Anda di halaman 1dari 104

SSW18-Ad PageIFC 12/14/04 9:08 AM Page IFC2

SSW18-Ad Page 01 12/14/04 10:25 AM Page 1


SSW18-TOC 12/14/04 10:36 AM Page 2

TABLE OF CONTENTS

How-To Magazine for Wood Crafters

ISSUE 18 • January, February, March 2005

PATTERNS

Fantasy and Legends by Judy Peterson


Check out Fox Chapel Publishing’s New Scrolling Title 24
Jesus In Prayer by Santomarco Enzo
An Inspirational Portrait by an Italian Scroller 28
34 Man in the
Moon Mirror

Walt Disney’s Castle by Tom Sevy


SSW Brings You Another of German Scroller Volker Arnold’s Patterns 30
Man in the Moon Mirror by Liz Starnes
An Easy Addition to any Child’s Room 34
Champion Cyclist by Sue Mey
Customize and Scroll this Desk Plaque for any Bicycling Fan 37
Lion Cub Portrait by Sue Mey
A Cute Portrait for an Animal Lover 39
Calico Cat Intarsia by Kathy Wise
Work your Way Through this Intarsia Project Step-By-Step 42
Ultimate Puzzle by Tom Zieg
Stump your Friends with this Easy to Cut
46
but Hard to Assemble Puzzle

Dairy Delight Puzzle by Joanne Lockwood


28 Jesus in
Prayer

A Travel Puzzle for the Little Ones 48


Friendship Quilt by Brenda Herthel
Show your Friends How Much They Mean to you with this
Easy Picture Frame 51
Whitetail Deer & Habitat by Lora S. Irish
A Big Trophy for any Hunter 52
Classic Ford Tractor by Troy Thorne
Scroll a Tractor Right Out of Farming History 58
Slope Sided Box by Jim Stirling
Use Found Wood to Scroll a Trinket Box 60
Sun & Bird Wind Chimes by Paula Wendland
Be the Envy of Your Friends with this Easy to Scroll
Wind Chime Project 64 37 Champion Cyclist

2 Scroll Saw Workshop • Spring 2005 Table of Contents


SSW18-TOC 12/14/04 10:36 AM Page 3

ON THE COVER
Steve Malvolta shares his creations and
techniques for making layered marquetry
16
Layered Marquetry
puzzles in this special 8-page section. Puzzles

Bowling Box by Timothy Lack


Make your League Pals a Keepsake Box 67
The Lord is My Shepard by Jeff Paxton
Scroll the Memorable Passage into a Desktop Decoration 68
Spring Bunnies by Frank Droege
Welcome Spring with this Scroll Saw Segmentation Project 71
Daydreaming Cats by Terry Calway
It will be Love at First Sight for Feline Fans 72
FEATURES

24
Fantasy and
A Legend’s Passing
SSW Pays Tribute to the Late Patrick Speilman 15
Legends Layered Marquetry Puzzles by Steve Malvolta
Stack Cutting Landscapes to Produce Beautiful Puzzles 16
Vasilissa and the White Horseman by Terry Lawrence
Cutting and Painting Different Layers
Creates Unique Effects 41
Scrolled Interiors by Robert Duncan
Brad McFarland’s New Career in Scrolling 54
48 Cow
Puzzle
DEPARTMENTS
Publisher’s Column . . . . . . . . . . . . . . . . . . . . . 4
Letters to the Editor . . . . . . . . . . . . . . . . . . . . 6
Info Exchange . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bragging Page . . . . . . . . . . . . . . . . . . . . . . . 10
News & Notes . . . . . . . . . . . . . . . . . . . . . . . 12
Clip-N-Save . . . . . . . . . . . . . . . . . . . . . . . . . 74
Classifieds . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Advertising Directory . . . . . . . . . . . . . . . . . 78

Publications Mail Agreement #40649125


Return Undeliverable Canadian Addresses to:
Station A , PO Box 54
Windsor, ON N9A 6J5
andria@FoxChapelPublishing.com

Table of Contents Scroll Saw Workshop • Spring 2005 3


SSW18-Publisher's Column 12/14/04 10:37 AM Page 4

PUBLISHER’S COLUMN
Dear Readers, How-To Magazine for Wood Crafters

Our new editorial team at Scroll Saw Workshop has a lot of enthusiasm and is
committed to making each issue better than the last.
I’d like to introduce the main editorial staff at SSW—Administrative SPRING 2005
Manager Shannon Flowers and Associate Editor Bob Duncan. Volume 6, Number 1 (Issue No. 18)
Shannon handles the flow of articles in from contributors through the The “How To” Magazine for Wood Crafters
editing and production processes. She sets deadlines and ensures a good mix Internet: www.ScrollSawer.com
of articles in each issue. Scroll Saw Workshop Magazine
Shannon’s main goal is to get readers more involved in the magazine. You 1970 Broad Street
East Petersburg, PA 17520
know what you like and don’t like, so let us know. If you find a great project Phone: 717-560-4703 • Fax: 717-560-4702
idea we haven’t covered yet, let us know. If you want more projects by a “In the heart of Pennsylvania Dutch country”
specific contributor or in a specific style, let us know. Our Mission:
Shannon, a beginner scroller, has cut out several puzzles—and gave them To promote scrolling as an art form and enjoyable
all away already. For Christmas last year, she got a DeWalt scroll saw, and pastime–for all ages and all skill levels.
really hasn’t had much time to spend scrolling. She did make a house number Publisher . . . . . . . . . . . . . . . . . . . . . . . . . .Alan Giagnocavo
and used her scroll saw to cut around pipes when installing laminate flooring Administrative Manager . . . . . . . . . . . . . . .Shannon Flowers
Associate Editor . . . . . . . . . . . . . . . . . . . . . . . . .Bob Duncan
in her new house. She has taken classes with John Nelson, Barry Gross and Art Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Jon Deck
Ron Posten. Contributing Editors . . . . . . . . . . . . . . . . . . . . .Tony Burns,
Shannon spends a lot of time searching for the highest quality projects to Rick Hutcheson, John A. Nelson, Judy Gale Roberts,
Patrick Spielman and Diana Thompson
offer our readers. When searching, she finds inspiration by those scrollers
Subscription rates in US dollars:
who have elevated their work to art. One year . . . . . . . . . . . . . . . . . . . . . . . . .$19.95
We’ve featured two of these in this issue—Steve Malvolta shares his Two years . . . . . . . . . . . . . . . . . . . . . . .$39.90
layered marquetry puzzle-making techniques, and Brad McFarland showed Canada
off a scrolled home interior project. One year . . . . . . . . . . . . . . . . . . . . . . . .$22.50
Showing these scrolling projects will hopefully stimulate and challenge Two years . . . . . . . . . . . . . . . . . . . . . . .$45.00
you to try something new. The old saying is that you only get better by International
One year . . . . . . . . . . . . . . . . . . . . . . . .$27.95
stretching your abilities. Two years . . . . . . . . . . . . . . . . . . . . . . .$55.90
Bob divides his time between searching for new and interesting scrolling
Customer service for Subscribers
projects, editing articles for publication, and keeping an eye on the SSW Please call toll free 1-888-840-8590,
forum. To find the forum, log on to www.scrollsawer.com and click on the 9 a.m.-5 p.m. Eastern time, or write to us
message board link. If you have any questions, post them—and expect a at our above address.
quick response from some scrolling world experts! Display Advertising/Classifieds
Please call or e-mail Paul McGahren, 717-560-4703 (ext. 42)
Bob sees scroll sawing as a hobby for almost everyone. A self-taught for rates and/or a media kit.
woodcarver and woodworker, scrolling was new for him. After working his McGahren@FoxChapelPublishing.com
way through several scrolling projects from John Nelson’s Scroll Saw Wholesale/Distribution
Workbook—all proudly displayed in his office—he gained an appreciation for Scroll Saw Workshop is available to retailers
the art. Now he is working on a black cherry love spoon. That way, if he for resale on advantageous terms.
Contact Paul McGahren (ext. 42) for details.
messes up scrolling, he should be able to fix it with his carving tools!
Identification Statement: Scroll Saw Workshop vol.6, no.1 (Spring 2005)
In the future, we want to keep bringing readers the best of the best when (ISSN#1532-5091) is published four times a year in the months of January,
it comes to projects, tips, techniques and ideas. In addition to motivating you April, July & October by Fox Chapel Publishing Co. Inc., 1970 Broad Street,
East Petersburg, PA 17520. Periodical Postage paid at East Petersburg, PA and
to try new projects, we want to show you that scrolling is not only a valid art additional mailing offices. POSTMASTER: Send address changes to
itself, but is a great way to embellish or detail other work. Scroll Saw Workshop, 1970 Broad Street, East Petersburg, PA 17520.
We are adding these new projects to our regular mix of classic scroll saw Newsstand Circulation Consultant
portraits, “Woodimal” puzzles, fretwork and compound cutting projects. So Howard White & Associates
(508) 984-5085
expect to see all the projects you love and some new great ones to tickle your
Domestic Newsstand Distribution
creative side. Curtis Circulation Company
730 River Road, New Milford, NJ 07646
Tel: (201) 634-7400 Fax: (201) 634-7499
© 2005 by Fox Chapel Publishing Co. Inc.
All Rights Reserved. Printed in USA
Alan Giagnocavo, Publisher Note To Professional Copying Services
The publisher grants you permission to make up to
P.S. The scrolling world owes a great debt of gratitude to Patrick Spielman, ten copies for any purchaser of this magazine who
states the copies are for personal use.
who passed away October 27, 2004. Pat’s writing and research on scrolling
was responsible for bringing many into the hobby For more see page 15.

4 Scroll Saw Workshop • Spring 2005 Publisher’s Column


SSW18-Ad Page 05 12/14/04 10:29 AM Page 5
Letters-SSW18.qxd 12/14/04 10:37 AM Page 6

LETTERS TO THE EDITOR


Inspired You will end up with a smoother and warranty service center was less than six
by Gary burr free cut and you will also end up miles from Mr. Sprague’s home. Always call
Browning with a perfect mat board pattern! ahead to verify a part or needed services
I enjoy your magazine and wanted to Rudy Yakovich are available before shipping a product or
show off a couple of original projects I Rock Springs, Wyoming traveling such locations. To find a service
have completed. The projects were center in your area, call 888-848-5175.
completed using Gary Browning’s Editor’s Note: In Issue #16, on page 42, we
techniques. published the pattern in blue instead of Praise for Volker Arnold
The toughest part of the project is black because the author, Tom Mullane, Volker Arnold’s lichterbogen and
locating and picking the photograph said he can see blue lines better against a pedestal and Neuschwanstein Castle
that has enough general interest to make black saw blade. We decided to continue to (featured in SSW Issue # 17) are
it worthwhile turning into a pattern. print the patterns in black so it will be absolutely gorgeous. Please let me know
Email from Robert Florczyk easier to photocopy. how I may purchase these two patterns
We also contacted our local Staples plus any more that are available.
More on pattern color office supply store. Experts there said you Thank you for doing a feature on him
To start printing your patterns in blue can bring in a pattern with black lines and and his daughter Lisa.
would do a tremendous disservice to they can make the lines whatever color Fred Schossow
your readers. The one color that copiers you want when they photocopy it! Leonard, North Dakota
(not color copiers) are least sensitive to
is BLUE. So, should you decide to “help” Finding a Service Center Editor’s Note: We planned on featuring
us by printing patterns in light blue, we My question is where is the nearest more of Volker’s work before we got your
would incur higher copying costs authorized service dealer close to me for letter, Fred. You’ll see in this issue a pattern
because we’d have to use color copiers. my Q3 Delta? for his Neuschwanstein Castle, which
At my Staples, color copies are about Roger D. Sprague we’ve called the Walt Disney Castle.
$0.89 each; black and white are $0.06. Falconer, New York Patterns for Volker’s Lichterbogen and the
Bob Bocock Pedestal have just become available
Murrieta, California Editor’s Note: Companies such as Delta through Tom Sevy at sevy99@mstar2.net
have websites providing locations of or at 801-264-9748. For more of Volker’s
First, I’d like to comment on the black service centers. A Delta authorized patterns, go to www.va-holzkunst.de.
line patterns. I cut a lot of patterns for
years with black line patterns. I thought
they were fine, until I got my first
Set it Straight
pattern in red—NO COMPARISON. Its
SAW EXPO, not Scrollabration
easier to follow the red line and it’s easier In SSW Issue # 17 (Holiday Issue) the
on the eyes. story about German scroller Volker Arnold
Next, I’d like to comment on your incorrectly said Volker was attending the
article on stack cutting. People seem to 11th Annual Scrollabration. Correctly, the
have a lot of problems with wood event was the 4th Biannual Scrollsaw Not a Tank
moving. Forget the tape and use Association of the World EXPO I recently retired from the Idaho Army
finishing nails the size that you would conference, which was sponsored, National Guard and have to comment on
need to go through all the wood you are financed and organized by SAW and its the Army “Tank” project. The weapon
members. shown in the article is an artillery piece,
stacking. Place the nails in as many of
not a tank. I believe it is a Howitzer, but
the waste areas as you feel you need. Cut don’t know much more than that. I made
those areas out last until you get to the Wrong dimensions in
church project the project, but substituted an M1-A1
last one. Then you can use tape to secure Abrams Tank. I found a picture on the web
In the pullout pattern for the steeple of
the pieces while you cut the last nailed the country church music box in SSW and cut where needed to show detail.
areas out. Just make sure the nails don’t Issue # 17 (Holiday Issue), there was an I have a hunch you have heard from
stick down through the bottom board incorrect dimension for the hole drilled more than a few of us that the weapon in
and catch on the table. up through the steeple. Correctly, you the picture is not a tank.
I also sandwich mat board between should drill a 1"-diameter hole 19⁄32" up Andrew Movius
the layers of wood while stack cutting. into the steeple Boise, Idaho

6 Scroll Saw Workshop • Spring 2005 Letters to the Editor


Coming Features-SSW18 12/14/04 10:37 AM Page 7

In the Next Issue of COMING FEATURES


Scroll Saw Workshop… INTARSIA HORSE
By Kathy Wise

SCROLLSAW
DOVETAILS WOODIMAL LION
By Jim Sweet
By Gary MacKay

Don’t miss a single issue.


ORDER YOUR SUBSCRIPTION TODAY!
888-840-8590 or www.scrollsawer.com

Check Out Our Upgraded Website!


www.ScrollSawer.com Go
Your online resource for everything from tips and
techniques, to events throughout the scrolling
community, to the world’s largest selection of scroll
saw books. Here’s a small sampling of what you’ll find:

• What’s New: see what’s in our latest issue of Scroll Saw


Workshop Magazine, or even our back issues! Check out our
latest new scrolling books, or take advantage of special
promotions such as our free issue offer!
• Resources: In this section you’ll find editor tips, contests, other
great sites and much more!
• Book Catalog: one of the largest and best on-line resources
for scroll saw and general woodworking books. You’ll find just
the book you need-whether you’re a beginner or a seasoned
woodworker.
• Subscribe/Renew: use this secure, convenient on-line section
to pay for your subscription, check your account status, order
a gift subscription and much more!

and Website
Your How-To Magazine for Wood Crafters
>

Scroll Saw Workshop • Spring 2005 7


Info Exchange-SSW18.qxd 12/14/04 10:37 AM Page 8

INFO EXCHANGE
Questions, Ideas and
Tips from SSW Readers

Rubber Glove Solution


I have very dry hands to begin with.
While scrolling, you naturally have a
tendency to break a blade or two. In the
process of concentrating on what you
are doing, your first reaction is to jerk
or twist away from the blade breaking,
which in turn could be critical to the
piece your working on, especially if it’s
an intricate piece.
I’ve found that with surgical gloves
(with a snug but not too tight fit) that
you are able to control the piece you
are working on better. Your hands don’t
have a chance to slip as much,
especially if your hands are dry to begin
with. Not only do the gloves protect
your hands from the broken blade, but
could also prevent a splinter from
rough wood. Instead of trying to feed the blade up through a large fretwork project from the bottom,
Bob Dixon feed it down from the top.

Lemon Grove, California


bending) I stuck the blade into a hole Cutting Curvy Lines
Fret Sawing and realized it looked like the mast of All beginning scrollers have trouble
I was recently commissioned to create a sailboat. following a line. Two contributers to the
a large (36" x 12") sign for a fellow I sailed the blade into the upper SSW message board passed on these
crafter. I soon realized that I needed blade clamp and pushed it down tips:
three hands to hold the board, tighten through the hole in the table.
the blade holders and align the work. Surprisingly the blade was aligned Plain Ol Ed said “A little something
Since the board was so large I directly in front of the bottom clamp. that sometimes helps when cutting
needed to use a spiral blade and keep After tightening the two clamps and curvy lines (and straight ones also)—
the board oriented in a single direction. applying tension I was happily on my don’t look straight at the line and blade.
When sawing fretwork I usually use the way. No more lifting the upper arm, Look at it from off to the side a wee bit.
“standard” method of leaving the trying to find the hole on the bottom of For some reason, it seems to help.”
bottom blade holder attached, the board, or bending the blade!
loosening the upper blade holder, For really thin wood the old M.D. Allen Sr. added “look ahead of
raising the upper arm, tilting the board, method still works the best but top the blade, not at the point the blade
and inserting the blade into a hole on down has saved many blades for me. enters the wood.”
the bottom of the board. This was not
fun with such a large board. As I was Bob Stachon
getting ready to put in a new blade Bay Mountain Crafters
(after breaking quite a few with all the Griswold, CT

Best Tip Wins Starting with the next issue of Scroll Saw Workshop, who ever provides the best tip will win. SSW will
award a $25 Fox Chapel Publishing gift certificate to the reader who presents the best tip to be published in Info Exchange.
So write in and help others with your tried and true ways to keep “making sawdust!” Send tips to Info Exchange, Scroll Saw
Workshop, 1970 Broad Street, East Petersburg, PA 17520 or editors@scrollsawer.com.

8 Scroll Saw Workshop • Spring 2005 Info Exchange


www.woodcarvingillustrated.com 9
Bragging Page-SSW18.qxd 12/14/04 10:55 AM Page 10

BRAGGING PAGE

Scrolled Keepsake Boxes


By Raymond Jones, Tulsa, OK

Raymond created both of these boxes out of solid mahogany.


Both had their roots in the late Patrick Speilman’s award
winning design books. The box to the left is made up of 72
pieces. It was finished with a gloss clear lacquer finish. The
box to the right was based on Speilman’s designs, but
Raymond embellished the outside with a few of his own
designs. It was made of 25 pieces and finished with the clear
lacquer. Raymond has been scrolling since he retired in 1984.

Light of the World


By Ted Hawkins, Kima, Australia

Ted was nice enough to share his award winning fretwork pieces
with us all the way from Australia. This piece won first prize in
the complex fretwork, first prize in the complex class and first
prize in best in exhibition at the First National Exhibition of the
Australian Scroll Saw Network. The piece was designed by Dirk
Boelman. The Jesus portrait and religious overlays were made of
silky oak and quandong. The frame was recycled western red
cedar, Tasmanian oak and pine with a walnut overlay. The
backing was burgundy velvet board and the background was
New Guinea rosewood. For more on scrolling in Australia, see
our summer issue.

Green Tree Frogs


By Claude K. Compton, Nacogdoches, TX

The two frogs were made using the natural colors of aspen,
poplar and western cedar. They measure about 7" x 10" and
were made using an intarsia pattern by Robert Hlavacek. The
frogs won first place in the “artistic” division of the 2004
annual contest in the Woodworkers Club of East Texas,
held in June.

Share Your Latest Work! Send a photo along with 100 words about you and your piece. Please provide a slide or a
professional print from film negative (no color copies). Include your hometown, the name of the pattern maker (if not yourself) and a list
of woods and materials used. Send submissions to Bragging Page, Scroll Saw Workshop, 1970 Broad St., East Petersburg, PA
17520 or email to editors@ScrollSawer.com. Digital images must be high resolution (300 dpi minimum) to be acceptable for
print publication.

