WOODWORKS: INTERMEDIATE PROJECT

SIDE TABLE

Heres a perfect table for use in a front hall, behind a living-room sofa or in your bedroom for showcasing your favorite knickknacks. Besides being
narrow enough to fit in a variety of locations, its two drawers provide convenient storage for small items. For intermediate woodworkers, the tapered
legs, doweled joints and close tolerances throughout will present a challenge but also produce great satisfaction when properly executed. And when
its all assembled, youll learn more about applying and using stains and finishes to protect the wood and keep it looking beautiful.

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TOOLS REQUIRED SHOPPING LIST

Hand Tools Item Quantity
Hammer 1x8 oak 1 @ 9', 2 @ 6'
Nail set 2x4 birch 1 @ 6'
4' pipe clamp 1x6 birch 2 @ 6'
18" pipe clamps (4) 1x4 birch 2 @ 6'
Doweling jig 1/4" birch plywood 1 @ 12" x 36"
4d finish nails 50
Power Tools
3/8" x 2" dowel pins 16
Tablesaw with combination
#8 x 3/4" pan-head screws with washers 2
rip/crosscut blade and dado blade
Oak drawer knobs 2
Saber saw
Tabletop fasteners 6
Router, 3/8" roundover bit
Jigsaw
Electric drill
CUTTING LIST
Miscellaneous
Pencil Overall Dimensions: 32"H x 48"W x 14"D
Tape measure Key Part Pcs. Material Dimensions
Safety glasses A Table top 1 oak 3/4" x 14" x 48"
Carpenters glue B Legs 4 birch 1-1/2" x 1-1/2" x 31-1/4"
120, 150 and 220-grit sandpaper C Front & back aprons 2 birch 3/4" x 4-1/2" x 37"
Clean, lint-free cloths D Side aprons 2 birch 3/4" x 4-1/2" x 10"
Respirator E Drawer fronts 2 birch 3/4" x 3-5/8" x 15-1/2"
Gloves for finishing F Drawer sides 4 birch 3/4" x 2-7/8" x 11"
Mineral spirits (for oil-based stains G Drawer backs 2 birch 3/4" x 2-3/8" x 13-3/4"
and finishes) H Upper drawer runners 2 birch 3/4" x 2" x 10-3/4"
Water-filled metal container with J Drawer runners 4 birch 3/4" x 1-1/2" x 10-3/4"
tight-fitting lid (for oil-based stains K Drawer runners 4 birch 3/4" x 3/4" x 10-3/4"
and finishes waste products) L Stop blocks 2 birch 3/4" x 3/4" x 6"
Minwax Wood Finish Stain M Drawer bottoms 2 birch plywood 1/4" x 10-3/4" x 13-3/4"
Brush or other good quality, N Drawer stops 2 birch plywood 1/4" x 1" x 3"
natural-bristle brush (for oil-
Recommended Wood: Oak/Birch
based stains and finishes)
Alternate Wood: Pine (stain grade)
Minwax Polycrylic Brush or other
good quality, synthetic-bristle brush
(for water-based stains and finishes)

WOOD FINISHING PRODUCTS

Recommended Finish
Prep: Minwax Pre-Stain Wood Conditioner
Stain: Minwax Wood Finish English Chestnut (or your choice
of any of the 22 Minwax Wood Finish Stain colors)
Finish: Minwax Wipe-On Poly Satin or Gloss
Alternate Finish
Prep: Minwax Water-Based Pre-Stain Wood Conditioner
Stain: Minwax Water-Based Wood Stain Verdigris (or a Minwax
Water-Based Stain of your choice, available in 6 wood tones,
60 custom colors and 8 bold Accents colors)
Finish: Minwax Polycrylic Protective Finish Semi-Gloss

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 CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2006-2007 SIDE TABLE

BEFORE YOU BEGIN
Good craftsmanship begins and ends with good work habits, so make
the following steps part of your routine workshop practice. If you have
any doubts or questions about how to proceed with a project, always
discuss them with your shop instructor.
Carefully and fully review plans and instructions before putting a
tool to the project lumber.
Work sensibly and safely. Wear safety goggles when doing work that
creates flying chips and sawdust; wear the appropriate respirator
whenever making sawdust or working with thinners or other solvents.
At the end of every work session, clean up your shop area and put
away all portable tools.
CUTTING AND ASSEMBLY
PROCEDURE
Glue the Top
1. To make the top (A), edge-glue together two 1 x 8 boards that are
49" long. Alternate the direction of the growth rings in the end grain of
the boards to prevent the top from warping. After the glue has dried,
cut the top to its finished dimension.
6. Mark the positions of the dowel holes in the sides of the legs and
the ends of the apron pieces (Fig. 3). Offset the dowels slightly on
each side of the legs so they wont interfere with each other. Drill
the 3/8"-diameter dowel holes.
7. With the tablesaw blade set 1/4" high, cut the grooves for the
tabletop fasteners 1/2" from the top edge of the front and back
aprons (C, Figs. 3 and 6).
Assembling the Table
There are three stages in assembling the table. First, construct the
frame from the legs and apron pieces. Second, make the drawers.
Third, complete the top, which has already been glued together
and cut to size.
Construct the Frame
8. Lay out and cut the two drawer openings in one of the long apron
pieces (C). To do this, drill 3/8" holes within the cutout area of
each opening. Then use a saber saw to cut along each line. Proceed
slowly and carefully to ensure straight cuts and square corners.
After the cutting, file and sand all edges smooth.

