PURVEYORS OF FINE MACHINERY", SINCE 1983!

10" Cabinet Saws w/fliving Knife 17" Heavy-Duty Extreme Series Bandsaw

---,
./,{
-.,.). w/ Cast Iron Wheels & Motor Brake
MoIor: 3 HP, 22fN, singlepttose ~ 1\1eU' __- Motor: 2 HP, 110Vl220V, singlep/)ase, THe
Preo;::isiOfl ground cost iTOr'! table ...f; , '" Lorger pr9Cision ground cost irm Ioble size:
Tobie size w{extension: 27' x 40' 24' x 17' ,-.,--
Arbor speed: 4300 RPM
Arbor: 'fj, '
Max,depth 01 cut (both): 3'h' @gel", 2'Y16' @45'
Tobte lilt: 5" tell, 45' right
Max, culling height: 12'
Mo~, rip capacity: G0690 - 30". G0691 - 50'
2 bIoc!e speeds: 1700& 3500 FPM
Approx, shiWing weight:

-
Double ball bearing blaae guides DfWX! IPIiSA.W
80690 - 603 ItIs. FlNe! &
ClJick change blade reloose/lenslooai MIT'ER GA.lIGf
G0691 - 644 Itls. INClU[)El)
Approx shipping y,'e~)t 4141bs
G0690
INWOOUCTOIN ~CE MOTOR BRAKE STOPS
SlADE IN J SECONDS!
'125000 &.HANDWHHLS
,-
w/Erlension Rails G0513X2B '1.+95'"
mWUSfAtm,U
~ SALE $1295 00 ,,1',1,90 fAnE INlrs SALE $1150 00 _
10" Lett-Tilting Contractor Style 2 HP, , 0" Hybrid Cabinet SOw 10" Left-Tilting Super
Table Saw w/ Riving Knife o Motor: 2 HP. 11(JJ122rN. single-phose Heavy-Duty Table Saw
Motor: 2 HP, 11 OVI220V, single-phase o PreciSion ground Ctlst iron toble size Molor: 3 HP, 220V, siog\ephase
Precisioo ground cast iron table size wiWings attached: 27 ' x 39h' Precision ground cast iron table
wtwings attoched: 27' x 44' Arbor: ',Ie' 0 Rip copocity 30' Table size wtwings ollached: 27' x 48~'
Rip copocity: 36' Uft-off fence CopaCity: 3' @ 90', 2W @ 45' Max, deptl1 01 cut: 3' @ 90', 2lA' @ 45'
CopOCity: 3Y" @90', 2 't .' @45' C<lst iron miler gauge Cutting Ctlpacity: 8' L, 26' R
Apptox. shipping weight: 342 Ibs. Approx_ shipping weight: 439 Ibs, Approx shipping '>'Itlight: 465 100.
tllCI.IJPrt SHor FOX"
ALl1MACUSSIC- HlICE

G0661
!.7s)SW- SHOP lUX
G0478
SALE .!BW" TOQ!r~
CI.ASMC- HICI

5695 00 SALE
~ 585000 ml!l ONLY '107500
14" Heavy-Duty Bandsaw 14" Industria l Resow Bandsaw 19" Heavy-Duty
~
. .. -..
,
MaiOI'; l Y.> HP, llCJJf120V,
single-j:tJ0S8, me, 1725 RPM ~ ..
.. ,.~
MoIct.2HP.IIOVf22fN,
sirlQl~phosa, THe, 1725 RPM
Extreme Series- 8ondsow
MoIor: 3 HP, 22fN. singlat11ose. lEfC
Precision ground cost iron kltJ.18

-
~ PfaciSlcln ground cost iron table Precision grouM cosIlroo table

-"
Toole ~n; 201'," x 14' Tobie sJZ9; leW x 14'/ ', ' Tabla size 26Y,' x 19' x l'h'
ToOle fill: 45' R IO' t Toble@: 4S R. S L Ctltting cq:o::itylltlrool, 18,/,'
Cu~ifIQ cqXlCitylllroot- 13'h' Mi~ ropocitylllrool 13'h' Max, cutting Ilei!/ll: 12'
Max. clJl1ing .'leight- 6' Max. cuMirxl height: JO' Blede size: 143' L (W . 1'/, ' wide)
o Blade sue: 92'h' to93'h' Blade size lOS' L ('Ii' . '11'- W) 2 Blaoo sp88ds: 1700. 3500 FPM
('Ie' . .y,' W) Blade speed: 3()(X) FPM Approx_ shl~og waight: 458 100
o Cos! iroo wtleels 6' r1l-SGW fence INCLUDES ALUMINUM!?f.SAW
Awox shipping weight, Appro~. sI1ippi!1ft wejght: FENCE AnACHMENT. DUAL
262 Ills 284 Ibs_ BALL SEARING BlADE GUIDES,
INCLUDES BlADE, CASf lOON WHEELS a: FENCE
INClLJOES MAP' III BAll BEARING
DnUXE AlUMINUM ISO 11001 BLADE GUIDEs&' MAOlIM
Ilf-SAW fENCE rACTORYl MITEII GAUGE Ito too 1
&. WO~K LIGHT MAPEl" FAC10m
110 8001 G0514X
G0457 . .
G0555X !625W" FACTORY! ONLY :. ....."""'- ONLY

,
SALE '575 00 mlIiI '895 00
SJ
aCIINICAt SEI!VICE:
~,C'NG Coo 570!>469MJ
q 09WOOOM ~ fllX: &QO43a-5>'01

W"(~~~~\?g~C(1 3 GREAT SHOWROOMS! BELLINGHAM, WA MUNCY, PA SPRINGFIELD, MO __

 , OVEt A MIUlOH SQUARE fEET ~ACKED TO THE RAFlERS WITH MACtlINE~Y '" TOOlS
, 2 OVERSEAS QUAlITY CONlROL OFFICES ST.t.FFEO Willi OUALlRE[) G4!IULY HtGIHEEIIS SUMMIER SALE
GRIZZLl IS GIVING YOU HOT JUST OHI, l1l'i - . - . . . .TOE ... LSI
, ILIGE PARTS fACIlITY WflH OVER ) WiLlIQIrj P,uTS IN STOCK AT All nMfS
REDUCED PRICES! FREE Stll"PING!
- , .......... _-""".
, millED SERVICE TtCHHlClANS.u AU. 3 LOCATlOIIS
eo 10 QRlZlI.f.COM' TO 5& THE fULL SElECnON Of SALE midi
I OOTH 15845 ' MOST Of!{)Ets SHlf'I'EO THE SAME DAY 2' ffOIJR Oi:OEItiNG BY 1'tiON OR OHliHE

15" Planers 8" Jointer w/fxclusive Digital Height Readout

Motor 3 HP, 22fN, s~18-phose
Pnlclsion ground cost iloo laDIes
& ertsMkln wings
TotlI8 SiZI:! 15' x 20'
MID. cuttl~ heigh! 8'
Feed rata: 16 & 30 FPM
C~tJhaod Sj)OOd' 5000 RPM
Bulnin IT'IObIle bose
Mognelk: solely switch
Hoov;.o.fty cost ilon consndion
Appmx shipping weigh! 675 lOs.
G0453
J lJlad9 Cultelflead ONLY t9SOOO
G0453Z " "-
SpirolCuH09rneod ONLY $14950
13" Planer w/Dusf CoIlecffon
Motor: 2 liP, llQ11, s'flgl&-ptlose
Mox. cutting wid1h: 13'
Mtlx. cutting height 6'
Mcu. ClAIing depltl: '/lA'
MAKO
ItO 1001
Moler: 3 HP, 2'XN,
singlephose, lEFC
""""
Precision ~rolJld
east iroo IabIes
TolrII klble size: e ' x 76W
InIEIEId klble siZe: e' x 43* '
".eu""
"numv
.... IlOeQ
4 lOW spiral runertleod
Cuttemeod $pIlEI(I: 5350 RPM
Max. f'ObtleIing depth: 111'
~UX9 cost ~on Ieoca size. fXTiA LONe; INltID TAW
35'l x 1'I,W x 5' H "EXTRA TALL mICE WITH
ApPfOx stllpping WBlght R"CI(" PINION AD.J\..ISWfNT ~
,
iD 5971'" G0495X ONLY $179500 ~
6" Parallelogram Jointers 8" JOinters w/Bulfffn MobIle Base
Molal: I 'll HP, l)OVn2(N, slnglephose MoIor: 3 HP. 2'lf:N, 5 ngJ&.ph'l<;EI. me, 3450 RPfd
CutIMleod speed Precislon gfOlJ"ld cost iron 100Ies size. 6' x 55'h' Pr!!dsloo groood cost Irooillbles slze: 9' x 72'h"
8IXlO RPM Robbelrog oopoci!y: !h' Mox. depl1 01 ell ',i' Robb8Iing CIlpocily: 'h' Mox. do3p/I1 of ell: !Io'
Feed rule: 19 FPM
_HSS
Knives: 2 double--
Cult8rt1eod speed: 4850 RPM
Pttoll&lc9OO1 'lIble odjuslmenl . .
Culteltleod speed: 5000 RPM
Detuxe cost iron Ience SlUI: .""'"
r~"aAFlfY
~x. shipping
weight. 95 lOs
CenI9r rTlOlfi8d 18IlC9
Bumin mobile bose
,, 35' l x 5' H
Buin.in mobils tI(&j """".".
o Approx. shippioJ Approx, shippirlg \WIght: 552 Ibs
IWIlghl: 382 Ills,
INCWO(S 2'1( IJrlCLUOUrm
IAHfY PInK_lOCKS

..
DUST PORT"
COUfCTION MG, G<l604X G0656 ~
SlOE HANDlES KNIFE C>JTTEIIHEIO.O <.
I HJP II' WINGS
~ PORT... BlLlTYI ONLY $65000
SALE
$75000 I
G<l604ZX --'~-
~ORYPR1C,$375O 9
G0656X
ONLY '89500 ONLY '1095'"
12" Baby Drum SOnder 3 HP Shaper I 'h HP Cyclone Dusl Collector
Sooding moIor 1 1~ HP, 110'1, singlephose Mellor: 3 HP, 2'XN. singl&-pOOse wtreversing switch Moklf: I II.> HP, 11 QIIaw, Slngie-phose,
Conl'eyOl'molor: 'Ao HP, 11 OV, singllTphoS4l. Precision ground casl iron loble mc Doss 'F', 60 Her1z13450 RPM
~llIlaDle speed 0-15 FPM TClbIe w/sloollald wing ofIoched: 30W x 20W IntDke hOle !ll:z8: 6'
[)um surface speed: 2300 FP~ 3 lnl9l"chongeob1e spindl9S: y/, ;t,' &- I' ImpellEll": 12'11' sleel
Mcu. stock dlmensloos: 12' wide x 3W Itlick SpiJ"l(]le 1roV91: 3' Suction C(lpocIt{.
Min sIod< Ioogtt e' SpIndle speeds: 7CXXl &- lO,CXXJ RPM 1025 Cf),l 0 2.6 SP
Sending draT! $ize: 4' ,:~~ Spindle ~ings 00 labIe:
SoJnding belt 3' fIoolo; & loop ~. skrt\c pressure, I
HI', 20/,' , 4' &- o'h' ...;.,;:;, (In. 01 ..wier): 10.3
WOx. stlippmg Approx. stliPPiflll Filter: .022 microns
'MJighI: 160 100, weigh! 307 Ills (99% flfllci&nCy)
Filter soooce wee:
INCI.I.IOtS M~GNrnc
POWER SWITCH. MITER
96 sq, n.
GAiJGE. fEJoK:E wm; o Collectton tIrm1:
HQU).[)()WN SPRINGS 35 gal , sIee!
"Wrox shippif"rij
weighl~ 313100.
GI026 j9~

ONLY '92500
 PROJECTS
30 Limbert-style Arts & Crafts Table
14 Super-simple Shelf/Towel Rack
47 Great Gift! Tlipered Music BOI
56 Router Table and Organizer
66 Desktop Printer Stand
70 Quick Jig: Fuce-ridin' Saddle Jig
SKill BUILDERS
18 Suuess Secrets for Applying Shellac
22 Challenge Skill: Cutting Beveled Tapers
16 Safely Rout Rabbets on Narrow Parts
38 On the (over: Tips from Norm
SO Rout Perfectly Matching Hinge Mortises
59 How to Install it Router-table Insert Plate
TOOLS (,{ MATERIALS
24 4 Ways to Rev-up Your Router Table
26 Pick the Perfect Table-mounted Router
52 Great Substitute Wood Products
Theft'! mOf~ to lif~ than oak, pint, alld plywood. Uk!
thr~! IIf'W(OmNS, far I.'.ampie.
S4 5 Problem-solving Hand Tools
62 Tool rest Rail-guided (ircular Saws
76 Shop-Proven Products
Tilt new Unisaw and more.
DEPARTMENTS
6 Sounding Board
8 Shop Tips
72 Ask WOOD
88 What's Ahead
 1 '---
__S",eP",te",m",b",ec..'",20",O",9_~ _ issue 192
- on the web - woodmagazine.com

POST A PROJECT, PICK UP A PRIZE!

Bullt a project you're praud ofl
Upload pktllres of It to one of
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ONLINE PROJECT CONTEST <ltleast $1,000.

FREE VIDEO:
TEST YOUR
OWN JOINTS
You don', need high-tech testing
equipmeflt to learn if your joinery
methods are sound. WOOD Tube
user Todd Clippinger(rlghr) shows a
super-simple method at
woodrnagalioe.(omilestyoufjoints.

2 BUCKS TO A
BETTER SHOP
Find downloadable plans for nearly 100
jigs, organizers, aoo other shop helpers,
such as the folding work table alright. for
only $1.99 eilch. Visit the WOOD Store at
woodmagazine.(om/store, and dKk on
~WoodwoJtlng P\ans,~ then ~S2 Tuneup\'-

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3
 !I01BANNIVERSAItr HOT NEW '"
machines are bKM<:I
by ~ 2 Year Warranty!

f~"---2-1-.-5-HP
---B-A---
ND S-A-W~~~~~I~~~
WOODSTOCK
SLD)
INTE R NATIONAL, INC.

~~lN~G
~T~AB
1989
~LE
2009
~S~A~W~~'.##'
MACHINES :.
FOR 2009~
~
r
I
,..
,..
,..
with Foot Brake
5 HP, 21{1V, single-pha~ THe motor
Precision ground cast iror! table
Table size: ltW.. W)( 29'h' L
..
,.
with Scoring Blade &: Riviag Knif
,.. 5 HP, 220V, single-phase. TEFC motor
Table size with extension wings: 40" W x 47' L
Sliding table size: 12'/. W)( 63" L
,.. Max, cutting height: 14' ,. Scoring bladedia.: 31,i'

~ ,.. (utting capacitylthr~t: 20" ,.. Scoring blade arbor

speed: 8,000 RPM
,.. 8ladesize: 165'L('I"-1 ~' W)
,.. Main blade arbor
,.. Blade speed: 4,600 FPM
speed: 4,000 RPM
,.. Deluxe cast iron fence with extruded
,. Single lever locking
aluminum resaw fence attachment
renee
MADE I~
WI770 21"Baodsaw ISO tOOl W1811 10' Sliding Table Saw
FACTORY!

18" OPEN END VARIABLE SPEED

WIDE-BELT SANDER PlANER/MOULDER with Stand
,.. 2H~ 22{lV, ~ngle-phase THC motor
,. 3 HP, 220V, singlephase, 1,725 RPM
,.. Precision groond cast iron table and
THC sanding drum motor
infeed & outfeed extension wings
,. Variable speed cooVyor feed rate
,.. Cutterhead speed: 7,fYX) RPM
,. Sanding drum speed: 1,850 FPM
,.. 2 HSS cutterhead knives

..
,. Rubber sanding drum dia: 4"
,.. Number of cuts per minute: 14,000
,. Pneumatic belt trocking
,.. Pedestal mounted control switch
,. Spring belt tensioning system
with variable speed coottol
,. 2 steel pressure rollers
,.. Dovetailed way with precision
.. "n ,. Amp load meter
gib adjustments
WI8l3 lB" WideBelt Sander W I8 12 Planer/Moulder

SPIRAL CUI'TEIlIIEAD PlANERS SPIRAL CUTTERHEAD JOINTERS

with B.w.t-iD Mobile Hue witla Par.Uelogr. .. Adjustable Bed.
,.. llOV or 220V, single-phase, TEFC motor
,. 3 HP 01 S HP. 2m, Single-phase motol
,..Precision ground cast iron table
,. Predsion grooOO cast iron table &
,. German"made carbide Insert spiral cutterhead
extension wlr\9s
,..Quick adjust levers
,. 2 speed gea r box
,. 2 adjustable bed rollers
,. German-made carbide insert spiral
cutlerhead
>- large center mounted
cast iron fence
~ Pedestal mounted
safety switch
~~
~
.
.~ . . .,- - -
,. Pedestal mounted thermal ov~load ,. 8uiltln locking mobile base
magnetic safety switch (WI7SSS &W1741S)
,. Built-in locking mobile base
WI7SSS 6',1 Y.! HP Jointer
WI742S IS' Planer Wl741S 8",3 HP Jointer
W1754S 20' Planer W l744S 12', 3 HP Jointer (does not include the mobile basel

VISIT OUR WEBSITE OR CA LL TOLL FREE TO FIND AN AUTHORIZED DEALER NEAR YOU. 11265R
 woodmagazine.com
September 2009 Vol. 26, No.4 Issue No. 192
EDITORINCHI(F
BIUKRIER
Managing Editor Deputy Editor
MARLEN KEMMET DAVE CAMPSELl
Art Director Sffiior De>ign Editor
KARL EHLERS KEVIN BOYLE ._._-
TedmiqlJe!; Editor Tool Ii; Technique! Ed itor
808 WllSClfII BOB HUNTU
Mu l t i m~ia Editor Mullim~ia Edilor
LUCAS PETERS CRAIG RUEGSEGGER Kevin crl"Jted this
chefT)'Ire,lle table
Design Editor Mwciate M Oire<;lor using mortise .... nd
Jeff MERTZ GRfGSEUERS t<!noo joinery.
leN designed and Pl'OOLKbon/Offi<:e Man.oger Adminislrl~V<! Mlillanl
buil\ this ",ua~rsawn MARGARET (LOSNER SHERYl MUNYON
white oak des!< for
hi' wife. f't1ot09raphm
JASON OONNEUY, scan umE, JAY WILDE
Conlributing Illustrators TIM CAHILL. LORHAJOHNSON, ROXANNE L.MOINE
Tedmio:al Comultan~ JEff HALL DOUG HICKS
Contrioolill<] Cr~ft\tl1an JIM HEAVEY
COf1lributing ProoIread~rs BASS KLEIN, IRA LACHER, JIM SANDERS
SUBSCRIBER SERVICE
Go la woodmaogazine.com / helJ' Of write ta
WOOD magaz ine, P.O. Box lH19, BDOr'le, IA 50037-0439
,
i i ,I
M.,n,eting Manager AMANO" ~LHOOT
Adv~rming Ma~r JACK CHRISTIANSEN
A.:coont hewtive RYAH INTERLANO
Mdrk built this Direct Respon~ Adwrti>ing R~prc""nla~"" LISA GREENWOOD color. hardwood
I'Idfnut jt'welry Assistant TIM BAARDA floors, woodwork 11m wood, metal Of
cabinet for his ATLANTA: Na<ig~le Me.Ji~ fiberglas~ door~.
daughter, Wlwn DETROIT: RPM A>\OCi",~<
(Imed, it doIJbles C~lSh~1I Thnology provides the deep
J.\ J night5tand. Sminels M imag~r
JEFF STILES tones of lin oiJbased stllin with the low
Coosum~r M.m:~till<] Direclor TODD BIERLE odor, fast drying and easy clt'anup of a
M\.OC,ate 0;1101" or Mark~tin<:lNewS>tand TOM DURING waterba sed stain.
Pl'oduniOl'l Mana~r SANDYWIUIAMS
In add ition, the Advanced GtHn Pha$e
Adve<tiWlQ Oper~tklll~ ManagM JlM NELSON
ECommem. MJMgfr MATT SNYDER
Resin Dispersian T<!chnalo91 utilizes
environmentall~ friendly resins that
Vile PreOOeotlGroop f/I.,blilhN TOM DAVIS result in a VOC comp liant product.
MERED~ PUBLISHING GROUP
With it> delicious new (Olors, Ultra Max
~residentJACK GRiFfiN
Wood Stain gives ~ou II great look th at is
Executiw Viu Pl'e<id<!nt DOUG OLSON also good for the environment.
Chief R..... ~n"e Offker TOM HARTY
Finaoxt &. Admino$lrJtion MIKE RIGGS
Manufa.::turil1g BRUCE HESTON
COl1!umer r-.hr'Qting OAVIO B"U
Corporalf Sale.! MICHAEl BROWNSTEIN
Met'edith J<50" JEANNINE SH"O COWNS
Interactive Moo;'" LAUREN WIENER
Corpor~te Marketing N"NCYWEllfR
R~'Mrch BRITTA W"RE
Chief Technology Office!' TINA STEIL
New M~i~ MJrketing SO!rVic('s ANDY WILSON
Direct Re>pO<'l~ and Travel PATTI FOLlO

I're~ident ~rId Chief EKe(utiw OtIi<:el STEPHEN M. LACY

Chairman of tht Board WILLIAM T.KUR
In Mtmoriam E.T. ll\ef41dith II I 1193)-2003)
Our subJ(riben list il ocu\ionally made a\'ili lable to '~re4"ully lel<!c\ed
firml who,"" products m~y 00 of inlff<'st \U you . If you ptd"er not 10
receive information from t~se ,omp.ni~ by milil or by phone, ?e.~
1<'1 U5 know. Send your request along with yoor mailing label to Maga.rine
CUltomt'f SerYice, PO !lox JH52, Sooow, lA 500370452.
(; {opJrighl MortditJI torpoltliotl2009. All n~ rtwr'ltd. PT1ntlHl lll Ult U5,A.
~ ,UOiI Silt!
aelMftn IMI order C09It:! of WOOD flH rt:I.Il~
.,. ~""' ilifl'jj ..... ~.,.b""""..rd]lh.1MI
woodm.g.llne.c:om
Sounding Board _
OUT bulletin board for letters, comments, and timely updates

nSlplioes new home for jewelry

Thanks for the Index

Thank you for reinstating the annual
article index in issue 188 (December/
January 2008/2009). That listing of
articles has proven so helpful to me
over the years. Because I don't have a
computer, I'm not able to use your
online index to search for articles.
My adult daughter recently asked me to from red oak to match her bedroom set. -Elwyn ~It Radford, III.
hulld her a jewelry box to replace her 1 modified the design slightly, adding
fa lling-apart store-bought one. After wooden drawer glides and a beveled
thumbing through myoid magazines, frame around the top for a catch-all. Article updates
she decided upon the Shaker-style valet Naturally, she loved it. Thanks for the Issue 189 (March 2009)
on page 41 from issue 188 (December! inspiration! For the Shop Tip on page 14, the
January 2008/2009). I gladly made it - Ron Dudtl5ton, Hafftord CifY, Ind. spacer must equal the length of the
hinge minus the diameter of the bit, in this
case a 1/." spiral bit.
hsue 188 (I)cccmber/ January
Toy crane proves a big hit with the kids 2008/2009)
When 1 saw the toy crane Underwriters Laboratories (UL) has
project in issue 185 (page moved up the date for manufacturers
68, September 2008), [ to comply with i1$ tablesaw riving-knife
Immediately noticed that requirement. As a result, aU tablesaws
its scale matched my manufactured after Jan. 31, 2010 must
G-gauge electric train set include a riving knife in order to get Ul
approvaL
and several toy trucks I'd
made some time ago. I
built the crane, and it Please work safely
was a resounding hit In order to show you precise details in
with kids visiting at photos, we trequef'ltly remove safety
Ch[istma .~ tIme. They guards. In your work,. be sure to use all
dove right in and started ~fety deviCes, as well as wearing vision
playing. and hearing protection.
-Mike Eff~, Crofton, Wis. - WOOD mogoline i!1itoo.