10 Scroll Saw Workshop • Spring 2005 Bragging Page


SSW18-Ad Page 11 12/14/04 9:07 AM Page 11

Scroll Saw Workshop • Spring 2005 11


News & Notes1-SSW18.qxd 12/20/04 1:53 PM Page 12

NEWS & NOTES

Gizmos and Gadgets Sanding in the Tightest Places


For scrollers doing fine fretwork,
Scroll Saw Patterns Mitchell’s new abrasive cords make
Cut in Thick Metal? sanding a whole lot easier.
You just never know where you’ll see Mitchell’s new cords take the place of
scrollers work. I was surprised to see the folded strips of sandpaper
some familiar patterns with a twist on a traditionally used to remove the rough
recent visit to my in-laws in the edges or burrs on the inside of delicate
Midwest. “Butch” Utter has an scrolled pieces. The cords range in size
incredible Plasma-arc cutter system that from Number 46 at 0.15" down to
can cut out any scroll saw pattern in Number 66 at 0.012". That way, you
solid metal up to 1⁄4" thick. If you ever have a wide variety of sizes to choose
have a project that requires this type of from.
strength or are just interested in visiting The variety of sizes allows you to
a unique workshop, he’s located west of match the cord size with the kerf of the
Lincoln, 5 miles off Interstate 80. scroll saw blade. Then you can remove
Butch’s Welding, 319 1st Street, Milford, the burrs from even the single blade-
NE 68405, 402-761-3320. width accent lines, such as the eyebrow
SSW Publisher Alan Giagnocavo lines of Judy Peterson’s fantasy and
legend scroll saw puzzles (See Page 24).
The Number 66 abarsive cord is
almost as thin as the fine jewelers blades
Butch Utter uses a
Plasma-arc cutter
used by Steve Malvolta for his layered
system to “scroll” marquetry puzzles (See Page 16). In fact,
out patterns in solid the Number 66 is fine enough to be
metal up to 1⁄4" thick. threaded through the eye of a needle!
While he didn’t use the plans exactly as
designer Paul Church set them up, British The cords are impregnated with
scroller Warren Pickles made his own foot- aluminum oxide, silicon carbide and
powered scroll saw. Church developed and crocus. They come in 50-foot rolls,
sells the plans for a modern version of the
which range in price from $11 to $15.
classic foot-powered machine.
To purchase Mitchell Abrasive cords,
Paul’s design uses PVC pipe, a gear contact your local woodworking supply
selection ratchet from a bicycle wheel, store.
and a couple maple boards for the arms.
“The plans (and the one I made)
show the frame being made of PVC pipe,
but you could easily adapt it to be
Foot Action Scroll Saw Plans made out of metal or wood,” Paul said.
When the power goes out, most scrollers Above, you can see a wood adaptation of
pack up their tools. But hardcore Paul’s design.
workers (or those under a tight “I constructed mine using a drill
commission deadline) now have another press, drill, simple miter box, and
alternative—a modern foot-powered hacksaw,” he added. “The wood pieces
scroll saw. cut from the maple for the arms on the
Designer Paul Church developed the saw were cut by a friend on his radial
plans for a foot powered scroll saw based arm saw. So you don’t need any
on a ratcheting design by W.F. & John expensive equipment to make this.”
Barnes Co. Paul updated the project The plans, which cost $5.99, are
using modern materials to make the saw Abrasive cords in a variety of widths allow
available only through Paul’s website, scrollers to do fine detail sanding in delicate
as easy to build as possible. www.fallononline.com/footpower/. fretwork and along kerf lines.

12 Scroll Saw Workshop • Spring 2005 News & Notes


SSW18-Ad Page 13 12/14/04 9:07 AM Page 13

NEW!
The Newest Books!
The Best Patterns!
Order Today for Hot-Off-the-Press Delivery

Fantasy & Legend Puzzles for the Scroll Saw


By Judy and Dave Peterson
Create Unique and Entertaining Puzzles of
Timeless Legendary Creatures.
Dragons and Gargoyles. Unicorns and Mermaids. Griffins and
Hydras. These mythical creatures all come alive in Judy and
Dave Peterson's latest book, Fantasy & Legend Puzzles for the
Scroll Saw. Integrating a lifetime passion for mythology with
their expert scrolling skills, the Peterson's have created a
menagerie of beings in the form of interlocking, upright puzzles.

ISBN # 1-56523-256-9 $14.95 80 pages

Make Your Own Model Scroll Saw Portraits, Woodworker’s Pocket ONLY
4" x 7"
Dinosaurs 2ND EDITION Reference
By Danny A. Downs By Gary Browning By Charlie Self
with Tom Knight
How to Turn Everything a
7 Prehistoric Photographs into Woodworker Needs
Patterns Wooden Keepsakes to Know at a Glance
for the Scroll Saw Learn how to turn a Sized for a shop apron,
favorite photograph into professional and hobby N
EW!
Build fascinating
a wooden replica. With woodworkers will find Available
dinosaur models—like May 1, 2005
those sold in museums the help of a computer or everything they need to
—from plywood. Great for beginners or advanced a copy machine, a photograph can be turned into a know in this handy pocket guide. Chapters include:
scrollers, this book includes scroll saw basics, step- pattern for a strikingly accurate portrait in wood. In wood; joints; shop math; finishing, hand tools, shop
by-step instructions and a full-size pattern for this second edition, Gary Browning includes the set up, sharpening, power tools, tips, safety and a
Tyrannosaurus Rex—plus full-size patterns and trivia newest information on computer-aided design and glossary. Each of the chapters is color coded with a
facts for six other dinosaurs. Each of the 7 patterns pattern mounting materials. There are also several tab with the corresponding pages to help you quickly
produces a three-dimensional, 26" x 40" dinosaur ready-to-use patterns including famous faces like find a particular subject. In addition, the reference
model—or you can scale the pattern to your liking, Marilyn Monroe, John Wayne, Clint Eastwood, is packaged in a spiral binding to lay flat on a
from tabletop to life-size! Princess Diana and Judy Garland. workbench for easy reading while you work.

ISBN: 1-56523-244-5 $14.95 72 pages ISBN: 1-56523-251-8 $14.95 112 pages ISBN: 1-56523-239-9 $14.95 160 pages

Look for all of our latest Fox Chapel titles at your local bookstore and
woodworking retailer OR log on any time to www.FoxChapelPublishing.com!

TELEPHONE FAX ONLINE MAIL SHIPPING


(800) 457-9112 (888) 369-2885 Website: Send your order with Most retail orders shipped within 48 hours via U.S. mail. Allow
www.FoxChapelPublishing.com credit card number, 7-10 business days for delivery. PA residents add 6% sales tax.
Email: sales@FoxChapelPublishing.com check or money order Order Subtotal Shipping
(U.S. Funds only) to: Cost USA CANADA
Fox Chapel Publishing $30 and under $3.50 $5.50
Please mention code ASW018 when ordering. Attn: ASW018 $30.01 to $75 $4.50 $6.50
1970 Broad Street
East Petersburg, Over $75 $5.50 $8.50
PA 17520 Int’l. orders will be billed the actual shipping cost.
All prices in U.S. funds. Prices subject to change without notice.
News & Notes2-SSW18.qxd 12/14/04 10:55 AM Page 14

NEWS & NOTES

Events, Contests & Clubs


Skeeter’s Touching Story
Wins Customized Pattern
from Kathy Wise
Daryl Ertl of Viroqua, Wisconsin, has
won a free, customized intarsia pattern
of his late dog, Skeeter, from Kathy
Wise and Scroll Saw Workshop. Kathy,
who selected Daryl’s entry from ten
finalists forwarded to her by SSW, will Anyone Can Enjoy Scrolling
create for Daryl a pattern valued at $90. Anyone can enjoy scrolling; just ask the
Each entry included a photo of a dog Scrollsaw Association of the World.
and an explanation, in 50 words or less, SAW has put together a new 30
on why their pet should be immortalized minute program complete with video for
in wood. its’ chapters to use as an outreach tool.
“Skeeter’s story touched my heart,” Calling the program the ACES program,
Kathy says. “She was truly a loved it is designed for an average person.
member of her family. I just loved her ACES stands for Anyone Can Enjoy Scrollsaw Association of the World
perky schnauzer expression. It was like Scrolling. SAW says that by the time the developed its ACES program to foster
presenter introduces herself, plays the the creative joys of scrolling.
she was asking me to make her into a
beautiful intarsia work of art for all to 20 minute video and answers questions,
enjoy and remember.” the half hour presentation is over. we can get kicked off and pull in a few
Here’s what Daryl wrote: “Being the “The idea is to let as many people thousand more scrollers.”
runt of the litter with a heart murmur, out there know about the fun and Pat Lupori, another SAW official said
the vet told us that Skeeter would relaxation scrolling can provide,” they have received a good response
not have a long life. For 173⁄4 years, she according to SAW. “It also shows youths about the video from local SAW
shared the joys and sorrows of our a way to spend time at a rewarding chapters.
family. She awoke paralyzed and we hobby. And what better way is there for “We also displayed the tape from the
had to say goodbye. What a difficult and you to get out and enjoy meeting new club booth at the last Chicago wood-
sad day.” people.” working show,” she said. “As a result of
In the video, SAW member Rick that, several other woodworking clubs
Hutcheson takes a novice through all in the area have contacted us about
stages of scrolling; from the history of putting on a program for their members.
scrolling, to choosing a scroll saw and In addition we have been contacted by
even shows a few practice projects and several Boy Scout groups about putting
important techniques. on a program for them.”
As a beginning scroller, I found the The package includes the ACES
video a good introduction to the art. video, a seminar outline on how to use
Rick spent an appropriate amount of the video, a class syllabus for the small
time on the history of scrolling and group settings and even some practice
product selection, but really focused on cutting patterns.
how a person can get started in scrolling. For more information log onto
I think it is a great introduction to www.saw-online.com, or write to:
Kathy Wise created a personalized intarsia
scrolling as a hobby and an art form. SAW ACES Program
pattern for Daryl Ertl based on this image “It’s not really meant to be a training 610 Daisy Lane
of his late dog Skeeter. video,” Rick said. “It’s a program I hope Round Beach, IL 60073

Do you have something to share with SSW readers?


Send your information to News & Notes, Scroll Saw Workshop, 1970 Broad Street, East Petersburg, PA 17520 or email us at
editors@scrollsawer.com.

14 Scroll Saw Workshop • Spring 2005 News & Notes


601-Speilman Article 12/14/04 10:56 AM Page 15

A Legend’s Passing

Patrick Spielman,
scrolling legend and
author of more than 65
woodworking books,
Scrolling World died Oct. 27, 2004.

Mourns Death of
Patrick Spielman

I
n any field, one person stands head and shoulders above the “He was a generous individual who definitely liked people,”
rest. October 27, 2004 was a sad day when the scrolling Jim said. “He was a common, ordinary kind of guy. He would
world lost a great leader. talk to you about virtually any subject, but he loved scrolling.”
Patrick Speilman who was the founder of Home Workshop Jim said that Patrick made a lifelong contribution to
News, the predecessor of Scroll Saw Workshop, died of an appar- promoting scrolling as an art and past time. In fact, SAW
ent heart attack at his home in Fish Creek, WI. He was 68. honored him with its first lifetime membership award for his
A prolific author, who wrote more than 65 woodworking contributions to the scrolling world.
books, Patrick began his first book at age 24. He was working Dale Whisler, the “grandfather” of the scroll saw picnics, said
on two more books at the time of his death. that Patrick’s outspoken nature was a real benefit to the scrolling.
He started writing for Sterling Publishing Co., Inc. in 1978 “I always looked up to him as a leader in the scrolling
when his first book, Making Wood Signs, was published. Two of industry,” Dale said. “I still remember one of the scroll saw
his other books, Scroll Saw Handbook and Router Handbook, picnics where a youngster took him and said ‘Mr. Spielman, can
both went on to sell over 1 million copies. I show you what I did?’ The little fella took him over and showed
Alan Giagnocavo, SSW publisher and president of Fox Chapel him a train he made and a scrolled Maryland state map complete
Publishing, said Patrick will be missed in the scrolling world. with county lines. Pat stood there with tears in his eyes.”
“Pat’s scroll saw creations were leaps and bounds above Charles Nurnberg, president and CEO of Sterling
what other people were producing” he said. “I think he was Publishing Co. also said Patrick will be missed.
responsible for the growth of scrolling as an art. The high “We have been with Pat since the beginning of his
quality of his patterns and excellence as a teacher really raised publishing career, and are devastated by this loss,” Charles
the bar for scrolling worldwide. said. “He was a pioneer in the woodworking books industry
“Pat was also such a positive and encouraging force—I and his talent and passion to create books on the subject was
know the he mentored many scrollers who went on to build hands-down the best in the field.”
their own reputations for high quality work,” Alan added. “He In addition to his wife and often co-author Patricia, he is
will be missed.” survived by a son, Robert, two daughters, Sherri and Sandra;
Fox Chapel Publishing purchased Home Workshop News in and several grandchildren.
early 2000. At the time, Patrick said he wanted to spend more Funeral services and burial were held in Fish Creek.
time working on the creative ends of scrolling and not have the Memorial contributions may be made to the Patrick
business worries. Spielman Memorial Fund c/o Baylake Bank, Attn: Judy Smith,
Jim Barringer, president of the Scroll Saw Association of the P.O. Box 46, Fish Creek, WI 54212.
World said that Patrick will be missed.

A Legend’s Passing Scroll Saw Workshop • Spring 2005 15


583-Layered Marquetry Puzzles 12/14/04 11:08 AM Page 16

LAYERED MARQUETRY
A challenge to create and
a greater challenge to
assemble
By Steve Malavolta
Photography by Pat Berrett

A set of two matched puzzles with interchangeable


pieces. The puzzles are made of contrasting wood,
but cut so you can swap pieces back and forth
between the two.

A three-dimensional free standing


pyramid puzzle. Puzzles such as this
are supported by buttressing outside
or by pegging layers inside.

One of Steve’s more challenging puzzles is


the layered ring puzzle. In addition to having
the layers, the illusion of negative space
makes the puzzles even harder to solve.

16 Scroll Saw Workshop • Spring 2005 Layered Marquetry Puzzles


583-Layered Marquetry Puzzles 12/14/04 11:09 AM Page 17

PUZZLES
Puzzle making philosophy Steve uses his
marquetry techniques
My 26-year interest in woodworking has
to create a landscape
a lot to do with wood itself. I find it to scene puzzle. He uses
be a material that contains workable different woods for
qualities—variations of color, shapability different colors and
and textile qualities when finished—that embellishes the work
compliment the pieces that I make. with sterling silver
and small stones.
My puzzles have evolved over the
years. My earlier pieces were only nicely
colored and figured slabs of wood, cut
into somewhat undefined pieces and
then framed out. Currently I am
incorporating my previous inlay abilities
in a style similar to Intarsia and creating
landscapes, abstracts, and 3D archi-
tectural puzzles.
All of my woods are hand picked for
both consistency of grain, coloration and
figuration. These aspects all lead me, as
This puzzle uses
the designer, into creating the individual Steve’s layering
piece. The inlay work and the piece technique to
cutting is done on a scroll saw with a simulate flames.
jewelers blade.
I have always incorporated function
into my artwork and the puzzles
have become very important to
me because they allow people
to experience not only
visual gratification but
tactile enjoyment as well.
Each puzzle is made
with the intent to be
played, creating both
entertainment and
intellectual challenges.
I take pleasure in
knowing that I have
passed these aspects along
with each piece.
My goal as a woodworker is
to present my puzzles as an
enjoyable, playable, piece of
heirloom quality artwork. I recommend
you practice some of these woodworking
techniques and enjoy the pleasures that
the process of creating and the use of the
finished piece returns to you.

Layered Marquetry Puzzles Scroll Saw Workshop • Spring 2005 17


583-Layered Marquetry Puzzles 12/20/04 2:18 PM Page 18

Using his Challenging Puzzles


layering
One of the concerns I have in creating a
technique,
Steve gives a
puzzle is the challenge. My puzzles range
sense of from single layer entertainment to multi-
movement to layered, complicated sculptural
his puzzles. challenges.
These layers One of the initial challenges comes
really
form the fact that all the pieces are
increase the
difficulty of freehand cut, creating odd and irregular
his puzzles. shaped pieces. The next challenge comes
from the woods I work with—all
naturally colored and finished
hardwoods. Additionally, all pieces are
finished on both sides, so the puzzle
solver needs to determine which is right
side up before deciding where the piece
belongs. There is no flipping all the
cardboard sides down and all the picture
sides up, like you do with the stamped
out picture puzzles. I also cut lobes and
sockets into the frames of the puzzles,
Alternating layers
that way there are no straight edges or
of contrasting definable corner pieces.
woods increases If all of this isn’t enough, many
the beauty and of my style puzzles are layered—a
difficulty of this concept quite unique to my
puzzle.
puzzles. The challenge is
compounded when the various
layers are made of the same wood,
making it possible to assemble part
of a layer in the wrong level of the
frame. Most people only discover
this as they progress further into the
Steve used the puzzle assembly.
marquetry One of my more challenging designs
techniques to create
is a puzzle I called the “Layered Rings.”
a different landscape
scene. It incorporates all the previous

18 Scroll Saw Workshop • Spring 2005 Layered Marquetry Puzzles


583-Layered Marquetry Puzzles 12/14/04 11:09 AM Page 19

Another of Steve’s inlay-style puzzles, this one is also


embellished with sterling silver wire.

challenges plus the illusion of negative


space. The image created is similar to
layers of gears or cogs. Every piece and
all of the frame cuts have lobes and
sockets cut into them, but not every
piece is intended to connect into a
matching cut, thereby further confusing
the matter. This puzzle is recommended
only for the serious puzzler.
I also create one-of-a-kind
and limited edition
sculptural puzzles.
These puzzles are
often architectural
in form, stacking
layers of pieces,
creating three-dimensional
sculptures mounted onto a base
and often housed under a glass
case. These puzzles are frequently The layered rings add to the difficulty
frameless and held together by to these puzzles because it is possible to assemble
one of the rings out of order.
buttressing and/or fixed pegging
from layer to layer.

Layered Marquetry Puzzles Scroll Saw Workshop • Spring 2005 19


583-Layered Marquetry Puzzles 12/20/04 12:45 PM Page 20

Alder backer supports


Steve shares his thin puzzle pieces
Sterling silver wire highlights
dark wood skies
puzzle-making
techniques

A
self-taught woodworker, for the
past 24 years I have been
primarily involved in the
production of hand-cut wooden jigsaw
puzzles. In the beginning of my career I
was making lap dulcimers and guitars
and incorporating a good amount of
inlay on these instruments. With
holiday gift making being a tradition of
mine, I made a stand up serpent puzzle
for my nephew. This seemed to be the Colored
start of a new career and what I stone
sometimes consider an obsession. highlights
dark wood Lobes and sockets Mix and match
skies on each side pieces from stack-
Wood Selection and
increases difficulty cutting various
Preparation
woods
Making my puzzles starts with the wood
selection. I usually use nicely figured,
consistently dense and colorful woods. I
buy most pieces in 4⁄4" to 8⁄4" stock and
re-saw them to approximately 5⁄16" thick. wood I need surfaced. The 5⁄16"-thick density of the wood, teeth-per-inch on
I use the Delta 14" band saw fitted with stock is reduced to 5⁄32"-thick and the blade, and just what kind of control
a height extension, which allows me to finished with 220-grit sandpaper. I need.
re-saw stock up to 12" in height. At the Thickness planers can do the job, but One important feature on a saw that
speed my saw is running, I have found a because of the thinness of the wood, I look for is a quick-change blade setup.
1
⁄2" 4-hook tooth blade to work the best. chipping can occur, especially with the Since most blades last me an average of
Because of the thinness of my denser, figured grains. A backing board only ten minutes, I prefer blade clamps
finished woods, density and tightness of helps in this situation. Alternately, you that tighten by an Allen wrench or a
grain are an important factor. Once cut can purchase pre-finished thinner stock thumbscrew.
into the puzzle pieces, woods with from some wood suppliers. Also, pay attention to your blade
irregular density—such as oak—make tension. A blade that is too tight will
for weak spots. This increases the Tools and Equipment break prematurely. On the other hand,
possibility of breakage. Softer woods and I use a whole shop worth of tools to one that is too loose will give a beveled
checked, or cracked, woods also have create a puzzle from start to finish, but cut, producing pieces that will not slide
breakage problems. the scroll saw is my main tool and the in and out of each other freely. Once you
Once re-sawn, I take the one worth offering some advice on. Most find the proper tension of the blades in
material to a finish sander. I use a 36" reciprocating scroll saws will do the job your saw, pluck them like a guitar string.
dual drum and most manufacturers offer very By remembering these notes for each
sander at my useable and affordable choices. I am size blade you will have the correct
shop, but often currently using the Delta Variable Speed tension for your next blade installation.
rent time on a C Arm model, with some personalized You need to make sure that you keep
54" overhead modifications. I also like many of the the blade in the center when pivoting the
belt sander, parallelogram models. wood through its curvy path. If this is
depending on I find the variable speed adjustment not done you will stress the blade
the amount of to be very helpful since I work from 600 sideways, either beveling the cut or
strokes-per-minute to 1400 strokes-per- breaking the blade.
Re-saw and sand the four pieces of wood
minute, depending on the thickness and
to 5⁄32"-thick.

20 Scroll Saw Workshop • Spring 2005 Layered Marquetry Puzzles


583-Layered Marquetry Puzzles 12/20/04 12:46 PM Page 21

Thin-kerf blades Pnuematic approximately a 3⁄4" border to frame the


makes tighter drum sander bottom, top and side edges.
fitting pieces creates depth Tight-grained wood Be sure to make each section large
in landscapes gives strength to enough to accommodate the landscape
delicate pieces and interior pieces. In this style puzzle,
the sections will go right to the outside
edge so a starting hole will not be
necessary, but on enclosed shapes I use a
#70 drill bit for the starting hole.
Once the design is drawn, cut along
the lines with a 24 tpi blade with a
cutting kerf, or blade width, of .011".
This produces an identical section in
each kind of wood (4 sky sections, 4
Lobes and planets, and 4 mountains). When you
sockets mix and match, you get as many puzzle
extend into blanks as our original stacking of wood,
frame in this case 4.

allowing my landscape sketch to be seen


easily. Place a small dab of quick set
epoxy on each of the four corners and
clamp until dry. This will temporarily
hold the blanks together while you draw
in and make the inlay cuts. Highlight the darker wood used for the
Now draw the landscape. Remember sky scenes using sterling silver wire. Drill
each section of the design will need to be tiny holes and glue the wire in.