Make the Initial Cuts 9. Sand the legs and aprons with 120-grit paper, then smooth them all
with 180-grit paper. Dowel, glue and clamp the front legs to the front
2. Cut all the pieces, (B) through (N), to the dimensions given in the
apron and the back legs to the back apron. Then dowel, glue and
CUTTING LIST. Glue the drawer runner pieces, (J) and (K), together.
clamp the side aprons to the assembled front and back. Quickly wipe
away excess glue with a damp cloth.
Taper the Legs
The legs are made of solid birch stock 1-1/2" thick. If you have trouble
Make the Drawers
finding birch that thick, glue together two 3/4" pieces. The taper on
10. Drill the holes for the knobs in the drawer fronts (E, Fig. 1).
two sides of each leg is easy to cut with a homemade tapering jig.
Shape the drawer front edges with a router and 3/8" roundover bit.
The drawers are boxes assembled with nailsvery easy to make and
alignand they ride on wooden runners.
11. Cut rabbets 1-1/8" wide by 3/8" deep on the inside ends of the
drawer fronts, using a dado blade on the tablesaw. Use the tablesaw
3. Make the leg-tapering jig by cutting a 3/4"-thick piece of scrap
miter gauge to ensure square cuts. Clamp a stop block to the fence
plywood 5" wide by 33" long (Fig. 4). Draw the angled side as shown
to hold the piece the correct distance from the blade. Cut rabbets
in the diagram and cut out the notch with a saber saw.
3/4" wide x 1/4" deep on the back ends of the drawer sides (F) in
the same way (Fig. 2). Cut the grooves for the drawer bottoms (M)
4. To cut the legs, set the tablesaw fence 5" from the saw blade and
in the drawer fronts and sides.
set the blade slightly higher than 1-1/2". You must cut a taper on two
adjacent sides of each leg and leave the sides that fit against the
12. Sand all the drawer pieces, then glue and clamp all the pieces
aprons uncut. Place a leg (B) in the notch of the taper jig and slide
together except for the drawer bottoms. Push the bottoms into their
the jig across the table, holding it tight to the fence (Fig. 5). Use a
grooves after finishing, to avoid having to wipe the stain and topcoat
push stick to hold the leg tight against the side of the notch as you cut
out of the corners.
the taper. Rotate the leg 90 degrees in the jig so the tapered side you
just cut is facing up, then cut the other tapered side of the leg. Repeat
13. Drill pilot holes, and then drive finish nails through the drawer
these steps for the remaining three legs.
sides into the drawer fronts and backs. To make nailing easier, clamp
the drawer front or back in a vise so that the drawer side is supported
Drill the Dowel Holes
on the top edge of the vise jaw. Use a nail set to finish driving the nails
5. Drilling the dowel holes can be confusing unless you first mark
into the drawer fronts past the lips of the fronts.
which sides of the legs (B) and ends of the apron pieces (C) go
together. The easiest way to do this is to place all the legs and apron
14. Align the upper drawer runners (H, Fig. 1) between the front
pieces upside down on your worktable in the relative positions theyll
and back aprons. Use a clamp to hold them in place, then drill
assume when the base is assembled. Label each joint with a different
pilot holes and drive finish nails. Use a nail set to drive the heads
identifying mark so you can assemble it the same way later.
below the surface. Fill the nail holes with wood putty. Then glue the
stop block (L) in place at the bottom of each drawer opening in
Wo o d w o r k e r s Ti p : Drilling the dowel holes in the legs and aprons
the front apron.
is simpler and more accurate if you use a dowel-drilling jig. Place a
piece of masking tape on the drill bit for a depth stop flat.
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 CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2006-2007 SIDE TABLE
Affix the Lower Runners
15. To mount the runners (J, K) that guide the sides and bottoms of
the drawers, set the table base on its back and align the drawers in
their openings. Set them tight to the bottom edge of the opening in the
apron, with an even gap on each side.
16. Set the drawer runners in place and mark their outside edges
on the front and back aprons (Fig. 6). Mark where the ends of the
drawer runners join the front and back apron pieces. Leave a 1/32"
gap between the runners and the sides of the drawers. Hammer finish
nails through the aprons and into the drawer runners to hold them
in place. Use a nail set to drive the nailheads slightly below the surface.
Fill the nail holes with wood putty.
17. Finish the drawer assembly after the final topcoat is dry. Slide the
drawer bottoms (M) into their grooves and then fasten them with two
4d finish nails driven into the drawer backs.
18. Attach the knobs to the drawer fronts and pivoted stops to the
backs of the drawers. The stops are 1"x 3" pieces of 1/4" plywood.
Attach them with a single pan-head screw and a washer (see Drawer
Section View, Fig. 2).
19. Reattach the top to the base with table fastener brackets (Fig 6).
Leave a 1/16" space between the fasteners and the aprons to allow the
top to expand. Turn the rear drawer stops horizontal so you can slide
the drawers in place. Then turn the stops downward so the drawers
wont fall out when you open them.
STAINING AND FINISHING
Wo o d w o r k e r s Ti p : Though you may be tempted to cut short
your sanding, preparation and application time, dont do it.
These tasks are very important steps in obtaining a high-quality
finish. Remember, it is the finish, just as much as the fit and
smoothness of the parts that will have great bearing on how
people judge your craftsmanship. To ensure an excellent result,
follow the steps listed in this section and also the instructions
the finish manufacturer puts on its products.
FINISHING TIPS
Test the stains and finishes you are planning to use on scraps of
wood. On the back of the scrap, mark the stain/finish combination
and the type of wood. Allow all samples to dry thoroughly before
making your final finish selection. Save your samples for quick
reference on future projects.
All stains and finishes must be allowed to dry thoroughly between
coats. Remember that drying times can vary due to humidity and
other climatic conditions.
If you have some leftover stain or finish, wipe the can rim so that
stain or finish in the rim wont dry out and prevent the lid from
forming a tight seal.
Brushes used for water-based products, such as Minwax Water-
Based Wood Stains or Minwax Polycrylic Protective Finish, must
be cleaned with soap and water; oil-based finishes must be cleaned
with mineral spirits.
20. Sand all pieces starting with 120-grit paper, then move up to 220-
grit to complete the pre-finish smoothing. Use an orbital sander to
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remove any marks or scratches, then lightly sand by hand using with-
the-grain sanding strokes. Dust off the piece and wipe it carefully with
a clean, lint-free cloth lightly dampened with mineral spirits.
Recommended Finish
21. Apply the Minwax Wood Finish youve chosen to the interior
surfaces using a natural-bristle brush and a clean, lint-free cloth
following the directions on the can. The brush will help you get the
stain into the many inside corners and other tight spots. Allow the
Wood Finish to set for about 5 to 15 minutes, then wipe off any
excess. To achieve a deeper color, you may apply a second coat after
4-6 hours, repeating the application directions for the first coat.
Allow the stain to dry for 24 hours before applying the protective
clear finish.
Wo o d w o r k e r s Ti p : Different species of wood take to stain dif-
ferently. When using a combination of woods like oak and birch,
you may need to apply a second or third coat to birch to achieve
a uniform finish. When wiping off stain, make certain that your
last wipe with the cloth goes with the grain of the wood. This
way, any stain you might miss during wipe-off will be visually
minimized by the wood grain.
22. Apply Minwax Wipe-On Poly following the directions on the can.
Shake the can thoroughly. Apply a liberal amount of Wipe-On Poly on a
clean, soft, lint-free cloth into the wood. It can be brushed on or wiped
on with a cloth. Allow the first coat to dry for at least 4 hours.
23. Once completely dry, sand all surfaces very lightly with 220-grit
or finer sandpaper or very fine (000) steel wool using with-the-grain
strokes. Thoroughly wipe off all surfaces with a soft cloth. Apply a
second coat of Minwax Wipe-On Poly and set the piece aside to dry
for at least 4 hours.
24. Once completely dry, sand all surfaces lightly with 220-grit or finer
sandpaper or very fine (000) steel wool. Thoroughly wipe off the piece
with a soft cloth and apply a third and final coat of Wipe-On Poly. Allow
the table to cure for several days before using it.
Wo o d w o r k e r s Ti p : For an ultrasmooth finish, use 400-grit
sandpaper to apply the final coat of Minwax Wipe-On Poly.
Alternate Finish
25. Before applying Minwax Water-Based Wood Stain to a hardwood
or softwood, apply Minwax Pre-Stain Water-Based Wood Conditioner
following the directions on the can. This will help to ensure even
absorption of stain and prevent blotchiness that can occur with some
woods. After 1 to 5 minutes, wipe off all excess conditioner using a
clean, soft cloth. Wait 15 to 30 minutes then use 220-grit or finer sand-
paper to sand off any whiskers raised by the conditioner. Proceed to
the staining within 2 hours.
26. Do the staining in two steps, starting on the interior surfaces and
then do to the exterior surfaces. Apply the Minwax Water-Based
Wood Stain youve chosen to the table using either a nylon/polyester
brush or a cloth. Allow stain to penetrate no longer than 3 minutes.
While stain is still wet, wipe off all excess with a clean cloth thats been
lightly dampened with stain. Allow the piece to dry for 2 hours before
 CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2006-2007 SIDE TABLE

