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ctrntents

WOODomagazine August2001,lssue
134

proiects & techniques


U patio partycenter
Entertainin stylewith this deluxe
mobilepafty wagon.The design
includesdrop-leaftable extensions,
amplestorage,and a built-incooler.

52 patina-toppedjewelry box
Make this populargift item,and
learnhow we treatedthe copper top
to createa colorful,decorativelook.

60 street-smarthousesign
Helpfriendsfind theirway to your
door with this pleasingplaque.

68 great grates/pleasingplates
Spruceup your home'sinteriorswith
thesewoodenair grillsand electrical
*#':'' wall olates.
,$ idj',-.: r.

e a u e s
M the gallerythat reallysells
Visit Seattle'sNorlhwestFine
Woodworkingstore,and discoverthe
secretsbehindits enviablesuccess.

74 Louisianaheritagefurniture
Travelto Cajuncountry,and meet Greg
Arceneaux,makerof exquisitepieces
in the Creoleand Acadianstvles.

www.woodonline.com I
contents
August2001, lssue134

tools & materials


50 TLCfor powertools
Give your machineslong life using
these maintenancetips.

62 through-dovetailjigs
See which of these eight shop-tested
models offersthe best routingvalue
and performance.

departments
1 4 fail-safe router jig
Buildthissimple to rout
shophelper
precisionstopped dadoes
and grooves.

22 new crosscut sled


Checkout a niftycrosscutting
acces-
sorythat providesmiterstopsevery
1/2"overa full 180"range.

22

'*
,^

t.):/
BetterHomesand GardensaWOODs magazine(ISSN-0743-894X) is published
nine timesa year in February,March, April, May/June,July/August,September,
October,November,and Decemberby MeredithColporation,l7l6 Locust St.,
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additionalmailing offices. Better Homes and Gardenstrademarkregisteredin
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NSY lV2. POSTMASTER: Send addresschanges to Better Hones and
GanlensWOOD nagazine,P.O. Box 37439,Boone,IA 50037-0439.

WOOD magazine August 2001


Better llomes and Gardenso

w@ffilffi.
2001. Vol.18,llo.5 e lssue
JULY/AUGUST il0.134

Editor-ln-Chief
BILL KRIER
Executive
EditorJllllHARR0LD
Managing
EditorMARLEI{ KEMIIIET
Assistant
Managing PETER
Editor/Features J. STEPHAI{0
Design
EditorJAMES R.DOWl{lllG

Turn your shop ideas


Senior
EditorJAI{HALE
Projects SVEC
EditorDAVE
Products CAilPBEIL
Techniques
EditorJIMPOLI0CK

into free tools Shop


AssistantDesign
Builder
Manager/Project CHARTES
Editor/Project
Manager
Production/0ffice
Administrative
Assistant
Builder
MARGARET
SHERYT
l. HEDLUIID
KEVlllB0YLE
CL0SNER
MUI{Y0I{
Reader-Contact
SpecialistBEl{VOllRUDEt{
L0RNA
Illustrators J0H1{S01{, R0XA}l}lELeM0lNE
MARTY
Photographers
Contributing BALDWIN, DOUGE.SMITH
Technical DAVE
Consultants HEI{DEBS0]{,GARRY SMITH
Contributing
Craftsman JIMHEAVEY
ArtDirectorTIMAIEXAIIDER
ArtDirector
Associate J0HllMEEK
saidthat the bestthingsin ArtDirector
Assistant CHERYL A.CIBULA
It's been
Ilife arefree,andI certainlycan't PublisherMARK HAGEN
arguewith that. Especiallywhen Advertising 333N.Michigan
Oflice: Ave.,
Suite
1500,
lL60601
Chicago, Phone:
312853-2890FM:31258S7906
thosefree things are power tools. Manager
Advertising JIMHUGHES
That'swhy I'm so thrilledto tell you MailResponseManager CAROIY]{DAKIS
AccountExecutiveR01lGOLIYIINAS
aboutour latestcontest.DeWalt Account NEIL
Executive KIRBY
IndustrialTool Companyhasteamed AccountExecutive
MABK LAC0MBE
(Detroit
248/356-321
6)
up with WOOb magazineto spon-
MarketingManager GERALLIE LEGASPI
sor the first-everGREAT AMERI- SalesAssistant
MARGARET TRAVIS
CAN WORKSHOPSCONTESTTM. SalesAssistant
THERESA C00KS
Winnersin variouscategorieswill DirectorWltLlAMR.REED
Publishing
sharein $10.000worth of tool Business
Associate Director
CRAIG FEAR
Product
Senior Manager RICK GR0W
prizes.And, you'll love this part All Advertising Manager
Services PATHENDERSH0TT
you needis a workshop,camera, Consumer Marketing
Director
KATHI PRIEI{
Consumer Marketing
Manager DAVE H01{0tD
pen, and paperto enter.If you havea
VicePresident DirectorJERRY
Publishing WARD
shop-smartsafetyidea,original work- workbench,or ideahelpsyou work more
MEREDITHPUBLISHII.IG
GROUP
benchdesign,problem-solvingorganizer, efficiently and effectivelyevery day. Then President
STEPHEI{ M.LACY
or just a greatall-aroundworkshop,you mail thesein, along with the completed Magazine President
Group JERRYKAPLAI{
may havewhat it takesto win. entry form. That's it-you're done. SalesMICHAEL
Grouo ER0WNSTElll
ServicesELLEI{
Creative DETATHOUDER
Soundeasy?It is. As you'Il seein our For its part, contestsponsorDeWalt BRUCE
Manufacturing HEST0l'l
contestrules on pages24 and25, therc are IndustrialTools will provide $3,000worth Consumer KARLA
Marketing JEFFRIES
DEAI{PIETERS
Operations
eight ways to win, eight categoriesfrom of tools to the winner of the Best Overall Finance MAXRUll0lMAl{
andAdministration
which to choose. Shopcategory,and $1,000in toolsto each ^lUleredlth
Now. I and the restof the crew at of the winnersof the sevenremainingcat- I conponetron

WltLlAMT. KERR. andChiefExecutive


President 0fficer
WOOD can't enter.but I would like to egories.You might evenbecomefamous
lll, Chairmanof the ExecutiveCommittee
E.T.MEREDITH
sharewith you a few insidertips that becausewe'll featurethe winnersin our
@CopyrightMeredithCorporation2001
might help your chances.First, take a March 2002issue. All riehts reserved.Printedin the U.S.A.
minuteor two to ensurethat your photos Just remember, the entry deadline is Customer Service Information: For service on your sub-
are well-composed,focused,and lit prop- October 1,2001.That givesyou plentyof scription, including change of address, contact us at
www.woodmagazine.com/service or call 8ffi/374-9663.
erly. Removeany clutter that might dis- time to showcaseyour beststuff. Subscription mailing address: Better Homes and Gardens
tract from the objectyou're showingoff- To all of you, the very bestof luck. I WOOD magazine,P.O. Box 37439, Boone, IA 50037-0439.
Pleaseenclose your addresslabel from a recentissue.Editorial
that will eamyou pointswith thejudges. can't wait to seewhatyou sendin.rl mailing addr€ss:The Editor, WOOD magazine, l716 Locust
Street,GA3l0, Des Moines, IA 50309-3023.For questions
Make your write-up short,but clear and on editorial, questions about how to reach an advertiser, or to
place an advertisement in our magazine call 8fi)/374-9663.
complete.If your handwritingis as hard to
readas mine, type your letter.Let us
know how your shop,storagesolution,
Y^!Ay^;!,,v To order back issues call 800/346-9663. Article reprints,
send $5 per article (no phone orders), include issue and name
of article, to WOOD Article Reprint Service, P.O. Box 349,
Kalona, lA 52247, check or money order made payable to
WOOD magazine.

to ^lP^l
WOOD magazine August 2001
talkin andtimelyupdates
back
comments,
boardforletters,
Ourbulletin

CIRCULARARC

ARC
ELLIPTICAL
The ins and
outs of arcs
In issue 126,you gave GarrYLibertY
of Quebeca simple method for draw-
ing an arc over a window or doorwaY.
It seemedto me that he was asking
for a circulararc; you gave him a
solution for an arc that is best com'
pared to the elastic line formed by a
beam being bent by a single, centered
load. This arc differs slightly from a
circularone, and to be syrnmetrical, stretchingstring at Fr, loop it over a . Almost everyrouter-bitmanufacturer
bit, but you aren't
the wood strip used to draw it must be pencil point held at T and, pulling it i makesa drawer-lock
homogeneousover its entire length. tight, tie it otf at Fz.Now, keeping the . likely to find one at your local home
To draw a circulararc, drive finish string tight, let it guide your pencil as center or hardware store. Look for a
i
nails at points A and B. MarkYour you draw your ellipticalarc, as shown woodworking machinery dealer under
.
desiredheight at point T midwaY in Drawing 2a. : Tools-Electric in your Yellow Pages.
betweenA and B. Placetwo slats -Klaas}terdoom, Netherlands
Bentveld, : You alsocan mail-orderthesebits
along lines AT and BT, makinga rigid i directly from manufacturers,or through
joint at T, as shown in Drawing l. major woodworking-supply catalogs.
Placeyour pencil point at the slats' The key to the i (MLCS offers its Katana drawer-lock bit
intersectionandnsliding the slats on draweillock bit review i no. 18850 for $39.00. Call 800/533-9298.)
the finish nails,draw the arc, as In the drawer-lockrouter bit review in .
shown in Drawing la. issue 129,the illustrationshowingthe i
Another pleasingcurve to use is an router table setup is correct, but Step . Better advice on Poor-
ellipticalarc. To draw this arc,find the 3 of the instructions doesn't agree.lt : fitting drill-press taPer
poor'fitting drill'
centerpointC, and mark your desired should read,"Positionyour router i The solution for a
height at point T. Measureline AC. Set table fence that distanceback from . press chuck Morse taper suggestedby
on PageI in
your compassto this dimensionand the upper cutting edge of the bit." i readerJohn Graber
swing an arc from T to intersectline -Ray Williamson, )nt. ' issue 131 won't
Peterborough, work. Thesetapered
AB at the two focal points, Fr and Fz, arbors have a drive tang on the end
as shown in Drawing 2. Drivefinish Touch6,Ray.Incidentally,manyreaders : tnatmates with a
nails at Fr and Fz.Tie a piece of non- haveaskedwherethev canbuv this bit. "2:,:,r;::;2rrirr,,,
WOOD magazine August 2001
10
talkingback

IIAISIGA PENFffT
OIIf F ASEEIiYAS
I$INGYOIIR ilIAfr(IF
roTlEulmmrc!

Gi*tsmil Exttulvo |.ilor ll*


The guesswork is orcr. So is wasteful,
inaccuratecutting. Now you'll know
exactlyuf,ere the blade will intercect
with your workpiece. Perfect for all
types of straight and berel cutting.

the taperedrecessin the drill-press norm. All my blades have recommend-


quill.Thetangengagesits slot well ed speeds well under 8n000rPm,
beforethe tapersmakecontact,mak- -John Bakes, B.C.
WestVancouver,
ing it impossibleto lapthe chuck
arborin the quill.Try replacingthe You're right, John,8,000is not rpm; it is
arborinstead.The Morse-taper arbor fom (feet per minute), a measureof the
5'OOOnm no{od tp*d on a chuck is a separate piecethat is speedof the blade's teeth as they come
fiortH and gttoodt crttlhg
1$amp universal motor with press-fitinto the ehuckbody.To aroundthe bend.
extemally accessible brushes has replaceit, openthe chuckall the way To put this in units we all understand,
poner needed for all tlpes of cuts .
and supportit, arbordown in an open we did the math. The averageunder-load
vise.Usea punchor a pieceof rod speedof the seventablesawswe testedin
and a hammerto drivethe arborout. issue128 is3,428 rpm. At this rotation,
Purchasea newone of the samesize, the teeth of a 10" blade are fraveling at
and reseatit usinga wood blockto 102 mph for Americans,or 164 kph for
cushionthe hammer. blows, our Canadianneighbors.
-KenneffiPlegefCapac,Mich.
Sfitfirglbtn wl|h bultfi bovol
lndcatan lbr ffii ardo tery.
Wrthour new eaqFtoread cofitrols, Thanks for your input, Kenneth.If you Desert dustbin has a
ewn tfe ticky cuts can be set uP
and made with confidence. can't find them locally, Gruzly Indusnial, olt€-?fmed Gactus
S00l523477 7, andWoodworker' s Supply, A readercalled to tell us that one of the
8Nl&5-9292, sell chucks and Morse- paffernsfor the DesertDustbin in issue
taper arbors.Woodcraft, 8N1225-1I53, t32 is incomplete.The cactuson the
sells the TaperMateMorse taper cleaner. desertscenepanel has only one arm, and
Call for catalogs. the row of lacing holes along one edgeis
missing. We've reprinted this part of the
patternon page 86. You can make a copy
E$enCqr Fwlde c#clb,
fior pofec{r bodt hrf,ie d lmd
The spin of the pageand mateit to your existingpat-
Frornomate crown molding to a
huge backyarddec*, make precise
on saw blades tern.We apologizefor the inconvenience.
adjustrnentswith ease & confidence. In your articleon tablesawsafetyin
issue128,you statethat a blade
Available at Sears, Sears Hardware,
and the Craftsman Catalog whirlingat 8,000rpmshouldinstill
at 800-437-9686 caution,but not fear.This sawyou
referto would instill both cautionand

sEnRs THECOOD LIFE


ATACREATPRICE
fear in me.Neitherof my tablesaws,
nor othersof which I am aware,turn
at this speed.Generally speaking, Mffifueff radss.
GUARANTEED*
anywherefrom 3,00H,000 rPmis the

12 WOOD magazine August 2001


qreat
- ideas
for vour shop

tail-sale
router iig
at through
A specialist
or stoppeddadoes
and grooves t: i,

f here are only a few things that can wandersaway from one, the other keeps
I go wrong when you're routing you from routing outsideyour layout lines.
dadoesfor shelves.Unfortunately,most Begin by laying out both sidesof the
of them ruin the job, so one of our free- guidethe dado.Clamp thejig's fixed fenceover one
lancecraftsmen,Erv Roberts,designeda bit along a of the layout lines, then slip the shelf stock
routerjig that's easyto align and cuts the fence.the cut betweenthe fixed and movablefences.
exactthicknessof the shelf. Best of all, is directly below Turn the wing nuts to snugthe movable
the router can wanderaway from the the bearing---one fence againstthe stock, and clamp it in
fence while you're working-without edgeof the cut automaticallyfalls exactly place. To make the cut, guide the bearing
ruining thejob. alongthe front of the fence.Erv's jig uses along one fence,then the other, traveling
The secretis a flush-trimmingpatternbit a router bit nanower than the dado you clockwise.To makea stoppeddado,use
with a bearingabovethe cutters.As you need,but hastwo fences.If your router the optionalstops.
Most of thejig screwstogether.Make
the movablefencefrom two pieces,as
3/t x 21lz x shown in the detail. Slip the bolts through
the holes in the narrow piece, then glue
the two piecestogether.To form the
shoulderedkeyhole slot in the fixed fence,
drill the 3/c"endholes,then rout thee/zz"
slot with a Vq"bit chuckedin your table-
3h x 21lzx 30" stock
mountedrouter.Now, centeringa3/q"bit
3 l c x 2 l l z x 1 2 "s t o c k on the end holes,rout a 3Ao"-deep shoulder
s/sz"keyholeslot in the fence'sboffom face.The end holes
(Cut in 2 passes.)
#8 x 111+"
F.H. let you add and remove the stopswithout
wood screw
taking offthe wing nuts.
Do you needto rout a dovetail or key-
hole slot?Simply install a guidebushing
in your router subbase,and adjust the
movablefenceto the bushing'sdiameter.I
Strip rippedfrom edge.
1lt-20x3" Written by Jeff Day
1 1 / r oh" o l e
Project Design: Erv Roberts, Des Moines, lowa
connectorbolt P lllustrations:Roxanne LeMoine; Lorna Johnson
1lt-ZQbarret
nut-! Photograph: Baldwin Photography

l/+" nut
Connecbrboltst3''tengttt0o.06K90,. :,
$4.50/10pack)and cross dowel(no. 06K70,
$2.50/10gack)are availablefrom Woodcraft-
'rllu"Fl-\,/o-20*3' 3lqxslax 2112" 3lqx21lzx71l+"stock Oall800/225-1153.Pattembits are available
--'112" stock
connectorbolt frorn EagleAmerioain varioussizes.Call
8OOl872-2511 for a catalog.

WOOD magazine August 2001


woodfd
toyourquestions
Answers fromletters
.==+
=--:-!

t'-:

andW00DONL|NEo
e-mails,

Raise panels every plece


through three or
with a tablesaw four times and still
or routet? back and do some
touch-up sanding.
I'm aboutto makemy first set of -BillSchreibet
f\
lg raisedpaneldoors.What'sthe
bestwayto go aboutit? I haveread
howto go aboutit on a tablesawusing lntarsia with
a jig. Or wouldit be bestto spendthe a bandsaw?
big bucksfor a panel-raising routerbit ,\ Hasanyonetrieddoingintr
set?| havea HitachiMVl23hprouter. \I witha bandsaw? All I have
-Dennis McFiggins, N.Y.
BrockPort, smallscrollsaw,andI canneverfol
the linesdueto vibration. How do you clean
A I have cut raisedpanelsboth waYs,
_Sid,WOODONLINE big sanding belts?
Fl tablesawand router bit. I was satis- ,tf lam lookingfor information
fied with the tablesawpanels,but the f, I have done severalintarsia pieces \{ aboutcleaningsandingbelts,
clean-upsandingwas tedious.So I A on a 10" benchtopbandsawwith a parricurarry
rorwide
druTrill,ofi^],*
boughta3Vz" diameterCMT bit. I have very small blade on it, and they were ,,,
the samerouter that you do and it works quite acceptable.I think the sandingis
great.I run the router at its lowest speed more critical than the method of cutting. A Performaxproduct manager
(8,000 rpm) for safety and to reduce -Robert Zink,GrandHaven,Mich. A Warren Weber offers a couple of
tearout.I run eachpanel over the bit at options, Duane.If your belt has a
build-up that can't be removed
least six times, taking a small amount of A Yes, use a /s" blade. Intarsia expert resinous
material with eachpass. lil luoy Gale Robertsusesa bandsaw with a rubber cleaning stick, soak it for a
-Jack Francis, lll.
Geneva, all the time. few hours in a couple of ouncesof
-WilliamBeatty, 0nt. householdcleanermixed with a quart of
Haliburton,
water. Or, go the heavy-dutycleaning
A For a thorough look at the different
Fl methodsof raising panels,check route with a 50/50 mixture of mineral
Issue62, August 1993.Call 800/346- spirits and lacquerthinner. Obviously,
9663 to order a copy for $6.95. the latter mixture is quite volatile, so
-trVOODo magazine cover the containerand keep it in a safe
place. Whichever method you choose,
If you want different profiles than finish up by scrubbingthe face of the
A
Fl just plain flat panels, I would go belt with a stiff nylon brush. A couple of
with the bits. Also, the raised-panel bits cautions:Soakingis appropriatefor
are supposed to reduce the amount of polyester-or cloth-backedbelts, but not
finish sanding you have to do. I have for those with paperbacking. And if
used the tablesaw on several projects and your drum-sanderbelt has a Velcro
really got great results. Once you are set backing, you might find debris from the
up, it is amazing how fast you can do face side lodging on the back. Finally,
panels.On one project, in two hours I set Weber suggestswrapping your belt in
up the tablesaw,raised the panels, and the oppositedirection when you re-
had the finish sandingdone on l0 good- install it. You'll extendthe useful life of
sized panels.It would have been about its abrasiveparticles.
panel -{trt00D magazine
the sameif I had used raised bits,
becauseyou probably would needto run Continuedon page 18

16 WOOD magazine August 2001


-l

woodforum

How to position a A I installeda track and usedit about


router table track |{ threetimes.Then I useda pieceof
| 'm buildinga routertablewith lauan plywood about 9xl2" for a sled,
l'ff
\{ the routerplatein the centerof and attacheda piece of scrapacrossthe
the top.Howfar shouldthe mitertrack niurow dimension,squareto the edge,to
be fromthe plateor the bit? serveas a sledfence.I mounteda hold-
-Pete Brown,Ortord,
Md. down clamp on that fence.Placethe
long edge againstthe router fence, clamp
A Get it as closeto the bit as you can, your stock againstthe sledfence,and
A while still allowingyour miter rout away.It works great.
gaugeto pass.Put your largestbit in -Bandy Walker,
Atlanta,
Mo.
your router,then placeyour miter gauge
directly in front at a point whereit will
clear the bit. That shouldtell you about How does ash
whereto cut the slot. compare to oak?
-Kevin Roberts,
Katy,Texas n Ourlocalhardwood millfolks
\l mentioned thattheywouldbe
A I just placeda commercialrack in sawingandkiln-drying someashsoon.
ll my shop-builtroutertable about3" Thisgot meto thinkingaboutusing likeredoakfor resaw-
from the front of the table.As long as someof it on my nextsmallproject- ing,jointing,planing,
the miter gaugeand all of your jigs clear makinga frameto hold400name androuting?
the bit, you should have badgesfor our church.I'veworked -Chuck Hosler0nalaska,Wis.
:;r::t:rO;;I;;r ,, mostlywithredoak,ls ashanything Continued on page 20

