues soften up and let go when they'rewarmed.)Then I pried off the dentil with a thin putty knife.Presto! I'm backin business with a new tooth.

Miter the end of the dentilassembly. Leave a full dentilat the miter, then cut the assembly to length. Nail it to the front of the standards with 6d finishnails. Maintain a consistent distance from the top of the dentilsto the ceiling.This spacemust matchthe heightof your crown molding(Fig.A, Detail7).

Nail molding to the front of the standards with 6d finishnails(Fig.A, Detail 3). Nail the plinthblocksat rhe bottom first.(Because the plinth blocksare wider than the flutedcasing, you'll needto rip ll4 in.from the width of the blockthat'sagainst the wall.)Nail the Colonialstop moldingevenwith the fronts of the standards; then applythe flutedcasing.

{m criczrn Woodlvo

rker

A p R i2 Lo o l

65

Glue mitered cove molding to the tops of the fluted casing.The cove molding should wrap around to meet the Colonial stop molding (Fig.A,Details2,4 and 5).

Nail the crown molding onto the dentilassembly. Mitereach endat the outside cornerandbutt the every other endsagainst the wall.Use4d finishnails of the wood l2 in.anddrivethembelowthe surface with a nailset.

Finishing Finish the standards,molding and shelvesbefore installation. This keepsspills and obnoxious fumes is comout of your living space.Afterthe bookcase pletely installed,you can touch up any cut endswith stain and fill nail holes with colored putty. For a blotch-free, even color on this birch, we applied Minwax Wood Conditioner before staining. Then we used Minwax No. 245 pecan stain to blend the maple and birch pieces. Finally, we applied a polyurethane varnish for durability. M

Sources from Rolling ladder and hardware are available Putnam Ladder,32 Howard St.,NewYork NY ! 0 0 1 3 ;( 2 t 2 ) 2 2 6 - 5 1 4 7 , Specif the length www.putnamroll ingladder.com. of rod (ours is I ft.) and the height of the finished ladder (ours is 7 ft.).Availablein a wide variety of hardwoods.Rolling ladder kits are also sold by ALACO Ladder, 5 167G St.,Chino,CA 9 l710, (888) 3 | 0-7040, www.alacoladdencom. Fluted casing(4 in.) and plinth blocks (4-l12 in.) are availablein a wide variety of hardwoods from Woodharbor Doors & Cabinetry,.3277Ninth St., Mason City, lA 5040l, (641) 423-0444, www.woodharbor.com.Call to order or to find a dealer near you. version of a popularstory This is a new and improved , h e F a m i l yH a n d y m a n . T f r o m o u r s i s t e rp u b l i c a t i o n

Optional: Install the rolling ladder hardware to the face of the instructions (see Sources, cabinet accordingto the manufacturer's at right).

cautio{ifflii lddaar. isi sdfegy hataid for smal! children. Adu|tsu|eriisionisadvised'..-.',.|,...'.

66

American

Woodworker

APRIL2ool

r=rl-l

trLl @@r

Presses
It isntt necessary to spend top dollar to get a Yery good machine.
Consistent, accurate holes. That's why drill presses havebeenfixures in woodworkingshops for overa century.Although it isnt thefirst stationary tool you should buy for your workshop,a drill pressis right up there amongthebasictoolsforwoodworking.We tested 28moderatelypriced (under$450)13-in. to 17-in. machines. The Basics The "sizd'of a drill pressis actually two times its throat depth (the distancebetweenthe column and the centerof the chuck).A 13-in. drill press, for example, hasa throat capacityof 6-112 in. Although we found a 6-Il2-n. throat adequate for most operations, we preferthe extracapacity of thelargermachines. However, it'snot necessary to buy anythingbigger than a 17-in.model.Twenty-inch machines, thenextstep up,weighalmosttwiceasmuch and takeup a lot morespace. how deepa holeyou candrill. The quill holds Quill strokemeasures the spindleand travelsup and down whenyou work the operator's lever (Fig. A). Most of thesemachineshave adequate strokes,about just as with throat depth, additional 3-ll4-in.long. However, strokecapacitymakes a drill press moreversatile.
d)

N4@d

rlll

Other Gonsiderations
Biggernumbersarent always better. Forwoodworking, havingl2 or.L6 speeds is overkill,especiallywhen a singleslowspeed worksfor almost everything. To havenumerousspeeds, thesedrill presses requirethree pulleysand two belts..We prefer a simpler designwith fewerspeeds. Unfortunateh only onemachinein this test,theIet IDP laIE is madethis way.Its five speeds covera wide range,yet requireonlytwo pulleysand one belt. Coincidentally, this machineis the smoottiestrunning and most quiet of them all.

3z
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American

Woodworker

ApRtL2ool

69

rl/r l-]ltr Fr,rhl'os


SLOTSl

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A W I D E , F L A T R I M m a l < e si t e a s i e r t o a d d f e n c e s a n d f i x t u r e s t o t h e t a b l e . S l o t s t h r o u g h t h e t o p a l l o w f a s t e n i n gf r o m u n d e r n e a t h . E v e r y m a c h i n e e m p l o y s a c r a n l < - o p e r a t e dr a c l < a n d - p i n i o ns y s t e m f o r r a i s i n ga n d l o w e r i n g .

w h

Gu4h g

f1
CLAMPABLE EDGE

''-qJ'r. *--.5

are offeredby Delta and Ridgid ATTACHMENTS MORTISING h o l d - d o w n s . T hD ee l t a t h e b e s tb e c a u s o ef theirsuperior l4-070 is the on/ydrill presswe testedthat allowseasy, fence, of the mortising adiustment front-to-bacl< unrestricted i t s s l o t sa r e p a r a l l e l . because

THE BEST OPERATOR'S LEVER has big,round grips and long, s t o u t r o d s f o r g o o d m e c h a n i c a l a d v a n t a g e . T h eg r i p s a r e smooth so they're comfortable to hold onto as you worl< the lever.The rods are threaded so they can be removed if they get in the way.

W I D E B E L T SD O N ' T S L I P ; n a r r o w b e l t s d o . W i d e b e l t s h a v e m o r e s u r f a c e a r e a t o s t a y i n c o n t a c t w i t h t h e p u l l e y s ,s o t h e y transfer power from the motor more effectively.Replacement b e l t s a r e n o t a s w i d e l y a v a i l a b l ei n m e t r i c s i z e s .

just reposition the belts on Changing speedsshould be easy; machines, getting the belts But too many and go. on the pulleys the belt tensioning because otTis difficult, or nearly impossible, Pick a machine that gives have enough travel. don't mechanisms (see pages 72 and73). yolr some slack Chart, comewith motors rated fromll2 to t-1/2 hp. Thesemachines A Ilz-hp motor is adequatetbr most drill press operations; 3lahp is more than enough. Sornemotors are totally enclosed and fan cooled (TEFC). TEFC motors keep dust out of the This isnt such a big windings, which protectsagainstoverheating. concern in a drill pressbecausethe motor is mounted aboveand away from the action.

What to Expect
Drill presses are designedfor metal work, but woodworkers have adopted them, even though woodworking doesn't normally require a machinist's precision. To make drill pressesthat are attractivelypriced for woodworkers,manufacturerstrade abit of accuracy for affordability. The drill presseswe tested aren't as preciseasa machinist'stool, but they're fine for woodworking. And some of them are downright cheap! First,all Two compromisesmake thesemodest pricespossible. quill playbetween the of side amount the machines have a small of and the head,and there'snothing you can do about it. Sideplay is a nuisance, but it has little effecton most boring operationsif you

70

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Wor)(l\\ orlicr

epRtL 2o0t

SPINDLE BEARING
SPINDLE

CLOCKSPRING

SWITCHES D E S I c N E DF O R S A F E T Y lil<e these "On" from Jet,are large, obviousand front-mounted. switches are prorectedso they can'c be pushed accidentally."Off" switches srandproud so they're easyto hit in an emergency.

CHUCK KEY

4.egfilifli;fi;s|**

OPERATOR LEVEB

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F I G .A . H O WA D R I L LP R E S S WORKS *'.
PADDLE STYLE O N - O F FS W I T C H E S a r e t h e e a s i e srto operate-you can evenshut the machine down with your shoulder i n a n e m e r g e n c y .w A e l l - p l a c ec dh u c l < l<ey holder ( t h i so n e i s o n a R i d g i d i)s a " g 1 , 0 0 0 " i m p r o v e m e ntth a r coststhe manufacturer next to nothing! T h e h e a r to f a d r i l l p r e s s i s i t s s p i n d l eB . e l t st r a n s f etrh e m o t o r ' s p o w e ra n d r o t a t r o n t o r t t h r o u g ha t o o t h e ds l e e v e i n s i d et h e p u l l e yT . hese spindle t e e t he n g a g e l o n gs p l i n e s o n t h e s h a f to f t h e s p i n d l eT . h es p i n d l e rotatei sn s i d e t h e q u i l l ,a h o l l o w steel c y l i n d e trh a t m o v e s u p a n d d o w ni n s i d e the machined heao. T h r sm o v e m e nits r e g u l a t e b d y a p i n i o ng e a ro n t h e s h a f to f t h e o p e r a t o r 'ls ever a n d t e e t hc u t i n t ot h e b a c ko f t h e q u i l l .A t e n s i o n ec d l o c ks p r i n g assists thereturn stroke a n d h o l d st h e q u r l li n p o s i t i o a n g a i n stth e h e a d .

usesharp bits and proper fbedrates. However,it may causechatter when you usea sandingdrum, or a big bit without a centerpilot, like a rosettecutter. Higher-quality machineshave an adjustable split-headdesign that allowsyou to eliminate side play.However, they're more expensive-$600 and up. Another compromise is the churcks; they're not great. The biggestannoyanceis that they clon'talwaysgrip bits,especially big ones,securely;sometin-res they slip.The easiest waysto compensate are to usethe chuck key in all thr"ee holeswhen you install a bit and to use a lessaggressive feed rate when you drill. The chucks also allow a small amount of wobble at the businessend of the bit,but not enough to get hung up about. Ifyou havea bug about precision,

you'll haveto spend more money,either fbr a better chuck (about $80) or a better machine. Limitations When you use sanding drums in these machines,the lateral pressureyou exert can amplify any vibration allowed by the side playbetweenthe quill and the head.This combination of pressure and vibration may cause the tapered joint between the chuck and arbor to break loose.If it does,the taperedparts will probably be damaged.When you use your drill pressfor sanding,go easy. Keep the quill housed in the head and raise the table up to meet the drum. The samefactors,lateralpressureand vibration, combine to make milling operations difficult, as well.

A merican

\\,'oodu'orker

ApRtL 2001

Rod-Style Depth-Stop Mechanisms

MANUFACTURER/ i FINAL MODEL i COST


Bridgewood BW I 758F CentralMachinery j $206 (includes

are Best
LOCKING

ryrye

!1!-ting) i$e
i $350 Street Price t o - u /
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CentralMachinery $29 | (includes 43389 I $6 handltng) Crafuman 229 l3

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229l5 Crafrsman

: $300 StreerPrice

$350 StreetPrice

3-114"

1Yes

i l/2 hp;8A

: Excellent

Fair i Good -ii*"rr""i

i $350 Street

3 / 4 h p ;l 0 A

Excellenr
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75-2oO flcrizzly \-/ G7944 $248(lncludes


948 shipping)

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J e tJ D PI T F S E

WE ESPECIALLY LIKErod-style third nut, with three nuts.The mechanisms l<eeps the locatedunder the stop collar, quill extended.lt's a low-techquill stop.

l4JF JeJ t DP
l4MF J e tJ D P I $370 StreetPrice : 7" 3-3i8' Yes t TEFC;

LoboDP-016F

I$369(includes :6-112"

3"

Yes

tIhp;16,4

StarS40l7 Tradesman 80805

i$330(lncludes i6-112" shiPPing) i $75 - -------+ I $200 StreetPrice 6-5/8"

l3

Yes Yes

i3/4hp;12.54 l/2 hp;6A

F"it Fair

]fair : Poor

3-114"

ft;' ij'i7a;;, - -e-ir8r __ .--j, I r-lle ] G i$+0iii..r,J".W;;dr;[ciTar.]i il;p;;;DnLi


DEPTHSTOPS are common, RING-STYLE to use,and but we find them more difficult more likelyto slip.

iilhG I sroo

*--l*:Ja;-

|$ snlPPtng) ; i - /5 ,i_ :_-*,II.-_,?1_-_

: Excellent

Fair

I $30shiPPing; I - -li''

i i ll+ np,t zR

ii;;l,;*

$/5 snrPPrng)

r2f=/^rif f 5 r - ( -t-r L-L=lF-ll L'- -\i

I.-ft= -L L:

f a:,21: L:JL\-L=

A Comfortable Operatorts Lever


More than anything else,howthe quill advancelever feelsin your hand shapesyour perception of the machine. We prefer the traditional threaded-rod design to a single three-arm casting. the lever should be at least 3/8-in. thick and For good leverage, 8-in.long. A few machines have ergonomically formed, soft-plastic grips. They re a big improvement over the smallish, serrated,hard-

plasticballs that are most common. But the most comfortable grips of all are the plastic balls found on the Delta 17-965. They're larger than any of the others,and they're smooth.

