NO.

68

NOTES FROM THE SHOP

$3.95

FIVE-DRAWER

CHAIRSIDE CHEST

No. 68

April,1990

1------

EDITOR'S

Wrodsmith
Ednor l)fJl\ltld 8. Peschkr

l>e$lgnDirector Ted KtulicrJc

\Innag;ng&blo,

I)oul(ll," L. Hie""

.\......
..rstantEdi,,'"

J. Strohman
Jam,... ~I.
Dolan
Tt'rT)

Pro;ea 0esII(n<1' K.m 'I1W1kd

Illumaoro 0 ... ;.1 Kre)11ng
C.. I') Clui......,....
Rod SIOIIkes

l'hti. GI"w",,1Q
C;rapbics Director J~)nSnyder
l'roj<ctSupplit< 1.<.11. ,-Inn Gurbart
CuoI01llC'I'ServX..., \Ill" Un"" MOtTOW
c",_s.n",r U"""Jo_
U001l>om"""n
Ktl" Bradford
0;,'0" Rhodes

Kt{IoItine Hines

COnl'nO Bmnson
VI.'kl Edwards

'I1le !>mith
Conorolk'l' Paul E, GnI)
~
Unda O'Rourt<e
(.:omputer~'I;
Kt-n 'liner
~ct",,",.o\dministrator D..uao '11. Udsu-r
Admmi_. No,,,,A. Scott
~nd,yBaum

l".~

Sou",ebot>kJen.

~I'"

Kenl A. Buck((>n
Shop M"" " .. "-"\of t~urtiA
Build",~'bioi....,."..
Itt:hit Knru...e
Jon&hrie
St. Loui>. '10 SWre
Bcrl<dey. CA s.- \11_1 ~""'_
o.-- \loines.lA "'_ 1\ , W.I~

Woodsmilh (1SSN 0164 4114) i. publish<-d

blmonthll' (F~bfUM)',April. Jun. Augus~ Oc-

lober, !J<,mbtr) by I\ood'milh Pubfi<hin

Co. 2:!'.l()(_d Ave, ()n M, "eo, LI50312.
\\oodsmith i~a r~l'lltC'r("d trademark of
II ... 1.mIIb 1'IIIIIC.JIiDa Co
CCop)";llt 1990 b) l\ootIsmrth PIIhIbbing

Cowp&n). AD riRblO """",,,.

Su,*ripdons: One lear 16".,,,,.) SI5.95,

...".) raM; (12 isou,,,,) S27 ,lIS, Canada and For

"Ho:Add$ll.OOpo.T>""".l!,S, ~.. d.only.Singit,opy price.S3,95,

s.condClassP_

PaId.. o,.,.MoinaIA

:uxi lll~o$cn.
PO!itm8Sb!r: Str.11 loh,ne, of i.ddre5~ to
lIood.tm t~,Bw. 4'1), 'I I 'I0Iri>.1L 6!0>1
SUbocripUOD Qu...uon'l? Coli 1iOO-ISS-m15
cn,l't"'itknLS; ~f~03),
7:30 om to b;3O

COLUN1N

Sawdust
L

ik~ most weodworkers, I really enjoy

g~lting into the details and techniques
ofworkingwilh 1001<.So. in thisissuewe're
introducing a new feature article: Tool
T, -chniques.

\Ve plan 10 hayt an nrucle like this m

e....,.ry i"ue - a pajI< or two devoted 10 a
particular shop 1001thai ....ill ,ho" tips 00
ho.. to get the meN out o( Ihat tool Thic
lime we're sho--ing a collection 01 tip> for
th, driDpres. (_ pajI'" 14and 15).
We've also expsnded our Questionand
answer feature '1'alkinR Shop" 10 two pag.",
so WI.! can provide mon In(omlatiou in thb
(om1311oo.
This is all part o( Ihl.!32page expanded
""rsion o( Wood.,,,,, til thOI'illU1ed .. ,th the
laS! issue. With the ex!r.l pajlt" " e 'llbe able
10 "'ow Iargcr prujet:t.-. and h,"e more art).
d., on toolsand woedworking [('Chniqot..,.
AlonRwith lhe issuv, ",,'n' "",uling out
Ihe new \Vood~1II11"Slol'tclIwloR.The idra
behind thiscalaJog is 10 rcplacethecld "protective cover." (( you've been -;ubscribing
(or awhile, you kilo lhal ....I.! used the proI"''live cover to sho the cov." of the b3ck
I...
-ue.....and list their content..
:-:ow."ith the new catalog,,~areabk 10
..how a 1m more projt_>(1~ from piL" i,....
ut.'S
and Rivea description ollh"m \h ";11..1,,,
uSCil 10 provide mort' in(omliltion on l'roo
jl'ClSupplies. TIliswili u,ually include ilems
relaled 10 thecutrem i"uI' BUIw,' hupe 10
hi, able to present a li'lul ;IlIlhl" SUp"hl~
available (or paSI projl-<'I, a, lhe catalog
grow .....

"')', J im is learning a 101and having a lot o(

Iun in the 1\,,,,~{Bmil/lshop
JOII ""yder has also 'wwd on 10 help
with Iht, graphics of Ih~ new catalog and
"ilh our direct mail packaR<'s.A>. the cata10j( .",,,,,,ranee improvc-; il "ill be the re'nit ..r Jon', ('{fort",
illrt'ady planned
St'\'rnI <1WIR\"', including"., 'S 10 produce
the "h.>lrC3ll!loR on a computer. (floe nev.
compun-r tf'Chnolog) ~n lhi ...area is as-Inundinll',) ,,-(,'n: also louldnR into a way 10
,lI'nduc<' pholo, of pruj<'( I' in fullcolor.
nil- an'. thai's gn.wing Ih.' fastCSIhere
i...customer service. \\'ht'll the first

H,",

"',JlHI,,",ltJ,

CalnluK (.. nlt' out, we were

d.lug. d ....ith onlt-'" lincla Morrow, the

m:m.1R(r of this gTOUp. wa ... ulm4J-.t over-

..1t,>lm.-d,and "'"

'penl

1110>1of

her time

111nn~ne ....prupW
~()r1uI14ttclv
'-'t \\c,1"(' abh- to 11i~ some
IIh'lol ,.....ple, C"ndl,', V",ki, Mic, Unda
JIUlt', .It,d Kri~jl)t~
an' ,111 tlllxi"us

to help

witlt (,nll'rs (or back i~'Ut~

or project
!>UI~"'<"Th.l1 if< up 10 K"II)' and seen to
fillt! ,,,,'rylhtn!! in our bulginll "':lA!bouse
onollt1l1 &1"",,,1110 ~ou II', an operation
thai ...."". like il "IQIlII up o.emighL
II tlh an th.. acti\1ly.I.t~li,' ha, been on a
non .Iop pun:hasing C)"k' (ur th, pa$1.""'O
monlh, 'fhj. =01,11 ,nuURh palX'rwork
Ihal Paul (our conlrolh'r) hir~d Linda
O'R"urkc 10 help wril" c11(....ks and spend
lIIor ... ~ And SOilgoc~,
''T, U.)IISS1'QRE.
"1tiI~thinl!'i "' ....egro ..
tllllh. reo "e were abo in th< proc("'5ofcJos.
iog Th. 1I'ood$",;lh $torr in SI, Louis.
Tht St. Loub >lore was Ihe fir'l
I\'"od.." II,$!~and il "'a, ajll't'al Olle_ By
Ino!Ot accounts it ~'as tht- larg(>sl~most
"t)mplelc siore for woodworker. in the
counlry. It was fun iU,IIO walk in thaI store
and wander around looking althings,
BUIil was a mailer or beinll in Ihe "'TOng
plact 81 Ihe wrong time TIw ,lOre "'3S Jo.
calrd nexl 10a Iargt' shopping mall calJed
thtSl,I.oui<GaIIeria Th.,ownt'roftheGaJ.
~ wanled 10expand, l'nfortunatd)'. the
1.....x/xmll/rStoreandaoouIIOOhomesand
30 other busln~s
were in Ihe way.
To mnkc a long story ,uIOr'l,Ihey lore
down thc \I'ood,,"'ilh SI(Jr. alld pul in a
p(\rkingloL It wasagr.al ,lOre 111 missiL
~'f}U

To round OUIthe caLalog. on lh.-la.-I p,g,.

" ..... included abri('Iind,'x to pr"j ...dS, plu'
n f.w ..xtra tips. I hop...Y"U .n~.), il
l>FWF,\CES,I usually 'PI'lId mOsl,,(this
column lalkiog .boul w'1(Jdworking. BUII
would like 10 talk aooul ,"m,' (If the new
llL",ple who are v.orl<inl{ht'r.,
la~fallwe began k>oklllllloran8l;....iSlanI
.'(lilur. Jim Dolan, .. ho, ,,",n a k)n~mc
sukriber. respondt-d. JIm ... , .. orkin!! in
th,' Phoenix .readuing lrulrk.-ung ~an:h
and consulting (orcc..l'pt.r:ttt' nl\\,: ....Jt.ltcrr...
After talking 10 Jim aboul alilhe lypical
job inlerview stuff. I a,k"d him why he
"allied to work at W..",I","I/1. lie said thai
I'very lime he build, a proit'Cl he learn,
"'",elhing new. He wanlt'd 10 help other
~'T '''iSLE. The nt'XI ibsue of
"uodworkcrs learn iiihal h.. had learned I\', ..t '. Ilk r.-:o.69) "ill be mailed during
and ha,'t' 8$ much fun doinl! i1. ~.,.,..u.".,10

..

".,.~""-'~

pm, Ct.'llIr1ll1i~. wt<'kday.only

~------------------~---------------------------7~2

W ",xhmll h

!'oJ". 68

[ N s [ [) E
A
LOOK
r---------------------------------------4~

Contents
SIr grl'lll
1TIes l Techniques I '4l
L!..J

Ii/l . [rom fellou: wood

uorkrre: 1. ,\'(!I?'(JI('SIOCkPugll Block.

;t, Fence

SIOIl, .~ Sia mp Dispenser Idea.

1,. Router Tablt: Hold-in. Jig .. 5. Sanding

Tube. Ii. fill/I(/Rubbing Deft Finish.

If6l
Ch,.<Slr[ru
and pane!
I2..J tio highligltlEc/ u-ith fll1/ed bra.,~

IChnirside Chest
L. ~

1111"

rOIMlnIC'

..J.

knob, orr. Rill" tu make thi volmu cabinet all heirloom "I"uJed

ITool Techniques
1...

11141 Dlilf
Pres.-1';ps alldjigllj"orget
tillY th nu).t
o!yolIl'drill press.

I~hop Notes

!)II/

-.J

....,;I

11161n'(I()(I,,"lilh
tip and ide(l~froln inside the
Shop; 1. A Molding
SOIlIR

.._-.:.~_~~

.. _ ...J

.l1iler BOJ', 2. Cull ill!! Duplicate Tenons

.j,

DI'(IlI'l'r ('IIII'lIr",~.

Tool Trchniqne:

pagel~

PilI/If SI(lIlIl

page 18

SOlld/)(I/JeI'J)i"l)(,lI~el'

page :t6

ClCllllpillg ,\fodi,ie

and Tenon Joint ...

111s1 ture.this
J I/'~T)/r,d by CI~~{1""lall"'(!lle !IIMI;'
whl/t oak:plant stand IIses

[plant
Stand
L-

..J

trod" ioual IIIlIrl i,'l! 111111(P"OIl joi l1ery.

I~

Here 'x a ""xii '" for ."oring qoarter

shre! . OJ XIIl/tiPCI pe rill you r shop.

Plus a Rlirk jifl !1I1" ('lIltlng sandpaper to
the correct .izejill' (/ pod ,.ancler,

IToois of the Trade

'----------""'

1Talking Shop
'-

__

...:..:.
__

'-

1~

n'e lake

1111

;111" /lIlt

look al JJI".

Stiki! Saudpap r.

I~

..J

Comment 1"1(1 QIIl'.,lions about

jointers IlIld planers; band S(lU'
blade ...: runnersforju;: IIlid diRTKlsiJlg of
oily raq.

[ou~ce,~
L.O...;.;,,;,.... ,;.;;.

N o. 61>

11321theHlll'cil"al'l'
n upptie needed fO
project ill thi . issne.

I'

.J

________________________________

_.J

F R 0 ~1

F ELL

0 \X'

WOODWORKER<"

Tips & Techniques

NARROW STOCK PUSH BLOCK
\\1lco ripping

-tock.

by cutting a ~''''Ihick spacer to blatl,.la) oUIa suur ...It'I~XIIdr

10 01,111'11 the thickness 01 "Mil li<och '1l('p is h h,~h and
usin!!> posh <tick Iwon; about yourripll IK" nil' width islaJrh !,oIl' wide to !'uit djfft n nt stock
catching II"..push .Iick betwe..n critical berau......you 9."'3.n\th
thlCklll""" Then, ,'111 out tho
Ih. blade and !he It'll<' In,1..ad push block Itl fil ,"ul:l) cverth.. laces. I I CUInun, U';Ol! lit. band
(II a pu-h stick, I bu,;1 a pu,b rip fenCl, but not '" u!:ht thalli ...3'.... but ~"'Oucould at"" USi. a
block that straddle- m) np bind,
''0111111: ""' or back "',.. )
{f.'IKe. refer to F II{ .!
..\Iter fUlling till" spacer, I
\eXl. I:lu(' the fact' 1"<'<"" I..
My push block vcr-, ... n b used I, Ihl(k ~l

,,,nllclOOl"k\
tlu .;,paC'trsolhl'ooCtllI11t"ftMt (.1
made out or 1\\'11 (;,,t
of Ihe- two rilt:4,lli'rt~.Cut the two both taft> pieces ridt.~fill tilt' l(~p
Mu'onite held tOI[l'II",r by 3 pieces 7"
II"d hi!!h "nuURh ()f Ih(' <II" labl e and It.. 'I"" r
'pacer And. to pu,h dill"n'nl to c-l(>ar any aIJju'tm('nl bolt....tl.l flt.'a" IJIt, top C)( your tabl '&.:1\\
tlucknesses ul 'h~k.1
cut 'tair the lop 01 tlu- 1"1' I"ne,' plu< ,. np f"f\l'(
'I, p notches on lb. lronl end 01 (the thic kness uf the spanr).
TII.n. to l!<1 a -ecure gnp on
Iht' pu,h block. I dn1t.d a ,
the \la ...)nile f ....te nearest the see f-lj( I
blade
'(.~.IOC'Ut the ...tepped ruts d13. hol, and ~;ucd a , do.. I
To make this pu,h bk" k stan on the Pll'l th t 1a('(."'S the :0>3\.\ 0''31' th.. back end 01 the S)>at"t'!'
,"VI' never

UII,'~!/I

really lel1cUJl1(onabl(' width

'"t'(_'~

I",,~

"

v.

fence. I al>o

hold a piece 01 ocrnp aga;n'1llhe

I.. "<'<"whitt- cun Ol!....... f-ag. 2.
1/,>bn1 SpaU""
Lak "",,1h. f'{(lnda

h',flf'lrts .\',,.,, 1'IIJf '''(J(J, Id()('k l~

",,1, rllt. I fl, f l'Jr "I'/Itl'fl IInr
(tJ r J
' n fd MOl K'I~MpU'nl",
\\ It ... n p11'/.
~ d I II piece

tAl'ONlli a t,
tcht'k
fluid br
,.'U!II oft}. _"""

IA. T"";
t red Ill; f) ~

CUT SPACH
WlOn< TO
maJPf(N((

FENCE STOP

llJ!hl 3lr.l""llh"

POS4TION SPACII

TOellA. "I'... '(NC'

STAMP DISPENSER

Tll,'otherrlay HI till' hardware

ware or ,",,'('tll,',,1supply stores,

I n~"'nllymad e a I,.,.. stamp

l found a Ilrt, ...I1\;td, ...(tlP

that Yo'orks ,l{rt'al t)1I In), mdi'il
arm.a" Cen' h'call,nab.-anl
C..:lamp conduit h.nl:~r hee
dra" iog) and l'all bt(,.. nd Cura
IInle over SI al 010,1 ~"",I hard

"nlt"rc* itr,' cliff('rt\nt sizes ()r

conduil hanK'.... \'311abl~.TIll'
on.. I boughl ha,an(lpenillgul

Cii~r,c'n"'('r~ from '1"J(J(I~,"it"

SCI t).) .-\....."..iLh m...,...' ,taJl'P di~
pt'nst'f'"':!o. -..om(.1imf""" tht" ...tamp ...
w D .. nltodra .. back m,.Je the
hold,,!, and th('} don't pull out

..tC)rc".