18 WOOD magazine August 2001


rrvoodforum

A Chuck,white ashis a fine substi- teeth to follow this rule. Use a 24-tooth
A tut" for red oak in indoor projects. bladeto rip a2x4, for example.
Note, however,that its extremehardness This method minimizes friction and also
makesit susceptibleto burning from reducesthe chanceof accidentallycon-
bladesand bits. It has a tendencyto chip tacting the exposedportion of the blade
when you usea router,too. To checkout with your hands.Anotherproblemwith
other species'characteristics, log on to raisingthe bladeup high is that you're
www.woodmagazine.com, and click on putting a much wider sectionof the blade
"Wood Profiles" under the WOODa inside the wood. That increasesthe likeli-
magazinebutton. hood of kickback if the workpiece twists
--jJV0ODmagazine thatfiveto seventeethshowabovethe slightly on its path acrossthe saw.
wood.What'sthe bestmethod? -+,00D magazine
-John Bissell,
Lampe,
Mo.
Tablesaw blades
take the low road A John,we took your questionto Got a question?
I'vereadditferent theoriesabout l.t Roger Cliffe, who wrote Table lf you'relookingfor ananswerto a woodwork-
n ingquestion, wite b: W00DForum,1716
\{ theproperheightfor yourtable- Saw: WorkshopBenchReference.The
lncrtst St, GA310,lles tloines, lA SIHP
sawblade.Somewoodworkers sayit ideal, accordingto Roger, is to set your flZif or e-mailus at woodforum@mdp.com.
shouldextend justslightlyhigherthan blade so that three to five teeth are in the Foran immediate answerto yourquestion,get
theworkpiece, for safetyreasons,and wood at a time and no more than V+" helpfromfellowwoodworkers by pmtingit on
oneof ourIntemetdiscussion groupsat:
somesayit shouldbe quitea bit high' protrudesabovethe workpiece.When
ww.rmodmline.com.
er,so thatthe frontteethcut downon you move from thin to thicker stock,
thewood.I usuallysetmy bladeso switch to a blade with fewer, bigger

WOOD magazine August 2001

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update

new Miter SOOOsled


revels in lncra-think
s if three Incra miter guides repeatablestops,a feat no other guide or addeda fxed right-side baseto support
weren't enough,Taylor Designhas sledcan top. the offcut piece and reducetearout.
addedyet anothercrosscuttingaccessory In fact, the Miter 5000 sled is so rooted Following the manufacturer's instruc-
to its lineup. But the newestaddition- in the Miter 3000 guide that, if you leave tions, we attacheda miter bar to the righr
the Miter 5000 sled-may be their finest out a few parts, you can make it into a side base,put the assemblyin the right
offering yet. 3000. But thoseextra parts make it well miter slot. and frimmed the excessbase
Like Incra's Miter 3000 protractor-style worth the additionalmoneyyou'Ilpay. material by running it through the saw.
guide,which we reviewednWoODa For starters,you get a spacious We then positionedthe basewhere shown
magazineissue133,the Miter 5000 pro- 22x23V2"melamine-coated, MDF sled in the photo below left, andusing a hex-
vides positive miter stopsevery Vz" over a basethat can carry stockup to 25V2"wide headwrench, tightenedthe expanding
full 180" range.That's a total of 3& through the cut. Incra engineersalso discs in the bar, locking the basein place.
The result is a low-friction, zero-clear-
ance "catcher" for your cutoffs. If you
need to make a bevel-cut on your righr
tilting saw, you can easily remove the
base. Or, Taylor sells spare right bases
that you can bevel to match your most
common cuts.

On the fence
Another bonus of the Miter 5000 is its
fence.Cut from the sameextrusion as the
Miter 3000 fence,this model boasts32" of
backup for your stock. Not enoughfor
you? No problem, becausethe fence tele-
scopesout to more than 64"-that's more
than 4" longer than the Delta 36-205,
which was the longestin our recenttest.
When you're swinging that much fence
from one end, you might worry about
deflection. Incra engineersaddressedthat,
as well, by adding an L-bracket that
securesthe fence to a T-fiack along the
sled's outboardedge.(That T-track also
acceptsan optional hold-down clamp.)
Our only complaint here is that you needa
hexheadwrench to move the brackets;
we'd like to seewing nuts or knobsto
speedthe process.
Becauseit bonows so heavily from the
Miter 3000, the Miter 5000 sharesone of
its foibles as well. We found that we still
had to be careful to make surethe sec-
ondary rack-and-pawlmiter-stop system

WOOD magazine August 2001


(2 MITEB
GAPACTTY SCATEI
eERFoRMATCe
nnntCS1l; I

, /ffH/,-=$t
i/s fld
$/,//ffis
r:,- /

M ,l
UI
5t

/=* ffi I ,oMMEr{Ts


ll,lCBA I Mitersooo1253/8" E D l Y l 3 6 ' 64" | 90 90 | 364 zoI szss
ISlS,ii,'JIl tl',$:*
;ii,1,lii,il:,',ff
?,93
ilOTES:
Formoreinlormation:
1. (ED)Expansion
discs a.I Exceltent 5. (.) Liletime
warranty on racks.
Forspecilications
0n othertypesof t00ls,clickon TaylorDesign
2. Withsledin leftmiterslot. 6. (U) UnitedStates
@ eooo "ToolComparisons"at www.woodmall.com www.incra.com
3. (RP)Rackandpawl 7. Pricescurrentat timeof article'soroduction. 972t418-4811
ffilr*,
(that givesyou the Vz"increments)was upgradekit to convertyour Miter 3000 to givesyou repeatabilityyou won't find
returnedto the "zero" positionbeforewe a Miter 5m0. anywhereelse-if you havethe budget.It
madeeachcut. costsnearly$300.But for the money,we
If you're kicking yourselffor buying the Would we buy one? can't imagineyou could askmuchmore
Miter 3000 guide when you could have You bet. Although we still like the sheer of a crosscutaccessoryand get it. |l
had the sled,go easy.Taylor Designpresi- simplicity (and comparativelylow price
Written by Dave Gampbell with Garry Smith
dent Chris Taylor told us you can buy an tag) of the Dubbyjig, the Miter 5000 Photograph:Baldwin Photography

www.woodonline.com

H.ffindthe Store to Make Wryb


Built a Porter-Cable
Them a Reality. Store to Show it all.

Seethe complete line-upof


Porter-Cable productsin the new
Porter-Cable store.Over9oo
itemsincludingpneumat-
store is now
t openwith overr5o JETproducts icsand cordlesstoolsto
in stock, includingbest sellers the hard-to-findwood-
a n d h a r d - t o - f i n da t t a c h m e n t s . workingaccessories. See
Complete product information the entirefleetof this
year'snewPorter-Cable products
includingcustomerreviewsmake
c o m p a r i n gp r o d u c t sq u i c k a n d at the storethat hasit atl.
, easy.Visit the JETstore and see
' why
JETis oneof the fastestgrow-
r ing brandsin the industry.
-.!6

Visit the f ETstore at


Visit the Porter-Cable
store at
www.amazon.com/iet www.amazon.co
mI portercab
le
dust collectors jointers planers
saws wood lathes the f ETstore touters sanders cordless tools
shapers sanders planer-molders generators the Porter-Cablestore
nailers & staplers air compressors
@RFFF
FRFFR.FFFFFF
rrvoodonline.
bygoingto www.woodonline.com
Howyoubenefit
WFFFPFSFFFEffi
tFFTFF'FFFFF
RULE$
C[|NTE$I
W00D@ andDrWA[T's
Magazine
American
Great Contesl
Workshops
Youtve got to see this 1. NOPURCHASE NECESSARY TOENTER ORWIN.

kitchen renovation 2. ForWorkshop


alonqwith6-8
3x5',ofyourworkshop
entries:
quality,
Send
color
showing
incompleted
photographs,
theoverall
no
entry
smaller
form
viewolthe
than

The October2001issueof WOODa will lavout,aswellasanvspecial areas. Include a shopoverview


ofthefloorpianthatshows
slietcl'r power tools, workbench,
featurea floor-to-ceilingoverhaulof a andstorage areas. Provide therough overall shop
dimensions. Spaces, workbenches, organizers, etc.must
kitchen,includingarticleson buildingand appear clutter-free inthephotos forproper presentation.
Alsoinclude anexplanation (50-250 words)of howandwhy
installingyour own kitchencabinetsand yourshopdesign worksforyou.Youmaycoversuchtopics
countertops. But you don't haveto wait asclimate control, lighting, dustcollection, efficiency,
organization, storage, accessibility, safety, special touches,
until that issuearrivesin your mail- etc.Specify whether theshopisa basement, garage 0r
dedicated outbuilding workshoP.
For0rganizer, Workbench and Safety categories: Include two
colorphotographs, nosmaller than3x5", clearlyshowing
cateoory plus
subiect a 50-100 wordexolanation ofthe
subiectihat fbcudes onfunction andimoortance tothe
box. You cancheckon our progress opeiation oftheshop. Adimensional sketch mayalsobe
submitted.
throughweeklyWebsiteupdatesbegin- 3. Entries mustbereceived byOctober 1,2001.Allentries
mustbepostpaid; collectentries willberefused. Youmay
ningJune2l .ln additionto gettinga enlerasmany categories asyouwishbuta separate entry
formandsepirate setof photographs are required foreach
glimpseof the work in progress, you'll entry.Entrant's shopdesign mustbeoriginal.
find serninarson enlarginga brick win- 4. Entries, including photographs, become propeO of
W00DMaguine andDTWALT Industrial ToolCompany and
dow opening,installinga window,apply- willnotbereturned. Entries mustbeworkcompleted by
entrantandnotpreviously published or entered inanyother
ing ceramictile, layingdown a vinyl-tile contest orhave wonanyother awards.
5. Thesponsors arenotresponsible forillegible, lost,late,
floor, andthe decorativepaintingtech- misdirected, damaged, delayed orstolen entries. Entry
niquesof stipplingand stenciling. constitutesoermission to usewinner's name, hometown,
entryandphotograph ofselfandshopforeditorial and
www.woodmasazine.com/handhorne/ proirotional purposes bysponsors, unless prohibited bylaw.
Emolovees andimmediate familv members ofMeredith
Coiooiation and DTWALT and th'eiratJiliatesand subsidiaries
areineligible.0pento U.S. andCanadian residents (except
0uebec), 18years andolder.Subject toallU.S. federal,
andlocal
state lawsandregulations. Voidwhere prohibited.
6.A panel ofjudges lromMeredith Corporation and
woodworking experts willjudge allentries based onoverall
Find out what tools other woodworkers rate tops oroanization
sh-oo
ofshop,
andarranoement
safetv offloor0lan,
oftbolsonoi about
completeness
October
0t
1,2001.
Ask any woodworkerhow they feel about a particulartype or brandof powertool, and Winners
October
willbeselected
31,2001.
andnotified
Alldecisions
bymailonorabout
olthejudges arefinal.
you'relikelyto get some strongopinions.Now,open up that discussionto thousandsof 7. Thefollowing eight(8)prizes willbeawarded:
a.Best0verall Shop - $3,000 worthofDEWALT Tools
woodworkers from aroundthe world,and watchthe fur fly! You can join in the fun in DTWALT Tools - $1,000 worthol
b.Best Shop Utilizing
severalways.To posea questionaboutany tool,respondto someoneelse'squery,or DTWALT Tools
- $1,000
c.BestProlessional Woodworker (one-man) Shop
just soundoff abouta tool experience,go intothe'Tools and Tool Buying"discussion worthof DTWALT Tools
d.Best0riginal Workbench -
Design$1,000 worth of
groupat http://talk.woodmagazine.com I DTWALT Tools
On the bottomof that same page you'llfind individualtool-reviewgroupsin whichyour e.Best Storaoe Solution or 0roanizer forOne or More
PortablePow-er Tools - $1.000 worthofDTWALT Tools
fellow readers post their reactionsto the most-recent WOODmagazinetool reviews. f. Best
Storage Solution or0rganizer forPower Tool
Accessories iDrillBits,Blades, Sandpaper, -
etc.) $1,000
worthof DTWALT Tools
g.Best Storage orOrganizer solution forHardware - $1,000
worthof DTWALT Tools
h.Best0riqinal Workshop Safetv ldea(Must beableto
ideabyphoto)- $1,001
Get your hands on WOOD's best stuff represent
Theaooreoate retail value
worthof DTWALT
ofallorizes offered
Tools.
inconnection
Did you know thatthe top projectsandwoodworkingtechniques to everappearin withthisc-ontest isU.S. $10.000. Thevalue ofeach
individualorize isbased ontheitem's cunent retail priceas
WOOD magazinehavebeencompiled in a of
series handybooks? You'll find titles,rang- setforthbyDTWALT's suggested listprice andwillbe
orovided totheselected contest winners. Theoddsof
ing in price from to
$5.95 $12.95, devotedto: winning willdepend upon thenumber andnature ofthe
. Shoptips . Holidaydecorations entries
eligible received.
8. Winners are responsible for applicable tues. Winners
. Gifts . Furniture willberequired tocomplete anAffidavit ofEligibility,
Ownership andLiability/Publicity Release andSelection Form
. Scrollsawtechniques . Routertechniques within14daysof notification 0ranalternate winnermaybe
selected.Prizes arenon-transferable andlthere is]n0
. Weekendprojects . Countryprojects substitution orexchange forcashinlieuof [any]prize.
Winners should allow4-6weeks fromDTWALT's recei0t of
. Outdoorprojects ' Shop-made tools theirSelection Form fordelivery.
Go to http://woodstore.woodmall.com andclick on WOODBooks 9. Photos olwinners andtheirshops maybepublished in
theMarch 2002issue ofW00D.Fora listofwinners, send
in thelefi-handcolumn. a separate self-addressed stamped envelope after December
1,2001 to'Great American Workshops," 1716Locust Street
(GA310),DesMoines, lA 50309-3023.
WOOD magazine August 2001
shffi
youworkfaster,
ti
Helping andsafer
smar[er.

top shop tip grab a mi ddl e


size without
Stacker stores dumpi ngthem
sanding sleeves al l out.
When I bought my o s c i l l a ti n g To organize
sp indles ander ,I d i d n ' t c o n s i d e r my sleeves,I
how to store six differentsizes of cut three rings
sleevesin three grits. They fit for each diam-
i ns ideone anot h e r.b u t I c o u l d n ' t eter of sanding
sfeeve trom 1/2"
stock, each
ri ng sl i ghtl y
smal l erthan the sandi ng
sleeve it will hold. I then
stacked them layer-cake
fashion, topped off each
stack with a s/e"
dowel rod,
and glued the three stacks
to a base.
I slippedthe sleevesover
the ri ngs,and put the hol d-
er next to my sander.Now
I can quickly grab any of
18 di fferentsandi ng
sleeveswithout fumbling
or dumping.
-LarryApps, Syracuse, N.Y.

Hold the drill presses!


Herets another way to
set threaded inserts
Threadedinserts are awfully handy
for shop jigs and knockdownfurni-
ture, but frankly,they're difficultto
thread into solid wood. Even using a
drill press to start them can be tricky.
Here'sa method I like to use.
Start by coating a fender washer, catch in the hole, as shown above.
and the threadsof a machinescrew Now, put a dab of epoxy in the hole
that fits into the insert,with wax. Slip and drive the screw and insert into
the screw through the washer and the workpiece.After the epoxy sets,
thread it into the insert. back out the screw.
In y o ur w orkpi ece,dri l l a hol e a l i ttl e -Jim Downing,
deeperand slightly smallerthan the W00Do magazinesenior editor
design
insert so that the threadswill just
Corttirrueclon page 28

26 W O O Dm a g a z i n e A u g u s t 2 0 0 1
shoptips

Horseshoe magnet U-shapedhorseshoe


kicks cutterhead creep magnetoverthe Plan-
I enjoyedreadingPaulLonergan'stip er's height-adiustment
for stoppingcutterheadcreepon his handle,as shown below
Delta22-540planerin lssue#123. left.lt holdsthe handle
Insteadof using a clamP,I Placea firmly in place,yet can
be removed
easilyto adjust
the cutterhead.
-Jerald Holland, Sheet-metal
screw
Austin,Minn. at-J | \

R=€
w
Effi
Goffee cans tom, then drivethe screws
make great throughthe holesfrom the
second hands insideof the coffeecan.
To finish both sidesof a Pro- After coatingone side of the Pro'
ject at one setting,I suPPort ject, I turn it over and rest it on the
it on empty coffee cans fitted screwpointsto comPletethe iob.
with sheet-metalscrewsthat Althoughthe screwmarksseldom
protrudefrom the bottoms, show,coatingthe "best" side last
as shownaboveright.SimPlY ensuresa mark-freeiob.
pokeholesin the can bot' lrank J. Bober,PineCWN.Y

WOOD magazine August 2001

Wetaketheguesswork out
of startingyoulownbusiness.
Turnyour passioninto profit! companyof its kind backedbY
Furniturerepairand refinishing morethan 13oyearsof industry
is a mutti-billiondollarindustry YourGuardsman
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@MffiU
Build a flexible weapon cut out its shape.Next,I clampor /q" hardboard template
in the war against dust screwthe templateto my benchtop,
I liketo beatdust and woodchipsby placethe workpiecein the cutout, Cutoutto fit part.
capturingthemright at the source.So and sandit with my random-orbit
sander.lf you don't havea router
table,you couldusethe same
processto roundoverthe edgesof
a hard-to-handle workpiece,provid-
ed it's thick enoughthat the router
bit's pilot bearingclearsthe top of
the template.
-Bob Weigel,Tucson,
Ariz.
Continued on page JO

I builtthe flexibledrill-pressdust-
collectionsystem,shownabove,wilh
a few feet of heavy-gauge electrical
wire anda jumbohoseclamp.(Look
in the automotiveor plumbingaisleat
your hardwarestore.)
I foundthat solid-copper grounding
wire offersthe bestcombinationof
Hi gh Iff.?'#i,li!!ff '
:1,:'J1ilX.,',lo'
strengthand flexibility,allowingme
to easilypositionthe hose'snozzle.
i'iff
You can useeitherinsulatedor bare
copperwire.
Perfo rmance Yffi:i:H.TlUf:Xlt'
lXi:,1i;
state-of-the-artrouteroperatesat a con-
-John Patrician,
Abington,Mass.,
viaW00D0NLlNEo
Router sistenttorqueandspeedfor extremely
smoothoperation anda cleaneredge.
F _ -! , - r+'ctightweightfor greatercontrol,hasa
f gI n ;:;.; ranse
of speeds,
andincrudes
soft
Hands-off sanding of start,dustcoltectionport, andQCspindle.ThenewFEINRT-1800 is designed
shapely parts for the cabinetmaker,
solidsurfacefabricatorandserioushobbyist.Catl.1-
WhenI needto sandsmallor odd- 800-441-9878for moreinformationanda dealernearyou, or visit us on
shapedpieces,I first tracethe part thewebat www.feinus.com.
onto a scrapof Vc"hardboard, Finishing is just the beginning

Fein@
then
FeinPowerTools,Inc. 1030AtconStreet
www.woodonline.com Pittsburgh,PA75220 1-80044t-9879
shoptips

Thumbs up for storing I built a block,as shownat left,to old dowelcenters,and it dawnedon
poly glue nose down holdmy polyurethane bottleupside me:Thesegadgetsare perfectfor
I can'ttell you how manytimesI've down when not in use. Air trapped locatingthe screws!lfound a couple
grabbeda half-usedbottleof inside rises to the top (now the bot- thatfit the top of the keyholeslots,
polyurethane glueonlyto find a skin tom) of the container, so any barrier andwhen| (l mean,my wife)was
of hardenedglue betweenme andthe formed by the cured glue keeps the happywith the shelfplacement, a
uncured glue.Rather glue near the top of the bottle when sharprap on the shelfleft me with
than gettingfrus- it's upright,preventing furthercuring clearmarksfor the screwlocations.
trated,lfound a in the container. -Mike Glennon, Mass.
Weymouth,
way to makethat -Jan Svec,W00Domagazine proiectseditor
barrierwork for me
ratherthan against.
Dowel centers
mark the spot
Bore holes My "honey-do" list recently included
to accommodate
glue spoutand cap. buitdingsome knick-knackshelves,
and becausethey neededto be
sturdy, I opted to hang them using
keyhole slots. But I've never had
much luck markingthe screw-holes
accuratelyon the wall.
Laminatetwo
About the time I was finishing uP
3 x 3 x 11/2"blocks. construction,I stumbledacross my
1 Continued on Page 32
WOOD magazine August 2001

furatomyof a
perfect mitef.
43298Sure-Loc
MiterGauge
w/Tru-TracBar
$gg.ee

From its interlockingteeth to the


backboneof the system,the expanding
miter bar,this is the miter gaugeyou'll
want to get your handson.