applying a second coat, if desired. Allow the piece to dry overnight

before applying the protective clear finish.
NOTE: Minwax Water-Based Wood Stain is available in 6 wood
tones, 60 custom-mixed colors and 8 bold Accent colors. This
means that you are not limited to just traditional wood colors (pine,
oak, walnut, etc.). Instead, you can actually pick and apply a color to
complement the dcor of the room in which the table will be placed.
For this reason, make sure you look over all of the Minwax color
charts or go to minwax.com before making your final selection.
27. After allowing the piece to dry overnight, apply Minwax Polycrylic
Protective Finish following the directions on the can. Stir the can
contents thoroughly before starting and periodically repeat the stirring
during your work session.
28. Working a small area at a time to maintain a wet edge, apply
the first coat. Work quickly and make the final strokes in each
newly finished section using with-the-grain brushstrokes.
29. Allow the finish to dry a minimum of 2 hours. Then sand lightly
with 220-grit or finer sandpaper wrapped around a flexible sanding
block. Thoroughly dust off and wipe all surfaces with a cloth lightly
dampened with water.
30. Repeat steps 28 and 29 to apply the second and final coat.
FIRST AID: In case of eye contact, flush thoroughly with large
amounts of water for 15 minutes and get medical attention. For skin
contact, wash thoroughly with soap and water. In case of respiratory
difficulty, provide fresh air and call physician. If swallowed, call Poison
Control Center, hospital emergency room, or physician immediately.
DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.
Contains solvents which can cause permanent brain and nervous
system damage. Intentional misuse by deliberately concentrating and
inhaling contents may be harmful or fatal.
WARNING: This product contains chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.
CONFORMS TO ASTM D-4326. Contact a physician for more health
information.
When using water-based wood finishing products:
CAUTIONS: Use Only With Adequate Ventilation. To avoid overexposure,
open windows and doors or use other means to ensure fresh air entry
during application and drying. If you experience eye watering, headaches,
or dizziness, increase fresh air, or wear respiratory protection (NIOSH
approved), or leave the area. Avoid contact with eyes and skin. Wash
hands after using. Keep container closed when not in use. Do not transfer
contents to other containers for storage.

PRODUCT SAFETY FIRST AID: In case of eye contact, flush thoroughly with large amounts
For your safety and the safety of those you work with, always read the of water. Get medical attention if irritation persists. If swallowed, get
safety warnings, which manufacturers print on their labels, and follow medical attention immediately.
them to the letter.
WARNING: This product contains chemicals known to the State of
WARNING! Removal of old paint by sanding, scraping or other means California to cause cancer and birth defects or other reproductive harm.
may generate dust or fumes that contain lead. Exposure to lead dust or DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.
fumes may cause brain damage or other adverse health effects, especially CONFORMS TO ASTM D-4326. Contact a physician for more health
in children or pregnant women. Controlling exposure to lead or other information.
hazardous substances requires the use of proper protective equipment,
such as properly fitted respirator (NIOSH approved) and proper
containment and cleanup. For more information, call the National Lead
Information Center at 1-800-424-LEAD (in US) or contact your local
health authority.

DANGER: Rags, steel wool, other waste soaked with oil-based stains
and clear finishes, and sanding residue may spontaneously catch fire if
improperly discarded. Immediately place rags, steel wool, other waste
soaked with these products, and sanding residue in a sealed, water-filled
metal container. Dispose of in accordance with local fire regulations.

When using oil-based wood finishing products:

CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS. Contents
are COMBUSTIBLE. Keep away from heat and open flame. VAPOR
HARMFUL. Use only with adequate ventilation. To avoid overexposure,
open windows and doors or use other means to ensure fresh air entry
during application and drying. If you experience eye watering, headaches,
or dizziness, increase fresh air, or wear respiratory protection (NIOSH
approved) or leave the area. Avoid contact with eyes and skin. Wash
hands after using. Keep container closed when not in use. Do not transfer
contents to other containers for storage.

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FIG 1. TABLE DETAILS

Tabletop Fastener (6 reqd.)

1
/2" Rad. (side and front edges)
A
1
/2 " Tabletop Overhang

4"
1" Rad
. (front corners)
H D
C
Saw Kerf
H Glue Only

5"
K
D J

4d Finish Nail-
L 2 per Joint Set
and Fill
F

M
F
G E
N
B 3
/8" Dia. x 2" Dowel Pin
(2 per joint)

B
1-1/4" Dia. Oak Knob

In this area
taper leg on 1"
inside two 1"
sides to 1"
square (see
taper jig).

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FIG 2. DRAWER DETAILS

4d Finish Nails

G E
Glue Glue
1
/4" F
11/8"
3
/4" DRAWER ( PLAN VIEW)
3
No. 8 x 3/4" Pan-head /8" 3
1
/8" Rad.
Screw and Washer /4" Dia. Hole

4d Finish Nail E

G F
7
/8"
1 3
/4" /8"
N M 1
/4" x 1/4" Grooves

DRAWER (SECTION VIEW)

FIG 3. LEG AND APRON DETAILS

C
3
/8"
D B

3
/8"

1
/8" x 1/4" Saw Kerf Front and Back
3 1
/4" /2"

1 /2"
1 1"

D 11/2"
1
2 /2" 1
2 /4" 15" 21/2" C
3" 11/4"

3
B /8" Dia. x 1-1/16" B 3
/4"
Deep Dowel Holes

SIDE DETAIL FRONT DETAIL

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FIG 4. TAPERING JIG FIG 5. CUTTING THE LEGS

3
3 /8" Blade guard removed
for clarity only. Always
use your guard.

Taper Jig

33"

1"

3
1 /4"

5"

FIG 6. REATTACH TO BASE FIG 7. MARK THE DRAWER RUNNERS

1
/32" Gap

Tabletop
Sawn Groove Fastener

1
/16" Gap

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 WOODWORKS: INTERMEDIATE PROJECT
PORCH SWING

Kick back and relax with this fun-to-build weekend project. The smooth, gentle glide of the porch swing will keep you daydreaming for hours.