HOW TO REACH US
F~ tdYit;r.
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onlinf forums ~t woodll\iguinuomtforumi.
To contMt Ivr Hit",:
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Updates to ~sty published p~
For an up-Io-<lale listing of changts ~ dimemions
and btJyin~- guidt SOIJr(ts from issut 1 thlOU9h today,
go to W<MIlImagulnf.(orn/fdltOrilil.

6 WOOD m~8l.tne Scpu.'mtx'r 2009

Shop Tips
Helping you work faster, sm arter, and safer
Flawless flutes from a rail-riding router
The Federal Bookcase p roject from
WOOD!!> magazine issue 131 (March
2001 or woodstore,net/fedbook.html)
inspired me to flute t he columns o n the
fireplace sur round J was building for
my new house. Because I didn't have a
router edge-gUide to m ake the fluting
jig in the article, r came up with my
own solution shown here.
I m ade the entire jig out of material
from my scrap bin. I placed the gUide
cleats on the bottom so they slide easily
along my workpiece. (They can be
removed and reattached with screws for
different-widt h workpieces.) Steel rods
slide easily through the edge-guide
sockets on my plu nge router. I t hreaded
8 W OOD milOgnlnt
Top Shop Tip
one end of each with a die, and secu red
them to the fluting jig with lock nuts.
The router rides along the rods and
secures in place with locking screws. I
marked the centers of the flutes o n the
rod with a felt-tip pen and aligned each
mark with the centerline m arked o n my Woodworker Jon Norman has a dream
routcr base before routing t he flute. The shop. For an auto mechanic, that is.
stop blocks damped to the ends of t he The full complement of mechanic's
workpiece em ure the flutes are all the tools he inherited includes everything
from wheel balancers to transmission
same length . The two columns came jacks and take up mmt of hb 30x40'
out perfectly matched and dressed up shop. He's carved out a space for his
the fircplacc surro und beautifully. woodworking too ls, though. And he
- Jon Norman, Heooerlon, ftxUl put them to good use finishing the
house his uncle helped him build.
For sendi ng this issue's Top Shop Tip, Jon
will receive a Delta 46-460 variable-speed
midI-lathe . That sho uld help skew Jon's
shop toward wo od working ag ain!
Top tips earn tools!
Tell us how you've solved a workshop
stumper. If we print it, you'll get $100
and a copy of 450+ Best-Ever Shop Tips
(woodmaga.line.com/450tips). And, if
your idea garners Top Shop TIp honors,
we'll also reward you with a
tool prize worth at least $300 .
Send your best ideas, along
with photos or drawings and
your daytime phone number,
to: Shop TIps, WOOD
MagaZine, 1716 Loc.ust
St" LS-221, Des Moines,
IA 50309-3023. Or, by
e-m ail: shoptips@Woodmagazine.com .
Include your contact info in the e-mail.
Because we try to publish orig inal
tips, please send your tips only to
WOOD3 magazine . Sorry, submitted
materials can't be returned .
continued on f'ilge 10
Sept~mb<:r 2009
 The
acretTo
Flawless
Edge
les
With
NO

.....'c"'-. How It
- Works!
co..:v
 Shop Tips
A hole new way to
store loose screws
I'm sure I'm not alone in having a large
assortment of screws in my shop. Here's
how I organized them: I laminated four
pieces of V..,.16x16" plywood. Then, I
drilled a grid of 3" holes at the drill
You oorl"t need an army of clamps to get
the job done; you juSt need the right ones
The Kreg Klamp Table"" is the ultimate
'helping hancf around the wOfk shop and
the ea~ie'St way to get perfectly flush
PocletSCrf.'w Joiflts, one after another.
VEISITIlE WlBU1lITIOIl
Carriage-bolt clencher
If you've ever had a carriage bolt slip
when the square collar tears out the
wood grain, here's a ~olutlon for you.
Clamp a steel bar or a flat tool wrench
_.kreUlDDI.CDm 1800.441.8638 10
press using a hole saw. Finally, I glued a
piece of hardboard to the bottom, and
once the glue dried, I filled the orga-
nizer with screws. Mine fits nicdy into
my workbench drawer, keeping the
screws close at hand.
-/~ IkImtm, Calgary, Alto.
1'0" plywood laminated to 3" thkk
(or a rasp if it's really stubborn) over the
bolt head, as shown. The friction on the
head gives you enough grip to finish
tightening or loosening the nut.
-Richard Wood, Applwn, Wis.
cOlllifllled 011 page 12
 Magazine's

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SLtlject to Official AoJot1 at WWfj.'o\'OOdf1laOalI!le.comfslloWdoWn. 110 ~tliIse necessary to lief 0( '11111. To ent8r, visit wI'M.WOOdrn!l<}alt)e,com/sIlOWtIown, eomplete t!le rogistr.JtiOI1 form . tIltn tallow
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Shop Ti[lS

Transform obstructions Into shelf space

Compo\mding the problem of my basement shop being too
small, its floor is dotted with jack posts supporting the floor
joists above. But [turned the problem into a solution with
this post-mounted tool platform.
The collar (A) holds the platform at the preferred height.
Once secured, I rarely. if ever, move it. Clamps (8) and (C)
allow the platform to swivel around the post. Tightening
the knob on (C) locks it into position on the post. The tool
platform itself can swivel on<-1:': you loosen the center
hold-down screw.
-Jim Murphy, Perth, Ont

.i.
Tool platform @
All parts
'A' plywood;
;. pam A, B, C, and 0
aretwopieces

.. ... -
lam inated together.

v.":W round knob

0===
'I." carriage bolts
5" long
-.
;d' . .. ' . - . . - ,.
... - * Hi" -fa

l . . .... ... . =-.. ._.

...
-. ," _"
""

All carriage bolt$ a re Yo . 3'11"

e.cept the three S bolt$,

.... ,, -'
.. -. A--' ,.

continued on page 14

12 WOOD magazin e September 2009

 INTRODUCING OUR NEWEST SAW

Go to sawstop.com/wifeapproved and we'll send her a persuasive

inlormalion kil, including a OVO thai will close Ihe deal.
Easy-change
chuck-In-a-chuck
My d rill press has become much
easier to use thanks to a keyless
chuck I salvaged from a dead cordless
drill. After removing the chuck from
the cordless drill, I simply threaded a
%",2';"" steel bolt Into the v." keyless
chuck and cut off the head. The bolt
chucks into my drill press, making
bit changes a breeze, especially for
small bits. As an added benefit, when
I change betwe<:n small and large
bits, I don't have to raise and lower
the table height to account for the
difference in bit length; I simply
remove the keyless chuck and insert
the longer bit.
-Mart Albrecht, Cody, Wyo.

For a
Daily Shop Tip
visit
woodmagazine.com/tips
 Sj1!!p Tips

Multl"tasklng tablesaw sled

I saw nUll Mulliki n') Shop Tip "s..crifi -
ciaJ insert saves sled's integrity" in the
November 2007 issue (no. 180). which
prompted me 10 send in my version,
shown here. YI It 1111 It ""r,",,,
As w ith Don '~ design, my .<;a(.Tifida l 16x l'Ac" F.H. t-~Y
insert prolongs the sled's life by allowing
me to replace- the insert when it gets
chewed up beyond repair after making
bevel or dado ClitS.
[ took the idea a step further, however
by giving each insert a different job. The
one shown here dol"S 45 miters, but J'vt'
alw got an insert for crosscuts, one for
dadoes, even one for cutting box joints.
- William Ktnntdy, 51. httrlburg, Flo,

cQntinl/ed on page 16 ~x Yo" miter-gaugc runoer

15

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 Shop Ti~

Superior dowel
V(sit your local Woodcraft store today where center f inder
you'll find dozens of uses for our professional To find the center on the ends of a
grade Square Drive HIGHPOINT ~ Extra Torque dowel, I made my own center
., Flat Head Screws. finding tool. shown below. With the
.

.~

-'
-"-
HIGHPOINT Xt- Rat Head
Screw Assortment Kit
We"ve gatllered a complete saoPlete
dowel resting in the V's, I rotate it
against the point of a pendl inserted
into the pencil rest. As the dowel
turns, the pencil traces a circle
set of our most populal" uflIlCated SCieJS centered on the dowel's center.
We added tho driver bits and !"land dllve~ By raising or lowering the pendl
you"11 need and packaged lnem all in a r('St, I can dial in dead center on any
durable Cllst()ffiIZ<ltlle USAm8l!e case dowel, hut I find a small circle
Here"s a greal opporturuty Iu stock up on adequate for drilling or chucking lhe
sizes vou are sure to rleel:L
dowel into my lathe.
Each assortmIInt cantalns (2)'1 x 2" and -Mark Ostrom, Linditrom, Minn.
(2).2 x 2" DrlVllf Bits al\d ~1 and #2 Hand
!)rivers, and (50) ~~h of the following
16 Sizes sizes: 116 in Y:!", '1/;" and 1y;" lellgths: .8
"~"1 " "IY.",lW"I~,2" 21'<" 2li"
800 Total Screws 3" lengths and .10 in 1)la"" 2", 2W,
3" Ier.gths

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(actual ~I:z:e)

,6 WOOD m lt!loulne September 2009

May you r clamp exceed your grasp
My hand strengt h is not what it used to be, making it hard to
tighten clamps. So I applied the force of my mind to the
problem. I simply drilled v." holes in the handles of my
clamps and glued in short dowels. Now I've got leverage and
all the clamping pressure J need.
-KMnnh Gibbs, xMIlJburg, Pa.
Eliminate crank-handle crankiness
My auxtliary drm.press table adds a lot of surface area for
better stock support t han the sma ll factory-supplied table.
But It's so large, every timE.' I wanted to raise or lower it, 1 had
to slide it away {rom the tablee1evation crank in order to
turn the handle-frustrating to say the least.
I fi xed the problem by replacing the crank with an old
socket, which I had drilled and tapped to accept a setscrew.
The setscrew location corresponds with the fl at part of the
crank shaft and locks it into place. Now I simply use a
ratchetlng socket wrench to raise or lower thE.' tab lE.' .
-(onc~ Ofti" Siotu City, Iowa

17

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Finishing School

Shellac:

or a centuries-old finish, shellac I Mix your own finish shellac color, the more care you need to

F offers plenty of modern benefits: It

dries quickly, doesn't darken with
age, produces few odors, and you can
i To mix sheJJac from flakes, first decide
on a concentration (called a cut)
matched to the job you're doing, as
take because dark. sheilac, like stain,
collects in and highlights scratches.
A cloth pad makes applying a 1- or
repair damage in a jiffy. But its onc- shown In the charts at right. For }1.1'z-lb cut of shellac nearly foolproof.
time popularity faded for a reason: Fast example, 3 lbs of shellac flakes in one Each wiped-on coat goes on thinner
drying reduces leveling. Also, it suffers gallon of denatured alcohol produces a than a brushed-on 2 or 3lb cut, so you
a shorter shelf life and takes a back seat 3-lb cut of shellac (the cut used for may need more coats. Also, wiping
to poly's resistance to abraSion, heat, premixed shellac). You can thin works best on flat project part surfaces
and spills (especIally alcohol). premixed shellac for different jobs, too. finished separately before assembly
Despite that, shellac beats polyure- Flake shellac deteriorates about six because you don't have to worry about
thane as a rubbed-out finish that can months after mixing, so make only finish becoming trapped In corners.
pop the grain on such woods as walnut what YOll need immediately. Flakes To make an applicator pad, wrap a
and mahogany as it leaves a wafrn dissolve best when ground into powder tightly-woven, lint-free fabric, such as
color. And that's only the start: IPhotoB, page 20], and mixed with a an old linen handkerchief or washed
A thin wash coat keeps stain from fresh, unopt'noo (:3n of denatured
blotching such woods as cherry. alcohol. Allow the shellac to dissolve A cut for every job
It S('ais resins in pine. overnight; then pOll! the mix through CUT USES SHElLAC
By adding universal colorants, such flnc cheesecloth or a paint filter to light wash coat fOf
as Mixol or those used hy paint stores, strain debris and lumps [Photo c:, page ,/z-Ib controlling blotches
, 0'
you create a colorful, semi-transparent 20). Label and date the cut. Medium wash coat,
o-Ib airbrush sprayer l1f1 Ol
finish [PhotoAj. Or mix in alcohol-
based dye for a tinted shellac finish. Make application easy l-Ib
French polishing, , OZ
Prepare the wood for finishing by touch-up sprayer
Choose flakes or premixed sanding up to 220 grit. The darker your 11/:-lb Wiping, paddinq 3 Ol
Shellac makes such a ver~tile finish 2-lb General finishing, 40'
partly because you can alter it to fit brushing on
your needs. Want to deepen wood's 3-lb Se<lling knots, s~p; 6",
natural color? Shellac flakes vary from brushing for
garnet to orange, amber, blonde, and
the mo"tly clear super-blonde. . experienced users
MIX thiS amO\.int of shellac (by weight) to one
pint (160.') of alcohol.
Do you value control or convenience?
Mixing shellac from flakes opens up
more color optiom, lets you control the
Customize canned shellac
thickness of the shellac, and guarantees CHANGE ADD THIS TO THIS
freshness. Premixed shellac saves time, IN CUT ALCOHOL SHELLAC
but it's more limited. For example, 3lb to 2 lb 2 parts S pa rts
premixed Bulls Eye Shellac contalm 3lb to ll b 3 parts 2 parts
wax that makes It unusable as a sealer 2-lb to l -Ib 1 part 1 part
under polyurethane. SealCoat comes Zlosser premlxcd shcllac equals a 3-pound cut
de-waxed, but produces thinner coats Adding Mlxol t4 oxide red and '10 red to a whill! the sealer equals a 2pound cut.
than Bulls Eye Shellac. (See Sou rces.) quart of SealCoat makes a translucent finish. continucd 011 page 20

18 WOOD m l g n lnl Sfoptemb!or 2009

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Flnlshlng School
T-shirt, around cotton batting or a baH
of wool the size of a golf ball. Then
pour enough shellac into the inside of
the pad that it starts to moisten the
outside cover wUhout dripping.
Beneath a light angled to reflect
finish flaws, make long strokes across
the wood. Wipe outward from a moist
edge without going over the same area
repeatedly. As the pad dries, replenish it
with more shellac. If the pad begins to
harden, add alcohol to soften it.
After 4S minutes, sand tl1(' first coat
lightly using 220 grit. Apply additional
coats, but now walt at least an hour
between them before sanding.
If the pad begins to drag while
applying more coats, that's the wet
shellac partially dissolving the coat
beneath. To minimize that, wipe a strip
on once and move on. Unless you apply
too much shellac at once, you won't
leave ridges on the work surface from
the edges of the pad. Four wiped-on
coats should do for most projects.
[]
Brush In a rush Grinding flakes to a powder {left) helps shellac dissolve in denatured alcohol, leaving fewer
After you get the hang of brushing on globs on the bottom of the Jar.
shellac that dries In minutes, not hours,
applying polyurethane will fee l like FINE HAIRS LEAVE FEWER RIDGES
moving In slow motion.
Start with a natural-hrlstle brush.
Traditionalists prefer hadger hristle, hut
any brush with fine, natural hairs will
do. Fine bristles, like those on the brush
shown [Photo 0 1, leave a surface that
levels within shellac's rapid drying
time. If you're a shellac newbie, use a
I-lb cut for the sealer coat and a I1h-lb
or 2-lb cut for topcoats.
Instead of brushing back and forth as
with poly, lay down shdlac in one pass.
Make long stmkes out from a wet edge.
If you see brush strokes on a dried coat,
thin the shellac until it levels off before
drying. If you miss a spot, keep going
and catch it with the next coat.
a brush leaves . gllp-free
Allow the sealer coat two hours to body of this brush leaves len to sand than
dry in a well-ventilated area before synthetlcbristle paint brushes.
sanding with 220-grit. Then wait two
Allow shellac to dissolve onrnlghl In alcohol;
hours for each topcoat to dry, and sand then strain II through cloth or a medlum-
away mistakes or brush marks. mesh filler to remove lumps and impurities.

Take a shine to shellac surface between grits with mineral Sources

Before rubbing out several coats of
shellac, give the finish at least two days
to dry in a well-ventilated area. To
begin, level the surface by sanding from
320 grit up through 600 grit using wetl
dry sandpaper lubricated with mineral
oil to prevent clogging. Clean the
spirits and check your progress.
For a high-gloss finish, sand up to
1,500 grit. Then polish the surface with
an abrasive, such as rottenstone, in
mineral oil or an automotive buffing
compound (available at auto parts
stores) and a stiff-backed felt pad .
Premixed shellac:. 8ulls E)'I' St\e11iK (dear Of al1'lbe<)
or S.ealCoat. U1S~ CO, D~.com. Available at nome
cen~ ~nd hardwar@SlOft!S.
Shelll' fllke,. SoperbIonde('S22.7{W1b),amoo
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20
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our information kit including OVO!

1-800-995-0221
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Make Short Work of
Long, Beveled Tapers
Compound cuts may feel more like geometry than joinery.
But our easy-to-make jig eliminates any complex math.
B
evel~ and tapers go together like
oil and water if you spend too
much time worrying ab<'lut the
math. Even aftel you figure all the
angles using sophisticated cail'.liatiom,
you'll sti ll need to translate t he math
into exact saw ~ttings fullowed hy test
cuts. Good luck with that.
For a nomath approach. USP the
si mple jig like the one we created 10
make the be:vded and tapered sides of
the Limbert-style table on pagd2.
Build a custom tapering Jig
Unlike some jigs, you'll tailor t his one
to suit your project part sizes. First cut a
tapering-Jig base from flat sheet ~toCk,
such as medium.density fiberboard
(MOP), 8" 10nglo'r ilnd 2' wider t h an the
22
blanks you'll taper. (For t h e 13)(28"
pan els Oil t h e Utnb ert-style table, we
cut the base 15)(36".) Then, from scrap
about !/to" thinner than your test pieces
or p roject parts, cut four 2x5" hold
dowm and stopblocks for the ends of
the workpiece and a J Ihx24~ stopblock
for the long edge. (For other projects,
cut t his stopblock 4' shorter than the
edge being tapered and b~vded.)
Next cut four workpiece blanks and
four MDF test blanks v." oversize In
width. Mark the outside width of the
narrow and wide ends of the prol~
part centered o n one test blank. Now
follow the six Simple steps shown In the
photos to cut the beveled tapers. For Bevelcur one edge of the base to 45.
more information on the jig, go to 1 (Vou can 3dju ~ t
the bevel angle later, if
woodmagazinc.com/beveledtaper. necenary.) Then set the Jig base asIde.
WOOD m.gnlne Septemb.er 2009
 ~ROCKLER
~

Create With Confidence

Stock up for your

next project and
SAVE $10
eenter Centerlhe test blank along the length of
2 outside face of II test b lank, and marX
the ends. Then use II combination square or
3 the Jig base, and align the bevel marks
with the beveled edge ofthe base. Before
sliding bevel to transfer 45 bevel liol's on the installing the stopblocks, mark the stopblock
blank ends. tNlgl!s that will butt against the test bllln k.