Wide Belts
with narrowbeltsrequiremore Widebeltswork better!Machines thebeltsslipon bits,because with bigger to use, especially finesse you haveto stop When this happens the pulleysmore easily. to thebelts. drilling andaddmoretension

72

American Woodworker

2L oot ApRt

I
I

ONIOFF SWITCHES

i MoRTrsrNG I arrncnmrrr

j swrrcx FRONT MOUNTED ] STYLE


i PushButtons

COMMENTS and CONTACT Worl< light;big table.(800)235-2100 Cast operator's lever w/ formed grip.(800) 423-2567 Worl< light;cast operator's lever w/ formed grip; bigtable; very reasonably priced. 1 wide base; I (800)423-2s67. Variablespeedmechanism; work light;castoperator's lever w/ paddedgrip; chuck key holder; extended mainrenance chuckkey holder:extendedmainrenance I Worl< light; (800), contractis available. 377-7414

No Yes

No ; Yes

Dry
Wet
I Yo. 1

i Toggle Toggle

NA ii:i : Yes I Yes

I Yes;3nuts --+---'--'--1-------------i Yes; 3 nuts i Wet I Wet I Yes:3 nuts j Yes

No , Yes Yes

Yes 1 Yes

Work light;chuck key holder; big table; extended maintenance (800) 377-7414. conrract is available. parallel slorsin table;grips I Wide base; havecoarseserrarions. i (800)438-2486. Wide base;grips havecoarseserrarions. (800) 438-2486.

Yes Yes No

, Yes No : Yes

Yes ; Yes

i Dry ' -'---'


'

: Yes Yes

'-

r------------

I Yes I Ves

----;--'-

I yes

I push Buuons i Toggle I praat" i Paddle

big table:quill lock.(800) 438-2486. , Wide base:

Yes

''''''-,'''------':'j-----t--:
I Wer I No j yes i yes

Dry

j Ves

Work lighusoft-plastic grips.(800) 523-4777. Work light;soft-plastic grips;wide base; big table;tall-belt changing may be difficultfor personsof smallstature;depth stop is hard to lock. (800) s23-4777.

Yes;3nuts Yes iNo ]No ,Dry Yes:3nuts

i Yes Yes Pushbuttons

Work light,exposedbulb;wide base;l/2" chuck;must remove depthstop collar to installmortising artachmenr. (800) 274-6848. exposedbulb; wide base; must removedepth-stop I Work lighr, collarto

4-684 8. lT_glryIi:il,s__1!:5!Tl t 800\ 27


Mortising attachmenrin.fua"J; rnw, r".ou" work light;wide base.(800) 274-6848.

O"pifr-r."p ."fi.. t" intoff ;

Rocker

i Work light, exposedbulb;chucl< can'tgrip l/ | 6" bi(800j Z%laOBO

Pac
Paddle

aa flllie5"rq:::d3 !!:y'.9: !T: ta99l ?J!:9-l

grips;chucl< key holder;Americ;-;; 1 Work light;soft-plastic I (800)4-RtDG|D.

;i;.-

i Rocker No

Work light,exposedbulb;chucl< can't grip l/ 16" bit. (626) 334-6668. Bigtable; chucl< can'tgrip l/ 16" bit.(626) 334-6668. Work light,exposedbulb;chuck can't grip l/ 16" bit. (626) 965-06?1 . Chuck key holder;undersized table; good value, but hard to find;sold throughAce Hardware stores.(800) 243-51| 4. Chucl<key holder; big table;excellentvalue,but hard to find;sold throughAce Hardware stores.(800) 743-51r1r4.

IG
,ljil
No

iNo --iil;_'-

-- i D r y iN. i ;i--iN" Yes D.y

.N"

l-N;-Yes

, No iit--

--,---_..:

:!_____L_

il No
i r ;

No
- l

:No
l-- -

,Dry
t r . ,

-^'-

-i-

'-

- -: - -_*--------|---

iNo

Work light,exposed bulb;chuck can'tgrip |/|6" bit.(800) 654-7702. i Mortising attachmenr included. (800)645-9292. Work light;soft-plastic grips;chuck can't grip l/ | 6" bit; musr remove depth stop to installmortising attachment. (800) 235-2100.

A Clamp-Friendly Table Drill press tables, especially roundones, aren't greatfor


woodworking. Formostoperations youll wantto adda fence or an auxiliarysurface, sothebesttables areonesthatwill be easy to clampto.Rectangular tables with a wide,flat rim running around theperimeter areclearly superior. Bigger tables arebetterthansmall ones. Welike "dry" tables because theyre slottedandeasy to keep

"Wet"tables, clean. designed for metalwork, have T-slots instead of slotsandtroughsaroundtheedges. These crevices fill up with wood shavings. A Rod-Style Depth Stop To setdrilling depth,we prefera rod with stopnutsto a ring with a thumbscrew. Stopnutsareeasier to setand oncethey'relocked together, theywont slip.

American Woodworker

ApRt 2L 001

73

Editors'Ghoice
Hor*sGo /Atof;d

Falff;Lcg Chcl-crc
is that the A commoncomplaintwith drill presses chuck falls out. Failureusuallyoccursbecause the parts weren'tproperly cleanedbeforethey For a good joint, the mating werefirst installed. , il m u s t b e s p o t l e s s - a n y g r e a s eo surfaces (includingoil from your fingers)or dustparticles this taperedjoint to fail. that remain can cause fit is compromised, Onceit fails,and the tapered the joint is likely to fail again.

Delta 17-965 | 6- I 12 in. $3 50.


P R OS It was outstanding. This rnachine has pl enty of pow er and a lon g, It runsquietly, 4-7l 8-in.quillstroke. vibration. and is a with mir-rirlal j o y t o o p e r a t eT . he quill advance mechanism and the operates smoothly, smooth,round grips on the o p e r a t o r ' sl e v e r sa r e t h e m o s t The of anv we tested. comfortable
quick action ; *r

t T I G H T L Yb y i n s t a l l i nig KEEPTHE CHUCK FITTING properly the first time. Beforetheir initialassembly, the arbor and the cleanthe insideof the spindle, an insideof the chuckwith a solventthat won't leave thinneror naptha).Then oily residue(suchas lacquer Retractthe chucl<'s slipthe arbor into the spindle. jawsand slidethe chuckonto the arbor.Setthe joint with a single tap on the bottom of the chuck with a mallet. Don't usea steelhammer. rubber or plastic

nut depth-stop (right) is ur-rique and worksgreat. There's a genuine quill lock (it F the head) tl-re quill against presses that locksquicklyand positively. The table raisesand lowers srnoothl yand w e l i ke t h e largebase. Wealsolike Delta's t 1 7m o r t i s i n ga t t a c h m e n( asan whichis available 935;$40), installseasilyon this ar-rd accessory
machine. A work light is also available

( 2 5 - 8 6$ e2 ; 0).
CONS The 17-965 l-rave of We a couple rninor gripes. hood. hasan openmotor and a plastic

Mortising Attachments
to exertthe amountof force Drill presses aren'treallydesigned with large( 1/2-in.)mortisingsets. mortisingrequires, especiaily no largerthan 3/8 in., the use,and mortises But tbr occasional is time-consuming and Installation attachments are adequate. you haveto removeseveral often tedious.On somemachines (see ChartComments, partsbefore you canmounttheattachment page73).When you useyour drill pressfor mortising, put a

to keepit thebase andthebottomof thetable, supportbetween geta mortising from flexing.Ifyou plan to cut lots of mortises, machine. Switches in. Theymakeit difficult have safetybuilt Thebeston-offswitches and easyto turn off in an to turn the machineon accidentally pushbuttons.For Fordurability, welike industrial-style emergency. switches. we like paddle-style convenience,

74

A rnerican

Woodq'orker

A P R I2 LO O l

BestBuy

BestBuy

BestBuy
Rl6lol

Central Machinery ?Al 44 | 3 in.' $206* PROS Although Cer-rtra l a c h i n e r yt o o l s M haven't faredwell in previous Americarr Woodworkertests, tl-ris one perfbrrned adrnirably, appears to be n ell madeand is available delivered fbr $206(there's a $6 handlingcharge). Youcantry it out fbr 30 daysand returnit fbr a full refund, if you'rer-rot satisfied. If bottorn dollar is y o u r t o p c o n s i d e r a t i o ng ,ive this rnachine a try.

Grizzly c7944 | 4 in.t $248* P R OS This machinef-eels better to operate tl-ran otl-rer s r n a ll throat-capacity machir-res because it'sbuilt big (taller a n d h e a v i e r )a n d i t d e l i v e r s good po\,ver. Its operartor's levershavelong rods with comfortable grips.We like the paddle style on-off su'itch, althoughit isr-r't recessed. Grizzll, is k n o w n f o r i t s r e l i a b l ec u s t o m e r service.

Ridgid DP I SOO | 5 in., $3OO P R OS This machine is likablebecause it'suserfiiendly.lthaslongoperator's levers with cornfortable grips,a recessed paddlestyleor-r-ofTswitch, a built-in work light, a decent tableand a chuckkey holder. A good r-nortisir-rg atterchment is available ( A C 6 0 0 0 5$ , 2 5 ) ,b u t o n l y b y s p e c i a l order.It runs qui etl y ar-rd srnoo t h ly. What'smore, Home Depot backsit by offeringtheoriginalpurchaser a lifetime warranty.

coNs

coNs

The 38144 comes with a roundtable, an The G7944 hasnarrowbeltsand a ringopenmotor,a ring-style depthstopand styledepthstop. There's noticeable side narrowbelts. The unusual, castoperator's playbetween the quill and the head. Ievertakes somegettingusedto. * Priceincludes shipping in the 48 * Priceincludes contiguous states. shipping in the 48 contiguous states.

coNs
The DP 1500hasnarrowbelts, a ringstyle depth stop and an open motor. Other sirnilarlypriced rnachines have deeper throat capacity.

Work tight Manymachines comewith built-in work lights, whichyou'dthink would be a greatfeature. Unfortunately, they'reall mounted behindthe bit and castits shadow in exactlythe wrong spot.Big bitscreate big shadows! On somemachines, thebulb protrudes and maygetbroken.We think a bettersolution is to buyan after-market gooseneck work lightwith a magnetic (920). base

Recommendations It'sa buyer's market,sobe choosy. Competitionhasdrivenprices down-we don't seeanyreason to spendmorethan $350. Look for package deals,free trial periods and attractivewarranties. And watchout for shipping costs. Besureto consider thetotal cost of gettinga drill press into your shop. fW

American Woodworker

ApRtL2oot

75

E d i tb ey dD a v e M u n k i t t r i c k

F$hlns

Tps-

NA|L POLI! -*'BRt!6H

Kit Touch-Up Podable


Mixing tiny amountsof stainfrom big cansand cleaningbrushes all for one little touch-up job usedto drive me crazy. While watchingmywife upplyfingernailpolish,l had a moment The clearll2-ouncebottlesareperfectfor storing of inspiration. brushesneverneed stainsand the self-storing different-colored with lacquer I rinsedout someold bottlesand brushes cleaning! I keepa little thinner and filled them with my most-usedstains. plasticcup in my kit for mixing customcolors. Eggleston Charles Gary,IN

A TrueBlack
cast, a bluishor greenish Blackdyesusuallyleave asit seems. wood isnt aseasy Ebonizing is really India ink,which But a good the grain. oil stainslookwashedout and paint obscures asa fast-dryingwaterborneliquid a very finely ground pigment,doesthe job. It's available at art supply stores (BlackCatWaterborne India Ink. Dick Blick Art Materials. 800www.dick933-2542. b l i c k . c o m# , Zll0l2006; $7 per pint). As with any waterborne finish,raisethe grain beforeyou apply the ink. Dampen the wood with water,letit dry and sandlightly to cut down the swelled fibers; then brush on the ink. Once dry, it's compatibleunder any finish. Riemann George Ann Arbor.MI

Before Glue You Strip


When restoringold beat up antiques the typical is to strip, repair sequence and then refinish.I like to changethe order a bit and re-gluethe loosejoints and do repairs first. That way I don t have to worry about gluesqueeze out-it's taken care of when I strip. Also, any new wood used in repairsgetsworked up like the old wood, which helps it blend in better.After stripping,all I haveto do is sand and refinish. SeanDaly RI Providence,

U :<
J E t! f N J J

m o z z. z U m T
L!