Carefully cut along the lines for the cut into pieces, so don’t make these
At this time I often add in highlights.
landscape. sections too small or delicate. Also
Sterling silver wire works great for stars
Layout when drawing the landscape design,
in the darker sky blanks. To do this, drill
Each style puzzle has its own process, remember that you will want to have
but for the most part I work in a manner
very similar to marquetry.
Start by choosing up to four pieces of
differently colored wood and cut them
all to equal length and width. Today I
will focus on setting up for a single layer
landscape puzzle. Once the four pieces
of wood are cut, position them so the
more exciting section of grain is always
in the upper section and facing up. This
will orient them in the sky area of the
inlay drawing.
The next step will be to stack them,
with the lightest colored piece on top,
Using the different cut-out elements, mix and match to make four different puzzles.

Layered Marquetry Puzzles Scroll Saw Workshop • Spring 2005 21


583-Layered Marquetry Puzzles 12/14/04 11:09 AM Page 22

to the puzzle by locking it all to the


Making Delicate Cuts frame.
Since the blades I use are so fine I want to To limit the amount of looseness
eliminate as much stress on the blade as from the kerf of repeated cuts, make sure
possible. One way is to check what I call the that each side of each piece has a lobe
“parallel stroke” of the saw by viewing the
and socket connection. Another useful
blade from the front-the top and bottom
clamping point should be perfectly aligned.
technique that helps with looseness is to
To check it, move the blade to the up position, occasionally join two adjacent pieces to a
then place a flat piece of material on the single side of another piece. Do this
cutting table just against the blade. Slowly every fifth piece or so.
move the blade to the lowest position of it’s
Using a pneumatic drum sander, sand the
edges of the sections of your choice down
stroke; it should not move any further away Lobes and Sockets
to create a relief effect. or closer to your to your placed material. If Lobes and sockets are the mirror images
there is any movement from side to side, this of each other-the negative and positive
holes for two different gauge wire. Then will cause extra friction on the blade, portions of the cuts you make. The lobe
dip the silver wire in super glue before shortening its life. Some older saws have an needs to be a well-defined cut; I relate it
inserting it into the hole and cutting it adjustment for this on the back portion of the to the head and neck area of the human
off. Make sure that it is protruding just a upper frame. Newer saws usually don’t have
body. The neck part needs to be
bit on both top and bottom sides of the any sort of adjustment, so some shimming at
the blade clamps might be necessary.
narrower than the head but still wide
blank. Once the glue is dry you can lay enough to avoid becoming a weak spot.
the blank on a belt sander and smooth This well-defined area of the piece is
the silver down to the surface of the what creates a good locking puzzle
wood. into the edge to approximately half of its piece. The size of the pieces are not too
I also highlight by drilling a cupped thickness. Then finish sand these edges important, but keep in mind that you do
hole with a burring bit just shy of the on a 3" pneumatic drum sander with not want to make them so small or
depth of the wood. Later, I glue a half 220-grit paper. delicate that they will easily brake when
dome stone in the hole for the detail of a being played. My pieces average
moon to the rising wooden planet. Piece Cutting and Finishing approximately 3⁄4" square.
In addition, I do some relief work to After 24 years of practice, planning and Because of the irregular shape of the
the sky and planet at this time. The relief cutting of the puzzles are a spontaneous sections in the designs, freehand piece
sanding adds depth to design. I’ve found exercise for me. I just plan the pieces as cutting is almost mandatory. I find it a
that the best way to accomplish this is to I cut, but as you start, it would be a good lot easier to cut pieces that are not
hold the section at about a 15-degree idea to draw your pieces out ahead of drawn; it relieves the stress of trying to
angle against the idle pulley of a belt time. follow a line. But it has taken many a
sander fitted with a 60-grit belt. Bevel First, draw a pencil line border years of cutting to get me to this point.
approximately 1" in from the outside Now piece cutting is almost a meditative
edges. Anything inside this border state for me. However, as I am cutting,
becomes puzzle pieces. Then switch to a I am planning at least four or more
31-tpi blade with a kerf of .008". This pieces in advance.
finer blade enables you to keep the Until you get to this point I
looseness from the kerf to a minimum. recommend drawing your pieces out to
Because of the thinness of the blade, cut give yourself a guideline to follow. The
single sections at a time. Stack cutting grid system often used in puzzles can be
seems to create too much bevel in the modified to work within the irregular
cut, preventing the pieces from sliding shaped sections. My pieces are cut in a
freely into each from both upper and very traditional style, making sure that
lower directions. As I cut along the line there is at least one lobe and socket on
marking the border of the frame, I will every side. In this manner, each piece
include a lobe or socket for each cut creates a side to an adjoining piece-a
Using a very fine blade, cut out each of adjoining puzzle piece-eliminating process that then just steam rolls
the puzzle pieces leaving a lobe or a straight edge pieces and helping tighten through the whole puzzle.
socket on each side of the piece.

22 Scroll Saw Workshop • Spring 2005 Layered Marquetry Puzzles


583-Layered Marquetry Puzzles 12/14/04 11:09 AM Page 23

Assembly flipping step. I usually


As I cut the puzzle pieces-usually in wait 24 hours between
groups of four to five, I will end up in a each oiling.
dead end. Then I stop the saw and The next oiling will be
transfer them from the saw to a piece of a lightly-applied hand-
newsprint. Puzzle assembly is fun, but rubbed tung oil. Start
when working in the shop, jumbling the with the backside of the
pieces can quickly eat into my profits. pieces and wait an hour or
so before wiping off the
excess. Again, wait 24
hours before sliding the
puzzle pieces into the
already oiled and dry
Sand the puzzle first with a belt sander frame. Then apply tung oil
then with a pneumatic drum sander to to the assembled puzzle and frame. Once
soften the edges. again, wait an hour or so before wiping
off the excess.
Most of my puzzles are backed with After another 24 hours, apply a light
4
⁄4" alder. Cut a piece slightly larger than coat of the “Liquid Watco Satin Wax,”
the puzzle itself. Then glue the frame buffing to a finish after it dries.
sections on to the alder backing using
Tightbond Glue. Once dry, trim and
square the frame using a table saw and
radial arm saw. Then finish sand these
Glue the puzzle frame to whatever board frames on a belt sander and then soften
you are using to back it.
edges on a 6" pneumatic drum sander,
each time working with a finer grit,
Once the puzzle is completely cut,
ending up around 220-grit.
place the frame sections around it and
On the back of each puzzle, I list the
transport it to the sanding table. Hand
woods and sign and date each one, using
sand both the top and back surfaces of
a Foredom Flexshaft with an etching
the puzzle with a rubber sanding block
burr.
fitted with 220 grit paper. Then hand rub
them with 00 steel wool to burnish them
Finishing
to an even a finer finish, making sure
For the first finish, brush on a coat of
that all the burring and pencil marks are
“Watco Natural Oil” and wait until it
removed. To turn the puzzle over, use a
begins to thicken before wiping off the
manila envelope-slide the puzzle off the
excess. Do this to both sides of the pieces Finish the puzzles with several coats of oil
newsprint onto the manila envelope,
using another manila envelope for the finish before waxing it.
then butt it up to the fold, close the
envelope and flip it over. About the Author
Steve Malavolta lives and works in Albuquerque, New
TIPTIPTIPTIPTIPTIP Mexico and travels the country selling his puzzles at
art shows. The puzzles range in price from $50 to
Cleaning off sanded puzzle pieces $3,000. He welcomes personalized and custom
Use compressed air to clean off the puzzle commissions. He also has made available kits
pieces before finishing. To do this, sandwich including pre-finished, cut and sized wood blanks,
the pieces in a wood screened frame. To blades, sterling silver, patterns and instructions for
make a frame, assemble two rectangular many of his designs. Steve can be contacted at:
wood frames and attach window screen to the 1350 Marron Cir NE
frames. After the puzzles are secured by the Albuquerque, NM 87112
screen, use compressed air to blow out any of 505-293-4893 email: Escapader@aol.com
the dust and steel wool remnants.
In-Process Photos by Valerie Gooch

Layered Marquetry Puzzles Scroll Saw Workshop • Spring 2005 23


586-Fantasy & Legend 12/14/04 11:20 AM Page 24

Fantasy & Legend


Scroll Saw
Puzzles
Cutting in This Interlocking Style
Increases These Beauties’ Appeal

By Judy and Dave Peterson

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this pattern for the
personal use of the buyer of this magazine.

24 Scroll Saw Workshop • Spring 2005 Fantasy & Legend Scroll Saw Puzzles
586-Fantasy & Legend 12/14/04 11:20 AM Page 25

This project is among more than 25 in Judy and Judy started cutting the
Dave Peterson’s new book, Fantasy & Legend Scroll fantasy figures because of her
Saw Puzzles, available in February 2005. Mermaid
own interests—she bought her
is made from aspen and stands about 61⁄2" tall.
first copy of Edith Hamilton’s
Mythology when she was ten.
Like any artisan, though,
customer demand drives her
choices. When a customer
asked for a Welsh dragon, she
designed a pattern from a
Welsh flag and liked it so well,
she made it the logo for her
business!
Judy has a personal
preference for cutting on the
right-hand side of the blade, so
all of the patterns in the book,
including Mermaid and
Rearing Unicorn, are set up to
be cut that way.
The book takes you
through cutting out the Welsh
Dragon step-by-step and
includes information on
sanding and finishing
completed puzzles. The patterns are

T
he freestanding unicorn puzzle sits MATERIALS & TOOLS grouped by ease of cutting, from easy to
there on the table at the art show. advanced. Some of the puzzles contain
Materials:
Your want to touch it, but there is • Temporary bond spray adhesive small pieces so any of the patterns can be
something about picking up a puzzle (repositionable) enlarged and probably should be if the
that makes you hesitate, but Judy and • Clear 2" packing tape puzzle is for a child under the age of 3.
Dave Peterson say go ahead—as long as • Sandpaper, 220 grit
In addition to the unicorn and
• Sanding disks
you keep it vertical, and don’t tip it over. mermaid pattern, there are patterns for
• Flat trays
The Petersons are sharing their • Glue box creatures straight from classic Greek
mythological creature puzzle patterns • Metal tray mythology, European folklore and some
and techniques in their new book • Paper towels Chinese dragons included in the book. A
Fantasy & Legend Scroll Saw Puzzles • Plastic bags, gallon resealable few landscape puzzles round out the mix!
from Fox Chapel Publishing. The book • Rubber gloves
Much of the cut line detail in the
• Rubber finger pads
will be available in February 2005 book’s patterns involve cutting in and
• Board of approximate dimensions and
In addition to providing incredible 7
⁄8" to 1" thick backing out of the cut. Among Judy’s tips
patterns for fantastic creatures, such as • Danish oil are two ways to cut a sharp point: make
unicorns, dragons, a mermaid and a • Various stains, if desired a sharp turn if you have the skill or make
griffin, Judy designs the patterns with a turn in the waste wood, assuming there
Tools:
interlocking pieces so they can be picked is waste beyond the point you’re cutting.
• Scroll saw with dust blower
up. She uses hardwoods, such as cherry, • Skip tooth or reverse tooth blades #5, The next issue of Scroll Saw
maple, walnut and aspen in addition to #7 and #9 Workshop will include Judy and Dave’s
the exotic woods redheart, lacewood, • 2" square tips on how to make a living scrolling
and paduk for her puzzles. She prefers • Disk pad
and how to present your scrolled works.
• Drill with variable speed lock
hardwoods because there is less
• Drill stand Order Fantasy & Legend Scroll Saw Puzzles from:
breakout in the dense wood gives a silky, • Flap sander Fox Chapel Publishing
smooth finish when sanded. • Dremel or other rotary power tool 1970 Broad St., East Petersburg, PA 17520
Phone: 800-457-9112 FAX: 888-369-2885
• Dremel bit for grasping sandpaper www.FoxChapelPublishing.com

Fantasy & Legend Scroll Saw Puzzles Scroll Saw Workshop • Spring 2005 25
586-Fantasy & Legend 12/14/04 11:20 AM Page 26

About the Authors


A former teacher and librarian,
Judy Peterson found her niche
in life as a woodworker. A
winner of many design awards,
she sells her puzzles at art and
craft shows around the country.
She also has written two articles
featuring her puzzles for Scroll
Saw Workshop, “Hardwood
Advent Calendar/Nativity
Puzzle,” (Holiday 2004, Issue
#17) most recently. Her
husband, Dave, is a senior
systems analyst for a small mail order company. His
interest in computers, databases and spreadsheets
makes him suited to run the record-keeping side of
Judy’s small business. Add a digital camera, a flair
for writing and a little organizational skill and
out comes a book. Fox Chapel Publishing
published their first book, Dinosaur Puzzles for
the Scroll Saw in August 2002.

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this pattern for
the personal use of the buyer of this magazine.

26 Scroll Saw Workshop • Spring 2005 Fantasy & Legend Scroll Saw Puzzles
586-Fantasy & Legend 12/14/04 11:20 AM Page 27

Rearing Unicorn is made from aspen


and is about 9" tall.

Fantasy & Legend Scroll Saw Puzzles Scroll Saw Workshop • Spring 2005 27
463-Jesus in Prayer 12/14/04 11:21 AM Page 28

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this pattern for
the personal use of the buyer of this magazine.

28 Scroll Saw Workshop • Spring 2005 Jesus in Prayer


463-Jesus in Prayer 12/14/04 11:21 AM Page 29

Jesus
in
Prayer
An Italian Scroller Creates
this Gentle Jesus in Wood

By Santomarco Enzo

S
croll saw portraits are always
popular across the United States,
but this timeless image of Jesus
comes to us all the way from Italy.
Scrolled out of Baltic birch plywood, it
can be framed for all to see.

Step 1: Attaching the pattern. I attach


the pattern to the plywood using temp-
orary bond spray adhesive. You can also
put a piece of carbon paper under the
pattern and trace it onto the plywood.

Step 2: Drilling blade entry holes.


Using the 1⁄16"-diameter bit, drill the
holes you need to cut the inside portrait
details.
Step 6: Accenting the portrait. Attach
Step 3: Cutting out the portrait. I use a
MATERIALS & TOOLS
the black cardboard to the back of the
fret saw frame with a #2 blade. It can project to highlight the image. Then add Materials:
also be done using a scroll saw with a • 1 piece, 1/4" x 8" x 10" Baltic birch
the mat board to the front of the portrait. plywood
blade you are comfortable with. • 1 piece, 8" x 10" black cardboard
• 1 piece, 12" x 14" black mat board
About the Author
Step 4: Sanding the project. Using 220 Santomarco Enzo works as a
• Temporary bond spray adhesive or
carbon paper
grit sandpaper, go over the entire project fireman when he isn’t designing • Clear coat finish spray
to remove any burrs. Be careful around and cutting intarsia or other scroll • Wood glue
the more delicate parts of the fretwork. saw projects. He is interested in
religious and nautical designs. He
Tools:
lives in Talsano, TA, Italy, with his • Sandpaper, 220 grit
Step 5: Applying a protective finish.
wife Nicoletta and their sons Alessandro, 15, and • Drill with 1/16"-diameter bit
Spray the clear coat finishing spray Mattia, 13. He is a member of the Scroll Saw • Fret saw with #2 blade or scroll saw
over the whole project to protect it Association of the World (SAW). He can be blade of choice
from the sun. reached at enzo.santomarco@virgilio.it.

Jesus in Prayer Scroll Saw Workshop • Spring 2005 29


529-Disney Castle.qxd 12/14/04 11:21 AM Page 30

WALT DISNEY ’S CASTLE


Becomes Breathtaking Night Lamp
On a Shelf or in a Window, This Volker Arnold
Design Creates a Magical Mood in Your Home

By Tom Sevy
Design by Volker Arnold

T
he four projects in this article all
feature the image of Germany’s
famous Neuschwanstein Castle.
You might not be able to pronounce the
name, but you’re sure to recognize the
image as it served to inspire Disney’s
Sleeping Beauty Castle.
These projects offer a substantial
challenge to the experienced scroller,
and there is a less intricate pattern, with
fewer interior cuts, for those with less
Figure 1: Night Light Assembly
experience. Also, if you look carefully,
you’ll find some surprises—but I’m not
telling what they are. I know that
scrollers like to modify patterns and like TIPTIPTIPTIPTIPTIP
to come up with creative ways of
displaying them. Attaching patterns
Use packaging tape on the project to help
I have taken these two patterns and simply making an ornament to hang in a
lubricate the blade. You can attach the pattern
developed four different projects, which window using a transparent suction cup,
and then cover the entire pattern with packing
are in the German tradition. The first is or framed on a wall. Then, there are two tape. However, I suggest you cover the wood
window lights. One window light has with the packing tape, and then attach the
Did You Know? the castle front and back. The other pattern to the tape. If you apply the pattern
window light has a castle as the back, directly to the wood, you will usually have
The Story of the
Neuschwanstein Castle
and a “frame” made by eliminating the some of the adhesive residue to remove from
castle from the pattern and keeping only the wood. If you apply the pattern OVER the
When you look at Neuschwanstein Castle,
the details on each of the four edges tape, you can easily remove the tape without
it is easy to see why Walt Disney chose this
castle as the inspiration for the Sleeping of the pattern. You might want to try leaving any residue.
Beauty Castle, which is a central attraction this technique of creating a three-
in all Disney theme parks. Located in the dimensional effect by making a “frame”
German State of Bavaria, the castle was built with other patterns. The fourth project, Cutting the Castle and Frame
by King Ludwig II, between 1869 and 1886.
and my personal favorite, is a night lamp Step 1: Decide the project you want to
The official website (in English) for
Neuschwanstein Castle is: that can be placed on a table or shelf. make. Remember there are two versions
www.neuschwanstein.com/english/index.htm. My night lamp version of this project of the castle pattern, Beginner and
won a Blue Ribbon at the Utah State Fair. Advanced. For the Night Lamp and the

30 Scroll Saw Workshop • Spring 2005 Walt Disney’s Castle


529-Disney Castle.qxd 12/14/04 11:21 AM Page 31

Window Lights projects, use the pattern need. You Additional patterns for
very small drill bit like a #70 to create
in the pull-out pattern section at full can attach Walt Disney Castle on the the blade entry holes. All projects are
size. For the window ornament, reduce the pattern PATTERN PULLOUT backlit, which means the vein lines will
it to the desired size. To hang it on a to the wood be quite prominent. They should be
wall, you will probably want to put it in with a temporay bond spray adhesive, or neatly cut and be an even width for
a frame or attach it to a backer. use clear packaging tape (see TIP). maximum appeal. I highly suggest using
a spiral blade since it will create a wider
Step 2: Prepare for cutting. Photocopy Step 3: Drill 1⁄16"-diameter holes and vein line than a single cut of a regular
the desired pattern in the size that you make the cuts. For the detail lines use a blade.