@ t-ooo-27e-4441

@ r-877-Roo(LER
rockler.com/go/V | 355 '1181O
@ Code
Circle No. 900
shoptips

No headstands to lock then attachedthe bar to the jointer


that base in place cabinetdirectly over the knob holes,
To eliminatebendingover to lock the using self-tappingscrews.
casterson my jointer's mobile base,I I cut two lengths of 3/8"threaded rod
extendedthe factory locking knobs that extend from the wheel to about
as shown below. Here's how. an inch beyond the steel bar. After
ln a steel bar the same width as the turning one end of the rod into the
mobile base,I drilled holes slightly base's lock-knobhole, I put a jam nut
largerthan, but spacedthe same as, and coupler onto the free end of the
the knob holes on the mobile base.I rod and a jam nut on the shaft of the
factory locking knob. Finally,lthread-
ed the factory knob into the coupler,
as shown, and tightenedthe jam nuts
TheElectronics againstthe coupler.

that
Superstore -JanSvec, W00Do magazine
projecteditor

toYour
Comes Door
Crutchfield'scataloghas Gauge prevents
morethan 140pages planing problems
packedwith the
Anyone who has planeddown stock
latestaudioand
to different thicknesses knows the
videoequipment,
comparison frustration of planing materialtoo
chartsand
buyingtips Rout slotswith
you won't find straightrouterbits.
anywhereelse.
There'sevenmore Allthe Bose,
bigbrands:Sony,
online.Vsit our HarmanKardon, JVC,
0nkyo,
Infinity'
Polk andmore'
Audio
weDs*eror ln-walr
speakers,infraredrepeaters,wall plates Lock knob with /e"threaded rod l1/zu
long insertedinto bottom :, Stockbeingplaned
andeverythingelseyou'll needfor
beautifulcustominstallationwork.
Self-tappingscrew thin. To prevent this, I created an
And, onceyou've found what you want, attachessteel bar
accuratethicknessgauge by routing
you'll find a fantasticshippingdeal,free
lifetime tech support,and a 30-dayTotal
and fabeliflg 1/c", 3/8" , s/a", and 3/q"
, 1/2"
Satisfaction Guarantee. It's neverbeen notches in a piece of plywood. lt's
so easyto get the featuresand perform- proved faster and more accuratethan
g
anceyou want. ,,+cabinet \ a ruler.Q

your: 'i.';'catalog
Wis.
MarkLiska,Manitowoc,
Galltodayfor
SHpsfrssm
& ffew Ev*ffitre
Ts"threaded rod.
insertedinto lock
prss
**&trw#&sd1$rscnkfimg
. Need dowelsto matchan exoticor
unusualspeciesof wood?Learnhow to
makethemyourselfin the Outdoor
ServingCart projecton page 34.
. Routerguidebushingsand templates
can helpyou massproducepieceswith
identicafcutoutsor shapes.On page
/------]rv\ 70, see how we used them to makethe
Mobilebase Wheel wall plates.

32 WOOD magazine August 2001


Tucked neatly beneath the hinged center
lid is a mahogany-linedice chest. With its
four cubic foot capacity, you'll be able to
keep plenty of refreshments on ice.

34
To apply even
pressure, clamp
plywood scrap
over the cladding.
Strips wedged
between the car-
case and the scrap
apply pressure at
the bottom.

f lesigned by Jim Downing, our


I fDesign Editor and resident boat
Lr, builder, this deluxe outdoor serv-
er combines great looks with durable
materials and construction techniques.
To resist the weather, we've used a
marine-grade wood finish and caulked
the ice chest lid and drop-leaf table
extensionsjust like a boat deck. And
with our step-by-stepinstructions, you
should have smooth sailing building it
from beginning to end.

Start with the carcase.


then build the draweri
3/+" plywood, cut the drawer
J From f Retneve the drawer bottoms (K).
*?
I shelf (A), vertical panel (B), bottoms Cut the drawerpartsH, I, J,L, M, N
(C), back (D), sides(E), front panel (F), to size. Form the rabbetsand dadoesin
and drawerboffoms(K) to the sizesin the the parts,as shown on Drawingla, then
Bill of Materials.(We usedA./B exterior- form the finger recessesin the drawer
gradeplywood.) Set the parts K aside. fronts. Glue and clamp the drawers
Qlnstall a3/c" dadobladein your table- together,drill the screw pilot and coun-
{ru*,and cut thedadoesandrabbetsin tersunk shank holes, and drive the
partsB-E, whereshownon Drawing1. It screws.Remove the clamps, and set the
is not necessaryto make stoppeddadoes drawers aside.
for the drawer shelf (A) and vertical
panel (B). Cut thesedadoesall the way Now line the ice chest
acrossthe back (D). The unusedportions and sheathe the exterior
of thesedadoesareeithercoveredlater or
1 To make the Vq"-thickcladding and
hidden from view. I band pieces O-S, V-AA, CC-FF,
QCut the skirt (G) to size,and form the NN, OO, rough-cut 3/q"stock Vq" widet
tJarched cutout, as shown. Now glue andVz"longer than the sizeslisted.Make
and screw together parts A-G, assem- half the numberof 3/c"blanks asthe parts
bling them in alphabeticorder. quantities listed. Resaw and plane two
Use clamps to hold the parts V+" pieces from every 3/q"blank. Letter
together while you drill screw the piecesfor later identification.
pilot and countersunk shank
QCutthe parrsO to finish length,andall
holes. Remove the clamps Lbut four of them to width. Lay the car-
from one subassembly after case, front down on your workbench.
you drive the screws, and Place3Ao"-widespacersin the cornersand
move on to the next assembly. fit 10 interior side claddingpieces(O) in
Use an exterior-grade glue. place. Trim one of the four rough-width
(We used Titebond II.) pieces to make a snug fit between the
Note: The skirt (G) protrudes spacers.Removethe cladding,and lay out
beyond the bottom of the car- glue beads, as shown on Drawing 2.
caseso the cart sits level once Clamp the claddingin place,as shownin
the castersare installed. PhotoA. Make surethe endsof the Os are

35
*7a" rabbet t/q" deep

patiopartycenter 22V2"
4)
l-- zgyo"
Note: .Widthof groovesand dadoes
to matchthicknessof PlYwood.
4
*7+"dadoes th" deep
II
145/e'
*3/q"
rabbel1/4" deep

143/c"

ll-\
|
r
102/a
'/ )l
),)
|
-\
\l

231/2"
Y4u,;, na" #8 x 11/z'F.H.
wood screws

'" ,ru)'
pirothore
1t/q" deep
7sz"shankhole,countersunk

'5# / #8 x 11/z'F.H.wood screw

Finger
recess

%" chamferson the bands'insideedges,


as shownon Drawing2.
Rip the horizontalcladding (S, W,
X, EE) to width. Set asidepartsW,
X, EE. Chuck a chamfer bit in Your
table-mounted router, and rout 1/8"
chamfers on the outside edges of the
upperhorizontalcladding(S). Trim the
flush with the top of the carcase.Remove scrapoverthe cladding,andapplyweight cladding to length so its ends are flush
the spacers.When the glue dries,turn the until the glue dries. with the carcasesides.Glue and clamp
carcaseon its back,then sides,and repeat Cut the carcaseside bands (Q) and the parts S in place.
the operation. the carcasefront/back bands (R) to Cut blanksfor the handles(T) to the
Trim the interior bottom claddingto size. Glue and clamp them in Place. size listed. Make two copiesof the
length and rip all but one piece to When the glue dries, sand the bands Handlesfrom the WOOD PATTERNSa
width. With %0" spacersall around,fit flush with the inside cladding and the insert.Cut them apartat the breakline,
the cladding, once again trimming the outsideof the carcase.Chuck a chamfer and adherethem to the blanks' ends
last piece.Spreadglue, placea plywood bit in your handheldrouter,and rout the with sprayadhesive,forming a mirrored

36 W O O Dm a g a z i n e A u g u s t2 0 0 1
t/a" chamter alonq inside
edge afterassem them to final width. Rout /s"
chamferson the outsideedges
rl
I
and ends of all but the three
over-widthpieces.Rout cham-
Applygluebeads1" apart. ferson theendsandoneedgeof
thesepieces.
| ,-- Customcut cornercladdingpieces
to widthto fit insideof icebox. Placethe carcaseon its side,
and lay out I I of the Vs,
1" hole t/2" deep starting flush with the front
edgeof the side (E), and keep-
t/a"chamfer ing the parts pushed tightly
together.For the lastV, rip one
of the over-widthpiecesso its
ripped edge is flush with the
back (D). Do not chamferthis
edge of the cladding piece.
3/s"chamfer Now glue and clamp the verti-
28'
alongtop edge cal claddingto the side, keep-

I of doors ing the upper ends againstthe


handle'slower edge.Use cauls

II
StrikeplateI
secured with bar clamps to
spread the clamping pressure
acrossthe entireside.When the
\ glue dries, remove the clamps
3" and cauls and repeat on the
I Brassbulletcatch
otherside.
Retrievethe lower hori-
No chamfer zontal cladding (W).
along Rout %" chamferson the front
bottom endsandupperedges,makinga
t/a"chamfers CARCASECLADDING mirror-imagepair. Trim them
to lengthso the rearend is flush
3/6"gap alongoutside with the back (D). Glue and
edgeof cladding,filled clamptheWs in place.
with polyurethanesealant Place the carcaseon its
front, and lay out 1I of the
11/zx 181/2"
continuoushinge
Vs on the back, this time start-
ing flush with the squareedge
of the lastcladdingstripon one
tzq"bullet catch
side. Rip the last wide strip V
Strike plate
r Brass escutcheon pin so its edge is flush with the
cladding on the other side.
Retrievethe piecespreparedfor the Chamfer the ripped edge. Once again,
carcasevertical cladding (V). Trim using cauls and bar clamps,glue and
pair. Chuck a Forstner bit in your drill them to length, and rip all but three of clamp the claddingto the back.
press, and drill the holes where indicated.
Bandsaw and sand the ends to the pattern
lines. Chamfer the handles' entire outside
edges (the face without the hole), and
about 5" back from each end on the
inside edges.Set the handles aside.
Rip two 1xlx30" blanks for the
towel bars (U), and form them as
shown in the shop tip, rigltt. Trim them
to length. Capturing the towel bars in the
1" holes, glue and clamp the handle
assembly to the carcasesides so the tops
are flush with the bands (Q) and the
ends protrude equally.

www.woodonline.com
patiopartycenter
Hole drilled , s/a"chamteralongtop edge
Retrieve one back/front horizontal to fit pull 7/ only,routedafterassembly
cladding piece (X), and trim it so Mortisecut to fit pull,
the ends are flush with the side cladding. centeredbetwee2-
Chamfer the two ends and the upper lhe chamfers4n$)and
the widthof t9.
edge. Glue and clamp the cladding in ->^q
place at the bottom rear. rush
rins
"---;rassPurl
Turn the carcaseonto its back. Cut Dff@J*-
the front panel lower band (Y) to
size, and glue and clamp it to the front
ur\
PULLDETAIL
panel. Cut the fi'ont panel side bands (Z)
to size. Chamfer the ends and edges that
abut the handles (T) and vertical Top chamferrouted
cladding (V). Glue and clamp the side afterassembly
t%o"hinge
bands in place. ---'-*
uY--
As with the back vertical cladding,
mortise 7a" deep,
cut after
f'Al
cut the front panel vertical cladding assembly
(AA) to size, and chamfer the ends and
edges, leaving one piece wide with one (\
unchamfered edge. Fit the cladding
Brassflushringpull
across the panel. rip the last piece to
width, and chamfer the ripped edge. Glue
and clamp the cladding in place.
Retrieve the other back/front hori- /a" chamfers along all
zontal cladding (X), and trim it so edges of cladding @)
the ends are flush with the panel's side
bands. Rout chamfers on the ends and
top edge. Form the t/gxt/,s"waterstop on
the bottom inside edge, where shown on
Drawing 2a. Glue and clamp the hori-
zontal cladding in place.
Ts"chamfer

Build a pair
of matching doors
Cut the door panels (BB) to size.
Retrieve the door upper/lower bands
(CC) and door side bands (DD), and cut
them to size. Glue and clamp the bandsto
11154a
the door panels,as shown on Drawing 3.
Retrieve the door horizontal DOORASSEMBLY
cladding (EE), and trim them so the
ends are flush with the door side bands.
Rout chamfers on the ends and one
edge of each piece. Glue and clamp the
upper horizontal cladding in place with Drill a hole in eachdoor for the pulls' dado blade in your tablesaw, adjust it to
the square edges up. Set aside the other center recesses,centered vertically cut to this depth, and form the tt/ro"-
two pieces. betweenthe chamferson the horizontal wide hinge rabbets in the doors. Cut
Trim all the door vertical cladding cladding and horizontally on the width two pieces of continuous hinge to
(FF) to length, and all but two to of the door vertical cladding,as shown length, and hang the doors. Leave a t/g"
width. As before, chamfer all ends and on Drawing3a. Chisel recesses for the gap between the doors and the front car-
all but one edge on the two wide pieces. back protrusionsthat house the pulls' case panel.
Position the pieces on each door, ripping ring pivots.Positionthe pulls and mark Note: Our hinges canle with ]/2"-long
and chamfering the wide ones to fit. their perimeterswith a utility knife. screws. For increased holding power
Glue and clamp the vertical cladding to Form the mortiseswith a straightbit in we replaced them witlt 3/t" screws.
the door. Retrieve the lower horizontal your handheld router, cleaning up the Mark bullet-catch locations I /s" to
cladding, and glue and clamp it in place edgeswith a chisel.Drill pilot holesand both sides of center on the front
with the square edges down. Rout the drive the screws. panel's lower edge, as shown on
-7s"chamfers on the doors' top edges, as Measure the knuckle diameter of Drawing 2a. Drill the holes. (We used a
shown on Drawing 3a. your continuous hinge. Install a right-angle attachment with our drill.)

38 WOOD magazine August 2001


Spaceboards /10"
Applywhitepolyurethane
caulking apartalongall edges.
betweengaps afterassembly.H
1/q"gtoove 7a" deep
t/+"trom top edge
/ - s/q"
\- \/-'"

Applyglue beads
about 1" apaft.
'/ox3,(."tenon,
ll/ rsle'lor]9
)l-z/a"

-->',.,,
7a" rabbet t/2" deep
along all bottom edges

-ll-
t\
221/z'
3/a"

211/2"

t/e" chamfers 3/ra"eao between


'/' ;llillanks
LIDASSEMBLY t/+"grooves/s"deep
Do not chamferends.
,
l/+"trom top edge

t/o'groove 3/s"deep
/
from top edge
Add the chest lid edging (JJ) runs acrossthe leaf's entire A=r,t/o"
and leaves width and has no stub tenonends. t/e"chamfersafterassemblv
Cut the lid and leaf edgingpartsGG, Cut the lid panel(LL) and leaf pan-
HH, II, JJ, and hinge rails (KK) to els (MM) to size. With your dado
size. Set the hinge rails (KK) aside. blade, plow the rabbetsin the panels'
Install a V+"dado blade in your table- edgesand ends, forming tonguesthat
saw, and plow the grooves in parts matewith the groovescut in the edging.
GG-JJ, as shown on Drawing4. Sand Glue and clamp the lid and leaf edging
the corner radii on the leaf end edging to their respectivepanels, measuring
(JJ),whereshownon Drawing4b. diagonally to check squareness.Lay
Install a V2" dado blade in your them on a flat surfaceto dry.
tablesaw,and form the stub tenons Retrieve the lid cladding (NN) and
on both endsof the lid/leaf short edging the leaf cladding(OO), and cut them
(GG), as shownon Drawing4a, and one to size. Thesepiecesdo not get cham-
end of the leaf long edging (II), as fered. Cut 35 spacers3/tox3/qxl".Apply
shownon Drawing4b. glue beadsto the plywood lid panel,as
Note: Leaf constructiondffirs slightly shown on Drawing 4. Bed the lid
from lid construction.As in lid construc- cladding in the glue, inserting spacers
tion, the leaf short edging (GG) has betweenthe piecesand clamping cauls
Apply light clamp pressure to the cauls.
stub-tenonendsand is capturedbetween acrossthe cladding,asshownin PhotoB. Use a pry bar to push the cladding
the long edging (II). But the leaf end When the claddingis securelyclamped, against end spacers. Tighten the clamps.

www.woodonline.com 39
patiopartycenter
removethe spacers.Repeatthis procedure
with the leaves.
After the glue dries, remove the
clampsand cauls.Rout chamferson
the lid's edgesand the leaves'edgesand
outboardends,as shown on Drawings4
and 5. Retrievethe hinge rails (KK) and
chamferthe ends.

Hinge the lid and leaves


to the carcase
Lay out thelid hinge'slocationon the
cabinet's rear edge, as shown on
Drawings5 and5a. Chuck a straightbit
#4 x3/q"brass F.H.wood screw
t/a"chamteron ends only

hinge

in your handheldrouter, and clamp a


straightedge acrossthe carcase.Rout the /a" chamfers
hinge mortise, as shown in Photo C.
11/zx 75/e"
continuoushinge
Positionthe hinge and drill the screw
pilot holes,but do not drive the screws.
Lay the lid topside down on your #4 x3/q"brassF.H.woodscrew
bench. Position the hinge, centered
side-to-sideand 1/s" from the rear edge,
as shownon Drawing5a. Drill the screw
pilot holes, and attach the hinge. Place I t--- l-/t/2" -----------n
the lid and attachedhinge in the open I i* 81/q"----n I FINALASSEMBLY
position on the cabinet, and drive the
screwsinto the previously drilled pilot
holes.Closethelid. lq"
tl
Form the leaf supports(PP),asshown tl
on Drawing 5b. Cut four pieces of I
l*
continuoushinee to leneth. Drill screw
LEAFSUPPORT

pilot holes, and attachthe hingesto the


diagrann
cutting
supportsso they both fold forward. Lay
the leavestopsidedown on your bench.
Position the supports and attached
hinges,centeredon the leaf width with
the supports'endsflush with the leaves'
inboardends,as shownon Drawing5c.
Mark the screw locations,drill the pilot
holes,and drive the screws.
s/qx48 x 96" Exteriorfir plywood
Retrieve the hinge rails (KK), and
clamp them to the leaves,inserting