This project is designed with a unique suspension system made from ordinary 1/2" black steel pipe (commonly used for gas piping). It slips
through the swing frame to act as a cradle and to eliminate stress on wood joints. Eyebolts are fastened through the steel pipe and covered
by soft rubber caps to prevent accidental scrapes. The swing assembly is then supported with a welded steel chain that is securely fastened to
solid framing in the porch roof.

In this intermediate-level project, youll gain experience in working with templates to make shaped pieces and doing some complex and precise
assembly. And after you build it, youll learn more about applying and using finishes to protect the wood and keep it looking beautiful.

Caution: Swings are inherently dangerous for small children. This swing moves slowly, but it has hard edges that can give a nasty bump. Kids will
love this swing, but never let small children play around it unattended.

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING

TOOLS REQUIRED
Hand Tools Power Tools Miscellaneous
Hacksaw Miter saw or circular saw Tape measure Minwax Wood Finish
Adjustable wrench Drill with bits and screw- Safety glasses Stain Brush or other good
Block plane driver attachment 120-, 150- and 220-grit quality, natural bristle brush
Bar clamps Jigsaw sandpaper (for oil-based stains and
Table saw Clean, lint-free cloths finishes)
Orbital sander Respirator Minwax Stainable
4" roller Wood Filler
Gloves for finishing Construction adhesive
Mineral spirits (for oil- Thread-locking compound
based finishes) Exterior spray primer
Water-filled metal container Black or brown spray paint
with tight-fitting lid

SHOPPING LIST CUTTING LIST

NOTE: The wood for this project is cedar, a naturally rot Key Pcs. Size & Description
resistant species. White oak, cypress, and poplar are also A1 2 3/4" x 5-1/2" x 17-1/2"
good alternative dense woods that wont mar easily and stain (side seat braces)
beautifully. A2 1 3/4" x 5-1/2" x 14-1/2"
(center seat brace)
Item Quantity
B 2 3/4" x 3-1/2" x 10-1/2"
1"x 6" x 8' boards 7
(front arm braces)
1"x 4" x 8' boards 3
C 1 3/4" x 3-1/2" x 43" (front stringer)
1-1/4" galvanized deck screws 2 lbs.
D 1 3/4" x 3-1/2" x 40" (rear stringer)
1-5/8" galvanized deck screws 2 lbs.
E 1 3/4" x 3-1/2" x 40" (lower back brace)
1/2" unthreaded black pipe 56" long 1
F 1 3/4" x 2-5/16" x 43" (center back brace)
1/2" unthreaded black pipe 51" long 1
G 1 3/4" x 1-1/2" x 40-1/2" (top back brace)
Pilot hole/countersink drill bit 1
H 2 3/4" x 5-1/2" x 35" (center back slats)
3/16" welded, zinc-plated chain 17'
J 9 3/4" x 2-11/16" x 35" (back slats)
1/4" threaded eyebolts 4
K 2 3/4" x 1-13/16" x 35"
2-1/4" quick-link eyes 8
(tapered back slats)
3/4" rubber caps 4
L 2 3/4" x 2-1/2" x 10-1/2"
(arm supports, waste from parts P)
Wo o d w o r k e r s Ti p : Knots can weaken a board and spell M 2 3/4" x 3" x 22-1/4"
disaster, especially on furniture, so be sure to select knot- (horizontal arm supports)
free boards. N 6 3/4" x 2-11/16" x 41-1/2" (seat slats)
P 2 3/4" x 5-1/2" x 27" (arms)
Q 1 1/2" (13/16" outside diameter) x 56"
black steel pipe
WOOD FINISHING PRODUCTS R 1 1/2" (13/16" outside diameter) x 51"
black steel pipe
Recommended Finish
Thompsons WaterSeal Waterproofer PLUS
Tinted Wood Protector Honey Gold (or your choice
of Natural Cedar, Nutmeg Brown, Rustic Red, or
Coastal Gray).

Alternate Finish
Thompsons WaterSeal Deck & House Semi-
Transparent Latex Stain Cedartone (for a cedar
appearance), Briarwood (for a brownish tone),
Woodland (for a reddish tone), or Superwhite
(for a white appearance).

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 CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING

BEFORE YOU BEGIN 7. Use a table saw to cut the center and top horizontal back braces
Good craftsmanship begins and ends with good work habits, so make (F and G) from 1x4s. Set the blade at 27-1/2 degrees for the bevel cuts.
the following steps part of your routine workshop practice. If you have
any doubts or questions about how to proceed with a project, always 8. Mark a diagonal taper onto a 1x3 as shown in Fig. 1 to make the
discuss them with your shop instructor. two outer slats (K) from this single piece. Cut along the line with your
Carefully and fully review plans and instructions before putting a jigsaw, then use a block plane to smooth the cut edge.
tool to the project lumber.
Work sensibly and safely. Wear safety goggles when doing work that 9. Assemble the back as shown in Figs. 1 and 4. Lay all the back slats
creates flying chips and sawdust; wear the appropriate respirator (H, J, K) face down on a flat surface and slip temporary 1/4" spacers
whenever making sawdust or working with thinners or other between them to help maintain consistent spacing. Fasten the bottom
solvents. brace (E) to the middle slat, using a framing square to make sure
At the end of every work session, clean up your shop area and put theyre joined at 90 degrees. Start at the center and work out to the
away all portable tools. sides. When you get to the fourth slat on each side, check your spacing;
you may need to adjust it so the outer edge of the tapered slat (K) is
CUTTING AND ASSEMBLY flush with the end of the lower back brace.
PROCEDURE
10. Cut the curves on the back assembly. Make a simple beam
1. Cut all the parts to the dimensions shown in the CUTTING LIST.
compass from a scrap of wood as shown in Fig. 5. Flip the backrest
Using a table saw, make 1x3s from the 1x6s.
assembly over and nail one end of the compass 14 inches from the top
and in the center of the 1x6 back slat. Insert your pencil into the 1/4"
2. Notch the front arm braces (B) with a jigsaw to accept the front
hole drilled in the other end of the compass and draw the curve. Cut
stringer (C) as shown in Fig.1. Fasten C to both parts B with 1-5/8"
along the mark with your jigsaw. With the backrest assembly in this
deck screws. Drill pilot and countersink holes and apply a dab of
position, measure and mark a 2-1/2" line parallel to the bottom edge.
construction adhesive at each joint.
11. Hang the lower part of the back assembly over the edge of the
Wo o d w o r k e r s Ti p : Why use construction adhesive instead of
work surface and slide the seat assembly onto it. Place the seat frame
carpenters glue? We used Liquid Nails brand LN-600 because its
assembly you built earlier onto the backrest assembly. Its crucial to
waterproof and resilient. Construction adhesive will help your
align the rear seat frame stringer (D) to the 2-1/2" line on the backrest
porch swing stand up to both weather and stress. Apply a small
so the remainder of the assembly will fit together. Glue the joint, then
bead at every joint. If the glue oozes slightly, let the excess harden
clamp and screw the assemblies together.
and then cut it off with a sharp putty knife or wood chisel.
12. Drill 7/8" holes in the horizontal arm supports (M) to the exact
3. Draw the curved shapes for parts A1, A2 and P onto hardboard
dimensions shown in Fig. 1. Then glue and screw these pieces to the
templates, shown in Fig.1, cut them out and trace them onto boards.
front arm braces (B) and the center back brace (F).
To cut them out with a jigsaw, clamp them to the workbench to keep
them from wandering while you cut the curves. Sand the curves smooth
13. Glue and screw the seat slats to the seat braces. Start in the back
with 100-grit sandpaper. Drill 7/8"-dia. holes with a sharp spade bit
and leave approximately a 3/16" space between each piece. Trim the
into parts A1 and A2 as shown in Fig. 2 for the front pipe hanger.
last slat to overhang the front stringer by 1/2". Plane the transition
piece on the curve of the seat and at the leading edge of the front seat
4. Trace the angle of the center seat brace (A2) onto each side brace
slat for maximum comfort. Also shave off any high spots in the seat slats
(A1) to locate the holes for attaching the rear stringer (D). Again,
with a block plane.
drill pilot holes and glue and screw the seat braces to the front stringer
and the front arm braces. Next, glue and screw the rear stringer to the
14. Test-fit the pipe, chain and connecting links in the wooden assem-
seat braces.
bly. This is a good time to discover any glitches and correct them before
you do any finishing. Slide the pipes through the holes in the seat frame
Wo o d w o r k e r s Ti p : Youll need to pre-drill holes for every screw
and along the back, leaving an equal amount exposed on each side.
so you wont split the wood or break off the screw head. To make
this process easier, buy a special combination bit that can drill
15. Drill a 3/16" hole in the center of the rear support pipe, then screw
and countersink in one operation.
a 2" No. 8 sheet metal screw (use a 1/8" pilot hole) up into the center
back support. This connection will keep the pipe from sliding to one
5. Drill through the front arm braces (B) with a 7/8" spade bit after
side while the swing is in motion.
youve glued and screwed the side seat braces to them. These two holes
will complete the pathway for the front pipe support (Q).
16. Drill 9/32"-dia. holes for the eyebolts. Angle the eyebolts slightly
toward the center of the swing to minimize the torque on the pipe and
6. After you assemble the arm braces, stringers and seat braces, glue
prevent the lock-screw from breaking.
and screw the curved front arm supports (L) to the sides of B as shown
in Fig. 1.