Walt Disney’s Castle Scroll Saw Workshop • Spring 2005 31


529-Disney Castle.qxd 12/14/04 11:21 AM Page 32

Step 4: Clean up the wood. When the TIPTIPTIPTIPTIPTIP


cuts are completed, sand the back with
220-grit sandpaper to remove most of Choosing wood
Because the pattern can be used to make
the fuzz. Then, touch it up with small
several different projects, read through all of
needle files to make a really nice project.
the instructions to determine if you need to
stack cut the pattern. Select your wood
Step 5: Apply a finish. The traditional accordingly. Use good quality Baltic birch (or
German method is to leave the Baltic Finnish birch) plywood. The many intricate
birch unfinished so that the wood is a details would likely break if you used solid
lighter color. A finish, however, protects wood. Be sure to sand both sides of the wood
the wood. It also strengthens very with 220-grit sandpaper before attaching the
intricate and tiny parts. Any kind of oil pattern.
finish will work well; I prefer boiled
linseed oil diluted with an equal amount
halfway up, and one centered on the top
of paint thinner. Apply any finish
for attaching a hanger. You can use 13⁄4"
AFTER assembly so that the glued joints
lengths of 1⁄4"-diameter dowel or 1" x
will be stronger.
13⁄4" scraps of Baltic birch plywood.
Position all spacers so they are hidden. If
Making a Window Light
using two castle cutouts, make sure the
Two options are offered for making a
flags are facing the same direction and
window light. Version A has two castles
use a right angle to assure that the front
stack cut from the less detailed pattern.
and back pieces align. I found it difficult
One is for the front and one for the back.
to position clamps when gluing the
Version B makes use of a frame for the
spacers, so I used a heavy book as a
front and the more detailed castle for
weight.
the back.
CANDLES IN WINDOWS Step 1: Cut the spacers and light
The light holder for Version A is cut
from 1⁄4" x 13⁄4" square Baltic birch
A German Tradition holder for the version you’re making.
plywood with a 1"-diameter hole in the
Today, you may see candles in windows in Note that Version A has the light
homes and wonder about their significance.
middle. This hole is made with a
mounted vertically, whereas Version B
It seems this custom can be traced back to 1"-diameter Forstner bit or you can cut
has the light mounted horizontally to
16th-century Germany. Around Christmas- it on the scroll saw. Mount the holder
hide it behind the bottom of the frame.
time, families placed lit candles in the horizontally about 1⁄2" above the castle’s
windows to symbolically light the way to archway. Insert the light so the electric
Bethlehem. In modern times, candles in Step 2: Glue the spacers and light
cord is not visible through the archway.
windows light the way for travelers holder. Use seven 3⁄4" spacers to provide
throughout the year and indicate the home The light holder for Version B is 1" x
adequate strength: one in each of the
is a welcome stopover for anyone needing a 13⁄4". It is mounted vertically near the
four corners, one on each side about
place to rest. bottom of the castle and frame so the
bulb will be sideways and in the center.
In both options, the electric cord exits
SPECIAL SOURCES through the bottom of the project. If you
• The light sets are available from National Artcraft Co., 7996 Darrow Rd., use anything other than a “Snap-In” cord
Twinsburg, OH 44087, www.nationalartcraft.com, email set, it will be necessary to design holders
sales@nationalartcraft.com or call 888-937-2723. to accommodate your choice. The most
• Volker Arnold’s wide range of scrolling patterns were included in the 2004 Fall important thing is to keep the bulb and
Catalog from the Wooden Teddy Bear. A CD collection of Volker’s patterns and socket out of view as much as possible.
photos, as well as Volker’s collection of more than 300 paper-cutting patterns
suitable for scrolling are available from Tom Sevy, sevy99@mstar2.net. Many of Step 3: Apply finish and insert the
Volker’s patterns and creations can be seen on his website, www.va-holzkunst.de. light. When the glue on the spacers and
• Spiral blades are available from Mike’s Workshop, PO Box 107, Brandon, SD 57005, light holders is dry, apply any finish that
www.mikesworkshop.com or 605-582-6732 you choose. Then, insert the light and tie
a loop of clear fishing leader or strong

32 Scroll Saw Workshop • Spring 2005 Walt Disney’s Castle


529-Disney Castle.qxd 12/20/04 1:20 PM Page 33

white string around the top-center open. The cord can exit either side of the Step 4: Center the light holder on the
support. Make it long enough to place holder or through the 3⁄8" slot as shown back, and make it flush with the bottom.
the window light in the desired position on the pattern. Attach with Aleene’s Tacky Glue or with
in the window. Put a nail or screw in the screws. The use of screws will allow
top of the window frame to hang your Step 3: Assemble the night lamp. Cut removal of the light holder so you can
window light. four 1⁄4"-diameter dowels 1" long for more easily put the night lamp in a box
spacers and two pieces of any light- for mailing or storage. Use two small
Making a Night Lamp colored wood—I used pine—3⁄4" x 1" x diameter 1" screws. You’ll need to drill
The night lamp requires two frames and 7" for the base. First glue the bases two 1⁄4" holes in the light holder where
one castle. The frames are in front and centered from side to side and flush with indicated on the pattern. These holes are
back, and the castle is in the middle. the bottom. The pieces will be in this to allow you to insert a screw driver to
Stack cut from 1⁄8" Baltic birch plywood order: Plexiglas backer-frame-base- attach the light holder to the base of the
using a #2 skip tooth blade with reverse castle-base-frame (see Figure 1). Clamp Night Lamp. Make sure you first drill
teeth to reduce fuzz. For the “veins” use or weight until the glue is set. Then, glue pilot holes to avoid cracking the
a #1 or #3 spiral blade, preferably with the 1"-long dowel spacers about 1⁄2" Plexiglas with the screws. If a finish is
reverse teeth to reduce tear-out. below the tops of the trees on each side desired, apply to wood parts only when
to hide the spacers. The dowel spacers the glue is dry.
Step 1: Cut the Plexiglas about 1⁄8" are important to reduce the chance of
smaller than the outside of the castle breaking. Step 5: Insert the light, turn it on and
frame using a #5 or #7 blade at a low to enjoy. This project will provide a
medium speed. Leave the paper cover on comforting glow in any bedroom or a
the plastic and also put packing tape or nice highlight in a living room.
masking tape on both sides to reduce the
likelihood of the plastic melting as you MATERIALS & TOOLS
cut it. (See TIP box for hints on cutting Materials: About the Author
plastic.) Attach a copy of the pattern • 1⁄8" or 1⁄4" Baltic birch plywood to size and the Designer
needed for project
with adhesive spray and cut the plastic Tom Sevy is a Licensed Clinical
• 2 each, 3⁄4" x 1" x 7" pine (Night Lamp)
about 1⁄8" smaller than the outside lines. Social Worker who relies on
• 1⁄8" x 81⁄2" x 11" white translucent
Plexiglas (Night Lamp) scrolling for relaxation. He has
DO NOT cut any of the detail. Remove been scrolling for over 12 years,
the tape and pattern. Smooth the edges • 1⁄4" Baltic birch scraps (for Night Lamp
and for window lights but had his first exposure to scrolling at age
with fine sandpaper. Attach to the back • 1⁄4"-diameter dowels or Baltic birch scraps eight (that’s 54 years ago) when he helped his
of one of the frames with Aleene’s Tacky • 2 each, small diameter 1" screws for mother make animal figures for a church
Glue so it doesn’t show on the edges. Use Night Lamp (optional) Christmas fair. Tom enjoys trying new ideas in
• Temporary bond spray adhesive scrolling and also enjoys coming up with new
a heavy book or other weight while the
• Clear packaging tape ways to use patterns. This is Tom’s fourth
glue sets. • Sandpaper, 220 grit contribution to Scroll Saw Workshop magazine.
• Aleene’s Tacky Glue or wood glue
TIPTIPTIPTIPTIPTIP • Watco or boiled linseed oil diluted
50/50 with paint thinner (optional)
Volker Arnold lives in Dresden,
Germany. After being laid off from
Cutting Plastic • Clear fishing leader (6- or 8-pound test) his job as a Design Engineer, he
Heat buildup from the saw cutting the or strong string for hanging ornaments expanded his scrolling and pattern
or nightlights
material can cause plastics to melt. design to the point where it has
• White Snap-in Light set with 7.5-watt
Experiment on a scrap piece of Plexiglas. If bulb, plug and on/off switch #140-634-
become full-time employment for
it melts when you cut, try a #5 and slow the 08, $1.95 each with minimum order of Volker and his daughter. He works many craft
saw speed. five. Other light sets are available, but I fairs, and has a store in Dresden. Volker is very
think this type is ideal for these projects. creative in developing new patterns and
innovative ways to display his patterns. This is
Tools: the third time that Volker’s patterns have been
Step 2: Make the light holder. Cut out • Drill with 1⁄16"-diameter and #70 bits featured in Scroll Saw Workshop.
the pieces for the holder patterns on the • #2/0 reverse tooth blades If you have any questions, send email to the
pattern insert. Cut the hole with a • #1 or #3 spiral reverse tooth blades author, Tom Sevy, sevy99@mstar2.net, or send a
Forstner bit or cut with a scroll saw. • 1"-diameter Forstner bit (optional) letter to Tom Sevy in care of Fox Chapel
• Needle files Publishing, 1970 Broad St., East Petersburg, PA
Assemble the light holder with Aleene’s
17520.
Tacky Glue or wood glue. Leave the ends

Walt Disney’s Castle Scroll Saw Workshop • Spring 2005 33


544-Man In The Moon 12/14/04 11:20 AM Page 34

Man in
Brighten a Child’s Room;
Stack Cut to Make More Than One
Moon
Mirror
THE

By Liz Starnes N
T
he Man in the Moon Mirror is a great baby shower gift. It’s Step 6: Apply a finish. Spray with clear coat finish until the
a terrific, colorful addition to a child’s room. If you want to desired sheen is achieved. Allow each layer of finish to dry
make more than one, stack cut several of the layers, which completely before adding another layer. Avoid spraying the
will reduce the time you’ll need to make multiple presents. area where the Plexiglas layer will be glued. When the finish is
no longer tacky or cool to the touch, you may
Step 1: Drill the entry holes. Make a copy of the pattern, continue constructing the project.
reserving the original for future use. Spray the back of the
pattern copy with temporary bond spray adhesive. If you wait Step 7: Add the Plexiglas layer. Once your finish is complete
a few moments before adhering the pattern to the wood, it will and dry, glue the Plexiglas layer to the back of the project.
usually stick much better. After
Additional patterns for
Man in the Moon Mirror on the
ensuring the pattern is MATERIALS & TOOLS
adequately adhered, drill blade Materials: • Sandpaper, 150-grit
PATTERN PULLOUT
entry holes where necessary. • 1 piece, 1⁄8" thick x 81⁄2" long x • Temporary bond spray
81⁄2" wide mirrored Plexiglas adhesive
for backer
Step 2: Cut the interior. Make all the interior cuts, working • Clear coat finish spray
• 1 piece, 1⁄8" thick x 3" long x 3"
• Wood glue
from the center to the outside. Your last cut should be the outer wide oak for five stars on Man
in the Moon (I prefer the look • Masking tape
edge of the design. Continue working in this manner until all of solid wood, but plywood • Blade wax
pieces are cut. may be substituted, small scrap
pieces may be used.)
Tools:
• 1 piece, 1⁄8" thick x 9" long x
Step 3: Sand all pieces. Using 150-grit sandpaper, sand 8" wide solid walnut for the
• #5 blades
each piece. Man in the Moon overlay • Drill with 1⁄16"-diameter bit
• 1⁄4"- to 1⁄2"- thick x 11" long x • Palm sander
14" wide oak for the clouds • Router with desired edge bit
Step 4: Cut the mirrored Plexiglas backer. Do not remove
the protective film from the Plexiglas until after you complete
your cut. The heat from the blade during cutting can fuse
TIPTIPTIPTIPTIPTIP
Plexiglas back together. Several measures can be taken to avoid
having this happen. Use masking tape to cover the cutting line. Be Cautious With Elements That Won’t Need Finishing
The pattern lines should show through the masking tape. After adhering the pattern for the Plexiglas layer, cut the layer out but
reserve the paper cutaway. Spray the paper pattern cutaway again with
Waxing the blade also can help keep the blade cooler. It may
temporary bond adhesive and adhere it to the back of the project where
be necessary to lightly sand around the edge of the Plexiglas the Plexiglas layer will be glued. Then, you can spray clear coat finish
after the cutting is complete. without worrying that it will over spray into the area where you will
glue the Plexiglas layer. Always be careful when there is an element of
Step 5: Glue the pieces together. Once all the pieces have your project that won’t require finishing. Sometimes the finish on the
been sanded, assemble the project. Following the diagram, glue other pieces will prevent the glue from sticking well or later the glue
the wood pieces where indicated. DO NOT glue the Plexiglas will “pop” away from the wood.
layer at this point. Allow the project to dry.

34 Scroll Saw Workshop • Spring 2005 Man in the Moon Mirror


544-Man In The Moon 12/14/04 11:20 AM Page 35

N N N

Cut by John Martin

About the Author


Liz Starnes began Carolina Scrollworks over
seven years ago. Her latest collection of
woodworking patterns is coming together
slowly but surely as sidekick, Lucy, her
cocker spaniel, waits patiently beside
the drawing table for walk and treat breaks. Liz plans to
resurrect her website, www.carolinascrollworks.com, soon.
You may contact Liz by emailing her at lizcsw@carolina.rr.com.

TIPTIPTIPTIPTIPTIP
A Colorful Alternative
Instead of cutting the mirror frame and inserts out of hardwood and
staining them, cut them out of plywood and paint them to match
the décor of a child's room.

Man in the Moon Mirror Scroll Saw Workshop • Spring 2005 35


544-Man In The Moon 12/14/04 11:20 AM Page 36

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

MAN IN THE MOON OVERLAY


cut from 1/8” contrasting wood

TIPTIPTIPTIPTIPTIP
SPECIAL SOURCES Cutting Tight Corners
Test cutter John Martin has the following advice when cutting the stars
• Mirrored Plexiglas, plywood, hardwood and blades and wavy elements out of the clouds: Saw into the tight corners then
Sloan’s Woodshop, 3453 Callis Road, Lebanon, TN 37090, back out and reverse the cutting direction to provide the sharp corner.
888-615-9663, www.sloanswoodshop.com. Turning into such corners tends to give a rounded effect.

36 Scroll Saw Workshop • Spring 2005 Man in the Moon Mirror


574-Cyclist-Lion Cub 12/14/04 11:34 AM Page 37

Champion Cyclist
Scroll and Personalize for All Cyclist Fans Patterns for
Champion Cycist on the

By Sue Mey PATTERN PULLOUT

I
enjoy watching cycling on television Step 1: Sand the blanks. Using the palm along the grain of the work piece at a
and never miss the ‘Tour De France.’ sander, sand all wood pieces both sides to slight angle.
Having won this race for the sixth 320 grit. This reduces the amount of
year running in 2004, Lance Armstrong is hand sanding to be done after cutting. Step 5: Square the bottom straight
a phenomenal athlete and an inspiration edge of the cyclist. I use a disc sander. If
to many. This is not only a project for Step 2: Photocopy the cyclist pattern you are adding a name to the base, sand
cycling enthusiasts, but also a good seller at 100%. Then attach to the wood, the bottom edge of the 5⁄8" hard wood to
at craft shows and cycling events. using temporary bond spray adhesive. a level edge. Use the 3⁄4" x 10" x 4" piece
of hard wood and square the four edges
TIPTIPTIPTIPTIPTIP Step 3: Drill the blade entry holes. on the disc sander.
First drill with the 1⁄8"- diameter bit.
For simple patterns such as this one, transfer
Carefully drill the holes in the small Step 6: Personalize the cyclist by
the pattern to the work piece by using carbon
paper and a stylus. Keep the pattern in place areas using the 1⁄16"- diameter bit. adding a name. Using ‘Microsoft Word’,
with two small pieces of masking tape. Step 4: Remove the burrs created by type the name you would like to add.
drilling the holes. I use a scraper blade Highlight the text and click on ‘Format’,

Champion Cyclist Scroll Saw Workshop • Spring 2005 37


574-Cyclist-Lion Cub 12/14/04 11:34 AM Page 38

then “Font”. Select a scrollable font—


“Cooper Black” or “Forte” are two
recommended options. Select “bold” and
under “Effects”, select “outline”. The
Scrolling in
font size should be approximately 80,
depending on the quantity of letters in SOUTH
AFRICA
the name. Match the total size of the
letters to the size of the base. Adjust the
character spacing by highlighting two
adjoining letters at a time and clicking on
“Format”, “Font”, “Character spacing”, In some places, scrolling is the main
until all letters are just joining. The first- form of woodworking, in other places,
and last names are cut separately. When such as South Africa, it is almost
you are satisfied with the results, print unheard of. Scrolling represents a very
the name and transfer to the 5⁄8" work small percentage of the woodworking
piece, as described in Step 2. Repeat industry as a whole. There are regional
Steps 3 and 4 for the name.
woodworkers’ associations, where the
membership consists of mainly wood
Step 7: Make the inside cuts of the
cyclist. Using the #7 reverse blade, turners and carpenters, but no official
thread the blade through the blade entry scrolling associations are in existence.
holes and make the inside cuts of the Many carpenters use a low end
cyclist. Slow down the speed of your saw
of this magazine.
pattern for the personal use of the buyer
You may make up to ten copies of this
Note to professional copying services.

Photocopy at 100%
scrollsaw for odd jobs and very few
when cutting the wheels, to ensure
scrollers make a living from their craft;
better control. Then cut the outlines of
the market is just not large enough to
the cyclist. For the name: do the inside
cuts first, then the bottom pieces, and support it. A variety of scrollwork can
lastly the outlines. be found for sale by hobbyists at craft
markets.
Step 8: Remove the patterns. Then sand The best imported scrollsaw
the work pieces by hand with 320-grit,
available in South Africa is the Hegner,
then 500-grit sandpaper to a smooth
which is also my personal saw of
finish. Be careful when sanding the name
pieces, as they are very fragile once cut out. choice. The DeWalt saw is no longer
imported, but I was fortunate to have
Step 9: Round over the corners. I use MATERIALS & TOOLS been asked to put it through its paces
the router with the 1⁄4"- diameter round- Materials:
for a few days. Many low end scroll
over bit to add a decorative edge to the • 3⁄4" x 8" x 6" maple or hardwood of saws are imported from the East.
choice for the cyclist
base. If a router is not available, soften Scrollsaw blades, the better quality
• 3⁄4" x 10" x 4" maple or hardwood of
the edges with 150-grit sandpaper. Sand choice for the base sandpapers and finishes such as
the base by hand with 320-grit, then • 5⁄8" maple or contrasting hardwood of Danish oil, are, of course, also
choice for the name (optional)
500-grit sandpaper. imported items and very expensive.
• Sandpaper, 150, 320 and 500 grits
• Temporary bond spray adhesive
Step 10: Remove all sanding dust. • Wood glue
Most of our indigenous woods are
Then glue the cyclist to the center of the • “Super Glue” or crafter’s glue very hard due to the harsh weather
base with wood glue. Glue the name in • 4 felt pads for bottom of base conditions and therefore not ideal for
place on the base in front of the cyclist. • Clear finish of choice scrolling. Native woods include yellow
Apply finish of choice. Using a small wood, stink wood, iron wood, wild
Tools:
drop of “Super Glue” or crafter’s glue, • #7 Reverse tooth blade olive, red ivory, tambotie and teak in
attach felt pads underneath the base, to • Drill press with 1⁄8"- and 1⁄16"- diameter bits certain regions. Other wood types are
protect the surface of the desk or • Disc sander and palm sander
indigenous to Southern Africa, i.e.
showcase where it will be displayed. • Router with 1⁄4" round-over bit

38 Scroll Saw Workshop • Spring 2005 Champion Cyclist


574-Cyclist-Lion Cub 12/14/04 11:34 AM Page 39

About the Author


Sue Mey lives in
Pretoria, South Africa.
She has been scrolling
for about 10 years and
combines scrolling with
painting and decoupage,
using the techniques to create colorful clocks
and children’s bedroom accessories such as
toy chests, bedside lamps and curtain
tiebacks. She also makes kitchen accessories.
A cat lover, she is pictured here with her
favorite wild cat, a cheetah. Check out her
website for more of her work,
www.geocities.com/meydenhart.

African mahogany and Zimbabwean


teak. Also available are jacaranda and
imbuia, but these trees are not
indigenous to South Africa.
Imported woods can be obtained
from wood merchants at a high
cost—I like to use maple, birch, ash
Lion Cub Portrait
and oak and have been lucky enough Scroll Saw Workshop Brings You This “Roaring”
to work with Brazilian cherry, holly, Project All the Way From South Africa.
purpleheart and zebrawood mailed to
me from the USA.
By Sue Mey
The quality of plywood generally
available to us is also not the best and

T
he lion is one of South Africa’s “Big Step 2: Drill the blade entry holes with
often have voids in between the
5” animals, together with the the 1⁄8"-diameter bit. Carefully drill the
layers, making it less than ideal for
elephant, leopard, buffalo and holes in the small areas using the 1⁄16"-
scrolling. Furthermore, the thinnest rhinoceros. There is nothing more diameter bit. Remove burrs created by
ply available is 1⁄8" and these boards adorable than a baby animal, especially a drilling the holes—use a scraper blade
are only good on one side. I buy lion cub, with its erect ears, huge paws along the grain of the work piece at a
imported Birch ply from a hobbyist and whimpering, snarling little cries for slight angle or sandpaper.
store to produce scrolled book marks food and attention. This project will be
and key ring holders. popular with the young…and the not so Step 3: Cut out the pattern. Using the
young—how can you not love that face? #2 or #3 reverse blade, thread the blade
I draw inspiration from nature through the blade entry holes and cut all
and am never without my digital Step 1: Preparing the wood and the black areas on the pattern. Start with
camera when I travel. Wild animals pattern. Sand the wood before applying the inside areas and finish with the
and pets are my favorite subjects. the pattern, using the palm sander. This straight cuts which form the inside
Sometimes a beautiful piece of wood reduces the amount of hand sanding to frame of the portrait. Slow down the
with interesting grain patterns will be done later as well as the risk of speed of your saw when cutting fragile
inspire a special project like a breaking fragile pieces when sanding parts like the eyes and whiskers and use
keepsake box or hand mirror for a after cutting. Photocopy the pattern at a zero clearance insert to reduce the risk
particular person. 100% and attach to the wood, using of breaking these parts.
temporary bond spray adhesive.