To US<' thi's "II,h block. set il

everthe f.II(',..with thenotchon
the push bl<,,'k 0" r the workp"'<:" To htlp hold Ihe stock

:Vi'- P<'ri,'('1 lor m..... CCIIC\',

To u,," Ih,~hangl"l'" a "'op.

qmpl~a.tat tl It o\'('r the t.;)p of

Ihe I,OC(' ("ith Ih~
"""fl'\" fa('in.~a\\t.I~'
1".n1 tht" (t."llce. ,,(.(.
rl). :-.0.... S('I th"
'Iup the right d..
I.n .... Irom Ih"
b1Jd~aod Iigb'~n
the" ...rr(''t' dtlWn
TIl, n <:0 ahead and
l."1E.AM
111.lk,) (tur C1Jl~"
CoCWoU'
r,.d JoJ, ,I,.,."
(""DUll'
HANGER
.I1r1

;II"J"'~Ct'/If,"

The kit ~"ntly hold, Ih~

>lamps in pia",' lnr 'Iorage and
when the .Iallll" art' ol....ded.
the} pullcJut Slltoothl~' and
..'cnl)
J" Tr.'ftdl('DlI
(;'ftJt 1'aJ' .. "(lr~tafl

.." nl)
10 kt -t:p this fn.)m
llu)II)l11illR. I 'l"JmpJ~IIluNI a ,mall pi",'"
ul Il"it to Ihe cas ...

Olur SMAU.
fELT PAO

INCASE

abc.)\lc tht stamp's

path. " ....draw;n!!,If.

.fler glulJIII th" f..-lt
in pbc~.the <tamp>
..,., too hard tQ pull
oUI.IU'llig'tlly sand
Ih,' bottom Qf Ih~

,1.Imp holder.

SAND10"01-\

or

HOlDER TO fIT

tNTOCAS5:-


ROUTER TABLE HOLDIN JIG
I'vedesigned this wooden wheel
Jig 10 bold 3 workpiece light
agains' the f('nee on m)' router

There's another advantage

Since the wheel is Iree-rolling.

it's easier to push the board
through this jig than J)3!"t all the
fingen; of a Ieatherboard,
Eliil"'" Notr: IVliih fi,ii! ;ig

table. But it can also be used on

a table saw. band saw. or drill
press a. well

il dO(lS)I'(

Typically. this would be a job

for a featherboard, bUII've found

U'drks (/ff'(I'.

that f~atherboatds can be diffi

cult to clamp down parallel 10 a
fence, and a featherboard with a
straight end won't work "ith a
curved workpiece, Also. since
this jig only touches the wood at
one point (the edge oi the
wheel). it applies more direct
pressure than a featherboard.

cr liU....,ll ittjc~. 4"d your tl'Ork

N,,>(I. stand the pk"e on end
piec ha 10 Of /I fairly CU/I andcut a l".<feep,lot (or a wheel
Itisiell/ lvidl/t Ijr tJ,ick)IC$$.
well. see Fig. 2
To provide clearance for
To make the jig. cut a piece of
curved
wcrkpieces, 1 trimmed
~.'"'Ihickstock 2~4""ide. Then
dnll a hole for th~ dowel -axIe- 45' angles oli the end with the
centered on the width and :rIb'" slot. see Fig. 3. Finally.inscrtthe
from one end. see Fig. 1. (Xote; wheel and dowel into the jig.
By making two jigs. YOIlcan
I used a 1".<Jia.to)' wheel.)

1)1"(tf'r/lt

klckback-yoll s"()"ldslilll"~

SID oowtl HOU

TO FrYWKUL HOL.t

keep pressure righl before and

after the workpiece passes Ole
bit. Or they \'30 be slacked on
top of one another for wll or irregular-shaped pieces, The jig

also can be clamped to the fence

to hold a piece tight to the table.
PII,p Slodd(ll"l/
Jt'~"1lp.loltYI

PUSH

$Ilt
oowtL

SOARD

TORT -

_...

WllI'tL

a,

(?'ti!;W:l:::~::..!;l

UHGHOF
PlK.
OPTIONAL

CUT SlOT
WI D[It Tlo4AN

TH( noCKNESS

OFWHlEl

1"~

SANDING TUBE

HANDRUBBING

DEFT FINISH

Slice the lube down its length

.To sand COVC\l. I wrap sandand
slip the L'<Ig. of the sandpaper around small lengths oi
clear flexible plastic tubing. paper into the slit,Then wrap the
Most hardware stores carry this sandpaper around the III be and
type of tubing. Choose a tube hold it tight.
RirlulI'Cl J. SII'tJhm(111
diameter smaller than the radius
of the cove.
11fotlJrt Pteasant.Iou

I use a lot of Deft Semi-Gloss

The paper wiU actually buff

the finish and produce a semi,
gloss sheen.

\\'"ad Finish in my business.

While it does give an adequate
finish. I could never get that

"hand-rubbed" look I wanted.

Afler some experimentation, I
found a very simple method to
improve the look of this finiSh.
All you need is a brown paper
bag (the kind you gel from the
grocery store) and 101.$of elbow

grease.
T~
stan. simply"uta fewsmall
square pieces of the brown
paper bag. and then vigorously
rub rhe finish with these
pieces. The paper is slightly
abrasive.but it won't cuuhrough
the finish.

No. 68

Ben Caglial'tJ
.11IIrphil e. Culi!orllw

SIND IN TOUR nps

If you would like to share a
tip or idea, just send in your
idea to Il'ood.mith. Tops and
Techniques.
2200 Grand
Ave.. DesMoines, lown50312
We will pay upon publication $15 to $100 (depending
on the published length otthe

tip). Pie ase include an explanation and a sketch or

photo (we'll draw a DeW one).

HEIRLOOM

PROJECT

Chairside Chest
The inspiration f01"this frame and panel walnut chest was an
old~fa$hioned spool cabinet used to display thread at general stores. But
it's just as handsonle sitting alongside a chair or sofa at home .

ne of the most interesting features of this chest

isthe least obvious - the back of the cabinet is
ju.t1l$ beautiful as the top and sides. lt's designed to
have a finished look wherever irs placed in a room.
TIle inspiration for this proiect wssaa antique spool
cabinet Thesecabinets were used til display lind store
thread, and they usually sat on a counter or in the
middle of the store. Since they could be viewed from
all sides.the back had to look as nice as the front,
VRA\\'1lRS.
Though frame and panel construction is
characteristic of spool cabinets. I've made a couple of
changes fronllhe typical design, First. I increased the
drawer height so Icould store something larger than a
spool of thread. Bull used traditional dovetailjoimscn
the drawers -a nice feature in these cabinets,

TOP,Anotherchaogc is the top of this chest, II isn't

solid stock. hu, a walnut frame around a walnut ply.
wood panel. Ii the top were solid, you'd have to figure
oUIhow 10anchor iuo the ease 10allow for expansion
and contraction with seasonal changes ill humidity.
Since a frame and plywood panel won't expand or contract significantly. it can be glued down 10the case.
"'000.1 used walnutand walnut plywood to build Ih~
chest TI,e drawer sides and backs are hard maple. as
arc the imeriorweh frames,
IIARDWARE"''iD fiNISH. The knobs on the drawers
are classic fluted brass spool cabinet knobs. (Two
other styles are available, see Sources, page 31.)
I finished the chest with tWO coats of satin poly
urethane varnish, sanding lightly between coats.

WU<l<bmlth

Nu.6S

EXPLODED VIEW

MATERIALS

TOP FRAME v
SIDES

CASE
A <000 " 00 (4)

~ TOP FRAME fRONT/IIACK

a s.o.

(5 MOU>ING FRONT/BACK

DUST PANELS @l
TOP SPACRS ~

DRAWERS

E FronlSfttosOJ

7::::::~::!r"

F SIde Ponels(2)
G Bod< Ponel (i)
H PoneIMoIcI'ng

-@ BACK RAILS
@ BACK STlLES

,Sf( 'AGe 13)

BASE

SIDE PANELS

I KIC~boordFrtI8l<(2) .x327'1.1
J KlCkboord$iOO$(2) ~.x3-17""
K MOIdngFn/8k(2) ~.x 1~.27~.
l MoIOogSb (2
~.xlh-17!.

WEll FRAMES

WEI

-l 1-23
'I' !. J4~
o OustPonelsCO)
~.pIy 13.x2n.
p Orowe<GuIdcs(IOl'I'.x 1;.-14~
Q TQPSpoc...,OJ
'1'", 'I'.-14\?

SIDES
~

(!)
MOLDING
SIDES

-WEII
FRONT/BACKS

/
tlj
FRONT
STlW

"

o
KICKIIOARD

l'

""
KICKIIOARD
FRONT/BACK

CUnlNG

SIDES

,2

Foc:no Slrtpo (0)

S Molding frtJ8k (2)

MoIcIAng Si<)Qo (2)

/(

T
U
V
W

PANEL
MOLDING

DRAWERS

'1'. x ~

23

SIDE
RAlLS

hply-13x23

SUPPLIES

OVERALL DIMENSIONS:
23" H x 27'2- W

~.2"'-17v.
'1'. x 2~.
-27'1.1
'1' 2'1. - 17~

Front>(Sl
'I'.x3~23~
Bocks(Sl
l-2 x2'+t 22'A!
2 Soda. (10)
~ x 2!>lI- 141.
M BoI1:.:oms=_::(5:.;.)
__
...;\",.",pIy-,--1_4...;~:..;x...;~;._;;...o

~"

SIDE

Frome f"18I< (1)

Frome Sides(2)
Ponef(1)

~.2"'-271,.

X
y

STllES

MOLDING
FRONT/BACK

00<.

N So

TOP

ft./' DRAWER
GUIDES

STRIPS

M ro

: _,<'!_

FACING

Bod< SIlos OJ
Bod< RoC$ (2)

J.! MOlDING SIDES

"'..x2 ..181~
'1' 212
~ 2~-18'.
'1' 2-22
~.x1'1t-18~4
It.pIy lIhx 15
'.pIy'21~.x
15
;.x~'lofl rgll

aIs(4)

lit

171'2- D

urnbOr a>d plywOOd (See belOW)

..., 1f0>Net knobs

4 F >0101 nylon g!Ide lope

Qvor1 .."., po/yIJtell>Ot>e YO IIIISh

DIAGRAM

1. XS 9& (Two kord 3.3 ad. Ft. lochl

' ... MAPU PLY.....

JI

9.

~." WA&.NUT
PLY. 16* x 24"

w
'.

JIi

5 C3.~ad. rt.)

1= ::
a

I,

9. (T VItO a.ord 2.7 lid.. R. &xh)

NOltGRAJN
DlItK'r1ON
t.WALH\JT
lilY. 2.4- .....
G

M
F

A..

r
No. (Ill

M
j

lli-nJ 7

SIDE AND BACK FRAMES

I began building the
chairside chest by
"laking the side and
back frame, of the
C3S('. The frames are
," hardwood with a
V," plywood panel.
SIIlE ~"lIt\.'n~
Slat!
work on the two side
frames by cutting four side stiles (A) and
four side rails (8) 2" wide. see rig. I.Then
cut lheslik1ilSv,," long and the rails 12"long.
""CK I'RA,\I. Since the back frame has to
be the same h~ight as the side frames, I also
cut the back frame pie.:es at this time, see
fig. 4. Stan by cutting rwo back stiles (C)
2W' wide and Ihe same length as the side
frames (lSV.'?11.encut the two back rails
(D) 2" wide and22"loog.
The stiles and railson all th ree frames are
held together with open-ended mortise and
tenon joints. see Fig, la.
MORTISE.I cut the mortises in the stiles
with a V4" straight biton the router table, sec
Fig, 2. Raise the bitll't6" above the table. and
position the fence so the bit is centered on
the workpiece, see Fig. 2a.
Next. I clamped a stop block to the fence
to limit the length of cut. Position the stop
block so there's 2\;1;" from the block to the
far side of the biL (Note: The mortise only
has to be 2"long to accept the tenon on the
rail. Butl cut it I,B"longer. so 1wouldn't have
to square up the rounded ends.)
TENON,After the menisesare cut in all the
sules, the next step i,to cut W'~ong tenons
on the ends of the "dis. To make the tenons,
I cut rabbets on both faces of me rails with a
:."widedado blade, see Fig. 3.
Sneak upon the depth of Cuton a test piece
until the tenon firs:;nugly into the mortise in
the stile, Then cut tenens on all the rails,
FROl\"fS'OI.F.S.Afterthe mortise and tenon
joints were complete. I cut two front stiles

1,1-,----:;.;;;;;~"'J-i

--:

Non:
ALI.
STOCK

"@

'."
THJCI(

SIDE

SIDE

RAlLS

STILES

18' ."

NOT:
l," ON acno","
Of MOfmJ(WtU
at covtalO 'IV

PANn H>OtO'NC

SIDE fRAME

STILE

"

M[AW.t
10 fAR $JD{

...............

"-4.~

~ --

22'---

ClNna 1...
STWOHfllT
_. ON lHICt(.N(SS

OF 5TIU

RAlLS

t -"....,.

r
(E) )%" wide by 18"'4 long. sec> 1'lg. 4.
When the case is assembled, these pieces
wiD be glued to the front ends of Ull' ;;ide
frames. refer to ~lg.10 on f~e 10. But I
wanted to cut them now since they hav.. the
same edge profile as the back stile' (C)
EDGE PROFtLE, "ext, 10 dress up the
edges, rout
, a round-over (with a shoulder)

on the outside comer of Ih~ back stiles (C)

and fronl stiles (E), sec Step I in Fig,S.
RA8Br. Now. rout a ....!'~widcrabbet on
the inside corners (opposil~ the roundover), see Step 2 in Fig. 5.The ,idt' frames fit
into this rabbet when Ill(' case i,a,<""'mbled,
ASS~tRt.Y.Finally, glue and damp th('
three frames checking that they're square.

STEP 1

,...--..,

- FRONT STILE

18' ...

a,

),." DAOO

,)> BACK RAil

,

",

PLY. FENCl

-:;:::::::::=--::~~41

_-

,,"y.

.:6'"""-'O.N ora.

BACK fRAME
r8ACK

a,

~,.

NOTE:
ClUTMORns!

NOTE:

AND

TENONS THf SAM!

AS ON $IDI: F'RAMlS,
Stt "IG. 2 ANI) 3

AU. STOCK ~~. THfCK

W(1(lrumlth

~.'