:< t
I o_ E

o
I o_ a z. a z.

z
E lrl

2 tr
UJ o
F E

76

Arnerican Woodworker

n p n t2 Lo o t

Fini,shin Tg ips

Hang Varnishing Up
I alwaysfelt the need for a secondpair of hands or doors. when it cameto varnishingshelves of A good solutionis to hangthem rp.A series screwed into the floor joiststurned my eyehooks shop ceiling into a helping hand. TWohooks into both endsof eachshelfallowthem to screwed in mid-air whereI can varnishall be suspended with ease. A length of bailingwire with the sides loopstwistedon the endsis hookedon the bottom the shelfwhile finishing. pair of hooksto steady David Banister Tallahassee, FL

/w
Tip, sendit to us If you havean original Finishing 'We pay $200 for eachone we with a sketchor photo. print. Send to: Finishing tfpi, lmerican Voodworker, 2915 Cnmmers Drirre, Suite 700' Eagan' carit be returnedand MN 55121. Submissions and payment. becorneour prqperry upon acceptance

Woodworker American

3 Year lndex
index for fhis isa three-year It I American Woodworker. # 64,Febfromissue includes articles #84, December'00. ruary'98, through thenissue Entries arelisted bysubject, Forexample, number andpage. "bandsaw fences, extra-large, 72:108" 108. in issue 72onpage appeared index isavailable on our A 5-year Web siteat rker. com. ericanwo odwo www. am
armchairs joineryfor,78:30-32 andGreene Greene Arts and Crafts style -57 74:50 stylesideboard, Stickleyash,source,82:77 y table, 8l :62-65; 84:7 4-7 8 assembf source,80:76 auger bits, ship, jig for,80:32 awls,sharpening 66:68 axes,sharpening,

.. skewers,78:22 bamboo

bandsaw blades folding tips,74:10 Ior resawlnS rated, 70:51 reviewed andAI,V sources, 79:56; 8t:50 storing,84:46 72:108 bandsawfences,extra-large, bandsawjigs 74:44 circlecuttin g, 65:34; 74:45 for compound cuts, -49 74:48 for dovetails, abrasives reviewed, 82:I 0I duplicator padstyle,74:88 pumice, 74:43 patterncuttrng, sources,74:73 for resawing,T4:46 66:32 abi'asivetape, howto tension, bandsaws 79:38 acid-free paper,sources, anatomv of,Z0:45 of,83:82 adjustablechucks,advantages reviewed 76:28-32 69:52-56; buyert!;uide, air compressors -94 andAWrated,T0:44-50 18;83:91 40;76:1269:32buyertguide, 4:45 cutting on,7 compound in,83:93 developments miters on,68:36 cutting spline adaptation, 73:22;80:13 easy-drain -29 -53 76:28 69:52 features andtypes, 13;83:92 69:32-33; 76:12features andtypes, ; 70:48; guide bearings,T4:84 up anairlinefor,83:94 setting source, 8l:50 guide bearings, 83:93 size andcapacity, guide blocks,?t:6.^ air filtration systems made, 65:32; 75:1 6 shopair cleaners, 69:85 ambient adjusting, andthrustbearings, guideblocks 3 guide, 69:88; 76:67,7 buyer's 74:47 guidelines, 80:44 capacity 70:45 guide.types, filters, source,80:47 resawrng shop-made from kits,80:43-47 for,8l:47-48 ielection blade 80:46 whento clean, 66:32; for,67:28 feeder airwatts vs.CFM ratings,explained,65:22 74:46 techniques, aluminum tubing,source, 78:82 for stopswitch AmericanWoodworke6tenthanniversary, movingfor safety, 70:38 68:60-63 table 74:8 brass, ammonia fuming, antiquing of, 72:30 adj ustingangle angles shop-made,8l:103-104 71:36 setting precise, tuning,74:47 ng,82:7 9 checker for sharpeni shop-made upgrading, Sl:51 annealing wheels copper,74:70 12 72: true-up techniques, g tooIs, 72:71 carvin small, shop-made l2 zero-clearance inserts, source, 83: antique tools work,67:20 bark, preserving on rustic about, source, 83:50 books profiled, 79:38 barrel bolt connectors,sources, 70:90-91; collector andrestorer g,78:12 baseballbats,makin 83:46-50 l8 67: basswoodcarving blocks,source, restoring, 83:48-50 81:69,72 batteries anti-sagpowder for glue,source, disposal, B3:69 77:70 anti-tip hardware, source, maintenance tips, 83:69 antfer, turning, 65:52-53 (NiCad) nickel-cadmium 74:62-66 appliance garage,for kitchen, recycling, 67:18 arbors,expanding, 67:28 (NiCad)compared to nickel-cadmium architect'sruleri using,77:8 NiMH (nickel metal-hydride), 83:69 l:24 fluting,7 architectural details, arched beading Ar chitectu rol G raphi c Stondords (American on drawer fronts, 75:lI cock-beading Institute of Architects),82:32 beds stones Arkansas sharpening ' design,8l:40-45 basic T5:8:77:l0 correction to oilstones, compared

sources, 8I :45 rail fasteners, 49;66:I 4 correction 64:44sleigh, beeswax mixing,66:60 shellac,66:58,61 over belt-discsanders -44 - 64;76:41 guide, 69:62 buyer's -42 69:62-63; 76:41 features andtypes, belt sanders belts repating,T5:17 76:34-36 guide, 69:58-60; buyer's reviewed andAWrated,79:66-69 for,65:34 dustcollection 76:34-35; 69:58-59; features andtypes, 79:66-69 jig for thin stock, Tl:38 2 8l:66-7 benches (furniture)r garden, of,72:30 bench grinders,height bent lamination 75: I2 for,sources, glues 72:64-65 techniques, BesseyMiter and Band Clamps,72:50-51 bevel angle blockfor grinding,82:80 67:49;7l:36;82:7 9 calcul ating, angle, functionality in a table,68:40 from distinguished bevel grinding 7I :69 bevel, sharpening for thesloped bezel, (aspropername surface on a cuttingedge),66:67 for Baltic,80:47 birch, plpvood, sources bird's eye maple buying,8l:30 8I :28-32 anduses, characteristics grading,8l:31 8l:33 sources. working, 8l.32-33 biscuitjoiners of,73:70-71 anatomy guide, buyer's 69:66-68 reviewed andAW rated,73:70-77 jig for,79:17 clamping 4 features andtypes, 69:66-67 ; 73:72-7 rence 75:1 7 adaptations, /J:/1, oeslgns, for,79:73 biscuit joints, techniques bits 79:59 Iock-miter, source, rustfrom,82:10 removing source, 7l :65 spoon bits, 68:24 blaik chalkboard paint, source, 84:24 blade cleaner,reviewed, 79:16 blast gates,modifying, bleach A-8,72:36 4 r ine,liquid,72:3 chlo acid,72:38 oxalic peroxide,72:38 iypesand use,72:34-38 blocks,jig for cutting,68:58 T5:8 blue stain in wood, explained, 32:12 board feet, howto calculate, bocce balls rulesof the game,Sl:22 turning,8l:18-23 bookcases lumber, 77:78-82 from reclaimed two-part, 82:56-63

American

Woodworker

APRIL2ool

3.Yearlndex Woodworker American


power 69:1l0- I l4;7 6:92-94 mitersaws, 64:68-69 bookends,bar clamp, ^ reviewed andAI4lrated, compound, 72:52-57 Boulfe inlays, 7l:83-87 bowls reviewed by othermagazines,83:58 64:50-51 coloring, reviewed and saws compound-mitei sliding 64:60-61 world'slargest, AW rated,84:98-109 bowlturning I 08-I I I 69: I 24-I 28;76: sanders, random-orbit basics,68:74-77 - 32 79:22 | d,75:66-7 reviewed andAWrate 74:24 b ases, beautiful router bits,69:24-25 reviewed, 7070-71 coringsystems routerguides andjigs,69:26-27 68:7 6 options, mounting andremounting -89 - 13 107 :85 4;76:104routers, 69:130 ; 83 nested bowls,64:32 by othermagazines,83:89 reviewed boxes I 38;76:114-116 69:136scrollsaws, ABCboxes,84:75 shopvacuums hinges on,79:20 installing 80:69-73 puzzle,67:58-61 reviewed andAl4lrated, - 146: 2-7 6 83:7 76:118-124; 69:140 tablesaws, irapezoid, 65:48-51 in other magazines,S3:76 reviewed rurneo - 122; planers, 76:9 6-102 69 :l 16 thickness 7l:72-75 multiaxis, :l | 6;76:98 69 I 2 (safety benchtop, 64:56-59;66: veneer techniques, reviewed andAI4lrated benchtop, ,79:83-87 note) vises reviewe d andAW rated,82:92 brass hardware and pulls T4:8 antiquing, pullsandhandles cabinetmaker's triangle, 79:75 source,82:23 tabinets brassrod stock,source,80:38 for drill press, 78:I 19-120 brass sheet and wire, source,72:57 entertainment breadboard ends hometheater,34:48-63 style,78:26-28 andGreene Greene walnut, 75:30-37 ;78:I 7 correction Brown, Molly ("Unsinkable"), 79:56 frling,77:64-71 s,7 9:I2 brass, source brushes, flammables, 82122-124 burls 79:14correction :54-63; Hoosierstyle,77 faceplate,8l:16 on a lathe centering -6I installing built-in, 78:56 defined,71:51 l4- 16correction keepsake, 66:54-56;68: butternut kitchen 70:94 anduses, characteristics garage, 74:62-66 appliance funguson,70:94 piesafe,79:70-77 buyer's guide rolling, 64:36-39 76:6-8 for power tools, accessories for,78:59 allowance scribing | -94 83:9 69:32-40;76:12-18:' ors, air compress tool,74:59 3 units, 69:85, 88;76:67,7 air filtration -32 47; 72:7 9 -83 workshop, 7| :4269:52-56; 76:28 bandsaws, cabriole legs 70:44-50 reviewed andAW rated, -44 I instructions, 80:55-6 step-by-step 69:6264;76:41 discsanders, beltcalipers,using,82:46 T6:34-36 beltsanders, 3:35 candle cup,sources,T 69:58-60 portable, beltsanders, -35 ed,73:28 candlesticks,spiral-turn joiners, 69:66-68 biscuit cane 73:7 0-77 andAW rated, reviewed 7I :59 aging techniques, blockplanes,83:34-40 prewoven, 7l:59-60 installing cordless drills,76:46-58 removing old,71:57-58 S3:70 reviewed by othermagazines, 71:60 source, jigs,reviewed andAI4lrated,84:66-73 caning supplies, dovetail -7| -6I 66:69 canoes,lapstrake, 76:60 69:80-83; drill presses, parts, 79:8-10 missing carving, replacing 0 2-7 9; 83:66-7 ss, 69:7 drills,cordle carving knives,toolsandsupplies 3 69:84-85; 76:66-7 dustcollectors, for burnishing,65:34 rated, 80:81-85 andAI,V reviewed 72:68-71 shop-made, 2,78-7 9;76:46,54-58 impactdrivers, 69:7 -94; 76:7 case ionstruction jigsaws, 4-7 7 69:90 jointer-planers, Iarge cases, 84:55-57 69: I 17,122; 7I : I 6 correction -39 64:38 details, sectional reviewed by othermagazines,83:65 -6l - 52;77:60 -65 -82;83:6 7 4:5 | web frames, 1 69:96100; 7 6:7 9 iointers, ' ing,79:14 in g, detect case-harden AI4lreviews andrates 6-inchmodels, r ability, 70:22 casters, mountingandmaneuve 77:72-77 79:74 cauls,shop-made, 106; 83:78-83 lathes, 69:102on a board,73:61 81:81-83 center,finding reviewed andAl4lrated, mitergauges chairs mortisers leveling technique, 67:28 d, 8l:73-77 reviewed andAI4lrate benchtop, patro,72:40-45 sanders spindle oscillating 79:60-65 Rietveld style, 82:82-85 reviewed andAW ruted, rustic,67:52-55 reviewed andAl4lrated, plungerouters, Tl:65 toolsfor making, I 6 correction 4I ; 68: 67:34pneumatic chair seats finish nailers,69:46-50; brad and ' ' duplicating, 77:45 76:21-26 for,72:42-43 supports
rl;. l