3
 CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING
17. Hang the swing using the quick-link eyes to join the lengths of
chain. This swing could be holding 400 pounds or more, so you must
anchor the swings chain with 1/2" screw eyes screwed at least 2" into
solid framing as shown in Fig. 6. Also, distribute the weight to more
than one joist or rafter by screwing a pair of 2x4s 54" apart and then
inserting the screw eyes into the 2x4s. The swing should tip back
slightly at the arms (about 1" from back to front) when it is at rest.
During the final assembly after finishing, squirt thread-locking com-
pound on the eyebolt threads. Be sure to cut the ends of the eyebolts
flush with the nuts for safety. When the installation is complete and
secure, remove the swing for finishing.
18. Before applying the finish, remove the chains and pipes. Sand the
pipes with 100-grit sandpaper, then wipe them down thoroughly
with a rag dampened with mineral spirits. Let the mineral spirits
evaporate off the surface, then spray-paint the pipes with exterior
primer followed by a brown or black exterior enamel.
19. Sand the wood parts with 100-grit sandpaper, paying particular
attention to the arms and the edges of the seat and back. Softer edges
will be safer and more comfortable and hold the finish better.
20. Wipe off the dust and vacuum the swing. Youll make better time if
you apply the finish with a small 4" roller and follow it up with a brush
to even the coat. Use the brush to get between the slats and then look
for runs and drips coming through the other side.
PROTECTING YOUR PROJECT
Any type of wood thats used outdoors needs protection from water
damage. Weve chosen Thompsons WaterSeal Waterproofer PLUS
Tinted Wood Protector to provide complete protection for your project.
It not only prevents water damage, but the coating also resists mildew
and U.V. (ultraviolet radiation in sunlight) damage, and it exceeds
industry standards for waterproofing on wood. In addition, Tinted
Wood Protector adds color without hiding natural wood grain.
Wo o d w o r k e r s Ti p : Always be sure to choose a waterproofer that
claims to exceed industry standards for waterproofing on wood.
FINISHING TIPS
When you apply Thompsons WaterSeal Waterproofer PLUS Clear
or Tinted Wood Protector, do not mix it with other waterproofing
products because variations in the final appearance of the surface
being treated may result. Also, do not thin these products.
Coverage: The approximate coverage of Clear Wood Protector on
cedar is 300 to 400 square feet per gallon. A gallon of Tinted Wood
Protector will cover about 250 to 300 square feet. The approximate
coverage of oil or latex stain on smooth wood is 250 to 300 square
feet per gallon.
4
Recommended Finish
21. Before applying Thompsons WaterSeal Waterproofer PLUS
Clear or Tinted Wood Protector, read and follow the directions found
on the back of the can. Be sure that both surface and air temperature
are above 50 F during application and for 48 hours after application,
and if youre working outside, do not apply product if rain is forecasted
within 24 hours of application.
22. The surfaces must be free of all mildew, dust, dirt, oil, soot, grease,
and other contaminants. If the surface is damp or wet from cleaning or
weather, allow the surface to dry thoroughly (a minimum of 48 hours)
before application.
23. Cover plants and shrubs and move all objects that could come in
contact with Wood Protector.
24. When you apply Clear or Tinted Wood Protector, do not mix it
with other waterproofing products because variations in the final
appearance of the surface being treated may result.
25. Before applying Wood Protector over the entire surface, a small
trial patch is recommended to verify color.
26. In most applications, only one light coat is necessary. Apply with a
brush, roller, applicator pad, or by dipping the piece into the product.
Regardless of which application method is used, remove excess within
15 minutes by redistributing it to drier areas or wiping it off.
27. Use only with adequate ventilation. Oiliness and tackiness will
result if over-applied or applied to wet or damp surface or if overnight
temperature falls below 50 F within 48 hours of application. Excessive
oiliness caused by over-application may be removed by scrubbing wood
with a concentrated degreaser.
28. Allow at least 48 hours to dry before you hang the swing. Drying
time will vary depending on the substrate, temperature and humidity.
29. Clean brushes and equipment with mineral spirits, then rinse with
clean water.
NOTE: The length of protection will vary depending on environment.
Perform the following splash test once a year to see whether reapplica-
tion is necessary. Sprinkle water on various sections of surface to be
sealed. If water absorbs and darkens color of substrate within 5 sec-
onds, the surface is porous and considered ready to be treated. If water
beads up or otherwise sits on top of surface, then surface doesnt need
protection at this time. For maximum protection from color change
and other damage caused by the sun, reapplication is recommended
every year. Vertical and horizontal surfaces will experience color
changes at different rates.
 CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING
Alternate Finish
If you want more color along with excellent protection, use
Thompsons WaterSeal Deck & House Latex or Oil Stain, both of
which come in Solid and Semi-transparent formulations and are avail-
able in 117 ready- and custom-mixed colors.
30. Before applying any of these stains, read and follow the directions
found on the back of the can. To ensure good penetration, do not apply
in direct sunlight or on hot days. Be sure that both surface and air tem-
perature are above 50 F and below 95 F during application and for
48 hours after application. If youre working outside do not apply
product if rain is forecasted within 24 hours of application.
31. The surfaces must be free of all mildew, dust, dirt, oil, soot, grease,
and other contaminants. If the surface is damp or wet from cleaning or
weather, allow the surface to dry thoroughly (a minimum of 48 hours)
before application. Shake or mix thoroughly before application
(mechanical shaking is recommended).
32. Since in-store color samples may vary slightly when actually
applied to wood (based on color, texture, grain, porosity, and type of
wood), apply the stain to a small test area and let it dry to determine
final color before proceeding with the entire project.
33. Apply stain with an exterior paint pad, brush, roller, or compres-
sion-driven sprayer set for low pressure. Do not use product in a
pump-up garden sprayer. When rolling be sure to go back and brush-in
stain to ensure even coverage. When using a pad or brush, keep the
leading edge wet and distribute stain evenly. This will help avoid lap
marks and keep color uniform.
34. Work from top to bottom or side to side in areas small enough to
allow the leading edge to remain wet at all times during application.
Use natural breaks as boundaries to divide large areas into more man-
ageable work areas.
35. One coat of stain is recommended, but a second coat can be
added if desired. Allow the first coat to dry thoroughly (approximately
4 hours for latex, 24 hours for oil) before second application. Drying
time will vary depending on the substrate, temperature and humidity.
36. For oil-base stain, clean brushes and equipment with mineral
spirits, then rinse with clean water. For latex stain, clean brushes
and equipment with soap and water.
IMPORTANT: Place rags, steel wool and waste immediately after use
in a sealed, water-filled metal container.
PRODUCT SAFETY
For your safety and the safety of those you work with, always read the
safety warnings, which manufacturers print on their labels, and follow
them to the letter. Typical safety advice and instructions will contain
information such as the following:
5
WARNING! Removal of old paint by sanding, scraping or other means
may generate dust or fumes that contain lead. Exposure to lead dust
or fumes may cause brain damage or other adverse health effects,
especially in children or pregnant women. Controlling exposure to lead
or other hazardous substances requires the use of proper protective
equipment, such as properly fitted respirator (NIOSH approved) and
proper containment and cleanup. For more information, call the
National Lead Informations Center at 1-800-424-LEAD (in US) or
contact your local health authority.
Contents are COMBUSTIBLE. Keep away from heat and open flame.
Contains ALIPHATIC HYDROCARBONS.
VAPOR HARMFUL. Use only with adequate ventilation. To avoid over-
exposure, open windows and doors or use other means to ensure fresh
air entry during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air supply, or wear respiratory
protection (NIOSH/ MSHATC23C or equivalent), or leave the area. Avoid
contact with eyes and skin. Wash hands after using. Keep container
closed when not in use. Do not transfer contents to other containers
for storage.
FIRST AID: In case of eye contact, flush thoroughly with large amounts
of water for 15 minutes and get medical attention. For skin contact,
wash thoroughly with soap and water. In case of respiratory difficulty,
provide fresh air and call physician. If swallowed, get medical attention
immediately.
DELAYED EFFECTS FROM LONG-TERM
OCCUPATIONAL EXPOSURE.
Contains solvents that can cause permanent brain and nervous system
damage. Intentional misuse by deliberately concentrating and inhaling
the contents can be harmful or fatal.
WARNING: This product contains chemicals known to the
State of California to cause cancer and birth defects or other
reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF THE REACH
OF CHILDREN.
SAFE DISPOSAL OF RAGS AND WASTE.
Rags, steel wool or waste soaked in Thompsons WaterSeal
Waterproofer PLUS Tinted Wood Protector may spontaneously catch
fire if improperly discarded. Immediately after use, place rags, steel
wool or waste in sealed, water-filled metal container. Dispose of in
accordance with local fire regulations.
CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING

FIG 1. PORCH SWING DETAILS

3/16" WELDED STEEL CHAIN

161/2" (ADJUST FOR FIT)

J 25" (ADJUST FOR FIT)

K
QUICK-LINK EYES G

11/4" SCREWS
F FOR BACK SLATS
H
H
B P
M
1/4" EYEBOLT
B N P (TRIM FLUSH WITH NUT)
L
M
R
NOTCH FOR C
D
7/8 " - DIA. HOLE A2
L 15/8" DECK
C A1 SCREWS
1/2" - I.D.
BLACK PIPE
11/8" TO
CENTER Q 3/4" - I.D.
CUT HERE RUBBER CAP
13/4" TO FOR A2 NOTCH FOR C
CENTER 621/2"
DEGREES
A1 AND A2
K K

EACH SQUARE EQUALS 1 SQ. INCH 7/8" - DIA.

L HOLE

P M

3/4" TO
CENTER
11/2" TO
CENTER

6
CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING

FIG 2. PORCH SWING END VIEW FIG 3. SEAT FRAME ASSEMBLY

B L
REAR
STRINGER
G (D)

A1

A1 A2 A1
M
SEAT
P SUPPORTS
B

B C
D

"-DIA. HOLE
7/8
B

FIG 4. ASSEMBLING THE BACK FIG 5. CUTTING THE BACK ASSEMBLY

G
NO. 4 FINISH NAIL

E 1 /2"
12 "
28
SP

1 /4 ER
AC
"S

1/4"
HOLE DRILLED
AT 14" FROM NAIL

CENTER OF BOARD

7
CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2004-2005 PORCH SWING

FIG 6. HANGING THE PORCH SWING

2" x 4" MUST

SPAN 3 JOISTS

1/4" LAG SCREWS

3/8"CLOSED (31/2" LONG)
SCREW EYE
(3" LONG)