4 HOId the long slopblCKk against the test
blank edge, and screw it to the jig base.
Then add the end stops and hold-downs.
With the j ig In position ilgainst the rip fence,
make the fltst bevel cut on uch lUI blank.
,
5 Remove all tlUI~estops, and turn the blink
end for e nd . Align the bevel marks on the I $10 Savings
ends of the lest blank with the beveled Jig
I I
edge. Reattach the long stopblod< against
th e beveled edge.
I
Certificate I
'10 get $10 off a $30 ordu, simply
Now see how you did I place yo ur order :n Rockler.com I
To test the results of your jig set-up, by entering promotion code V9328
tape together the fou r completed test I at checkout or call 1-.800--279-4441 I
parts and check for gaps along t he
miters. For the Limbert-style table, a 45 I
and use code 943.
0.- bt"-I_ '" ...........__ ....... J"'U-Otooo-tiono
I
angle leaves on ly a tiny gap on the
I
... ~ 1'1'_ purd>uo of $lOin ~ .......
~~c........bo~""""'''''''''
.............. Noa<ll . . ., C-'OOt>o _ _ _
I
inside corner of the joint that can be
filled wit h glue. More important, this
I
JI4IO"'._"'
oIIot'I .. 11.0<_ ..... """""" O<oIJ.No< I
angle Crt'att's a tight fit on the outside _ ~ <00II, LoiC!l"". ""'_CUI.
........ ~ ............... Ioa ....... b<koCla ....
~ !ItS.
corners where it matters most. I ~ CNC. FtROal ..... I\<>ddtr
Olf~r
c...
GW!
U plnel .oonoo.
I
If you see in side corner gaps greater
than 1116", decrease the blade tilt by a I I

6 Reattac:: h the end stops i

with the same end-stop edges against
the test blank as before. Then rip the second
half degree, tape a ';""-t hlck spacer to
the long stop, and recut t he beveled jig
edge. Then rip new bevels on each test
blank, and repeat until you achieve
tight jOints wit h no outSide gaps. Now
repeat the jig set-ups, and cut your
--- 4
1111111111111111111111111111 11
60000 0 0037

For II stort near you or

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-- --
8 I

bevel on each U~st blank. project parts . ~,

~ Radder. com 1-877 -ROCKlER

woodmagulne.com 23
Since 1954
Wise Bu~s
Rev up your router table
start with ill musl-have: ill good fence. It's essential for accuracy. dust collection, and
safety. I realiy like this WoodpKkls fence because. for $13S. you get everything you need:
tall fence plInels, l-slots, II dust port that actually fits my shop vacuum, lew-ling screws to
keep the fence square to the table, shims for offs~ Jointing. and II see-through bit gUiilrd.-

Ke-vin Boyle,
Senior Design Editor

I
I

"1 always have extruded aluminum And they appeal to my frugal side: All of the
T-trac k on hand b~ause I build ill hiudware (miter bars. T bolts, etc.) comes with this
ton of Jigs.It'$ SO versatile. And I model to use in All those setups- and it stili cosu 11'1$
wouldn't own ill router table without than buying two single mode ls!-
It or combo trICk. bKause they'n!
ideal for guidi ng ilnd SHuring these oal/I' Campbell,
lC(essenes: feather boards, stops, ol'puty Editor
w l ety guards, and ill miter gauge. The
(ombo tra<;k {miter U-channel and OuaIITandem Feather Boird . 1407, S3O;
T-slot slde-by-sldells perfect because Mu tseraft 8-476839200. ml lescrift.com
III those accessories work In It. Trust
me, buy exu.. lengthS of both-)'Qu'li
find yourself using It for a lot more
than routing .~

Jeff Mertz,
Otilgn Editor

)6' r.r,ac!I. ~71 , $16;

\
32" Combo TT.ad!Miter Tract.. t98S9. $25:

"F(M' years I used a fixed-base ,outer in my table. and every time

I rotated it to adju,! Ihe bit height the power :l.witch rotated 10 a
new spot. I was always fumbling under Ihe table trying to locate
th .. t switch. Then I tried this auxiliary power switch, and It was like
when someone inl/ented the automatiC bread slicer: Hallelujahl
Now I control the power without reaching below the table. I'll
n(>Ver own another router table without an auxiliary switch.

Bob Hunter,
Tools 8t Techniques Editor
Sa/tty Powef Tool Switcn. '~09;S. 530;
Rockier, 800-279-4441, rocklar.com

,.
 ---
s Ways to Beef it Up
Plan DP-{I()456 S7.95 Plan
Tool Stand
OpOO5n $4.95
Plan OP-00239 $5.95 Plan DP-00098 $7.95 & Roumg Cenl2r
Plan DP-00271 $8.95

Download any of these woodworking plans for the prices listed, or view a larger image, at woodmagazineOmiplans
To have paper plans mailed directly to you (add S3 per plan plus S+H), call toll-free 888-636-4478.
Please have your credit card available. WOO909

-_
---_
.... _- ..._......_----_
- .. -_ .. ...
Router Clinic
The Perfect
Routerfor
TableM
Is there such a thing?
We found three that fit the bill.
lthough you can mount nearly any handheld router
A upsid{' down in a router table, some are hetter suited
to this line of duty than others. For example, many
routers now sport built~i n lift mechanisms that you crank to
ad just bit heights from above the table, as shown at riXht.
without removing the router or reaching below the table.
These routers typically require an extra hole in th(' insert
plate to operate the lift mechanism . But beware: With some
of these routers you still have to reach below the tabletop to
lock the coliet, negating half the benefit of a lift.
H you already have a router you like and don't want to
upgrade, you might be able to get the same convenience by
installing its moior in a router lift. These units come
attached to insert plates with adjustment mechanisms built
in, as shown below. Keep in mind, though, that with prices
ranging from $175 to $450, a lift m ight cost more than a
nt'w router. Router lifts speCify which router models wil l fit,
and some require adapters.
A router 11ft, shown out of the t able, ra l~e s the router fully so you can
change bits above the tab le with out ang led wren ches.
A good table -mounted router makes bit
changes hassle-free. An angled wrench
to hold the sp indle sure helps.
You should also look for a router with variable speeds so
you can slow it down for large-diameter bits. Another
essential feat ure: eledronk s~ed control, which maintains
rpm~ when the routing gets tough. A 3-hp motor really hogs
away materia l, but a midsize model (Hi to 2lA h p) will get
you by if you taker lighter culS.
When mounting any router in a table, position it so the
variable-speed control will be easy to reach, becau~ this
cannot be cont rolled from above. Add an auxiHary power
switch to avoid reaching under t he table each time to power
the router. Also, be careful to mou nt the ro uter so any
above-the-table ad justments won't be covered by t he fe nce
during operation, because you Illighl nccd to tweak a bit 's
height with t he fence in place .
Recommended routers
We've used a lot of routers over th e years at W()().l)&
magazine, Th ese three ran k amo ng the best fo r
table routing:
Porter-CableIf892, 214 hp, 10,OOO ~23 ,000 rpm, $190,
888 -848-5175, del taportercable.com .
The 89~ fe ilture~ t wo power ~wi tc h es plus a spee<l dial marked in
rpm$. and its lift me<hanism works smoothly and accurately.
Triton .MOFOO1, 2~ hp, 8,000-21 ,000 rpm, $220, 888-874-8661,
tritonwoodwo rk lng.~om .
This easy-to-use rOUler With builtin !>.iIfl!l y switch won't
a~cide ntall y power up whi le you 're changing b its.
Freud *FT3000VCE, 3 hp, 8,OOO- 21,OOOrpm, $350,
800-334 -4107, freudtools.com .
YOll won't bog down thi s rob u.! rOllte r, and the spindle locks
from ab ove th e tab le for one-handed bit ~hilng es.
WOOD magaz1ne September 2009
 Everv Special

25th
Anniversary
Offer

&
The Complete Magazine Collection on DVD.

For the first time ever, you can own every Issue of WOOD magazine from
the past 25 years In an easy-to-use, easy-to-search DVD fonnat_
Thousands of Shop Tips
1,100+ projects with detailed instructions
Hundreds of woodworking techniques
Each high-quality DVD contains five years' worth of WOO D magazine.
Volume 1 - 1984-1989 Volume 3 - 1995-1999
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Volume 5 will ship in November upon completion of the final 200~ issue. WOO909
ClIJU..OGS CRAASMEN

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~--------------------------~
Limbert-style
Arts~
Crafts
Table
Around the turn of the
20th century, Charles
Limbert developed a
distinctive furniture
style. While Inherently
Arts &- Crafts, it also
used curves and decorative
cutouts. Here's our take on
one of his classics.

he beveled edges of this tahle's

T ba~ let the quartersawn oak ~rai n

ex tend rig ht to t he edge on all
four faces. Cutting bevels on tapered
panels might seem dau nting, but, using
pattern s and a lablesaw sled, we'll show
you how to cut four identically shaped
side:. that come toget her precisely for a
stunning appearance from any angle.

Pre~are the panels and

work the angles
Start uy edge-gluing oversize blanks
1 for the sides (A) and shelf (B) IMaterl.
als List./xlge 331. After the glue dries, rip
the ~Ides (A) so t he edges are para llel.
C ut the shelf to 13- square. Next, m ill a
fu: l ~ I Z blank for the shelf cleats (C),
a nd cut the sirelchpcs (D) to size. Tilt
your tablesaw blade to 3~ and rlp a bevel
on one edge of t h e shelf cleat blank.;
then ~et the stretch ers, cleat blank, and
shelf asid~.

2 With the tablE'saw blade stl !l tilted

3, bevel-cuI o ne end of each side (A).
Flip the panel over and end fo r end and
crosscut the opposite end to make t he

PRO EeT HIGHLIGHTS

Overall dimensions are 20 wide x
20 deep II 28W high.
Materials needed: Quartersawn white oak.

WOOD magul_ September 2009

panel 28" long [Drawing laj. Not~: The
bevels should be parallel, lIot lIlrgled toward
each other.
3 Without changing the tllt of the
arbor, mount a -W dado set on your
tablesaw. Measuring from the low side of
the blade, set the hlade height so the
highest tooth is Vi' above the table
[Drawing 1bl. Set the rip fence to cut a
dado 121 }\ ~ from the bottom edge of the
panel lDrawings la, 1b). Check your setup
with test cuts on scrap; then cut a dado
in each side (A).
page 22, to bevel-rip the sides and cut the
tapers at the same time.
A pattern develops
1 The openings in each side (A) afC
made using a template and a pattern
routing bit. To make the template, lay a
side (A) outside-face down on a sheet of
Yo!" MDF and trace around it. Cut the
MDF along the lines. Make two copies of
each Side Pattern from the WOOD Pat-
terns. insert. Spray-adhere a top and
bottom pattern to the template, aligned
they mirror the left side. Cut the$e pat-
terns along the solki lines before mount-
ing them to the side [Photo AJ. Draw a
line 12W from the bottom edge of the
template and align the middle patterns
with this mark. Layout the remainder of
t he curve, as shown in PhOl0A .
"" Drill ~' starter holes In the waste
Larea of the template and, using a jig-
saw, cut out the opening close to the
layout Hnes. Cut the leg profile at the
bottom and the
notch at the top, tak-

4 Relnstall a rip or Lnmbination blade

in the tablesaw, and tilt the blade to
4SQ. Use a shop-made jig, as shown on
with the left edge. Quldr. TIp' Short-
cut to a mirror ' map. The patterns lJ
for the right side mount facedown so
ing care to keep the
notch centered. Test
the fit of a stretcher

II!I OADO IN SIDES

,:,'

DEXPlODED VIEW
D, i
1
l :::------J. ' "
. U ""'~ j

'r- .1
.8 .. I on" F.H. wood screw'---_l
,' ~
D
".
-y '"
'8 x I on" F.H. wood Krew
3<' bevel
00 '""
101\.-1
~.

13" . ..I'l1
"........
~ dado
Wdeep
ang led 30
". 12~'

A
12\1."

.8 x 1 \10" F.H.
wood !-Crew

-4S 0 beveled edge

".
30bevel ----'~
o n bottom
! '"
Ir"-2-~-'-~
---'"' -'- - - ". -~
-"-~~_ :-.C~C-,-o-"ChCi'-Iow
:--&-----1 I
I stretcher, centered --1
m STRETCHER
.j.>, ~i _. ___ ~~
, C~ .. ~"notch in upper
\t' countefbofe
\II " deep, ceotered
'Mo' rounterbore \4" d~p
with o." shank hole stretcher, centered 1
countersunk. (entered
31
~!!!~~~~~~~middle
lind top patterns. trace along a piece of scrap placing the templ::";"'~::r.;;~:"{~:~~~""
flexed between tne Jines on the patterns. blocks. Take light pass.es to prevent chip-out.

(D) in the notch as you go. File and sand piece of Wthick scrap in the dado to preserve the sharp beveled edges. Apply
to the layout lines. position the cleat [Photo OJ. a stain and topcoat to the shelf only.

3 Using double-faced tape, fasten the

template to a side (A), aligned with
the ends and edgl:':;, and trace the outline
of the side [Photo B]. Remove the tern
plate and cut out the waste to within 1116"
Bring all sides to the table
(We used Varathane Gunstock stain,
topped with three coats of a wipe-on
l Ory-fit the four sides (AlC) with blue
painter's tape to check the fit. Make
sure the cleats (C) are on opposite sides.
satin polyurethane.)

3 TO assemble the base, mask off the

of the lines. Reattach the template to the
side and, with a pattern bit in your
router, remove the remainder of the
waste [Photo el. Use a chisel, sanding
block, and file to clean up the corners
the bit couldn't reach {Shop Tip below],
but leave the notches slightly shallow
for now. You'll ftle them to final depth
after the table Is assembled.
Measure the width of the bottom of the
opening in the sides, and also between
the dadoes, and subtract \4" from each
measurement. Use these dimensions to
layout the final shape of the shelf (8)
[Drawing 2J. Use a fairing stick to draw
the arches; then cut the shelf to shape.
Sand the shelf to 220 grit, easing the
edges of the arches as you do.
inside edges of the sides (AlC) next
to the bevels, and apply glue IPhoto EI.
Stand the sides up, and center the shelf
(B) between them. Hold the sides
together temporarily with painter'S tape
while you apply clamps and strapping
tape !Photo FJ.
4 After the glue dries, remove the tape
and clamps, flip the table over, and
screw the shelf in place IDrawing 11 .

4 RettieVe the blank for the shelf cleats

(C) and crosscut the parts to length
[Drawing 11. Drill a countersunk shank
2 Reassemble the sides (AlC) with the
shelf (8) and check the fit. Disas-
semble the parts and sand all pieces to
Round up the stretchers
and top It off
hole centered on the length of each
cleat. Glue the cleats In place, using a
220 grit, including the Inside edges of
the cutouts In the sides. Be careful to 1 Set up a 1ft" dado blade in your lable-
saw. Retrieve the stretchers (D) and

ElSHElF
1t-,- - - --13" - - - ----j

If you don't have

a vise on your
bench, try this
when filing the
corn ers of th e
cutouts; Clamp Distan.:t between .....
dad~s less~ 13'
a riser block to
your bench, then
clamp the side
(A) to the block.
This holds the
piece securely at
a comfortabl e
working height
and reduces strain
"
radius I I
on your back.

32 WOOD mOlgu.lne September 2009

cut a cEntered half.lap joint in each one
[Photo G, Drawing lcj.

2 0rY-fit the stretchers (0) in the

notches in the table base (AlBIC). If
the tops of the stretchers sit above the
tops of the sides (A), measure the dis-
crepancy (Photo H] and file the notches
to the proper depth.
Make four copies of the Stretcher
3 Hllf-pattern from the WOOD Put-
terns. insert and spray-adhere onc to
each end of each stretcher (D). Note that
the half-lap faces up on one stretcher
and down on the other. Cut the ends to
shape, and drill the counterbores and
shank holes where indicated. Turn the othe r two, then join th ose assemblies.
table (AlBIC) upside down on the
stretchers and drill countersunk shank
holes [Photo I). Sand the stretchers to
220 grit; then screw them in place in the
table base.

4 G'Ue up a panel for the top (E). Cut

the radius at each corner [Drawing 1l
flip the table base (A- D) upside down
onto the underside of the top (E). Center
the base on the top; then screw the base
to the top.

5 Remove the top; sand the base and

top to 220 grit. Apply finish, reas-
semble the table, and display it proudly
in your home.

Written by Cr.lg Rueg5eggoer with Je ff MutE

Proltct (\<>1;9n: Jeff Mertz Clamp ~:~~::-::-:::;::::~~WI;::;
illustrAtions: ROllanne l e Mo lne; Lorn_Johnlon poulble. Stret ch st rapping t ape around
corne rs where clamps won't reach .

Materials List
f,"I\'UD ~Ilf
Part T W l M~tl Qt)
.- '" "",," ,
'A ". EOO
,,"
'S
""" '" ,
-
E<lO
"C sht!If deats
'" ,.""" ""
'" 00
,
.,
D
." ,." ,."
'"
00
E<lO
""
AIi.b.... ls key. eQO-fdg~Joined QlIartersawn wilile
oa-k. QO-qUilrtersawn wnitewl.
Supplies: Spray ad~ double.fiKl!d I.lp@,strapping
tApe..lSxl14 flathNo;! wood SC~ (2).18X1 Yt Rilthead
wood screws 1m
Black .nd bit: Stadttd dado set, pattern route!" bit.
Meas ure the a mount the stre tche rs (OJ ~it
above the sides {A} and remove th is amount notches In the sides (AI a nd ~"
from the bottom of the notch. fl athead wo od screws inlo the stretchers (0),
Cutting Diagram
==-r Find more Mission and
Arts &; Crafts
fumlture plans at:
woodmagazine.com/ mlsslon

wGOdm.lgil.dne.com 33
-nl'SJ(~~n(JII;1'
. '.
.IUT PIOJEm MIllE SII'II'lI.

WaIl Shelf & Towel

IIou!lh perfectly suited for your bath or IcIkhen,
project also can be used to hold quHts IIId

WHAT YO U'll NEED

D
on't let the curvlng shapes and
precisely positioned towel bars
fool you. Using only simple tools.
2 COpy the Shelf Side Pattern in the
WOOD Pattern~ imeet. Mount it to
W hardboard wit h spray adhesive, li8-
readily avallablesupplics from your loca l saw to sh ape. and sand the edges smooth
home center, and the tips we provide. to create a template. Then drill a \t" ho le
you' ll h ave this project ready to ha ng in thro ugh each hole center.
Materials: ." cheny. W cherry (or a
beadboard pane!), two 1" birch dowels.
Blades and BIts: 1" Forstner bit, W
a weekend.

Start by cutting the parts

3 Lay the hardboard template on a side
(A), with the back edges and bottom
ends flush. Trace the te mplate onto the
rabbeting bit. W straig ht bit, optional
W counterslnklcounterbore bit.
1 Cut the sides (A), shelf (8), and top
(C) to size [Materials Ust, page 37].
side. lightly hammer a 6d finish nail
through t'ach Wi" hole to mark tht' dowel

34 WOOD "'ag ar ln. ~tembef 2009

The few minut"sspent creatlng.l templ.lte Jigsaw t~ sides (A) just to the waste sid e of Instead of measuring, use the shelf (8)
make it possib'" to ere"te id@ntielll, mirrored th" line you tr.le@dtominlmlzeundingto ItMlf to I.lY out the stopped rabbet on the
sides (A) with pre<isely aligned eounterbores. the line. underside 0' 1M top (e).