40 WOOD magazine August 2001


A drawersheli 3/q' 23Vt' 111/a' P 1
%0" SpaceS B verticalpanel 3/q' 231/qn
161/z' P 1 CC-doorupper/
C bottoms lowerbands 1'4" 3/a' 117Aa" M 4
Y4" 231/q'22Vz' P 2
Alignthese DD-doorsidebands%' 3/+' 18s/a'M 4
edges D back Yi 22lz' 333/q' P 1
E sides 3h' 233/q'33s/q'P EE.doorhorizontal
2 cladding 1/q' 3u 1115/6'' M 4
F frontpanel 3/i' 231/z'143/q' P 1 FF.doorvertical
@ G skirt Y4" 21/z' 22' M 1 cladding Vi 2u 125/a'M 12
H lowerdrawer GG lid/leaf
front 3/q' 97/a'101/z'M 1 shoftedging 1 ' 2 7 / B ' 2 2 ' / 4M
' 4
lowerdrawer HH lidlongedging 1" 3" 221/z'M 2
sides 3/qu 97/a'221/z'M 2 ll leaflongedging
1" 3' 271/4' M 4
J lowerdrawer JJ leafendedging 1" 3il 271/z' M 2
back 3/4' 9Va' 91/z' M 1
KK hingerails 1u 27/a'271/z' M 2
K drawer bottoms
% 10' 181/z'P 2
LL lidpanel 22t/q'17Vz' P 1
upper 0rawer
ffOnt 3/0" St/e' 10t/z' M 1 MMleafpanels Yi 22t/q'24t/q' P 2
M upper
drawer NN-lidcladding 13/q'163/a' M 11
sides 3/a" gt/s"llt2" M 2
00.leaf cladding 1/i 13/q'235/a' M 22
N upper
drawer
back 43/a' PP leafsupports Yi' 9" 17Vz' P 2
QQsupportblocks% 21/q' 3" M 2
O* interior .Paftsinitially
sidecladding 1/i' 2' 14s/e' M 44 cutoversize.
P* interior MaterialsKey:P-//B gradeexterior
firply-
bottom t/+' 2u 21Va' M
cladding 11 wood,M-mahogany
Q* carcase Supplies:#8x11/2"flatheadwoodscrews(48),
sidebands 1" 221/z' M 2 #8x1t/2"
brassflatheadwoodscrews (32),#8x3"
R* carcase fronV deckscrews(4\, #4xe/n" brassflathead wood
backbands 1/a' 1" 231/z' M 2 screws(150),#8x% panhead screws(16),2"
S* upper horizontal fixedcasters(4),11/t'chrome-plated
brasstail-
clddding 1/o' 3u 23t/z' M pieceassembly w/stopper, glue,
exterior
#8 x 3" deck screw T handles 1 3" 33Vz' M BuyingGuide
2
U* towelbars 1 " 1" 241/z' M 2 Hardware: 11/ax4$" pianohinges,
brass-plated no.
27H48, $15.50 each(4);brassflushringputls
V* carcase vertical
cladding 1/q' 2' 28' M 36 dscrews,no.127386, $9.99each(2);t/a"brass
bullet
catches,no.27H37, 0 pack(1pack);
$4,99/1
W- sidelower self-balancing
lidsupporl,
no,04Y31,
horiz.cladding1/qu 3" 233/q'M 2 $3.99each,
fromyourlocalWoodcraft
Available store,or call
X* bacldfront 800/225-1
153.
horiz.cladding1/q' 3u 24' M 2 Marinesupplies:SikkensCetolMarinesatin
Y* frontpanel woodfinishno. 539106, (2 quarts);
$30.99/qt.
lowerband 1/q" 3h, 23V2, M 1 whitepolyurethane
Sikaflex-291 sealant,
310ml
Z* frontpanel caulking
tubeno.174490, $13.99 ea,(4 tubes).
sidebands th' 3/ou 12i/4, M 2 CallWestMarine, 8001262-8464.
AA-frontoanel
vedicalcladding
% 2u 91/q' M 12

*Resawinto two halves


and
planestockto tZ" thick.
**Planestockto 1" thick.
*3/e
x 91/+x 96" Ma

*s/+
x 9't/qx 96" Mahogany
*3/qx91/q
x 96" Mahogany
h x 48 x 96" Exteriorfir plywood

**114a
*3/+ x7t/q x 96" Mahogany
x 91A x 96" Mahogany
s/qx 11t/qx 96" Mahogany
V
g/+x 51/zx 48" Mahogany *3/q *"
x 9t/t x 96" Mahogany 11/tax 9t/+x 96" Mahogany

www.woodonline.com
41
patiopanycenter
sealant,slightly overfilling
t/ra" spacers.Cut two lengths of continu- the seams.See the Buying
ous hinge to length, and center them over Guide for our Sikaflex
the t/ro" spaces. Keep the leaves' edges source.Make a solutionof I
flush with the hinge rails' ends. Drill the teaspoondishwashing deter-
screw pilot holes, as shown in Photo D. gent and I cup of water.Dip
Screw the hinge only to the hinge rail. your putty knife in the solu-
Glue and clamp the hinge rails to the car- tion and strikethe seamsflush
case. as shown on Drawing 5c, inserting with the cladding.(This also
|/I0" spacers between the hinge rail and forces out air bubbles.)Let
the lid. Keep the hinge rails' ends flush the sealantcure for 48 hours.
with the edgesof the lid. Removeany large accumula-
Clamp a pair of straight 8'-long 2x4s tions of excesssealantwith a
to the carcase, then clamp the leaves razor blade scraper. Then
to the 2x4s. as shown in Photo E, once Position the blocks, as shown on sand the tops of the lid and leaveswith
again inserting %r'" spacers between the Drawing 5c and centered on the width of your random-orbit sander and 8O-grit
leaves and the hinge rails. Align the the cabinet. Use the screws to mark the sandpaper to removetherestof the excess
hinges with the previously drilled screw pilot hole locations. Drill the pilot holes, sealant.Finish-sandthe tops to 220 gnt,
holes in the leaves,and drive the screws. and screw the blocks in place. and applytwo morecoatsof finish.
Swing the leaf suppofts down to their Apply I " masking tape about t/r6"
vertical position. Measure the dis- Apply an outdoor finish, back from the edgesof the icebox's
tance between the supporls and the car- and caulk the seams corner seams,and caulk the seams.Dip
case sides. Cut the support blocks (Qa) Remove the leaves, leaf supports, your finger in the soapsolution,and tool
to this width. Chamfer the corners, and lid, doors,hinges,and pulls.Obtain the joints, leaving a rounded fillet of
drill the countersunk shank holes. your 1V+"tarlpieceassemblyto verify sealant.Immediatelyremovethe tape.
its installation require-
ments.(We boughtoursat Finallyoreassemble
a local homecenter.)Drill your parts
a hole in the bottomof the Lay thecabineton its back,drill screw
ice chest, as shown on pilot holes, and fastenthe castersin
Drawing6. (To draw the the rear corners of the recessunder the
flange tight to the chest's cabinet,as shownon Drawing1. Setthe
bottom, we chamferedthe cabinetupright.
hol e' s top edge. To Installthedraintailpiece,asshownon
accommodate the tail- Drawing 6. Use some of the deck
piece'smaximum mount- caulkingto sealthe tailpiecein place.
ing thickness,we formed Fastenthe pulls, andrehangthe doors.
a counterbore from the Press the bullet catches into their
bottom, using a 3/s" rab- drilled holes.Transfertheir locationsto
beting bit chucked in a the doors'top edges,and installthe catch
handheldrouter.) strikes.Slidethe drawersinto place.
Finish-sandall the parts Screw the hinges to the lid, hinge
to 220-gnt Apply three rails, and leaf supports.Fastenthe lid
coats of Sikkens Cetol hinge to the cabinet and install the lid
Marine satin wood finish support,as shownon Drawing5a. Screw
to all the parts, except the the leaf support hinges to the leaves.
tops of the lid and leaves. Using the 2x4s and clamps as before,
Apply only one coat to align the leaveswith the hinge rails, and
these parts. (Additional screwthe hingesto the leaves.
coats are applied after Let the cart'sfinish andcaulkingcure
caulking the seams.) for at leastsevendaysbeforeusingit.
Follow the instructionson To drain waterfrom the ice chest,placea
the can. Be sureto saturate bucket inside the cabinet,underneaththe
exposedend grain.Seethe drain tailpiece.lF
Buying guide for our
1tla"chrome-on-brass Writtenby Jan Hale Svec with Charles l. Hedlund
tailpieceassembly Sikkensfinish source.
Prolectdesign:James R. Downing
When the finish dries, Kim Downing; Lorna Johnson
lllustrations:
caulkthesearnswith white Photographs:Baldwin Photography;Douglas E.
DRAINASSEMBLY Sikaflex-291polyurethane Smith; Hetherington Photography;Andy Lyons

42 WOOD magazine August 2001


a soundformula
| | for sales from I
tHd'UAllefy
rcalV sel16
Withannualsalesin the millions,
Seattles Northwest
FineWoodworking ranksas the mostsuccessful
retailwoodworking
cooperative in the nation.
t was formed in Seattle in 1980 by members, 15 account for 85 percent of
20 woodworkers concerned about all member sales.
the lack of outlets for their work. "Part of the successhere is shared
Each chipped in $50 or so to rent a retail diversity," Chris continues. "Besides
space. They found one in the city's our members' work, we go out of our
Pioneer Square, back then a run-down way to find interesting nonmember
and tacky area.Even so, it was a begin- woodworkers, who now number about
ning for Northwest Fine Woodworking. 250. I always say that we sell every-
Buioh how thingr huu. changed! thing from a $10 baby rattle to a
Today, Nonhwest Fine Woodworking $10,000table."
operates two 5,000-square-foot retail According to the director, other rea-
galleries-at Pioneer Square and in sons for the cooperative's successhave
Bellevue-bringing in more than $1 changed over time, yet one has
million apiece in annual salesof hand- remained constant."From Day One the
crafted furniture and other items of memberspoliced the work coming in so
wood. Twenty years 4go, the group that technically it is always perfect. The
couldn't afford to hire a salesperson,so finish is perfect. The design is contem-
they each had to put in time selling in porary, refreshing. One just can't copy
the gallery. After a year, though, the a Shakerchair and get it in the gallery."
woodworkers had made enough money
to hire their first salesperson.Now, the Aim for customers that
cooperative has 10 employees and a have money to spend
full-time director of operations. "Not that we don't sell to other people,
but the customers we aim for have a
Quality leads household income of $150,000 or
to sales success greater and fall into the 32 to 45 age
"'We're in three distinct businesses:fine bracket," Chris explains. "When we
furniture, gifts, and art," says Chris have that type of customer, they may
Brookes, the director of Northwest Fine spend $10,000 initially, but they have
Woodworking (NWFW). "And within no problem eventually spending
those areas, I've got supreme wood- $200,000 over the years. It's truly
workers who only build one-of-a-kind arrazing what they can spend."
pieces as well as those who produce To get to that customer, Northwest
limited-production ones. And of our 28 Fine Woodworking makes sure that the

45
the gallerythat reallysells
SeattleConventionand Visitors Bureau ers basicoperations,"notesthe director. What it costs to sell
knows of its existence.That's because And within the first 14 months theY Members of NWFW cooperative PaYa
conventionplannerslook for placesthat have to visit the shops of each of the price for sales,and for membershipas
their attendeescan visit when not in primary woodworkersbecausethe most well. Chris explains both structures.
meetings.And to do that, they start at difficult areaof salesis the referralprocess. "Within the gift category-interesting
the bureau. The airport also gets "That's becausecustomerscome in saladbowls, jewelry boxes,and such-
NWFW's attention. Chris makes sure not knowing what they want," Chris they just fly out of here.So I buy them
that the co-op has a display there once goes on. "The salespersonhas to take outright from the mostly nonmember
every two years. The result? "Sales to the customerthroughthe woodworkers' makers. But on the furniture side of
businessvisitors and areatouristsrepre- portfolios. Then, once the salesperson things, it's consignment.That is, the
sent about 40 percent of our total has a senseof what the customerlikes, maker pays nothing until the piece is
revenue,"Chris says. he or shemust becomemore definitive. sold. For instance,a member pays the
To have sales in the millions takes Then, through subtle questioning, the gallery a 32 percent commission. For
knowledgeablesalespeople-personnel customer has to be qualified to see if nonmembers,the commissionis 40 per-
who know what they sell and where it they're financially able to buy custom cent if the item tops $1,500retail price.
came from. Here's how that's accom- woodworking-not just dreaming. Under$1,500,the gallery'scommission
plished. "New salesemployeeshave a Salespeoplehave the responsibility to is 45 percent.And if we senda member
nine-monthtraining schedulethat cov- protectthe woodworker." a client for customwork, that is our [the

th ir co-
K"n Richardslivesin MapleValley,outsideSeattle.
He's been a NorthwestFineWoodworking(referredto
lJ
as the "gallery")memberfor six yearsand a profession-
al woodworkerfor more than twice that. He serveson
:!i
id

if
t
I
I
the co-op'sboardof directors,The followingis how
I
!
Ken believesmembershiphas benefitedhim as well as
what'sresponsible for NWFW'ssuccess.
o"l kept fairlybusy beforeI
becamea member,but it was
with moretraditionaldesignsin
domestichardwoods.I really
wanted to do contemPorary
thingsin exoticwood. With the
galleryl've beenableto pursue
that and becomereallybusy.In
fact, one of my first gallery
referralswas a couplefrom
Boca Raton,Florida,who had
Ken Richardsis all smiles come to the Northwestseeking
about his breakfrontshow- handmade,contemporaryfurni-
caseof Ceylonsatinwood.
ture.I endedup doinga dining
set and severalothermajorpiecesfor them."
o"The lastfew years,100 percentof my saleshave
beenthroughthe gallery.I don't evenhavetime to do
speculationwork becauseI'm bookedfor threeyears
with customwork."
o"l do some satisfyingwork with NWFW'snew-member
programthat helpsaspiringwoodworkersget overthe
humpfrom hobbyistto professional."
t"One reasonfor the co-op's successis its appealto a
:broad rangeof customers,all with differentdesign
tastes. Certainlythe gallerycouldn't have survivedif
everyonedid the sametype of work that I do."
o"NWFWis an inspirational communityasset."

WOOD magazine August 2001


46
Seewhattheysell
gallery'sl client for life. And there's lf visitingSeattle,stop by the NorthwestFinewoodworkinggalleryat 101 S.
one goldenrule for all sales:Our mem- Jacksonin Pioneersquare (20oli2s-0542).Thecooperative's galleryin
bers must never undercutwhat would Bellevueis locatedat 601 108thAve.,N.E.,plaza 100 (42s1462-s3g2). or
be the retail price.If a rockingchair has view its websiteat www.nwfinewoodworking.com.
a $2,000price tag in the gallery,ir has
the same exact price tag if a client
comesto their shop." and gets a sense of the person and A new memberalso pays a one-time
Becominga memberin order to sell where they're going with their work. assessment of $500, plus $100 for a
has its costs and requirements,too. "Potential members also have to come stockcertificate,thenagreesto pay $30-
Chri s out lines t he p ro c e s s ." Wh e n to one of the general meetings and give a-monthduesfor 72 months,for a total
woodworkersexpress an interest in a l5-minute slide presentationand talk of $2,760.After that, monthly duesare
joining, we ask them to put some of about themselves," Chris adds. "After dropped and replaced by funds from
their work in the gallery for up to 12 that, all the members vote. If accepted, salescommissions, which the coopera-
months.That way, they see if it sells, the new member must attend l0 of the tive usesto pay operatingcosts.Q
andget to know us aswell. If that works 12 board meetings during the first year
out, they submit a formal application. because the co-op doesn't just want Writtenby PeterJ. Stephano
Then,the membershipcommitteemeets members whose work will sell. They Photographs:Courtesyof Northwest
with the person,visits his or her shop, want members who are active." FineWoodworking

FT
Pob Spangler, a woodworkersinceig7S, membersto show and selltheirwork.Yet I
becamea memberof NorthwestFine havepersonally benefitedby raisingmy skill
Woodworking in 1990,and likeKen Richards, level;there'salwaysa subtlecompetition."
currentlyserveson the boardof direcrors, t"lt has becomesucha successful coooera-
Hereare histhoughtson membership and tivegallerydue to the focus.All wood, all very
why NWFWhas had suchsuccess. highquality,and it'sjuried.Shoppersknow
o"Thegalleryhelpedme tremendously in what to expect."
learningto run a business. Thatprobably o"Anotherfactorfor successis the huge
goesfor the othermembers,too, because diversitythe galleryoffers.We havepeople
woodworkersare mainlyjust a bunchof guys doinglimited-production work as wellas
with toolsand pickuptrucks," absolutely one-of-a-kind "
furniture.
o"AboutB0 percentof my salesare through
the gallery,That countsspeculationwork sold Bob Spangler's cherry
off the floorand referralsfor customwork." extension table and chair
o"NWFWis a tremendous still delight him.
opportunity
for

wrwv.woodonline.com
47
ust like a car, your woodworking
equipment will work better and
last longer with regular mainte-
How often do you need to stop
building projects and start cleaning your
machinery?That dependson how much
you use a given tool.
If you're a hobbyist who works in the
shop now and then, set aside one
Saturday every year for checking and
cleaningtools. If you're running a table-
saw all day, every day, you should clean
it every couple of weeks.
Here, we've laid out the essentialmain-
tenance steps for some common work-
shop equipment.

General Prccedures rusting, spray with TopCote, available


.Blow out dust from inside portable at woodworking stores or from
power tools by directing compressedair Klingspor's Sanding Catalogue,
through the motor vents while the tool is 8001228-0000, at a price of $9.95 for a
running. Wear safetyloggles, and don't 5.5-ounce can, item number BOS
.Cords. Check for frayed spots; check use more than 50 pounds of pressure. 1005. Allow the TopCote to dry to a
plugs for burned prongs. If you find any Blast around drill chucks, too. haze,then wipe it off.
flaws, replacethe cord and plug. .Remove rust from metal work surfaces .Clean plastic parts with a damp cloth.
.Brushes. Theseactually are solid blocks with degreaseror rust penetrant and an Use water, becausechemical solvents
of carbon. Some are accessiblebeneath abrasive pad. To protect against further can damageplastic.
two screw-on covers on the motor hous-
ing; others require removal of the hous-
ing. Replacethe brushesif you find rain- TOOL-SPECIFIC STEPS
bow colors on a spring, a collapsed .Tablesaw: Cleanthe movingpartswith a stiffwire brushand citruscleaner.Don't
spring-like the one being held above- use water,which rustscast iron.(Note:To get at allthe key spotson a cabinet-style
or a broken copper lead inside a spring. saw, you probablywill haveto removethe tabletop.)
Also replaceany brush that's worn down oSaw blades: Spraythemwithovencleaner,then buffthemwitha fine,knottedwire
near or past the limit mark on its side or brushmountedin a drill.
shows signs of burning or chipping. oRouter: Removethe collet,and clean its insidesurfacewith a round,fine-bristle,
.Arcing. Peer through the vent. slots brass brush.Cleanthe outsidewith steel wool or a nylon pad. Clean the subbase,
while the motor is running. You should and lubricateit with a Teflonlubricantor wax.
see small sparks at each brush. But if rPlunge routen Cleanthe plungerodswith a fine abrasivepad,and lubricatethem
sparks trail around the motor, have the with graphiteor wax.
tool checkedat a repair shop. oBandsaw: Clean off any sawdustthat has packedbetweenthe blade and the tires,
.Gfounding. Touch a continuity tester usinga Scotch-Brite pad or a lightwire brush.Replacethe tires if they'recracked.
from the grounding prong on the plug to .Radial-alm sawECleanthe track and rollerswith a rag dippedin a 50/50mixture
any metal on the tool. A reading shows of ammoniaand water.Then lubricatewithWD-40,and wipe mostof the oil off again.
that the tool is safely grounded. Also cleanthe columnwith a fine abrasivepad, spray it with WD-40,and wipe otf.

50 WOOD magazine August 2001


I
,)
Clean,lubricate,and adjustthemregularly.
r tools
!
You'llget yearsof faithfulservicein return.

.Cracks. If the machine vibrates as it


shuts down, that could be a sign of belt
problems. Check the belt, or belts, and
replaceany that are cracked.Always buy
one of the same series and length. If the
marking has worn off the old belt, take it
General Procedures You'll find theseon tools such as sta- to a supplier as a reference.You can find
.Noisy gears, or oil leaks behind the tionary planersand worm-drive saws. local belt suppliers under "Power
spindle, indicate that the greasehas bro- .Sealed bearings on most newer TransmissionEquipment" in the Yellow
ken down. Openthe tool housing,andput power tools require no lubrication. Pagesof your telephonebook.
a modest amount of medium-weight However, some less-expensivetools .Tension. When you tap a belt with your
grease on the gears. Or, you might have an oil hole that opens onto a hand,it shouldfeel taut, not slack.If you
chooseto take it to a tool repair shop. sponge, which feeds oil to a brass or push on it lightly, it should flex about
.Gearbox oil reservoirs require frequent bronze bushing. Apply only a few Vzz" for every inch between the pulley
checks.Top them offwith 90-weight oil. dropsof light oil in that case. centers.Adjust tension according to the
manufacturer's insffuctions.
.Performance. Spray a cornmercial belt
TOOL.SPECIFIG STEPS dressingon the belt while the machine is
oTablesaw: Applywhite lithiumgreaseor powderedgraphiteon worm gears,bevel running. This product reduces slippage
gears,and trunnions. and extendsthe life of the belt.
'Belt sanden Spray white lithiumgrease on the needle bearingsmountedon a .Pulleys. Make sure they're aligned
shaft in the idler roller. properly with one another and tight on
oPlanen Some bigger and older machineshave drive chains. Remove the side
their shafts. Use Loc-Tite, available at
cover and oil the chain. Spray Teflon lubricantor graphiteonto the jackscrewsthat hardware stores, on the threads of set
raiseand lowerthe tableor cutterhead.lf your modelhas oil cups on top of the table, screwsto keep them secure.l
apply a few drops of oil in those. Checkthe rollersfor buiH-up.Clean metal rollers
with solventand a fine wire brush,and clean rubberrollerswith a hand scraper.
Written by Jim Pollock
oDrill press: Apply a Teflonlubricantor graphiteto the height-adjustment rack. Photography:D.E. Smith Photography

umnn woodon|ine.com 51
o bring you the best and freshest project
designs, we travel throughout the country. On
one of these prospecting trips, we discovered
Peter Dellerl, a talented designer and builder from
Holyoke, Massachusetts.
Peter's unique jewelry box features a striking cop-
per lid with a patina pattem that you can duplicate
easily. (See the instructionson thelbllowirtg pages.)
But the beauty of this box lies more than skin-deep.
The removable tray and system of interior dividers
multiply the storage area and keep the contents neat-
ly organized. A stylish, paper-thin cork liner looks
great and cushions valuablejewelry.
To make it easy for you to build this box, we
assembledthe hardware, cork lining, and other com-
ponents into a convenient kit. See the Buying Guide
accompanyingthe Bill of Materials, and you'll soon
have a gem of a jewelry box.