S_IO lIT lilT

-";".68

PANELS AND MOLDING

I' \.'FI." ~exL rot the two side panels (I')
Alter th~ thl'\'\' fran"." "ere dry. I routed a
rabb<'l on tht' in,id, fact 01 each I'ramt' to and hoc" panel (G) to fit bet ...een the rablk'Ct PI a 11.' plywood panel, ref er 10 Fig. 7.
bet, (~ott" The grain runs ,'Erticall) in all
RA118t'l'. To rout the rabbets, moonta~if
three pan elv.) Ttl make the panels lit. I
rabbt1 bit in the router table and raise il to round<'ll the comers .ti~hllyto match the

see FIR.!!. 1'0 make tht' >Iri"" rot 4"thick

stock 1..,." wid. Then round over both
edges w;th a :}.roun<k('f' bit, see FIR Sa.
1\0'"trim a \it" ,tnpoff each edge. see Fig
lib. And rut """h 'tnp .",. wide. see Fig. &.
Once Ihe mnldioll <hip' were cuuo ..ridth,
equal th" thidUle" of the plywood. see Fig. round corn..", in the rabbets, see ~-tg.7.
6a \\'llh tht, in,id~()f3frame Iyin!!face down
MC)IJ)I"('.<;. After the panels were glued in Imitered each end 10fit inside the frame. see
on the routvr table, rout a rabbet all the way place, I 111"1'"decorative panel molding
the miteriolliig on I)(J~I'16.Finally. glue the
around the fnunt. see Fig. 6.
strip. (II) on tht [rnnt fat" of each frame. strip, 10the fnun,' ;U1dpanel. see Fig. 8.

THfCKNlSS
Of PLYWOOD

~'

.....n

""'~

MrrlR ENDS Of

...---_MOl.OtNG TO

r"

Q.

fRAME

".

Non,

_.
IIOUT

.......

, ... ItCHJNO..
OWl &IT

ow

IHSIO( 'ACt

b,

Of AU

GWt

WASTt

IOOI.DtNO

lOfUM(

......

ANn

ROUND

Q,

(0l!HfaS
GlUt ,~..
,",YWOOO
TO '''AMI

c,
WAST'

NOTE:
Slot ANO

.UN OItAlN

VPTI(AUY
IN AU. 'AHt15

lAC" 'IAM[$

BASE
Thebaseofthechesi
(f)nsist!tofamolding

frame gluedon lopoi

a kkkboard Crame.
see Fig. 9.
KltIUIOARD. To
build the kickboard
frame. stan by rippin)! the kickboard
front/oork (I) lind sides (J) to a uniform
width Olt'ight) of3" Thenmitcrthefrontand
back pi,,,,,,, so tlll'Y measure 27Vl' (from
looll'poinl to longpoint) and the side pieces
mea-ur 17J., r.stt:I'ig.9.
To hC'111
oJign the comers, cut a ken in
each mitt r........~ill. 9a. Then cut a spline to
fit th, I<lori, (~hop :O;ow'Splines can be re",v.Tll'rom oolid "ockorcut from .\14>ocite.)
\1011>1'[; flC."t~.Alter the kickboard

tram,'

i, Jllurd together. cut the pieces for

the molding frame. 'ee Fig. 9. The

front/hock (I<) and sides (L) are ripped to
a uniform width or 1<,"
Before mitering the pieces to finished
length. I routed a l1o" round-over (with a
shoulder) 00 the lOP outside edge 01 each
piece. "',. Fig !Jb.Also rout a~",wide rabbet
to fil over the kkkboard Crame. (These are

No. 68

Iht"

..,an14.'prUlt"Ciurt,

as on the

frame

stiles,

I'(f<r10 fill 5.) Thl'll miter the pieces to

k'ngth ...., tilt' rab~" in the molding frame
";11,il on the kkkboard once it's assembled.
1.1Ier.thl' b",, b sc!'\'Wed 10the bottom oj

rhe {'"3*. bur Jr'~tcl"'I~"'ltodo this if the counleNlnk -hank hoi e-, are drilled inthe mold-

in!! frame oU". -ee ~ig 9b.

"ftl'" the hclc-, are drilled. glue the molding frnrne on top "I till' kickboard frame,

I(tCf(IOAJtO

,-:l.-

a.

CUT Sf'UNt

TOf"

SAWKtlfS

,_-' .....".'-1

..

...

b)

\!J
KICK BOARD
fRONT/BACK
NOTE:

OLUI MOt.OINO

to KKK,o.ao

KICK BOARD
SIDE

,
9

ASSEMBLY
After
s..sembledand
screwedIlle
to case
the base.
Ill. base isthen
complete.
can be
FROJloTsnus TO FRAMES. Start assembling the case by gluing the front stiles (E)
over Ille front edges of the side frames. see
Fig. lOa. Check that the inside corners are
square and the ends of each stile arc ftush
with the top and bottom of the frames,
SII)E TO IlACK t'Jl,\)lES. Nexl. glue and
clamp the side frames to the back frame 10
form a lJ.shaPt'd assembly that's open in the

f~~;~~~;~~~C}~;;AUG~N~f
10

a.

FIION<STnf

""""",,-

r: G~':~

""'o-t....

$1D< fRAlOts

GlU. fROm

FWSItt':.

SI~~

SECONO:
Gl'" SIl>t

FItAMU

TOBACK

rJtAM(

TOP VIEW

front, see I'ig. 10.

SCREWOS BlISS.Alter the glue dries. tum

the case aSS<!mbly over and center the base
on the bottom of the case, Then mark the
locations of the screw holes on the bottom
edges of the case by pushing an awl through
Ill. countersunk screw holes in the b3S<'
molding strips.
Finally.drill pilot holes and screw the base
to the t'3SCWiUl No. 8x IV." ftalhead wood
screws, see Fig. lOb.

,..--1'~"

_8x
f.h
WOODSCst,lW

KfCKaoAaO

WEB FRAMES
With the case
screwed 10 the base.
the nCXI step is 10
build six web (ram~
10 connect the cabinet sides and suppon the drawers.
CUT

TO

SIZE.

11

WEB FRAME

WEB SlOES

10

--

WEB
fRONT/BACK

----23

Begin by Ctltting all

the frame pieces 10 a width of I". see Fig. II.
o. wu
To determine the length of the front/backs
~1).Ill
easure the distanceberween the case
SIlK
sides (24 V~
in my case). Then.since drawer
guides win beglued to the sidesonhe frame
(refer 10 I'ill. 14). subtract the thickness o(
two drawer guides (lW'). So I cui twelve
web fronts/backs (M) 23" long. see Fig. 11.
To determine the length of the web sides
(N). measure ti.cdis13ncebetween the fronl
and backstiles (I4~"). Nowcul twelve sides
10 this length. see rig. II.
JOINERY.The web frame pieces are joined
with open mortiscand tenonjoints, To make
thls joinl. first Cut an open mortise (slot) in
K((P H""'OS 12
CI1AROF 1m'
Ihe end of each of the web sides (N). see Fig.
- R
Iia Center the mortise on the thickness of f-1tOUTt='
TAau.
the piece, and CUi it to depth 10 match the
width of the front/back pieces (1").
Next, I cut the tenons on the ends of the
web front/back pieces (M). see Fig. lib.
Sneak upon the depth of these cutsuntil the
tenonsjust fits the mortises.
Now glue all six web frames logcti.cr.
checking thai the corners are square.
NOTE:
1)t:ST PANElS. To keel> a drawer from
ROUTRAIInONIOTTOM
catchingon anyhems in Ihe drawer below.!
INSiDE EDGE
glued II." pl)nwooddust panels (0) 10rabOFwtaFRAME
bets routed along the inside bottom edge of
each web frame. see Figs. 12and 13.

----

NOTE:
AU. $lOCK

> THICK

NOTE:
GlUt UP SIX
flltAlw\S AND
CHtCX FOR SQUAWI

13

CUTPANU
TOfrT

GLUEPlYWOOD

RAUD
GlvrPANU
fOlOnOM

0' WE' fltAME

O.

DRAWER GUIDES
!kf",,' installing the web frame, in the case,
I add.d drawer guides to five of th" fram.,
(or the live drawers. see Fig. 14 11", top
(mOledoesn't need drawer guidl",
1>lIAWt'KGItDES.Cut Ih(' ten drawer
guides (P) 10 a width of 1'1'," and Ill<'same

length as the web ,id," (1'1. see Fig. 14

Before gluing th,' drawer guides to the web
frames. drill countersunk mounting holes
through each guldl. see Fig. 143.
Ailcrthe holesare drilll"'. glue the drawer
guides IUthe sldes 01the web frame. To WI'-

SECOND:

14

OlUi oW>tS TO

"",'1';11.15.

lS

,,'

(NOS Of fa,A,MlS

ve-nt... Jr.1 added ,",1~adherinJ!nylon JllId,

t"pc 10 Ih, 101' of each frame. see ~1S1 U.
TOI' 'PAL' I(. To keep the lOP (nUlit' Ihe
,,'nw wldlh the other fra1l1~s.JlIUl1I:\(,"
'\',"'I""'('r (Q) on each side o(thi. (,.,unt'.
toO wo

TOP
SPACER

_ONlY

O.

fiRST:
-

DItIll C<>UtfJ'DSUHI(

sotWHOUSOf<
INSIDE Of QUlDlS

o.

o.

1 .,....,.,.I_

I,, DRtU. "l.

& COUNTtIUVNK

..

wtl ftA.Ml

,AHa

TOPWta

'RAMl

SKAHKHOU

' ~

,41,-

/tSft

HYU>N
GUD< ~
SOUKU _

ORAwtR
GUIDE

/
.;
."

tre

GWIRUSH'ON
109 ANDIOTTOM.I

N[[DlOJ

INSTALLING WEB FRAMES AND FACING

To position 11ll' web
rra",~ in Ih,' ea-e, I

INSOT wta fRAMlS

16

THttOUGH TOP Of CASI

17

used a spact-r syc;.

tern. 1"('(I'r to Fig 17.

This kN'PS all five

101' WIll SHOUlD

drawer opt"ninJ:!'t

id.ntical

--

BOTTO".N'''E.

Nexl, to determine

}'OU

""'rt'Wed

in

'"'

DR&l.1)7

N.QTHCUS
.. CASl

n"mC)\C'

the'

NOTE:

_'Tsn
SPACWON
0U04~

18

o.

ClUl ANDClAMP
'ACING STItIPS

TO'RONTOI'
WIll-IAMB

can remove Ih..m and

pIac-e-.

AU.SPA(W
SHOULD aE
UNIfORMHE~tn'

ClAMP flUSH TOP

ANDIOTTOM

b"lIin assembly. For each frame. in scn

'pal:':rs and then a web frame, Then drin
pilol ho,k, and screw the franll' 10 Ih~ca .....
\1 I'(,'TRJ"'"Aft er all oflh. .. cb fram''''
art"

.f

o.
I

this measurement (Ill,', and

hdghl.

Sl'ACltS

MO\OINO

L1l('~ilt" or

di"d"lt b)' fiv,.1lten rillIt'll "jla(('1'" (on,,(or

each ,jolt o( th e dra .. er openingl to thi>
..idth (~hl.
see Fig. 17
l'Ocxt.in...nall the web fram in th.ca.se
and "'paral" them with 'pIKers
,. Fig. J 7
I( the top frome isn't Rush with Ihl'lupuf the
case. ndju~1 the height o( a/ltl u- spacers,
(:>;011" K<.'e1> all the spacers idenlical.)
\.~. 'IKI.I Once the spacers art' euuo the

flMPOaMT

aAS.

17vt"). Then . ubtrsct the cembined thickn," 01 till' fivel'l'Jll3ining(ram,.. (~ ,.

\0". 10 determine th<- hei!!ht 01 each

CflrTI.'<1

2'.~

SITS ON

Ilw spacers, measure from the 00110",web

(mnl<' to Ihe top of the case (in Ill)' casco

'J):k~r.lal

,-

IOTTOM

~b)'in~th"
bouom \\~bframe tbrou.I!h the top o( the
caseuntil ;1";!Sontht ooS('moiding. '><'C rig.
In. '1;0\\ drill pilol holes through Ih" mountinl! hoi,.". and screw the (rum" 10 tI,, case.
Sl'i\( .....
f(:)..

IWGHWITH
toO Of CAS<

~piIC't"~

and IIlue walnut facing SlripS (R) to the

(ronl ,,( each frame. S<.'C Fig. III.Cut IIWSlrips
to fil between the frontstil es (1::), and damp
Iht'lll ill place wilh C-clamps. sec Fig. Ilia

CUTUHGTtt 10 ,"
Ilf1WflN fRONT ,nus

fACING STRIPS -

l.' )."

\!ACING

no..

fltONf!~!1

OFw("~

II

TOP
Aftenheweb frames
and facingpiecesare

_-

19

in place. work can

begin on the top.

MOLDING
FRONT/BACK

The top is a mitered

hardwood
frame
around a ~ ply
wood panel. refer to

~ig.
20.
To make the top look thicker and add an
interesting edge prolile. Iglued a separate
molding frame on topofrhe case first. Then
Iglued the top to this frame,
MOIJ)ING FR."-"' To make the molding
frame. start by resa wing enough l'2"-thick
stock for a front, back (both S). and two
side (T) pieces, see l'ig. 19.Then rip th~
pieces to a uniform width 0121-1s".
Before mitering the pieces to length. rout
a W' round-over (with an I-Is" shoulder) on
the bottom edge. see Fig. 19a.TIl"" miter
the pieces to length so they're IV." longer
(long-point 10 longpoint) than the width and
depth of the case (271'." and 11v..'~.
After the frame piecesarecut, screw them
down to UICtop of the case so there's a uniform overhang on all four sides. (ln my case,
the oYel'nang measured 'III".)
TOr FRA."E. Now work can begin on the
lrame and panel top. To make the frame,
start by cutting enough :y,"thick stock for a
front, back (both U). and two side (V)
pieces. see Fig. 20. Then rip tile pieces to a
uniform ",idth 012\1,".
Before cutting the pieces to length there
are a numoorof routing steps to go through.
see Fig. 2L First. rout a \14" round-over (with
a shoulder) on the top edge of each piece.
see Step I.
Next. to create a decorative channel between Ute frame and the plywood panel. I
routed a very small rabbet on the inside top
corner of each frame piece. see Slep 2.
To keep the frame pieces and plywood
panel aligned, I used a spline cut from V,"
Masonite,see Fig. 20. To accept the spline in
the Imme pieces. Irouted \I," slots on the
inside edges. see Step 3 in Fig. 21.
After routing Ute Slots, miter the four
frame pieces (U,V) to length so they're V4"
longer (long-point to longpoint) than the
molding frame.
P.'\NEL.Next, CUI a ~," plyw ood top panel
(\V) to 61within the frame. Once the panel is
cut to size. use thesamerouter set-upaswith

D.'ll ~t

pttOT HOtU
IN CASI

a.

cer SPUN'S

...unu
@
TOP PANEL

~ ... PlYWOOOCUl'lO frtl

NOTE:

coon

ANDGlUl
TOP TO CAS(

MOLDING

o.

..

21,,-

l.SPUN.
.- MA$ONlTE)

21

STEP 1

1'0'

ROUND-OVER

err----

STEP2

NOTt:

.,..,.

ROUT WITH 109

FACEDOWN

USE
STlWGHT

fOR AIL

_"",_1-

FOtJRSlIPS

STEP 3

STP4

Center it on the case so there's a uniform

overhang (\Is") on all foursides.see rig.lOb.

12

OF PAN!L

the frame pieces to rout a V..'I slot on all four

edges. see Step 4 in Il;g.21.

"ASSD18LY. Now cut the splines from V."
Masonite to lit between the frame and panel
Then glue the frame around the panel wiUt
Ute splines inplace. see rig. 20a.
After the glue dries. glue the frame and
panel assembly down to the lOpof the case.

SHORTER

THANU'NGTH

, ".. SlOT (unER 8fT

Woodsmllh

No. 68

DRAWERS
The la"l 'Itp on the
chest b 10 make Iht

22

BACK

drawe r-, I ,I'"'wel by

~"""1'HICl(J

rp

mllkillg Ihe' lipped

drawer trum-,
llRilI\. N .'II(l~'Th.