D EXPLODED VI EW
1<0" stopped rabbet
%" deep, on
bottom side

. .....l\~:::;;."1 o

1 eounterborti .til. deep E

l d~i H Y.t" 1ong E

'8xl W FJ-i.
wood Krew

lEI SACK DETAIL

t~
I- ~i~'~~
I ~m

hole ntcrpoints [Pho t o AI. Place the
template, pattern down, on the other
side and repeat. Pick the right Jigsaw blade
4 JIgsaw the sides (A) to shape [Ph oto
BI. (St'~ the Shop Tip right to choose
the best blade.) Then sand the profile
As a versatile tool, jigsaws will c.ut
through anything from ceramic tite to
brass rods, depending on your choice
smooth to the line. (To spee<l the sand- of blade. For dean cuts on gentle
Ing process, use the drill-powered drum curves in hardwood lumber, outfit
sander on page 20 of issue 185. Down- your jigsaw with a 20-tooth-per-inch
load free plans to build this jig at (tpi) blade, like the one shown. The
woodmagazlne.com/drillsand. Then go blade's narrow body also helps you
10 woodmagazine.com/drilhanding for cut tight curves w ithout binding.
a free video on usIng the drum sander.)

woodmagillln. com 35
 until you n!ach the
~~~~*,~!;(~)k'~Pth'
(8) 11 outofallgnmentas accessory makes quick work of boring
mark on the opposite end. you drill,,,,,,,;; screws. holes In the top Ie).

Drill a I" counterbore ~' deep at the

5 nail marks on the sides (A). (We used
a Forstner bit. If you use a spade bit, lay
the bit tip on the edge of a side to be
certain the long center spur won't blow
through the opposite face.)
6 With a W rabbeting bit, rout the
back etlge of the shelf (B) to accept
the back slats (D) [Drawing 11.
stain the project, stain the towel bars
before assembling the shelf.
Assemble the shelf
1 From scrap plyv.'ood, cut two 6><8 W
spacers. Clamp the space~ to the
sides (A) with the edges and ends flush
lPhoto E]. Place the shelf (8) between the
both back screws fI~t, then repOSition
the clamp to add the front screws.
3 Center the top (C) on the sides (A),
and check that the rabbet ends are
flush with the Inside faces of the sides.
Clamp the top in position. Drill coun-
terOOred shank holes in the top; then
drive the screws [Photo Fl .

7 Mark a centerline on the rabbeted

edge of the shelf (8) and on the
underside of the top (C). Align the two
centerlines and mark the shelf ends on
the top (Photo Cj. Then rout a stopped
rabbet on the top IPhoto 0 ] and square
the corneN; with a chisel.
cut two towel bars (E) to length and
B sand them to 220 grit. If you plan to
sides with the rabbet to the back facing
up. Mount the towel bars (E) between
the sides, and clamp the assembly.
2 Drill munterbored shank holes for
t he shelf (8) screws [Drawing 11 . For
the #8 screws, drill l.2' shank holes and
~. pilot holes. Drill counterbores W
deep. (See ' Cover up screws with these
two accessories" on the next page for a
pair of timc"saving tools.) Drill and drive
4 Cut ten 20' -long back slat (D) blanks.
If you have a router table, use a
straight router bit to rabbet the blanks
*'
[Drawing lAJ. If not, rout them freehand
with a W rabbeting bit lSkHl BuliderJ.
Qufd tip! Swap 19 slats fot' om' ~
pando If you can't find \4'-thick cherry i
stock at your local supplier, substitute
beadboard plywood. Cut the panel to fit
the rabbeted opening in the back, stain

SKILL BUILDER
Rout quick, safe rabbets
with this simple Jig
Guiding a handheld router along 2"-wide parts to
cut 20 rabbets in 10 blanks can turn into a dicey
balancing act. However, thj~ simple jig makes
repetitive routing a breeze.
Segin with a Yox6x28" MDF base. Then add
three W-thick MDF pieces-a 4><20' piece beside
the workpiece and 4x6" pieces at either end-to
capture the back slat (D) blank and support the
router base.
Insert a blank into the jig recess. Starting at the
left end of the jig, rabbet the jig and blank edges,
as shown at right. Then turn the blank upside
down, and rout a second rabbet. Repeat for the
other blanks.

36 WOOD magnlne september 2009

 Cover up screws with
these two accessories
Counterslnkl

'loft spacer

).i,.'~~,~)::,,~~~~,:,~:;~;~;:~ .Thl,~d",
Cherry gel stai n {olors pine beadboard
plywood without blotching. Nail the back on using a
after finishing the rest of the shelf. shadow lines and allows for eKpansion. Counteulnk

it to match the cherry [Photo GJ, and

attach it with W brads.
Pilot-hole bit
5 crosscut the back slats (0) to length,
then rip the rabbeted edge off the
two outside slats. Sand the slats to 220
grit and stain, if desired.

6 Attach one narrower outside slat (D),

with the rabbeted edge up, using W
brads. Then attach two-thirds of the
'I," plug
Two low-cost drilling accessories
help you hide the screws used to
remaining slats, separating them with a assemble this shelf. The W
countenink/counterbore bit (Sf('
W -thlck spacer [PhotoH]. (A crafts stick Sourc:es) drills a counterbore, a
will work.) When you get to the last six countersink for flathead ocrews, and
slats, space them eventy apart within a pi lot hole in one pass to save time
the remaining 5pal~ and nail in place. and increase accuracy.

7 BUy or make }k"wood plugs W long,

and glue them in place over the
screws. Cut the plugs flush with a sharp
To fiJi the counterbore, make
plugs in scrap using a plug cutter
made for use in handheld drills.
chisel or saw (Photo 1] and sand smooth. Then Saw or pry the plugs loose.

8 Finish-sand parts to 220 grit. Apply

stain, if desired, and a dear finish.
(We used Minwax no. 607 Cherrywood
saw {Uts plugs flush without
marring the surrounding ~u rfa't!!. Then
~mooth them during finish-sanding.
gel stain to lessen blotching, followed by
two coats of wipe-on polyurethane.) .
Written lly Bob Wihon with Kevin Bu)'li!'
rNjed de~igrJ: Roger K"lnd"l A "'" ,,' ,.." 20' C
2
1I1L1ltr~tions, Rou.nn e LeMoine; Lorn_Johnson B shelf
" ,. ,..-'''" cc
C top
D* back slats "" ,.- " 2" C

Cutting Diagram E towel bars

~Parts Initially ,ut
l"diam.
oversire.
3]\','
'"
See instructiOns.
2

uUse cherry dowels if avai lable.

A B o D
Materials lley: C-<:herry. B-blrch
~ x 7Y~ x 96" Cherry (S.3 bd. ft.) SLlpplies: fSxl y," flaltlead wood >crews, .16xJ'<' brads.
"Plane or resaw to the thickness lisled in the Materials Ust. Bits: }\a'~raight bit.~ rabbeting bit. I' ForSlnerbil.

o o o o Sources
Counter,lnk/ (oLlnurbore bit : _8 cOOJmersink 00.
~ K 7 Y~ x 96" Cherry (S3 bd. ft) SOJI)oI.06, $7.80,l.I"I' valley, 600-87J.8158 or leeo.-alley.com.

---=
PlLlg cutter: Selfcentering II. -diame!erpiug
o Ultt~r no, 1.'1810375, $16..05, McfeeIy's< 600-4417917 or

o x 3'12 K24' Cherry (.7 bd. ft.) ---0 ......Cherry dowe l (2 needed)
1" diam, x 36'
mdce~.

woodmagaIine.(Gm 37
 Watch FREE videos of our
visit with Norm Abram at:
woodmagazine.com/ video

38
 e's the Elvis of woodworking. And,
H like Elvis, the world is on a first-
name basis with him. Instantly
recognizable with his plaid shirt and
beard, Norm Abram carries the torth as
today's biggest woodworking celebrity. At
public appearances, people stand in line
for hours to meet Norm and get his auto-
graph or photo. Everyone turns to look
.
when he enters the room.
But get outside the scope of wood-
working and Norm is just a regular guy
going about his business. And df:'!';pite
the fame of a television career, he's
friendly, modest, and accommooating.
He just happens to make his living in
front of a TV camera.
"The two shows [The New Yankee
Workshop and This Old Hou_~e, both on
PBS) have been reaUy good tome," Norm
says with a sheepish grin, as though he
doesn't deserve the adulation. "I have
no desire to be a big celebrity. I enjoy
what I do, but I also enjoy my privacy."
A star Is discovered
In the barn
Thirty years ago, television producer
Russ Morash hired ?\~orm, then a private
contractor, to build a barn for him. ~He
impressed me with his quality work and
small scrap pile, ~ Morash recaUs. When
he finished, Morash offered him a roLe
on Thi_~ Old House, a new show that
focused on restoring old homes.
"But we didn't just throw him into the
show became he had never been on TV
before/ Morash Q)'s. "The host would
ask him questions and he'd answer. He
,"''",W;'' off-",,,",, w. w,," ,b,.
'~bi;;;~ ; build two c;herry b edside
t;: h is home.
W'OOdmllg _d ne. cOom
Age: 59
Family: Wife (Elise), 1 daug hter, 1 stepson
Hometown: Milford, Mass.
Educ:atlon: University of Massachusetts
(mechanical engineering &: production
management)
Work history before TV: Construction
worker, self-employed general contractor
First appearilm;:e on Thil Old HOUle: 1979
First episode of The New Yankee
WOl'luhop: 198B
First woodworking tool: Ha ndy Andy child's
tool kit
First piece of furniture I built: A bookcase
for college when I wa5 17 yei:lrs old
ProfessIonal Influences: My father, who was
i:I ca rpenter
Toughest woodworking skills I've learned:
Carving, gild ing
Hobbles outside woodworking and
carpentry: Boating, fishing, travel, cooking
Norm's Favorites: Norm searc;hes for the best co lor
Furniture style: Shaker, Ea rly American, and grain matc;h for a cherry
Arts and Crafts bedside ta b le.
Wood species: Cherry, mahogany
Furniture finishes: Tung oil, wipe -on polyurethane
Hand planes: Low-angle block pla ne, shoulder plane
Car: 194B Ford coupe that I restored
Sports teams: All Boston teams
TV show (that I'm not In): The 50prono5
V.c.tlon spot: Off the beaten path, preferably on or near the water
was-and still is-so credible and believ- thing about television, once you create a
able and honest." character It's hard to jump out of it. If I
"When r first started with This Old wanted to become anonymous I'd shave
H{}u~, it was scary," Norm remembers. my beard and wear a solid color shirt
"But I quickly learned that if I just did and probably go around unnoticed. But
what I knew and stopped worrying now it's part of who I am."
about the camera that I would be okay. As is his well-worn leather carpenter's
I'm still amazed that I've made a career tool belt. And don't forget Norm's mes-
out of what I enjoy doing." sage about shop safety-most viewers
Soon Morash had another idea. uWe know it by heart- that precedes the use
were building a Lot of nice Ihlngs In the of power tools on every project. The
shop rather than on-site," he says, Hand American Academy of Opthalmology
one day I asked Norm if he could build recently honored Norm for promoting
furniture for a TV show. The public the usc of safety glasses.
loved It right away." Russ and Norm
tho~ht this new show about wood-
working might last for three or four ''I'm still amazed that
years. Little did they know.
~The secret to The New Yankee Work-
I've made a career out
shop, right from the start, is we build of what I enjoy doing."
real, practical projects that people like,"
Norm say~.
Norm answers his critics
Glad to be In plaid To be fair, Norm has his detractors. Some
To help build the show's identity, Morash say he builds furniture like a i:3rpenter,
urged Norm to develop a look. "When citing his regular use of pneumatic nail-
the show started, Russ said 'Wear plaid ers. Norm admits his roots developed In
shirts, they're good for the camera: That carpentry, but al~o recugnizes the prog-
automatically became my trademark.
But by and large, beyond television, I
ress he's made as a furnituremaker.
"Certainly my skill level is much
don't wear them very frequently. One higher than when I first started The New
39
 "I've always enjoyed what I do. I'm always going to be
doing something that revolves around building or woodworking,
maybe teaching, maybe learning some more."
Yankee Wori:slJop," he says. "'There are
many craftsmen out there who are bet
ter than I am. I see myself as a fairly
ordinary woodworker. Uke any crafts-
man, you want to take some of your
early pieces and throw them in the fire-
place; you don't want anyone to see
them. But it's your history. It shows how
you've progressed at your craft.~
And the brads? Norm points out that
there ace more nails in furniture than
most people want to admit. uWhen you
look at antiques that are a hundred or
more years old, they've got a lot of cut
nails in them. I think there's a place for
them that's not offensive or violates a
craftsman's work.~
Norm considers his future
After 20 years and hundreds of projects
on The New Yankee Workshop, what's
10 Things You Might Not Know About TIre New Yankee Workshop
1. Norm desig ns and builds each
projec t . He does get some help, though,
from shop assistant Wade Burcher, who
maintains the tools, shop, and grounds,
as well as applying SUbsequent coats of
finish to projects offcamera.
2. One for you, and o n e for me.
Norm builds two of each project, and no
more. He keeps one and producer Russ
Morash gets the other. OccaSionally,
they donate one of the pieces to charity.
3. It really is a twoday show. When
Norm says "Well, good morning!" about
midway through a show, It a<.."tually does
signal the start of a second day. They
tape half the show one day, skip a day,
and then come back and finish. '" like a
day off in between taplngs so, can make
any adjustments," he ~ys.
.... Norm does not promote tools on
the ... how. Yes, most of the tools in The
New Yankee Workshop rome from the
show'~ major underwriters, Delta and
Porter Cable, but PBS rules reqUire all
brand names to be masked over. "I might
recommend a type of toot for a job, but
never a particular brand. If I usc a tool
on the show it means it works well and I
like It," Norm says.
5. (Gasp!) Norm does make mIs
take .... Prior to taping an edlsode, Norm
spends days fine-tuning his designs and
techniques to work out any bugs. "When
it comes time to produce the TV show, I
know exactly what I'm going to do."
next for Norm? "My wife ~ys I'm never
going to retire," he chuckles. ~She likes
to joke that I can't walk across the room
without accomp!lshingsomething along
the way. And I've always enjoyed what
I do. I know I'm always going to be doing
something that revolves around build-
ing or woodworking, maybe teaching,
maybe learning some more. I know I
don't wanl to be a pitchman, go out and
scll product. N
When asked to ponder his legacy,
Norm pauses to consider, as though he's
never thought about it before. "I think
it's going to be less about what J built
and more about what I taught or inspired
people to do. I'd like to be thought of as
the guy who did a TV show about wood-
working, got people of all ages interested
in woodworking, and brought them a
lot of enjoyment."
During our visit to Old Sturbridge Village,
No rm recorded a p ro moti onal spot for a
lon l P8S tel ~vl51on na tio n.
6. Norm's not just a powertoul
guy. It only seems thai way because he's
trying lO appeal to a mass audience,
most of whom me lXlwer tools. In real-
ity, he uses a low-angle block plane and
shoulder plane on nearly every project,
though they seldom make the cut for
the show.
-
~
,...
7, Time demands a f ew conces-
sions. For example, Norm has an
industrial-sized, wide-belt sander in the
shop, but you never see him use it. "We
use tools that our viewers have," he
explains, "but we work on a production
schedule and there are deadlines to
meet. It helps me do that.'"
8. He doesn't live in the past. Norm
regularly uses a cell phone, digital cam-
era, iPod, and laptop computer. He uses
the Internet, as well, for research and
shopping.
9. No sponsors, no show. fuo under-
writers withdrew their support after the
Z008l>('ascn, leaving only longtime sup-
porters Delta and PorterCable for 2009.
"If they left we'd have to find another
major sponsor or get PBS funding, but
that 's hard to come by. Otherwise, we'd
be done. It's always a good day when
Russ says 'We've got underwriting for
another year'."
10. The camera add... square foot-
age. Because of Wide-angle camera
lenses, the New Yankee Workshop
appears larger than it is. In reality, the
working part of the shop measures
26x36', about the size of a threecar
garage. It's half of a two-story barn that
Norm built, but he uses the other half
for finishing projects, office space, and
storage for tools and accessories. Norm
moves most machines around on mobile
bases for filming each show.
 Benefiting from furniture designs of the past
From Us inception. Norm Abram and
Producer Russ Morash grounded The
New Yankee Workshop In a foundation of
traditional furniture styles. At the begin-
ning of each ephcx:le, Norm visits a
museum or historical site to see a par-
ticular piece or furniture crafted long
ago, He takes measurements and photos
of the piece, then goes back to his Bos-
ton shop and builds a ~lmllaT version.
"I'm drawn to functional furn iture
and less to something for art's sake," says
Norm. "I look for good proportions, and
ask 'What's different about this than the
other projects we've done before? What
haven't we shown people before that we
could teach them?' And we want some-
thing that our viewers want to build,"

Going back to the roots

One of f'.;;orm's go-to SPOlS for project
ideas b Old Sturbridge Village, a livi ng-
history ]8305 settlement in Sturbridge,
Mass. Norm has buUt ... Ix Nm Yankff'
projects based on pieces he discovered
there, indudlng the butterfly table
shown al right.
"'We're grateful to museums and places
like StuThTidge for allowing us to come
in and film these projects," he says.
"'Places like thee are our heritage and
our resources for discovering the history
of fumituremaking and so much more.
"To me the anonymous craft.~man {uf
a bygone cra] is the ultimate inspiration
because the work that he's left behind
atl these years later speaks for itself. nhe
pieces arej well-made, and they were
made without the tools we have today."
So what does he look for, and how
docs hc start after chOOSing a pie>?
"One of the things I love about lOOking
at an antique Is the proportions. The old
pieces of furniture just feel right. And
I'm not "'0 much interested in making
t"xact rt"pltcas as making a plec.:e lmplred
by it. When you're looking at antiques,
allow yourself the freedom to make
slight changes and adapt the design to
your own needs."
Norm shows WOOD- mil9il1zine's 80b Hunter 50me ofthe detai1~, su(h as splayed legs, that
fasdnated him about this butterfly table at Old Sturbridge Village.
of the anglt" YOll shoot bI.'Cause any dh-
lortion could alter the dimensions or
proportions of your project."
Norm traces any curves or unusual
shapes when he can. With turned fea-
tures he takes precise measurements of
diameters and spacing. "Sometimes I
just hold my tape next toa leg and shoot
a photo or video of It, and tht!n figure
out the measurements back in the shop.
It's not critical to get each dimension to
the 32nd of an Inch; U's the proportions
that I'm looking for."
Always ask permission from the owner
or museum staff before approaching the
piece. ., hey might provide you with
dimensions or other pertinent details.
If you can't get close to the- piece, take
photos from multiplC' angles. Then usc
nearby objects, such as floorboards, elec-
trical outlets, or stair~, to determine scale.
"'Guess at the approximate dimensions,"
Mit's not critical to get em:h
dimension tv the 32nd ofan
inch; it's the propurtions
that I'm Iook.ing (Or.'
he says, "and use your photos to maintain
the proportions. You really only need a
f{'W dimensions to get started."
Ib de-terminI" an apprOximate angle-
splayed legs on a table, for examp[e-
shoot phOlOS of the square standing
next to tilt" angled clement. Then esti-
mate the angle back in your shop.
If po~slble.~h(Jot photos of hard-to-
see areas for details, as shown be/ow.
Draw details on graph paper to help
you maintain proportion. You can also
enlarge photos {or full-size patterns.

Norm's reproduction tips

. If you're interested in reprodUCing an
anUque, Norm suggests you bring along
a tape measure (standard and fabric), a
6- square, tracing paper, graph-paper
sketch book or notebook, and a digital
camera or video camera.
"The digital camera has become a very
valuable tool when you're trying to
document an old piece of furnlture.
With any camera you have to be careful

woodmlO9Uln<l!.com 41
Norm'slaws
for buying and
using lumber
Nearly four decades of working with
wood have taught Norm truths that
apply to most wood-selection scenarios:
Norm typically buys only the wood
he neffis for a specific project, most
often from a local hardwood dealer that
lets him sort through the stacks for
choice pieces.

"Don't spend a lot of money on a
board that's longer than you need," he
says. "But if you find a really spectacular
piece, even though you might not need
it right then, buy it because those boards
can be hard to find."
"The biggest mistake people make is
they want every board to be perfect. I'll
take a piece of wood with a small defect
or two and then work around them if
the rest of the board Is really good. Even
though I'm frugal, J realize there's always
going to be some waste."
Visualize where a board wil l fit on
your project. If you need to create match-
ing parts, get them from a single board.
Don't begin working the wood as soon
as you get It in your shop. Instead, let It To maximize prized figured wood, Norm cautions that the yield Is typi-
sit for a few days to equalize its moisture re:saw it into thinner pieces and laminate cally pretty low with reclaimed wood. It
content with that of your shOp. them onto less-expensive stock . takes more time and muscle to get the
If possible, get your hands on old, lumber into a workable state as com-