68:24 chalkboard paint, source, 79:56 chalk marking pencils,sources, cherry 78:45;79:77 sources, T5:58 veneer sources, making, 68:82-85 chessboards, chests blanket -45 -p anel, 78:37 frameand hooechest -45 78:37 fiameand-panel, chests of drawers cabinet, 84:82-89 sewing Shaker chisels 8l: l4 bevel-angle, 32:80 angle blockfor grinding, andusing choosing -49 68:46 paringtechniques, 82:81 theblade back, flattenine lathe reviewed hollowing tools deep ,72:58-62 74:10 restoring blued, -68; 72:18 66:67 sharpening, 10 hollow, 78: sharpening 72:58-62 small, shop-made, storage rack,74:58 Christmas tree ornaments 70:75-77 snowflakes, turned,77:26-32 I 66:5 chuck-adaptorfor drills,reviewed, circles centerfinder,73:62 jig for bandsaw,65:34 cutting cutting safety,64:32 circular saw blades carrier for,70:38 65:32,69 cleaning, holderfor,66:34 andAW rated, reviewed combination, 65:64-68:71:14 65:65 vs.all-purpose, combination l2 74: for radialarm saws, gum andpitch,73:20 removing box for,74:60 storage teeth 65:69 sharpness, determining types,78:16-17 thin-kerfl80:68 clamping 7I :24 workpieces, angled jig,for curves,78:20 padsfor miterjoints,72:47 pressure notched 72:27 panels vertically, clamps 77:48 cam-action. coopering,T4:21 edging,77:96 padsfor .plywood,78:18 prpe vise, 68:36 bench asan auxiliary 80:l3 expandable, 2:30; 78:18 guirds for,7 joints,67:30 to spread using pneumatic, 77:46,49 BarClamp/Quick-Change Quick-Grip T4:84 Spreader, reviewed, 83:104 Quick-Grip 73:81;79:77 sources) spring for holdingsmalloffcuts,TT:48 74:18 improvised,

82

American Woodworker

nPntL2ool

AmericanWoodworker 3-Yearlndex
cutting boards and blocks lor storage mini,70:82-83 64:30;70:38 hanging, cutting gauges 74:58 7l:38; racks, 65:47;73:14 tuning, 77:49 8I :6I 74:41; source, toggle, ; 78:82; using,65:44-46 cs, 73:7 8 andcharacteristi types 66:48-49 cutting lists, howto devise, 64:I 8 for finish-safe, cleiirers, sources cyanoacrylate adhesive clocks 66:12-14 using,64:67; sources movements, . : : r': i' 67:l8 radio-controlled, self-setting, :)r:' for making, source,65:62 supplies 'i aado blades, for contractor saw,81:10 size wall "'''ilidoes Shaker,65:58-62 80:77 blowout,preventing, 65:82 anduses, cocobolo, characteristics rcpairing,77:57 collets dado heads rustfrom,82:10 removing 8l:86 tool reviewed, height-setting 76:8 ange, for quick-ch sources (safety note) dance floor finishes,65:12 34 Cooke, Edward S.,Jr., 78:24, lead, for pencil denatured alcohol,asa solvent coopering 77:13 67:48-49 calculating a curve, 66: 18 for cutting, dentils,setup clamps,74:21 out,81:92 dents,steaming 67:48-51 a door, fileholder, 80:36-38 desk accessories, coPPer 80:32 64:32; detail sanders,shop-made, aging,74:72 -73 74: I6 diagonals,measuring, hardware, 74:67 shop-made dichloromethane (DC M), characteristics T4:73 sources, anduses,73:56 74:68 toolsfor working, disc sander cordlessdrills for,67:30 discs cheapskate accessories,83:70 -70 -58;83:66 reviewed,8l:86 Delta guide, 69:72-7 9; 76:46 buyer's dividinga board,73:58 in,83:68 developments 66:50-53 doors reviewed, accessories drill-and-drive -68 4:65-66 on a cabinet,T bi-fold,installing 69 :72-73;7 6:46-47 andtypes, features ;83:67 flush-fit, 79:78-8r cordlessdrill/sawcombos,74:83 65:42-43 construction, frame-and-panel 70:7 0-7| coring systems,reviewed, 72:72-78 tombstone, corner joints dovetailjigs 82:17 tool for,shop-made, sanding for chopping,64:30 countersinks workposition, 80:24 for comfortable ToolCompany, 75:89 Beal pins,75:18 formarking tip,73:88 Rabbit countersink GiffinTec Jack d,84:66-73 reviewed andAl4lrate coves thebit,84:10 setting cuttingon a tablesaw for spindles, T4:20 fence for,68:34 quick-clamp -48;66: 18 for steady cut,77: l4 correction; 64:47 technique, usingwith a router,84:92-94 75:34-35 dovetails, 84:86 for makingsliding Craft EmergencyRelief Fund (CERF), shop-made, 64:40-43 67:24 dovetails and,83:18 credit card fraud, theinternet 74:48-49 band-sawn, crosscutsledsand tables I 65:60-6 cutting, blind mitered, for tablesaws -43; I with,67:58-6 makingpuzzles 75:38 sliding, shop-made, sliding l0 78:17 correction; 82:1 - 43;84:86 routerj ig for,64:40 stop,80:24 sliding routingtapered, 77:39-40 crown molding 7:42-43 hand-cutting,T through, cutting jig for,73:20 dovetail saw,sharpenin'g mitersaw,84:57 with a compound doweljoints handplaning,T3:82-85 ror profile, anatomy of.,73:84 ogee Jlgs TT:63 sources, cupboards dowels and cylinders corner gluing intoblindholes,80:24 67:6267; 7| :24 Colonial, 78:45; 8l :69 hardwood, sources, thegrain) cupping (warpacross 67:30 measuring diameters, correcting planing, T4:18 in doorpanels,77:10 , slotting,64:32 grainorientation to avoid,68:43 for,78:20 storage 66:36-40 curved seat slats,steam-bent, turning, T9:28 curves downdraft dust collector for,7 3:22 inside, techniques bandsawing 14 83: Deltamodelreviewed. 68:34;73:60 drawing, shop-made,80:66 jig for clamping,TS:20 joiningcurved draftihg,cuttinglistsasa part of,66:48-49 :6 boards,77 drawer guidesand slides 3:47, 49;8I : 12 layingout,7 77:70 filecabinets, sources, lines, curved 67:28 tracing 75:88 for heawloads, 84
American Woodworker A P R2 To Lo 1

drawers assembly,78:20 ceiling hung,78:49 - 43;849| -94 64:40 dovetailed, details,84:92 design TT:64-69 filecabinet, fit, checking,S4:87 'ioint construction stvIe,78:32-34 andGreene Greene jig, 84-91-94 with a dbvetail lipped, making 12 problems, 84: wearaway g, 66:68 drawknives,sharpenin for drills, drill-and-driveaccessories, 66:50-53 reviewed, drill bits 76:8 for,sources, collets quick-change andgrinding sharpening 78:65 brad-point, Forstner,TS:67 spade,78:66 78:63 techniques, twist,78:64 sources l4 mm brad-point,79:34 79:34 brad-point, half-inch 8l:69 taper-point, keyless, 67:30 drill chucks,shop-made 66:52 drill-fl ip-drive systems,reviewed, 70:38 holes accurately, drilling,deep drillingjigs holes, 84:l4 for centered holes,68:34 for pocket 72:85 features, reviewed, 84:22 KregK2000 72:84-89 sixshoptested, prooucuon, / l:Jo drill presses tabIe,73:20 auxiliary 76:60-61 buyer's fuide,69:80-83; 78:ll9 - 120 cabinet, shop-made, depthstopfor,70:36 I ; 76:60-65 69:80-8 features andtypes, JIgS 77:20 for knifesharpening, shop-made,67:I2 tableandfence, drive belts 83:24 to V-belts, link typecompared S3:24 sources, drum sander 80:64 shop-made, dustcollector, sanding, 77:48 template kitsfor,77:49 dry brushing,65:70-72 7l:22 dry-erase markerboard, source, drying wood, air-,8I :50 game, 70:56-58 dueling-disks dust bags 18 hangers for,82: shop-made replacements, 68:36 shop-made dust collection about,80:67,85 andbooklets books clothing, 80:65 protective 80:62-68 tipsforbetter, dust collectors bags guidelines, 80:82, 83 selection sources,80:85 79:16 gates, modifying, blast 3 76:66-7 guide, 69:84-88; buyer's 1-85 80:8 reviewed and,\Wrated, capacity 76:67 required, 69:85; size ; 80:84 accessories, chipandoffcutseparation sources,80:62
l , . .

lndex 3-Year American Woodworker


80:62-63 separation techniques, chipandoffcut retrofitfor easy,67:30 cleaning, downdrafttable 14 83: Deltamodelreviewed, -made, shop 80:66; 8254 76:66-67 features andtypes, 69:84-85; ; 80:82 filters,80:82-83 ducts,80:26 grounding leaks, sealing,80:83 mountins,82:38 for,80:67 pipefittingsandconnectors quickhookupfor,66:34 remote controlfor,80:l 14-116 (safety note); for routers,65:14 80:66 shop-made note) for a router, 65:14(safety anatomy of,80:82 single-stage, sources,80:85 cyclonic, anatomy of,80:82 two-stage risksfrom,80:104 dust, health dust masks and helmets of Occupational Safety National Institute recommended, 80:68 andHealth sources,80:68 dyes 72:3 4; 82:108 bleaching, 75:62 colormixing chart, for dyingwalnutsapwoo d,75:62 recipe sources, T5:64 water-based stains, 77:ll0 water-based removing,82:108 for workingwith,67:20;75:61 techniques 't

i, ." ebony,sources,8l:61 -ilge banding 72:51 mitered edges, t0 I clamp for,81:12;83:98shop-made edge gluing for,78:51 clampracks PonyEdgingSpringClamp,review,77:96 boards,77:6 edge joints, on curved with a router, 78:20 edges,rounding electrical outlets 77:96 Automatic Power Switch, Craftsman note) fastening tricks, 65:I 2 (safety installing cabinets around, 78:61 ovalsand spirals ellipses, drawing guide for,73:47,49 with string,64:30-32 efm, source,65:62 enamel finishcomparedto lacque671:94 end grain finishing,75:62 planing,64:16-18 sanding, T9:54 sources, 8I :69 epoV, specialty, escutcheons inset, 70:74 installing T0:74 sources, Excellence in Craffsmanship awad winners 1998,70:78-81 extension-cordholders loading techniques, 73:22 shop-made,82:18
f1'ta'+ St't+1

face frames for cabinets .ry4 argnrng, /vilJ for removable, 70:22 hardware mitered, 8l:78-79 rabbeted edgingfor,77:21 fasteners caddyfor,65:34 shop-made tabletop, shop-made, 80:26 sources, 74:41 tabletop, featherboards anatomy of, 68:79-81 makingandusing, 68:78-79 for clamping to a fence,68:81 router-table, 68:80 68:78-81 tablesaw vertically, 7I :36 for workingboards feet, furniture plasticfor outdooruse,72:44 endgrainfor outdooruse,84:30 sealing fiberboard panels I:22 formaldehyde-free , source,T panelconstruction, 68:7 I in raised information on.75:83 reference
l ' '

86

American Woodworker

A P R2 rL ool

American Woodworker 3.YearIndex


figure bee's wing,Tl:50 bird's eye,71:51 burl,Tl:51 curly,7l:51 cuttingplanksfor,7l:49 guide, definitions andvisual 7I:48-51 designing to showoff,14:76-79 factors that determi ne,7I:48 feathercrotch,Tl: 9 fiddleback,7l:50 horsetail, Tl:49 mooncrotch,Tl:49 moonshine swirl,Tl:49 mottle,7l:50 quartersawn fleck,71:5I quilted, Tl:51 ribbon,Tl:50 stripe,7l:50 swirlcrotch,7l:49 tigerstripe, 7l :51 file cabinets and holders desktop, 80:36-38 tour-way, 77:64-7I files auger-bit, source, 78:65 auger-bit, using,78:65 (safetynote) to scrapers, T0:18 - converting el6ment,70:ti3 fllets, asdesign finishes adhesion, testing for,80:98 antique cr acl<Ie, 72:l 8 booksabout,75:64 bubbles in, reducing, 77:lll coloring wood,64:51-5 t for duribility,6S:44 flammables labinet for,82:122I24 food-safe, 68:7 7; 78:10 4 heat-resistant,68:22 repairingandrestoring colormatching,T3:17 insectremoval,65:22 techniques, 66:20 stripping, 73:54-57 ; 78:18 "tie coatj'using for adhesion, 77:l0B finishing before assembly andglue-up,66:59 avoiding drip shado#s, 8I :9b;82:104 dry brushing,65:70-72 drying booth,shop-mad e, 65:34 endgrain,75:62;81:90 finalrubout,82:8 flooding andwipingtechnique,78:106-I l0 gramenhancement, 64:86-88 levitating your workpiece for,80:I 00 padsponges,8l:90 porefilling,74:86-89 prefinishingtechniques, 70:98I 00 ra$eogram avoiding, TT:II0 asa.prefihishing step, 78:I 06 supplies, sources, 74:57 ; 75:37 touch-ups andrepairs, 73:98-l0Z touch-up supplieS, sources, 73:102 woodbleach ing,, 72:34-38 fipple, (mouthpieieon a musical instrument), making a,7526 fire hazirds ' flammables cabinet for finishingsupplies, 82:122-124 fish eyes,(finishingflaw),correcting,68:100 flatsawn lumber defrned,74:76 effecton frgure,7I:49 . floor locks,inachine, 75:16 fl oors, mappinguneven, 78:57 fl ush-cutting Jaws,sources, 78:45 fluting, arched,TI:24 fly rod casesrTl:22 folder sources andusing, 77:70-71 food-safe 68:77;78:104 food safe,portable,82:20-23 frame-and.panel construction anatomyof,70:67 carcase, for file cabinet, 77:64-69 doors, 65:4243; 79:76-77 makingcurved,67:51 reversible stileandrail cuttersfor,7l:72-74