To derermine the
<ju' 01 IllI' drawer
I'ronL. (X). m.'3'Uf'C
a drawer op.:ning (Il0l indudinll IIu- R1ick
Mp) and add :j,. 10 IIIl' h'';1(111and w,dth
This allow for 3 ~\<"lip on all ,'11"<,... of the
drav.\,r. le~ e" for drawer cltaranct, see
Filll3. (In my case. ~ x 23'.".) 'Then cui
fiv('drawer fronts from l"'lhkk stock.
I'N".' I.F.F.I)(;E. Aller the dl'3""r [ronts arc

cut to size, rout a round-over "'ill\ a shoulder

Oil .11 lour edges 01each drawer Imlll. _
~"'II I in ~'I:.
24. Then. 10C",1t' a lip. raul a

SIDES

ta.. THICIC)

(,,,,- THtel(,

IIO'TTOMGR(l()\ f_ "',xI. CUIgrooves in all

the drn.. er pieCl~ for the l," plywood bottoms ('\A) To prevent the groove from

i,rc,",,,k~e. rip v!thickdrm<crbocks(y)

anel sides (Z) 10 match Ill<' ...boulder-to...j"tU!do r..id!hofthedraw''I'IrnnI. '' ~'11. 25
'1",,11cut the five draw,-r b;,,'k, (" lolh.
....mc length as the shoulder-to -houlder
length ollhe: drawer fronl (22'IlI").".(. FiJI.
22. Finnlly, cui the len drawer ,id,~ (Z)
llh"lonj(.
J(IlM"O. After all .,1the picc.'" "'('rc' Cui. 1
routed ~i' dovetail joinls 011 thccornor-, ~t

sbowingon the ,iclt-"Ill" drawers. 1located

il",itwouldcullhrough thcdO\'etaiI sockets
in the drawer front....... tl,l( 26.
1wanted Ihi. gtOCove'lR the same location
on the drawer Iront. back. and sides. BUI
there's aproblem -!hI' drawcrtip, Itmakes
the drawer front wid.rthan the other pieces.

23

24

To solve this problem. 1made an auxiliary

fence that fils "",i.rlhe lip.see Fig. 27.Then

ine shoulder 011l1~drawer (ronl (nolthe lip)

J'i~25. War more on routing do\,tlail ...and a rides.gainS! thv knee: If)'ou use this same
do\'clail,ij(.".....Ifoods.. Ih "0. 58.'
fence foralii he pic....,. th" groove willbe cui
GAP FOR D.AWU
CLtAUJ'ICI

UP ON
All (DGU 0'

DAAwta 'RONT
Dl{AwtaKNOI
(Sfl SOUl'CCS.

PAO' 31)

_wt.

,t....our.ou

a.-

..
....wt.

....

fRONT

>1<" rabber CIn the back side. -v ;'11'1,2.

I!-" "-'''-'D <IDES.
the drawc'r fronl

"nen

_-

DtILlHOU
lomKHOa

'.

25

mpl

fOOHT

o.eJ

-,

the sam dbtance (rum the shoulder on lh"

drawer ImOl 3' u is from the th( b..ttom ,'CIII"
of lb. dr.",r back and <id............ Fill. 21<.
Wlwn cullifllt the groove. 1did it in 1"0
pa...~,. nlf"ing the K.-nt:t' between pa .....(....
!'inn' ~,' hardwood ply"ood i...
uflt'n k"
than l ,. thick. ", eak upon the finolt'lll until
the l,lyw.,,,d just Iits Ihe greove Then, cut
Ihe bottoms (M) to size 10fillhe drawe",.
I'IIJ .... I3dC)r~ assembly. I drilled shank
holt, 10mourn the knobs. l.ocaw the boles
:11"," 11'0111
each end and centered on the
heighl 01 Ih,' drawer. see Fig. 22.
Finally. 1 assembled the drawer- and
finished Iht' chest ";Ih polyllre th.llle.

_WI.

""''-

fRONT

OOvtT All lIT

C!

IIOUTU
T....

'INCt

1',," ROUND011(. ,..

2',

STEP 2

--~
''-;,.:;J

26

27

(-CLAMP

..,

'LOCK

Offsn

ftNe(
C-\ MASOM1l)

.....wu

CIN11:a GtOOVI
ON SOCKfT

CUT I ,,-oup OROOYI

'-fOR oaAwtl. lonOM
THlOUGH DOVITAIL SOCK"

NII.6!l

ct

~,
I

_\1111.

'1\ i

"Jl

UAV'INti

.....WIlIfIIONT-rt ,

28

{
l
I-

....

RNCI

J._

<!r .
_wt
....ac

"'NO llOCK
IN
SAIoU
IOSllION
4 10 7-.........

-7"1oIOU

:l

1\.) .)\r
I,
I

11

TECHNIQUES

TOOL

Drill Press
I

've olt('11won" e red why tool

mnnufactnrer-, don't dt-.ism
drill pn',,,'" for woodworkers,
'n,,' l)robl"1II Is IIii' tabh- Drill
pr("~ tabl..., "tl nln\ost aJW"J)!~
tOO""all, hard to damp onto.
and don'l .. ork w"'l with a fcoee.
T.\111.f .\.' II ~'t
'( L The fir;t
addition I would m"k." a large
auxiharv r.tblc Ill. tab., shown
hcw I' JU'I 1""0 ptt'('(' of ply.
wood ....bottom u"" bolted 10the

metal tabh- and another one

"n.,.,d on lop. (Ihe plan, for
thl,arem \\"'-__
($"
~o.54.)
nil" t)1" uf wblc pro,;d"" a

,f'

'urla<'~ 10'UI'lXlrt !arRl' and

10nRworkPIt,,t, It abo provitlt-~It way I" (laJnpji!.~, ~top:>.
and a r,.II<I'W thetable.
\Vhith brinK'up another polm,
I woul<l also add" fplIl'e 10 the

1..1bl.,The-on hown i,dampc><1

to th. r.tbk' "'th 11I11.",-dblocks
en the bottom of thc knee.
"'ERT. The original plans (or
wi...lablt 011.....',h(J'~ a reee-s for

a replaceable in-en (~~" ~1...

",.,it,) onthe center ru the ply wuod tabl"

Th.'!Y "0' a probk'l11 with this insert, It
didn't 'oU) on pL...... \<'fY ,",.D. so chips and
",,,du,t colk...-tt-dunder the insert and kept
il trum lying flush with the lop. The solution
0'3, to "''Pla ... il .. ith an insert made from

'II," plY"'(~~1

'f\' "'FRT

On the ongmallabk-. the top

~. r "l:lu(~1 to the bottom lay.r So Ibuilt
a n,""- L,bk' and made- th~(('P

la)t."f" In ('AU

-ection .. ThN_rnr.t'45 bevelson the outer

,-dg..... to h.. 1dtI,, I, nee. and bevels on th<
in,id -dll' , to huld th. in>l'n in 1M.:t'.

nu-n Iadded a nc"

ccmersecucn

to ".", ..

a< a nopbceabl, m-en. This Jlio.'tt is also

b.-< eled on both '-dill ....and .lidc' between
the oul<'I'sccncn-, - like a ,lidinR dovetail,

Wbik I "a'.t

it. I made >e'<."...) extra in-

-ert-, to

..tid.., in 3' the c>ldont"S gt:lchewed

up. I dri1k- hu'" in un" msert '" I could
k,,,,.,. a drum ...md er into II. SCI" inset photo.

BORING MORTISES
bit is centered on Ihcl thi"'kn"c;~
of the workpiece. 111"n ju,t drill
a serk-sofhok lu r""Rh out tlumortise, see ph"I" at kft. ,I-'or
more on (hi", ,tchni<lul.'t'e
(\'(It)(/.,J"i,h \"0. (,.1 )
STOP BLOCK.

Ttu- ftnc.. not

onl), h..Jps aliJ,.. the .... rkpi

and the bll. ilal-opro_id,,,,

a)
10 clamp on a <tup block If lOU
Cl.AMI'ST~
1
c!amp<top block, on tht f(nc t
IUXIC fO
__
an
RNa
both end'ol tht'" orkpit'('l". th(')
dwne the limil, of Ihe morti ....
nu,.wayyou can repeal the O1or "Ha
Icl
tise- on~"'ral pit't-t...
-;
-R~.-~~
,

.'\, mcnti<ll",d above, I added

a fence 10 the aUXIliary table.
This fence ,'omt"<in handy when
SPAC.W RUX,,-, 1I1",...,.r. il
drillinjlOul morti"",
the workpi('('(' i,"t'ry IOIlJl.y<>u
n,tba'irproc<-durc here iSlo can't gcl tht "..:on<l ,lop block
adjusllht' (enct.'so the mortising on the!feltct'.ln Ihis('3~'yo1Il'An

14

m,~

Fill, 2.
length of the spacer
should equal the distance beCUI a spacer and place it IW('.'n 1111'centerpeints of the
against the stop block 10 position fir-land second holes.)
the first hole. see tlR, I.Afll-r
Ihen drill out the waste bedrilling the firsl hok-.I'l'111.O\-etl,. l" een the IwO hoI..." and use a
'pac e r and drin a second hoI,' ~I eJlO,,'110 clean up tht.' <id(1'< and
th. otfl(-r end of the morti", .. ""
th,' t'nd, uf th< mortise.
usc a set-up that involves one
SlOPblock and 3 spacer,

s,ACt'a I40CX AND

MOVI WOItKJltfCI AGAtNSf
ST~OlOCI(

an .,1
.
.
.= ,lNCf
b
MOIlflSfHO

SP.la.

~~.K"K'

IlO(K

WOttIOttlCI

UTI r-'
'f"" .......
IUX1<

"

:-:0.68
,

DRILLING DOWELS OR BALLS

BlHJ)"Gnl~JI(. Thvbascof
I '''G mE nco To driD a h"I,' bottom 01 the long groove To
the jig i...
cut from a pil -c"(of'" ,". centered on the width 013do.. ,,1. drill. hoi<'.na .. eoden baD. po';'
thick stock 4 .. id, b) Iti"IOIll{. position the Iencl'so the point of lion Ih.point ofthe buwhere the
-ee rlg.t.Thena \J.:ruo\'~:
j'l"Ul a brad point bit lines up" ith the t1ft f) \"', inter-ect,

.It you',, ,,,,'r tried to drill a

hek- in a do" d or 3 ball. you
kno" h"" tough it i,10 k,,,,, the
pit"l"t~from ,hdulR around. This
jig ",I\,..lhat prubll'm

dow" the knlflh "hh. b.....

To do tlli,. I >l'I tilt bladl' on
my table saw to IS' and rni,,'(! it
~ ..above the tabk Then I po,i
lioned the renee So the (k~pt',t
par! or the CUI WR' centered on
the width eruie b" se. Nnw make
two passes, lurninll Ihl' piece
end-for-end between l),,''>'''('o;.,
8)1
adding a seeond k~K'V(1
nt'nJK~
the base, you t'3II drill into balls
FinaDy. I cut 1\\0 ,h<>l' hold
downs and attached thvm tu Ih,'
base with carriaRt' bolt ....

THICKNESS SANDING

COUNTllIOl'I

t ."

CAUIAGI' &C)t.TSIN

..onOMor

110

CUT
VoGlitOOvt
Af4.s

'!tAD POtNT
.n~KS

WINO

NUT

"Sf ,ott

DtltlUJNO
GItOOVl

UUDlOOUI.

~-------~----~--~==========~

:-';0" teed the workpiec be- rate. and make light passes
t
w
een the drum and th, (,,,('(, (about the U,it:kn",,'ol a piayinll
acll)' th~ -ame thkkOl'" 111<
WIUp I use "-qui.,,, 3 I, nee and
Irom rillN 10 le(1 (agai.bt th, card), Periodically dean the
din'Ction ofthe drum's roratien) drum wuh a rubber belt cleaner
drum sander, ...~. ph"t" alldt
SA~()[.'G 1~"'I;"RT.
'1'0 ensure see Fig, 1. UyOll feed it (rom I~ft -o u dO<'!'n'tbum the wood,
thedrum makescontac; with the to right. the spinning
lull width or Uw 'trill, il hns to hi drum will grab the
1 O.. U'RISIIINCt
lowI'n'd slillhtly below th,' sur- workpiece. pull it
lace 01 the table. You can lower through. and shoo; il
the drum imo II hoi" drilled ill a off the table. To be
piece of pl)'Wtl<l<1
tha!', clamped ....re, use a push Slick
(aspinningdrumcan
to the table or 1lI:.k" th, table
NOTE:
take off skin as \\ en DONOr
shown on the pr, -viul" pa",'
....... NG
Itl-""OV( MOttl
Wh"n I n d 10 -and thin
11t1(.'K.'E-"~S wu T" thick- as w ooo) .
THAN .... IN
OttUM totAT1OH
<tril" 10 a uni(nnn thickness, I ness sand the -.trill'. mount your
for th~ smooihesa ()H( PASS
u-e a drum -andt r on the drill largest drum in the drill chuck
results when Usinll
pn-..., Fer piccc...like drawer (Set the spt't'd to no mlln' than this technique, maindividers or tambour (roll tQP 2.000 RP:\I.)
tain a steady reed

stripsyou n...-d -.tnJl' that an- (X

......

ENLARGING HOLES

I It
~I 4
':~I>"'_':~:~

to suppc.n tht" point of tht' bit in

the first hole ,,I(rto the photo

at left,
Of COUI'\o<. YUU
lIyuid the
problem by drilling til<'counter
bore hole fir!<t.tl1l'n C('nl"rillj(
the smaller bit in th(' poinll"'t by
the larger bit
E"IAR(;t'(; HUU., But H
you'v~ already drilh-d Ill,
smaller hoi,', (lr .f you want t"
cnIarg\o an .xi,,;nll h"lt .. you\t

'''til

To do this IiJ1d 3 bit th~ ",m,'

size as the firsl hole. Chuck thi-,

bit in the drill, then 10'""r .t lOt<>

the hole (with the power turned
off). see Fig, J. Now damp th,'
workpiece to the table in thi.
position, and retrnct Ihe bil frtlm
the hole.
Next. put a tiJlhHiuinll dowd

illl" th. fil"'t hole. Then replace

the fir-I bit with one for the
lar".'r hole ,ile, see Fig. 2.
Nowwhen you bore th(' larger
huh'. it will 1><- exactly centcred
011 Ill<' slIlallrr 0111.'. And since
th,' p()int of U,c bit i$ supponed
by th. dowel. it won't drift off
r('nter ur wobbll'_

Rot to pto\id. '-Uppt)n r"r the

Ho.. many tim('>. ha" you dnllpoinL

dnll.-d a ho....ani} to di-cm.,,,
Plugginll the Ii"'t hok' ... Ih a
Ihal )OU n.."kd a ,Iilolhtly1arJ:er dowel .,.;11 iii'(' ,"ppon for the
hok' Or )00 n,..'ded 10 add a latg ... drill bil BUIh"", do you
Ctlllillt "N)f'f

aJlt'f lhf! pilot holf'

",
..
h aln.tdy driJk..J'

Th,' problrm you (ace with

dthrr of th~,,' 'ituations is that
th~ drill b.t willdrilt oIl center or
wobbl, Ut'CRUS('lhcf'("snothing

N.., (>l;

make sur\" tht' bit

j,

exactly

cf<ntered to drill th~ ,,'cond

hole? If)'ou Wantth, nl'" hoi. to
be exa<'tly concentric wilh the
pxisting hole. Ihey mllst h.,.
the same centl'rpoint.