recycled lumber. "Not only is it good pared to new stock. "You have to be
'The biggest mistake people enVironmentally, but there's a lot of careful or you can damage your tools.
make is they want every board character in that wood," Norm says. Expect to find a lot of nailS, loosc knots,
~And if it's truly old-growth timber, then grit, and dirt. Even rust left from a nail
to be perfect. it's going to have really tight growth can dull pia ncr knives or saw blades.~
rings, so it'll be more stable ewon if a Invest in a mt'tal detector (about SI00
When edge-gluing tabletops and wide board is two feet wide." to $200) to find metal you can't see.
panels, match the color and grain of the . To find Old-growth timher, look for When cleanlngre<,"yc1ed lumber, avoid
face that will show. Forget about the buildings heinR torn down, or simply bending any cut nails, which can break
orientation of end-grain growth rings. falling down, and ask the owner or con- off in the wood.
Look at both fa0!5 of a board, because tractor if you can help dispose of the Sand old boards with a portable belt
one might look much different than the boards. Old barns, warehouses, and sandcr to rcmove surfacc debris and
other. You can often hide a lesser-Quality docks are good sources. expose obscured nails. An exposed nail
face inside a proje<"t. ~We love to get hold of old attic floor could tear costly drum-sander belts.
Avoid warped boards entirely: You'll boards. They're typically a pretty decent Saw off the ends and edges of reclaimed
waste too much material machining pine with tight growth rings, they don't stock with a blade you're willing to sac-
them to size or get only small workpieces have a lot of wear, and they're probably rifice. There's likely grit embedded in
from them. not heavily nallcd.~ those areas.
Ukewise, use an old set of planer and
jointer knives for cleaning old stock.
Install new knives to machine the wood
to final dimensions.
Norm likes to leave nail holes and
defects in the wood for character rather
than filling or patching them. "What's
the sense of using reclaimed lumber and
not shOWing part of its history?~

; Writt~n by Bob H... nt~r

d~aned off with a belt sander. That's wh"n a broken-off nail show~d up. Ptlotogfapln by 8r,.n M~".,

42 WOOD mag.line September 2009

Slant-Sided ~

"
"
llSIC ,
0.-
,
~ "
-, - -
,

"
OX
Mahogany and maple blend
"-

~ ,
,
,"

harmoniously in a box ~

as beautiful as the

id vou know that a music move-
D ment playmg m the palm otyour
hand is barely audible? Only
when mounted to a board docs it reso-
nate loudly enough to fill a room with
its tinkling melody. Build a beautiful
box like this to hold the movement, and
the lucky owner enjoys a serenade every Compose a box
time she lifts the figured maple lid.
Besides the music movement, the only
other hardware you'll need is a pair of
1 From Wthick stock, cut a 2%><10"
blank for the front (A) and two
2~x7 blanks for the siues (B).
stop hinges that keep the lid propped
upright while the music plays. See
page 51.
Sources on
2 USing a lh" straight bit in a table-
mounted router, rout a rabhet In the
back end of each side (B) [Drawing 1].

woodmagad~.com 47
 DBASIC BOX
"'" rabbelS
>to deep
I!JHANOLE RECESS TEMPLATE
r ,.,"=1 6
r - - - - 9"- --
F''''"11 ,~"
-,
PROJECT HIGHLIGHTS
Overa ll dimensions: 9" wide K 6W
deep ~ 2W high.
Splines reinforce mitered and
butt jointed corners and provide
contrasting accents.
Open the lid to start the music and
reveal the brass movement sheltered in
a windowed compartment.
Music movements come in a variety
01 melod ies. Sources on page 53 lists
some choices.
3 Reset the routcr-tablC" fence to rout
thc)t"owlde lid rabbet inside the top
edge of the front (A) and sides (8) IDraw-
ings 1, 21. Note that the sides should be
mirror images of each other.
4 MiteHut both ends of the front (A)
so the finished length Is 9" [Dr;!lwlng
1]. Miter-cut the front end of each side
(B) so their final lengths are 6Yl.
S RiP the back (C) to width to match
the distance from the bottom edge
of a side (11) to the shoulder of the lid
rabbet [Drawings 1, 2J. To determine the
length of the back, dry-fit the front (A)
and sides (B), and hold the miters
together with masking tape. Cut the
back to length to fit hetwccn the rabbeb
in the sides.
48
'4 ' ~ \/""deep V," from bottom ~dge
~ )( 1 )( 2" 5plines
USing a !It" straight bit in the router
table, rout a lA" groove ;;1&" deep in
the front (A), sides (8), and back (C) for
the bottom (D) [Drawings 1 and 2J .
Time for recess
1 To make the recess for the lid handle
(l), create a template from Yo!" ply-
wood the same size as the front (A)
[Drawing 101]. Cut the notch out of the
tcmplate, then usc double-faced tape to
fasten the template to the front (A) with
the ends and edges flush.
2 ChuCk a \-4" straight bit into youI
router; then install a W outside-
diameter guide bushing in the base.
Ho'~: The bit must be long enough to ex-
ti.'nd 1 )1~~ below the router base.
3 Place the template and front (A)
assembly, template side up, on a
router mat, or use double-sided tape to
secure it to your bench. Set the router bit
for a h&"-deep cut in the front (A), and
lOut around the template notch (Photo
AJ. Score the top edge of the front to
prevent Chip-out as you rt'move the
rem ainder of the waste In the recess
[Photo B]. Square up the recess corners
with a chisel.
4 TO determine the size of the bottom
(D), dry-fit the box and measure the
inside dimensions. Add 'Yt6" to each
dimension, and cut the bottom to size
from 1A' stock. Sand the inside faces of
the front (A), sides (8), back (C), and bot- After routing a shallow rec~S5, use a crafu
tom (D) to 220 grit. knife to score from the edges of the rec~ss
down the to p edge otthe front (AI. Routing
S Assemble the box {Photo C1. Do not
glue the bottom (D) so that It can
expand and contract freely.
a recess ",," deep creates a notch by cuttIng
through to the rabbet along the top inside
face of the front (AI.
I A blade with an a lternating top bevel
(ATB) tooth pattern leaves a V-shaped
ridge in the kerf. That results In small
gaps between the spline and the
bottom of the kerf. To fiK this, plane A ~~=~
or sand a piece 01 scrap so it fits easily ,
into the kerf. Attach a strip of 150-grit
sandpaper to the edge of the scrap,
and sand the "V~ naL

El SIOE SECTION VIEW

~'i
-
sides (B). Slide Into place. ;;,;. ,
SKure the miter Joints with masking tape.

,~
. , " 8"

.,.I I
~
1 [ 0

J '" ' ; ;:"

1---\10"-
"-l r=:: I I

THE BOX

Bevel intersects botlom comer of . miter'Qauge extension

rt=~:::=:;;-

.
jig to cut ~-deep kerfs toward the bottom.
II

Accentuate the positives

1 To add the contrasting splines, first
make a spline-slot Ilg like the one in
Photo D. (Down load a free plan for It at
woodmagazlne.comisp1tnellg.) Clamp
the box In the jig and cut kerh for the
splines [Drawing 1]. A rip blade, or a blade
with raker teeth, cuts I.:erh with flat bat-
toms. If the kerfs aren't flat, see the Shop
rIP aOOw for a solution.
4 Turn the box upside down, and draw
ines lW from each corner [PhotoEj.
Glue the feet (F) in place- aligned with
these marks. After the glue dries, use a
flush-cutting saw to trim the excess
material from the splines (E) and feet.
Sand the splines and feet flush to the
box with I SO-grit sandpaper.
S Cut a handle filler (G) to fit the recess
in the front of the box, and glue It In
2 use the kerf to help position the box
as you bevel the front (A) and hack
(C) [Drawing 3]. Remove- most of the
waste on the flist pass, then take light
passes until the blade cuts just along the
lower edge of the foot (f).
3 Remove the miter-gauge extension,
and rip an 8- bevel on one or its
faces. Reattach the extension to the
miter gauge wllh the narrow edge down

2 P'ane or 'esaw and sand a 1 x 17"

maple blank to ftt snugly in the kerfs.
Cut the splines (E) to length from this
place (Drawings 2, 4].

Bevel the sides

{Photofl. Bevel the sides (8) ofthe box In
the same manner as the front (A) and
back (C). Then sand the outside faces of
blank IMaterillls Us" page 51 and Draw-
ing11. Glue a spline Into each kerf, mak-
ing sure it seats fully against t he bottom
1 Make a 12"-long miter-gauge exten-
sion from l W -thlck stock and attach
it to the miter gauge. Tilt the tablesaw
the front, back, and sides to 220 grit.

Handle the lid

ofthe kerf.

3 For the feet (F), cut a 14xHh 10

blank. Cut the feet to length from
the tJlank, and miter-cut two corne~
[Drawing 4J.
blade S from vertical, turn on the !law,
and raj~ the blade through a blank
zero-clearance insert ]Drawing 31. Rabe
the blade 2W above the table, and cut a
kerf through the extension.
1 To determine the size of the lid (H).
measure from the back edge of the
back (C) to the front of the rabbel in the
front (A). Subtract \-\," to get the lid
width. The length of the lid is ~. Jess

woodm~azl ne.com .,

"".
. 13x Y,"br.ns
bras\~t~~~ingl;.-_"lF~.H~.ij.Wood K)
'" 1'>4"
WillS'" lrimme<l aner assembly
than the measurement between the out
side edges of the rabbets in t he sides (8).
When ripping the lid to width, bevel the
rear edge al 8" to match the bevel on the
back of the hox [Or.wlng 41.
l C.U! the handle (I) to size. Glue it to
the lid (H), centered from side to side
and flush with the bottom edge of the
lid [Drawing "1.
3 eu! the hinge mortises [Skill Builder].
Sand a slight chamfer on the rear
edge of each mortise to provide clear-
an~ for the hinge barrel. Drill i /!, pilot
holes in the back (C) and lid (H), and
screw the hinges to the box. Check chi.'
length of the SCTewj; beforr! installing them
in the lid. If they would poke through the
top faa. cut them to length. Before drlv.
ing the shortened screws, drive a steel
screw into the pilot hole to preth read it,
then remove the screw.
50
D EXPLODED VIEW
, /Trim supplied SCI'1!'WS for lid to~ long.
,
sure
feet st ay In place as ),ou clamp them,
a"bewl
outside'"e
against
SKILL
Create hinge mortises that match
perfectly between the lid and
box by using a template and a
guide bushing in your router.
From W plywood, make a
template to fit snugly in the
rabbets in thl! top of the box
(right). Install a guide bushing
and a straight bit in your rouler.
To create mortises eXactly as
deep as the hinge leaf, use the
hinges to set the router bit depth
(bottom right). Place a leaf under
each side of the template. Lower
the bit through the template
until it (ouches the benchtop;
then lock the height adjustm~mt.
Secure the template to the box,
and rout the mortises.
Center the same temp late on
the lid. Tape the template face
that faced up on the box against
the u nde~ide of the lid. Rout the
lid mortises. Square the corners
of the four mortises with a chisel.
 And now, a little music
1 Cut a poster board template the same
size as the bottom of the music
movement. Mark on the template the
center of the key and sound holes, and
the locations of the mounting screws.
0, K). Drill %I"-diameter holes at these
locat ions using a brad-paint drill bit.
Then countersink each hole to accept
the head of a #3 wood screw. Screw the
window to the music case, then glue this
assembly to the bottom (D) of the box.

2 Position the template in the ixlx as

shown in Photo G. Mark through the Time for the big finish
template the hole centerpoint".

3 TO prevent chip-out when drilling

the holes, support the bottom of the
box with a piece of scrap. For the move-
ment we used, we drilled a \.i'-diameter
sound hole and a ;nz"-dlameter hole for
the key. Drlll slightly oversize holes for
the mounting screws to allow for fine-
tuning the position of the movement.
A From W -thick stock, rip to finished
help position the music movement
"tWidth the music case fron t and hilck
OJ and music case side (K) (Drawing 41.
Miter-cut one end of the music case front
and back to finished length. Miter-cut
both ends of the music case side to a
finished length of 3". Cut a small notch
in the front 0) to allow the wire on the
music movement to pass through.
1 Remuve the hinges and the window
on the music case. Sand all parts to
220 grit. Then apply a finish. We sprayed
on three coats of an aerosol semigloss
lacquer, buffing with 0000 steel wool
between coats.
2 JI1stall the music movement in the
music case before reinstalling the
window. Carefully bend the start/stop
wire for the movement so that the move-
ment shuts off when the wire reaches
the bottom of the rabbet in the side (8)
[Photo H). Reinstall the hInges and lid.
Then wind the movement and let the
music play.
Written by Craig Ru .. g~ .. gger with Doug Hid..
I'foject desi9n: Je ff Mert%
lItu~lr~tiQns: Roxanne LeMoine; Lorna Joh nson

5 sand the music case front and back

U) and side (K) to 220 grit. Then glue
the music case together. Use masking
tape to clamp the miters, and put a tem-
porary spacer in the open side to keep Materials List 11"II~tlW~ln
the assembly square.
Qty

6 TO make the window on the music

Part
,. ,..
T W L 1-.4 .. 11

,.' '"
'A MG
case, fasten a piece: of \.fI"-l hlck clear """'
acrylic to a carrier board to prevent chip-
ping and splitting while l'utting it to
'S
C "'"
"'" .

".
,. s,,
W
7!t"
MG
MG
size. Cut the acrylic to fit the outside
dimensions of the mUSiC case [Drawing
41. Polish the window's edges by buffing
D bottom
'E splines
'F f~l
. ...,. '''',..
7'1-\," MG
M'
M1 ,"
with 400-grit wet/dry sandpaper.
G
.,
handiefilkM" " . M1

Use needle-nose pliers to shilpe thl! mu sic

movement's start/stop wire so music starn
7 Place the window on the case, and
mark with a felt-tip pen the location
for a scrt!w centered on each case piece
H
h ,ji,
". 5~ 1"

"" "
M1
MG
when the lid opens and stops when It CI05e$, :::ticcasefmntl h " 1\4' 2:)1" MG 2.

K musiccaseside ~" 1!4" 3" MG

'Parts initially (ut oversize. ~ tilt' in5tru<tiI)llS.
Cutting Diagram Mliterilib key: MG-lTklhogany,ML- mapie.
Supplies! Ux l'l" br~>s flathl!ad wood scre-..r.;, tllox \-2"
brastop hinges. !t"-thick acryli< pl~stiC. mUSiC move-
rMm.
Blades and bits: RipandcrosS(lA blades. \4" and l'l"
straight routerbit5, ~' router9uidebusl1il'l9.~" brad
point drill bit.
"" x 5 'l..x 36" Mahoq<iny (15 bd. ft.)
Plane Of resaw to the thickni'~ses listed in the Materials List. Sources
Hinges: Bo~ stophin9es(2) no. 70391. $30.99 [pairl
-- Rockier, 800-279-4441. roc~ler.com.
-- @ Musil; mOVflJlenu: llrahrns'lull~by" no. 3C>45-8;

~ -
~
- "Amazing Gra(e" no. 30448; ' Silent Night" no. 30446;
-P(Kheibel's Canon in DMajor" no. 30591; ' ~ GrNt TIlou
..

, '0j'0['0
'0 Art"' no. 30452, $7.89, Kkx:kit. 8()O..SS6-2548, kioct.it.com.
~-

. . .
Music ~t><l'Vai labiefrom RO(kl~r: "Slue Danube'
--
E
.
'l..x7\l.ox24 Maple(.7bd.ftJ
no. 34338; -Greensleeves ' flO. 36223, $1259.

woodmaga~lnlt.",om 51
Branching Out:
4 Substitute Wood Products
"green" thinking have led to a number of new woods. Here are four of our favorites.
Hardwood: Lyptus
The holy-grail quest of the lumber world has long been to find
an inexpensive and sustainable alternative to genuine mahog-
any. The various African and South American sunstitutes that
rise to the challenge often be<ome increasingly unavailable
and pricey as they gain prominence.
In steps Lyptus. A eucalyptus hybrid grown in sustalnable-
growth plantations In Brazil and distributed by Weyerhaeuser
(800.320.9720, lyptus.wm), Lyptus reaches maturity In about
15 ye3IY---2 to 4 times faster than similar hardwoods in colder
climates-keeping Its price low and Its availability high.
WHY YOU SHOULD TRY IT: The color of Lyptus ranges from
light pink to a deep cherry tone, and it finishes easily. While
Lyptus's hardness, durability, and price are on par with hard
maple, Its fine grain rcsembles genuine mahogany. You can
even find Lyptus plywood in a variety of thicknesses, colors
and core options.
WATCH OUT FOR: Splintering. Lyptus splinters easily, so back
up your rouUng, cutting, and dcllllng with scrap. (Some wood-
workers choose to wear gloves when handling Lyptus to avoid
the small splinters.) Like hard maple, Lyptus can be tough on
your tools. Use carbide-tipped blades and bits and make sure
that they arc sharp to reduce splintering and tear-out. When
routing, make multiple passes, removing no more than 'AI" of
matcrlal at a time.
Sheet Goods: Combination Core
As manufacturers continue to reduce the thickness of veneer
on sheet goods, it becomes easier to accidentally sand thIOugh
that thin outer skin. And while hardwood-veneered sheets of
medium-density fiberboard (MDF-core) give you smoothness,
they're not suitable for applications where rigidity and strength
count. Our advice: Take a look at combination-core sheet
goods. Marketed variously as Combi Core, Armor Core, Classic
Core, and Pro Core, combination-core sheet goods sandwich
softwood plies between MDF layers, which are then faced with
hardwood veneer.
WHY YOU SHOULD TRY IT: O>mbinatian<ore sheet goods
blend the best qualities of plywood and MDF. The plywood
core- proVides rigidity and holding power for screws whlle
keeping the weight to a more manageabLe level than MDF-
core sheets. The MDF layers ensure that the imperftx:t piles
don't telegraph through the top layer of veneer, giving you a
smoother surface and a Void-free substrate. These sheet goods
arc perfect for desktops or other surfaces that need a hlgh-
gloss finish where surface irregularities might otherwise stand
out. Check with yOUT local lumber supplier for availability.
WATCH OUT FOR; Price. You'll pay from 5 to 20 percent more
for comblnatlon-core than for veneer- and MDF-core sheet
goods. But that's not nearly as much as replacing the plywood
you ruill<.'d while sanding out surface irregularities.
In combln1ltlon-coN! sheet
goods, smooth MDF rep laces
the outermOSl piles, but leaves
the Inner piles for rigidity.
Out door Projects: lpe
Looking for the ultimate, Insect-repellent, rot-resistant wood
for your next outdoor project? Take a look at ipe (pronounced
EE-pay). Ipe's rich color and unmatched durability have made
It the darling of deck construcllon for several years. Lumber
retailers Increasingly stock Ipe as dimensioned hardwood.
When fin ished properly, ipe makes a striking choice for o ut-
door furniture. planters, arbors, and footbrid ges.
WHY YOU SHOULD TRY IT: Ipc's durability seems a lmost
magical. Naturally resistant to decay, moisture, insects-even
fire-it 's so dense that It actually sinks In water. And, though
its price runs about twice that of cypress or cedar, with proper
treatment, outdoor projects made from Ipt' will long outlive
these less-durable woods and may very well outlive you.
WATCH OUT FOR: Construction considerations. Ipe's hard-
ness is rough on cutters. Be sure to use sharp, carbide-Upped
blades and bits. To avoid surface t:h~k ln g, immediately treat
the ends of ipe with a wax-based cnd-
grain sea ler after cutting it. To
mainta in a rich walnut color, apply
an annua l treatment of a penetrat-
ing oil fin ish containing UV
inhibitors such as Penofln
(800-736-6346, penoftn.com).
This ipe chair will retain its
beautiful color thanks t o
lInflUlI1 re-coatings with I
penetratlng-otl flnl~ .
woodrTWIgulne. t om
Eco-sensltlve: Bamboo
No longer limited to a dietary staple for pandas, bamboo is
actually a grass with some pretty amaZing qualities. It grows
to harvestablc size in 3-5 years and regrows after cutting. Its
stalks can be cut Into strips and laminated to form a surpris-
ingly hard and stable woodlike material. Bamboo Is making its
way into all types of applications, from flooring and kitchen
countcrlops to sheet goods and decorative banding.
WHY YOU SHOULD TRY IT: Manufacturers. such as Totally
Bamboo (760-47 1-6600, totallybamboo.com), manipulate the
dlstinct yet subtle grain patterns and color, to produce a nearly
endless variety of patterns. As the even-toned, knot-free looks
of bamboo become morc and more popular, watch for an
Increasing number of products and materials made out of this
versatile and affordahl~ plant.
WATCH OUT FOR: Shredding. Use fine grits when sandlng
and shallow cuts when routing to avoid shredding bamboo's
fibers. Also, bamboo's porous end grain quickly absorbs all
liquidS. Seal surfaces agaimt moiSture with an all fini sh or
polyurethane to a\'Oid warping and swelling.
ManufactureB laminate bamboo either horizontally (left) or vertically
(right). Heating bamboo carbonizes the ~ond-colored stalks,
da rkening them to a caramel ton e.
53
 ot every woodworking task calls assortment of the best power equipment most produce excellent results right off

N for a tool with a plug or a battery.

Sometimes, the best tool for a job
is powered by your own two hands.
can't handle ('Very woodworking task.
A simple card scraper, for example,
has no speed adjustment, no a<:cessorles
the bat. All of them deserve drawer space
ncar your workbench.

Pei:k inside tht! WOOD. magaz.lne or attachmenti, and barely even an

workshop and you'll see nearly t'very
stationary and hand held power tool
Imaginable. But open the dra .....'Cts near-
est our workbenches, and you'll find
them filled with well-used hand tools
ranging from utlllty knives to block
planes. Thai's because even the greatest
instruction manual. Hut it can peel off
an old flnlsh faster and cleaner than a
random-orbit sander, and leaves an
almost-burnished smooth surface when
used on bare wood.
Some of these hand tools (see Sources)
require a bit of skill and practice, but