-69 jigsfor,7 tablesaw 0:66

American

Woodworker

ApRtL2ool

87

AmericanWoodworker 3-Yearlndex
framing square to a try square,73:63 converting truing,82:10 French curves,73:60 66:32 fretwork, sanding, gadgets,for drills,66:50-53 ganrma butyrolactone,characteristics and uses.73:56 gauSes andtuning,65:47;73:59 choosing 65:44-47 cutting, ; 73:l4 for matingparts,77:46 go/no-go, mortise, 65:44-47 thickness shop-made,80:30 glazes 70:84-86 finishes using, decorative 75:62 for,70:86; recipes makine,70:86 vinesar, 70:36 gloves]shop-t.d'. in a pinch, glue 79:7 7; 82:63 sources, extended-open-time, it into cracks,73:25 getting polvurethane ' moisturefor curing,70:22 old,73:12 removing soreaders -unorthodox,TS:20 de,7l:69-7| for,shop-ma tool holders for tool rests shop-made,7l:69,71 7I :69 tools, for woodworking 66:68 gutter adze,sharpening, 69:72,78-79; guide, impact drivers, buyer's 76:46.54-58 I roller,80:I infeed/outfeed aids,swiveling 57 72:52i nlays,Boullestyle, fromlumber,70:22'24 insects,removing on theweb,83:16-18 tools internet,buying andpartitions invisiblewires, for shelves 66:22;77:70 sources, 67:28 i rregu Iar shapes,rr acing, jam chucks shop-made,81:19 for.66:34 substitutes lapaneseplanes 8I :89 pull type,reviewed, jarrah 73:52-53 anduses, characteristics 73:51,53 sources, jewelry boxes,trapezoid, 65:48-51 iigs blockmaking,63:58 S4:14 for drillingor marking, centering, 70:36 for routing, centering, curves, 78:20 for clamping dowel-drilling source,82:77 64:16 on router, hinge-mortising, for miterjoint glue-up,72:47 on routet84:16 tenoning, 74'.2I for trimming corners, jigsaws -94; 76:7 4-7 7 guide, 69 :90 buyer's andAlf rated reviewed ,68:64-69 4-7 5 76:7 69:90-91; 68:65; andtypes, features 65:32 recycling old blades, jointer knives 73:16 setting, with magnet,65:32 77:20 sharpening, jointenplaners correction; 69:117 guide, buyer's ,122;7I:16 76:102 jointers andtuning maintaining, adjusting, 83: I 30 for square, checking initialsetup,77:74 pulleys 83:ll8 andbelts, - 122 g, 83:120 correctin iablealignment, l8-130 tuning,83:1 waxingthetable,83:126 -82;83:6 1-65 I 00;76:79 69:96buyer's suide, 6-inchmodels, ,,{W r."uie*tandrates 77:72-77 :77 on,77 cuttingrabbets in,83:63 developments -80;77 :7 3; featr.rres andtypes,69:96-97 ;76:79 83:61-63 126130 83: methods, fence aliqnment andsize,83:64 fence feaiures 4 :7 kniveson,77 setting methods. 83:122-126 jointing 73: l4 bv hand, 8l:8;82:70-71 with a router, jig for,78:51 router 73:14 gboard, with shootin wideboards,78:8 joints lockingtaper,TI:63 65:57 structural, repairing scarf,74:16

Hall,lohn,78.24 Hall, Peter,78:24 78:45 sources, flush-cutting, handsaws, hardware T4:8 antiquing, anti-tip,77:70 coPPer -73 yourown,74:67 hammering 74:57 sources, filecabinet,77:70-71 66:20 source, handles, solid-surface 67:I 8 steel, source, stainless -73 ade, 74:67 shop-m style, Stickley ratings and,65:65 hearing protection, decibel 76:8 hearing protectors, sources, I 78:6 around, cabinets heating ducts,installing hickory-bark 8 65:1 harvesting, w ith, 65:22 weaving seat hide glue 6;77:16 65:55-5 anduses, characteristics opentime,65:55 extending liquidvs.dry,77:16 4:57 sources,T recipes,65:55 800, Unibond 3:12 techniques,65:57 repair andremoval glue size,mixingasa sealer,68:98 ;7l:26;7 andmixing,65:54-56 selecting glue-up 65:57;79:77 sources, dowels,80:24 jointsandsegments, 65:50;72:46-51; hinges of mitered anduses, 82:64-67 characteristics European, 8l:14 instailing gluing,82:8 rub-joint butt.79:80-81 corners,TT:57 square 8l:65 punch, sources, center I ; 82:8 for,73:78-8 techniques 82:64-67 European, gluing into cracks and dowel holes,67:28 knife,66:57 go/no-go gauges,77:46 mounte d, 79:20 surfacegouges sources. T8:45 for hollowturning 72:58-62 butt,79:56,77 reviewed, T9:38 withbarrel boltconnectors, continuous sharpening 75:37 74:66; for,82:80 European, strop custom ; 82:67 -23 gouge, 80:21 hold-downs detailing jig,75:19 gouge, 80:20 for cutoff spindle-roughing I 7-18, 22-23 T3:25 80: workbench, 66:68; technique, 66: 34 hole cutter',shop-made, toolsandjigsfor,80:16 72:58-62 hollow-chiselmortising attachments small, shop-made, 78:10 sharpening, sources,80:23 grain enhancement,64:86-88 hollow turning grain painting toolsfor T3:100-102 reviewed, 72:58-62 to hideputtypatches, 72:58-62 hollowing, source, toolsfor deep Greene and Greene joinerytechniques 4 82:80 of., 78:24-3 honing,with strop, 82:80 of,8t:52-6t in thestyle honing guides,using, table side grid, quick,73:59 Hoosier cabinets 79: l4 correction 77:54-63; grinders building, for parts,66:20;77:63 sources shop-made,80:13 for,8l :39 housing horizontal boring swing-up vertical supportfor,7917 grinding drill press 78:14 horsepower,peakvs.rated, angles,Tl:70 bevel for,78:I 0 78:10 for,sources, stones humidors, woodselection conical tools,7l:71 hygrometers and moisture meters damaged T9:14 pin typevs.pinless, Tl:70-71 techniques, 81:50 grinding wheels 79:14; sources, T4:84 80:16 L607DualDepthProline, characteristics, Wagner's oxide, aluminum 80:17;82:79 dressing, T3:85 reshaping, ' sources,T3:85;74:10;78:64

88

American Woodworker

RPntrzoot

AmericanWoodworker 3-Yearlndex
B0:34 keyhole hanger,sources, 65: 18 kickback,on tablesaw, installing, 66:57 knife hinges, 82:80 knives,sharpening, knobsand pulls drawer anddoor,source,79'.77 2:94 source,T face-grain, for jigs,74:44 style, source, 84:89 Shaker 64:52-55 knockdown joints, tusktenons, kn ots, repairing, 72:I6, tn,84:32 checking joining,TT:6 curved, n,74:7 6 flat-,rift- andquartersaw distinguishing grading, 84:34-42 72: I6 knotandvoidrepairs, 7; 84:3442 74:7 6-7 andbuying, selecting fye, usingsafely, 73:56 tnree-way mltered. /ui)l->J motors :50 sources, 81 electric, l4 ratings, 78: horsepower understanding 70:59-61 multi tool, AI4lreviews, musical instruments 17correction 75:20-28;78: turninga whistle, 77:10 andsources, Nagura stones,purpose nailing, no-mar, 7l:38 nails brads bobby pin holder,84:16 nails,79:45 to finish compared 66:20 source, square-cut, National Hardwood Lumber Association 84:42 grading standards, of andInspection Rules for theMeasurement 82:12 Hardw oodsandCypress, National lnstitute of Occupational Safetyand Health (NIOSH), 80:68 recommendations, dustmask called free-edge natural-edge wood (also woodor wane-edged) bowl-turnin 9,74:32 n-methyl pyrrolidone anduses, 73:56 characteristics oak anduses characteristics white,66:74 64:20 cutting anddrying, -28; 78:I 7 correction ocarina,turningan,75:20 OccupationalSafetyand Health ratings Administration (OSHA), decibel protection, 65:65 for hearing oil finishes 78:106107 applying, Danish,66:78-80 food-safe,68:77 78:54; 79:62 sources, 73:51; oil stones correction to waterstones, 75:8; 77:10 compared oscillating spindlesanders guide buyer's andAW rated,82:82-85 reviewed routerto,68:34 converting reviewed,82:97 GrizzV reviewed, 82:96 hand-held PorterCable I outfeed rollers,swiveling,80:l 7l:76 overspray, defined, oxafic acid,forwoodbleach,72:38 67:7 4; 70:16 padauk,characteristics anduses, (safety note) paint frompores, 79:12 removing storing, T0:38 T9:12 stripping, panel raising j ig for tables 2-73 aw, 68:7 on router,73:39-43 veneered raised panel, 68:7 0-7 3 panels cutting on a tablesaw,66:32 techniques, 68:46-49 paring, chisel jigsfor,77:18 disease, steadying Parkinson's

machinefloor locks,75:16 of, CharlesRennie, profile Mackintosh, 67:56-57 66:22;77:70 magic wires,source, 70:26 sources, magnetic sheets, lacquerfinishes asa safety device,83:28 magnetic switches, to enamel, 71:94 compared 76:8 magnifiers, wearable, l8 72: crackle, creating, mahogany, sources, 80:54 lacouer nitrocellulose -;^ with, mounting on a lathe mandrels, reverse repairs,T0:26 blush 74:32 7l:94-96 solidcolor, spraying ctrrnnrno / {'\Fl maple removal, T2:38 andstain in,77 :ll0 bleaching compounds volatile organic anduses, 64:80 characteristics for,sources, 75:12 laminating,glues sources, 74:41 spalted, 83:26 laser guides, 74:16; with,72:69 safely MAPP gastorches,working lathe chucks marking gaugesand tools rim chucks,78:102-104 anatomv of.65:45 74:96 three-jaw, shop-made, quickshop-made,73:63 lathes -90; -83 using,65:44-47 :78 76:86 83 guide, 69:I 02- 106; buyer's 72:5257 marq uetry, Boullestyle, bowllathes, 76:90 andpractices measuringtools, equipment, lathes, 76:90 duplicator measuring, 67:30 diameters, 69:106; 76:90 mini lathes, for,74:61 storage 1 reviewed, 78:68-7 mini lathes methylenechloride buying advice, 83:78-80 79:12 anduses, 73:56; characteristics in,83:81 developments health dangers of,77:12 80:65 shop-made, dustcollectors, heart and,7 3:54 disease faceplates l:22 mica plate, source,T on burls, 8I : l6 centering 73:54 milk paint, removing, mounting, 74:30-32 reverse reviewed, mineral spirits Woodworking Lathe fetProfessional 34:28 disposing, 77:94 reusing,84:28 mini lathes mitered sticking,65:63 revlewed. /d:b6-/ I miter gauge andpower,83:80 speed features andtypes, 8l:82-83 7l:38 andholders, tooltrays EB-2Miter Gauge reviewed, Osborne l6 vibration problems, 67: 72:98-100 for,64:86-88 lauan,finishes reviewed andAl4lrated, 8l :8I -83 layout setting a|45o,71:36 dividing a board,73:58 miter joints quick grids,73:59 65:60-61 blinddovetail. 73:58-63 tipsfor accurate, gluing,72:46-51 reviewed, 82:98 layout tools, TriScribe -59 lock-miter, 79.57 lumberand,77:85 lead paint, reclaimed three-way with,68:54-55 leather,veneering mortise andtenon, 70:52-55 83:128 levels, accuracy asa straightedge, moldings lid supports 67:6465;71:24 Colonialstvle, inexpensive, 67:28 made with, 70:62-65 display sheives 78:45 sources, 73:82-85 hand-planed custom, anduses, 71:92 lignum vitae, characteristics with contemporary tools, 7l :24 period, made foad, shelvin g and, 75:7 9 reed,78:80-82 locks mortisers 70:73 anatomy of a half-mortise, reviewed andAl4lrated,64:74-78; benchtop, sources, B1:65 cam, 8l:73-77 | double drawer, 77:70-7 souping up,78:41 TT:70 drawer, sources, l2 techniques for using, 73: half-mortise, sources, 70: 74 mortises and mortise-and-tenonjoints 2-7 4 se, 70:7 installing a half-morti jig for,72:24 centering logs -50 dado-cut,65:32 81:49 cuttinganddrying,64:20; 75: l0 guidelines, design anddimension turning,6T:16 mortising, 73: l2 machine 78:12 LouisvilleSluggerbats,dimensions, routing, 8l:70-71 lowboys,66:22 'lumber -45 for,78:37 techniques calculating boardfeet, 82:t2
. i t' t
. 1 - ^ / ^ - 1