8
Old-Fashioned Push-Along Toys
RUNNING ROSY
A doll to kiss, a doll to cuddleat some time or other,
most of us have sought the cozy, clinging comfort of a
toy doll. Running Rosy is something more than a doll.
She's a sort of doll in a hurry, the perfect push-along-the-
carpet plaything for younger kids. This is a beautiful
plaything, a real delight for kids and adults alike. She's
strong, easy to make, nicely rounded for "learning" hands,
but best of all, her wheel-turning movement is just right
for active toddlers who like to push toys along the floor.
If you are looking to make a unique toy for a unique kid,
then this is the one.
MAKING THE TOY
When you have carefully studied the working drawings,
take the tracing paper, a pencil, ruler and compass, and
carefully set out the design on the wood. If you are going
to stay with my choice of materialsplywood sand-
wiched between solid woodthen you need six cutouts
in all: two solid wood outside body parts, two plywood
head and body spacers, and two plywood foot-wheels. If
you are wondering about my choice of materials, it's
pretty straightforward and logical. While the head-and-
body spacer and the wheel need to be strong in all direc-
tions across the grain, they also need to be safe for kids,
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www.TedsWoodworking.com
as well as relatively easy to work with a coping saw. All
things considered, we thought that best-quality 1/4"-
thick multi-layer plywood was a winner on many counts.
It's strong, it's stable, it's easy to cut, and it's easy to
bond layers together to give extra strength.
When you have made all the cutouts, rub the two foot-
wheels down to a smooth, round-edged finishso that
they are smooth to the touch and the total two-wheel
thickness is something less than 1/2". Next, establish the
position of the pivotal dowel holes through the wheel and
into the inside face of each solid wood body part. Then
drill them out with a bit size that gives you a slightly loose
fit for your chosen dowel.
To assemble: Glue one body part to one side of the
central head-body spacer. Set the two foot-wheels in the
cavity so that the feet are facing in the correct direction.
Slide the dowel in place, and, lastly, glue the other body
part in place so that the foot-wheels and pivotal dowel
are nicely contained.
When the glue is dry, rub the whole works down so
that the corners are rounded and good to hold. Aim for a
form that is going to be safe and comfortable in a toddler's
hands. Finally, use watercolors to tint in the imagery, give
the whole works one or more coats of clear varnish, and
the toy is finished.
it's easy to work, good to touch, strong across short grain
"necks," and it glues and finishes well.
Don't think you can cut costs by using the coarse-
centered plywood that goes by such names as "block ply,"
"stout heart" and "Malaysian." I say this because plywood
of this type and character tends to be difficult to work,
soft, almost impossible to sand to a good finish, and prone
to splintering. No, when we say "multi-ply," we are
specifically referring to the type of plywood that is built
up in thin 1/16" layers or veneers. A plywood of this
character has a smooth, white, close-grained face, it's
tremendously strong and it's great to work. Ask for "best-
quality, multi-ply, multilayer or multi-core plywood,"
and don't be talked into anything else.
Note, a sheet of 1/4"-thick multilayer plywood
should be made up of four or five thin veneer layers.

SPECIAL TIP
Wooden toys must be childproof! Being mindful that tod-
dlers are, at the very least, going to stick the toy in their
mouths, it's most important that all the fixtures, fittings
and materials be totally secure and nontoxic. Perhaps
most important of all, the wood must be splinter resistant.
With all this in mind, we chose to use multi-ply for the
central layer and for the wheels, for the simple reason that

USING PLYWOOD
Best quality multi-ply is a first choice ma-
terial for small cutout type toys. It is amaz-
ingly strong and it rubs down to a good
smooth-to- touch finish.

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STEP-BY-STEP STAGES
1 Check the component parts against the working
draw ings. And just in case you are wondering why I
opted to use two 1/4"" thicknesses to make up the 1/2"-
thick spacerrather than a single 1/2" thicknessthe
simple answer is that I had lots of pieces of 1/4" ply
that needed to be used up.
3 Test the wheels in the body cavity. They need to be
an easy loose-turning fit. Note that in this test run I
have the feet running in the wrong direction!
2 Fix the two wheels together with a piece of double-
sided sticky tape and rub them down so that they are
slightly less than 1/2" in total thickness. The use of the
tape not only ensures that both wheels are identical, it
also makes them easier to handle.
4 Rub the whole works down to a smooth finish.
Close your eyes to test the finishit's vital that every
surface, edge and angle be supersmooth to the touch.
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RUNNING REG IN HARDWOOD
Kids are so perceptive! When our Rosy toy was finished
and up and running, I took it around to the 5-year-old
girl next door for a bit of no-nonsense, in-depth criticism.
Of course 1 was expecting a little bit of praise, but, oh no.
All she said was, "But. . . where is running Reg?" So there
you go, we had no other option but to make a Running
Reg toy.

COUNTERCHANGE CUTTING
The clever thing about this project is not so much the
design, but rather the way the two contrasting thicknesses
of wood are cut and then counterchanged. It's an amaz-
ingly simple but subtle technique. All you do is sandwich
two contrasting sheets of wood together, fret the design
through both layers, and then swap the cutouts around
so that the cutouts are contrasting.
STEP-BY-STEP STAGES
PROCEDURE
Take the four pieces of woodthe sycamore, the mahog-
any, and the two pieces of plywoodand use the double-
sided sticky tape to make a sandwich that has the plywood
as the filling. When you are happy with the arrangement,
carefully press transfer the traced imagery through to the
sycamore side of the sandwich. Use the scroll saw to fret
out the outside profile. This done, ease off the outside
layersthe sycamore and the mahoganyand stick them
together.
Cut out the plywood inner shape and the wheels.
Then comes the very clever procedure of counterchange
cutting. The method is beautifully simple. All you do is
take the two profiles the sycamore and the mahogany, 1 Having fitted the very finest blade in the scroll saw,
all nicely stuck together with the double-sided tapeand very carefully cut the design down into its component
saw them down into all the little parts that go to make up parts. I t ' s important that you use a new, well-
the design. For example, with this design I ran cuts tensioned blade and go at it slowly, so that each and every
through at either side of the hat band and under the chin. cut is well placed and square to the wood.
All you then do is swap the cutouts around and put the
toy together in much the same way as already described.

2 Ease the layers apart,

remove the double-sided
tape and counter-change
the parts. Note the little
cut that goes to make the
design of the mouth.