Note: In presenting this projec't fo \)oLt,we stayecl


true to Peter Dellert's choices in high-cluality harcl-
ware and other building ntoterials. You can pur-
clmse a sr,tpplies kit (rtot inclucling wood) .for
$63.75 through the But:ittg Guide on page 57. That
mcD)seem expensive, but when you cortsider that
Peter charges $375 for this box, yoLt con under-
stand whr- he selectsonly 711,best hurdware. If you
wottld like to holcl doyvn your costs,sintply substi-
tute less-exltensive hinges, ntuke w,oodenfeet in
place of the brass ones, and flock the surfaces oth-
erwise coverecl vt,itltc'ork.

53
patinajewelrybox
First up, the box pafts patinatechnique
Using th'"-thrckcherry,rip a 4S"-long
board to 3V8" wide for the case
front/back(A) and the casesides(B).
Set your tablesaw's blade and rip
fenceto cut the groovesalongthe top
For great
andbottominnerfacesof the casepieces
(A, B). After you makethesecuts,test-fit
reactionsn
the thicknessof thecopperandhardboard
for the top panel(C) into its groove.Also
try simple
testthe fit of the cork lining and the hard-
boardbottompanel(C) into its groove.
chemistry
Cut the case front/back (A) and the
casesides(B) to the finished length
shownin the Bill of Materials. A m moni afumesare al l
Referringto Drawing1 and PhotoA, flyo, needto give
set up your router table to cut the shiny,new coppera
spline slots. Use double-facedtape to weatheredlook.But if you want to Firstn some shopping
join the outside faces of the front/back includesome eye-pleasing designs,let You'llneed a sheetof flat, medium-
(A) to each other temporarily.Position us showyou the secret. gaugecopper,self-adhesive label
onpage56
Continued Any materialthat can keep the paper,table salt,non-sudsyhousehold
fumes away from selectedareas can ammonia,the patternin the WOOD
act as a "resist"and producedesigns PATTERNSo insert,and a plasticcon-
on copper.To makethe ornamental tainerwith a snug-fittinglid. lf you pre-
panelsfor the box on pages 52-53 and fer to makeyour own design,we'lltell
Fastensidestogether
usingdouble-facedtape. the housesign on pages 60-61,we you how to do that with some leaves
beganwith the proceduresthat and a photocopier.
MassachusettscraftsmanPeter Dellert You'llfind copperat homecenters
uses to great effect. and l umberyards,or chec kunder
Eventually, we came up with a new "sheetmetalwork"in the Yellow
Supportblock
twiston the techniquethat makesit Pagesof your phonebook.Those
easierfor a beginnerto get reliable, companiesoftenhave a supplyof cop-
attractiveresults.Give it a try and add per and will sell you what you need,
a terrificdecorativetechniqueto your maybeat a betterprice.Lookfor label
project-bu ilding repertoire. paperat an officesuppliesstore.You
%" straightbit Of course,you don't have to limit can find varioussizesof plasticboxes,
sel1/q"above
routertable your designsto the leaf shapesshown with lids,at a departmentstore.
here.Try any natural,geometric,or
artisticshapesyou like.You can find Now, the art part
countlesssamplesin clip art books We usedJapanesemapleleavesfor
and software.And it isn't just for box our design.Put our patternin a photo-
lids and housesigns,either.lt could copy machineand copy it onto self-
be just the thingfor a servingtray, adhesivelabelpaper.Or, to make
door panelinsert,mailbox,or any your own design,arrangeleaveson
numberof otherapplications. the glasssurfaceof the copier,and

Morepatinapossibilities
Want to experimentwith variationson this technique?Try these ideas:
o "Paint"any shapeyou want with petroleumjelly,an excellentresist.
o For clear,sharpletters,use vinylletteringfrom a hobbyor departmentstore.
o Aftersaltingthe surface,cover it with coppersulfatemixedwith sawdustand
the ammonia,insteadof fuming.This methodcreatesa warm,browntone.You
parts can buy coppersulfateat a pharmacy.
agaigFt the fence o For a greenpatina,mistthe saltedcopperwith PatinaGreen,made by
a$"dright stop- ModernOptionsInc.and availablein art storesand otheroutlets.A 4-ounce
bleick. and lower
bottlecostsabout$5.50.
o Use brassor bronzeinsteadof copperto get a differentlook.

54 WOOD magazine August 2001


After the solventevaporates,peel copperabovethe ammonia.Lay the
A sharp-looking design calls for attrac- the backingoff the labelpaperand copperon the supportsand immedi-
tive shapes, a good layout, and precise affix it to the copper.With an X-actoor atelyput the lid on the container.
cutting with a sharp knife. othersharpknife,carefullycut around Ammoniafumesby themselvesturn
Any coating of salt will bring results, th e l e a v e s' outl i nes,
as show ni n coppera dark,olivecolor.The salt
but the density does make a difference. Photo1. You also can cut "veins"into producesa bluish,crustyresidue.But
Run a couple of tests before you work the leavesfor a more realisticappear- each paper leaf acts as a resist,keep-
on the piece for your project. ance. Removethe whitepapersur- ing the salt and fumesaway from the
roundingthe leaves.Cleanoff any copperunderneath.
stubbornadhesivewith lacquerthin- Checkthe progressafter about 4
ner,then wait a coupleof minutes hoursto see if the patinais developing
whilethe solventevaporates. evenly.Leavethe copperin the fumes
Spraya lightmistof waterover the as long as you like,but don'texpect
copper.Then sprinkleon an even, much morethan very subtlechanges
moderatedustingof ordinarytable afterthe first6 hours.
salt, as shown in Photo2. Different When you removethe copperfrom
amountsbringdifferentresults,so it's the container,as in Photo3, you'llsee
best to test the techniqueon a couple a dark backgroundaroundthe paper
of smallpiecesof copperfirst. leaves.Workingon a pieceof card-
boardor scrapplywood,scruboff the
paperwith lacquerthinnerand a stiff-
bristledbrush,as in Photo4. lf some
dark spotsremainon the copperleaf
images,that'sfine.The leaveslook
more naturalthat way.

run a test copy.Rearrangethem


untilyou like the designand the leaf
edgesappearcrispon the photo-
copy.Then,load self-adhesive label
paperintothe appropriatetray of the Remove the copper when the patina
copier,and printthe finalversion. appears complete. Rememberto
Usingpaperwas the innovationthat wear a respirator mask whenever you
gave us the consistentresultswe have the lid off your container.
sought.Our firsteffortsinvolvedgluing Scrub with moderate pressure and
real leavesto the copper.But that pro- check the look of the piece as you go.
ducedvaryingdegreesof crispness lf you accidentally remove too much
patina, carefully add salt where you
alongthe leaf edgesand varying want it and fume the copper again.
amountsof residueunderneaththe
leaves.Next,we tried plasticleaf
shapes,but we got sharp,shiny
imagesthat lookedtoo artificial.So we
And finally, chemistry
Now,you'regoingto use ammonia
tr
triedself-adhesive paper,and liked to transformthat blandcoppercolor Lightlyscrubthe background, but
what we saw. into a mottledblue.Ammoniafumes don'toverdoit. You want to eliminate
Cut the copperto size with shearsor will lingerwhileyou carryout this pro- any "muddy"appearancewithout
a utilityknife,and sand it with 18O-grit cedure,so set thingsup outdoors,in knockingoff all of the blue residue
sandpaperunt ilit ' s un i fo rm l sy h i n y . the garage,or in some well-ventilated createdby the salt and ammonia.As
Cleanit with denaturedalcoholto part of the housewherethe smell the workpiecedries,you'llsee the fin-
make sure nothingremainsthat will won't botheranyone.Wear a respira- ishedcolorstartto come through.
interferewith the next steps.Wear tor mask,too. The strengthof those Let the copperdry, then applyone
gloveswhen handlingthe copperfrom fumes can surpriseyou. Pour t/2"ol or two coats of paste wax. That will
now untilit goes into the ammonia ammoniaintothe container.Place protectthe patinaand give it some
fumes,so it won't pick up any oil from blocksof wood or otherdisposable luster.Or, you can spraythe copper
your fingers. supportsin the box to suspendthe with lacquer.lF

www.woodonline.com
55
patinajewelrybox
Continued from page54 t/e" groove /0" deep 63Aax 133Aa"
copper
1/a"trom top edge
the stop blocks 2ts/ro"from the centerof t/a" groove t/a" deep
t/e" ttom top edge
the router bit. Switch on the router, then
hold the front/back againstthe right stop-
block and the fence. Lower the wood Miteredends
until it contacts the table and support
block, and rout the slot by moving the
wood to the left until it hits the stop-
block. Repeatthe processfor eachof the

q
remainingmiteredends.
.:.. Referring to the Drawing 2, note that
. :the grain of the splineruns along its
shortdimension.Make the splinesby rip-
ping a cherry board 2s/s"wide, and thick-
ness-planeor resaw it to t/8"thick. Then
cut four splinesVz"long. r/e x 2s/e x t/z"spline
"'Cut two piecesof hardboardfor the
' ,top/bottompanels(C) to the sizelist-
X ASSEMBT
ed in the Bill of Materials.Cut the cop-
per panelto the samesize,then apply the
decorativefinish to the metal using the
procedure described on the previous
pages and the leaf patternsfound in the bow inward, making it difficult to
WOOD PATTERNSo insert. The cop- add the final box side,cut a 25/e"-
per merelyrestson the top panel(C), but long scrapwoodspacersffip, and
you'll need to glue the cork liner to the springit betweenthe panelsto sep-
bottom panel (C). To do that, simply arate them. Gently snug up the
brush a thin coat of white glue on the joints with a bandclamp, and make
Mark hingelocations
bottom panel and gently smooth out the certain that the assemblyis square beforecuttingoff lid.
slightly oversizedcork liner with a block and flat while it dries.
of wood. To apply pressure while the
glue dries, cover the liner with a piece of Now, mark for hinges
waxed paper,add the top panel, then set and separate the lid the box. Referring to Photo B, clamp
a toolbox or other weighty object on the '', Unclamp the box after the glue dries. spacersinto the kerfs, and make the cuts
stack. After the glue dries, use a utility , Use a pencil and squareto mark the along the front and back of the box.
knife to cut the liner flush with the edges hinge locations on the back of the box, Referringto Photo G, remove saw marks
of the bottom panel(C). whereshownon Drawing2a. by rubbing the cut edgeson a full sheetof
,''.,'Lock your tablesaw'sfence3/q"from 100-gnt sandpaperspray-gluedto a flat
Nextn assemble the box 't-" the inner side of the blade. and raise surface.Removethe tapefrom the inside
To protect the top/bottom panels (C) the blade about e/to"abovethe surfaceof cornersof the box and lid.
from the protectivefinish you'11apply the table. With the top of the box against Refening to Drawing 3, use a square
later to the wood. cover them with clear the fence, make a cut along both endsof to transfer the hinse-location marks
plastic food wrap. Wrap about 1" of
plastic over each panel edge, and
secureit to the back of the panelwith
maskingtape.
'Dry-assemble(no glue) the box
, parts(A, B, C), the copperpanel,
and the splines to make sure every-
thing fits. If needed,cut a nick out of
eachpanel'scornerto get them to fit.
, To keepglue squeeze-out offinte-
rior corners,placea strip of mask-
ing tape along each miter cut, where
shownon Drawing2. Apply glue spar-
ingly to all of the miters and splines,
and assemblethe box. If the panels

56 WOOD magazine August 2001


-Planeor resaw
to thicknesses
listedin the Billof Materials.
billofnnaterials
/i\
\t/
A casefronVback Vz 3j/a' 14' C 2
rA r^\ B casesides t/z' 31/a' 7' C 2
1 / 2 x 7 1 / qx 4 8 " C h e r r v \y \v
panels%" 63/6"133/6" H
C bottom/top 2
D handle- 1/bt 2Ve^ ?/d' S 1
1/ax 12 x 30" Hardboard
1/zx 21/zx E casedivider 3/a' 1u 13" C 1
F casedivider
fronVback 1/q' 1u 13" C 2
t/+"round-overs
G casesub-dividers
7a lu 21s/ta"C 10
H tray fronVback i/a' 7/a' 61/l C 2
e/o+"shankhole, I trayends 1/4" 7/A, 515Ag" C 2
countersunk on s/a' s/au 6
J traydivider C 1
61/zu -1/qu the insideface
1/ex515/taxl2tsAa K tray sub-dividers 1/a' 5/a' 213Aa"C 4
#6 x 7+' brass
F.H.woodscrew mtrror L]raybottom t/e" 5t%o 6tl+" H 1
-Cutfrom1/2x21/2x12"
blankandtrimtosize
Materials
key:C-cherry,H-hardboard,S-scrap-
wood.
BuyingGuide:Brassfeet(4);17+x1" brassbox
hingeswith screws(2); #6xs/t"brassflathead
woodscrews (2);.016x6%0x13%0" coppersheet;
6%ox13s/0" corkwallcovering; 5s/ax61/q"
corkwall
covering(bothpaper-thinDesigntex corkwallcov-
eringM6466 corkcubed); t/sv$ts/15y1)rs/1e"
mirror;
EXPLODED
VIEW labelpaperprintedwithleafpattern
fortop.Orderkit
JB-1,$63.75ppd.fromSchlabaugh and Sons
\1'2" brasshii$ Woodworking, 72014lhStreet, Kalona,lA 52247,
3/ax 11/q"mortises orcall800/346-9663.
% 0 "d e e p

3/sz"pilotholes
1/4"deep
6Vrax 133/ra"

Gluebrassfoot
.b
i intoa s/0"hole
t/a"deep. t/+"round-overstop and bottom
\J

the waste within the hinge's outline. Ror-rt


close to the lines, then finish the mortises
from the back of the box bottom and lid with a chisel. Drill pilot holes fbr the
to their inner edges. hinge screws, test-fit the hinges, then
Use a t,/+"brt in a small router, as remove them.
shown in Photo D. to remove most of
ffXa$qs
m mty$$mh
hamdXm
Cut a VzxZt/zxI2" piece of solid scrap-
wood (any wood that paints well).
Referring to Drawing 3a, mark the radius
and cutline on the wood. Use a scrollsaw
or bandsawto cut just to the waste side of
the radius, then sand to the line.
Referring to Photo E, put a /+" round-
over bit into your table-mounted
router, and rout the top and bottorn faces

www.woodonline.com
57
patinajewelrybox
of the radius. Use your mitersaw to cut
the handle to length. t/e"dadoes
1,/a"
deep
Refer to Drawing 3 to drill the handle-
mounting holes through the lid.
Holding the handle in place, push a fin-
ishing nail through these holes to mark
the position of the /::" pilot holes in the
handle. Screw the handle into place.
t
1"
Machine and a$semble
the dividers and tray
Referringto the Bill of Materials,pre-
I
pare blanks for the parts you'll need
for the divider and tray assemblies (Pans
E, F, G, H, I, J, and K) by planing or
resawing chery to the required thick-
nesses. Thenrip the blanksto width.
Crosscutthe casedivider (E) and the
case divider front/back (n to fit
insidethebox. tray endsfit easilybetweenthe front and sameprocedureyou usedearlier.When
Lay out the dadoeson pafts E and F, back of the box assembly. the glue dries,coverthe piecewith plas-
whereshownon Drawing4. Refeningto Drawings5 and 5a, lay tic wrap and test-fit it. Glue and clamp
Centerthe casedivider (E) insidethe out and rout the rabbets,grooves,and the tray assembly.
box, and position the case divider dadoesin partsH andL Notethatthehor- Crosscutthe tray divider (J) to fit,
front/back(F), but do not glue any of the izontalgroovein the tray ends(I) stopsat thenrout the dadoes,whereshownon
pieces.Crosscutand fit the case sub- the verticaldadoneareachcorner. Drawing5. Crosscutthetray sub-dividers
dividers(G), but do not gluethem. Cut the tray bottom (L) from hard- (K) to fit.
Crosscutthe tray front/back(H) and boardto the sizelistedin the Bill of
the tray ends(I), makingsurethat the Materials.Glue the cork liner. usins the Younreready for finish
and final assembly
Remove the hinges and handle, as
well as all the dividersfrom the tray
andbox. If necessary, patchthe plas-
tic wrap. Do any touch-up sanding
ETFAYI -u'"* necessary, but don't sandthe divider
llw partstoo much,or you could change
their fit.
-j Apply your choiceof finish.We
5/a"
usedthreecoatsof Minwax Fast-

7e" dadoes t/e"deep


t Drying Polyurethane ClearSatin.We
primedthe handle,then gaveit three
coatsof satinblack spraypaint.
Use a crafts knife to cut away the
plastic wrap, then remove the tape.
Referringto Drawing 3, drill holes into
the bottom of the box for the brassfeet.
Use a dab of siliconeor epoxy to secure
7a"rabbet the shankof eachfoot into its hole. Glue
t/e"deep
and screw the handleinto place. Install
the dividers,thenreplacethe hinges.
511AaX 61/q" COfk Have a %"-thick mirror cut slightly
undersizedfor the inner lid. We
installedours with four dabsof silicone
on the back of the mirror.JF
J t/a" groove
t/e" deep Written by: Robert J. Settich with Jim Downing
,/a
1/s"trom ProjectDesign:Peter Dellert
bottom edge lllustrations:
Roxanne LeMoine;Lorna Johnson
/
t/e" rabbet
II Photographs:Wm. Hopkins;
Baldwin Photography
/e" deep

58 W O O Dm a g a z i n e A u g u s t2 0 0 1
il ',, mark
ere's a simpleprojectto spiceup ffi,;otyourback,
', '" ', iines1tlc" from the top, bottom,
your home's curbside appeal.
,'r ., You'll find number and letter
patterns on the WOOD PATTERNSa
insert.Use the techniqueon page 54 to
apply an attractivepatina to the copper-
sheetbackground.We gracedour copper
with a dragonfly. Dragonfly and leaf pat-
terns are provided on the pattern insert,
but you can useany imageyou like.