/'

'FIRST: IDWOt ... U

an INtO (XiSTING
ROll ,Ott AUGNMlNT

15

s 0 ~1 E T) P S
-----------------------

FRO

OUR

-----------

S 11 0 r

Shop Notes

MOLDING MITER BOX

are ,",'Vend tools Ihat

.Th,,,

can bt

U~(1ttl

cut miters, Bul

FENCE.ll,e fence Slart. out a'

a block o( I \.O.!"tloick
hardwood.

thr problem I faced was hu" 10 1211," long.

("\IImile", on Ih. 'mall molding
The width olthe f"n('(' (wluch
'trip' (Clr Ihe Chair-ide Chest I will beit's heillht when mounu-d
"Pt"nl a lew nunun-s building a 00 the base) should be I," tall"r
<pt"Cialmiter bu. JU'! lor small than the maximum ('uttin~
pil'Ct", of muldlllj!
depth of the saw 10011be' U"nl(
n;An Nt;'. \\'hal\ ruce about to ("\IIthe miters, "'"" ~III.2 (Th...
this min-r bux i,the thick fence. h' allows (or the d.pth 01 t1w
It ha, I""'~'I'that
<Ul-d to groove in th e ba.sc.)
hold 1m ",,,, withoul any w<>bllk.
U)'Ou use a bat:k ....w. the.till
back .. ill control the dl'l>lh 01("\11
andgui<k il'"1"X.lCtly15'.

To build this miter box.

start by culling" ba-c oUI ol:jl.
&\;.t

plywood 3" wide by 12" long

'111,,0.to hold 110,("nrc in place,

cut a Itfoovt> nl"njllhe base 1'.,"
Imm till' back (~Ige. SC'(Ilg.I.

(\IT

as you're cutting tht. milt-" ....t th e middle section

photo at right.

\'''-'E\lBL\. To

Next, cut the (enn' block mto

three sections at 15 Milk,. so

the left (A) and right (e) seclions are both 5V~lonll. Save

'(NC!

a."'W111bl,

lhe

mitcrbox.Klu .. thcldlp;""
(AI
down first, '111e 11 pla(\' y"ur .., ..
all_insl tht end o( Ih,' "'III"""
tt) PD,ition (h,' middk'I'"~'" III)

121." LONG,

and gl",' il in pia,.... Finally,

(II)

your .....
1~again

(0

U5('

position tht.'

ri~ht I"I"l"C IC)

\\ hen u,inK the miter box. I
d.unl> it I.. my bench
,,,,,ylhillll ,"ady.

10

keep

SECOND ..". OACK

JAW I'M(('"

(Ul , ...

JIIIlct A &

AND QlUt IN PLACe!

T.wRfHAN

cumNQ

-.._

00'n< Of'
SAWttADI

IASI ....

I't_

f
(\If OAOO

I. 011"
WlOI

,.,.

FIRST: GUS.

,.,Ct A IlUSH WI"n4

(NO Of-

lASE

DUPLICATE TENONS
Ordinarily when I cut tenens
on mil s, It"UIthem 'one at a time.
But fur III(' 'mall rail. on the
Plant Stand in thi' """'. I did
""mt'thing dilfl"Rl1l
~iN.1 '-L1nl'd out .. ith a"ide
blank. Then I loutIQn~",on the
end, 01 Ihi, bl.ok. \\lotn the

Be sureto allow (orthl' "",

kfr(,

and also forchipuul a, Iht blade

completes ib CUI
RlPP"G "T11fMAII"- .-\lI.r rut-

ling Iht tongues. rip the blank

into 'trips to produce rail, with
identical tenons on their end"
'\('<. ~ill.
2.

NO (1II1'IJIT.

This

method

e lirninate ...chipout that can

oc....ur when cuttillR It.n()n.s one
a1 a time

ripp.-d Into ('quaJ.,ize

<tri~>. yuu've got rails with
blank"

tenons on the end-,

I'RFI'AIU"T1()\. Til do this, attach an auxili<oryfence 10 the rip
fenc e, Sl't ~il!.la
Then stan with blank wid e
enough lor aUlhc mib needed,

FIRST:

CUTfONQUIS ON
ENDSOf '\ANte

16

\
1

"
DRAWER CATCHES
TI",r(",

screwed onther II~t(/1' facl' (lr'll~ roil so tile pin is above the bottom 01the rail. sec Fig, :Ia.
frU"lrfllil1" than '.,)c:nillR 3 drawer back. ,(',' Vill. I
Wncn the drawer i~
pushed
To
get
thl'
drawer
in
or
OUIof
drawer and h8'in8 tht contents
duml) out 011 the 1100r. To pre- the cabinet. pivot the tumbuckkinto the cabinet. the 100S<' hinge
vent thi_ on the draw vr in !he so it clean. the top rail. Then, to leaf is pushed out 01 th( WAY
11ant Sland ())aile I~)I added a <et the catch. reach in,idl' th e Then the leal willIan down and
catch on the back 01the drawer, 0",," drawer and pivot thl' tum- kel'p the drawer from bl'ing
pulled all the way out,
n R'HIlI'U Ther e an' two buckk-v ..ni,"II~. ",tHJ,l. la.
diftt,"",. catch d("<o;j.J!11
...l've used
III'G~ cvrcu 111l second
To remeve the drawer. pun it
w htrta dra'ftt r fitsinto acabioo
mc1hod u....,. hinge a catch. out haII'II'a)' and reach into tlw
th.1Iha s a tup rail TI,c first Use" see .-111. 2 Sen'" on,' wal 01 the drawer. Then 1lip the 100""' h-af
a t I thi.k ,.. ,od.'Il turnbockle hinge to the back III th",.buwt
up and remove the drawer

nothing

more

(AilNn TOIt

OItAWU
RIONT

MOUNT
f1JRHaUCKU
CATCHON tNS10l
Of Dl.AW1A SACK

lA'ttlt

wrmoi-r

A RAIL lfllw

n' have a top rail.

{':thin'l doe ...

cut a notch in th.. top edge olthe

drawer back. see Fig, 3. This
aJiIl'" with a turnbuckle
'~r<II
c d up into the cabinet
lron\l' or top,
To in'!'o.c;rl or remove the
dnl'At r, pl\'ol th e turnbuckle' to
align with th, notch... -e
3a.

'lit.

lI'ith th.. tumbuckle closed, the

drawer can't com out

.... wtrt

''''''''''

HINGl
OItAWut
CATCH

CUTNOTCN
aN DRAWl.

lACK_

a.
OItAwn
lACK

"""'.uow
~
.......
..

<. ~\
'V
~.......

,woN

..

TO ......

'"

"""WIlt

>-'

CLAMPING MORTISE AND TENON JOINTS

.111t' trudlrionnl way to join
",)"Ins or ralls to I~g~is with a
Inorti~(.' and u-non joint. And
tha!', Illl'jolllt IuM'(Ion the Plaot
Stand on paq,' 18, lI'hile the morand u non, ar~n't difficult to
make, thl'~ can be diUk,,1t to
clamp uprom'('(lj

Ii,,

'1,,clamp,don'ta),.<t)""ppIy

Pfl""u('e in lint: ....ith the"mortise

ing down the wing IIU". the bars

keep the 1('11' aligl1l'<l and
counter the rackinl( ""u>('(1 by

the dampTo make a ",t 01

pressure bar-, ....tan
wnh acouple of 16"
lonl( 2,,4',.111<'11.
driB hoIt.-s 6Jrlht, WO
dia. carrial((' bolt-,

ClAIIPING.1 use the pn-ssure

Aftl'r IIw joint is Rlued and put

bars in combination "ith n conventional clamp (or e a ch

tenoned member in tile pro;".:!

1t.gltJl(r. alternate tighleElillg

Ihl' pre""r.. bar and the clamp

until tIlt' joints clese tight.

~,. CUllAQf

IOlfSAHO

a.

WWONut$

and t('Il(Jn Thi' can cause the centered on the

pi('\"'" to rack. leaving a gap aI thickne 01 each
piece and I' in lrom
th~ joint lim-. see
13.

'lit.

,'RP;,t RE B.\~ I solved the the ends

'ow .
measure
3Cr(.ts
...
problem by making a Sl'1of pressure bar, Irom two strips 01 their width and ril'
wOlld connected

by carriage

bolt. and wing nuts. By tighten

Nu. N;

them in hnlf . N'

fig. I.

17

....:.W.:........::E:..._E=-K
E '\I O_r__;_R_O~J__;_E

....:C_T

Plant Stand

The simple lines and the straighl-foruJardjoinery barrOtt' heat'ily from

traditional Craftsman-style [umiture. But tha! doesn' e mean it won't fit
in today's home. In fact ie's a perfect place for a desk phone.

\~
I

alw3Y, admired the idea

behind the Crnflsman-slyl~

fumilu!'\' thaI was mad" in the
",rly 1!IOCr~ and leatured very
li11ko ornamentation.
!lUI. often il looks heavy and
uut-ofpial.. e, especially when
<urrounded br other styk." of

furmtur e, !'hal', whv. when I

buIlt th" planl Sland. i trimmed
do.. n the trnditional heavy legs
and Illp 10 61 in a more contem(lornry wiling.
,,.., 1(;'<, One

onhe mostdi ...

tincuve features of this plant
stand Is It's I,'l!s. As is typical
with Ihls ';lyle of furniture, the
Icg.n ....rurri.'tlthrough the top,
l'Ili, makes foran interesiing de'ii1ll1, bUI nOlching the lOP and
111<-h~U fhra tighlfilaround the
k Ir'can lx, tricky.
The biggesl problem in
malung IlK lop and the sheU is
all" winl( fIJI' expansion and coo-

traction around the legs. To

",Iv" this problem, I CUI the lOP

and -h('U OUIof plywood. Then I
uved faciog pieces 10 make
111<'01
"1'1."rIO be notched.
JOIN"RI', The mortise and
It'nolljc,int~used LO join the rails
10Ihl'lew; call for a very precise
fit because there arc no lOPand
bouom shoulders on the tenons.
I didn't cut these shoulders 10

allow for the maximum possible

I(luc al'\'a on the 'I'."wide rails.
SIIl Ihere aren't any shoulders
on Ih. u-non-; you have 10 CUI
Ih. moruses to the exact size,
\l\TEJU..U. A'ill ASISH. Most

18

Crafl'man furniture was made

(rom while oak. and so j!'i,
our plant -tand. To give il an
aulh<'I1tk color. 1 used :l.ti"",..x
",",,,incial <IiIin. And IWOcoalS of
\ lin"-ax Satin Polyu rethane.

No, 6$

EXPLODED VIEW
@

@FACING

,.-@TOP

TOP

DRAWER
CATCH
,

DRAWER
RAIL

DRAWER
DRAWER
SIDE
S!9 DRAWER
BACK

DRAWER@
STOP

"" BACK
~APRON

RAIL

a, MORTISE DETAILS

c
DRAWER
RAILS

I.lG
(CROSS

SIEC11ON,

lEG
FACING

..

DRAWER
I
PULL
@
DRAWER
FRONT

'1'1." I

...

IS' CHAMfI:R

FACING

SHElf
ORAWPt
OPlNING

_,
2J,. ..

4'.,"

DI.AwtR
RAIL

LOWER
RAILS

"@

MOIl'llStS

RAilS

LEGS

OVERALL DIMENSIONS:
30"'-" H x 12

I,,"

X 12'j8"

CUnlNG

MATERIALS AND SUPPLIES

A Legs(4)
B Apfons(3)

Rolls(6)

TopJSI\elf(2)

E Foong PIeces (8)

F
G
H
I

o.ow", GuIdes (4)

0.0""" Franl (1)
o.owe<Sides(2)
o.OW8fBoc1<(I)
J o.owerBoHom(l)
K D<owerStop (1)

I"'ox I'A. ,30'-' 1.9Bd FI.,]llIo'lhi::I<whlteOO4<.

~. X

41<11'lO'~

~.x~'IO~
-1'. Ply- 10X 10
-1'. X 'It,10

~.x",.,10

~.x2'9~'9'tr1.
~X2"1J2,9

'll X2'91J2'9!r16

1;.Ply, 9'It x 10
CUlloFIl

1'.., 636 fl.9ad.ft.

A

3.SBd FI.. .',thlelcwMeOOl<

2 Sq fl., .'lhfck willie 001<
plyWood

A
~'.. X 41" ....

'!-_Sq. Ft., ",',thld<mople

'I4',lt'Ilck plywood tor drawer
bottom.
Min'NOxPl'ovlociOl$101n. ",pi
Sol'" OOIvurelhone ~ pt.
Bross bo I drawer pul. (See
Sources page 31.)

Woodsmlth

DIAGRAM

(1.5 ad..ft.)

19

THE LEGS
f-",

e-

v"

The fir,1 step in

building Ihe plant
stand is 10 make !he
foor square legs.

,I

"I

\10

X 1t.

SQU.AD

UNGTHlr

STOP

alOCX

k.."

()pt.'llil1g.

To
Ill\' mortise locations aligned,
clamp the )('1{> logether so the chamfered
shouklers are flush,see Fi~ 2.Then.Jecate
Ill" upper and lower limitsofthe mortises for
the apron, and drawer rails. by measuring
dO,,"I~I"andSll."fromtheshouldC1'line.
Sow u"" a "Quare 10marl< the limits across
the four)('g-....... ~ig2
OI!.\WI'R RAIL\lOImSES. Xext, you can

fimsh I.)injf oul th...dm ,,.,. mil IJlOfti5<'S.

The limillin., rePll"<'n1 the outer edge of
themeruse-, So. on t"'ooflll~ 1<.I(s. measure
"." (th. lenll\h of the mortise) in from the
limit lin v". -ee t-ia. 2.
Kcm'C)\! MOIC1l"",. :-;ow lay OUlthe morti,;t." (or thl' lower rai!.. 6" {rom the bottom
o(lhrlcg<. ,,(trto lhe side view on page 19.
To complete the layout, use a square 10
lran"fc'r the mortise locations around to the
adj~('(,nI<itlI' of each leg. Note: TIle from
legs are made as a mirrored set (righl and
lefl) and mu,1 be laid out and mortised as

-@lEG8LANK
CHAMflR ALLfOUR SlDB

WASTI

3O'ROM

aonOM

S<T
IlIAD<
AT 1'

Q.

,1tONt

LIn

lIIGHI

f.OHT
LtOS

\..

......

NOTE:

snacss

Lto'

SECnON OTAA.
ON PAGf 19 fat
,..,.,...
UNGTHS

(To kt't1llht """,n. and tall. flush 10the

M.r completing in<ide edj(e of tI,,lt Il'. th, mortises are off
Ill. layOul. Ill.. 0("'1 '<C'P is 10 driB out the 'I.) Th en >('1th. deplh <lop on the drill
morti ........I u-l'd the driD pres,. and a ~.' pre-< 10 produc~ a ~16'-d""" mortise. and
morti<ing bit, see ~llt :1. For more inronna- drill. ",tit.. of 0' "rL!pping holes. see ~ig.
3.
tion on drilling mortises. set' page lt. Sexldean out the mortise, >lopping shan of
(Another method is 10 use the Mortising the LtYOIlIhne-, see Fill. 4
toOole:Because the moruses are ouser,
Table fcalun'() in II'IHllhm.th
67.)
keep the inside edge o( the leg (the edge
To drill the mortises .stan by mounting.
bil in the drill pre,". Then attach an auxil- between the mortises) against t11~fenee,
SQIJARElll' "I~ "lltmSES. Aft.'r removiary fenc. 10 Ihe drill press table. This will
keep alllh( mortises equally spaced {rom ing most of the waste with the drill bit.
square the mortises 10the layout line with a
the lII"idr con ...r ofeach leg.
chisel,
""... rOIl 5. lip: Ilsea>ier 10fit tlte tenon
l'OSmOSTlI ~'.SCF_ Clamp the fence %"
from lh(' insidr edge of the bit. see rag. 3a. if you und"rcullhe moni .... st.." Fig. 5a
shown....... Fill. 2a
DRIU. nlE )Iom.,.,

"0.