90

American Woodworker

nPRt zL oot

lndex 3-Year American Woodworker


parting tools Ior turnmg shop-made,64:32 16 patterns, transferring, 73:25, 63;82:14, peg rack, whittled, 73:64-66 pegs,square for a roundhole,70:24-26 pencilholder,84:14 pencil marks, removing, 77:13 pencils sources, 79:56 chalkmarking, sharpening tips,73:60 perf-board on,8l:38 extending thehooks hooksfor,74:59 screw for,80:8 shelving -91 Phillips,Bill, profiled,7 0:90 photographs,making workingdrawings Irom. //:6 picture frames choosing themolding, 66:43 designing,66:42 joiningandreinforcing, 66:45 artworkin,66:46-47 mattingandmounting mitering andtrimming, 66:44 rustic-style, 8l:24-26 supply sources,66:47 pigment stains with,64:86-88 grainenhancement pine,bluestain in,75:8 planes block buyer's guide,83:39 Iow-angle,64:16-18 sources, S3:36 typesandfeatures, 83:34-36 cutting angles,83:40 edge-squaring guidefor,65:32; 67:14;70:14 flattening theblade back,82:81 Microplanes reviewed, Manufacturing Grace 77:102 handles, sources, 64:I 8 ironsfor flattening,75:17 moldingplanes -84 73:83 restoring andsharpening, -68 sharpening, 66:67 planing gang,77:47 withoutjointing,34:9 planing by hand edges of longboards, 75:I 8 roundstock, 74: l8 plastic laminates cutting on tablesaw, 77:22 jigs, Tl:38 cut without chipping, 72:| 4 plastic,ultra-high molecular weight,T 2:M;7 5:43 plate turning, 78:98I 04 plugs removing, T3:20 tapered, sources, 8l:69 plunge routers anatomy of,67:36 bits adjusting height, 67:28 Bosch l619EVS, review 83:104 - 107 guide, I - 133 buyer's 69:13 ; 76:106 reviewed 68:16 andAl4lrate d,67:34-41; correction; 78:76-79 Fein, review 83:104 plywood . ApplePly, source,74:59; 80:38 Baltic birch, source of void-free,80:47 saw, 78:50 cuttingwith a circular launched, 84:26 Europly in,77:8 veneered, avoiding tearout pneumatic brad and finish nailers anatomy of,79:44 79:47 avoiding, 72:20; blowout, tng,79:47 blowout,r epair - 50;76:21 -26 buyer's guide, 69:46 -47; 76:21 -22;79:43 -49 features andtyp es, 69:46 avoiding, 79:45 impactmarks, T9:49 sources, pneumatic clamps,77 :46, 49 pocket-screw joinery 72:85, 89 tipsandtechniques, withoutajig,82:17 polycarbonateplastic,sources, 75:43 polyurethane creating a custom sheen,78:8 glue moisturefor curing, 70:22 types,67:78-80 waterborne color,80:102 adding best brush for.82:104 77:106III characteristics anduses, I 02 sources, 77:ll0:'80: porch swing,66:36-40 pore filler sources. T4:89 water borne,74:86-89 powencord holders, loading a reel, 73:22 andcompound) power miter sarvs(conventional accessories,83:58 guide, 69:I l0- I 14;76:92-94 buyer's features 83:54-56 andtypes, d, 7| :83-87 reviewed andAI4lrate reviewed, Ryobi 33:14 yourneeds, 83:55 capacity, determining compared to radial-arm saws,83:55 dustcollection after-market solutions, 83:57 features andtypes, 69:I l0- I 14;76:92-93 laser cuttingguidefor,74:16: 83:26 stop, shop-made,75:14 work station for,66:34 work station, portable, 66:96; 68:12 power tools accessories for,76:6-8 caddyfor,79:100 storage devices, 74:60;82:34, 36 advances in portable, 83:30 technological horsepower ratingsof,7 8:14 understanding prefinishing,benefits of,70:98100 production shop techniques chair seats,77:45 clamping,TT:46 go/no-go gauges,77:46 repetitive work,safe practices for,77:47 sandwich clampfor routing,TT:45 tablesaw templates, 77:46 propyfeneglyc6l(humectant), source s,77 :ll0 protractor/depth gauge,source, 78:64 push blocks and pads fromconcrete floatpads,82:16 sources, 79:59 for Vega fence, 74:I 8 push sticks fastening with magnets, 8I :37 putty painting,techniques, 70:84-86 puzzles box. 67:58-61 correction Nob's neverending, 68:5657 ;70:18 solutions,68:59 quartersawn lumber creating thelook of,72:65 effect on figue,7l.49 rabbeted joints for drawers, 84:9I-94 locking, radial-arm saws compared to powermitersaws,83:55 problems, 74:l2 crosscutting l6 (safety note) rippingwith,7l :14random-orbit sanders guide, I fl buyer's 69:124-128;76:108reviewed andAW rated,75:66-71 discs, compared,T5:66 dustcolleitiontips,80:64 features andtypes, 69 :124-125;7 5:66-67 ; 76:108-109 padbrakes,75:66-68 revleweo. /5:ob-/ | runout,causes of,75:68 rare-earth magnets anduses, 66:65 characteristics 74:8 andcomputer hutches, asdoorcatches, 66:54-56 vise,66:62-65 in quick-release rasp,sources,80:61 reamer, tapered, source, 7I :65 reclaimed lumber,77:83-85 for embedded metal,84:18 checking red oak resistance compared to whiteoak,81:8 decay reed moldings,78:80-82 removable-sleeve systemsfor&ills, reviewed,66:53 practice s for,77 :47 repetitive work, safe reproductions Colonial style -67 ard, 67 :62 comer cupbo ; 7I:24 silver trays, 67:46-47 finish,72:18 crackle moldings for furniture, 67:6465;7| :24 nails square-cut, source, 66:20 Annestyle Queen g,75:ll cock-beadin resawrng avoidingwarp after, 79:l 4 74:46:81:45-51 on a bandsaw accuracy tips,81:48-50 respirators -ca activated rb on,77:12 organic-vapor cartridge storing,81:90 77:12 supplied-air, restoration (furniture andstructures) hidegluetechniques, 65:57;71:26 piece,68:50-53 anold case Rietveld, Gerrit, 79:60 rigidity, varies by species of wood,75:79-80 ripping, on a contractor's saw, 68:22-24 roffing pin, turned,79:24-34 rosewood,finishing, 77:109 round stock planing, I8 chip-free 74: layingout an intersection on,72:28 router bits sources, 81:61, 69 bushings,
. 1 - - - 1

92

American

Woodworker

APRT 2L ool

AmericanWoodworker 3-Yearlndex
73:20 care andcleaning, flush-trimming reviewed, 34:24 with Teflon bearing 73:39-40 primeron panel-raising, using,78:72-74 reversible stileandrail cutters, for,67:16 areno substitute shaper cutters I3 problems, 75: slipping 78:45; 8l:61 7 73:43; sources, ; 82:7 lock-miter, 79:59 pattern bits,74:66 round-over bits,78:82 point-cutting radius type,84:89 4 77:63; 78:7 reversible stileandrail cutters, types,69:24-25 in a shaper,67:16 using router jigs -27 guide, buyer's 69:26 cutting, Tl:38 for dadocenterline 66:32;7818,48; 80:28 for dadocutting, routing, for diagonal 78:80-82 for dovetails sliding dovetails, 84:86 forjointing, 78:51 Ior mortlses centered, 64:10;72:24 hinge,64:16 c\amp,77:45 sandwich joints,74:16 for scarf tenoning, S4:16 43 Router Mogic (Hylton), 73:42, routers for bases dustcollection,83:89 removable,83:88 shop-made,8l:37 guide, 130134; 69: 76:104-107 buyer's ; 83:85-89 1617 EVS reviewed, T5:90 Bosch's reviewed, MakitaRDI 100 83:12 reviewed andAW rared.78:76-79 wear. 75:13 collet with,78:48 crosscutting in,83:87 developments 131; 76:104-105; features andtypes, 69:13078:76-77;83:85-86 66:34 handle, shop-made, with a,78:20 rounding safety,67:16-18 vs.shape r, 83:22 table-mounted, knob for,77 :22 thumbscrews, shop-made router tables Bosch foldingtablereviewed, 84:26 Iences anddustcollection, Tl:ll2 with bit storage boxtype,73:40-41 43 pivotarm type,73:42g,70:36 self-centerin for vertical bits,73:42 inserts Excalibur EXRT2 reviewed, 84:25 shop-made,74:21 pull-out,79:104 ruhs point,75:88 center uses for broken, 77:l8 Rules forthe Meosurcmentond Inqeaion of HaftwoodsondCyprcs (National Hardwood Lumber Association), 82:12 molecular runner material (ultra-high 75:43 weight plastic), sources, 72:44; rust 74:61 preventing, on smallhand-tools, vaporcorrosion inhibitors, 75:89
94 American Woodworker

T3:56 anduses, SafestStripper;characteristics Safety circle-cutter s, 64:32 dusthazards health effects of,80:104 80:67 Codestandards, UniformMechanical paintandfinishstrippers,73:54-55 67 80:26, preventing static electricity sparks, tablesaws accidents, 64:62-67 mostcommon 74:83 with magnification, safety glasses, sanding blocks shop-made, 75:14 T9:56 sources. discholders,66:34 on drill press,77:48 79:54 endgrain, hand,78:23 inside corners,82:17 jig for holding Tl:38 thin stock, pads,64:32 flexible,sources, 79:56 80:32 smallpieces, 66:32; when io stop,68:20 sandpaper T8:22 dispenser, useful lifeon detailsanders,TT:21 extending filestorage for,82:14 for,82:3 6 overhead dispenser sources, T9:56 78:22 for"short"r oIls, 8l:92 unclogging, for layout,73:63 saral paper,using 68:94 characteristics anduses, sassafras, sawhorses knockdown andfolding, 79102 nesting, 8l :38 77:98 RWC-36, Stablemate jig forhandheld,T3:20 saws, sharpening 102 described, 83: SawStop,product development scorps,sharpening, 66:68 scraPers 78:104 burnishing, cablnet 1,68 sources, 80:6 (safety note) makingfrom old files, 70:18 80:107 sharpening, shop-made,64:32 80:6 1, 68 sources, squaring edge, 82:79, 8I scratch beader or scratch stock makingmoldings with,75:52-53 75:50-53 shop-made, ial,75:53 souices for commerc screw chucks mounting with,74:24-30 reverse screws with loose, 68:20 dealing drivingin tightspots,78:22 goodjointswith,79:62 making for perf-board,74:59 pocket-hole, 72:89 sources, sciibing adjacent edges, 78:60 walls, 78:60 cabinets between cabinets to walls, 78:59 penciladaptor for,68:36 scrollsawblades choosing, 7l:66-67 life of,7916 extending theuseful sources, Tl:67;72:57

storage,66:32 Tl:67 tension, types,T l:66-67 scrollsaws 138; guide, 69: 13676:114-116 buyer's shop-made, 73:20 dustblower, 69:136-137 features andtypes, ; 76:114-115 Makita SJ4o1,75:86 using,67:47 sealers l0 sources, 79: to avoid finishing disasters,63:98-100 using with,77:47 semaphore jig, turningduplicates 84:82-89 sewing cabinet, Shaker, Shaker style stands, desks, andcabinets,84:82-89 sewing 84:89 tools andsupplies, wall clock,65:58-62 shapers routers, 83:22 to table-mounted compared usingrouter bitsin, 67:16 sharpening tools, 66:68; 82:78-81 edge 78:l0 mortising attachment, hollow-chisel jointer knives,77:20 "scary 66:66-68 sharp'technique, 80:107 scrapers, I for sharpness, 82:8 testing sharpeningstones 75:8; 77:10correction Arkansas, I:22 care andmaintenance.T ceramic,Tl:22 diamond,TT:94 lndra, 75:8; 77:lUcorrectron 75:8; 77 :10correction oilstones, 77: 10correction types anduse, 75:8; waterstones care and storing,TL:\2 flattening,82:81 holdersfor,82:79 77: I0 typesanduses, fapanese, 75:104 shavinghorse,portable, shop-made, sheet goods 70:128 roll-around cartfor,shop-made, I sawing rackfor,80:1 shelf supports sources,T9:77 brass, invisible,64:30 magic wiresfor 66:22;77:70 source, for,82:59 using biscuits shellac applying, 66:60-61 anduses, 64:20 characteristics dewaxed TS:107 applying, instant,80:98 77:108 usingasa"tie coati' mixing,66:59-60 weighing,T4:20 for flakes. 77:ll0 sources stripping,73:56 shelves hanging installation options, 70:65 installing, 78:56-61 5:7 9 -81 man-made boardsas,7 design, 75:75-83 sag-proof 79:74 supportholes, drilling accur ately, 75:82 torsion-box, wall - 65;78':52-55 70:62 display,