Lion Cub Portrait Scroll Saw Workshop • Spring 2005 39


574-Cyclist-Lion Cub 12/20/04 12:49 PM Page 40

TIPTIPTIPTIPTIPTIP separately and dry-fitted to ensure the MATERIALS & TOOLS


two work pieces line up nicely.
To prevent tear-out underneath when cutting Alternatively, attach the portrait to the Materials:
a portrait, attach some carton paper (an • 1⁄4" x 8" x 10" Baltic birch plywood or
backing with thin double sided tape or plywood of choice
empty breakfast cereal box works well) with hot glue on the four corners before • 3⁄4" x 8" x 10" Baltic birch plywood /
thin double sided tape in a few places. Cover straight-sanding the edges. Detach the plywood of choice or MDF for backing
the carton with packing tape. • Black matting board or flat black
two pieces immediately afterwards, as the spray paint
Use a piece of your cereal box carton to
make a zero clearance insert—drill a small
tape becomes more sticky and difficult to • Sandpaper; assorted grits
blade entry hole in it and tape to your saw remove if you should leave it for a day or • Temporary bond spray adhesive
table with some masking tape. two. Remove all sanding dust. • Wood glue
• Packing tape
• Clear spray varnish
Step 6: Prepare the backing. If MDF is
• Saw tooth hanger
Step 4: Sand the portrait. Remove the used for a backing, spray the front, back • If you are adding a clock to the project,
pattern and sand the work piece front and edges with three thin coats of flat you also need a 13⁄8" clock insert and a
black spray paint, allowing it to dry drill press with a 13⁄8" forstner bit.
and back by hand with a sanding block.
Use 150-grit, 320-grit, then 500-grit completely between coats. If plywood is Tools:
sandpaper to get a smooth finish. Be used for the backing, cut an 8" x 10" • #2 or #3 Reverse tooth blade
careful not to catch and break any fragile piece of black matting board. Apply wood • Drill press or drill with 1⁄8"- and 1⁄16"-
diameter bits
pieces—take special care around the glue to the back of the matting board and • Disc sander, palm sander, sanding block
whiskers. I prefer to use a three-finger place on top of the plywood backing. • Clamps
sized piece of sandpaper without a Working fast, apply wood glue to the
sanding block, as one has more back of the portrait. Only small beads of
sensitivity for the pressure required glue are needed near the edges and on the frame sides. Attach at least two clamps on
when using one’s hand. fragile pieces like the whiskers—too the face of the cub and one on the
much glue will seep out once clamped. whiskers. If glue seepage occurs, wait
Step 5: Square the four edges of both Place the portrait on top of the matting until the glue starts to thicken, before
the portrait and the backing on the disc board and “square up” the stack on a flat removing excess glue in a small area at a
sander. The two pieces can be done surface. Clamp the corners and along the time, using a toothpick. For the MDF
backing, apply the portrait
directly to the painted backing as
described above.

Step 7: Drill the hole for the


clock. Once the glue has dried,
remove clamps. Drill the hole for
the clock insert to the correct
depth, using the drill press and
Forstner bit. Remove any dust.

Step 8: Sealing the portrait.


Apply several thin coats of clear
spray varnish, allowing the project
to dry thoroughly between coats.
Attach the saw tooth hanger and
insert the clock. Now the cub is
able to tell when it is time for it’s
next feed!

Photocopy at 100%
Note to professional copying services.
You may make up to ten copies of this pattern for
the personal use of the buyer of this magazine.

Lion Cub Pattern

40 Scroll Saw Workshop • Spring 2005 Lion Cub Portrait


477 Vasilissa & Horseman.qxd 12/14/04 11:34 AM Page 41

Vasilissa
and the
White
Horseman

Layered
Technique
Produces
Impressive
Results with
Minimal Effort

By Terry Lawrence

S
crollers are constantly on the Russian fairytale Vasilissa and the White
lookout for projects that look Horseman. Biliban's style also makes the
impressive, but don't require project easy to paint. Biliban's painting
hours of commitment or expensive techniques, like most of the other
materials. In this multi-layered project, illustrators of his time, did not use any
Terry Lawrence showed that a shading, and instead relied on flat colors.
spectacular project can be made using Constructed in colorfully painted
inexpensive Medium Density Fiberboard layered pieces, the finished piece is quite
(MDF) and craft paints. showy, but not difficult to recreate.
The piece is based on an early 1900s
illustration by Ivan Biliban of the

Vasilissa and the White Horseman Scroll Saw Workshop • Spring 2005 41
521-Calico Cat Intarsia 12/14/04 11:34 AM Page 42

CALICO CAT
The Cat’s Out of the Bag and On Your Wall for All to Enjoy!

By Kathy Wise and


Phil MacDonald

I
f you’re looking for a purr-fect intarsia project, this calico
or tortoiseshell cat makes a welcome addition to the art
collection of any cat fancier. The different species of wood
used will form the beautiful combination of black-, white- and
rust-colored fur. I used mahogany, black walnut and basswood.
The eyes and nose were cut out of locust wood. The black eye
insert is ebony. You also can customize the pattern for other cat
colors and markings, perhaps
Patterns for even to match your own pet.
Calico Cat on the
PATTERN PULLOUT Side view shows layers on this calico cat intarsia piece.

Step 1 Step 2

Make about ten copies of the pattern. Always keep a master copy Select your wood color. It is very important to pick a good color
to use later. Cut out and group pattern pieces together by color: and grain pattern for each separate intarsia piece. Your finished
Dark, medium, light and so on. Adhere color groups onto legal size calico cat will be much more appealing with careful planning. Pick
paper with glue stick. Copy each set of color-sorted patterns; save wood colors that will be close to a real calico cat’s coloring. Peel
a copy for future use. Tape contact paper flat on a board. Spray and stick the pattern pieces on your selected pieces of wood. The
adhesive on the pattern and contact paper and put together. Cut contact paper will enable you to reposition your pattern piece if
out each paper pattern piece. Contact brand contact paper seems you change your mind on grain direction.
to work better for me than other brands.

42 Scroll Saw Workshop • Spring 2005 Calico Cat Intarsia


521-Calico Cat Intarsia 12/14/04 11:34 AM Page 43

INTARSIA

The cat, which measures 12" x 24"


is made of mahogany, black walnut
and basswood.

Step 3 Step 4

Check your blade angle. Make sure your #5 blade is square to the Cut out your backer board using 1⁄4" plywood. Use a full pattern
saw table. Equally important is having flat wood for a good cut and cut inside of the outside lines about 1⁄16" all the way around.
and fit. Plane any wood that is not perfectly flat. Using a scroll Sand and stain just the edges. Mark your glue side. For this project
saw, cut out all the pieces using 3⁄4"-thick wood. it’s pretty clear which side is the front, but some projects are more
symmetrical and you can easily make a mistake and glue to the
wrong side.

Calico Cat Intarsia Scroll Saw Workshop • Spring 2005 43


521-Calico Cat Intarsia 12/14/04 11:34 AM Page 44

Step 5 Step 6

Lay out all the cut pieces as you get them done on a full pattern To make shaping easier, group body sections together and glue
taped to a work board. Check for fit and make adjustments as with “Super T” glue using an accelerator to set up in ten seconds.
needed. Now is the time to make any wood color or grain This super glue technique is only temporary for sanding and
direction changes if you do not like the overall look. On this shaping large sections and will break apart to sand the inside
project, I decided I did not like the direction of the grain pattern on edges of each piece. See the Tip box.
two pieces. I recut and replaced both. Keep in mind the entire
piece will darken with the finish. It is a good idea to test the color
of your wood before you start to cut. Take a small sample of the Step 8
wood you plan on using and put some gel varnish on it, to see
what your final color will be.

Step 7

Lay out the shaped pieces on a full pattern. Make any final
sanding adjustments. Lay out on backer board to check fit. Any
trimming of overhanging edges can be done with a Dremel
sanding tool after the pieces are glued to the backer board. Then
simply retouch up the bare edges with dark stain.

SPECIAL SOURCES
• Kathy Wise Designs Inc. is happy to present
You can make your intarsia project come alive by carefully shaping the Cat Collection Intarsia Series. Eleven other
your pieces to achieve varying depths. I did most of the shaping cat patterns, including a Siamese, Persian and
and sanding using a pneumatic drum sander. I used an air tool American Shorthaired Tabby, are now available.
with a 1⁄2" sanding band to get the small details and round inside Patterns are $10, plus $2 shipping (in the U.S.A.,
edges that I couldn’t reach with the big drum sander. As you work Sitting Black & $4 in Canada). For a free catalog sheet showing
with the pieces, try to visualize the different levels of a real cat’s White Cat #406 the New Cat Series and other patterns, contact:
body. If you have a cat in the family, take a look over its face, legs
and ears. The careful shaping of the varying levels will give a nice Kathy Wise Designs Inc. • To see Kathy’s Intarsia
3D feel to the finished piece. Don’t be afraid to experiment. You PO Box 60 Catalog and Order
can always recut another piece. Form On-line, go to
Yale, MI 48097
the website,
Fax: 810-387-9044 www.kathywise.com
kathywise@bignet.net
Sitting Siamese #403

44 Scroll Saw Workshop • Spring 2005 Calico Cat Intarsia


521-Calico Cat Intarsia 12/14/04 11:34 AM Page 45

Step 9 Step 10

Apply varnish finish. Using a soft rag, hand wipe Bartley’s White Glue together and finish. I like to tack together sections of my
Base gel stain on the white pieces. Let set a few minutes and wipe project with 100% silicone glue. This prevents them from sliding
off with another clean rag. Let dry overnight. Put a coat of gel and moving when I glue. Group together the head, leg, body and
varnish on all white pieces and let dry overnight. Apply final coat of tail sections. Place a small drop or two of glue in between your
varnish. Using a soft rag, hand wipe natural gel varnish on all other pieces, press together and arrange on a pattern board for correct
pieces. Wipe off with a clean rag. Let dry, put on a second coat. placement. Let dry overnight.

Step 11
Use Super Glue to Hold Sections Together for Sanding
Try using “Super T” glue with “Quick Set” accelerator to hold small
or large sections of your piece together for shaping. Hold your two
pieces together and put one or two tiny drops of Super glue on
the bottom, add a quick spray of Quick Set to the bottom area. Set
down on a piece of scrap paper and make sure your two pieces are
completely flat and fitting tightly. Do this quickly as it will set up
in about ten seconds. Add other pieces to your section one at a
time, making sure they are flat. Do not use too much glue, as it will
be difficult to break apart and will run down and stick to the paper.
Now you can shape an entire leg or body section on the
sanding drum and get a nice, even flow from one piece to the
next. When you are done shaping and sanding, sharply rap the
section on a tabletop and it will come apart easily. Be careful
with small delicate parts because too much force will break the Arrange and glue pieces to backer board using Titebond glue. If
wood apart. If two pieces are stubborn and don’t break apart, you need to realign a silicone-tacked piece, simply pull apart. Glue
simply recut with the scroll saw on the parting line. Be patient as and weigh down with sand bags or clamp. Let dry overnight and
this technique takes a little practice, but the finished results of then put on one more finish coat of varnish on your cat. Saturate a
your intarsia piece makes it well worth the effort. cloth, squeeze out the excess and wipe a light coat of varnish on
the entire project. Attach a sawtooth hanger and your calico cat
project is finished. A special thanks to my father-in-law, Phil
MATERIALS & TOOLS MacDonald, whose help with cutting out this project enabled me to
Materials: finish it in time for the article deadline date.
• 3⁄4" x 12" x 12" dark walnut (D) • Super T glue
• 34⁄ " x 8" x 10" white basswood (W) • Quick Set accelerator
• 3⁄4" x 8" x 10" mahogany (M) • Gel natural varnish and base
• 3⁄4" x 2" x 2" locust (Y) white gel stain About the Author
• Wiping rags Kathy Wise started designing special dog intarsia
• 3⁄4" x 3" x 3" light oak or
other light wood (L) • Sawtooth hanger patterns for her father-in-law, Phil MacDonald’s, intarsia
• 3⁄4" x 2" x 2" ebony (B) • 100% silicone caulk business. When a customer asked for a hard-to-find
• 1⁄4" x 24" x 12" plywood breed or a special likeness of their pet, Kathy would
for backer Tools: make the pattern. She found that she enjoyed designing
• #5 blade original patterns and creating her own unique intarsia
• Roll of clear shelf contact
paper • Drill with 3⁄16"-diameter bit works of art. For over 23 years, Kathy has designed and sculpted
• Temporary bond spray • Pneumatic drum sander thousands of dog and animal figurines for the giftware industry.
adhesive • Dremel with sanding band
• Titebond glue • 1⁄2" sanding drum

Calico Cat Intarsia Scroll Saw Workshop • Spring 2005 45


390-The Ultimate Puzzle 12/14/04 2:49 PM Page 46

THE ULTIMATE
Apply Black Paint and Cutting Lines Disappear
By Tom Zieg

Photocopy at 200%

Note to professional copying services.


You may make up to ten copies of this pattern for
the personal use of the buyer of this magazine.

46 Scroll Saw Workshop • Spring 2005 The Ultimate Puzzle


390-The Ultimate Puzzle 12/14/04 2:49 PM Page 47

PUZZLE
T
he making of this puzzle is quite
simple, really. But putting it together
will drive your friends mad. The
next time you want to create a stir, give this
puzzle as a present or get it out at a party.
How good are your puzzle-solving skills?
Check the handy chart to find out.
And for those of you who are not
satisfied with just a black puzzle, we
posted a different pattern for a red
puzzle on our web site at
www.scrollsawer.com.

Step 1: Prepare the wood.


Using a rag, dampen the top
surface of the board with
water to raise the grain.
When dry, sand with 220-
grit sandpaper and once
smooth, wipe down with a tack
rag. Spray paint with black latex paint.
After the first coat has dried, sand with for any 90-degree
220-grit and wipe off dust. Then apply a turns. The first cut divides the
second coat. Finish the preparation by puzzle into two pieces, making it easier
applying a clear spray finish. to cut on a 16" saw. Be sure you cut
completely through the puzzle sections.
Step 2: Affix the pattern to the black And make sure you don’t make any 90- MATERIALS & TOOLS
surface with temporary bond spray degree turns. Sharp turns like that will Materials:
adhesive. leave little gaps from the blade that • 1/4"- 1/2" x 141/2" x 141/2" square
interrupt the smooth flow of the puzzle • Sandpaper, 220 grit
• Temporary bond spray adhesive
Step 3: Cut the puzzle, making sure lines. Those gaps can give the person • Spray paint—black latex
you make the first five cuts in the order assembling the puzzle hints of where the • Clear spray finish (optional)
shown on the pattern. The suggested pieces go. • Tack rag
cutting order will segment the puzzle
into five sections and eliminate the need SO HOW GOOD ARE YOU? Tools:
• Scroll saw with throat 16" or larger
Completion Time Rating • #2 reverse tooth blade
TIPTIPTIPTIPTIPTIP More than a month “C’mon man, what’s
the hold up?”
Making the Puzzle More Difficult About the Author
to Assemble 2 weeks to a month “Oh, well. At least it
wasn’t longer.” Tom Zieg of Lincoln,
Paint both sides of the puzzle, and it really Nebraska, loves woodworking
becomes difficult to assemble. Prepare the 1 to 2 weeks “Movin’ right along, and also finds time to share his
bottom surface as detailed in Step 1. Use aren’t we?” knowledge with others
temporary bond spray adhesive to affix a 1 day to 1 week “Hey, you’re pretty through books and magazine
piece of paper to the completely dried bottom good.” articles. He has written
surface to protect it from damage as you cut numerous articles for Scroll Saw Workshop. His
Less than 1 day “Did you cheat?” latest article, “Country Church Music Box,”
it on the saw.
appeared in Holiday 2004 (Issue #17).

The Ultimate Puzzle Scroll Saw Workshop • Spring 2005 47


573-Cow Puzzle 12/14/04 11:33 AM Page 48

DAIRY DELIGHT PUZZLE


At 6 Inches Across—It’s Perfect for Church or Car
Here are two painted
versions of the same
project, with shading
added to the cow at
right by a more
advanced painter.

Travel Size
Puzzle Provides
Hours of Toddler Fun
By Joanne Lockwood

T
o put it in county fair terms, this Step 2: Cut and Sand. Cut out the
project’s a blue ribbon winner. You’ll project. Remove the tape. Sand and seal
have a great time cutting the cow all the pieces with DecoArt DS17 Multi- How about making a locket in miniature if
puzzle, and children will have fun putting Purpose Sealer. You do not want to seal you really want to challenge yourself!
it together and taking it apart. It’s also a inside the holes, as the pieces will not
great visual aid showing youngsters the come out if the grain is raised. It is best line of glue on the underside of this piece,
many different types of food that come to do the sealing before the puzzle pieces align it with the 1⁄8"-thick bottom piece
from cows. This is a great gift, but it is not are cut. Let dry. Re-sand. and clamp. Using a wet cotton swab,
meant for tots who still put objects in their remove any excess glue. Do not put the
mouths. To avoid such a circumstance, Step 3: Trace all the patterns. Then pieces back in. Let dry.
enlarge the pattern accordingly. I used a adhere the pattern for the puzzle pieces to
thinner top layer but decided a thicker a 1⁄2"-thick piece of wood with spray glue Step 5: Sand all of the small pieces well,
one would be better, so there is more room or transfer paper. Do not use carbon paper! especially on the edges if necessary. If you
for the peg. use a new blade when cutting, sanding will
Step 4: Drill entry holes and cut puzzle probably not be necessary at this point.
Step 1: Getting Started. Cut all three pieces. Using your smallest drill bit, drill
pieces of wood to size. Sandwich them in blade entry holes next to each puzzle Step 6: Align all three pieces and use
the order given in the materials list, top, piece. Insert one end of a #5 blade into the the 1⁄4"-diameter bit to drill a hole in the
center and bottom. Use masking tape to hole you drilled by the cheese, re-tension ear for the axle peg, which is indicated by
secure around the edges. Adhere the cow your blade and cut the piece out. Repeat the X. Insert the peg through the top
pattern to the top piece with spray glue. this process until all the puzzle pieces are piece, add a tiny drop of glue to the tip of
Spray only the pattern, not the wood. cut out. Leave the pieces out. Put a thin the peg and insert into the hole.

48 Scroll Saw Workshop • Spring 2005 Diary Delight Children’s Puzzle


573-Cow Puzzle 12/14/04 11:33 AM Page 49

MATERIALS & TOOLS


PAINTING NOTES
Materials:
I have painted two versions of this piece. One has very basic painting, for • 1 piece, 1⁄4" x 61⁄2" x 61⁄2" Baltic birch
which directions are included. More advance painters may want to shade where plywood (for top)
shown on the other version. I do not recommend painting the edges of the • 1 piece, 1⁄2" x 61⁄2" x 61⁄2" pine or birch
plywood (for center)
pieces. I did and had to really sand to get them to slip out easily.
• 1 piece, 1⁄8" x 61⁄2" x 61⁄2" Baltic birch
Using the largest brush, basecoat all of the three main pieces in White Wash plywood (for bottom)
except the top of the 1⁄2"-thick (center) piece. Wash the top of that piece with • 1 piece, 1⁄4"-diameter wooden axle peg
cut to 5⁄8" length
Soft Black by diluting the paint to an inky consistency with water, which allows
• 1"-wide masking tape
the grain to show through. Try not to get any in the holes. Allow this paint to dry. • Sandpaper, miscellaneous grits
Next paint the front of the cow and the puzzle pieces. Let this paint dry • 6" square of a brown paper bag
before applying the detail ink with the Micron Pen. At this point, allow the • Yellow wood glue
paint to dry overnight. Then apply just a misting of DecoArt DAS13 Americana • Repositionable spray glue or Loew-Cornell
Grey Transfer Paper and brush tub
Matte Spray finish with the puzzle pieces out of the cow. I used a matte finish
• DecoArt DS17 Multi-Purpose Sealer
on mine, but DecoArt Americana has a high gloss finish if you prefer. All • DecoArt DAS13 Americana Matte
products I used are non-toxic when dry. Spray finish
• Loew-Cornell paintbrushes:
PAINTING PALETTE USING DECOART AMERICANA ACRYLICS AND SATINS Series 3400 angular in 3⁄4" and 1⁄2"
Series 3350 #2 liner
All paints listed are Americana Acrylics except for Shimmering Silver: Series 3000 #2 round
Cow front: Apply pattern with graphite paper. • .005 Black Micron disposable pen
• Paints DecoArt Americana Acrylics:
Spots/tip of tail Soft Black White Wash, Soft Black, Toffee, Hi-Lite
Hooves/horns/eyelids Toffee Flesh, Terra Cotta, Dusty Rose, Country
Red, Mink Tan, Cadmium Yellow and
Snout/udder/inside ears Hi-Lite Flesh Americana Dazzling Metallics:
Shimmering Silver
Nostrils Dusty Rose
All liner work can be done with Soft Black and a liner brush, or the .005 Tools:
• Small “Quick clamps”
Micron Pen. Be sure to skip areas. It looks better than a solid line. • Drill with 1⁄4"-diameter bit, and the
Puzzle pieces: smallest bit that will accommodate a
#5 blade
American cheese Cadmium Yellow • #5 double-tooth blade
Swiss cheese White Wash to lighten
Butter Cadmium Yellow
About the Author
Milk can/heart Shimmering Silver/Country Red This is the third article for Scroll
Cottage Cheese/lid Country Red/White Wash Saw Workshop by Joanne
Cone Terra Cotta Lockwood. She previous
contributed “Scroll and Paint
Ice cream Country Red/Mink Tan. Tic Tac Toe Game,” Holiday
Cream and Milk cartons White Wash, milk carton also has Mink 2002 (Issue #9) and
“Gingerbread Man Countdown to Christmas,”
Tan center Holiday 2004 (Issue #17). A scroll saw teacher
Steak Country Red with touch of Soft black for more than 15 years, she has been
Brush mix it on your palette. instrumental in introducing thousands to
scrolling through her video and books, including
Yogurt Mink Tan Learning to Use Your Scroll Saw, which has sold
All details are done with the Micron Pen. more than 50,000 copies. She lives in Sparks,
Nevada, with her husband, Max.