V.

Q.

/')

OGSn "

flNCl Q ..

r-f1'--".J..

.... tu

"" lNSfOt 'ACl

TOW "*"0 , l.NCf:

20

C\TTO SIZE.Stan

work on the legs (A)

by curring four
~
blanks{rom~stock
'-(J Vl6" actual thickness) 10I VI'," square. To altow room (or the
pyramid ,hal)<"at topoteach lell, cuuhe four
"'II blank, a liult'lonstcr than needed (32").
CIIA.\lfERnn lH.S. To (onn the pyrtlnlid,
I cut four ,hamfr,.., on the end o( each 1<.1(.
Stan by tilunll the table saw blade to IS .
To mak,' sun- that each 1"1: i,cut 10 the
same knll1h, """'" anauxili3l)' fence 10the
miter lr.Iug~ and clamp a >lOPblock 10 the
ft"flCt', "" ~iR I. Adju<t Ih. lop block so the
base of the dwmfl'f' i,3IY' from the bottom
of Ih., I.'!! (AI, "'~' Hg, 13. To CUIthe (our
-.idl'd cham f-r. "mill)' make four passes. ro"'ling Ih" 1'11'<" b<twee n passes,
"()Im'~ l.'I)l'EXO\. The legs are joined
to tht apron. on the ,ides and back with
moni"" and tenon Joints. Across the front of
the <land. I used IWO:,I"widerails to make

a drawer

'I-

~.'

.SUDI. lIC
aACK ANO ,0!tfH

...._

','

-'0,.

SOUAA1UP

MORTISES

to LAYOUTUN'

No.6h

APRONS AND RAILS

The next StCP is to
make the aprons (B)
and rails (C) that fit
into the mortised
legs. To maintain
the plant stand's
simple slyle.1 made
all the aprons and
rail" the same
length. However, the aprons and rails have
to fit Oush to the inside comer of each leg. To
do this. offset tenons need to be cut on the
ends of the aprons and rails.
TENONS. Start by cuning three oversize
(4l'.!"wide) blanks for the aprons (B) and

CUT RAIL
ftNONS

one 6"wide blank for all six rails (C), to an

overall finished length of 10l'.!".
The problem is keeping the tenons a('CUrate and avoiding chipout on the ends. To
solve the problem I cut the tenons on a wide
blank. then ripped the blank to make the
aprons and rails. see Shop Notes. page 16.
STEP O~'E.To make the aprons and rails.
cut the offset tenons on the ends of the
blanks in two steps with a dado blade. First.
attach an auxiliary fence to the table saw rip
fence and position it SO the blade will cut.
V."wide rabbet. see Step 1in Fig. 7.
111en, using a test piece.adjust the height
ofthecut until it.equals thedisiance between

..@APRON
_,

tTHUE",etS)

ON A 6 WIDE
'lANK, THEN RIP
TO nNAl WIDTH

AUX,fINCl-..

-..Jtl

.....

y_

,t

lNS1Dl

fAct DOWN

~'i
'":
4!i

R~

.'1
, s'

I'

fACE

.~.~

8
INSIDf 'ACE
Of AHONS,

.AIIS

STEP 2

CUT
RAlln
ON OUT
$lDEfAa

CROSS SECTION

TOP AND SHELF

Once Icompleted the

II"fi;;?-"'PlI

aprons (B) and the

rails (C). I started
working on the top
and shelf (both
labeled D). (The top
and theshelfareilltcrchangeable.) My first
thought w-as to use a
hardwood blank. UICOnOlChthecorncrsarrutd
the ICb"S. But this creates a couple of problems.
The first problem has to do with the way
solid wood expands and contracts with
changes in humidity. As the wood expands. it
pushes the legs apart, When it contracts, it
leaves. gap between the legs. P1us.notdting

CUTTO,IT.)
MORnsr

(S,)( PIECES)

'"

OUI'
"""itT
ON [*",SIOI

:;

IN,SIDf;t,\

STEP 1
(Ill A \11-

l~,.,

.L

FA-aU'

I' ..

., .

l.....
_.... ..-.;.

.
to-

in ~,

die inside edge of the leg and the mortise

(a"). refer to Fig, 8. when the height is set.
rabbet both ends of the blanks on the same
;".lIk face.
STEP rwo, To finish the tenons. I cut a
rabbet on the ol<liIide face of the blanks. To
do this. stan by flipping the iesr piece over.
Now, adjust the blade height to produce a
V4" tenon and make a pass over the blade.
see Step Two in rig. 7. Ilthelenon doesn't fil
the mortise. adjust the blade height until you
have. good fit.
Finally, rip the aprons (8) to a finished
width of 4 Vi'.and cut the six rails (C) from
the other blank to a width of:, ", see Fig. 6.

around four legs to get a tight fit isn't easy.

PlYWQODTOPA:<DSHF.1F.lnstead.1made
the top/shelf (0) from :}'4" plywood. (Plywood is more stable than hardwood. so
movement shouldn't be a problem.) Then I
attached :v...-thick hardwood facings (E) to
cover the plywood edges and create the tight
fitting notched comers. see Fig, 9.
DETE~nNE TIlE CORRC1'SIZE. The ply
wood top and shelf are cut to fitbetween the
legs of the stand. This means the length of
the plywood sides is the same as the
shoulder-te-shoulder length of die aprons
and rails (10" in my case). see rig. 9.
CUI'llNG 11IE PLYWOOD, Aiter you've determined the correct size the next step is to

cut the plywood top and sheIL Stan by screwing an auxiliary fence to the miter gauge.
Then position a stop on the auxiliary fence

so it's 10" away from the blade. Cut the two

10" blanks in two passes, turning the pieces

90' between passes. see Fig. 10.

The next step isto make the facing pieces.
Usingthe same method ason the aprons and
rails Icut a wide blank to length. then ripped
the pieces to width. Since the facing pieces
(E) are the same length as the sides of the
plywood. Iused the same stop block setting
to cut the !V4"-thickfacing blank to length.
see Fig. 11. With the blank cut to length. all
that's left is to rip the facing pieces to a
finished width 0(7~'.

IlNGTH
OF fACING
(QUA.L$ SHOUlDE.
DLMtNSIONS Of RAJI.S

No. 68

\XIoodsmtrh

21

TOP AND SHELF ASSEMBLY

CUlling thr PI<'t'r, fur the top and shelf is
tair!)' '.'1
Ihe Irick)" pan i, gluing the
!acinI: pie<'" ll.ult 10the edges of the pi)'.
wood To do this, 1-e1up a clamping fixture

on a"',' plyv.,JOdbase,

Begin b)' l'l'mO\Ilng one 5lnigb~1!'! from

the ply"ood base and rotate 1Iw lOp pie
90'. Then lack the !ltnlightcdge back in
pI~,'<t' till 13.
:\exl, to kt-ep Ih~ last 1"'0 facing pieces
Hush with Ihe ,ides 01the plywood top.I cui

ClA\lPIM. reen Rl Start by placing the

lop Plvct (ilIon the plywood
betw ...n a couple 01 14", 12 PlYWOOD
lASE
long slmi~hl,'<lg,'s. see Fig. 12.
Then tack Ih" slraightt'dges
down to til(' pl)'"o,"1 base,
GUf f\tI~(;0' r-;"w, gloe
and damp 1Ill'fat'jng pi,,,,C'l> (E)
in pla<~ The '-Itaillhwdlles will
kl"'P th. m nu'" to the end. 01
the top
C1,l'h eck thaI the
e;..:inl!i,flu'" to th,' top ,urlact>
ofth~ top po-ce, ........tig. 12.
l '-I't ....... \(. t)t RI...OCk..e-, After
('A 0 ldilinJ! pe":,\y,,,art" altaC'hed to

th, lop ""d lb.' ,hdl, Ihe oth er

FACING
e;..:ingJM<'<~.,ran 1M, glu,"" on.

b.,,,,

four ~.wi~
'J)a<:~rblocks.see rig. 13.
Finally, '<Ii~ thl" 1"0 remaining facing
pieces (E) ""1.. ,...'0 the <pacer blocks and
clamp the 8''<mbly in place until the glue
dries, see Fig 13. Thl'O repeat this procedun: lor ihe <hel(

scaAP

1TIWGIIf
""'IS

pi.""

---

Kt"'AQrfOS
__
nus.. WITH
AU

TABLE ASSEMBLY

Rt"thc-r,1U'lwf' .,.jdc,'unus. I~('h unit is a mirrored "'1 and i,made up 01 one front and
back I.g (t\), all apron (13) and a nul (C).

togNher with the r..maining apron (H) and

the mils (C), M'l' Fill. 14.
SIan by IIluillSl the lower rails into the
lower mortises In the side units. Then, 10
keep the 'land square during damping,lay
the <helton lopoflh.dowl'rrail., see Fig. I I.
Now, glu<' th., IWO front drawer rail. and
Ihe back apron in place. This ume 1used the

refer to ~.XI~
oded \I......
pag~19.
:\01.. I marl. a jilt 10 k""J) the legs from
rnckinl{during!lh.. .., ..,.,pQge 17.
JO" nIt '10"". All,.,. the side units, are
' ....1llbk'll th nl'xl 'taR~I~ 10 join thl'm

IOPIOk"'1lth~.''<'mbl)' square.see Fig. 14

(Dt>" glu~ Ihe lop on Y' L)
OR,\WF.Jc(;11D~
\\'hilt- thc table i,dry.
ing. you can <;tart "orl<ing on 1Iw drawer
guide-. Thtdrawerguides(f)arecutfrom

Once you've (Olllplt-lt'tl811aching the facing

pi..."" nn~1 ~s.",mbly can begin. Instead or
Irying to glut, "I> .11 the pieces at the same
timl', 1dividl'd lilt' a.",,-,nblyinto IWOstages.
Mil. I vrrs 11w flrst ,1lIg~is to glue I~

14

USI TO' to KlIP l10

AS5IMI&.Y SOUAll

ARST:
ASSfMIU

DRAWER GUIDES

15

SlD(UNIT$

,.

(f"
'.,
r-'

SECOND:

JOJHlHI:

r-..
..W1n4
lAIlSAHO
IA(I(

"""""

ra.

~-

,\

1\

~=

f:/ f

, 1,\!

ANOtAU

kllPRUSH
Wln41tA1U

".......~

:1"

"

lOP TO
4H.ON$

)'

_Wit

~~

OW'.ND

c.......,

F'

I~.

lll~'" TII~
srr. I'o"ition the drawer
gujd,,"" Iht)n- nu,h withthe dm ...er mils
(e) 11...n.lllu, Ih,' dra",'r guide.. to the in<ide oftlw ,td .. apron' ....~' Fig. 15.
ro"/~Jt~.u .tinaJl},I""'\'UI'et),,,1JJp. apply
gIut'luthclop,-d"~'''IIh<'aprun,andtheupper
~~ ...rniI. and clamp th, tOPD1 place,...,.. r18.
16.
Then 1itI1h<'.J1cl!. apply ut' to thl' lOP ot
the raib. and clamp the <h"1(do.. 'll

~~

~,/.

rails nnd lilt' b;"'k Itl)rnn .....~" Fig. 15.(In my

c:aMthi~W3~II'''.)

16

(cut TO nTI

Ii"

l," "i(JU~ltl hw."k tu fit between the! upper

1.:.
_t

-1....

lAO<

71
CROSS
SECTION

Gt.UI SMfll
TO 1tAJl$

No. 68

THE DRAWER
ing, (In my ease this was 2%" x 10".) Then below. Then. dry assemble the drawer 10
using ~-Ihick stock. cut uie drawer Iront measure torthe drawerbottom (J). And CUi
(G) l;j rr less than tbe widlh of the opening the drawer bouom (rom
plywood.
(91~16"). and It.rl' less than the height onhe
I)RAWER sror. To keep ihe drawer flush
opening (21~.l2").see fig. 17.
in front when it's closed. 1glued a drawer
SIDES AND BACK. Now cut the drawer
SLOp(K) 10lhe back apron. To determine
sides (H) and back (I) to the same height the correct size of the SLOp.position the
as the drawer (ronl (21%2"). Then !rim the drawer front flush wilh the drawer rails.
drawer sides 9" long. and the back Io'l" Then trim thesropsoitfitsbetween the back
more information, St." ::V.'oodJJt)lith No. 58.
shorter than the drawer front. see Fig. 17.
of the drawer and the inside of the back
URA\VER FROJo."T.Since the size of the
Once Ihe drawer pieces are cut to .w.o, cut a apron. see Fig. 18.
drawer front (G) dl.'lermlnes the size ofLhe groove for thedrawer bouom, see FIIl.17a.
Finally. Iadded a turnbuckle catch lO tlw
other pieces, I made Ihis piece fU'SLTo do
CORN'ERJOL'T.Finally.to make thecomer back of the drawer. For more on drawer
this, stan by measuring the size otthe open- joint. follow the step-by-step instructions catches, sec page 17.

Once lhe stand is assembled. all that's left is

to build the drawer. However. since the
drawer 61$flush to the front (ace of the mils
(iI's not Upped) there will he a gap at the lOP
and on the sides when the drawer is installed. The trick is to make this gap as small
as possible.
Note: II you prefer 10dovetail the drawer.
the opening is s ized for Vt' dovetails. For

V,

18

17

HAWU CAra-.
(S(( SHOP NOTES}

BACK
BOTTOM

(":II-PLYWOOO)

Q)

II))-llSS

1>1.,.

DRAWlR
oPtN1NG

a.

CROSS
SECTION

DRAWER
STOP

aonOM

ORAwtR

LOCKING DRAWER JOINT

BesideS being Sirong
andea,;yromake.Lhi~
drawer joint doeso't
require any special
equipment,

All

, $A\Y

SID<!
.W>f
HUGHT

you

>"--...!-

need isatable sawwith a combination blade.

This joim is sized for a :jt~-thickdrawer

~'

ftfOtf

USE DRAWIR

CUT A SfNGU KERf' ACROSS

SlO(SfO('K
105fT RNCI!

80TH (NOS 0' tACH

DRAWE. srOl PrECE

<,
.

'.~,

front wilh VI"lhick sides and back.

"NC' .

ll'OU

_wtR

f:.(Ii: c_

."

!I

I'

~
INSlDf FAC( _)

I
!
Since the drawer in the plant stand fits
Rush, you'Dneed to be careful of lhe fit. I'd
To make UU! fiJ'8t cuL ....., tho lf~'Ntn, lcdh ih.ejCnce ar:11119a.l! a $WP,
recommend using test pieces and sneakUlg
thICk drolt,r "id. to po8iltoll ttu:
kerf botI~""ds of th~ drawer (fijie6
,,,,I), (/t~iY($icJ~fa~.. dl)l071llgaill8ttl" tabl.
up on all of'the cuts untillhey're perfect.
fenc. Then m i$r fJusbl",l~ ',dyhl to 11,'.
"_SAW 'LAO<!

m<e.

DRAWl.
'RONT

ON(MO

RAJ.. t

.lAO'
...,..--

f.- '.,.

II

Cl

MOV[flNC
TO CatAtt
TONGU10
flTSAWKW

]I - "'"'"'"

Rni~., blad,1)1111.djll~lj"'tlrr to H",k.