First, determine the size


'{ Decidewhat you wantyour signto say, ,9""iWhenyou are satisfiedwith your lay-
i and what size letters and/or numbers '." .,out,planestock(We usedmatrogany.)
you are going to use. Enlarge tlre to /2" thick and adherethe characterpat-
characters (A) tems to it with spray adhesive.Orient the
patternsso the wood grain is horizontal.
Scrollsaw the charactersto the lines, then
removethe patterns.Reanangethe charac-
ters on a sheetof paper.Measureand mark
lines I Vc" otJt from them. as shown in
Photo A. This is the sizeof yourback (F).
(Our back was 5Vzxl6vt".) Set the
charactersaside.
":''sDeterminethe lengths of
-..1':you,top, boffom, *d tid"t
by adding 1" to each
dimension of

.r.
- . - . : ' s Lr tt . t y \\,/L rt
's"; jffarne or
n.#

.ir*€ j

. i1 frgusenumber the back. (Becauseour


back was 16V2" long,
'.:.
" \r irhtoa our top and bottom lengths
:. i 1;;*
i :f
tl
were I7Vz".Our back was 5/2"
;i,;:iid;ffigtronable
. . .,
d' '* 'r:',
from the pat-
tern insert to your desired size, and
wide, making our sides6Vz"long.)
,
i adcSraqq urrrangethem as they will appear. (We Noq form the frame
r*a
used one line of 3"-high letters on our 'i From l"-thick stock, cut blanks 4:/+"
fi: ,'"'j
sign.) To accommodatea longer line of i wide to your determinedlengthplus 1"
*:" r f*.
characters,extendthe endsof the top (B) for the top (B), 3V+"wide to your length
andbottom (C). More lines canbe added plus 1" for the bottom(C), and3/+"wtdeto
by simply lengtheningthe sides(D). your lengthplus 1" for the sides(D). Copy

WOOD magazine August 2001


#4 x 1/2" brassR.H.woodscrew
1 6 - g a u g ce o p p e rs h e e t
)
t/+"chamfers
Note: *To determinedimensionsee instructions.

b r a s sR . H .
r/c" rabbel wood screw
1/2"deep r/+"chamfers
7a" holg 1/4"deep Copper
with a s/sz"sha hole
centeredinside
7a"buttonplug i
I
*

i
L o/\
#B x 2" brass
F.H.woodscrew
16-9augecoppersheet

t/e"hole
1" d e e p

A characters 1/z'
t/q" chamfer B- top 1 43/q' ** M 1
EXPLODED
VIEW t/a"hole C- bottom 1" 31/t'
**
M 1
D. sides 13/qu**M2
/e" dowel 1t,/q"lono
E ovalback th' 31/2, 41/z' P 1
F back 1/i P1
- PartsInitially
cutoversize.
the Top and Bottom from the pattern clltout in the top, where shown on ** Dimensionor quantitydetermined
bytheconfigu-
insert and adhere them, centered on the Drawing 1 and 1a. ofyoursign.Seetheinstructions.
ration
len-eth to the blanks. Scrollsaw, then Change to a chamfer bit, and rout the MaterialsKey:M-mahogany, plywood.
P-lluan
sand to the pattern lines. Drill the coun- front edges where shown. Using a
Supplies:sprayadhesive, glue,/a"
exterior
tersunk holes where indicated. Remove chisel, sqLlareup the chamfers' inside dowel,#4xtl2"
brassroundheadwoodscrews (--),
the patterns. corners on the top and bottom, as shown #8x2"brass
flatheadwoodscrews(2),
Install a rabbeting bit in youi"table- in Photo B. %"mahogany buttonplugs
(2),exterior
linish,
mounted router, and rout the rabbets clear
epoxy,16-gaguecopper
sheet.
Miter the frame pieces to length, and
in the back edgesof the top, bottom, and dry-assemble to check the joints.
sides. and around the inside of the oval Apply glue to the miters. (We used
Titebond II.) Clamp the frame together
with a band clamp. When the glue dries, When the flnish dries, drill screw-
drill %" holes in the corners and glue in shank holes through the backs and
dowels, as shown on Drawing 1. Sand copper sheets and pilot holes into the
the dowels flush. frame. Screw the copper sheetsand backs
Cut the plywood backs (E, F) and in place.
mating pieces of l6-gauge copper Arrange the characters in the frame,
sheet to fit in the rabbeted openings. then epoxy them, one at a time, to the
copper sheet.
Add the finishing touches Mount your si_enusing #8x2" brass
Apply a patinato the copper,follow- flathead wood screws.Glue the button
ing the instructions
on page54. plugs in the counterbores.iF
Finish-sandall the wood piecesto
220 grit. Apply two coatsof sparure- Written by Jan Hale Svec with Kevin Boyle
Project design: Kevin Boyle
thaneto the frame,backs,charactersand lllustrations: Roxanne LeMoine, Lorna Johnson
two button plugs, sandinglightly with Photographs: D. E. Smith Photography;
220-gritpaperbetweencoats. Baldwin Photography

www.woodonline.com
61
'
- / ,ffilf
( @ '
\-'i-

fl
Gw
-l

joints. One edge of the templatenavi-


gates the bit for cutting the tails; the Dovetail bits
taperedslots in the other edge direct the
bit for cuttingthe pins.
& pieces
lf you'rea springchickenwhen it
We'll focus on thosejigs, but we also comesto through-dovetail joints,
included two incremental-positioning here'sa quickprimeron the parts.
fixtures that attach to your router table. And, althoughyou'refree to break
Although not true through-dovetailjigs the rules,we'vealso includeda
(we'll explain why later), thesefixtures few guidelineson whichpieces
belongwhere.
also are capableof making a number of
otherdecorativethroughjoints.
(Editor's note: We opted not to test
Porter-Cable's Omnijig becauseof its
high cost. The 24" jig sellsfor $360 and
can only do half-blind dovetails; to make
through dovetails,you must buy an addi-
tional templatefor $160.)

Do TD iigs get a bad rap?


Through-dovetailjigs have a reputation
for beingdifficult to setup anduse.Con- Tails. When viewedfrom the face
sequently,novice woodworkersmay shy of the workpiece,a tail lookslike,
away from them. We're happy to say we well,the taperedback end of a
found that reputationlargely undeserved. dove.You shapethem by routing
In fact, of all the jigs in our test, only with a dovetailbit, as shown oppo-
the Craftsman 25450 took longer than sife. For cases and drawers,cut
aboutten minutesto assembleand setup. tails in the side pieces;for a chest,
That's becausethe Craftsmanjig (unlike you shouldcut them on the front
the virtually identicalVermont American and back pieces.
Pins. Routedwith a straightbit,
23461) comes completely unassembled.
pins look like rectangleswhen
It took us about an hour to turn Crafts- viewedfrom the face of the work-
man's bagsof partsinto a dovetailjig. piece.When buildingdrawers,pins
The Keller 2401 comesasa pair of alu- go on the frontand back;on case-
minum guide templates-one for cutting work,the top and bottom;and on a
pins, the otherfor cutting tails-that must chest,cut them in the side pieces.
eachbe attachedto a 2x6 fence that you
provide. (We used a length of I3A"
micro-laminatedbeam instead.)A line
scribed on the bottom of each template Making ends meet
showswhereto align the fence. Thanksto the double-edgednatureof the
The Katie Jig was readyto go right out templatesor guide fingers,pins and tails
of the box, but we checkedthe alignment cut with thesejigs can't help but align.
of the tuning-fork shapedguidesjust ro For mostof thejigs, you seta stopto reg-
be sure.The remainingjigs requiredonly ister your workpiece,cut the tails, rotate
minor assembly. the template or guide-fingerassembly,
and cut the pins. The Keller and
UniversalJointerstrayfrom this formula,
but that's not necessarilybad.
Making dovetailjoints with the Keller
is a lot like cutting them by hand, but
faster.And it could hardly be more sim-
ple: Eyeball the tail location,clamp the
tail templatein place,and rout the tails.
Using the freshly cut tails as a guide,
scribethe locationof one pin on the end
of the pin board,and line up the pin tem-
plate on your marks, as shown at left.
We marked all three pins for this photo, Clamp,rout the pins, and you're done.
but you really only need to scribe one to Instead of a rotating template, the
accurately locate Keller's pin template. Universal Jointer uses template inserts

63
'tailblazers LEFT: Six pockets
on the Graftsman
and Vermont
that fit into a templateholder. After cut- American jigs set the
ting the tails, you replace the tail insert bit depth for dove-
tailing stock from
(shown on bench in the photo below) Vr1" thick.
with the pin insert. Rout one side of the
pins, then flip the pin insert end-for-end,
then rout the other side of the pins.

A fitting tribute
Although aligning pins and tails with
thesejigs is almost automatic, actually the jig that help the process.
getting them to fit together becomes a They weren't perfect,but they
different story. Step one-shaping the got us in the ballpark (if not
tails with your router-is pretty straight- the infield) without any calcu-
forward. Fitting the pins to the tails can lations,which we appreciated.
take some trial and error (and a few With the tails cut, it's time
piecesof scrapwood). to fit the pins to them. Moving
For routing tails, you only needensure the pin template slightly for-
that you cut them at least as deep as the ward on its fence widens the
pin board is thick. Don't go overboard pins for a tighter fit; shifting it
here:You don't want to wastetoo much backwarddoesthe opposite.
time sanding the ends of the tails flush Arguably the most elaborate
with the pin board when you're through. systembelongs to Leigh with
(About /s" extrais plenty.) graduated scales, shown at
When settingyour cutting depth,don't right, on each end of the tem-
forget to include the thickness of the platebar. Thesescalesoverlay
guide template in your calculation. To index lines on the bar support
save you some head-scratching,the to give you a handy visual ref-
Craftsman and Vermont American jigs erence when adjusting the
have pockets (top photo) on the front of template.Eachend of the tem-
plate moves independently,
Keepa screwdriverhandyif you use the though, so we had to be care-
UniversalJointerto cut throughdove- ful to make both scalesmatch
tails.You mustchangethe template
threetimesfor eachjoint. to keep the templateparallel to
our workpiece.
The Craftsman and Ver-
mont Americanjigs usea singleknob on ABOVE:To tweakthe pin fit on the
LeighD-4,loosenthe knurledbrass
the sideto slideboth endsof the template, knob and shift the templateforwardor
keeping it parallel to the workpiece.But, back.Theyellowscaleis for through
they don't provide a scale,so fine-tuning dovetails;the greenfor half-blindswhen
the fit is by-guess-and-by-gosh. Still, we the templateis orientedto cut that ioint.
had little troublefine-tuningthe fit on our
test boards.
Screw slots in the Keller pin template help or hurt in your quest for clean-cut
allowed us to adjust the templateon the pins and tails.
fence.but we never neededto: With the Just as a zero-clearanceinsert on your
fence set to the scribedindex line during tablesawreducestearout,so doesa back-
assembly,the joint fit togetherperfectly. ing board on a through-dovetailjig.
The Universal Jointer offers some lati- Keller's and Katie Jig's fences back up
tude for adjustment;the Katie Jig, none. your cuts very nicely, but we liked the
Nonetheless,we were very pleasedwith Keller betterfor a couple of reasons.
the fit of thejoints madewith thesejigs. First, the templatesnever move on the
fence, so once you've cut into it, it will
Quality is iob one always prevent tearout. When You
The hardnessand grain of the wood, your changethe spacingof Katie Jig's guide
router speed,and the sharpnessof your fingers, you cut away more of the fence,
bits are but a few of the factors that con- as shown top left opposite.
tribute to the quality of the joints made Secondly, when it comes time to
with a dovetail jig. But the jig itself can replace it, Katie Jig's fence is an odd

WOOD magazine August 2001


After using the Katie Jig with various tail spacings, we found that we'd destroyed the KatieJig's tuning-forkshapedguide
part of the fence that backs up the stock to reduce tearout. fingers(in hand)moveindependenily
to vary tail-spacing;Leigh(on bench)
splits the forks to allow variablysized
and spacedtails.

thickness- .720"-and that thicknessis width. Hampton House offers optional making them by hand. You can't change
the only control you have over the fit of guide fingers, to mix or match with the the pin width, but you can vary the spac-
the joint. Terry Hampton of Hampton the ones that come with the jig, but they ing by routing individual pins and tails to
House, the manufacturer of Katie Jig, also requirea different router bit. match.(It's this samequality, by the way,
told us that a user "can take any t7a" As we already mentioned, cutting that allows you to cut mating dovetailsin
stock-which is usually less than a full dovetails with the Keller is much like the edgeof curved stock, say,the arched
3/4"anyway-and plane or sand it down
to .710-.120" for a replacementfence if
he or sheneedsto."
On the Craftsman,[-eigh, and Vermont Tabletop TDs
American jigs, you can clamp a backer Incremental-positioning jigs,
board under the template to eliminate such as the lncra 16" Ultra,
tearout,and this works pretty well. The shown at right, and the
Universal Jointer has no wav to accom- JointechJS-1827,use a sin-
modatea backer. gle dovetailbit to shape both
the tailsand the pins.But
Pin size and spacinE: you can't cut a straightpin
Control to the'last ti''tail with an angled bit so the
One complaint we hear from old-school pins requirea second router
woodworkers is that machine-cutdove- cut and a small amountof
tails are too perfect: identically spaced clean-upwith a sharp knife
and all the samesize.Of all thejigs in our or chisel.More importantly,they lack the comptetepin-to-tailsurfacecontact
test, only the Leigh D-4 gives you com- of a true through-dovetail joint.
plete control over the width of the pins Havingsaid that, we must admit that these jigs are capableof producing
andthe distancebetweenthem, satisfying some of the most mind-blowingjoints you'll ever see, such as double-dove-
the fussiestcomplainer. tails (a dovetailwithina dovetail),double-doublebox joints,"box-tail"joints (a
If you look at the guide fingers on the box joint withina dovetail),cornerpostdovetails,and other exotics.lf you're
Leigh jig, shown on the benchin the top into box-makingand more concernedabout dazzlethan gluing-surfacearea,
right photo,you'll notice that eachguide considerone of thesejigs.
finger looks like one half of a tuning fork. Both the Incraand Jointechsystemsare essentiallyhigh{ech router{able
Changing the spacing between the fences that snap to any r/sz"incrementfrom the bit. A right-anglecarrier rides
tapered ends of the fingers alters the along the fence keepingthe workpieceperpendicularto the routertabletop
width of the pins, and separatingthe par- whife movingit throughthe bit, as shown above.
allel endsincreasesthe distancebetween Pin size and spacingis determinedby detailedcharts in the manualand
the pins. Besidesreplicating a hand-cut an extensiveset of color-codedtemplatestrips,which mountto the fence
dovetail look (with amazingrepeatabili- carriage.Once you've calibratedthe fence systemto the centerof your work-
ty), you cancreatevirtually any patternof piece and set the correctbit depth,you clamp your tail boardsto the right-
pins and tails you like. angle carrierand cut the first tail. Slide the fence to the next mark on the
In a similar fashion, Katie Jig's guide template,lock it, make the next cut, and so on until you've cut all the tails.
fingers,shownin-handin the photo attop Next,you cut all the pins in the same manner,this time usinga different
right, can be moved to spreadthe pins set of marks on the template.Finally,you repeatthese cuts with the pin
out. But, becauseyou can't split the tun- boardface-upand flat on the table. Performance-wise, we found littlediffer-
ing fork, the pins will all be the same ence in ease of use, and none in the qualityof the joints they produced.

wurw.woodonline.com
'tailblazers
top of a chest-the only jig in the testthat fer Leigh's cam-actionleversto the twist- /o
*=/o
can make that boast.)
The other product in our test that can
to-tighten knobs on the Craftsman and
Vermont American.) That limits the /--s,
i/5=
.: l Pi s=/

/s/il l
make variably spaceddovetails is the stock length to your benchheight.
UniversalJointer.However,the process One other note regarding capacities:
/s IR
I

tsl/s=/
s/
of leaving out somecuts and constantly Some manufacturersoffer larger and/or
repositioningstops and the jig left our smaller versions of the jigs we tested.
pl EI
headsspinning. Katie Jig, for example, also comes in a
Blanket Chest model (widths up to
.--*
€ - / Q,* t //ci /F''
A few more points 26V2") and a Junior model that works
before you buy with Vz"-thickstockup to 6" wide. Keller
Go wide, go long. The width and thick- also sellsa 16" capacitymodel (1601),a
nesscapacitiesof eachjig are shown in 36" model (3600), and a phenolic 15"
the chartat the end of the article,but what model (Journeyman1500).
about length?To a large degree,that's .Bits, bearings, and bushings. It's
determinedby how the jig, your bench, always interestingto seewhich of these
and your workpieceinteractfor the job. necessary items the manufacturer
includes with the jig. For instance,the
Craftsman and Universal Jointer jigs
don't come with bits. Craftsmandoes
include guide bushings,but they only fit
on a Craftsman router. Ver-
mont American usesthe same
bushings as the Craftsman,
but also sendsalong a univer-
sal router subbasethat accepts
thosebushings.
oStops,in the neme of dove.
Except for the Keller, all of tl0IE:$:
thejigs comewith at leastone
'1. joints,this 3. (B) Bearing
work stop that fixes the loca- Besides though-dovetail
productalsocanbeusedto cut: (G)Guidebushing
tion of your workpiece for (B) Boxjoints
(E) Exoticthrough-ioints 4. (.) Canberepositioned
both the tail cuts and pin cuts. (Keller (double dovetails,
etc.) alongboardfor wider
offers an accessorystop,or you can sim- (H) Half-blind
dovetails workpieces.
pin
(S) Sliding-dovetail (..) Requires
reversing
ply clamp a scrapwoodstop to the jig.) (T) Tenons holder
template onfence.
lf you wrotedownthe combinationof The Universal Jointer's stop system, (.) Optionaltemplate
required
5. !ncettent
stop partsand holes,you couldcome shown at left, consistsof threeparts that, 2.(AL)Aluminum
backto the UniversalJointeryearsfrom (GN)Glass-filled @ eooo
when usedin variouscombinations,posi- nylon
now and cut a perfectlymatingjoint. (PP)Phenolic-coatedplywood ffirui,,
tion the workpiece at any %" increment
along your tail board.
The sky's the limit with the Keller, oWhatelsecan you do? All of thejigs in
Katie Jig, and Universal Jointer. These our test also can be used to cut box
jigs mount directly to the workpiecewith joints, althoughyou needto buy an addi-
clampsyou provide.As long as you can tional template to do so on the
reachit (and safelysupportboth the stock Craftsman, Leigh, and Vermont
and yourself), you can cut it. Katie Jig American jigs. On the other hand,
takes advantageof this arrangementby those threejigs also can do half-
selling handlesthat mount to the jig: For blind dovetails out of the box-
shorter workpieces,you can flip the jig the others can't. The chart at right lists
and workpiece upside-down to cut the thejoints eachjig can produce.
joints on a routertable. tail anywhereyou can fit the jig. In our
On the other hand. the Craftsman. Which to choose opinion,you can't go wrong with thisjig
Leigh, and Vermont American jigs dependson how you use for day-in, day-out dovetailing.
mount directly to your benchtopor to an You can't beat the sheer simplicity of On the other hand, you won't find
oversized plywood base that in turn Keller's 2401.The morejoints we made, another through-dovetailjig that gives
clampsto your bench.A clampingbar on the more we kept coming back to this you as much control over size and place-
the front of the jig holds the workpiece workhorse. Although you can't change ment of pins asthe Leigh D-4. When you
vertically in the jig for cutting. (We pre- the sizeof the pins, you can plant a dove- figure in its ability to do half-blind dove-

66 WOOD magazine August 2001


/ sg-
s-/i,
t8/=trS,
t8/=tr8l !i lt<fl r l

ffiF.fl
d#9[s# t: ta
_s
o{
/€"/
S
5/.o**

It requires
assembly,butoncesetup,thisjig makeswell-fitting
joints.A goodvalue.SeeVermontAmerican comments.
Virtually
readyto useoutof thebox.Canmakevariablyspaced
dovetails.
Withoptional handles,
alsocanbeusedatooa router
table.Alsoavailable
in "Junio/'model
for smaller

s0meways,oneof the mostversatile.


Theonlyjig in thetestthatcancutvariably sizedandspaced
dovetails at thesametime.Manualis lengthy, butclearand
Alsocancut lsolocandotherdecorative
A veryprecisejig thatworksbeston pieceslessthan18" wide.
Bitsmaybe harderto find,but manufacturer listssomesources
in themanual.
Thisjig is virtually
identical
to theCraftsman25450,exceptthatit comes
mostlyassembled, withbits,andwitha replacement baseplatefor using

a truethrough-dovetail
iig, butit cancuttheioint.Routertable-mounting
maximumlength0f workpiece you canworkwiththis typeol jig. Excelsat decorative
ioints,such as double-dovetails,
double-doubledovetails.
doubleboxioints.etc.
design,andjointquality.
Similarto lncra16"Ultrain function,
Welikedthetemplate organizer in thebackof lhe owner'smanual.

,,.
Ftr||liroinfdluafi0ni, ,,r.-. : .' ,'... ., ''
: I " l . . . I l . : . ' i ] . : '
.

6. (B) Alternate bits 7. (.) Lifetime


warranty
on racks Craftsman Jointech Leigh Universal
Fixtures
(BJ)Box-joint template VisityourlocalSearsstore. 800/619-1288 800/663-8932 t24n$-8644
(BP)Routerbaseplate 8. (C) Canada www.sears.com/craftsman www.jointech.com www.leighjigs.com
(C) Production clampkit (U) UnitedStates
(F)Alternative fingerguides HamptonHouse(KatieJig) Keller Taylor (lncra) VermontAmerican
Design
(G)Template guidebushings 9. Pricescurrentat timeol article's 317/881-8601 800/995-2456 97U418-4811 800t742-3869
(H) Handles lor routertable
use production. www.katiejig.com www.kellerdovetail.com www.incra.com
(HB)Half-blind dovetailtemplate
(l) lsoloc-joint
templates
(M) Multiplemortise-and-tenon attachment F0rspecilicalions
on othertypesof tools,clickon
(S) Guide-finger spaces "ToolCompailsons" al www.woodmall.som
(TL)Template library

It's your turn


to talk 'tails
Agree or disagree,we'd like to
know your thoughtson the
through-dovetail jigs in our
test. We've set up an
tails, box joints (with optional template), than the Leigh (but without the ability to lnteractiveTool Reviewat
sliding dovetails,and more,it's arguably vary sizeor spacing).It alsocomesmost- www.woodonline.com for you
the most versatilein the test, and should ly assembled,and with a router-base to sound off. Besidesyour
handle most of your joinery needsfor a adapter and bits, unlike the similar fellow woodworkers,the
very long time. Craftsman25450that costs$45 less..l manufacturersof the jigs also
For occasional use, go with the will offer their two cents.
Vermont American 23461. It produces Written by Dave Gampbellwith Dave Henderson
Photographs:Baldwin Photography
well-fitting joints for about $150 less lllustration:Brian Jensen

www.woodonline.com 67
l- r
I
l^ \ --r^
I
i-' t r t-
J

greES
'--/ ---t

LLLLLLLLLLLLLLLLLLLLL

tand
I

Or=
'pl
lt\-

ates
Youjust can't
find hand-
fashioned
accentslike
thesein stores.
Here'show to
makethem
yourself
.