Diary Delight Children’s Puzzle Scroll Saw Workshop • Spring 2005 49


573-Cow Puzzle 12/14/04 11:33 AM Page 50

This design is not intended for children


under 3 or who still put things in their
mouths, as choking could result. For puzzle,
enlarge the pattern to a size suitable for the
age and safety of your child.

CREAM
WHIP
CREAM
SOUR

BUTTER

O
O
C
H
C

A
E
T
L
COTTAGE
CHEESE
MILK

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

50 Scroll Saw Workshop • Spring 2005 Diary Delight Children’s Puzzle


555-Friendship Quilt 12/14/04 11:53 AM Page 51

FRIENDSHIP QUILT
Share Great Memories with this PICTURE FRAME
Unique Photo Display
By Brenda Herthel

G
ood friends are like a Step 5: Cut the outside of
quilt you can wrap the project. Cut the
around yourself for perimeter lines, then make
comfort. Now you can honor sure they’re straight.
those bonds with this lovely
photo frame project. Fill it Step 6: Add the finishing
with treasured memories, give touches. Sand as necessary to
it to your best friend and remove any rough edges in the
watch his or her face light up letters and other small areas.
with joy. Spray with a polycrylic finish
of your choice, sanding lightly
Step 1: Prepare the blank. between layers. Finish with
Make a photocopy of the several layers of spray, letting
pattern to attach to the wood. each coat dry well before
Keep the original for adding another. A piece of
reference. You can cover the crumbled brown paper bag can
block with clear packaging also be used as superfine
tape or just attach the pattern sandpaper. Once everything is
to the plywood with the embellished (see TIP), attach
temporary bond spray an 11" x 14" piece of fun foam
adhesive (See TIP). to cover all pieces on the back
Patterns for
for stability, and let dry.
Friendship Quilt on the A sawtooth hanger or
PATTERN PULLOUT other hanger of your choice
Step 3. Cut out lettering first. Work your will finish the project.
Step 2: Drill blade entry holes. In the way around the pattern, cutting out the
square picture cutouts, it is best to drill a lettering with a #5 reverse tooth blade. TIPTIPTIPTIPTIPTIP
starter hole near each corner. Drill a Make sure that you have free clearance to Embellishing the project
starter hole in each word, near the bottom be able to turn your project 360 degrees on Use your photos for the larger squares, filling
of an end of a letter to ease into the line. the table to easily follow the printed lines. some or all of them with memories. The
Stack cutting can give you more control. lettering and smaller squares can be backed
with fun foam, material, scrap booking
MATERIALS & TOOLS
Step 4: Cut the boxes. To help in cutting paper or felt. Attach items with small drops
Materials: of hot glue or Aleene’s Tacky Glue.
• 1⁄4" x 11" x 14" Baltic birch plywood straight lines on the inside of the picture
• 2"-wide packaging tape frames, use wide tape to attach a metal
• Sandpaper, 100 grit ruler or a straight piece of thin metal to About the Author
• Temporary bond spray adhesive the pattern along the line that you want to Brenda Herthel has been
• Spray finish, clear scrolling for about four years
cut. Cut from the starter hole to the
• Sawtooth hanger and designing patterns for the
corner and then continue down the line
last two years. She lives with
Tools: of the ruler. Stop when you get to the next
her husband and family in
• #5 Flying Dutchman reverse blade or corner, and remove your blade. Reinsert
similar blade
Lake Elsinore, California. Brenda has a website
the blade in the next hole. This technique that offers freebie patterns of all different kinds.
• Drill or drill press with 1⁄8" drill bit
helps with making square corners. Log onto www.bigwood2littlewood.com.

Friendship Quilt Picture Frame Scroll Saw Workshop • Spring 2005 51


598-Whitetail Deer 12/14/04 11:53 AM Page 52

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

52 Scroll Saw Workshop • Spring 2005 Whitetail Deer and Habitat


598-Whitetail Deer 12/14/04 11:53 AM Page 53

From
North American
Wildlife Patterns
Design by
Lora S. Irish

Whitetail Deer and Habitat


T
his Pine Tree Path project featuring a Step 2: Drill blade entry holes. Using a Step 4: Remove the pattern. After the
whitetail deer is among the 61 1⁄16"- diameter or smaller bits, drill blade pattern is removed, sand as needed with
popular patterns featured in my entry holes. 220-grit sandpaper. Clean sawdust away
book, North American Wildlife Patterns for with a clean cloth.
the Scroll Saw. What makes this one and Step 3: Make the inside cuts first.
many of the other patterns especially nice Using a #3 reverse tooth blade, make the Step 5: Finishing up. Stain if desired
to scroll is that full scenes with habitat inside cuts. Then change to a #5 reverse depending on your choice of wood. You
areas can be designed for one continuous tooth blade to cut the outside of the can also finish this with a clear spray
piece of wood. Before starting the project, pattern. Do not remove the inside pieces finish such as a semigloss type. This
make a few copies of the pattern and save until you finish cutting the entire design. pattern and the others in my book are
the original for future use. created so they can be easily used
MATERIALS & TOOLS individually or added to corner brackets,
Step 1: Sand the wood and apply the Materials: weathervane arrows or framed edges.
pattern. Start with 100-grit sandpaper • 1 piece, 1⁄2" x 81⁄4" x 11" hardwood
of choice
and work up to 220-grit. Then remove • Sandpaper, assorted grits About the Designer
the sawdust from the wood with a clean • Temporary bond spray adhesive Lora S. Irish is a nationally
cloth. Next, spray the back of the pattern • 2" clear packaging tape known artist and author whose
with temporary bond adhesive and • Finish of choice other Fox Chapel Books
include World Wildlife Patterns
adhere the pattern to the wood. You can Tools: for the Scroll Saw. Visit
cover the pattern with 2" clear packaging • #5 reverse tooth blades
www.carvingpatterns.com, her
tape to lubricate the blade. • #3 reverse tooth blades digital pattern warehouse. This website features
• Drill or drill press with 1⁄16"- diameter free patterns and patterns for purchase.
or smaller bits

Whitetail Deer and Habitat Scroll Saw Workshop • Spring 2005 53


537-Scrolled Interiors.qxd 12/14/04 11:52 AM Page 54

ScrolledInteriors Archways, gates,


wine racks and
more from
Brad McFarland

By Bob Duncan

This scrolled archway


was Brad McFarland’s
ticket out of the
corporate world into
full-time woodworking
and scrolling.

Brad McFarland used his scroll saw


to turn a part-time hobby into a
full-time career.

I
t all started when Brad visited Cindy’s Wine Cellar in
Bellbrook, Ohio. He saw the store’s logo, and it looked like
an interesting project to cut out with his new 24" Sears
Craftsman scroll, so Brad asked permission to use the logo. He
gave the completed work to the store.
It was this logo that inspired Tom and Lynda Mays to
commission Brad to do two years worth of scrolled interior
work—all in mahogany—in their wine room, The Grape
Escape.

The logo Brad cut out just for practice that led to a two-year
commission.

54 Scroll Saw Workshop • Spring 2005 Scrolled Interiors


537-Scrolled Interiors.qxd 12/14/04 11:52 AM Page 55

Brad incorporated scrolling with woodworking to produce Making the Archway


12 separate projects within the house. Within a short time, The biggest challenge on the archway was to actually form
word spread about his work and his confidence soared. He soon the arch frame.
picked up enough commissions to leave the corporate world “I decided to build a custom steamer from an old gas
and start his own custom woodworking business, The Sawdust barbecue and a piece of gutter,” he said.
Shoppe (937-367-3121/www.TheSawdustShoppe.com).
Brad said he broke down the larger projects into more
manageable pieces.

Brad steamed and formed the arch framework.

A decoration for a kitchen cutaway was one of the 12 projects


Brad made.

“The approach to the grapevine arch and gate was to look


at them as many small projects that would all join together,”
he said.
He also offered some tips to scrollers who may want to try
similar large interior projects.
“Before making any cuts, check your wood for defects like
knots, checks and splits and lay out your design to eliminate
any sections of wood that may compromise the strength of the
finished piece, even if it means wasting some wood,” he said. Next he cut and fitted three individual panel inserts.
As in most scrolling projects, Brad said the right blades
make a difference.
“Make sure you use the right saw blades,” he said. “It may
not seem like a big deal at first, but you’ll soon find out the
right blade makes all the difference in the world.
“I also recommend saving your scrap cuts,” he added. “In
delicate sections of the grapevines I’d often tape the scrap cuts
back into place with blue painters tape to protect them while
finishing the rest of the cuts.”
Body positions and attitude are also important, according
to Brad.
“The last two are really important: Get comfortable because
improper seating, lighting and body position will physically
drain you,” he said. “Lastly, have fun. If you’re not enjoying
what you’re doing, then it’s just another job and the finished Oval insert blank and the oval insert Brad placed into the
product will reflect it.” center panel.

Scrolled Interiors Scroll Saw Workshop • Spring 2005 55


537-Scrolled Interiors.qxd 12/14/04 11:52 AM Page 56

Brad shows off


the center panel
midway through
to completion.

Two of the three panels finished.

Brad shows off how the panels were joined with


dowel joints. This was a decoration for a kitchen
cutaway that was one of 12 projects Brad made for
Tom and Lynda Mays.

Brad did a dry fit before final assembly.

Making the Gate


The biggest challenge when making the gate was finding
motivation.
“This project was my single biggest challenge, mentally and
physically. Several months into the project, I had to walk away
and let it sit for fear I would sacrifice my workmanship in my
pursuit of just getting it done.

Brad started with a


gate frame layout
for fretwork.

56 Scroll Saw Workshop • Spring 2005 Scrolled Interiors


537-Scrolled Interiors.qxd 12/14/04 11:53 AM Page 57

Brad cut each


piece of
scrollwork from
a fitted blank
(lower right.)

Each panel is fitted to corresponding frame rails.

Brad used 168


dowel joints to
join one gate.

He shows
off the
gate after
it is
Lower right panel has been cut from the fitted blank.
glued,
screwed
and
clamped.

Dowel joints were used to secure scrollwork in each panel.

Scrolled Interiors Scroll Saw Workshop • Spring 2005 57


584-Classic Tractor 12/14/04 11:51 AM Page 58

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

58 Scroll Saw Workshop • Spring 2005 Classic Tractor


584-Classic Tractor 12/14/04 11:51 AM Page 59

s s ic T r acto
Stir Enduring Memories
la r
With This Popular Ford
By Troy Thorne C
I
learned to drive tractor on a 1952
Ford 8N Jubilee tractor, so this
project brings back fond memories.
This classic tractor design is presented
in its most basic form, but feel free to
adapt to a clock project or a shelf
design, too. Whether you live in a more
urban area and pine for the old spring
traditions, or if you live in the country
and see them every spring, this classic
tractor portrait is sure to become a
cherished addition to any home.

Step 1: Preparing the wood. Plan to


cut at least two tractors at the same
time by stack cutting. Photocopy the
pattern. Using temporary bond spray should help in removing the paper from tractor piece. Also glue on the Ford logo.
adhesive, attach the pattern to the the wood. To remove any remaining Place an even flat weight over the frame so
wood, spraying the pattern, not the adhesive, use the palm sander to lightly it adheres better. To hang the project,
wood. Since you are stack cutting, place sand the surface of the wood with a few install a wire hanger and two cushioning
a few wood blanks under the top piece grades of sandpaper such as 100, 150 tabs (self-adhesive) on the bottom two
and tape the surface of the cutting area and 220 grit. Sand the back of the piece corners of the back of the frame opposite
with 2"-clear packaging tape, which with rough-grit sandpaper to eliminate the wire hanger.
also helps lubricate the blade so the any fuzzies that may remain due to the
wood will not be as likely to burn. spiral blade.
Step 5: Applying a protective finish. MATERIALS & TOOLS
Step 2: Adhering the pattern and Spray a clear coat on the surface of the
Materials:
making blade entry holes. Drill blade wood to protect it from the sun or leave • 1 piece, 1⁄8" x 7" x 9" Baltic birch
entry holes for each cutout section of the it as is. Allow to thoroughly dry. • 1 piece, 1⁄4" x 7" x 10" walnut (frame)
pattern. Use as large a bit as possible for • 1 piece, 6" x 8" black felt backer mat or
easy blade feeding. To make the holes, dark background material
Step 6: Cutting the frame and Ford
• Sandpaper, course, medium and fine grits
use a drill press if you have one, so the logo. Using a #5 blade, cut the walnut • 2"-clear packaging tape
holes will be straight. frame and the Ford logo. Sand as • Double-sided tape (for stack cutting)
necessary. • Temporary bond spray adhesive
Step 3: Cutting the project. Start with the • Clear coat finish spray
most delicate sections in the engine area Step 7: Attaching the background. Hot
and work your way out to the edges. As Tools:
glue the background felt or material to
• #2/0 spiral blade, #2 reverse standard
you move from the center to the edge, cut the wood on the back side. Let dry after and #5 blade
the area closest to the one you just cut. placing an even, flat weight over the back • Drill with #61 bit or bit that is smaller
side of the project for firm adhesion. than the cutout areas
• Palm sander (optional)
Step 4: Removing the pattern and
• Hot glue gun
burrs. When all cutting is done, remove Step 8: Framing the tractor. Glue the • Scissors
the paper. The tape over the pattern walnut frame to the outer surface of the

Classic Tractor Scroll Saw Workshop • Spring 2005 59


460-Slope Sided Box.qxd 12/14/04 11:51 AM Page 60

Slope
Sided
Box
Create a Charming,
Rustic-Looking Container
from Found Wood

By Jim Stirling

Y
ou never know when and where
you might find a piece of wood
meant for your scroll saw. This
box was created from a stout, dry oak
limb found outside the Scroll Saw
Workshop office during my visit.
This box is made using the principle
of the sloping core cut. Tilting the table
while cutting out the core will produce a
conical piece that slips down snuggly
into the case of the box. Slicing this core
will then produce a base for the box and
a lid-retaining ring. The principle can be
used to make many other shapes of
boxes. Examples of pieces I have made
are a map of Australia and a maple leaf.
A heart shaped box is a winner for
Valentine’s Day.

Preparation
I cut a suitable section for the box off the
branch with a handsaw, then, I sliced
this horizontally on the band saw. The
first cut removes the bark and 1⁄4" of
material on one side to form the base of
the box. Using this flat surface against
the guide, I then sliced the material into
two pieces, one forming the case of the
box and the other the lid. Each piece
must be thin enough to be able to pass
under the arm of the scroll saw. In our
case, each piece had to be less than Boxes showing the shape of Australia and a maple leaf are other examples of
2" high. scrolling using the sloping core cut principle.

60 Scroll Saw Workshop • Spring 2005 Slope Sided Box


460-Slope Sided Box.qxd 12/14/04 11:52 AM Page 61

Step 1 Step 2

Before starting, make sure the height of the wood fits under your The piece that is flat on both sides will form the case of the box.
saw’s arm. The cutting height for each piece of this project should Place this on the table with the widest side up. Using a pencil and
be no more than 2". ruler, mark straight lines about 1⁄4" in from the bark on both sides.
Also mark similar lines 1⁄4" from the ends. Round off the corners to
make a rectangle on the top of the piece.

Step 3 Step 4

Turn the same piece over and, using a pencil, make a straight line Place the wood on the saw table in front of the blade. Using the
about 1⁄4" from the bark on the two long sides. On the ends of the back left hand mark as a guide, push down the right hand side of
wood, mark lines that connect the longitudinal lines on the top to the table until the blade is parallel with this line. Leave the block
the bottom longitudinal lines. These lines will be used to indicate of wood where it is on the table, and using a hand drill and a 1⁄16"-
the amount of table tilt when cutting. diameter bit, make a blade entry hole somewhere along the left
longitudinal line. You should be able to bore vertically. If the drill is
too short to go all the way through the wood, make a drill bit
from wire. Cut wire that is about the same diameter of the bit and
about 3" to 4" long. Sharpen the end on the belt sander into a
chisel shape and put it into the drill chuck. You should be able to
drill the remainder of the hole with this. Don’t drill into the scroll
saw table!

Slope Sided Box Scroll Saw Workshop • Spring 2005 61


460-Slope Sided Box.qxd 12/14/04 11:52 AM Page 62

Step 5 Step 6

Insert a #9 straight, cutting blade into the blade entry hole and Remove the conical core from the box case and then remove the
install the blade in place. Cut out the rectangular core in a blade from the center of the case.
counterclockwise direction. Remember to be patient with your
cutting. With this thickness of wood, the blade is really being put
to the test. Too much pressure will break the blade, too little will
overheat it.

Step 7 Step 8

Push in the core piece into the case until it stops, and using a Remove the core piece. Mark off the base of the box. Using the
pencil, draw a line around the bottom of the case onto the pencil and your curled middle finger as a guide, make a
protruding base. There was about 1⁄16" protruding on my box, but rectangular mark 1⁄4" above the mark you made in the last step.
your results may vary, depending on the angle of the cut. Next mark off the lid-retaining ring. Draw a similar rectangular
line 1⁄4" down from the topside of the core. If the core is small
enough, slice it on the scroll saw; otherwise use a band saw. The
MATERIALS & TOOLS table will still be tilted at the proper angle, so that when the core
Materials: Tools: is placed on its side, the blade will cut vertical slices through the
• Handsaw • Band saw wood. Cut along all three marks. This will produce four slices of
• 1 piece, 21⁄2" x 6" x 3" dry • Drill with 1⁄16"-diameter bit or wood. Only the top and third from top pieces will be used.
branch wood, with bark still on just big enough to let the
• Pencil scroll saw blade through
• Sandpaper, 100 grit • Ruler
• Loctite Outdoor Wood • #9 straight, cutting blades
Worx-Easy Flow System or • Belt sander
any other wood glue

62 Scroll Saw Workshop • Spring 2005 Slope Sided Box


460-Slope Sided Box.qxd 12/14/04 11:52 AM Page 63

Step 9 Step 10

Cut the lid-retaining ring. Take the top slice, and using your pencil The lid-retaining ring will be glued onto the bottom of the lid to
and third finger as a guide, mark off a rectangle about 1⁄4" from hold the lid in place. This lid ring will fit snugly into the top of the
the edges. Drill a blade entry hole and cut out the core as done in box. Using 100-grit sandpaper, gently sand this piece smooth. Also
Step 5. sand the bottom of the lid.

Step 11 Step 12

Follow these instructions to help correctly position the lid-retaining Using the belt sander, smooth the 1⁄4"-thick rectangle piece, which
ring: Place the lid upside down, and place the box case upside will be inserted into the box and become the bottom. Glue the
down on top of this. Align the edges of both pieces. Then take bottom into the box. Push the bottom out until it fits snugly. After
your pencil and mark around where the inner edge of the case the glue is dry, you may need to use the belt sander to sand the
meets the underside of the lid. Using Loctite Outdoor Wood Worx bottom of the box.
glue or another wood glue, glue the retaining ring onto the bottom
of the lid. To ensure a good bond, apply some pressure. Put the
lid, ring down on a flat surface, and then balance something
weighing a couple of pounds on top. Allow the glue to dry for a
couple of hours. FURTHER READING
By Jim Stirling
Scroll Saw Castles
About the Author Create unique, collapsible castles with this unique scroll
This is the third article Jim Stirling has written saw relief technique. Includes cutting diagrams for eight
this year for Scroll Saw Workshop. His most projects.
recent article for the magazine was “A Toy $12.95 plus $3.50 S&H (parcel post)
from the Land Down Under,” Summer 2004
Available from:
(Issue #15). Born in Australia, Jim is known Fox Chapel Publishing
for his techniques to scroll collapsible castles 1970 Broad St., East Petersburg, PA 17520
and relief scenes. He lives in Norway, on Phone: 800-457-9112 FAX: 888-369-2885
Stirling Station, with his wife, Edel, and their www.FoxChapelPublishing.com
two children. Or check your local supply store.

Slope Sided Box Scroll Saw Workshop • Spring 2005 63


468-Sun & Bird Wind Chimes 12/14/04 1:20 PM Page 64

Photocopy at 100%

Note to professional copying


services. You may make up to
ten copies of this pattern for
the personal use of the buyer
of this magazine.