What's in your shop?
Got it favorite must-have hand tool? Tell us
about th~ tool and how you use it. Email
bob.wllsof'l@meredith.com,orwriretoBob
Wilson, WOOD magazine, 1716 locust St"
LS-221, Des Molnes,lA 50309-3023.

1 Bench chisels
Like a trusty pocket knife. you'll reach
for a sharp chisel to help with a host of
odd jobs. Ours gel a regular workout
smoothing the walls of mortises roughed
out on a drill press. For this task, you'll
want a chisel at least I" wide to pare the
walls, as shown at right, and a W or ~.
chisel (or the nearest metric equivalent)
for the ends. We prefer chisels with bev-
eled edges, which can reach into tight
corners or betwe~n hand-cut dovetails.
Other use,: Keep a set handy to tweak
the fit of all kinds of joints, not just
mortise-and-tenons. We also use bench
chisels for everything from trimming
off tiny bits of glue squeeze-out, to
squaring router-rabbeted corners on the
backs of hames, to shaving finish flaws
from flat faces.
Success secret: Tougher steel genera lly
costs more money. So buy the best qual-
ity you can afford, even if that means
settling for the smallest available set o r
buying individual chisels as needed.
Then learn how to hone a razor's edge
Chisels flatten the walls and square the
on them. To see a free video expla ining rou nded corners on this d rilled mortise. A
a no-fuss sharpening technique, visit guide clamped to t he workpiece kee ps t he
woodmagazine.com/sharpenlngvid. chisel at a 90 angle.

WOOD m agnl.... ~t~mber 2009

54
 2 Contour sanding grips
Look around your shop long enough,
and you may eventually find some
object the right size and shape to usc as
a temporary backer for sanding a profile.
Instead, skip the search, and get a set of
these pliable grips. Their varied contours
sand everything from crown molding
contours to 1(8" round-overs without
altering the profile. A full set includes
angled, concave, and rounded shapes.
Other uses: Use the narrow handle to
reach decp into grooves. Or flex the
handle against a gentle concave profile
in place of a foam sanding pad.
Success secret: The small sanding sur-
face area wears quickly, so frequently
rewrap the grip with fresh abrasive.
Small sanding tools have a way of disap-
peari ng; keep them organized in a kerfed Foam sanding pads work well on broad
scrap block, as shown at right. (u~s, but contour sanding grips reach into
and around tight curves and Vgrooves .

~a~'~t~~"SO~~~lel~~ood'
scrapers smooth wildly figured woods
md
without tear-out. On straight-grained
wood, they also can eliminate at least
one of the coarser sandpaper grits needed
to remove tool marks. Use curved or
goose-neck scrapers to shear tool marks
off gently rounded profiles.
Other uses: Try removing a defective or
damaged clear finish by sanding it away,
and you'll quickly discover "corning."
That's when finish turns into hard globs
that clog sandpaper and mar a surface. A
card scraper quickly peels off film fin-
ishes-including polyurethane, which
resists abrasion, as shown opposite top. If
necessary. follow up by finish-sanding at
180 or 220 grit, and you're ready to
refinish the surface.
Success secret: Card scrapers work by
planing off wisps of wood (or finish)
using a tiny hook along the edge. To get
a hook that's just right, see a free video
at woodmagazine.com /cardscraper.

4 Low-angle block plane

You'd need a stack of sandpaper to pro-
duce the smooth surfaces ldt by a few
strokes from a well-honed block plane.
Keep a sharpened one handy to perfect
mating fat:es before edge-gluing joints.
Other uses: Try a low-angle block plane
to cleanly trim proud end grain from a
butted corner jOint or through-dovetail
joint. Unlike sandpaper, it block plane
removes an even amount of wood when
chamferlng a sharp edge.
Success secret: Tune up any new plane
by first flattening the sole using Hm-,
220-,320-, and 600-grit wet/dry abrasive
sheets lubricated with WO-40 on a piece
of plate glass. Rub the sole back and
forth, rotating It end for end periodi-
cally, unt il it's uniformly shiny.
Then hone the blade using tips from
the sharpening video mentioned earlier. With the blade set to remove shavings less
Keep It sharp by storing the plane imme- than paper thin, a ba~ic block plaM peels
diately after use. away burn marks in a couple strokes.

5 Flush-trim/dovetail saw
With no tooth set, these saws help you
trim plugs or dowels flush without scar-
ring the surrounding wood. As an add&..l
precaution in soft woods, such as pine,
first push the exposed plug through a
hole in a worn-oul sanding disc, as
shown at right. Then sand flat the
remaining nub.
Othe r uses: At least one saw (see
Sou rces) includes two interchangeable
blades-one for flush-trimming, and
the other with a rigid back for making
super-thin kerfs for hand-cut joints,
such as dovetails.
Success secret: ror flush-cutting, flex
the saw body to keep it pressed fi rm ly
against the wood surface, and cut on the
pull stroke. Don't rotate the saw handle
In a way that angles the teeth enough to
dig into the surface .
Sources
Blnch chlseb: Bo~ed sel of 51~ beYeledgechisels
(\4', 1\', ~', ;"', I', '~i bylrwin MarpleHlO. :won, $70,
flodler, aoo27'}-4441. or rodderLOm
Contour UoOOln9 pads: Set of15, flO. 513Z82.1O. $14,
Lee Vall~ Tools, aoo87HI158, or leevaHey.com
Cant ic:rllpen: Setoftwo BAHCOSwedi:ih scrapers.
flO. Cll110 ,$ 18, Woodcraft, 81)0.225-1153, or
woodcraft.com
Block plilne: W1itas iI+oron Planena.OSm.oI, $BS,l.e1!
Valley Tools.
FluJhcuttlng/ d<wetali saw: Dozulti fluJh-(ut{ A disc placed abrasive -si de down around
doYl:!tail !klW set ....ith two ~Jde, and ooe handle flO. the plug prevents minor saw tooth scratches
22305, $37, Rockier should you accidentally pivot the blade.

WoodmIl9I1zln...com 55

hen YOUT router accessories
W have scattered around the
shop like chips fl ung from a
panel-raising bit, corral them in the
drawers and cabinet of this virtually
56
indestructible, easy.to-make router table.
You'll gain a rocksolid worksurface.
with quick router access to adjust and
change bits. Then see page 24 for acces-
sories to make a great table even better,
Begin with the case
1 Cut the base sides (A) to size [Mlterl-
alsUst. pagr6JJ. Then cut the shelves
(B), d ividers (C). base tops (D), and
d rawer 5Upports (E) l4" longer than
required.
2 DadO and rabbet the ha..e sides (A)
a nd d ividers (e) [Drawings 1 and 1al
to accept the shelves (8) and ha~e tops
(0 ). Qukk rip: Don't rabbd yuur rip &
fence. Atwcll a "'"thick sacrifIcial fimce to V
yOllr rip feria with dvuble-(Uced tape whm
rabtxting less thllJf 1" from your rip fence.
Cut da do~s in t he upper sh elf (8) to
recelve the div iders (e).
3 Rabbet the inside back edge of each
side (A) to a<xept the lower hack (F)
and upper backs (C) [Crawing laJ.
4 Lay out t h e drawer-support (E) loca-
tlons on th e sides (A) [Orawing 1111.
Nesl7.e t he dado set to the drawer-
mpport t hickness, and dado the sides
and dividers (C).
5 After allowing for plywood thkk
ne!.S variatio n s, t rim the dividers (q,
base tops (D), and drawer support5 (E) to
length. Then cut the base rail (H) to Size.
Sand a ll plywood parts to 180 grit.
6 Rest one side (A) dado side up o n
your ben ch . Glue and insert a base
lOp (D), two drawer supports ( E.), and the
upper shelf (8) In the base side d adoes
and rabbet [Drllwlng 1]. Then gl ue and
add a divider (C) a nd dam p the assem
bly [Photo AI.
 ;
square ,I while drawer supports (E) rest in
clamp the subasse mbly. t he other base side (AI.

r
Em SIDE & DIVIDER DETAIL
20

!.
' /~v rabbet
~" deep ~" deep
,....
'\to- r.lb~"""'\.
, DEXPLODED VIEW
1
,
,.., IN"dadoes \ ~.

*"deep

,,
't"
.. >~'d~~ ~.
@
-

locations of
1/
<1
J
fSK1Y2" FHWQod
~.det!p r8bb4!t
lIo' d~p

,.
I
I

LEFT51DE
(Inside face shown)
_."., 1
1
34'11"

I
round-over wraparound hinge

'0'-;::.1
J
7 Atter the glue dries, glue and insert
the bottom shelf (8) and base rai l
(H). Temporarily add, but don't glue, the
and Insert the divider into the upper-
shdf (B) dado. Glue a nd insert the
drawer mpports (E) and base lOp (D), fol-
at the front and back for mounting
screws to Install the top.

other side (A) 10 align the assembly
[Photo 8J wh ile damping.
O Attach right-angie clampi ng blocks
Orosupport the other d ivider (C). Glue
lowed by the sIde (A) LPhotoCJ . Now add two simple doors
9 Cut the lower back (F) and upper
backs (G) to fit, and set them aside.
Drill .!:2- holes through the base tops (0)
1 Measure the height and width of the
bottom compartment, then cui two
doors (I) ~. shorter than the opening

57
 D DRAWER
.-
w,,''',
'1:1'
deep
~
14" groove '4" deep
'I, from bottom edge
II RDUTER-TABLE TOP
YJ" rabbe-t to match depth
of router plate Insert
".. chamfers
routed after
assembly
and ~o narrower than half the width of
the open ing jOrawlng 11.
2 0n each door (I), cut the finger pull
with a jigsaw and sand smooth. Rout
W round-overs on the inside and out-
side edges of the half-circles. Ease the
other edges with ]20-grit sandpaper.
3 MOU I1 t the hinges on the door (I)
edge opposite the finger pull 2" from
the top and bottom. Lay the cabinet on
its side and raise the door on risers (ours
werc W thiCk) W IX>sltlon it beside the
cabinet. Use a '1'i6"-thick spacer between
the bottom edge of the door (1) and tht'
lower shelf (8) to position the door.
Screw the hinges to the case IPhotoOI.
4 Screw a magnetic strike plate to the
door where shown and position a
5.
1911:."
~
Resting the door (1 ) on risers letl you control hing e
placement on the ' lise side tAl, Center pilot hol es In the
oblong hing e slots to flne tun e the door position later.
9 ~ 12" insert
i.:Iminate.
screw the tops together, but avoid glue
magnetic catch on t he plate. Then close
the door, look t hrough the open back,
and mark where the magnetic catch
touches the underside o f the upper shelf
(B). Drill and mount the magnetic catch
on the upper shelf. Now turn the cabinet
on its opposite side and repeat steps 3
and 4 for the rema ining door.
Make a six-pack of drawers
1 Measure the height of the drawer
openings and rip a 38"long blank
~6" narrower than t he opening height.
Cut the drawer sides (K), backs (L), and
bottoms (M) to size [Drawing 21.
2 0n the blank for the drawer fronts
U) and each side (K), cut a drawer
bottom groove where shown.
3 Cut each fro nt (J) Y16' shorter than
the drawer opening width. On each
drawer front, jigsaw a finger pull and
~and it smooth. Rout 1,ok" round-overs on
the inside and outside half-circle edges.
4 Rabbet both ends of each drawer
fro nt U) and d ado each drawer side
(K) to accept the drawer batk (L).
S sand all drawer parts (J, K, L, M) to
180 grit. Then glue and assemble
them [Drawing 21. and check for square.
Top off your router table
1 Cut two tabletops (N) about 11..- over-
size [Drawing 3]. Mark the aIea on
the lower tabletop where t he router-table
insert will mount. Glue, clamp, and
and screws In the router-table h15ert
area. Allow the glue to dry overnight,
then cut the top to 5lzc.
2 eut the tabletop end trim (0) to
match th e top assembly (N) ends.
Glue and damp the end trim flush wit h
the tabletop and the front and back
edges. Then cut the tabletop side trim
(P) to fit the WIdth of the top and end
trim (N/D). Glue and clamp it flush with
the tablelop and end trim. Finish-sand
the top assembly (N/O/P) to 180 grit .
3 Cut a sheet of plastic laminate l'
oversize for thetopassembly(N/O/P).
Adhere it centered on the tabletop. Use a
flush-trim ro uter bit to trim the laminate
flush with the trim (0, Pl.
 MDF fr~m.

0Y'~
C;;;;;;'d:;-:-:';;;;:::ibi.;;':;;;~ ;;;;;;;..;;;;;;;;~ ,N,'O/lP)" the n frame
It with MDF strips wide enough to acco mmodate your router base.
o
WIth ~-thick spacers inside th e MDf frame, rout clockwise through
the laminate and upper MDF tabletop (N) in Yo"-deep passes.

MDFframe

,
frame comeT0016 remove stoc:k the rabbeting bit can't reach. bearing num-trim bit rout~d earlier.

Install a router base plate Quldr tip: Use multiple passes. Plunge iJ

1 Center the insert plate on the table-

top, and fra me it with MDF strips
clamped and double-faced-taped to t he
tabletop (Photo EI. Rt!move the insert.
Note: The router-table imert W( lISf'd (SU
Soul'l'a) has a W-wlde rabbet around the
underside edge. If yow insert lacks tl1ls lip,
modify the spaw thickness and buslring
diameter to adjust tire dimensions ill the
~lIowing steps.
2 TO leave a Yz"-wlde lip. first cut the
table assembly (NIDII') opening I"
~maller than the insert size. To do Ihis,
install a Y.!" straight bit and W guide
bushing on your router. Secure Hi" -thick,
W-wide spacers to the Inside edge of t he
MDF frame using double-faced tape.
Plunge-rout t hroug h the laminate and
top layer of MDF, working dockwi~
around the frame w it h the router bush-
ing against the spacers [Photo F].
rout in 'A"-deep pa_~.re.~ to the maximum lJ
length of the bit to amid overtaxing both
rtlutrand bit Remove the oW_thick spac-
ers and the unglued upper layer of the
tahletup (N).
3 Using a drill b it with the same radius
a~ the router-table insert corners,
dri ll one hole through the top at each
corner of the routed opening IPhoto Gl.
Then, in the framed opening corners.

..... oodmogill.ln .... com 59

o dri",,'h,,'., with ill bearing-gu ided bit Chamfering the ends of th e f@ncedustport(T)helpsitform II tight
to create ill lip that will accept the InuTt. seal against the fence front (0) and base {RI.

El ROUTER-TABLE FENCE

_~l6" ~Jfj
t -,
~
16~"

__ - .-
. ..
5

~)( 3'1>" carriage boll- i

drill holes Into the top layer sl1ghtly
deeper than the Insert thickness.
Note: Oll{ router-table insert hal ~'-radills
romers, so we used a Wdillmeter drill bit.
If }'\'JilT insert corner radius exceed.~ #;", drill
these holes before routing the top.
4 Remove the MDF frame from the top
assembly (N/O/P), turn the top
assembly upside down and draw lines
between the centers of the holes. Cut
out the opening with a pgsaw.
With a bottom-bearing flush-trim
S bit, rout from the table underside to
clean up the opening [Photo HJ.
Tum the top laminate side up and
6 install a Vz rabbeting bit set to th~
depth of the insert thickness. Then rout
a Y2" Iabbet around the top opening
[Photo IJ. Clean up missed areas betW('Cn
the rabbet and the W holes with a chisel.
Quick tJp: L ighten up on your flmd ~
pass. An jnsert that rt!.')ts flush WW, the V
Wllter-table top is crucial for smooth table
TOuting. Removt mmt Of the materlo.l for the m
FENCE CLAMP BLANK
lip supporting rhe insert in one or two passes,
bur make the final pass a light, skimming ~6\4"
one ro leaV(' a smooth, unifunn lip.
7Test.fit the insert in the opening. If ,.. hole ~"'f:""~~ :;2::~
= j-
2~"
, the fit is too tight, lightly trim the
plate on a tablesaw. If the plate is too
loose, glue narrow filler strips around
@ '. @
~ ~_ -l
"<1
the tabletop opening. 3"_~ I ~"
8 Rout a 11' chamfer on the top and
bottom edges of the trim (0, P); then
ease the corners with sandpaper.

60
Build a fence for your table make a 1\i2 ><2 ihx6W blank [Drawing 4111. base, and check for square. Now reattach

1 Cut the fence front (Q), base (R), and

supports (5) to size [Dfawing 4J.
Clean up the edges by cutting the blank
to 2W wide. Square both ends, and drill
the hardware, gather up those long-lost
router accessories and get organized .

2 G1ue the fence front (Q) to the bast'

(Rj. Then add the supports (5) and
check for square.
C\lt the fence dmt port (Tl to size.
3 Sand a 45 0 chamfer on ooe end of
the port to fit against the fence base (R)
[Photo J). Then chamfer the top end
until the dust port rests flat on the sup-
ports (5).
#," holes centered on the blank edge and
1" from each end. Then drill correspond-
ing holes in the router fence base (R)
Written by Bob Wll oon with l eff Mert z
Project design: Ku ln Ro yl e
IIlultratioru: Roxan ne Le Mol n lt; Lorn a lo h nro n
where shown [Drawing 4).
6 Saw the fence clamps (U) to size, and
bandsaw notches where shown.
Insert a carriage bolt through each clamp
block and add the washer and knob. Materials List
Remove all the hardware, fin ish-

4 Rore a centered 2Y.!:" hole in the fence

dust port (T). Glue and clamp the
7 sand the parts to 180 grit and apply
a finish. (We used two coats of wipe-on ....
Part T
FlPliI~I-lIO~llt
W l Mill. Qtr

,
port j n place. Center a plastic dust port polyurethane, sanding with 320 grit A ,,~

'" 20" 341'..'

" ,
.....
[see Sources] on the fence dust port; then between coats.) l>" 19Yo" 25\4"
B' shelves
" ,
drill aIllI screw it in place.

5 10 make the fence clamps (U), lami- 8 MOUl1t the top assembly (N/O/P) to
the base. Then drill and screw the
C' dividers
0'
Yo" 14~'
Yo" 19W
" " ,
"'~-
BP
nate two pieces of W plywood to lower back (F) and upper backs (G) to the ,
E' drawer supports
" "" 19W MDF

Cutting Diagram G
F lowe-back
upperbac~ . ""
j\" 20 ~' 25'14"
1M,'
"OF
"DF
,
H base rail
'" "" 24.."
" 2
R
Q H
doo,
Drawers
'" 15"- 12~"
"
r

_ ... _.- K
l
drawer fr{)!lIS
drawer~

drawer bad:s
J.<" 4"'"
Y.." 4J'i.
5'1,.,."
191'/
Y," 3";'. S?I."
8P
P
P
6
12
6
M dr~wer bottom~ Yo" 5l'11;" 15Yo' MDf 6
Tabletop
NH tabletop Yo" 2m" 30W MDF 2
@
tabletopefldtrlm~' ly," 21W P 2

,-'"
~ II: 4S II: 96" Plywood Q fencefrorrt 3.- 36" BP
R
S ""'" "'"
fence supports .- ,."
3Y'- 36"
2l'1" " ,
'" ,
T fence dust port 4~.

u- fence damps
" '"
Ill!" 21"<" 3"
"'"
Be

'Parts initia.y cut oversJze See the imtN(t~

Oftaminate two pitt:es to mak~ these p.ar~ See lt1~ iM!ructioM.

Mat~rlals k~y: MDF-mffiiumdensity fiberboard,

Medium...:len~i'y fiberbOilrtl
P popI3I", BP- oir(h plywood.
Supplies: .S:..}/" flatood wood !.O"eW~, .SXl Yl'llat
he<>d wood Wew"S, plastic; laminate 24X36", "It" sur ~
(21 '!\x3\f,. Cill"riage bolts W. ;a' washers (2), magM(
catches (2).
Blada and bits: '" rcund-OW'r, ]I," straight (with J.<"
bushi~~ bottombeanog flush-trim, chamfer, Yl" r~obet
ing bits; 11", 21'>" dMU bits;dado~t.

I @ IN
Sources
Routertable Insert. AIIln-Ooe Router Plate
Kit!':lx12') 110. 93lB, S35,MLCS. 800-533-9298,
':4 II: 7\4 x 96' Popl/lr (5.3 bd. fl.) (2 necd<>d) mlaiwoodworking.mm.
~f>la~ or resaw 10 the thlckne~s listed in the Material5 U~t. Univerul dUlt port. Fot atliKhiogd 1),:\" ho~.1.tIe
no. 92031, $7. Redler. 8002794441, rockler,com.
No-mortbe hing~s. flat~ ~*,'st~ing niOO!l
!W j'0 hi()c}eS {4j IIO.A03100TG9 PI(, $2.51 eiICh, Woodvrorke~~
liardware. 800 31!3-o1311, Of wwhardware..:om.
3A x S'h ~ 96' Poplar (4 bd. ft.)

wDOdmag a ~l n lt.co m 61
 ..=-.::
,,",-
=-~
-~
~-=
=-':::: I'

leek and sexy. smoothly riding a
S shiny aluminum rail, leaving in its
wake not a ttlttered mess, but crisp,
clean edges ... one thing Is certa in: This
isn't your father's circular saw. Dad, meet
the rall-gulded saw-the next genera-
tion of portable circula r saw.
Rail-guided saws beat other eire saws
hands down in four areas:
They cmsscut spllnter.prune veneered
plywood as well as or better than a good
tablesaw and a top-flight blade.
SP6000 with a 6W bladc and 55" rail)
will set you back S465; the Festool
TS75EQ costs $625 with Its 814" blade
and included 75" rail. (Add $125 more
for the 55" extension and connectors
that let you rip an 8' sheet of plywood.)
For about the same pricc, you could
Instead buy a good c.:ontractorstyle
tahl e~w with a cleancutting blade.
so, are raUguid('d saws worth It? We
challenged five machines in a variety of
hardwoods, softwoods, and 5heet goods
On cut quality a nd power
If you've ever ccoss<:ut oakveneered ply
wood, you know that the porous graIn
makes It dIfficult for ncarly any saw and
blade tn Wi cleanly. And the brittle sur
face of melaminecoated partidetxldrd
chip5 if you look at it wrong, much less
cut it with a power saw.
All of the saws delivered impressive
cuts [Photo A] on the ~ kee pe[ " workpiece
in both materials, thanks to the zero-
d~arance edge-a sacrificial plastic strip

Cutting any odd angle Is a brt."eze. to find out. Here's what we learned. on the tral,;k that you cut the first time
When you need to rtart a cut in the
middle of a workpiece (a sink cutout CLEAN CLEAN THESE CUTTING MACHINES
comes to mind). a rail-guided saw makes
the lob faskr, ~fer, and more accurate
than any other method, panly because
the zero-clearance edge of the rail shows
exactly where the blade will cut.
Finally, hooked to a vacuum, the
guards thal surround the blade increase
dust-collection efficiency. leaving the
floor nearly as clean as the cut.
With quality, though, comes cost. The rJ
IO...."eSt.prlced saw/rail pairing (Maklta All five rail'guided saws delivered cabinet-quali t y crosscuts like this In birch-ve neer plywood.

WOOD m A9Ukte ~tffilbo:!f 2009

62

DeWalt's antikickback mechanism, engaged by this kn ob, bloc ks backward movement
without restricting forward motion on the rail.
you use it. Like a zero-clearance throat
insert in your tablesaw, it virtually
eliminates tear-out and fUlling.
These machines excel at cutting sheet
gcxx1s; but could one replace your table-
saw? In 4/4 poplar, tipcuts required some
sanding or a light jointer pass before glu-
ing. Cuts made by thC" cordless lJeWalt
DC3515KL felt smoothest while those
made by the mrded DeWalt DWS520SK
needed a bit more attention.
Flut in thkk, dense stock (we trleJ. 8/4
hard maple), ripcuts tested the limits of
some saws. Although the corded DeWalt
and both Festool units displayed ample