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DESIGN OPTIONS
TOY SAFETY
Traditional wooden toys are enormous fun! Wood-
workers like making them and kids like playing with
them. But you do have to bear in mind that the average,
intelligent finger-sticky toddler is generally going to do
his level best to push the toy in his mouth and/or up his
nose, if not worse! If you are going to make wooden toys,
you have most certainly got to make sure that all the
structures and all the materials are completely safe. If you
are going to present the toys as gifts and/or make them
for sale, you are legally bound to make sure that they are
"safe, sound and fitting for their purpose." What this
means is that you must ensure that every part of the toy
is safeno splinters, no toxic materials, no loose parts
that can be swallowed. Be warned, ignorance is no excuse
under the lawyou must make sure that everything is safe!
The following will provide you with some good sound
guidelines.
Paint
Since kids like brightly colored toys, it's vital that you
make sure that you use paints that are completely safe
and nontoxic. Yes, your dad's old paint might still be in
good condition, and, yes, it would give a wonderfully
glossy, hard-wearing finish, but then again, it is almost
certainly poisonous! Most old paints contain all manner
of toxic mixes, everything from lead and antimony to arse-
nic. You must set out on the assumption that all old paints
are dangerous.
When 1 asked around, I was assured that all modern
paints are required by law to meet certain nontoxic, lead-
free standards. But when I took it a bit further and phoned
a paint manufacturer, they said that though their paints
do most certainly come within safe standards, they don't
necessarily come up to the standards required by the "Toy
Safety" laws. As you can see, the whole area of paints and
toy safety is somewhat difficult. I personally think that
the best advice is either to use water stains and cover them
with water-based varnish or to use acrylic paints. If you
are concerned about paints and toy safety, then it's best
if you write to various well-known paint manufacturers
and ask their advice.
Wood Types
Although I have had no personal experience in this mat-
ter, I do understand that certain exotic wood types are
dangerous if they are chewed. For example, I read of a
case in which a child chewed a wooden toy from a Third
World country, and the juices in the wood caused the
child to go into some sort of shock. II we err on the side
of safety and take it that some wood varieties are toxic,
then the best advice is to use only wood varieties that we
know to be safe. So, if we take it that modern American
and British toymakers know what they are doing, it looks
to me as if we should be going for wood types like lime,
sycamore, beech, birch, oak and pine.
Fittings
As I remember, kids are always trying to pry their toys
apart in an effort to find out how they work. This being
the case, it's a good idea to avoid nails, small pieces of
wire, and component parts that could in any way crack,
splinter or shatter. The best advice is to use brass screws,
glued dowels and glued layers.
Form
In many ways, the form a toy takes is as important as
its substance and structure. For example, if a toy has a
component part that is long, thin and spiky, or a part that
could be swallowed, or a part that could be inserted into
the ear or nose, then it follows that the toy in question
has been badly designed. If and when you are designing
your toys, or if you decide to modify this one, you must
make sure that it's safe. For example, it might be a good
idea to extend the walking girl's hair so as to make more
of a handle, but the question iswould it be safe?
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SHELVES

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It's rare that bookshelves look as interesting as the objects you display on them. After
all, how much can you decorate the edges of your shelves and sides? This unit is
unusual because the shelves and sides are beefier than you would normally see, and
the two bevel cuts on the front edges give these shelves nice visual interest. Best of all,
perhaps, is that this piece is simple and quick to build.

Dividers and Shelves

Start by cutting out the sides and shelves. The 1-1/2"-thick sides are made by gluing two Face-Glue the Parts: Once you've got
pieces of 3/4"-thick plywood together. The 1-1/4"-thick shelves are made by gluing 3/4"- your parts cut to size, glue and nail them
thick plywood to a 1/2"-thick piece. Note that the finished sides have a 3/4" x 1/4" rabbet together leaving the rabbet at the back.
Set and putty the nails, then rip the
for the back that's formed by gluing a narrower piece to a wider one. The adjustable and dividers to their final width.
fixed shelves in the side openings are all the same width. The center shelves are 1/4"
wider to account for the lack of a back.

To cut the sides, crosscut a whole sheet of plywood to the length of the sides first, then
rip them to width (11" and 11-1/4"). Cut the sides a little wide (1/16"), initially, to give
yourself a little room to saw off a square straight edge. This will give you a clean edge
for attaching a piece of maple later. Now nail and glue the dividers together,
remembering to offset the back edge for the rabbet. Place your nails so the shelves will
hide them.

Here's an easy way to cut the shelves. Rip them to width from a full piece of plywood,
then nail and glue up a length of shelving. Then crosscut the shelves to length from the
long pieces. You can get five 16" shelves out of a 96" rip. For even less work, cut the
shelves to length after attaching the edging.

Edges and Angles

The edges for the bookshelves are solid maple. Because the thickness of 3/4" and 1/2" Profile: The bevels on the edges are
plywood is considered "nominal," you will end up with finished thicknesses about 1/16" basically a "V" shape on the entire edge.
See the diagram at right for the details and
less. Rip your edging stock a little wide and attach it with biscuits and glue. With a flush- cutting angles. Clean up your saw marks
cut bearing bit in a router, trim the edging flush to the sides and shelves, then clean up with a plane.
your work with a plane or scraper.

The last step is to bevel the edging. The photo shows how I did this on the table saw.
Remember that the setup must change for the different width pieces.

Making it a Stand-Up Unit

The next step is to mill stopped grooves in the topmost and bottommost shelves to
accept the tapered sliding connectors that attach the sides together. The grooves in the
ends of the shelves are 3/4" wide by approximately 3/8" deep, and milled with a dado set
on the table saw. It helps to make a practice joint because the depth of the groove is
critical to a snug fit using this style of connector.

Installing the Shelves

After cutting the slots in the shelves, lay out and mount the small part of the tapered
connector to the side. The large connector will mount to the shelf groove with the wide
end towards the shelf front. Do a test fit on the shelves. The shelves in the side units
should be flush to the rabbet in the back edge of the sides. The center shelves should Mount Knockdown Hardware: Use a
dado stack to cut a 3/4" x 3/8" groove from
be flush with the back. the joint where the edge attaches to the
shelf to the back of the shelf. The
knockdown hardware is mounted in about
The next step is to cut the stopped grooves in the rest of the shelves for the hidden wire the middle of the shelf. It pulls together
shelf supports. If your blade is too narrow, take two cuts to get the 1/8" groove pretty tightly, so you might want to sand
necessary to slide the shelf onto the wire supports. Some drill and chisel work will be any bumps or ridges off the ends of the
shelves to keep from scratching the sides.
necessary to lengthen the kerf to accept the entire 9-3/4" length of the shelf wire. This
requires drilling and chiselling into the end of the front edge. Lay out and drill the
locations for the wire supports in the side and center sections so the shelf heights will
match across the bookcase.
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Now it's time for all the parts come together. Begin by assembling the two outside units
of the bookcase. Tip them onto their backs and attach the aprons to the bottom shelf
using cleats and screws. Next attach the side units together forming the center section.
The best way to do this is to assemble with the front facing up. Use a handscrew clamp
to hold up the sides while you're assembling. The apron on the center bottom can be
screwed onto the shelf and braced with corner blocks prior to assembly. Push the lower
shelf into place and mark the location of the apron, also called a "kick" or a base. Then
remove the shelf and add two stop blocks to the sides to support the center apron from
behind.

When you're happy with the fit of the parts, disassemble the bookcase and finish. I
applied a coat of light stain to give the maple an aged appearance. (I used about two
ounces of linseed oil and colored it with Olympic stains, one-half Early American
#41552, and one-half Red Oak #41567. 1/4 teaspoon of each.) Wipe on an even coat of
oil. Wipe off the excess and let it dry for 24 hours.The next day, lightly sand the surfaces
and clean them with a tack rag. Finish with two or three coats of a clear finish. Magic Wire: After cutting the 1/8" grooves
in the shelf sides, assemble the case. Tap
the wire shelf supports in and slide the
loose shelves in place.

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