Create a Musical for Your Porch


By Paula Wendland

The sun pattern has two sets of four Finishing and Assembly
holes marked at the bottom (labeled a- Step 1: For the sun, brush on a
h). These are for attaching the four basecoat of thinned acrylic gold paint.
chimes. You will use two holes to hang Thinning the paint makes it easier to
each chime so they hang freely. The cover all the cuts without clogging them.
larger hole at the top of the sun is for When the basecoat is dry, mix a lighter
hanging the finished piece, and the shade using white and gold. Sponge this
larger bottom hole is for attaching the on lightly over the darker basecoat.
bird clapper. These holes are indicated When the second coat is dry, sponge on
on the sun pattern by the heavy, bold a few touches of metallic gold highlights
dots. The bird pattern has one hole overall.

H
ere’s a project that’s not only shown in a similar manner, for attaching Sponge paint the piece. First,
interesting to cut but creates the bird to the sun. moisten your sponge in water and wring
soothing music for folks who the sponge nearly dry. Lightly dip a
need to slow down for at least a few Cutting the Basic Pieces portion of the sponge into the paint.
minutes each day. I’m dedicating these Step 1: Photocopy and attach the Then, dab your sponge a few times onto
Sun and Bird Wind Chimes to those of patterns. Either transfer the patterns a piece of scrap paper. This distributes
us tending to jobs and/or children and onto the plywood using Saral Wax Free the paint evenly through the sponge and
an upcoming summer that will fly by too Transfer Paper or glue them to the wood prevents “globs.” Lightly tap the paint-
quickly. You’ll be proud to tell your with temporary bond spray adhesive. loaded sponge over your work. It’s best
inquiring friends that you made these to start out with a too-light rather than a
wind chimes. But beware, they’ll likely Step 2: Drill the blade entry holes and too-heavy application. You can always
ask you to make one for them. cut. Using a 1⁄16"-diameter bit, drill all add more paint later. Practice on scrap
blade entry holes as indicated on the wood until you get the texture you want.
Getting Started patterns. Then use a #2/0 Olson blade to
First, buy your wind chimes. (See cut out the pieces.
SPECIAL SOURCES.) I chose a four- TIPTIPTIPTIPTIPTIP
chime set sized 41⁄2"- to 6"-long. If your Step 3: Sand the edges lightly with Stain your pieces if you like
chimes are smaller or larger, reduce the 150-grit sandpaper to remove any burrs. Instead of sponge painting, staining this
pattern size accordingly. project is an option. But since the finished
If you decide to enlarge the pattern, a Step 4: Drill the hanging and chime project will hang outside, be sure to use an
bit thicker plywood for the sun piece holes. A 3⁄32"-diameter bit should be fine outdoor varnish to seal it. Since you will be
to drill these holes. Use a finer bit if you staining and finishing both sides of your
would be better, say 1⁄4" to 3⁄8". The bird
pieces, remember to wipe off any varnish
clapper should stay at 1⁄8" thick, because have one for the remaining holes. Insert
that seeps through the cuts right away, so
you want it light enough to sway in the toothpicks during painting and finishing your finish stays even on both sides.
breeze. to help keep the holes open.

64 Scroll Saw Workshop • Spring 2005 Sun and Bird Wind Chimes
468-Sun & Bird Wind Chimes 12/14/04 1:20 PM Page 65

Step 2: For the bird, a medium brown


stain would be best, but you can always
experiment and see if you like the look
of sponge painting on that piece, too.

Step 3: Start to assemble the pieces by


placing them on a tabletop
approximately as you want them to
hang. If possible, measure the area where
they will be hung, so you can determine
the best overall length of your finished
piece. Tie the monofilament or nylon
cord firmly to the S-hook, using a square
knot, and tie the sun piece to the other
end of the line. Seal your knots with a bit
of clear nail polish or white glue for
extra security.

Step 4: Attach the bird to the sun,


following the procedure used in the
previous step. Attach the chimes to the
sun as follows: Tie a fat knot in the line.
Thread the line up through Hole A, from
left to right through the first chime, then
down through Hole B. Pass thread up
through Hole C and repeat for the
second chime. Tie off firmly. Do the
same for the other two chimes on the
other side of the clapper.

SPECIAL SOURCES
Aluminum Wind Chimes
Sunshine Discount Crafts
12335 62nd Street N, Largo, FL 33773,
800-729-2878, www.sunshinecrafts.com

Cut by John Martin

This color palette contains metallic paint, gold paint, white paint and
a mixture of gold and white paint for the second color coat. The
photo at top shows how the sponge looks after the excess paint has
been dabbed off onto scrap paper. Photo at bottom, left, shows the
second coat of mixed colors being sponged onto the sun.

Sun and Bird Wind Chimes Scroll Saw Workshop • Spring 2005 65
468-Sun & Bird Wind Chimes 12/14/04 1:20 PM Page 66

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

h
a g
b
c f
d e

MATERIALS & TOOLS


Materials: • Stain of choice
• 1⁄8" x 9" x12" Baltic birch plywood, or • Outdoor polyurethane varnish
larger if you prefer (sun)
• Small S-hook
• 1⁄8" x 4" x 7" Baltic birch plywood (bird About the Author
• Clear nail polish or white glue
clapper) Paula Wendland is a crafts
• Copper wire, at least 20 gauge and 8’ to designer, and artist and an
• Tracing paper
10'-long (optional)
• Saral Wax Free Transfer Paper or illustrator of children’s books.
temporary bond spray adhesive Her last article for Scroll Saw
Tools:
• Set of aluminum wind chimes Workshop was “Wizard
• #2/0 Olson blade
• Sandpaper, 150 grit Nameplate and Switch Plate”
• Sanding tools
• Heavy-duty nylon monofilament line or thin featured in Summer 2004 (Issue #15). She lives
nylon cord • Drill with 1⁄16"- and 3⁄32"-diameter bits
in Evanston, Illinois, with her husband, Donald,
• Acrylic paint in gold, white and metallic • Paintbrushes
and their two children. You can reach her at her
gold: Delta Ceramcoat or Delta Gleams • Wire cutter
company, Nighthawk Studio, via email,
brands
pzwend@comcast.net.

66 Scroll Saw Workshop • Spring 2005 Sun and Bird Wind Chimes
585-Bowling Box 12/14/04 12:12 PM Page 67

Bowling
Trinket Box
You Can Make Nice Keepsakes
for Your League
By Timothy Lack

E
verybody likes boxes and here’s one you can scroll for
your high-rolling bowling buddies. These boxes can make
a nice season ending gift for league bowlers. Trinket boxes
such as this one are a bit more difficult to make than the napkin
holders I shared in the Holiday 2004 Scroll Saw Workshop (Issue
#17). But such boxes also stand out at craft fairs. Box: Use a darker 11⁄2"- to 2"-thick stock. Mahogany or black
The pattern I am providing here comes from my walnut is among my favorites. The 1⁄8" drill hole may break out
LackWood.com website. Using a #5 skip reverse tooth blade, the bottom but about 1" deep is enough. First, cut the inside of
you’ll need to cut three pieces for the box. I usually use a #58 the box. Then, glue a slightly larger square of 1⁄4"-thick stock
bit to start the inside cuts. The three pieces to be cut are: to the bottom of the box and cut the outside dimensions
through the two pieces. A 1⁄8"-diameter dowel that’s 1" long is
Cover: Use 1⁄4"-thick stock or plywood. I like to use maple or a glued into the bottom of the cover. Then slide the dowel into
light-colored wood for the top and bottom to contrast with the the hole in the box to act as a hinge.
darker box (see photo). Drill the 1⁄8" hole as far through the cover
from the bottom as possible without breaking out the top of the Bottom: Use a piece of 1⁄4" x 39⁄16"x 39⁄16" stock or plywood.
cover. Notice the cover plan is drawn in reverse with the “X” for As I mentioned, I like to use a light-colored wood that matches
“Strike” on the wrong side so it will be correct when assembled. the cover. The bottom is glued to the bottom of the box after
The cover will be pivoted on a dowel to open and close the box. cutting the inside hole of the box. Then, cut the outside,
You should leave the line on the outermost cut on the cover so you assemble the cover by inserting the dowel into the hole and
can sand it to fit exactly on the box after assembly. sand the whole thing smooth.

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

Patterns courtesy of
LackWood.com

Cover (do not drill all the way through—see text) Box

Bowling Box Scroll Saw Workshop • Spring 2005 67


511-Lord Is Shepherd.qxd 12/14/04 12:11 PM Page 68

The Lord Is My Shepherd


Keep this comforting message close by with this attractive desktop plaque

By Jeff Paxton

W
ithout a doubt, Psalm 23 is one of the most popular TIPTIPTIPTIPTIPTIP
passages of the entire Bible. We hear it read at
Using The Pattern As A Wall Plaque
weddings, funerals, and see it printed on greeting
This pattern can easily be converted so that it can be hung on a wall in
cards, and also framed hanging in homes and churches. The
your home, office or church. Simply enlarge the pattern 130% to 150%,
comforting message of the psalm is what draws us repeatedly depending on the size you desire, and ignore the instructions for the base.
to this passage of Scripture. To hang the plaque on a wall, there is no need to attach any hangers to
You can scroll this piece to sit on a desk, or to place on a the back of the project. Simply place a nail in the wall, and hang the piece
bookshelf or mantle as a constant reminder of that comforting over the nail. Using the 1⁄2" oak will hide the nail very well. When you
truth that the Lord takes care of His own. Better still, scroll this stain the piece, keep in mind that the words of the project will look better
project to give to a friend or family member to remind them of and will be easier to read on a wall that provides contrasting colors.
this wonderful truth.
Step 1
section.) Use a premium quality temporary bond spray
adhesive to attach the pattern to the wood. Make sure the grain
of the wood is running in the direction you want before
securing the pattern to the wood. If the pattern lifts while
cutting, apply some clear packaging tape to keep the pattern in
place. The packaging tape will also lubricate the blade to help
keep the blade from burning the wood. It is not necessary to
cover the entire pattern with tape, just those places that are
smaller and tighter, thus requiring a slower pass in the 1⁄2" oak.

Step 3: Drill the blade entry holes. Use a drill or drill press
Step 1: Carefully select the wood for this project. Look for to make the blade entry holes with a 1⁄16"-diameter bit. As
some oak that has the grain visible with a certain character that much as is possible make the entry holes near right angles or
will stand out when stained. For this project, I purchased the corners in the areas to be cut out. By starting and finishing a
1⁄2" oak in a width of 6" x 2', which is common at most home cut in these places, you will ensure that your cuts turn out
centers. I then cut the wood in half, leaving me two pieces 1' smooth, and you’ll reduce wear and tear on the blade caused by
long x 6" wide. Using a premium wood glue and a clamping cutting through a lot of waste material.
workmate bench, I glued the two pieces together. If such a
workbench is not available, three bar clamps will work just as Step 4: Cut out the pattern beginning with the most difficult
well. By preparing your work piece this way, you get to select letters, and work to the larger and easier cuts. Make sure all
the wood that will look best, and save some money as well. inside cuts are made, as well as those that make the cracks in
the rocks at the bottom of the pattern, before making the final
Step 2: Photocopy the supplied pattern at 100%. Using outside cut. To make the outside cut, drill a blade entry hole
some scissors, cut around the edges of the pattern so that there near the bottom corner and begin here rather than cutting from
will not be any overlap when you the outside of the wood. By using a blade entry hole for the
Patterns for
Lord is My Shepherd on the glue the pattern to the wood. outside cut, you keep the entire piece intact until you complete
PATTERN PULLOUT (Find the pattern on the pull-out the final cut.

68 Scroll Saw Workshop • Spring 2005 The Lord is My Shepherd


511-Lord Is Shepherd.qxd 12/14/04 12:11 PM Page 69

Step 5 mineral spirits to remove the glue residue. Allow the piece to
dry thoroughly before sanding. To remove any small splinters
or rough edges on the letters, use some 150-grit sandpaper
wrapped around a nail to get inside the letters. Final sanding is
done with 220-grit sandpaper.

TIPTIPTIPTIPTIPTIP
Getting The Wood Level Before Gluing
Since you are actually gluing two flat pieces of wood together for this project,
you must make sure the bottom and top of each piece are perfectly flat
before gluing. If not, there will be cracks or voids where the pieces have been
glued together. I suggest using a belt sander to get the proper fit. By holding
the pieces together and applying some pressure with your hands, you can see
any areas that are not perfectly flat, and smooth them down with the belt
Step 5: Remove the pattern from the wood using a hot air sander. Keep working the wood until the pieces fit perfectly together.
gun or mineral spirits. Use a small paintbrush with some

The Lord is My Shepherd Scroll Saw Workshop • Spring 2005 69


511-Lord Is Shepherd.qxd 12/14/04 12:11 PM Page 70

Step 6 Step 9: Apply the stain. Before staining the piece, check to
make sure that no glue seeped out when gluing the pieces
together. Any glue that did seep out should be removed with
sandpaper because the stain will not penetrate the glue and
will leave a yellow streak on your project. Blow all the dust
from the piece, carefully removing any debris from the inside
of the letters.
Use a small brush to apply the stain. Work the stain into all
the letters and crevices in the rocks. Working from both the
front and back of the piece will help get complete coverage in
those hard to reach areas. Allow the stain to dry for 24 hours.
Blow the entire piece again to remove any dust that make have
Step 6: Cut out both the smaller first tier of the stand and settled on it. Then apply three coats of a clear gloss finish spray
the base piece to the dimensions listed in the Materials & waiting at least 30 minutes between each coat. Allow the piece
Tools list. Sand both pieces with 150-grit sandpaper followed to dry at least 24 hours.
up with 220-grit. Check to make sure the top piece will sit
squarely on the base with no space or cracks showing. Also MATERIALS & TOOLS
determine the direction you want the grain of the oak to run. Materials: Tools:
• 1⁄2" x 11" x 9" oak • #3 Flying Dutchman reverse
After wiping the pieces with some tack cloth to remove the • 1⁄2" x 101⁄2" x 1" oak (stand, tooth blade
dust, glue the smaller tier to the top of the base, making sure first tier) • Drill with 1⁄16"-diameter bit
to center the top piece onto the base piece. Clamp the two • 3⁄4" x 12" x 21⁄2" (stand, base) • Clamps (2 bar clamps, and
pieces together and allow to dry for 24 hours. • Sandpaper, 150 and 220 grits small C clamp)
• Tack cloth • Scissors
• Temporary bond spray adhesive • Ruler
Step 7: Sand the stand to remove any glue that may have • Clear packaging tape • 1" paintbrush
seeped out. Do final sanding with the 220-grit sandpaper. Set • Premium wood glue • Belt sander (optional)
the piece with the shepherd and words onto the stand. Before • Medium brown stain • Hot air gun (optional)
gluing, make sure both pieces will fit together without voids or • Mineral spirits • Air compressor (optional)
cracks. Blow any dust off of both pieces with an air compressor • Clear coat finish spray (gloss)
or remove the dust with some tack cloth.

Step 8 FURTHER READING


By Jeff Paxton
Words of Faith in Wood
Learn to express your faith in wood with 53
inspirational “mix and match” scroll saw patterns.
$14.95 plus $3.50 S&H (parcel post)

Available from:
Fox Chapel Publishing
1970 Broad St., East Petersburg, PA 17520
Phone: 800-457-9112 FAX: 888-369-2885
www.FoxChapelPublishing.com
Or check your local supply store.

About the Author


Step 8: Glue the pieces together. Use a premium wood glue Jeff Paxton lives in Russellville, Arkansas with his
to secure the pieces together. Use at least two bar clamps, one wonderful wife Marci, and his two children Austin and
on each end to secure the pieces together. A small C clamp may Ashley. He is the senior pastor of the First Baptist
Church of Dover where he has served for over 16 years.
also fit between the shepherd and the staff, along with a grip
When not working or scrolling, Jeff likes to play golf
clamp on the end to provide additional pressure to give a tight and “piddle” with his water garden. He has written
bond. When using the bar clamps, be very careful when several articles for Scroll Saw Workshop magazine, including “Bless this
applying pressure so as not to break the piece, since the letters Home,” which appeared in Fall 2004 (Issue #16). You can e-mail him at
will be more fragile. Allow the piece to dry for 24 hours. jpaxton@cswnet.com or fbcdover@cswnet.com.

70 Scroll Saw Workshop • Spring 2005 The Lord is My Shepherd


592-Spring Bunnies 12/14/04 12:12 PM Page 71

SPRING BUNNIES
Segmentation Style—
Perfect Wall Art
for a Child’s Room

By Frank Droege

T
his colorful scene of spring
is another example of scroll
saw art I call mosaic
segmentation. You’ll end up with
a piece that projects a look of
intarsia but this segmentation has
a flat surface, and the numerous
colors are from paints, not
different colored woods.
Rounding the corners will give
the finished artwork the illusion
of a ceramic tile. This project can
hang as a plaque but if the loose
pieces are not glued, you can give
your child a puzzle.
Begin this project by making
multiple copies of the pattern while Step 5: Sand the project. Start by dry your choice, paint the sides and edges of
retaining the original one. Remember, assembling the pieces inside the frame each piece according to your color plan.
you can simplify the project by removing and sand them with the 220-grit
lines and decreasing the number of sandpaper. Then round over the edges of Step 7: Glue the frame to the backing.
pieces in any pattern. the pieces with the handheld grinder. Starting with a corner piece, carefully
Leave the outer edge of the frame square. assemble and glue the pieces in the frame
Step 1: Prepare the blank. Start by with yellow wood glue. Add any fine details,
cutting out a piece of wood a little larger Step 6: Paint the project. Use a tack such as eyes, with paint or a woodburner.
than the pattern you wish to scroll. Then cloth to remove any sawdust from the
glue the pieces. Then, using the acrylic paint of Step 8: When the glue has dried,
Patterns for according to the manufacturer’s directions,
pattern Spring Bunnies on the
onto the PATTERN PULLOUT MATERIALS & TOOLS apply a satin varnish to the entire piece.
board. Then hang the piece for display with
Materials:
• 3⁄8" x 11" x 9" white pine or white cedar sawtooth hooks or wire and eye hooks.
or softwood of choice (pattern board)
Step 2: Using the #2 reverse tooth • 1⁄8" x 11" x 9" (backer board) About the Author
blade, first saw the frame and then the • Temporary bond spray adhesive Frank Droege of Voorhees,
remaining pieces. • Sandpaper, 220 grit New Jersey, is an award-
• Acrylic craft paints of choice winning, multi-talented artist,
• Yellow wood glue who especially enjoys painting,
Step 3: Remove the burrs from the segmentation and painted
• Acrylic varnish
backs of the pieces with 220-grit intarsia projects. Between
• Sawtooth hooks or wire and eye hooks
sandpaper. exhibiting at juried shows and creating his art,
he writes articles for Scroll Saw Workshop and
Tools:
Step 4: Transfer the numbers to the • #2 reverse tooth blade books for Fox Chapel Publishing. His most
• Handheld grinder or micro motor tool recent articles for SSW were “Stylized Butterfly
bottom of each piece. Then carefully pull
with 1⁄4" sand band, for smooth edges Segmentation,” featured in Summer 2004 (Issue
the paper pattern off the wood. • Woodburner (optional) #15) and “Nantucket Lighthouse,” which
appeared in Fall 2003 (Issue #12)

Spring Bunnies Scroll Saw Workshop • Spring 2005 71


497-Daydreaming Cats.qxd 12/14/04 12:11 PM Page 72

DAYDREAMING CATS

Turn These Felines into Cash at Your Next Show


By Terry Calway

F
eline lovers are sure to love this Step 3: Using 1⁄4"- and 1⁄32"-diameter bits, splinters that may have occurred during
whimsical scene of house cats in drill blade entry holes at a location on the Step 3.
their favorite spot—on a window pattern that you feel comfortable with for
ledge looking out. The portrait with the cutting out the unwanted material. I use Step 5: Insert the scroll saw blade of
hardwood base is classy enough to be the smaller drill bit in the tighter areas that your choice through the blade entry
displayed anywhere, and it looks a lot don’t give you much room and the larger holes and start cutting out the unwanted
harder to make than it actually is! drill bit where I have more space. material.

Step 1: Make a copy of the pattern. Use Step 4: Sand the back side of the stock to Step 6: Remove the pattern from the
scissors to cut the pattern to the 6" x 81⁄2" keep it flat on the saw. This removes any wood, and using 220-grit sandpaper,
size to fit your plywood piece. sand the burrs off of your piece. Sand
TIPTIPTIPTIPTIPTIP the entire silhouette to your desired
Step 2: Using temporary bond spray Minimizing Splinters finish. Remember to always sand in the
adhesive, apply When drilling blade entry holes into a direction of the grain.
Pattern for
the pattern to Daydreaming Cats on the pattern, use scrap wood under your piece to
the plywood. PATTERN PULLOUT keep splinters to a minimum.