3a

"1!7'1'

No. 66

AD'UST.lAO.
HEIGHT UNT1\.

lONGU,'\"'00

.ACK.......

f"

.-

,;

OJ'II''''''''' tn end of dl'll"'''''

fmllt. leltVillgulimglle tofi! kerf.

fIN

_1 ~

l-

' .',

DRAWlR FRONT
FACE up_

lRlM lONOut

to omw

"".ADO

It

_IJ_

.
lOWER &lADE

.'. -".

CIIl .",CK
tONGUE TO
DfPlH Of OAOO

.. ..
1:

I:t~

;. ~')

.....

"'"

To trill' tlu: UJ1IIl"" III I.ellYU" lower

FinaUy. cut to'lgu~ dramer back
4 tho
blad "lid
U,. fn, ' until: 5 piece. Adjust
bladll /wigllt "nul
nit

"WI'"

lOlll1u.bottom. out in kerfin dnuoer sid.

t}",

the IO'lgueji1s ktif;1I dl'(l.J<'r sidu.

23

S HOP

PROJECT

Sandpaper Storage
W

h~nt.vrr } use a finish sander I'm

amazed at what a great tlmesaver it
is. However. IIII'tim. I save using !.hesander
is 1I,,,ally }",I IryinlCI() h)('410and then cui
sheets of snndpal)('r
1\01any mort' Wev. designed a system
of OiJ)<IJX'n
,I"""", to store pre-cut sheets of
sandpaper -0 Ih,,)' <14)' Ilat. And. 10hold the
,11',"'('-0.I mad. a 'Io~e bin that also holds
the sander. ,..,,,.,holo al righL
sl..ln~
n,,,,k,,,,,,dl..,jgn is simple. II's
,'plY" uod <CJ\ er pi('('(' and a base oi .'
\la...,nill, connected by fabric "hinge",
made the ske<'es 10 bold
sandpaper for a quarkr..;ht'el finL<hsander.
However, by "hanginR Ihe size of the
,I"" ..." tht'y could be I1I3de 10 hold halt
,h,,<'" ur even full ,II,,,,..,,of sandpaper.
~'T(IRo\(;t111".0",'(' Ifinish(, making the
sleeves, Id('Cid,,()to make a bin to keep them
in. The bin is ,iz('() to hold four sleeves .will1
pltnly of ('(10111 Idl over to hold my palm
sander. II)' pUlling the sander on lop of the
bin. Ih~ weight help, keep the sandpaper
Oat. -ee photo al righl.

'"l." 'ilL I

THE SLEEVES
r"'ldeterminethe

To make the '

size

of sandpaPM'<h :t you need. In my case this

is tWO, Svt'. nWTI add \.'!' to both dimen<ion, 101I<'llh~'~','\e..ue(5"" 6"').
lliF Ct)\l'H:-. Aller}ou,,,delemrined!.he
size of Iht ...lc.."Vt;_ )"OU can rut out the l'.;"'
plywood COV(,1'8 (A). To do this. CUI a ply.

2
12',"

s-~

,.
(O~(R

wood blank S..ide b}' 12".long. This is

x
enough for Iwo cove", plus \1<" for the saw
FIRST:
kerf. (Two blanks will make four sleeves.)
OttIU. .".
CUTOI1'S.
make lt easy It) pull the MOll ClNTtllO
UNGTH AND
sl(......-es out 01111.' bin.lhc covers have a semi- ON
WtOTHOf
circuL"II'cUI-oul.To make the cut-outs, driU or ILANK
CUIa Il"l'-dIam('ler hole in the center of the
blank. Then rut the blank in half.see rig. 1.
'",-'>O'm.I~I..~~.ooee the covers are cut
3 HING(
IO'il('.C'llIlh, ooses(R)oulofV." Masonile
10match ibe COH'''' (5".6"). see rig. 2.
FABRlt"" r.f. \\'i!.hthe bases cut. the next
<lep is to 111m'ona Iabn<- hingt' 0 used C3I'I\'3S)
SIan b) pIa.'inll 3 scrap block under !.he
00",10 kt'<'Pit k",'''' with the cover. see fiR.
3. Then. align the bouom edges ~ apart.
'\0\\ apply.Rlut' to the bouom inside)" of
both piecl' Ihen place a 2.....,"wide piece of
fabric over uie glue. so it's flush to !.he OUI
.ide edlll'S of tilt' cover and base.
Finally. fold the sleeve so the edgesof!.he
I,'
SPACI
cover and base are flush, and clamp the bot10medll(' unulthe IIlue dries. see rig. 4.

"0

,_

24

./

"

..
....
0

...

@ ......
(OvtR
.,' ... 'l'WOOO

r-

@
BASE

t 4"

."

MASONlTl-

s
~

Non:
SLOVI

HOU>S
QUAAl'l1t

SH(TOF
S.\NDPAPI

.....

AlJGH TOP AND

IASlRUSH.
1M... CLU<II'
UNTIl.GlUl

<,

"1".68

STORAGE BIN
After organizing my sandpaper in th ..
sleeves. I still needed a way 10 keep the
sleeves io order. So J made a simple storage
bin OUI 01scrap plywood. see photo.
ntE BASEA.'inlL\CK.To make the <Iorag~
bin. begin bytuttinga :\<0" plywood base (C)
and buck (0) slightly widerthan the sleeves
(5'4<") Then. trim the base {Cl I-t less than
the length of the sleeve (51t~1.And ('1'1 the
back (D) 6" high.
TIlE smes. To complete the bin cut two
sides (E). fi"-high and 7"lonl(. see Fig. 5.
Finally. assemble th( bin by gluing tile
back piece (D) behind the base (C), set' Fig.
S.TI,en glue the sides (E) to the base (Cl and

BACK

SIDE

CROSS
SECTION

/'

."

SIDE

r:

back (0). see Fig. 5.

SANDPAPER cunER

Storing sandpaper is one thing. cutting u ro

si7.eisanother, I I)uilt thiS$gsol oouklQuickly
cut sheers of sandpaPl1'
The jig actsasagauge 10 measure nndcut
quarter sheets of sandpaper 10 fit our finish
SIII1der.Using the jig is a rwo-step operation
I'ilOl. a full (9" x II'? sheet of sandpaper is
put into the jig and cui in halL Then the hall
sheetsareturnedse in U:ejigaod CUI in haJJ
again. So you end up with quarter-sheet

CK STOP

NAil STRJPS

Sl1t1PS AAI
CENTn
STOP_

NOTE:

.......THta(, ~." WtDl'

cur TO LENGTH

JIG CUTS
11'JSH(ITS

n'_~(NDSTOPS

'6

AN.
I.

SHIns

'2"
HACKSAW
-ILADE

(41.2"" 5 \,oJ') pit!Ct'S of sandpaper,

\IATERI\I$.All that's needed for the jig is
a piece nf :t4" pl)'Wood for a base. five lr,'

thick stops, and a 12"long hacksaw blade.

see drawing at right,
.\Tr,\CR THE 5roPS. Starting with a 6114" x
12~' pll"'Ood base, nail the end and back
,lop, Ou.h with Ihe ~odsoflh e base. leaving
11"between them. 111cscstopsaret(,rl("aring
the fullshee ll~ngthwise.
Once the paper is 10m lengthwise, it
needsto be lorn in baJJiIg3in.Thals\\hyth~
center stop is poSitioned back SJ.'z"
Cl1'lTlXIT
ED(;F_After the slops are nailed
down, I screwed on a cutting edge made
from a 12~ong hacksaw blade.

B,[ol'c ... ,.. u'lirg (he /lOrKS(JII' blad. to the

jro/ttojth. jig. c(1l1l1tm~itlkt/; ree?llr"{)tli "9
Itoie.. Till" 1",,,,tll)'l f/lI'tt~1t ./igldl"nW."
pI !/Itxll)d OO~f'(tnlisrrctt' iIt pillCt'.

No. 68

II .\,. ..

- Fh. WOOOSCRlW

SANDPAPER CUmNG JIG

ITOP Vlf\M

~----12'~"-----_'

a.

'\"'"

r-- ."

... _4'",-

..r

...

"_

.L

",YWCOO
SC1UW
IlIAD.

......

,
. --:.'.!...:J

lAS.

..,."

\1\,"

=r=
.l~

AlIOV.

SUI'ACf

'6

fh. WOOOSotl'W

First: To lilake/i ....1Cld.pltU4illlPei If">lgfh

I(II~'
I>ctl('f{e1lIh,t".o L$l.ap.wp$.IJ(j/.d
_1<.. 1 01 jig u~(h 01lt h(J>rd"'"ife plilling

down act'tml lIock8(1'" biad~ .:Ith Ihe 01,,...

Woodsmith

~----II"----

Second: Toc><t8IJndjXJ.(Wrto)I'nihd",..,.
piace narrow end o[ piece Qgailral. center
Hold {II plae' and tear [''In
PUplll"dlJWIIeeress iICkS<!wblodf.

$/Op.

.. u! of

25

S HOP

PROJECT

Sandpaper Dispenser
T

h(''''''' a r"lalivl'l} new CYJ)eof sand1);II'<'rIh"l WI"'" started using in the

Wood.lII,tI, 'hop. 11'. ralltd Slikil and II',
made by :JM l"i"'I~lll(r("oml:s.in 4V'!"-widC'
roll, and h,,,. ,licky adh,,,ivc on the back.
It, d",illl1('d 10 OOh,l'\' IighLly 10 a special
pad .llkl"..nu.unlt-d It' tilt baSt" oi an erbual
fini..h .....
tndt r
fh, wh"l. Idt"3,.. lila'

tI".

V()U can lear off a

pi",,, "r
,11< kl '-ll,dP;;", t; .,Iap it on the
bottom 4,1tht 5alld. r, and K" to work. You
don'l ha\t 10 fillbl the , lounps thaI bold the

papt'l' In lilt '-llIdcr (For more on Stlkil

flBIxr.5<" 1001, 01 lilt 1Mlde on ~
28.)
Uhl" "~I
It ()nn' Wt bougbt '-OIIlC roll,.,f

th., paper,
It \\Quld

~t~anlt'(J a

bt"lH:I.'

....a~to store it. And

to have away to measure and

rear uft lilt "Ilitl amount 01 paper lor the

sander. I d,'fid,-d In make a dispenser thaI

would do allthi"
Thhpl)'wood dis~n"'r holds two rolls o(
Sllkll r~IIK-r, I'lus. II provid..~ a mca.uring

-..llrfru.t'Sf' you (an determine the exacr

amount or ~~'I)('rY'.ll Al'OO before you tear it

off. ".~ ,h"ttl!'> on 0Pl>o..,itl.' page,

ASSEMBLY
Thi-, di<p<:n",r I' JU"" box mack IrI>ma-,'
plyvonod ",Ih I"~ hml:,-d lid ...
(('T .-'Itlt'

rn

'Il.f.

fRONT'IACK

ptn...r.firslrul.Ii\1!x
12" basse (A). Then
cuI I,,,. rmnVback (8) 1""''''' 10a finished
'lIt: "I:n " x 12'. s...., Flf( 1
0",,1 the ba-- and from/back pieo."satl'
f.."lII.thv m Xl 'tcl) i~
tt' cut (our 31,-.."' x 4ll\"
sld"./dividl'r-. (e), Then 1'U1mortises (or
h.nl(~' in Ih<,I"" "d,' pieces, refer 10 Fig. 3.
,\."'~ 11111.\ I ,wrtcd J'''-'Illbly by gluing a
frum/back ,,;1'1',(Il) flush 10 Ihe edge of tile
base,
!'if! I Then I IIlued the four
"ide~/divid(-rs (C) in pl(lC('onto the base
Once Ihl' ,idr,/d;viders
arc glued in
place, the I\'maininll (runl/back piece can

MATtIUAU UST

To make the dis-

bo

logt1h"r with um,h nail,

1'()I' Th~ lOP (If !h,' dispenser is acwaIly
twulid. (D) and a layoul board (El Icut all
thn -e
fronl the .ame 6~" x 12l-t'
blank-ul:)<, ph ...ood, """ Fig. 2.

..

f
cumNG GIAGIIAM
C

<.,.

be gltlt'd on. '(0- If you don't want to wail

(or Ih, gtUt 10 dry. you can laCk the pieces

.~

C~
010

16'

6',"

...._~B

BASE

SIDE/
orVIOR

...

LAYOUT

BOARO

25"

...

.L

r--",

For Ihe lid,. cut an h Ioog piece from on e

end o( Ihi, blank. and drill a 11t'-<liaml'll"r
fing-"r hoh- in 111('center of this piece. :\0"

cut i,in half 10 pruduc~ Iwo lids. each 31!i '0"

x 6h". "'" AI( 2.
ATfAC" UI>s. Finally, auach the lids with
IWO 2""long bun hinges. 5' Fig. 3.

61."
---

1',

MaImS(
to O",tH

"'~=~=.=.=~==========~O:F=H~IN_G_'_:-_~:::-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-~:_J

26

LAYOU, BOARD
Once the hinged lids are screwed 10 the dispenser. the next SLOp is 10 'linch Ihe layout
board (E). This board is made out of the
leftover piece from the lOP blank. refer 10
Fig. 2. Since this piece is air.ady cut II) the
correct width (6W). all you have (0 do is
trim nro length (4"). see Fig. 4.
The layoul board is both a length gauge
and a cutting device. TIle length of the board
(,I") matches the length of paper needed for
my quarter-sheet pad sander. This means t
can pull out.the paper until Ireach the cod of
Ihe layout board. and then tear of{ just the
amouni l need, (Or if you have a sixth-sheet
sander you'll need to mark reference lines
on the laYI,ulboard, referlo the Slep-byStep
below.) There's only one problem - the
edge of the plywood isn't sh arp enough 10
tear tbe paper.
('I ~11l'Or.Jl(;t;s. To solve thls problem I
screwed sections nf a hacksaw blade 10 Ihe
edges of the layou! board (El. 8<.'" Fig. 4.
To mount these blade sections, start with
a 12" hacksaw blade. Using a pair of pliers
with sidecuuers. sllipof{thc mounting hail'S
on either end of the blade. Then, cuI the
blade into two 5""1".lonl(section s, 'WeFig. 6.
MOl ",,~Nr. 1I0US. The next step IS 10 Incare and mark Iwo mounting' holes in each
blade section with a punch. see Fig. 7.

CROSS SECTION

NOll:HAClCSAW alA ..

Nnos

10 &1 ",." A80Vl1H[ TOP

SURFACE Of lAYOUT &CARD

NOll:
OWE

LAYOUT BOARD
INPlAC(

STU(IT
$..,..01> .....
tIOU

ctffltIIiNG
IN 0I'I1'IING

Once the hole locations are marked on

both pieces. the mounting holes can be
drilled. Because the blade is so thin. irs not
necessary 10 drill a .hank bole. Ijust used a
countersink billa drillth(' holc.11tis way all
you have 10 do is stopdrilling encethe widest
pan of'rhe hole is the same size as the screw
head. sec Fig. 8.
SCREW TIlE EDGE ON. Finally. position
the blade section so iI'S centered on the

.....

LAYOUT BOARD

../

width of the layout board. The teeth of the

blades should slick 1-16" above the surface of
the layoul board, see Fig. 5. Then screw the
blade sections in place with No. 6 x I-'l' Oalhead wood screws. see Fig. Y.
CUIE IN l'IACt;. Nowgluclhc layoutboard
in place on top of the dispenser so it's
centered between the lid pieces. see Fig. 4.
To usc the dispenser. follow Ihe Step-byStep directions below.

USl5tlAAP
PUNCWAND

CNTfIlHOU
OHWlDntOf

lIlA.'

COUNTU-

SINK

SCORr ANO

.....
K

STOPORJWNG

RtMOVE HOU

WHI:N SCRlW WlU.

ON HACKSAWat.A0l

frT fW$H IN MOLI--

,6 xlJ2"l

11\.
WOOOSCtl[W

USING 'HE DISPENSER

'JlledI8pell.~errallb
'l.'fI'dfiJrquarl.rr
(IT xi.rII,~het.7f St:f'

sa ndrr.