power to slab off strips of 2"-thlck hard
maple, the Makita and battery-powered
DeWalt DC351SKL required slower feed
speeds, which sometimes resulted In
burning on the cut edges.
Because of the spring-loaded plunge
system, setting cutting depth on these
saws isn't as simple as on an ordinary
eire saw. Instead of pivoting the base,
you must set a depth stop. All operate
easily, but we prefer DeWalt's scale that
shows cutting depth by the thickness of
material you're cutting- the lh" setting,
for example, actually projects the blade
W below the saw base to account for the
rail thickness. On the metric-marked
scales on the Festool and Makita saws,
wootimaguine.cOfn
you need to set the stop to at least 16mm
for the blade to cut completely through
12mm (11:") stock.
Rail detail. make the dlff
A slot on the base of each saw fits over a
raised gUide rib on the 7'-ish-wide rail,
and knobs let YOu dial in the base/rib fit
precisely. As a practical matter, you can
easily cut pieces as narrow as 4-5 Vi:'
(depending on the saw), as long as that
rib remaim over tht! workpit.'"l.:e. A little
iury-rigging with spacers enables you to
work narrower stock.
Pliable strips on the bottom of each
rail provide enough bite on the work-
piece so that, in most cases, the rail slays
put without clamps (optional for all
saw~). DeWalt's rail, though, didn't feel
a~ "gTippy" as the others, and in fact
slipped about W' on a 6'-long cut in
melamine without d<lmps. Still, wt!
almost <llways used the optional (and
pricey, see chart on page 64) clamps on
all of the rails: They mount on the
underside of the rail so they never inter-
fere, and we found that a little pressure
goes a long way. One clamp was often all
that was needed for a secure grip.
You can bevel-cut with these saws
[Photo BJ, but tilting the saws more than
about 25~ shifts the center of gravity
Although all of the saws cut ~vels, Makita
provides the widest range (-1~ to 48) with
stops at both 22.5" and 45' (not shown).
CUT HERE KEEP THE KERF OPEN
a lso sport
riving
enough to start lifting the base from the
rail. Makita combats this with a sliding
lock that hooks into a special channel
on the guide rib to prevent tipping.
Plunging to perfection
A rail-guided saw ellminates most of the
danger of making a plunge <.:ut: The hase
remains solidly on the rail throughout
tht! plunge; and an antikkkback stop,
whether built-in (DeWalt. activated by
the knob, Photo C) or mounted on the
track (Festool), prevents the saw from
moving backward during the plunge
cut. (Makita recommends mounting a
stop on the track, but doesn't offer one,
or suggest how to do that.) Index marks
on all of the saws show where the back
and front of the blade will cut at full
plunge IPhoto OJ .
63
Your guide to the rail-guided saws
DeWalt DWS520SK, $500
DeWalt DC351SKL (cordle), $900
!8oth prices Include S9~ rail)
800-4339258, dewa lt.com
If you plan to do a lot of plunge-cutting in shet't goods,
either of these saws~identical except for the power source,
motor, and sticker price-with built-in anti kickback stops
and intuitive cutting-depth scales (marked in inches)
Is an excellent choice. The depth-stop lock knob
tightens easily, butean be tough to unlock, especially
If you have limited hand strength.
In plywood, even the offcut pieces displayed a near-
cabinet-quality edge, minlmlz.lng waste. Unique to
DeWalt: Glide strips on the side of the blade guard
provide a no-mar surface for cutting flooring along a
wall or trimming the bottom of a door without the raii.
And you can run the saw along either edge of the
oeWALT OWSS20SK rail, so you don't have to turn it end for end
to change cutting direction (but we didn't
see much benefit to this feature). The cord-
less DC351SKL cut 34' of inch-thick poplar on a full
one-hour charge of its 28-volt lithium-ion battery.

SAW RAil PERfORMANCE GRADES (4) TAmiSCliill5j

BRAND MODEL

46"1$80,
DEWALT
102"/$230*

l'
FESTOOL

110 2,000--5,200 Ii)!:, 48 2~ -1-48 sY: * B C,R lOA 8

Narrower WQ~pj;>,ce5 can be cut using spacers Excellent s, (B) Carbide blade
the same thickrwss as stock. Good (C) Clamps
(K) Antikkkback stop
2, (*) Saw and rai l sold separately Fair (R) Rail
Poor (5) Speoalty blades
3. (*) lOr rail c.osts only $100 when purchased In
kit with iaW and 59" rail 6, (0 Czech Republic.
(G) Germany
(U) United Kingdom

WOOD magulnot Sf!ptfmoo 2009

 Festool TS55EQ (6\14" blade), $500
{Price includes 55" raill
Festool TS75EQ (8'1." blade), $625
(Price includes 75" rail)
888-337-8600, festoolusa.com
Just because something was first doesn't make it best. But
in this case, Festool's veteran TS7SEQ outshone the
upstarts. Its I3-amp motor tackled 8/4 hard-maple rips
without complaint, and it left clean edges in melamine
and veneered ply, even on the waste piece. Where
blade changes proved a three-handed operation on
other saws, Festool's "Fast Fix" system loch both
plunge depth and arbor rotation with one flip of a lever.
(The detachable cord makes blade changes safer, too.)
We do have qUibbles: Is it too much to ask for impe-
rial (inch) depth-af-cut scales instead of metric?
And the depth indicator doesn't include the
thickneS5 of the rail, so you have to add a
couple of millimeters to cut completely
through your material. We liked FestooJ's
quick-ratcheting clamps, but they're pricey-S38 apiece.
The TSSSEQ, a smaller version of the TS75EQ, with a
lO-amp motor and a 6W' blade, provides 1}'j6" less thickness
capacity than the TS75EQ.

Makita SP6000, $465

(Saw and rail sold separately. This price incl udE! s a 55" rail.)
800-462-5482, makitatools.com
The SP6000 both delighted and disappointed us. We like it
for bevel-cutting, because it provides the widest range
with stops at 22.5 and 45", and it features a unique lock
to keep the saw from rocking off the rail
on wide bevel-CUts. For scoring tear-
out-prone materials, a shallow preset
depth ~top projecu the hlade ahout Wi
after making this cut, you then release the
stop and through-cut at full depth. \Ve found
this scoring cut necessary to leave a
splinter-free edge on the waste side
of the Cut. But the SP6000 lacks
features common on the other
saws, such as an antlkickback
stop for plunge-cub and a riving
knife. And in Z"-thick hard maple, we had to slow the
feed rate, resulting in burned edges.

7. Prices cUrient at Tops of the track saws

time of arlkle A rail-guided saw will never replace a tablesaw, but it sure outperforms any panel saw we've
production and tried (at a much lower price, too), and doesn't limit you to perpendicular cuts-you'll gel high-
do not include quality cuts at any angle. OUf Top Tool, the hefty Festool TS75EQ, displayed ample power and
shipping, where
preCision in everything from sheet goods to thick hardwoods. If you'll work primarily in sheet
applicable.
(*) With 55' rail. goods, and make plunge-cuts at that, we call the lighter-weight DeWalt DWS5Z0SK and Fcstool
TS55EQ different but equal. Buy the DeWalt if you value a hetter llepth-of-cut ~ystem more than
easy blade changes .

woodm~IIIln ... (om 65

Corral the Clutter
Printer Stand
Create-and organize-space under your computer's
printer with this weekend project.
First, build a case
1 To make blanks for the bottom a nd
top (A), case sides (B), center parti-
tion (C), top and bottom trim (D), and
shelve." (E), start with ~-thlck stock.
Edge.glue four ~43 panels. (See More
Resources, page 69.) After the glue dries,
plane the blanks to *" thick and joint
the edges square to the faces. Edge-glue
paIrs or bianks together to create two
IS"-wide panels [Photo AI. Lay a straight.
edge across each panel at several polms
to check for flatness. After the glue dries,
~and or scrape the loint flush i f needed.
2 cut the top and bottom (A) to length
from one blank [MAteri als Ust. page
69J. (You'll rip them to width later.) Cut
the case sides (8) and center partition
(C) to length from the other blank.
66
TO get a perfert gratn match between
3 t he trim p ieces and the top and bot
tom, rip the top trim and bottom trim
(D) from the front edge of the top and PROJECT HIGHLIGHTS
bottom (A) [Drawing 1]. Mark the mating
edge<; so you can glue them back later In Overall dimensions: 20W wide II 15~
deep II 9W high.
the samt' orientation.
A Set up a dado blade to matc;h the
~ hickn{'Ss of the panels. Cut \4"-deep
Partitioned shelves keep paper and
envelopE'S handy.
Orawers store ink Of toner cartridge~
dadoes In the top and bottom (A); then and Wlall office supplies out of sight.
lower the blade to cut \ol--deep dadoes In
the case sides (8) and center partition Skill Builders
(C) [Drawing 1]. Back up the cuts with a l earn how Lo jOin panels wider
than the capacity of your benchlop
follower board to prevent ehlp-out. Then
planer - and make them flat.
rip these parlS to fina l width.
5 R1P the shelves (E) to finished width
[Dr;swing 1[. Dryassemble the case
This project incorporates many fe atures
typically found in large finefurniture
pieces: raised drawer fronts, cootoured
and cut the shelves to fit snugly between feet. and shapely profiled edges.
the sides (B) and center partition (C).
Small clamps keep the ends of the joint lin~ Mow the workpiece (A) onto For a joint Ii i
flush . Chedt that the joint is flush along its left end hits the left-ha nd mark; then rout trim (0) exactly as it wn cut
length as you tighten the large clamps. until the right end hits the right-hand mark. for the top and bottom CAl.

D EXPLODED VIEW
\4" cove

1t17~ 1 19" -~
(
Wir~br~
Yo' rabbet
I~ 0 \10" deep
'.

,.-
I

~14'
~
1Io" roundover
wit h ill 1',,' shoulder

lIo'rOl.lrxkl\ler
with a Yoo' shoulder

6 use a straight hit In a

routcr table to cut \4"
rabbets along the back edges of the case
sidcs (B) IDrawing 11. Then rout stopped ROUTING DETA il ICI FEET DETAIL (bottom view)
rabbet .. between the o utside dadoes of
the top ami bottom (A) (Photo BI. Ito" 'to"
,
7 NOW you can glue the lop trim and
bottom trim (D) hack onto t he top
and bottom (A) IPhoto C1. Arter the glue G Glue
d ries, TOut a W cove on the undersid e o f area
the top (A) along it s ends and front edge
(Drawing lJ . Rout a " . round-over with a
\16' shoulder on the ends and front edge D
of t he bottom IDrawlng, ..].

woodm.g lne.com 67
Position the da mps to apply pressure
directly across the dadoes Ihal hold the case
sides {S) and shelves (EI.
8 FinlSh.sand the case pieces (A-E) to
220 grit. Glut the carcase together
[Photo 01, making sure the case sides (B)
anu center partition (C) are tight against
the back of the trim (D) and that the
shelves (E) are flu~h with the front edges
E!OAAWER (2 needed)
\'.r'rabbe!
Yl' deep
19' bevels
THE EN DS
68
TOdillmpt~h~.~!?!~~!!l~!
glue up, use strips of pai nter's tape across
the miter joint iIInd from corner to comer.
of the case sides (B) and center partition.
Check that the assembly Is square.
9 Measure between the- rabbets in the
back of the case and cut the back (F)
to fit in the recess. Set the back aside for
the time being,
THE EDGE S
teillr-out where the biillde nits the cut will
cleaned up when beveling the edges.
Now form the feet
1 From Wthick stock, crosscut two
4"-long blank.~ for the back feet (O)
[Drawing 1]. Then miter-cut two pairs of
4".long blanks for the front feet (G),
Next, make three copies each of the Left
and Right Foot Pillttems from the WOOD
PalternSfi insert and attach one to each
cur,
blank with ~pray adhesive. Cut the feet
to shape on a SCl'olhaw or ba n d~w, and
sand the edges smooth. Quldr TIp!
YO'" tfnu In "'"If. Stick two fcct
toget her with double-fal-"ed tape and cut
the profile In both at o ne time.
2 0 lue the four mitered feet (G) into
two pairs [Photr;t E], When the glue
has dried, finish-sand the feet to 220
grit, To attach the front foot as-;emblles
to the case, apply glue along the fun
length of the front foot, but only to the
front 2" of the: perpendicular foot [Draw-
ing 1bJ. Then clamp the front feet to the
case, On the back feet, apply glue only to
the rearmost 2", and then damp them
In place.
Build a pair of drawers
1 Measure the height .md width of the
drawer openings and cut two drawer
fronts (H) from *"thi(:k stock to \oU"'ess
Iha n the.\e dimensiom.
2 Tnt your tablesaw blade to 19" and
Insta ll a zero-clearance insert around
the blade IMore Resources). W1th a sadd le
jig (see page 70) stradd ling the rip fence,
set the fence as shown in Drawing 2 .
Now b{'wi the {'nds of both drawer
fl'Qnts (H) [Photo FJ. Set the saddle jig
aside, reset the rip fence [Drawing 2bl,
and bevel the top and bottom edges of
each drawer front.
 Create the illusion
of a gap
Instead of being suspended on
drawer slides or guides, these
drawers simply slide along the
bottom of the case. YOU'll have
a gap above and along each
side of the drawer, but not

below it. So you have to create
the appearance of one.
That'$ easy to do by simply
sanding Of planing a slight
-
drolwer.ldenlical diagonal measurements chamfer along the bottom edge
mean the drawer is square. of the drawer, as shown at right.
Take a few light passes; then
Center a hole on ~ach drawer front slide the drawer into the case. If
3 to accept the screw for the knob
[Drawing 2]. Then cut the Y.z" rabbets to
the ~gapH looks equal on ai! fou r
sides of the drawer front, you're
accept the drawer sides. done. If not, keep removing
mate rial with light passes until
4 Cut the drawer sides (I) and drawer
rucks 0) to size [Materials List] .
Machine grooves the thickness of the
the gaps look balanced.

drawer bottoms (K) [Drawing 2]. Then

cut dadoes across the drawer sides to
accept the drawer backs. Cut the drawer
bottoms to finished size and glue up the
drawers [Photo G] .
Create a {:hamfer along the bottom
5 edge of each drawer, as explained in
the Shop Tip at right.
Finish It up
1 finish-sand aU pieces to 220 griti
then apply lhe finish. (We used Red
2 Attach the brass knobs [Drawing 2}.
Then fasten the back (F) to the car-
case with #17xl' brads .
Chestnut stain from Varathane, and
then applied two coats of a semigloss
polyacrylic from Minwax, sanding with
320-grit sandpaper between coats.)
Written by Craig Ruegsegger with Kevin Boyh!
Project design: Jeff Mert:r.
Illustratiof'W ROllann" L"Moln,,; Lo.-na Johnson

Cutting Diagram Materials List

' ... ' lIlO ', Il l

ri' ~ Wi! 'fu

Case T W L !oMI Ql )
,,"
I
10
SL

1m k -1
A'
B' """'""""
""" .-'" ""
20Y.!'
Th'
W
W ,
'" ,.-
,.)( 51'1)( 96" Oa~ (4 bd. ftJ celller
'Plane or res~w to Ihe thicmess listed in the Materl.als lIsl. c partition
B.O w
,
D' boo "'""""
"m '" '" 20Y.!" 0
,
E' 'ihel~
'" '" 13b" ro
oe
F b;od
'" ". "" Th"
,
~x 517)( 96' Oak (4 bd. ft.) (2 needed)
G
Orawen
f~'
'" 4" 0

H fronlS ~. 3~" 8'tio' 0 2

H H
., Y.!'
Y.!"
3~'

3~'
B~'

6ho"
0
0
4
1
*x SV; ,,96" Oak (4 bd. ft.) K botloms \4' B%." 11\.1" 01' 2
'Pam initially"'t rHfIlizI!. 'iH tM instruCtionl.

Materiall key: EO-ed~9Iuedoak,O-oak, OP--oak

MORE RESOURCES
FREE VIDEOS
. -Zero-Clearance Insert" at
woodmag.uine.oonvUivideo
"GtuingUpFiat Panel\"' at
woodmagan.comfpanels
Y'1t 24 It 14" Oak plywood
plywood.
Supplies: SpraV adh~we, ~17xl' wire bradt
81* altd IHts: Staddadoset; ~ Cl:he.*" rouod-
over,and~' straight router bits..
Source
knobs: I" brass knobs (2)1'10. 36467, $4.69, Rockier,
S<lO-279-4441, rockle r.com .

woodmaga:r.lne.tom 69
Quick & E-IDJjg

Saddle
Jig
Not just a one-trick pony,
this fence sadd le rides to
your rescue when balancing
tall pieces on the tablesaw.
unning a tall workpiece

R against the rip fence of a

tablesaw can be an awkward
and dangerous operation. The piece
wants to tip in just about every
direction. This sliding saddle jig
solves that problem.
A workpiece damped to the jig
against the stop can't shift as it
moves past the blade. The tall fence
and stop steady lanky workpieces
for end-grain cut.~ , such as when
beveling the ends of the drawer
fronts for the printer stand on page
66, or when cutting tenons and
open mortises for bridle jOints, as
shown in the photo at right. As a
bonus, the stop backs up the
workpiece to reduce Chip-out.
Build the jig to fit the width and
height of your saw's rip fence. When
measuring the height, make sure you
take into account any bolt heads that
may extend above the top surface of
the fence.
Assemble the stop, tall fence, and
bridge first. (Use brass screws, not -- .. <
8"
glue, on the stop so you can replace it
as it gets chewed up.) Before screwing TALL
FENCE
the short fence to the bridge, put a
playing card between the short fen<.:e
and the rip fence to ensure a smooth
sliding fit.
When using the jig, the work-
'\ \
#8~l\1lF.H.
Locate bra>~
screws fur stop
above h lghe~t
piece should be clamped in place, wood screw blade setting.
as shown in the photo. Gu ide the
jig with both hands, pressing down I
to the table and against the blade
side of the rip fence. By gripping k Width of _ I
the workpiece at the top of the tall rip fence .....,
fence, your hand stavs well out of
the path of the blad~ .

70 WOOD m"g",:r.In., S~plember 2009

 or email: WoodcraflFranchiseOwoodcraflcom

~p:lg
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When woodworking is your passion, and owning your own
business is your goal, Woodcraft can help you take your skill
and expertise to the retail level.
... I think of Woodcraft"

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batween l IT 10 1 3.'16'
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23 Ga Pina. AI80 avail.DIe as a kit Us- 22 G8 318' Crown _
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G~ '10'" woodworkln~ toll'" NOW)
Ask WOOD
Answers to your questions from
HAVE A QUESTION?
For an answer to your woodwork ing question, write to ASK
WOOD, 1716 Locust St . LS221, Des Moines, IA 503093023
letters, e-mails, and WOOD Online or e-mail usat askwood@woodmaga:l:ine.com. For immediate
feedback from your fellow woodworkers, post your questions on
one of o ur woodwo rking forums at woodmagazine.comtforums.

Safety-fying the shop

Q . llm let'lving on a trip and I'm worried that my kids
might hurt th@mselvesplayingintheshop_Could
you give me some suggestions for quickly securing my
garage shop?
Pal Smith, Surry, Vo.

A _ Here arc a few tips for child-proofing your shop, Pat.

First, clean up. Put away all portable power tools that
can be stored and tidy up the floor to remove any tripping
hazards. Next, unplug all power tools and secure the plugs.
The simplest way to do this is with small, inexpensive
luggage locks through the plug, shown right. Finally, remove
all blades, bits, and knives from tools and store them in
locked cabinets.
And have a quick talk reminding your family to use
caution in the garage. When you return from your trip,
follow through with a more thorough shop safety education.
Who knows? What starts as a lecture in woodworking safety
might become a family hobby.

Q.
The straight scoop on wood grain
Your plans fortne Cninese Checker Board in the
. October 2008 issue (no. 186) say to bandsaw the
drawer opening out of the front, but you obviously
didn't do it that way because the grain pattern of the
drawer matches. Tell us what you really did.
-Gl'Ofge Long, San Francisco
Good grain selection begins at your hardwood dea ler. Take
your cutlist along when you choose your stOCk, but rather
than simply choosing boards to use as little stock as poSSible,
select boards with an eye toward compatible grain patterns
and matching wood tones. In the case of the Chinese
Checker board drawer front, straight-grained oak made the
task of aligning the grain easier.

A
George, your critique Is actually a compliment to our
builders' ability to choose grain in projects. In this
case, we cut the drawer front from the end of the board
directly adjacent to the game board face, as shown below.
If you prefer cathedral grain and stH! want it to match, cut
the drawer front from the game board face, as shown bottom,
at your tablesaw and glue the three front parts back together.
Be sure to account for the blade kerf when sizing the game
board face blank.

Straight Grain

~-------
Cathedral Grain 1.Ripfirst
2. CrolScut drawlr
front
3. Glul bottom strips
back totop

72 WOOD m.gnlne September 1009

What to do when spring back springs

as lOJA~ x 4~

. 7,000 RPM o;pindle Rpeed.

Each spindle is powered by its
own motor
1l-{:i2 FPM variable feed speed
See-through top S"UUM for view-
For th is exam ple, we used V? strips to get ing cutterheads III action
sig nifican t springback. Wl1ere the shape of Compact machine dimen!!ions:
cur ves is ( ritical, use Yo. or thinn er st rips. 54~x42Wx47lh~

Q The glue-ups for the curved arms on my

. Morris chair seemed to go well, but when I took
t hem out ofth! forms, there was spring back. I used
Titebond III and 'Ia"-thick strips of quartersawn white
oak. Should I be doing something differently?
-Peter 8rad5haw, Doral, Flo.

A You could try epoxies and plastic resin glues that are
. stiffer than typical wood glues, Peter. But like you,
we reach for plain, yellow glue for our cold-bent lamina-
tions because it's cheap, easy-to-use, and readily available.
You're also on track with the Vs'-thick strips. Just take a
cue from your glue-up and relax a littlc. Don't swcat some
spriogback in your Morris chair arms, which will be firmly
screwed in place. When you can't count on fasteners to pull
the part to the corroct curve, create your bent laminations