72 Scroll Saw Workshop • Spring 2005 Daydreaming Cats


497-Daydreaming Cats.qxd 12/14/04 12:11 PM Page 73

TIPTIPTIPTIPTIPTIP Step 14: Using masking tape, cover


your finished base completely—top and
Blade Use Suggestion bottom.
Use the smaller numbered blade for the
delicate cutting and the larger numbered
Step 15: Put on your rubber gloves and
blade for the easier cuts.
mask before spraying the silhouette with
primer. By holding the base, you can
Step 7: After finishing the scroll saw rotate the item to get into all the nooks
portion of the project, set your and crannies. Allow the primer to dry.
silhouette aside and get your router out Repeat this process with your black
to make the base. spray paint. Always spray the paint in a
well-ventilated area.
Step 8: Take your 3⁄4" x 2" x 9" piece of
wood and cut a 1⁄8"-wide slot down the Step 16: After the paint is completely dry,
center of the length approximately 1⁄8" remove the masking tape from your base.
deep. Your “Daydreaming Cats” is now
complete!
Step 9: Using the 3⁄8"-diameter round-
Base Detail
over bit in your router, set the depth of
the bit to go into the wood about 1⁄8". overnight. The finish must be
MATERIALS & TOOLS
This will give the base a “step” look. Go completely dry before continuing to the Materials:
• 1⁄8" x 6" x 81⁄2" plywood of choice
all the way around the top—on the same next step. • 3⁄4" x 2" x 9" wood of choice
side as the groove already cut in Step 8. • Sandpaper, 220 grit
Step 12: Dry-fit the scrolled silhouette • Masking tape
Step 10: Once the router portion of the into its base. The silhouette should fit • Temporary bond spray adhesive
work is complete, sand the base to your snugly without too much pressure. This • Black spray paint (glossy or flat finish)
desired smoothness. Remember to sand • Primer spray paint
can be achieved by sanding out the
• Clear coat finish spray or stain color of
in the direction of the grain. groove until the scrolled piece fits nicely. choice
• Wood glue
Step 11: Be sure to put on your mask Step 13: Place a couple of drops of wood
before staining or spraying the clear coat glue in the slot of the base. Insert the Tools:
• #3 and #9 reverse tooth blades
on the base to reach your desired finish. scrolled silhouette and let it dry
• Drill with 1⁄4"- and 1⁄32"-diameter bits
Allow the stain or clear coat to dry completely in place. • Router mounted to table
• 1⁄8"-diameter straight bit
• 3⁄8"-diameter round-over bit with bearing
• Scissors
• Rubber gloves
• Mask for painting

About the Author


This is Terry Calway’s second
article for Scroll Saw Workshop.
His first article, “Horse Lover’s
Picture Frame,” appeared in
Fall 2004 (Issue #16). Terry is
an electrician who has always
enjoyed “tinkering.” His designs are also
featured in a few art/craft shops near his home in
the Buffalo, New York area, where he lives with
his wife, Debbie, and daughter, Mercedes.

Cat Detail

Daydreaming Cats Scroll Saw Workshop • Spring 2005 73


538-Chattering.qxd 12/14/04 12:12 PM Page 74

CLIP-N-SAVE
By Joannie West
Controlling
This new column offers tips, tricks,
CH-CH-CHA-CHATTERING
techniques and troubleshooting advice you
can use today to solve common problems
experienced by scrollers on their journey
from a “new blade” to expert. In this
issue, we tackle the always-frustrating
subject of scroll saw “chatter,” and what
blades work best for thick wood.

H
ow many times have you been
sawing along smoothly and just
as you approach a delicate turn,
suddenly, the wood lifts out of your
hands and begins jumping rapidly up and
down, ripping the project out of your
Chattering, when the work piece bounces up and down on the scroll saw table, can easily
hands? This is called chattering.
damage delicate fretwork, but it is easily preventable if you take your time.
Chattering happens when the teeth
of the blade catch on the wood, drawing Wrap the wood in clear packaging Don’t use a dull blade. The life of a
it up and down with the blade’s tape. The adhesive provides lubrication blade can vary quite a bit among brands.
movement. Chattering is not only and allows for freer movement of the As a general guideline: if the blade has
annoying but can be potentially fatal to blade. It also reduces burning. One or been in use for more than one-half hour
your design. First, it can make your two layers wrapped all the way around or has signs of burning, it is time for a
blade wander off your line. Second, the project usually does the trick. new blade.
delicate pieces can break off when the
wood bangs against the table. Proper hand position and pressure is Go easy in the corners. Slow down on
What causes chattering? More important. Finding the balance between those corners. Again, it is a balance
importantly, what will prevent it? Keep applying enough pressure to prevent between going fast enough to prevent
this list near your work area and, for a chattering and little enough to retain burning but slow enough to prevent
chatter-free cutting session, review it fluid movement takes some practice. chattering. It is often helpful to position
before you turn on your saw. Keep in mind that the amount of at least one finger close to the blade on a
pressure needed will change with the tight turn. This puts the pressure right
Choose quality wood. Warped wood thickness and type of wood. Make sure where you need it.
will cause chatter because the cupped you apply even, downward pressure on
shape keeps the wood from laying flat the workpiece. Don’t force the wood into the blade. If
against the table. Buy quarter sawn wood the blade is bending and leaving a notch
when available because it is the most at the back of your throat plate, you are
stable. To reduce warping, store wood on exerting too much force. If the wood is
its edge so the air circulates evenly. forced into the blade faster than the teeth
can cut, then the teeth will catch on the
Remove burrs from the back of the wood.
wood. Drilling almost always results in
burrs. Liked warped wood, the burrs About the Author
keep the wood from laying flat against Joannie West is a frequent
the table. You can lessen their severity by contributor to Scroll Saw
Workshop. She also enjoys
using sharp drill bits, drilling slowly and sharing her love of
using a backer board. Lightly sand the Good hand position keeps steady pressure woodworking with others
back and remove all splinters before on the workpiece, reducing the chance for through classroom instruction.
cutting. “chatter.”

74 Scroll Saw Workshop • Spring 2005 Controlling Chattering


SSW18-Ad Page 75-Classifieds 12/14/04 9:07 AM Page 75

CLASSIFIEDS
CLOCKPRINTS Archival quality clock faces feature unique
designs or traditional styles, including Shaker and Mission.
Clock faces can be custom fit to your clock.
www.clockprints.com <http://www.clockprints.com/>

OTT-LITE TRUE COLOR LAMPS! Bright, glare-free, perfect for


color matching. Bring daylight illumination inside! Discount
prices! www.lumenlight.com (800)742-4289

WWW.SCROLLIT.COM
We carry lots of Scroll
Saw Blades and
Accessories. Olson,
Flying Dutchman,
Books, Patterns, Steel
Squares, Small Drill
bits and Woodworking
Plans. There are many
tips for Scrollers too.

Scroll Saw Workshop • Spring 2005 75


495-Cutting Thick Wood.qxd 12/14/04 12:10 PM Page 76

CLIP-N-SAVE
By Frank Pozsgai

Cutting
THICK
THICK WOOD
WOOD
A Blade That Cuts Like
It’s Slicing Butter

Cutting thick wood,


such as these puzzles, Blades for cutting
requires a change in thick wood include, from
blades. Scrolling expert top, Delta 40-194, Delta 40-
Frank Pozsgai offers his 193, Delta 40-192, Sears’ Craftsman
suggestion for blades 29440 with pin ends, Olson no. 408, and
that zip through thick Olson no. 407. The Olson 41001 pinned
hardwoods. blade is not pictured.

29440 with pin ends. These blades are TOP-RANKED Scroll Saw Blades
.100" wide and have ten regular-style for Cutting Thick Wood
teeth per inch. They cut well in wood up
to 11⁄4" thick but struggle with 2" stock. 1. Olson 408
or 40800
Delta’s plain end blades 40-193 and
40-194 are aggressive blades but are 3⁄16" 2. Olson 407
wide with 10 regular teeth per inch and or 40700

C
1⁄4" wide with seven regular teeth per
utting thick wood is always
tough, but there are several inch, respectively. These wider widths 3. Delta 40-192
blades that make the job a little prevent the close radius cuts most
easier! I can recommend six blades from scrollers are used to. 4. Sears Craftsman
three different companies. While many scroll saw blades offer 29440 (pinned)
While it is obvious to me that few a narrow width to do close radius cuts,
scroll saw blades can ever clear out the tooth style (hook is most 5. Delta 40-193
sawdust/chips properly to avoid aggressive) and number of teeth per
burning, The Olson Saw Company’s no. inch (fewer is better) and set (ETS— 6. Delta 40-194
408 or 40800 Thick Wood™ scroll saw Every Tooth Set) combine to prevent
blade (tooth set range .027-.029) was the burning in the most stubborn and
About the Author
best blade, followed by Olson’s no. 407 volatile wood.
Frank (Csaba) Pozsgai has
or 40700 Thick Wood™ scroll saw blade Remember, the thicker the piece of been a consultant for several
(tooth set range .022-.024). Each of hardwood cut, the greater the chance of scroll saw manufacturers and
these two blades is .080" wide for close it burning. Hardwoods I have cut with continues to design, fabricate
radius cutting and has seven hook style these blades include white and red oak, and sell accessories making
Eastern maple, Eastern ash, purpleheart, scrolling easier and more fun. He
teeth per inch for efficient chip and dust has written several books on scrolling (including
evacuation. The no. 408 cuts through cherry, black walnut and Alaskan yellow metal and plastic) and has a business called
these hardwood pieces like slicing butter cedar. When cutting such woods, I Pozsgai’s Designs, www.pozsgaidesigns.com,
and without burning even in the tightest suggest placing 3M clear tape or any specializing in scroll saw innovations. He worked
turns. The Thick Wood™ blade is also clear packaging tape over the pattern. for Bethlehem Steel in the metallurgical department
This type of tape helps lubricate the for over 16 years, which has given him a great
available with pins—no. 41001.
advantage when selecting the type of scroll/band
Other blades include Delta’s 40-192 blade to further prevent burning when
saw blades in cutting various materials. He can
with plain ends and Sears’ Craftsman cutting with or against the grain. be reached at frank@pozsgaidesigns.com.

76 Scroll Saw Workshop • Spring 2005 Cutting Thick Wood


SSW18-Ad Page 77 12/14/04 9:07 AM Page 77

Subscriber Services
The staff of Scroll Saw Workshop is dedicated to
providing you with the highest level of
customer service. The information below will
help you if a problem should ever arise.

Questions about your subscription?


Scroll Saw Workshop Magazine
1970 Broad Street
East Petersburg, PA 17520
Phone: 1-800-457-9112
Fax: 717-560-4703
Email: subscriptions@scrollsawer.com
If you email us, include information from the
label in your message – especially your
subscriber number and mailing address.
When your write or call us, include mailing
label information from your recent issue of
Scroll Saw Workshop. If it is not available,
please give us the name and address used for
your subscription.

How to read your mailing label.


The number circled to the far left of the label
indicates your customer number. The number
circled on the far right indicates the expiration
date. Your customer number enables us to
locate your account quickly and accurately.
Please enclose your label with all
correspondence.

Customer Number Issue # Mailed Expiration Date

Directory
Comments & Suggestions
Write to the above address or email us at
shannon@FoxChapelPublishing.com

Editorial
For editorial information, call Scroll Saw
Workshop’s editors at 717-560-4703, write to
the above address, or email at
editors@scrollsawer.com

Information
To request a catalog of books and magazines,
call 1-800-457-9112.

Events
To have an event listed in our events section,
call Bob Duncan at 717-560-4703, write to the
above address, or email at
duncan@FoxChapelPublishing.com.

Please include dates, location, hours, prizes,


admission charges, show content, and contact
names with addresses and phone numbers.

Scroll Saw Workshop • Spring 2005 77


SSW18 Ad Directory.qxd 12/14/04 10:56 AM Page 78

ADVERTISING DIRECTORY

Hawk Precision Scroll Saw R.J.R. Studios


www.hawkwoodworkingtools.com www.rjrstudios.com
Discover the next generation of scroll saw with the Are tired of the belt sander? Are you knuckles
new Hawk G4. Enjoy the versatility of a giant 26” bruised? Are you looking for a professional way to
throat and vibration free performance cutting do intarsia? We have what you are looking for!
materials up to 2-5/8” thick. Patented design and Call us for details or visit our website at
exclusive features make the Hawk the choice of www.rjrstudios.com
professional scrollers. Send today for your free
demonstration video.
R.J.R. Studios, 81 Tindall Road, Robbinsville, NJ 08691
Hawk Woodworking Tools, P.O. Box 369, 1801 Vine St.
609-448-2414
Harrisonville, MO 64701 • 800-487-2623

Roberts Studio Sloan’s Woodshop


www.intarsia.com www.sloanswoodshop.com
We provide patterns, videos and OnLine Scroll Saw To place an order, call, fax or write us. Please
blades. Three ways to order: by calling Mon thru include your phone number and street address (no
Fri 8:30am to 5:00pm EST, visiting our web site PO Boxes for orders.). We are open Mon-Fir 9am-
www.intarsia.com or by mailing your order and 5pm, Sat 9am-1pm Central Time. When you call
payment to our address below. us you’ll talk to more than just an order taker!

Roberts Studio, 2620 Heather Rd., Seymour, TN 37865 Sloan’s Woodshop, 3453 Callis Rd., Lebanon, TN 37090
1-800-316-9010 615-453-2222

Wildwood Designs Wooden Teddy Bear


www.wildwooddesigns.com www.woodenteddybearonline.com
Scroll saw patterns and supplies, including blades, Over 1000 scroll sawing patterns and 75 books
clock parts, books, plywood, hardware, and tools. available through our free catalog which also
Order the latest clocks and scrollsawing products includes Olson Scroll Saw and Band Saw Blades,
via the internet or through our free color catalog. forstner bits, drill bits, clock fit-ups, music
We offer the best prices and the most products for movements, needle file sets, shaped sanding grips,
the most enjoyable one-stop shopping experience. pens and pencils, and much more. For a free
catalog call 1-888-762-9149.
Wildwood Designs, PO Box 676,
Richland Center, WI 53581 • Phone 1-800-470-9090 Wooden Teddy Bear, Inc. P.O. Box 33917, Portland, OR
97292-3917 • Phone 1-888-762-9149

Mike’s Workshop Peterson’s Custom Lumber


(605)582-6732 888-796-9663 ENTHUSIASTIC SCROLLERS WANT
TO LEARN ABOUT YOUR PRODUCT!
www.mikesworkshop.com www.petersonscustomlumber.com
Page 77 page 75
Advertise in
National Artcraft Co. Prox-Tech
(888)937-2723 (877)PROXXON
www.nationalartcraft.com www.proxxon.com/us
Page 77 page 75 Scroll Saw Workshop is devoted exclusively
to scrolling from cover-to-cover and attracts
Ocooch Hardwoods Woodcraft Supply a passionate scroll saw audience that
(888)322-2432 800-542-9115 actively seeks the newest tools, materials,
www.ocoochhardwoods.com www.woodcraft.com and accessories.
Page 77 Page 11
Let us connect you with
your next customer.
Olson Saw Company Wooden Gear Clocks
(203)792-8622 715-955-4104 Call Paul McGahren @ 1-888-840-8590 ext. 42
www.olsonsaw.com www.wooden-gear-clocks.com to learn more about the advertising
Page 11 Page 77 opportunities in Scroll Saw Workshop

78 Scroll Saw Workshop • Spring 2005


SSW18-Ad Page 79 12/14/04 11:03 AM Page 79

SHOW OFF YOUR WOODWORKING PRIDE!


Introducing Five New T-shirt Designs for Woodworkers
Our two previous
t-shirt designs have
been so popular, we
now offer five great
new designs. These NEW!
100% cotton shirts
make great gifts for
the woodworker in
your life—or for
yourself!
T-SHIRT STYLE $12.95 $14.95

ADULT SIZES MEDIUM LARGE X-LARGE XX-LARGE

Eat Sleep Carve TS001A TS001B TS001C TS001D


You Should See What I Saw TS002A TS002B TS002C TS002D
Proud to be a Carver TS003A TS003B TS003C TS003D
Proud to be a Scroller TS004A TS004B TS004C TS004D
Insets show design Proud to be a Woodworker TS005A TS005B TS005C TS005D
from back of shirts
Proud to be a Woodturner TS006A TS006B TS006C TS006D
CHILD’S SIZES SMALL MEDIUM LARGE Child’s Sizes
Order yours TODAY!
Official Workshop Helper TS007A TS007B TS007C all $12.95
800-457-9112
www.FoxChapelPublishing.com

WCI 18 WCI 22 WCI 24 WCI 27 SSW 13 SSW 14 SSW 15 SSW 16

Back Issue Special! Best Deals - $2 Each


Limited quantity–– Cover price: $5.99 each SSW Collector’s Set: $22. Save nearly $50!
when they sell out, Order one magazine below: $5 each Scroll Saw Workshop Issues Available:
they will not Order two or three magazines for $4 each SSW Issue 1 SSW Issue 10 SSW Issue 14
Order four or more for just $3 each SSW Issue 2 SSW Issue 11 SSW Issue 15
be reprinted! SSW Issue 6 SSW Issue 12 SSW Issue 16
SSW Issue 8 SSW Issue 13
Woodworkers like you know that our two magazines—Scroll Saw
Workshop and Wood Carving Illustrated—are the leading how-to WCI Collector’s Set: $48. Save over $100!
resources for carvers and wood crafters. Several of our back issues are Wood Carving Illustrated Issues Available:
sold out (and are now collectors’ items!) The remaining copies of these
WCI Issue 2 WCI Issue 11 WCI Issue 20
two popular publications are now being offered to you at these great
WCI Issue 3 WCI Issue 12 WCI Issue 22
prices. Act now, because once they’re gone, THEY’RE GONE! Please WCI Issue 4 WCI Issue 13 WCI Issue 23
note that Scroll Saw Workshop Issues #3, 4, 5, 7 and 9 and Wood Carving WCI Issue 5 WCI Issue 14 WCI Issue 24
Illustrated Issues #1, 9, 19 and 21, have sold out and are not available. WCI Issue 6 WCI Issue 15 WCI Issue 25
WCI Issue 7 WCI Issue 16 WCI Issue 26
Fast, Secure On-Line Ordering at WCI Issue 8 WCI Issue 17 WCI Issue 27
www.FoxChapelPublishing.com WCI Issue 10 WCI Issue 18 WCI Issue 28
or call toll-free: 800-457-9112

Scroll Saw Workshop • Spring 2005 79


SSW18-Ad Page 80-IBC 12/14/04 9:06 AM Page 80
SSW18-Ad Page 80-IBC 12/14/04 9:07 AM Page 81
SSW18-Ad Page BC 12/14/04 9:08 AM Page BC2
Walt Disney’s Castle
Page 30 - SSWC Issue 18
Difficult

© 2011 Scroll Saw Woodworking & Crafts


Light Holder for Version A
Window Light

Light Holder for Version B


Window Light
Light Holder
Night Lamp
3 pieces
Easy
Frame Only
Man in the Moon Mirror
Page 34 - SSWC Issue 18

CLOUDS
cut from 1/4” to 1/2” contrasting wood

© 2011 Scroll Saw Woodworking & Crafts


STARS
cut from 1/8” contrasting wood
544-Man In The Moon 12/14/04 11:20 AM Page 36

Photocopy at 100%

Note to professional copying services.


You may make up to ten copies of this
pattern for the personal use of the buyer
of this magazine.

MAN IN THE MOON OVERLAY


cut from 1/8” contrasting wood
Champion Cyclist
Page 37 - SSWC Issue 18

© 2011 Scroll Saw Woodworking & Crafts


© 2011 Scroll Saw Woodworking & Crafts
Calico Cat Intarsia
Page 42 - SSWC Issue 18

D
M
D

D
D

D
W
M
M
D
W
-1/4"

-1/4" M
M
W
-1/4"

lack
Copyright 2004-05© D
Kathy Wise Designs
PO Box 60
Yale, MI 48097 W
r D
kathywise@bignet.net
www.kathywise.com -1/4"

r wood W
-1/4"

M
D

D
M D

D
B
Y
D
W
D L
W

M W
M D
W
W
D W M

D
M W

M
D

D
D

-1/4"
W
M
-1/4"
W
D
53 pieces
Legend
Start with 3/4" wood
Grain direction
-1/4"
B..............Black ebony for pupil or stain black
M
D..............Dark shade of wood
W M..............Medium shade of wood,
an orange red for calico color
L...............Light shade of wood
Y...............Yellow golden shade for eye
-1/4"
W..............Any white wood
-1/4"..........Sand down or use 1/4" thinner wood
....Carve out area
Friendship Quilt
Page 51 - SSWC Issue 18
© 2011 Scroll Saw Woodworking & Crafts
The Lord is My Shepherd
Page 68 - SSWC Issue 18

© 2011 Scroll Saw Woodworking & Crafts


1st Tier

101/2 "

Base

12"
Spring Bunnies
Page 71 - SSWC Issue 18

© 2011 Scroll Saw Woodworking & Crafts


Daydreaming Cats
Page 72 - SSWC Issue 18

© 2011 Scroll Saw Woodworking & Crafts

Anda mungkin juga menyukai