68 W O O Dm a g a z i n e A u g u s t2 0 0 1
he family-room renovation in s/'rax 23/qx 51/c"Plate holder
the April issuehad so many cus-
tom features that we couldn't
shareall of them with you in that single ,;:
issue.Now, we can show you how to t/+" hole
la" chamter
make the wooden wall plates and t/+" dowels s/q"long
adaptableair grills that helpedturn that
datedspaceinto a woodworking show- 61/s"
place. You can size the air grills to fit sAaX23/qX51/q"

any opening, and even use them for 3/qx1O3/ax16" 17/a"


projects that have nothing to do with
your home's heating, such as shower
grates, hot plates, or welcome mats.
Let's start with the wall plates.

Pleasingplates -23/4"

Theseplateswork for light switchesand


receptacleswith the same rectangular thick s/tax2Vqx12"
shape(sometimesreferredto as "decora- and5V+"long.
tor" or "designer" switchesand recepta- The width of the
cles). We show all of the plans you'll stock depends on how
needfor one-,two- or three-gangelectri- many receptaclesor switchesare
cal boxes.If you havean outletwith four covered by the plate-provided you
or more switchesgangedtogether,you orient the grain vertically on the plate.
easily can extend the dimensionswe One-gang plates should be 23/q"wide, router's subbasemust be large enough
give you for the three-gangplate to pre- two-gang plates 4s/2" wide, and three- to span the openingin theplate template
parethe necessarystockandjigs. gang plates6Vz"wide. If you can't find you'll usein thefollowing steps.
Onceyou make a few simplejigs, you stock wide enoughfor boxes with three- For singleplates,you'll needa router
can churn out plates that or-more switches,or don't subbaseat least 6" in diameter: double
adapt to most any interior want to glue up stock to plates require a subbaseat least 8" in
by changing the wood width, you may want to ori- diameter; and triple plates require a
speciesor varying the edge ent the grain horizontally. L)"-diameter subbase.We made our
treatment. For example, Make two copies of the auxiliary subbasefromt/n" clear acrylic.
we'll show you how to appropriate plate pattern After drilling a hole in its center large
make plates like the one in from the WOOD PAT- enough to fit around the s/s" bushing,
Photo A. That cherry plate TERNSo insert, and apply adhere it to the router's subbasewith
has a chamferededge, but them to the top and bottom double-facedtape.
you also could rout a cove of the plate blank with spray Turn your router upside-down,place
or round-overinstead.And, adhesive.Even if you're not the plate templatepin-side-upon the
by taking the basic proce- making a mission-style router's subbase,and adjust the straight
dure a few steps further, plate, you'll needthe pattern bit so it sticks 3/ta"abovethe template,as
you can produceplatesthat to locate the Vs"screwholes. shownin Photo B.
have a distinctive mission look (more on Now, placethe plate blank pattem-side- Position the plate template on the
that later). down in the basejig and position the basejig, aligning the plate-template
Note: To make wall plates, yott'll need plate holder so it butts againstthe blank. pins with the "1" holes, as shown in
a couple of simple jigs. First, build the The blank should fit snugly, but not so Drawing 2. Clamp the base jig to a
base jig and plate holder shown in tightly that it proveshard to remove. benchtop,androut a3Ao"-deep recessinto
Drawing 1. You'll need to resaw or Dependingon your needs,build one
plane to thickness the s/ta" material. or all of the single-, double-, or
Attach the three thin pieces of the base triple-gang plate template(s) shown in
jig to the 3/a"plywoodwith glue andfin- Drawing 2. Reinforcethe glued template
ish nails. The plate holder is adjustable buttjoints with biscuits,dowels,or pock-
and does not mount permanently to the et screws.
base jig. Put a r/2"straightbit and 7a"bushing
into a handheldrouter.
Begin vrrithblanks, end Note: Dependingon your router and the
with handcrafted plates size of wall plate you make, you may
No matter what size wall plate you needto add an oversizedauxiliary sub-
make, you need stock that's 5/t6" base to your router's base. Your

www.woodonline.com 69
grates& plates
SETUP
PLATE-RECESSING 3/qx3x61/a"
3/qx3x107/8"
17/ta
3/qx3x4th"

3/qx3x23/+" 3/+x3 x23/a"


/+" dowel
1/+"long t/+" holes
t/q" hole
Plateholder
3 / + x 3 x 1 O 7 / a " (Shownin single- 3/cx3x10z/a" e/qx3x41/a"
plateposition)
Plate blank l
(Doubleplateshown)

thebacksideof the plateblank,as shown Build theplate-holetemplaleshown Simply removethe plate blank. (Use the
in Drawing3 and Photo C. Rout around in Drawing4. Replacethe platetem- 2" hole to push the plate out of the base
the inside edges of the template,then plate with the plate-hole template, jig.) Cut a piece of aluminumflashing
cleanout the middle of the recess. aligningits pins with the "1" holes in that fits into the recess.Place the alu-
the basejig. minum pieceinto therecess,andtracethe
Replacethe t/2"straightbit with a t/+" shape of the plate hole onto the alu-
straightbit, and leavethes/s"bushing minum. Cut out the markedhole, staying
in place. Adjust the bit so it cuts com- just outsidethe tracedlines,with a metal-
pletelythroughthe plateblank when you cuttingscrollsawblade.
set the router on top of the plate-hole Apply a coatof epoxyto the recess.
template.SeeDrawing5. roughenup one surfaceof the alu-
Rout aroundthe inside edgesof the minum with 8O-grit sandpaper,and
plate-hole template to produce a adherethe roughenedaluminum surface
switch/receptaclehole, as shown in to the recess.
Photo D. Repeatthis stepwith the plate- Drill t/6+" countersunkholes,
hole templatealignedwith the "2" holes where marked on the paper pat-
for double plates,and the "2" and "3" tern. The countersinksshould be deep
holesfor triple plates. enough to accommodatethe head of a
If you are making mission-style #6xVz"ovalheadelectrical-fixture screw.
wall plates,skip to the next sec- (You'll find thesescrewsavailablewith
tion. If you are not maktngthe mission- heads of various colors such as black,
style wall plates, you're nearly done. white, almond, brown, brass,or bright
zinc.) Removethe paperpatternand any
adhesiveresidue. Rout the edges as
desired,sand,and apply finish.

ROUTINGTHEPLATEREC How to add the mission-


look to the wall plate
Removethe wall-plateblank from the
basejig. Drill a blade-start
hole in the
centerof eachtiny squareon the pattern,
and cut out the squaresusinga scrollsaw,
as shownin PhotoE.

Plateblank

70 WOOD magazine S e p t e m b e r2 0 0 1
s/+x3x10z/a"
'
Triple-gang PLATE.HOLE
TEMPLATE
plate.template
3 / +x 3 x 7 l V t a
3/qx3 x3"
327/sz V +x 3 x 7 1 1 A a "

e/+x3 x61/a"
/+" dowel
3/cx3x3" 1/+" long

Plate-holetemplate Plateholder
(Shownin triple-
plateposition)

Plateblank(Tripteptateshown)
Basejig

With a straight bit and router table, Cut a piece of .025" copper sheet
rout a Vs"rabbet Ve"deeparoundthe that fits into the recesson the back
edge of the plate, where marked on the of the plate.
pattern.See Photo F. Remove the paper Placethe coppersheetinto the recess
patternand any glue residue. (no epoxy), and mark the switch/
receptaclehole with a pencil,asshownin
Photo G. Also mark the middle squarein
eachsetof threesquares.
Removethe coppersheet.Draw diag-
onals to determinethe centersof the
marked squares,and drill %" holes at
their centers.Cut out the switch/recepta-
cle openingsusinga scrollsawandmetal-
cuttingblade.SeePhoto H.
Apply a coat of epoxy to the wall-
plate recess,roughenup one surface
of the copper sheetwith 8O-gritsandpa-
per, and adherethe roughenedsurfaceto
the recess.Sand and apply finish to the
wall plate. Use #6xVq" brass flathead
screws to mount the plates to your
switchesor receptacles.(The flared edge
of the screwheadwill indent the copper
as you tightenthe screw.)

7a"guidebushing
t/a"straightbit ROUTING
THEPLATE
HOTE
setto cut
throughblank Plate-holetemplate

Plate holder

71
plates
tablesaw'sblade and mount it to your
miter gauge,as shownin Drawing7.
Mount a t/q" dado set in your table-
saw, and adjustit for a %"-deepcut.
Position the miter gaugein the left-hand
miter-gaugeslot, and cut a slot through
the auxiliarymiter gaugefence.
Detach the auxiliary fence. and reat-
tach it so the dado set cuts another
V+xVq"slot spacedexactly t/2"to the left
of the original slot (as viewed from the
tablesawoperator'sperspective).
Glue a Vqxv4xl"pin into the slot on
the right, with the pin sticking out the
VIEW
EXPLODED front face of the fence.
Place one edge of your t/)" stock
against the fence, with its right end
againstthe pin. Cut a V+xVa" dadoacross
the width of the stock.Placethe dadoyou
just cut over the pin and cut an identical
dado. Repeat this process as shown in
't/2"rabbel Photo J until you reachthe oppositeend
Rout a
t/t" deepon back outside. of the stock.
edge after -4
Now, cut the strips
that make up the grill
Remove the miter gauge,replace the
dado set with a ripping blade, and set
the rip fence Vq" from the blade. Rip u
piece of scrapstock to Vq"wide and test
the fit of this piece in the dadoesof your
Gremt Srffites /2" stock.Adjust the rip fence until your
Most homesbuilt in the past50 yearsor suit many situations.For example, the testpiecesslip easily-but not sloppily-
so come with somepretty blas6air vents. one in Photo I was designedto emulate into the slots.
The typical metal, louvered variety are old metalgratesin a 1920shome. Rip the dadoed stock into striPs,as
inexpensiveand practical,but they do lit- shownin Photo K.
tle for your home's aestheticappeal. The secret's
Enter these wooden air grills. You can *n the prep work
build several in a single weekend,then Note: To build a grill and sur-
installthem in placeof your hot-airvents rounding frame like the one in
or cold-airreturns. Drawing 6, you'll need two pieces
In this article we'll show you how we of stock (we used red oak):
made the air grill on page 68 - it was .One piec€ of t7t" material for the
featured in the April family-room reno- grill that's at least 1" Ionger and
vation. You can modify these grates to wider than the grill opening.
.One piece of shxlt/t" material
long enough to go around the grill.
Keep in mind that the width and
length of the air opening has to be
in 3/t" increments, so you may need
to adjust the width of the 3/t" mate-
rial to fit your particular
duct opening.
From 3/q"matertal,make
an auxiliary miter gauge
fencethat's 3" wide and
as long as your Vz"
stock. Center the
1/+ x th"
fence on your
guidepin
{qx3x24"
auxiliaryfence
72
ilCUTTINGLAY Usedry-spacedshort strips to align
Cut mark the long strips as you glue the
short strips into place,
startingat one end.

SooK
stock, the length of
the rails equals the width of
the grill plus 2V2".The stiles' length
equalsthe length of the gnll plus 2Vz".

ffi*6-"" p sto"' Use


.the
pegs ano a prece
of scrapwith nvo straight
and parallel edges to frim one
ff Use a tablesawand dado set to cut the
q*Yframe half lap joints, shown on
Drawing 6. Dry-clamp the frame and
check the fit of the grill in the frame.
long edgeof the grill assemblyflush with Trim the grill or the frame as necessary
a long strip, as shown in Photo N. Use for a tight fit.
1) Spacethe cut strips Vz" apartto deter- double-facedtape to help hold the scrap
r'".Jmine how many long strips you'll ff Place the grill on top of a %"-thick
straightedgeonto the grill. \*J spacerjust smaller than the grill in
need for your air grill. Take note of how ,"ftRemove the pegs and straightedge. width and length. Apply glue to the half
many long stripsyou've reserved,and set {-JTrim the grill's oppositelong edgeby lap joints and along the frame edgesthat
them aside. Save the others for cutting holding the just-cut edge against the contact the grill. Assemble the frame
into short strips in the next step. fence.Use a miter gaugeto trim the ends. around the grill by first clamping across
;! Line up the strips edge-to-edgethat
*?
Sand the face sidJ oithe grill (the side
will becomeshort strips. Starting at with continuousshort-stripedges)using
one end of these strips, count over the a random-orbit sander.
number of dadoesthat matchesthe num- Cut the frame pieces from the 3/+"
,,'l
'*'l*
ber of strips you saved for long strips. stock. In the caseof our lV+"-wide
Make cut marks across those strips, as
shown in Drawing 8. Ne
"*"ightedge
aligned by pegs
ffi Align the dadoes on these strips by
u", placing V+xV+"pegs into every sixth and held down
with double-faced
or seventhdado. Crosscut the strips into
tape will help
shorter lengths using a miter gauge, as flush-cut the
shown in Photo L. short-strip
ends.
Let's assemble the grill
lLuy out the long strips,notch-side-up, its width. Removethe spacer,then clamp
I on a flat surface,and spacethem apart each corner to securethe half laps. Add
with a few ungluedshort strips,as shown another clamp across the length of the
in Photo M. Starting at one end of the assembly.SeePhoto O.
long strips, glue the short strips into -f
If necessaryfor mounting purposes,
place, pulling out the dry short strips as i rout a V2" rabbet, V+" deep on the
you go. Use an /s" dowel or paint brush back side of the frame. as shown in
to apply glue to eachnotch. Drawing6a.i
t/xt/x3"
S After the glue dries, cut two Written by Bill Krier with Jim Downing
fl* pegs that fit into the holes in the grill. lllustrations: Roxanne LeMoine; Lorna Johnson
Photographs: Baldwin Photography

www.woodonline.com
73
*,1ouisiana's culture and people are as was a true artist in wood, so from him I
t, diverse-and
sometimesmysterious- did learn abouthand and power tools and
1,,is:v;1,;i..,;,
as gumbo ingredients.Discovered how to use them. But after two years,I
and claimed by the French in 1682, the realized that art alone wasn't fulfilling
Wheth vast area of Mississippi River Valley,
bayous, and coastal plain that became
enough. I wanted to do something that
impactedpeople'sdaily lives, not just the
Louisiana was influenced at times in its lives of those who appreciated art.
Acadian history by the Spanish,then American Eventually,I cameto the conclusionthat
sefflers after the Louisiana Purchasein furniture had the sameartistic quality to it
Greole,G 1803. Between 1760 and 1790, nearly
17,000 French people from Acadia in
as sculpture,but it was utilitarian, too."
Even at that point, though, Greg was
Arcene easternCanadaarrived,driven from their
homesby the British. All the while, trick-
designingfurniture in the rustic style. So
when he left schoolto "deal with the real
furniture les of immigrants from WesternEurope,
and even Haiti, Jamaica, and other
world" as a ca{penter'sapprentice,he set
up a small shop in Lafayette and began
islandsfiltered in to blend a rich heritage. building what he had designed."With my
speaks of a Covington, Louisiana, craftsmanGreg Dad's help, I got a radial-armsaw, a cir-
Arceneaux,50, traceshis ancestryin the cular saw, and a few hand tools; all I
richhistory state to the early 1700s,when long-ago
relatives from French Canadasettledon
needed for rustic furniture." he recalls.
"My first chairs were made from cherry
land grants from the French government. saplings with the bark on-all mortise-
To him, the state's history and culture and-tenonjoinery. Then, becausethere's
aren't as muddled asjambalaya. a tradition in Cajun country of using
"Creolesare descendants of the original 'hide'
seats-stretched rawhide with the
French explorers and French-speaking hair still on-I took thosechairsto an old
Spanish colonists," he explains, "and man to have them done in black and
usually representedthe upper classesin white cowhide."
old New Orleansand SouthLouisianafor Greg's desireto further understandhow
nearly 200 years. Acadians are those furniture was made grew as he worked.
whose French families originated in He learned what he could, where he
English Canada-basically owing their could, and kept on building, buying tools
living to fishing and farming. Now, their
descendantsare what most people refer
to when they say 'Cajun.' Anglos recall
an American-Englishheritage."
' ''' :,
.-
Greg, now known in the state for the
Louisiana-heritagefurniture that comes
out of his five-man workshop,beganhis
woodworking ciueer as an art sfudent. "I
went to Louisiana Statein the early sev-
enties with art in mind," he says."Once
there,I focusedon sculpture.My teacher
Liz, Greg'swife and partner,studiesa
furniturereferencebook at the Creole-
style,cypressdining table.The buffet,
smallchair,and box behindher are all
basedon early Louisianapieces.
really became curious about ture was passeddown also differed a lot
heritage furniture. It was a from what is done today.
time of a cultural rebirth of "Peopleback then didn't want to inher-
the French tradition in it their parents' or grandparents' stuff
Louisiana,"he recalls. "A lot becausethey believed that their spirits
of people in my generation came with it," he recants."I've read and
saw that rich culture being heard about people piling belongingsup
eroded, the very thing that and burning them! Somealsogot stashed
madeLouisianaspecial. in barns. In fact, many of the finest
"My family had been in Creole and Acadian pieces have been
Louisiana for centuries,but I found in barns under a pile of old oil
really hadn't beentruly aware cans. And of course. the weather and
of that wonderful heritage insectstook their toll, too, especiallyin
until then," he continues. southLouisiana."
"And I was, by definition,
really a Creole." , ,: i,:r.:;",;..l!,'l:
l.j.".,ofii:;',i.,". i
r :.l:,;1;;l:i,{lj:,i::r

"It was only in the last 10 yearsor so that


.
\ . , 1 : i I seriously focused on developing this
"Even as a high schoolstudent Louisiana style of furniture," says Greg
I liked antiques," comments "Before then, I was building anything to
Greg. "Yet I didn't see much help me makea living."
old French-style furniture In the late 1980sGreg was instrumental
around-meaning Acadian in forming the Louisiana Furnishings
and Creole. (See sidebar Industry Association. For an annual
Greg freehands cypress through the bandsaw to
rough out a cabriole leg. below, "Acadian and Creole: meeting, the group brought in Thomas
What's the difference?")But I Moser, the Maine designerand furniture-
as needed. Finally, he abandoned his car- have to say that the distinctionsbetween maker renown for his Shaker-inspired
pentry to focus on woodworking. "But I the two are ones that I draw. Historians pieces. Greg and his wife Liz became
was just scraping by making furniture may not have the same conclusions good friends with ThomasMoser, asthey
and doing some millwork, like tapered becauseI don't think the styleshavebeen still are today. "He really helped me
'"Then studiedthat much. focus on what was necessaryto createa
postsfor porches,"he remembers.
I got a job at the naturalhistory museum "Anyway, I wonderedwhereit was," he distinctivefurniture line," saysthe crafts-
in Lafayette as head of exhibits," Greg continues."It turned out that what was man. "I give him credit for helping me
says. "I built the bookcases,library left was mostly in museums,plantations,
tables, display cases, shutters, and did and other historic sites.My theory about
trim work. It endedup being 10 yearsof why there is so little left is that the
really greatexperience." MississippiRiver Valley hasalwaysbeen
From there,Greg went on his own once prone to flooding, and the early French
again,building furniture of his design as settlerslived along the rivers. Therefore
well as commissions."That's when I the furniture suffered.And the wav furni-

Acadianand Greole:

Greg likesto call his pieces"AmericanFrench"


or "Creole-and Acadian-inspired." He explains:"lt's
a distinctstyle. My Creolepieceshave aspectsof
FrenchProvincialfurniture,but not all of the intricate
moldingsand carvings.For instance,I likethe curveof
the cabrioleleg in the Creolepiecesand the senseof
motionthat it creates(see photo right).You get the
feelingthat the piececouldget up and walk away.You
don'tget that out of the angular,moresimpleAcadian
pieces(see photo /efl).They reflectthe rural,agrarian
natureof Acadianlife.Creolepiecesalso usuallyhave
ornamentationin the form of a scallopedapron on an
armoire,table,or case piece,"he pointsout. "There's
this essenceof Old Worlddesign,but the focalpointis
the woodthat was availablein the New World."
develop furniture that has become dis-
tinctive and recognizable. John Thomson,produc-
"I think early l-ouisiana fumiture is a tion manager,cuts tenons
on the shop-builttenoner,
beautiful forrn" and fairly classic," he a benchtoptablesawfitted
adds. '"Vvith its simple lines, it standsup with a split dado set.
well with traditional styles and also
mixes easily with contemporary because
of the simple detail."
For his line of furninre that rangesfrom
$400 for a lamp table to $12,000 for an
armoire, Greg employs many of the sitme
woods thatemly Louisiananswould have
used. In his shop you'll find stacks of
cypress-dense "sinker" stock from
recovered sunken logs; recycled boards
sawn from building timbers; and young,
second-growthwood. Then there's cher-
ry, longleaf pine, walnut, hickory, and
pecan. Some mahogany occasionally
shows up, too. It would have been avail-
able in l8th-century New Orleans
becauseof the city's seaportstature.
Missing are the now noncommercial
woods that would have been put to use. trunl$ 18'in diameter.And what amazes A close look at Greg's furnifure reveals
"Mulberry went into a lot of chairs," me is that they cut them all down-all two of his joinery frademarks,neither of
Greg notes, "and redbay became furni- gone by the emly 1930s.Then the cypress which result from modern power tools.
ture, but you can't find it now. And oak, cutters moved to the Pacific Northwest First, there's the peggedtenon, shown in
although available, was hardly ever used becausethey had the technology to cut the closeup photo above. "The square
back then." big, butfressedfiees. Why, we don't even peg of pecanprovides a mechanicalbond
Greg, however, despite the other wood have some old trees protected in a park to the mortise-and-tenon," he advises.
he hason hand,baseshis furniture line on somewhere so people could see what a "It's a little bit of insurance as well as a
cyprcss. "Here, people arc very taken 1,50Gyear-oldtneelooks like. A big tree decorative element. The customers feel
with cypress," he points out. "At one like that is far more majesticthan any fur- reassuredwhen they seethat peg."
time, the tneeswere huge-150'tall with niture I could ever build." According to Greg, squarepegsalso add
to his furniture's perid look. " On many
Joinery fram of the old pieces,the pegs were square,"
days of old he says,"becausedowels are a compara-
Although Greg shives for tively recent development. I do like
authenticity in his joinery, turned pegs, though, but they take time."
including the much relied on The second trademark is the dovetail.
mortise-and-tenon, it's not "All of our drawers have hand-cut dove-
always feasible."\Me do usebis- tails. They take longer than machined
cuits in edge-joining a tabletop, ones, but they're our signature," Greg
for instance," he admits, "but notes. "And unlike English dovetails,
they're principally for align- which have real fine necks,ours iue more
ment. And why not? I think that like the French. They're large and not as
Chippendalewould have used a refined. In fact, we may use only one on
router had they been available a drawer side."
back then. As a craftsman as Building furniture in a climate known
well as a businessperson, I've forits humidity begsa questionregarding
got to fiy and produce the prod- joinery and wood movement. Greg's
uct in the most efficient way responseis a sfudiedone."It's not unusu-
possible without impinging on al for us to have weeks of 100 percent
its integrity. And I can feel good humidity, and that causes problems
about doing that." because wood's natural tendency is to
absorb moisture when humidity is high,
In his eighties,CharlieBerger
still puts in half days at the and give it off when it's low," he says.
shop. Herehe calculatesa "But as long as we engineerproperly, we
tenon cut on a pecanchair. don't have problems. Yet, if we were to

77
furniture
heritage
Louisiana
glue tops down and glue panelsin place, stantly. You can't stop it. So
we'd have horrible disasters.Instead,we wood checks," Greg points out.
usescrewingstripsand screwtops down. "We try to limit our checking to
But, we rely on a slightly enlargedhole where it would normally occur,
so that the screwcan actually move back such as on the end grain and into
and forth with the wood. The head of the the flat gain. That's where we
screw holds the top in place, but the scribein a check mark."
enlargedhole in the apron allows it to Part of the trick to authentic-
move. Panels,such as on a cabinetdoor, looking distressingis to devel-
are alwaysfloated. op a layered effect, Greg
"We've sentfurniture to placesall over believes, as if it happenedover
the coun0ry that are much drier than the years. "Where we have a
Louisiana,"Greg continues."And no one worn detail, like an edge that
has ever called to say that a top or panel we shavedwith a chisel [seethe
crackeddue to wood movement." photo below leftl, we come
back and bang it with a ham-
tli:.r {.:iI,:r:'A
FiA*f ruE€$.*f:.d,S, *,'qil$,;. mer, like it got nicked years
Much of the furniture that comes out of later. We look at the underneath
Greg's shop looks as old as the pieces areas, too, what would be the
In the finishing room, Tommy Bourg evens out
they're meantto represent.They've been wear points. You want to soften
the aniline dye on an armchair with steel wool.
distressed.And to Greg, the technique the details because with age, The dye gives a rich hue to the wood.
hasbecomean art form. everything gets softer and
"Distressinghas many aspects,and a smoother. But with distressing,you tic. And oil really is pretty foolproof,
right way to do each," he says. "First, don't want to overdo it, either. You especially when you can have high
there'sinsectdamage-powder postbee- leave some sharp,machinededges,but humidity like we do.
they have to be where the piece would "When it's 100percenthumidity,andit
have been protected." frequently is in summer," he adds,"you
can't spray lacquer without getting a
f t . * * Y , l : ; * l ; . ; : i ? $ ' , ; i . # ' ; . i d i t , 1, r ; ' i blush. Oil is a much slower finishing
In Greg's shop, staining involves aniline process,of course,but it's consistent."
dye, as well as water-based and oil-based Greg generallyfigures on three to five
stains, whatever suits the end result. A coatsof oil, rubbedin betweenas need-
favorite there,though,is Minwax Special ed with #0000 steelwool. "Then we top
Walnut. "We use that for what I call our off the finish with a coat of pastewax to
'Tidewater' finish," he explains. "But give it a satinyfeel," he says."We exper-
whatever stain we put on, it never goes imentedwith a lot of wixes; oneswith a
directly on the raw, sandedwood. We lot of beeswaxwon't work aroundhere.
first put on a sealercoat of the final fin- The hot climate softensit, and it darkens
ish, Deft Danish Oil. That gives a whole with the humidity. A wax with a high
lot more control with how the stain is carnaubacontentworks better.It's much
absorbed.Cypress, for instance, won't harder and has a higher melting point"
get blotchy." and to me it provides a smootherfinish.
With other hardwoods,the story's a bit Generally, we use Treewax. But to
different. "After final sanding with220- accent distressing,we'll go to a darker
grit we go over the piece with a damp tinted wax. It works nicely to fill in the
cloth to raise the grain, then sand it and cracks, corners, and the distressingto
With a chisel,Gregshavesoff small sealit before staining," saysGreg. give the piece the antique character
areasof a cypresstable'smachined
edge.Finished,it will look centuriesold. In order to "preservethe characterof the we're looking for."l
wood" Greg prefers a penetrating finish,
Written by Peter J. Stephano
tles, mainly, and in the South,termites." suchasDeft DanishOil. "It doesn'tmake Photographs: Michael Taranova;
For tell-talebeetlemarks,Greg goesafter the wood look as if it's coatedwith plas- Baldwin Photography
the wood with an awl or ice pick to emu-
late exit holes, 'Just a few here and
'*,fl : 'f"#,q".$
there." To portray once-activetermites, ,.:'i:,::rl,: ,r, 1:i,,r,u,'f'*1if.:*fl'ij":t

he twists a piece of wire and poundsits For a brochurewith line drawingsof Greg'sfurniture,send a business-size SASE
impressioninto the surface,then tops it to: Greg ArceneauxCabinetmakers,67230 lndustry Lane, Covington,LA 70433.
off with an awl hole. Greg holds monthlyweekendworkshopsfor a cost of $250 per student. He also
"Wood also shrinks and swells con- furnitureplans, kits, and traditionalwoods, such as cypress.
offers Louisiana-style
For details,phone504/893-8782, or e-mailGregarceneaux@aol.com.

78 WOOD magazine August 2001


These
roductsthat
woodworking passed
wares ourshop-tested
erform
trials

Pgerless pngssure i However,


instead
oftherypical
125psi difference I found is that the Crafuman
from I 10 volts i
top-enapressure, thistwo-stage
model model comeswith pneumatictires.
! squashestheair twice,up to a maximum -TestedbyDaveHenderwn
To deliver the volume of air neededto i of 175psi.It's like packing60gallonsof
drive pneumatictools, suchas dual-action air into a 25-gallon tank. Make this draft
(random-orbit)sandersand spray guns, That factor alone allows you to run compulsory
you needa large-tank,high-voltage,two- high-demandtools longer than a same- The battle againstworkshop dust contin-
stageair compressor,right? That usedto sized,single-stageunit. But Porter-Cable ueson many fronts. We deploy shop
engineersalso set the cut-in pres- vacuumsfor small tools, dust collectors
sure (the pressureat which the for large tools, and air-filration units to
compressorbeginsrefilling the prevent airborne attacks.Now the folks at
tank) at 145 psi-far higher than Delta have infroducedanotherweapon:
the 90 psi required by most pneu- the 50-880DowndraftTable.
matic tools. The model I testedproffersa24x24"
I ran a dual-actionsanderfor work surface,surroundedon three sides
more than sevenminutesbefore by a removablecurtain that helps confine
this compressorcould no longer the dust to the suctionablearea.As cur-
provide the 90 psi to operatethe tains, though, they look more like vertical
sander.Even simply dumping air blinds.And that's a good thing, becauseI
out of the tank through my blow
gun took 10 minutesbefore the
compressorstarved.According to
the manufacfurer'sspecsheet,
the CPFC2TV3525VPdelivers
5.1 cubic feet of' ait p". minute
(cfrn) at 90 psi.
Performanceissuesaside,I also
was pleasantlysurprisedat how
quiet the compressoris. Standing
right next to the motor, I record-
eAa70 decibel(db) reading,and
at 10'away the level droppedto
65 db. (A typical shop vacuum
runs in the 8f85 db range.)
The upright tank on this model Delta58-880Downdraft
Table
Porter-Cable Jetstream Compressor doesn'ttakeup a lot of floor Performance *****
Performance ***** spacein the shop,and the large
wheels make it easyto move *****
vatue ***** CallDelta
at800/438-2486,
about for thosehome-enhancing orontheIntemet,
CallPorter-Cable
at800/487-8665,
orontheIntemet,
visit visitwww.deltamachinery.com
www.portercable.com. projectson my honey-dolist. I
can plug it in almost anywherein found I could move oversizedworkpieces
be the case,but Porter-Cable'sJetsfream the house,and the oil-free designmeans through the hanging srips and still contain
line of two-stage,oil-free compressors never having to say, "I'm sorry, I dripped the sandingdust to the tabletop.
requiresonly a 15-amp,1lO-volt circuit to oil on the carpet." To seehow well this stationarymachine
do thejob. You'll find similarly appointedhigh- works, I sandeda variety of project parts
The CPFCZTV3l2lVP model I tested pressweair compressorssold under the using both random-orbit and belt
stores25 gallonsof compressedair. Craftsmannameat Searsstores.The onlv
Continued on page 82

www.woodonline.com
81
productsthat perform

sanders-two tools with notoriouslyinef- belVdiscsander.it clearedthe air aboutas


fectivedustcollection.I wasimpressed well asa ceiling-hungunit.
with the suctiondisplayedby this That helpsjustify the $499 price tag on
machine,asI couldfeel air breezing the 50-880.If you subtractthe costof an
acrossmy handsas I worked. air-filtration unit from that price, you
Rubbergrommetsrimming someof the could figureyou're only spending
holeson the DowndraftTable'swork sur- $250-300for the downdraftfunction.If
facepreventedmarring on the workpieces. you routinely work largerpieces,Delta
They alsognppedmy workpiecewell alsomakesa biggerversion,the 50-855,
enoughto eliminatethe needfor addition- with a 36" squarework surfaceand l-hp
al holddowns,evenwhenusingthe belt motor that sellsfor $690.
sander.And, at 33" high,the working -Tested by RichBright
heightwasjust right when sittingon my
tall shopstool,but a tad bit low for use No more rrthree
while standing. (I'm 6'tall.) ticks past T2r1..."
Deltasuggests that the 50-880 A coupleof yearsago in a diner, I over-
DowndraftTable alsocan be usedas an hearda bunchof veteranconstruction
ambientair filter when you're not doing workerslamentinghow the new guys 25' Tape
EasyPoint
tabletopwork. Its t/z-hp.motor-about couldn't look at a measuringtapeand tell Pedormance ****
5/s"from r%e".Ratherthandefendthe Price $s
twice what you'll find on a typicalceiling- Value *****
hung air-filtration unit-seems twice as rookies(I'm guilty, too, of usingdimen-
orvisit
CallU.S.Tapeat800/472-8273,
loud,too. But whenI usedit while run- sionssuchas "17 andthreeticks pasta www.ustaoe.com.
ning my spindlesanderand stationery half "), I held my tongue.But whenI saw Continued on page 84

WOOD magazine August 2001

\
=Et Econ-Abrasives
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50/pk 100/pk 1 X 3 O $ . 8 1 e a 3X24 $.93 ea
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80D $16.42 $29.26C 1X44 .81ea 4YC1314 1.06 ea
100thru 150C $15.26 $26.95C 2112X16 .85ea 4X24 1.1Oea
F I N I S H I NP GA P E R 3X18 .86ea 4X36 1.35 ea
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100 thru 2804 $10.50 $17.58C 3X23314 .93ea O€9 6.24 ea
OTHER SIZES ON RESUEST
NO LOAD PAPEB(white)
HEAVYDUTYSPRINGCLAMPS
100 thru 400A $12.90 $22.40C
amps come w/PVGtips and grips.
"C' : 100 SHEETS Size Price
V e l c r o @V a c u u m D i s c s 4' $1.75ea
Hole pattern tor BqqehSsndelg 6' 2.25
8u 3.50
T#ffi"@
5' 80 .46 i'r'in
J U M B OR O U T E RP A D ( 2 4 ' x3 6 ' )
t . Itwillnotallowsmallblocksof wood
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applications. ROUTERPAD
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productsthat perform

the EasyPointtape,I flashedback to that The word "set" is key becausein a 90"
day and thought,"It's abouttime." lock-miterjoint, you usejust one bit to cut
As you can seein the photo on page 82, both sidesof thejoint. That geome0ry
EasyPointtakesall the guessworkout of doesn'twork on a 45ojoint, so thereare
measuring.While thereare otherfraction- two bits in this set:one to cut the tongue
ally markedtapesthat identify down to and the other to cut the mating groove.
%" increments,this productgoesa step I had little difficulty setting up the cut,
further:down to the hard-to-readVtoths. which is designedfor 3/+"stock.After a
At first, I thoughtit would be gimmicky, few trial-and-errorcuts in scrapto center
but I quickly becameenamoredwith how the groove-cuttingbit (shown lying on the
nice it is to actuallyknow the exactmea- routertable in the photo atleft),I milled
surementwithout havingto figure in my stylejoint keepsthe workpiecesproperly one edgeof my eight staves.I then repeat-
head.The 1"x25'nylon-coated tape alignedwithout the hassleof splinesor ed the processwith the tongue-cuttingbit
retractssolidly into its case,and showsthe biscuits.Now, you can get that same and milled the oppositeedge.The pieces
typical markings for studsand trusses. sftengthand stability when gluing up matchedperfectly.
-TestedbyGarry
Smith eight-sidedpieces,with the Sommerfeld Frankly, the occasionto make eight-
22V2"Lock Miter Set. sidedobjectsjust doesn'thappenmuch in
Locate and lock with my shop,so I can't justiff the costfor
a 45o no-slip ioint Sommerfeld22Y2"Lock-Miter Set myself. But, if you want one and need
I've alwaysliked using a lock-miterbit Performance ***** anotherreasonto take the plunge, you also
when making 90ojoints, suchasbox or $130 can usethis setto make sfong edge-to-
****:t
drawercorners.Besidesproviding more edgejoints in flat panels.Q
orvisit
CallCMTat888/268-2487. -TestedbyRichBright
gluing surface,the tongue-and-groove- www.cmtusa.com.

WOOD magazine August 2001


Continued from Talking Back page 12:
DesertDust Bin Pattern

tr r-]
a
\

SIDE
(2 needed)

.o
" hole

WOOD magazine August 2001


finishin touches
Woodworking workshops Preferred
debut at Home DePot pencil
The Home Depot companycalls it The Big Kid's Workshop,and wood
if you're just gettingstartedin woodworkingor want to, it may be The common"lead
perfectfor you. In cooperationwith RidgiGTools,Home Depot (graphite)pencilwas
launchedthe Saturdaywoodworkingclassin September1999at its first made in the earlY
Escondido,California,store. 1800s,and the
The four-weeklong classwas the brainchildof SteveWojtak, a favored wood was
former EscondidoHome Depot employeeand woodworkerwho easternred cedar.
now teacheswoodworkingfor Ridgid Tools. Stevesaysthat the But by the early
responseto the classeswas overwhelming.(At the time of this 1900s,the supPlyof
writing, the storewas kicking off its 14thclass.)"So far, I have largeeasternred
receivedrequestsfor informationfrom 13 other storesthat want cedartrees dwin-
similar programs,"he adds."Home Depot may soonhavethe pro- dled. Pencilmakers
gram operatingin storesnationwide." turnedto incense
At the EscondidoHome Depot,childrenfrom 6-11 yearsof age cedarfrom the
a
o spendSaturdaymomingsin the Kid's Workshop.Teenagersand PacificNorthwest.
F
o
adultstakeover at 12:30pm. "We tried to keepthe classsizeto 10 Eventhoughother
o
E studentsfor safetyreasons,"Stevesays.Becausehe hasmovedon NorthAmerican
I
(I to Ridgid to teachwoodworkingregionally,the programis now and South
E.
run by Hurley Dodd and Dustin Kuhn of Home Depot. Americanspecies
F
o
I In the classes,studentslearnto useRidgid stationaryand bench- have been tried,
(r
top tools and portablepower tools from other manufacturers. incensecedar still
A Home DePot instructor Projectsstartsimply with a birdhouseand get more complexwith is the world
oversees the oPeration of a favorite because
drill press by a woodwork- a displaycabinet.And get this, the workshopsaretotally free of
ing student in a Big Kid's charge.Home Depot absorbsthe cost of materials. of its lightness,
WorkshoP class at the While you're at it, checkoutWOODo magazine'swww.wood- straightgrain,and
Escondido, California,
Home DePot. workingbasics.com Web site.It supplementsthe classesperfectly. even texture.
Makersrip
nine pencilsfrom
Wood collectors convene each piece of
If you get excitedseeinga big batchof different can expectinformativedemonstrations on wood- cedar stock,called
woods,try to makethe InternationalWood working and wood and tree identification.There a slat.Then they're
CollectorsSociety'sannualmeeting(see"Wood alsowill be tradingof wood samples and field shaped,fitted with
trips. For more information,contactEarl graphite,sanded,
Collecting," WOOD magazine,Issue 126,
2000).It's August l5 through19 at Deemer,RD I Box 115,Bolivar,PA15923; painted,labeled,and
September
the Crown AmericanHolidayInn, Johnstown, 7241676-4353; e-mail <edeemer@juno.com>. ferruledforthe eraser.
Pennsylvania. PresidentEarl Deemersaysyou Or visit www.woodcollectors.org.

Plant a tree, then breathe easy


z
U
g, Accordingto the nonprofitorganization, Trees Forever(800/369-1269), a
z
u
- pollutants,
the same
U
maturetree annuallyabsorbs10 poundsof air
= amountemittedby a car driven3,600miles.In fact,scientistshavecalcu-
T
latedthat all of the globe'scarbondioxideis filteredthroughtree leaves
o over a 300-yearperiod.l
T
(L

WOOD magazine August 2001


I-GANGPLATEPATTERN DearReader:As a serviceto you,
we'veincludedfull-sizepatternson this
for flathead screw insertfor irregular-shaped
and intricate
r-stlyepl.ate;
projectparts.Youcan machineall other

t?ATTERN
\
I-l FJ projectpartsusingthe Billof
I lwl
/
| | Materialsand the drawingsaccompa-
rntersunk
holefor nyingthe projectyou'rebuilding.
J screw(all-woodplate) @CopyrightMercdih Corporation,2001. Atl righF resenrpd. Printedin the U.S.A. Mereditr Corp.,the publisherof WOOD PATTERNS@, allors he pur-
cfnser of ftis pattem ins€rt to photocopythese pattems solelybr histtreronnrpersonaluse. Any oher reproductionof these pattems is st 'rictlyprohibited.

PATIOPARTYCENTERsee page34 . JEWELRYBox see page s2


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