first. Then, springback or no, build the rest of the project
around the resulting curve_
Forrest Blades
For bLIildlng cabinets and fine
tumlture, nothing beats Forrest
saw blades.
Craftsmen appreciate the way our
blades de li~et smooth, quiet cuts
witho<Jt splintering, scratthing, or
tearoLJts. They know our unique
grade C-4 micrograin carbide,
proprietary manufactlJring proctlSS,
and hand straightening produce
exceptional results. In fact, indepen-
dent tests rate lIS #1 for rip cuts
and crosscuts. Older from any Forrest dealer or
rotaiter, online, or by calling directly.
From tile first cut 0<"1. I re$Zed thai Our blades are manutactuftld in 1m;,
this blade was J balgain al any price.1 U.S.A. and backed by our 3Q-.day.
Nothing else I have aJls c.omp8fSbIy. maney-back 91wantee.
calv~ Brodie, Spanaway, WA

Forrest Quality Shows

WoodworiI.er II -Best rated, all-
purpose btade lor rips and crosscuts.
Chop Master - Perfect fO( tight,
perfectly cut miter ioints wilt10ut
splinters.
__a-",_
~ ... ..
www.ForrestBlades.com
1-&:10-73-3-7111
(In NJ, cal 973-473-5238)
,

continued on page 74

woodm llg ulne.com 73

 Ask WOOD

Abrasives & AclhE.si"es

loeb Ughting b Rail

Fo$Ienef1 Kitchen OIQ(lnlu .n
Shell bracke ts and much mole ..

~ r Request a FREE catalog - Promofion '850

, ;'- IHardware
woodworkershardware.com
,- _ _ or 1-800-383-0130
Solid wood .........

Solid wood: What's In a name?

Q _ I've heard several manufacturers tout their
products as solid wood, butthey sometimes use
plywood panels for the case back. Can solid wood
furniture ( ontain plywood?
-Lynnt J. Arcnibald. DtKa/b, III.

A _ Since the Federal Trade Commission stopped regulat.

ing furniture labeling in 2000, Lynne, terms found
on those labels (such as "all wood," "wood products," and
uengineered wood~) make it difficult for consumers to know
exactly what they're buying.
Jaclyn Hlrschhaut, spokeswoman for the American Home
Furnishings Alliance helped us sort it out. She tells us that
the term "solid wood" only applies to furniture or cabinets
constructed of solid wood. Add a veneered surface or
engineered woods, such as plywood or MDF, and the
designation changes to "solid w<x>d with veneers" or "all
wood" construction.
Despite the negative connotation It has picked up from
mass-produced knockdown furniture, plywo<xl shouldn't be
a dirty word in the furniture bUSiness or In your own
projects. It Is strong, stable and offers consistent color. Used
properly, it can make an heirloom piece last even longer.

74 WOOD m agul ne S-eptember 2009

Choked up over
smoke smell
Q. We bought a hardwood bed
. from the classifieds, but
didn't realize that it had been in a
smoker's house. When it arrived
home, the cigarette smell filled tne
room. How do we get rid of
the stink?
-Ryall Johnson, Ankeny, Iowa Fallllr..s Have Saved Up To 50% On HeatfIIg Costs
A
And never hove 10 buy fueI- .n,11"', ker...ne, wood - &YO, lIIJuin!
Ryan, we posed your queStion
e ta Scott Cierzan, president of ,,,,1IMIIts
wIIIo 1Iyft-5iI:
First Call Construction of Ankeny, w .... C1St wiIh tt,dft.-Si!
Iowa, specialists in firC' and smoke hI"... fnt-~lICIfrte
Uleti. . _ltflly. IIUl lyiutMlrlKh
damage rcpair. ~For hard surfaces/ SIll, tOfllllett ptCICl of Mil
he says, "you'd be smprised what a o.n, .. ltnIS, .,rirtMwttGII, sol,
thorough surface cleaning will do." U.l.!isld
Scott's advice; Completely wipe down h'HI~-IIIIlC!)"IOIM
rwIIbIt 1IlOV) or ptI1IIOII.-! mOYI
the surfal-"e with water and a gentle
soap, such a~ Murrhy'~ Oil Soap.
Then dry thoroughly with doth or
paper towels.
Whcili llotlw Mali" or smgie room
mvon
'UlUIl E~J ,Mo,l".
APfllo"
""
..... "'.
~rkt

If the smell persists after thc

Hydro-Sil is a high perlormaoce lfldividual room
IHtamg $)'$trem rhat tan $(Iyt)"OU hund~ of doIlal"$
S'2000w
A' l!iOO w
5' 1250 ....
250300 sf
180-250 ~ r
13018000f
'"
'" ""
50"
surface cleaning, it means the smoke
molecules have sunk into the pores
in home healing CO$b by replocing old t:nd ineffi<:ient
heating. It can replo<:e or supplement your eMctric heat,
4'I000w
3' 750 w
l00-13O,r '"'" ""
""
.,,'
."'"
7S100sl
of the w(xxl OXldl21ng those 2' 500w 50-75 s1 $169
Q<I$ Of oil fuma(e and woad5taYe$.
molecules reduces them to odorless
..,
"Thetm:>s1.ts -Ca! lor a..ucthNl<lr_td.
Hydro-SiJ represenh economy in heating: inside rile
compounds. Scott's company uses an 110 fOli pOllum

'" "'.
OiKwnl
hecltef i$ a sealed <opper chomber filled with a harmleu

."."'" """"
ozone generator, but for a home tThMmoIlIrt illltudd.j
remedy, some quality time in the 5ilkone fluid de~ hw- heat retention quoliril. The 5' Hydro-Max750-1500w
3' 750w- SIIeoo6 $179
garage with a fan will suffice. Allid is qllicidy heated by a varying amount of miao-
0 ,,0-
As a last resort, if a trace of smell monoged propor!iQ!'lt!I pow!r, This exdusive technology "
Tota l "moom
remaillS, you can try scaling it into greatly increaie$ OMtgy saving$.
the furn iture by adding a couple chec~ Mosteri:grd VIS(! DiscoYer
coats of dear finish. This traps the
smell where the molecules will break
down and dissipate undetected .
1-800-627-9276 Zip ___ _

www.hydrosil.(om M..te<CanJ. Ill .. Or Oo&<;O\1Ir.-l.c<:oom Irn"""d"n;

75 Hriro-Sil, P.o, lo~ 6&2, forI Mill, S( 19115 "'"'

Expiratioo D;I\&
Sh<w-Prov~rtProducts About our product tests
We test hundreds of tool> and .!(<tswries, 001 o~1y th,m lrut earn at least three
These woodworking wares passed our shop trials stars for perfoJm.llXe make the final cut and appear in this ~cti<m. Prices are current
at me time of article prOOlKtion ami do not include shipping, where applicable.

New Unisaw makes the cut in our shop

t's not often an industry icon gets a

I complete makeover, but that's what

Delta did with its new version of the
Unisaw cabinet-style tablesaw. The
result: a greatly improved machine.
With changes hoth cosmetic and
functional, Delta is banking that
woodworkers-professional and
hobbyist-will pay a premium for a saw
assembled in Jackson, Tenn., of primar-
ily U.s.-made components.
This Unisaw has a massive one-piece
Gist-iron trunnion that virtually
eliminates alignment woes and vibra-
tion by ridding the saw of some of the
moving parts of the old assembly. On
the front of the saw you'll find both the
blade-height and bevel-angle hand-
wheels, a large, easy-to-read bevel gauge
with half-degree markings, and
bevel-stop adjustments.
The Unisaw's quick-release blade
guard system, which includes a three-
position riving knife, anti-kickback
pawls, and two-piece guard, is the Ix'st
I've tested . Why? Because Delta engi- nation blade, shown below. It cuts well washer, a soft-grip handle, and nine
neers put the release lever outside the in all materials without burning or adjustable angie detents. But the
cabinet under the fence rail, as shown tear-out, although it ever so slightly pointer sits too far bal.:k from the scale
below, so you can remove or adjust the scores edge- and end-grain. to rely on it for dead-on predsion with
riving knife without removing the More findings from our testing of a non-detent angles.
throat plate and Without tools. 3-hp model: Dust cont r ol. Although the new
They aiso made changing blades Rip fence_ Delta now ships a machine has dust-collection improve-
easi(>J, thanks to a 5"-wide throat Biesemeyer T-~quare rip fence with each ments, it's not perfect. It reqUires at
opening (my knuckles thank you, Delta Unisaw, and it features an improved least a I lil-hp unit to maintain airflow
engineers), easy-to-reach arbor lock, handle and lnck. Dialing In the right necessary to evacuate liust. The saw has
large angled wrench, and one-piece combination of firm lock and easy a 5" dust port, and comes with a 4"
arbor nut and washer. I Installed a :J!.- Sideways travel while still keeping it reducer. As you might expect, it cleared
dado stack on the arbor and still got the square to the blade proved fussy during dust better using the S' hose.
nut tightened fully. Delta also includes set up, but once there it's like a rock. Zero-clearance help. This is
a nut without the washer, which I used Miter gauge. The induded miter minor, but I appreciate that the blade
for dado setups up to 1" wide. gauge is a step up from what comes drops fully below the bottom of the
And I haw to give Delta credit for Its with most tablesaws these days, throat plate, so J didn't have to make
factory-supplied, 50-tooth, 10" combi- featuring an 18 1!l" har with T-slot any relief cuts prior to cutting the kerf
in a shop-made zero-clearance insert.
I wish all tahlesaw~ had this feature.

- Tnted by Ik>b Hunter, Too/s and Tochniquel Editor,

orld tn-e rest of the WOOD ~ magazitlf! staff

rt
Delta Unisaw 10 tablesaw
f>ertormance .... ****
Price 1t36-lH6 (3 hp, 36' rip cap.) S2,875
#36.lJ52 (3 hp, 52' rip cap.) S3,OOO
~36L552 (5 hp, 52' rip cap.) J3,200
Delta Mactlinery
800-223-7278; deltaportercable.com

76
Clean dusty air rather than breathing It
Not having used an air-filtration system in my basement
'WW'W.logosol.com
shop before, I was amazed at how much dust Powermatic's
PM1200
collected on its
outer filter after
only 10 hours
of normal shop
use. That jolted
me to he mort'
conscious of
the air 1 was
breathing.
To challenge
the PM1200, I
wore a respirator and blasted everything in my shop with
jets of compressed-.air, stirring up a smog-quality haze. I set
the cleaner on its highest of three speeds (nearly 1,200 dm) State-of-the-Art Website, Success
and left for an hour. When 1 returned the air looked crystal Stories, Forum, Technical Specs, Web
dear again, aild very little dust had settled onto my tools.
Rated to trap as much as 85 percent of 1-micron-sized dust Store, and FREE Downloads!
particles, this air cleaner makes me confident I can breathe
easier in my shop. The remote-controlled PM1200 has a
built-in timer that you set for up to nine hour~. !';I LOGOSOL
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-Ttsltd by Bob Wi/jon, Techniquts Editor
Solu ti on-driven wood p rocessing
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Unless I'm applying a

fast-dry finish like lacquer, . .- ...
things come to a grinding
halt when I have to wait
for one side of a project to
dry before coating the
other. For slower-drying
finishcs, such as pOlyure-
thanc, Painter's Pyramids
allow mt' to apply flnbh
(or paint) on the less-seen
side first, wait a couple of
minutes, and then simply
flip it over and do the
"good" side while the first
is still wet. These handy plastic gizmos leave only a pinhole-
slzcd dimple that's easy to rub out. They're surprisingly
stout for their size and don't tip over when I place
something on them. When not being used they
nest neatly out of the way.
-TtSf~ by Kevin 8oyle, Senior De1i9n Editor

hinm"l hnmi!h
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13 GA. HEADLESS PINNERS Jigsaws get little respect from
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Starrett's Dual Cut Jigsaw Blades
point in opposing directions, so
the to p teeth cut the tOP surface
on the downstroke and bottom
tccth cut the bottom surface on
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on stock thicker than i6". I com-
pared them head-to-head with the
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the Starrett blades cleaned up in Ted
oak, pine, Baltic birch plywood, and
even fin icky melami ne-coated
particleboard.
Uual-Cut blades come in two-
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get ex&CIty 1M malllriabi you need. PrW6!1t &6~maUng &ml(S and save cutting %2" to ." thick. They cost
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\he M-.n Master Pro. The per1ed tool d your worxtwor1Iirog panlOll Q formrr 5hop ltiXMr and
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Angles for oompound mi\ars. Mcxt.I 401155

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To . . . how the. . tools can help you today, go to
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Time travel at the speed of a 1935 Speedster?
The 1930s brought unprecedented
innovation in machine-age technol-
ogy and materials. Industrial designers
from the auto industry translated
the principles of aerodynamics and
streamlining into everyday objects
like radios and toasters. It was aho a
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of watch cases and movem ents carne
into being. In lieu of hands to tell
time, one such complication, called
a jumping m echani sm, utilized
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blance to the dashboard gauges and
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True to Machine Art ~sthf'tjcs, the sleek
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back, ullowillS a peck at the inlier workings.
dJstinctive, retro look of a jumping
display (not an actual jumping
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This watch is a limited edition, so
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Not Avo.iJahle in Stores
Stauer 1930s Dashtronic Watch S99 +5&Hg:
3 easy credit card payments of S33 +S&'H
Call MW to lith IUlvantagt ofthis il1niud offir.
1-800-859-1602
Promotional Code DRW270-02
Please mention this code when } "QU call.
Stlu~r
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1j,,, ,,,,., A..
,Sm ~um<vi la." M i ,,,,.~,ou 55337
www.stauer.com
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UNITED GILSONITE LABORATORIES
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FORREST MFG. CO., INC. Top quality
blades and dados lor an ultra smooth finish.
Circle No. 208.
FREUD SAW BLADES This 48-page
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for all Freud saw blades. Circle No. 218.
FREUD ROUTER BITS AJI Freud router
bits are represented ill this 84-page
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SAWSTOP SawStop table saws stop
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RoutElf" Bits. Blades, Tools and Tips. FREE
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AMERICAN FURNITURE DESIGN CO.
150 of America's best furniturs plans,
oomprehensive instruction guide. Catalog,
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U-BILD WOODWORKING PLANS
Since 1948! Hur.df9ds of full-size plans,
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THE BEALL TOOL COMPANY Invemive
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tools and accessories - unbeatable pricesl
Circle No. S83.
MAO SHAN MACHINERY' OEM & OOM
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MASTER...aAHD Brush sanding systems
for all woodworking shop&. Made in USA.
Circle No. 647.
MCfEELY'STM yOU" primary source lor
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woodwor1<lng and DIY necessities. Circle
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WOODCRAFT SUPPLY CORP. Over
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WOODWORKERS HARDWARE 0v6f
8.000 items stocked. largest selectlO/1 of
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Circle No. 713.
AFFINITY TOOL WORKS Manufacturer
of quality hand tools and pt'ooucts for
cabinetmaking, carpElfltry. woodworking,
Circle No. 734.
KREQ TOOL CO. Your one stop shop for
6\I6l'Yfhing Pocket-Screw related. Clrcl.
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LOWELL THOMAS TOOLS/ALPHA
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MORTISE PAL Mortises made easyl
Circle No. 824.
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M.L. CONDON COMPANY Single.
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mouldings. custom millwork. more. Clrcl.
No. 844.
LOQOSOL, INC. Portable sawmjlls,
pracisioo Woodworking machinery. Circle
No. 845.
STEVE H. WALL LUMBSR CO. Quality
hardwoOOs, plywood, exotic lumber. Ship
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Circle No. 856.
WOODWORKERS SOURCE HarcMoods
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No. 919.
WOODCRAFT RETAIL FRANCHISE
o.vn a Woodcraft Store - franchises
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Circle No. 924.
KLOCKIT The ~ing supplier of ckx:k-
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AZTEC STEEL CORP. Quality pm-
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lowest cost an~e. Circle No.1 064.
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DAKOTA ALERT, IHC. Ar1 alert SO!Jnds
1('\ tM house ...men someone enters the
drive. Circl. No. 1129.
~--~~~
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BAKER PRODUCTS Irdustry leader fOf
portable sawmiUs. resaws and woodworking
equipment. Circle No. 1428.
COOK'S SAW MFa., L.L.C. Portable
sawmills. Edgers. Sharpeners. Band
Blades ... Froo catalog. Video available.
Circle No. 1480.
EPILOG Wood engraving and cutting
systems - Low Price, High-Quality Laser
Systems. Circle No. 1518.
FREUD POWER TOOLS 16-page
catalog mustrates depeodab~ power
tools with traditional Freud quality,
Circle No. 1532.
QRANBERG INTERNATIONAL Alaskan
Saw Mill. Chain saw accessories. o\o1ade in
USA. Circle No. 1558.
GRD POWER TOOLS Professional
fastening systems and pneumatic powered
hand too/so Circle No. 1573.
MAXNC, INC. Manufacturers of
American-made eNC m~ls, lathes and
routers ... at affordable p!'1ces! Circle
No. 1612.
TOOLMART INC. Makita, DeWalt, Porter-
Cabie, Milwaukee, Bosch, f'reud. Circle
No. 1170.
WOOD-MIZER PRODUCTS Eight
Tablesaw
Portable Sawmills Available starting with the
LTlO at $3995. Circle No. 1805.
WOODMASTER TOOLS Multi-duty ~
that rroId, sord & saw. Circle No. 1820. Tum your tablesaw into
WOODSTOCK INTERNATIONAL, INC. the hyper-accurate
SHOP FOX Woodworking Machines offering workshop workhorse it
professional-level quality. Dealer supplied.
Circle No. 1824.
should be. You'll find
120+ pages of jig
plans, precision-
ADAMS WOOD PRODUCTS Offers a enhancing add-ons,
free catalog of their stock solid wood
components. Circle No. 1831. and time and
OSBORNE WOOD PRODUCTS, INC. A money-saving tips.
free catalog of table legs, cOlbals, and
iSland legs_Circle No. 1Na. " ''''' '~ I

OSBORNE WOOD PRODUCTS, INC.

WOOD CORBELS off8( classic corbels in a On Your
broad range of styles. Circle No. 1851.
Newss,.
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$6.99 U.S.
S8.99 Canada

Order online at woodmagazine.comJpublications

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PlNN STATIINDUSTRIES Award-
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PHASE~AMATIC, INC. Convert 1-phasa

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DUT. WISOI
RED HILL CORP. SUPERGRJ'" FREE Product Information
ABRASIVES Industrial quality sanding
beltS, discs, rol ls, Sheets at whOlesale prices
to small consumers. Circle No. 2065.

..'"'"
"
50
'"
'"
.58

...'"
tlM:t.ETIIE..as IELIW _~" IIDIS. t.s IUIIE.

""
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".
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""
151!!

""
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""
182-4
18 31
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""
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BEREA HARDWOODS Quality pen kits .13
806
"" "" 2121
and other turning kits. Circle No. 2127.

HUT PRODUCTS Woods, acrylics and ......'" ......'" ." 1573

1612
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2133

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Circle No. 2133. ~ .... nwanI1IIg
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~ drct. MIl. -4000. Ytu wII 1M DlkIiI ~lIIr.

PACKARD WOODWORKS Free Catalog ~ ---------------------------- to ENSURE PR1IW'T lWIDUIIG OF 'I'0Il11

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Tools and Supplies. Circle No. 2143. an __________ 'TA'" ________ .. ______ SefId 1:111'11 t.
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Pl!NN STATE INDUSTRIES Leading ~MNl~S; _____________________________ P.D.1u: &135, IilrhlIo, n 14lO1141S& I
supplier of Turning Ruducts. Pen kits, project, All. . HI w..u 11M" "''-J
PMO_E (ornoHAL) TIIb card ~ JInIia'l14, 21110 I
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Log on 10 www.WOODWorkersCenter.com Wood ~tazIne Septlll1lber 2009 83
 OEM" ObM o
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 The Largest
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Movements Kit 10 build ind~ 22"'- iron wheels
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What's Ahead
October 2009: Our special 25th anniversary issue (on sale "",.U51

Super-simple rocking horse

ful' -siu patterns and fast, S<rew-logether assembly help
you get this jXlny intothe homestretch quicker than you
can say"giddyup."

Drop-front Desk Build and install door and window trim

P1!rfe<t!y sized tOf a l'IOok ilnd a notebook computer, this d~k fits any room. The- door la~ flat for a Put yuur shop to work beautifying the rest of your home.
writing aoo work surface, and then folds up 10 hide what~ inside. Wt'li show you how to easily venffl Learn the secrets to milking your own (ustom moldings;
pdAels u!>ing tools you already own. then di5co~r a pro's advice for moontinq them.

Tablesaw tenoning jigs 25 top innovations of the past 2S years

Faster alld cleaner-rutting thcln a dado St't, Prior 10 1984, there were no befw:htop pYne~ Of one-
these messofili'S IThlke light-fining tfllOIlS handed baT clamps. We salute I~ and 2J more tools
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88
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