APRrL

Index American Woodworker 3-Year


free-form,80:34 workshop,6T:96 shoe-pof ish wax, finishi ng with,66:22 parts 68:24 Shopsmith machines, source, shopvacuums airwatts vs.CFM ratings,65:22 guide buyer's reviewed andAI4lrate d,80:69-73 features, S0:70 hose-holder, shop-made, 64:30 muffling from,79:l15-l16 noise plastic linerfor,source,80:64 77:101 RidgidToolVacreviewed, Ridgid WDl730reviewed, 77:100 tool-actuated switches, 80:7 I -57 sideboards,Stickley-style, 74:50 silicagel packets,source,67:18 silicon putty, sources, 79: 10 6-8-l0 squaremethod, 73:61 skew chisels -62 made, small, shop72:58 source,72:78 SL I E, defined, 82:70 sliding compound-miter saws advantages of,84: I 00-04 buyer's guide, 69:l | 4; 76:92-9 4 reviewed andAl'[ rated, 109 84:98features,84:l0l-102 II howthevwork,69:1 smoke alarms,dustand,80:104 snipe,eliminating, 79:85 soapstonecarving blocks,source, 67: l8 soldering wiring, electrical 75:58 equipment andsupply, sources, 75:58 with used, solvents, dealing 65:86-88 Sorbothane mounts, sources, 75:58 spalted wood finishing, 77:52-53 health hazards of.77 :53 making,77:51 77:53 sources, 77:51 stabilizing, working,TT:52 spalting,defined, 77:5 I Spanishcedar preferred for cigarhumidors, 78:10 speakers components for,sources, 75:58 high-quality for,7 5:57 soundreproduction making,75:54-59 spice boxes and racks instant-access rack, 7l:52-55 spindles dividingthecircumfe r ence, 73:61 repairing andreplacin g, 65:20 spline miters, miniature, 68:36 spokeshaves anatomv of.67:43 shop-made, 67:42-45 sources,80:61 using,67:45 spoon bits, using, 7l:65 spray booth, shop-made, 7l:76-7 7 spray painting and finishing shop-made boothfor,7l :7 6-7 7 andequipment for,81:92 techniques spring dividers,pencil adaptor for,68:36 square,methods for checking,T 3:6I panel,67:50 squaringcorners,on a curved stainlesssteel hardware,source, 67:18 stains applying bright-colored stains, 82:106 colormatching,T3:17 oil-based andwaterborne oohurethane Ilnlsnes. / /iIU6 static electricity,dust collection problems with, 80:26,67 staves, making,67:49 steadyrest,lathe for hollow turning, 84:l10I 14 shop-made,68:i20 steam bending, curved seat slats, 66:36-40 steel,rod stock, source,80:38 steef woof holder, 72:24 stipplingtool, shop-made ,82:16 stools dovetalled step stool, /ui/5-/ / nested.78:47' Annefootstool, 80:48-54 Queen shop,71:61-65

Woodworker

AmericanWoodworker 3-YearIndex
stop blocks drill press, adjustable, 70:36 tablesaw sliding, T0:36 workbench from old deadbolt. 79: i6 storage for the shop carts andcaddies, 79:100 drawers, rolline,80:8 hardware box."6+:tO+ lumberracks, 73:22;84:44 magnetic holders, 74:60 measurlng squares, 74:6 I overhead,84:46 power tools, 74:60; 79:100; 82:34,36 rackfor handtools, 74:61 tollrolls,74:61 toolslides,74:59 tool"bookl'79:100 story poles or sticks turningduplicates with,77:48 straightedges shop-made, 83:128-129 sources,83:129 test for,83:130 strippers disposing of residue from,73:57 using,73:54-57 strongback (partof acabinet), defined ,72:80-81 subassemblies, devising cutting listsfor,66:48-49
",,,':.:"t:'

blades andcutters aIigning,T2:26 dustvolume and,80:68 "ideal" height for,65:18 blade tilt. stize - 124; buyer's guide, 69:l 40- | 46; 76:l 18 83:72-76 DeWalt DW746reviewed, 75:9 I contractor tvDe -24 rippinghardwood,68:22

covecuttmg -48;66: technique, 64:47 l4 correction crosscutting tables for,75:38-43;78: I 7 correction developments in,83:75 dustcollection for,80:66 impact of blade selection,80:68 features andtypes, 69: 140141 ; 76:118-119; 83:72-73 mitergauges, sources, 83:74

,tables workstation, ""'' assembly 8l:62-65; 84:7 4-7B c,ollapsible workstation, 77:120 olnmg howto size,82:24-32 farm style,82:68-77 -44 kitchenandbreakfas t, 68:40 pedestal, T2:63-67 , legs factory-turned, sources, 82:77 mortising tapered, 8I :60 quickutility legs, 78:23 turned,82:42-46 outdoor, 73:44-51 parlor, 79:50-56 Parsons, 70:52-53 -67 pedestal,T 2:63 4-7 8 ; 80:7 picnic,80:74-78 side Greene andGreene-style, 8I :52-6i -41 treasured-bo ard,7 4:37 trestle how to size,82:30-32 tablesaw fences quick-clamp, for coving, 68:34 tablesaw jigs angle-cuttin g,70:38 angles greater than45degrees, T4:18 crosscuttins ,75:14 hold-dowl for.75:t9 panel-raisin g,70:69 for tapering,68:36 template cutting, 77:46 tenoning, 68:45; 70:68; 73:67-69 jig,65: vacuum resaw 104 tablesaws accessory storage, 79: I 00 blade guirds,6E:6q-65;66: l4 correction Sources,83:74

Woodworker American -Year Index 3


Tlre Problem: systemto hand cut perfectdovetails' To designan easy cuttingon a,66:32 panel satety 64:67 first-aid, emergency 64:62-66 accidents, mostcommon tableattachments sliding 74:82-83 Deltamodelreviewed, tips,77:8 prevention tearout tabletops fastening,80:26 6-79 for,74:7 lumberselection 64:57 tagua nuts, source, tambour doors,77:86-92 77:90-92 C-curve slats, sizing 77:88-89 S-curve slats, sizing 77:63 for tracksystem, sources tape 79:56 sources, 78:54; double-sticking, 100 residue, T0:98, with no adhesive 70:36 for convenie nce, prescoring 84:126 tapering legs,on ajointer, taPers jig for making on tablesaw,68:36 jointertechniques, 84:126 80:38 sources, taps and dies,metal-threading, teak, cleaning,6S:22 plywood, TT:8 in veneered tearout, avoiding tempering 2:7| g tools,T carvin shop-made small, for longlasring,T3:62 templates, materials tenons guidelines, 75:l0 design anddimension on router, 84:I 6 tablesaw -69 jig for,68:45; 73:67 tusk,64:52-55 80:30 thicknessgauge,shop-made, thicknessplaners (also portable) called benchtop guide,76:98 buyer's -87 d, 79:83 andAI4lrate reviewed - 122; 76:9 6-102 :I 16 69 buyeriguide, :20 gauge, shop-made,77 depth fot 80:62-63 improvements dustcollection - 122; 76:96-97 andtypes, 69:l 16 features ; 79:83-86 feed speed,68:22 knivei 77:20 sharpening, threaded inserts installing, Sl:10 sources,8l:10 77:23 th reads, cuttingin metal, 3-4-5square method, 73:61 tin panels 8:79:77 shop-made, sources,T9:77 I tool-actuated switches,80:7 7I:78 -82 too Iboxes,curved-top, 73:108 tool chest,flip-top, guideto,76:5 tool manufacturers, buyer's tool stand legsfor,77:23 adjustable 82:48-55 shop-made, ToolTests T9:66 beltsanders, j oine 0-77 rs,73:7 biscuit mitersaws, 84:98 compound tablesaw, 65:94 DW477benchtop DeWalt jigs, 84:66 dovetail dustcollectors.80:80 66:86 Table SLT60, Excalibur Sliding
o-lncn mooels,/ /i/ z- / / lolnters,
I I | - - - ^ - -

quickly youachieve profesional results guide lets saw sptem and The Solution: This place and ttre atthecorrect toholdthesaw It clampin position withlittleeffort. and
in ttrealuminum imbedded magnets rare-earth cut.3/4" anglefor a perfect correct keep thesawperguideandcovered with alayerof low-frictionUHIIWplastic from tlretails to chopout waste asyoucut.Youjust need fectlyaligned saw ontomaterialrl4ttto Iil thick.Ourdovetail andpins.Clamps daignedfor use specifically hasbeen guide. The22tpi with our dovetail longandhas0.005" is 2rty$t7ftt blade a 1:8guide of setpertooth.Includes A 1:6guide(for for mostapplications. is alsoavailable. softrnood) andSaw Veritas@l:8 Guide 05T03.02 $3t.95
(N.Y.rcidents, addsal.s lax.)

purchase, with orfree a $5coupon) $5(includes

1'800'871-8158 @E orcall:

I"ee\/all & oeplitc|s'


13669 N.Y. Ogdensburg, Street, LeeValley Tools Ltd.,12 EastRiver

cpE :li'J,-t"':1,fl;5,13;1:,1f,,
orfar 1-613-596-6030 call:1-613-596-0350 Overseas,

American Woodworker 3-Year Index


mini lathes, 78:68-71 miter gauges, 81:81 mortisers,8l:73 Oneway 2036 WoodLathe,64:94 o.scillating spindle sanders, 82:82 shop vacuums,80:69 j igs, pocket-hold 72:84-88 portable planers, 79:82 PorterCabie 7529plunge r ovter, 77:96 "Bammer" Porter-Cable Cordless Finish Nailer,67:86 random-orbit sanders, 75:66-7 | vises,82:88 tops (toy), turned, 70:56-58 torches,working safely with,72:69 torsion boxes design andconstruction, 82:50-52 howtheywork,75:32-33 trays, Coloniaisilv er, 67:4647 triangle, cabinetmake r's, 79:7 5 turning
a n l t e r .b ) : ) l - 5 J
, 1 . F - ^ - ^

Don't let your tools stand between you and truly professional rcsults.Use Starretttools, the choiceof expertcraftsmen for over I2O years. Youcan start by getting FREE, packed attractive, full-color catalogs, with information on top quality Starretttools. Circle thesenumbers on page1O7.

drivingwith a dead center, 82:44 duplicates jig,77:47 with a semaphore with storysticks, 77:48 halves.72:28 leaving a pommel,82:44 tegs table, basics of,82:42-46 reverse mounting, 74:24-32 spheres, 8l:18-23 spirals, 73:28-35 techniques for making multipies, 82:42 turning tools and supplies coringsystems, reviewed, 70:7 0-7| shop-made,67:28 sources baseball batbillets. 78:12 deadcenters,32:46 livecenters, 79:34 toolrests, 82:46 l2- 16-20 squaremethod, 73:61 UIIMW (ultra-high molecular weight) plastic, ' 72:44 sources, 75:43 ultra-highmolecular weight (UHMW) plastic,T2:M sources, 75:43 Uniform MechanicalCode, dust collection hazards, 80:67 universaftinting colors (IJTC),7 3:17 UTC (universal tintingcolors), 73: 17 Vacuumclamping Carter's MiniMachreviewed, 73:94-96 jigsfor,84:lB systems, source,77:49 West OakK-B4kit reviewed, B1:88 varnish food-safe, 78:104 spraying, 64:18;81:92 veneer making yourown,65: 104; 80:30; 81 :5I plain-sliced vs.rotary-sliced, 80: 106 removing antique, 7I :26 repairing, 64:7 0-7 3;65:57; 84:58 sawing tips,68:84 saws andcutters

2OI PrecisionTools 2O2 Saw Blades 2O3 Measuring Tapes, Levels, Tools

Stowerit

The L.S.Starrett Company 121 Crescent Street. Athol.MA 01_331

Tel.:(978) 249-5330t Fax:(978) 249-8495i www.starrett.com

Index 3-Year Woodworker American


68:84 sharpening, sources banding,68:85 cherrv. /5:5U "Hollowood" 65:22 veneered woodcylinders, quartersawn whiteoak,74:57 specialty,64:57 68:34-36 storing, veneennS leather, 68:54-55 68:85 sources, materials andsupply panels,74:53 panel, raised 68:70-73 techniques, 64:56-59 66:I 8-20 requirements, thickness tools,64:71 108 73: vinyl sheeting,sources, vises bench auxiliary,68:36 features andtypes, 82:88-90 -65 wooden, 66:62 q'uick-release howto avoid,82:91 racking, d,82:92 reviewed andAI,f rate sources,82:90 volatile organic compounds (VOCs) spirits, 84:28 irrmineral polluretha ne,77:l l0 in waterborne walnut mismatched, 75:64 coloring old,75:63 colormatching -64;77 :109 finishing, 7l:24;75:60 sources. 75:37 waterborne or water-basedfinishes TS:107 applying, :lll in,preventin bubbles 9,77 wax,66:22 with shoe-polish wax, finishing construction,T4:51-521' web frames,in case 77:60-61 75:75-79 issues for supporting, weight, design 70:26 wheels,sources, whistles 78: I 7 correction turninga,75:20-28; white oak 66:74 anduses, characteristics to redoak, 81:8 resistance compared decay andcolor, 66:60-61 white woods,finishing whittling 73 :66 sources, equipment, a peg rack,73:64-66 andpartitions wire supports, for shelves 66:22;77:70 source, wood 72:34-38 bleaching, identifying, 84:9 9 -80, 83 rigidityandstrength of,75:7 wood filler making,84:30 78:54;79:10 sources, using, 74:13 wood movement 75: l9 construction, in cross-grain screws and,68:20 woodworking goofs, 83:132 workbenches benchtop extension,64:30 -48 75:47 shop-made, I :40-65:4 65:38,65 drawings, construction folddown,67:30 fromanold door,82:34 for stopblocks 79:16 fiom old deadbolt, wedged-base ,75:44-49 workshop cabinets, 7l:42-47 kit for,64:67 first-aid emergency 67:96 flexible shelving, layouts, 69:15-19 77:18; space in small,68:34; maximizing 78:46-51:81:37 dangers, 80:104 noise andhealth outfitting 83:42-45 for less than$3,000, -39;72:7 9 -83 for,64:33 rollingcabinet setup,69:16-19 workstations 4-78 84:7 table, shop-made,8l:62-65; assembly 70:22 mounting options, casters, 78:49 77:120; collapsible, on,79:17 easy-tostowadd:18 caddv,77 mobilemachine inserts zero-clearance 83:12 source, bandsaw, 64:32;77:8 shop-made, for tallblades,66:20 T8:54 zero-radiusturns, cutting,

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MADE IN THE USA

snd OnUs ForQunlily,Perfiormsnne, "Yott CsnCouni


"Forover55years, we provided have onlythe - table saws ALLPUfiP0SE qualiU products and andportablecircularsaws. finest seruices. "That's whyI canmake ptionalguarantee : this exce Purchrce anyForest bladeor dadoand useit tor up to 30 darc. lt you Presidenl JimForrest, are notconpletelyatisfied for any reason, never anyriskto rcturnit tor a tall retund.There's you.You have my word on it."
Sale 10%0tf 15%0ft Pilce 1stElade2ndBlade

Forresl SuwBlqdes
K) $-es $ 8 9 $ 10"x or3/32' 30T (1/8" Kerf). $4 8 1/4" x 40T (3/32" $ 8e$ Kerf) 8"x 40T (3/32" $4 $ 8e$ (3/32" 7 1/4" x 30T Kerf) Fss $ 6 2 $ K).. ts8s $ 8 0 $ 0mm(5/64" 5 3/8\40Tx1
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84 84 59 76 miter, tor slidingcompoand designed Specially miterchop,and 157o Off 0ll Sale 107o ndial saws. x 60Tx 5/8" 8 114" $+s0 $ e 8 $ e 3 60Tx 5/8" 8 lzz'x s++s $107 $101 x 5/8' 10'x80T $+3S $ 1 2 5 $ 1 1 8 1 2 ' x8 0 T x 1" $+49 $134 $127 T1 " 1 5 ' x1 0 0 x $+e8 $179 $169 14"x1@T x x 40T x 5/8", 9'x 80T x 5/8", forprices. Call Designed lor radial atm ot tablesawsotl sale 1lP/o Olf 15% tine crosscat.

-ForSears *.ForDeWalt Portables Cordless & Makita

ITLLLETIIJ,Lgrooves gettlat-botloned and nosplinleriny Yoa nelamine. $ix when oakplEand even croscutting (incl.3B2" two 244a0th oat' 44ootlr chipper), chipperc in-factory the for sharpForest set standard technicians plus 1/8"t029F2"groaves. side blades shins.CUE processed inSto 5 days. Please ening! Most orders Off2ndSel 0f{ lst Sel 15o/o SalePrice 1|P/o blade. additional include UPS of$6+$1foreach 6"set $f0 $242 8"set $389 $260 10"set $e$ $314 perfeclly. 12"set $449 $404 220nn & 300nn melamine Cuts olt Sale llP/o 0ll 15% available. Aurbest Runner case 10" Blade carrying ,0r Pilce Price 1sl 1sl Elade Blad ZndBlade plywood Included Ff,EE FIEE withyour o sets. vourorder! blade. 10"x80 T (1/8'or 3i32"K) $i9 $143 $135 wilhin30 daysandreceive Order 54 12"x80 Tx1"(1/8" K) ${8+ $163 $1 in DISCOUN CT OUPONSothers 14'x80Tx1",xl00Tx1", 8",7 1/4", 14"x100Tx1", for prices. , Call $15 of anybladeor dado! lor in-house sharpening *3 coupons per 1 coupon blade. at$5each. Use

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Visitourinternet store
0R, stoles.yahoo.coMorestman

Manufacturing Forrest Company Road 457River NJ07014 Clifton,


Tech, Inc.877-228-0908 CallSharp WestelnGanada: 800-229-4814 sales:Call CMR- RonCollier 0the1 Canadian O 2000 Forrest

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Shop Solutions

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Prcss Table
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Clamping a fence to this shop-made table is a cinch. Slidestandard clampsinto slots to fastena fenceor workpiece anywhereyou want. There'sno needto buy aluminum track or dedicated clamps. Drill dozens of holes into your insert!With our simplesystem, you'll alwayshavea fresh surfaceto drill into.Movethe insertin and out, flip it end for end,or turn it over; there's plenty of room for lots of holes. Ensurea tight fit for your insert by countersinking a pair of flat-head adjustment screwsinto one side.

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Remove the dust from a sanding drum througha vacuumhose insertedinto the table'sdust well. Adjust the heightof the drum in the dust well to take advantage of the entire surface of your sanding drum. Make extra insertswith differentdiameterholesto match eachone of your sanding drums.

tandarddrill press tablesmay be fine Q tJfor metalworking, but they sureare frustratingto usein a woodshop.Attaching a fencewith woodworking clampsis a pain in the neck;findinga cleanbacker board canbe a realchallenge; and building a contraptionfor your sandingdrum makesyou wonder, isn't there a better drill presstable out theresomewhere? Surethereis,if you dont mind spending someseriousmoney.You could shell out $100 and order a drill presstable from a catalog. Ouch! Next add another of accessories dedicated to only that $30 table.Ouch again! We'vekicked around lots of ideasin the AW workshop and designeda topnotch drill presstableyou can makein a few hours for far lessmoney.The materials are simple and probablyalreadyin your shop. You don't need to buy any fancymetal hardware, clampsor.knobs. but you will need Joineryis equallyeasy, a dado bladefor your tablesaw. If you have an originalShopSolution, send
it to us with a sketchor photo.'Wepay $200 for eachone we print. Sendto: Shop Solutions, American Woodworker, 29 I 5 Commers Drive, Suite 700, Eagan, MN cant be returnedand 55121. Submissions become our property upon acceprance and Paymenr.

American Woodworker ApRtL2oot

111

S h o pS o l u t i o n s
Materials rails.Choose Any hardwoodwill work for the table's medium-densityfiberboard (MDF) and tempered hardboardfor the top and bottom.Youll needabout materialsare a half sheetof each.Theseengineered plywood. than to warp less likely genera\ flatterand hole, a drilled around MDF won't splinteror puffup so it'sa perfectbackermaterialfor drilling holesthat go all the way through a workpiece. After you build the table,set asidesomeMDF to makemore insertsin the future. Differentbrands of so it'sbestto use MDF mayvary slightlyin thickness, insertsarePrethe make sure the exactsamestuffto top. ciselyflush with the table's Construction tablebyworkingon a flat surface, Build a flat drill press Usecaulsor suchasa door or the top of your tablesaw. cinder-blockweightswhen gluing.You dont need but it must be equallyappliedto all areas. much force,

Cut dadoes in the rails (A).The fit betweenthe dadoesand your hardboardshouldbe fairly loose. A too-tight fit will makethe table difficultto assemble.

Cut notches in the ends of all the ribs (C).Test their fit into the rails.

Glue the rails (A) and mountingboards (B) to the bottom (D).Insert some ribs (C) but for alignment, as temporary spacers removethem before the glue sets.

glue to Glue the ribs (C) in place.Apply the dado and the bottom of eachrib.To you only haveto glue and clamp make it easy, gluethe plugs(E) a few ribs at a time. Finally, to the rails(A) to enclosethe dust well.

114 continuedonpage

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American

Woodworker

A P R I2 LO O 1

S h o pS o l u t i o n s
Glue the top (F) to the ribs.Note: Don't applyglue to the two middle ribs that support the center waste piece! Once the glue is set,turn the table over,as shown here,and cut four slots for the clamps.Cut awaythe waste piece drill a hole where the insert goes.Then for your vacuumhose and pilot holes into the mountingboards(B) for attaching the table to your drill press.

VIEWFROMBELOW

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Thanlcs to AW senioreditor TbmCaspar for this ShopSolution.

WASTE PIECE 1/g" wlDE SAW KERF

LIST CUTTING
4:-1 /4 "H x 32" W x 1 6 " D Ov e ra l l Dimensions Part Name
A
b

Qty.
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Material
4/4 Hardwood

Rail

Dimensions 3/4x2 x32

Notes Cut1/8"-deeo dadoes

Mountinq Board z Rib 14 Bottom 1


Pluq Top Inseft z 1

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F
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4/4 Hardwood 3 1 4 x 2 x 1 4 - 1 / 2 Hardboard 1 / 4 x 3 - 1 / 4 x 1 6 Notch corners 5/8"x1-7/8" " hole Hardboard 1 / 4x 1 6x 3 2 1-3/8 forvacuum hose Hardboard 1/4x3-1/4x3-9/1 MDF 3/4x 16 x32 Crosscutafter MDF 3/4x4-1/2x17
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American Woodworker

Insert Superabbet'" root #RC-4e360


. 2-sided replccecble ccsbide knives. . 18 dillerent deptrs with one tool using optioncl collcrs. 67800 (21 piece collcr kii) r Maintain excct tolercrrces. r Choose lrom 3 dillerent dillerent crppliccrtions: ccsbide knives lor

RCK-30(wood/plywood) m (soli cstd hcrd wood) lHff SRK-30 lfl rnr<-so (solid srulqce/ssv'/MDF)

Get lt

by Dave Munkittrick

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"Bubbling Tonsu" by Aaron Levin-e

Maple Big-Leaf Quilted


Quilted big-leaf maple is a real gem of the forest. Its look that seems figure hasa three-dimensional spectacular jewel moved. as it's facets of a like the to shift Quilted figure appearsin severaltree species,but by far the most spectaculardisplaysare found in the big-leaf maples of the PacificNorthwest. it'sa rare find, quilted big-leafmapleis in short Because To savemoney,woodworkers supply and is very expensive. will often resawthe stock to use as veneer,door panels, jewelry box or humidor lids and as accentsin furniture. Instrument makersfavor quiltedbig-leaf maplefor acoustic electricguitar tops and harps. guitar backsand sides, Quilted figure has a lot of end grain that is prone to tear-out,so it can be a real challengeto scrape,sand and finish. But the end result is alwaysworth the extra effort. We bought this quilted big-leaf maple from Northwest Timber in Oregon. They try to keep a good supply on hand and sell it in random lengthsand widths. The lumber is gradedaccordingto the intensity of the figure.At the very top is Musical Grade followed by AAAAA down to AAA. from 414to l2l4 The wood is availablein thicknesses and pricesrangefrom $12lbd.ft. to $25lbd.ft., depending on the grade. Source
NorthwestTimber P . OB . ox l0l0 OR 97352 Jefferson,

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Note: Quilted figure varies from tree to tree and from board to board. Expectvariationsin color,shapeand size of the blistersin eachquilted pattern. /W
Know of some GreatWood?We'd love to hear about it. Write Dave Munkittrick at dave-munkittrick@readersdigest.com.

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