If YQ'l'yr

I(.xi,tga~;.rIJI~,tlleet1(" nder,nutrk' th,' lllynul

1)O(l),'fII();"diro.le its II'idtll

No. 68

thr lid alid unrol! r"oMgh

lVith th' co"....' kngth 0/ pa per
2 141
3
Infit u'mr pad $i:e.
the /a(/olll
rolled, hold thelid riflud and Ipqr",)
boardfor qua rter-sheet;
at ti" penci!
paper

111"

('01'('1'

II.. po""r. T"~111'" ",,,mg' rfl"",be'"

lill</UrIl8i..r:tl,-s}",,,1 ilizt. TIl<IIdost I"~lid. hold t'O diff."ml grits u!Slikil paper.
$1(/1'

(till

Z7

----

TOOL

x x n

--PROl1liCT

R E v I E \'(' ~

Tools of the Trade

I

think finish 'onder- are

great. Bill. I ""'m 10 spend
100 mU('hlim(' IlimblinRaround
Irying 10 RN the sandpaper
lucked unde: the clamps on lIw
snnder On,' solution to this
problem is an adhesive-backed
'illndpap<'rlrum :1~1called StikiL
TI'H \,,,. 'fKt.\
Rathcr
than \\:t...a.illJ: a lot (,i time lI'};ns::
10ReI Ih. -andpap< r under Ole
paperholdool1 clamp>. with
Sblril,,'ndpa;X ry"u ,""ply peel
off Ih e old pieer "I
and "'tick on a

~pa.,....

rubber or klt-ba"'d "rbital finj ....h ~;.,an(ltO'.

(SOle:

')"11(;'manufacturer

(IOt'~n't n-commend fastening

Ilw f..l'iIlR 10 a Ielt pad. I've
teund, Ihough. Ihal it's fine 10
UM,' 111<."conversion lacjng on a
r... llpadtrs/oJlgnRl/fI
I fro 'elf;"

pl{l,~.Hul il vou e...r try to remove the facin~ youll probablv

tear th. pad.)

"'IT.

P\J.,,\I '\",f]<
Then, as il
thi~ ivn't confu!O.ing enough ..

,~

therf'~sonto other option. It's

one It's

Palm ~d"r Nt and ;,.

di,tnbulcn through :1\1\ Home
I')'odlk-I' Ili\"ion to hardware
and h.,mt.' centers, (StOOl is distributed Ihrough the Construetion 1>I\,i ...inn.l
11", Palm Sauder Kit isapiece
of '"Ih, ,i,,-b.,'k,d vill)1that can be per'HI PAD
mruu-ntly ollUd ... d III Ihe base of your
The OIh"r 1'1n "(Ih,, "sy-tem" is the sp,xial sultltr. "11u' $:0(1(1nt'\\s l~ i1 only costs about
pad on tIu-bunmllllfthe ... nder Thepad has l~o dullar ... "11''''1),,(1 Jlt'WS i~
it only comes in
a mclal ba,-kinR pia'" with fabric-covered a quarlt'r,lk'\"t -.:11'1 l\\ajlablc along with
urethane loam glu.'<I10it 111.,foam is m"d. thi> kil are pre-cut quaru r sheets 01adh eto an exact hardnc .......
lf the foam j .. lO()~lllit <ive-backcd sandpaper, IThe)"'re called
wi n deiam'l);) It'd IIrinll U'C Too hard and tho -Adh.,j, ,.I\a( ked Palm sand. r Sheets.")
sander w ,IIJump around on the" orkpiece
There's 01\(' more thing I should mention
\\ \U.\Il1lm. Ior the pa-t f..... years. about the ~I
and Palm sander Kil ~)1"
Porter-C abl .. has bee n fining their quarter terns. E\C1l1t)OU uscth('~"")''lf1n''.}"OUcan
and half""",ct <:mdcts with :-,tikil pad. a_, >!iIl use ,"'ndart! ...,.,dpaJ)<'T Simply place
...-tandard t"CtUlpnll nt HO\\('\'er~ou
can aL.;.o ~ ....ndpoper o, ..r the pad or lacing and
buy a r'pla ...m'ol pad lur older modd cro,"P it in pb.."t a, you n'ImLaily vo"oukl
Pon..,..cabk (1l".:k"eUl and \lakiL1 quar
ECONOMY
tcr'h ...1,",ld," .hrough ,,'Vera! dilferent
STIKIT
mail ortit-r."",panio,. M" ~urc"" page 31. ~mec.t.l"g< M)' ),.,u ","r m ovcr regular
Slikil paP<'ri'n'ln'ally ne" In lac!. it's been (K,.le: You haw I., 1'Cmov~the Iclt pad on paperbyu,inll!"ikiL Dot, thbmean il COSl'
u<ed on IIi".,nndc,", in .he au.omotive and Ih"....;;alld~....b,ior, i,"lailing the Stik;1 re- 22'!.lc<.?
m~lalworkinlt industries lor over len years. pL1C('ment pad.)
IIyou buyllw Sllkit ")'>olemto save money.
\\!hal
aboul
IlHal'hing
Ihe
Stikil
papt'r
The only -at diflcl'I!n('~i,lhal il'$ now "'ail
i think you're Riling 10lx' di<appointed. The
able in rolls lor quaner and half-<heel pad directly 10 Ihe rubber or Iell base of 01)' 22'1r.qavilll(' .Ilt: calalog, reler 10 is the
...."der?
<3nde,",.
amoulll "I pu.",r Ihaf' "'a'ied under the
It\probably 1101al!ood idt'a. Wefoundoul clamps of a ",nd"r You ,;ave on paper. buc
BUIthi' ,.uff" nol just a piece of slicky
Ihe hant war ho\\ .;tic", Stikil can be. "-,, Uk Stikil paJlt'r i,mu.-h more "xpcnsl\'e IX'r
sandpaper. It, a I"'.,.pan -syslem:
\8R.\.o,n,..., The r""l pan 01the <y""ilemi, anached a pi.'C.olSlJkit paper 10the rubber
:;quar. in..h In fa.: I. compared 10 =dart!
the .andpaJ)<'r. \\ hit-h"coaled \\;tha qlicon ba",ofa Rrobl5Md,'!'and used itforcoupie aluminum .,xid. or garnel <andpaper
carbid~ abra,;' .. T}'J)icaIt)whl.'Il you buy ofd'r~ \\lwn we remuved Ihepaper. panol withoUIan .dh.,i,'(' bat-king. il can bt: o' ....r
;;;Iicon carbid .. paper (,uch a;, 3\l's 1'''';':\1- th, rubber b., ... came..,th il
",xc 3.. f'xpcn ...j\r. per.;q~ in..:h ..
h"" or -'\'CI_>rJ)t) ") it', a dark gray color.
:\nd. il 'ou u'"" Sukil paJ)<'1'"'Ih a reh pad.
E't'n though Ihe paper; .. mo", e>:pensi,.
each time )'()U rt n1(1\'f._the paper someoflhe
)et the Slikn pa",'f1' aim"" while.
than n-gular sandpaDl'r. I .;tiJlllk. u<ing th..
"'lbe whi.t' coloron theStikit papctcomes
felt corn~s ""Ih II.
StikJl ') ,tem It,qu;':'k and easy 10change
,()" fR'-ICI\ f \CI'G. ThaI', why 3~1 th~ pap,:r n<1all 01Ih" ,'nerg} oj thp sander
ITom a coating 01rill(' Slerale applied ov('r
Ihe ,ilicon carbide." t'xplaint'd R('d make, a S.ikil Con'en.lOn Facing. It', an i!'lo trnn~(lrrt'dto thi" \\oritpll'Ce.
Peloquin. Technical Service Specialist lor adh~,iv ....backl'" Pll"" of rabric (the same
Also. oncr Y"u'v~ nlounll"d. Stikit pad or
fubric
Ihat"-IJntlw
Slikil
pads).
and
itcomt's
3M. "'lbi'cooting helps pr..'Vcotloading and
con\'('~i()nfaling (In YOlif '\3nd~r.loubave
dOAAingalthe paper. especially when sand- in a ,h1.'c1larR" "nouRh 10 fil a half-;hCCI the choir. of u,llIg. ,1/" rr~J1Ular""1dp'lX'r
s.1ndcr. BUIil call b~ cut down to fil smaller or Ihe adho,ivt-back.d Stikil paprr
ing 6ni~hes or painl:
DCW

<"llk.'f)

quick. 11', t'3"'~'and there's no

lumblinR around .. ith th.
clamp,
8uI. even morv important i~
that iI3"IU311),improve-, Ih('W3,
Ihe sander work. Ir Ihe sandpaper is held to the s311<1er
with clamps. it's
hard 10 secure tl1I' paper liRht against the
pad '111~rt'\alway,!;()me"'lop: (Evenifthe
paper i, tighl to Ix'!!in with, it loosens up as
you u'in~ .1.)This allows the pad to move
indep<'ndenlly 01 Ih., paper. so the orbital
action or th, sa nder i, nul being transferred
to Ihe workpiece, The sander is just sliding
around m liltl, circl,,, on top 01 the sandpap<r.
Wilh Slikil SUldpalX'rlhere 'sno -.lop- berween Ih,' I.. d and th~ paper. So all the
cncrlO i, Iran,lerred directly Irom the
sand," 10 Ih,' W.,rkpi....'t'. This makes lbe
pOlX'rclll much (a,.1('1'

~I).

6t-i

AND

COMMENTS

QUESTIONS

Talking Shop
JOINTERS AND PLANERS
.1'/11 ronsid ril'!/ Illllliilg (1
jflfJrt.r (,r a joil,lel'lplaJ/rT lor
11'1/ ~"(II'.n"'ltl"
tV' "Il!1 tIll
,~i(,1(ill I,."ir" 1/"'11 il) gol

"(1

clean up and square one edge 01 planers, a pressure bar) flattens

a board 90' (or any angle) 10an the workpiece tight against a
adjal'elll surface. This is useful table or bed, sec Fig. 4. Then

J"" Illarkwcll
(;I't' "t'ill, , S,,11' I, ('(, )"(;1 11111
Before l make any recommenda-

when you're preparing stock [tjr

cdg ....gluing,
A jointer can also 11<.' used I"
OalWna far,'on a board, see Fig,

tions, lt's important 10 have an

I, In performing' this operatieu

JOtNTER
lLAntHlNQ
IKE IAC(
OfAPIEQ

OF STOCK

'--

understanding 01 what a jointer

(Il' a planer can do (or YC)u. K ote

thaI I listed these as two separate

machines.

The confusion in the rcr-

minoiogy comes when a deal..r

tries to s,,11a '1oinler/pJa"cr,"
Unless it's a combinatlon rnachine land they'r e usually expensivel, it's probably only a
joinler It won't plane stock LOa
uniform thickness,
WARPD

tCUPPfD}80ARD_

Q. r

_;-,

RUN OVE. JOIN111t

TO RATTfN ONE fACE -..

b.

RUNNING $(CONO FACE OVlR

cF4 :.

.;-;,

board through a thickness

planer. the infeed roller flattens
Ih,' board against the bed, bUI
the board will return 10 its
warped Stale when lt comes out
the outfeed side. \I'hat you end
up,,;tb isa board that'splaned 10

FIRST:

FLAntN ONE FAa"",:)

ON JOINrtR
".,-

a..r

-"tn_

SECOND: THIC"NI$S P......

b.

TO GtT ornra fACE PARAW1.

TORlSr

bUI iI's still not Oal along its enIn many situations, there are
lire width or length.
other tools that can be used in
TIlE sssr APPRO,'CR. The ell.... place o( a jointer. To prepare
iest method (or getting wood stock for edge-gluing. a good
both nat and to consistent blade 00 a well-tuned table saw
",II work. Narrow stock can be
thickness is 10usc bot" ajointer
and a thickness planer. The stood on lodge and run through a
jointer is used to gel one (3('(' of rhickness planer .. 4s (or flattenit's limited 10 the width 01 me the board Ilat, and then the ing one face before thickness
knives , A4' jointer, for example, thickness planer planes the planing. you can use a hand
will only Oallena piece ~""id
e, otherside paralleho the Oatside. plane or belt sander.
There are usually two or three !1('(' ~-tg.3.
But a thickness planer really
knives in the cuuerhead Ihat
JOINTER OR PL.t\NER? Now
shines" hen you need 10"thicktake small chips out of the work- back to the original Question. ness" plane a board (-\14" down to
piece as It's pushed QV{'( the Technically, it's probably besuo
Vi' (or example). It's time conknives, see Fig. Ia, lVilh the cut- buyajoinll'J'firsL You can use it suming and difficult 10 do this
terhead n.>vnlvingfast enough,
10square IWO adjacent edges for with a hand plane. and almost
OICchips overlap each other and cdge-gluing stock. And, as ex- impossible 10do accurately with
result in 3 Oat surface
plained above, you shouldn't ajointer.
So ajcimer isa perfccttool for
WORKPlKl"tsFl.AT AN_D
'(uirkly Oanening or removing
4
UN1fORM THtCKNES5 Af'.Tf1t
warp (r<lma one faCl' of a narrow
THt('KN($$ P\ANING
board. see Fig. 23 and b. \\'hal a
\
jointer C;UI'Ido is plane a board
to a /(I'ifOI'"

thickness,

Ifyou turn the board over and

run the other face over the
jointer, ihe face "ill be Oat. bUI
there's no guarantee II will be

J04NTrR "",SCHTRlSUlT_

parallel with the first race, see

IN TAP1t[O aOAAD

Fig.le, That'sthejobota planer,

l'lAS~:JI,Actually, Iprefer 10
call a planer a "thickness planer"
to indicate its sole purpose. A.
tbe workpiece is fed into a thick-

c.

parallel 10the table, see Fig. 43.

lkfol't'dl'C,ding 10buy a thickness planer, you should be
aware o( what il won " do (or you.
It W(lII'1take l\\iS! or warp out of
a board, II you run a warped

aunitorrnthicknessandsmoeth,

fl(O
DltUCfK)N

knives in the cutterhead above

the workpiece trim the top face

teed a piece into a thickness

planer until one facc has been
flatu-ned (on a jointer) first.
BUI realistically. I think I
would buy a thickness planer
first. Especially since the introduction of home shup thickness
planers (or under S.';OO.

CONVEX

Ajointer is designed
10 perform a couple of opera- ness planer.asprinz-loaded feed
lions. First. it can be used LO roller (and. (lI1 some thickness
J()I\'TER.

No. 61'

29

S HOP

TALKI'lG

BAND SAW BLADES

1'... """,,/

ent

that th.../ '11'" .ltffpr

t,M111,IKltt{"'IIX

nv(,iiabl,1 Otl

bllttlll!(Iu'

'"I'

blll/l.It. ""hat'..,
u'IIt'" _liQuId I
liSt' f (I("Ii tYIJe oJ" blt'tlf,1

drlTl

,.,.nr",

(1)1,1

ard pattern alJow~ more teeth

per inch. It CUtsthe t\nl()(.'ll(_~t.
but doesn't cut as qUickly in
thick or gummy wood. 1111'

STANDARD

SKIP

problem is the 11'1111.,,ar.' '0

small that th<y can filJ up \\ ith tooth and a line perpendicular 10
sawdust and O\'rrh~llh .. bhode Ih~back otthe blade.
Typically, standard and skip
SKIP TOO'IlI The 1an!.1' gulleI" on xkip tooth bJad(' ...."001> tooth blades have a 0' rake
up more sawdu-a and carry il angle, see Fig, 1. On a hook
Ihrough Ihe block tooth. th.. angle b bt"",,"n 5'
BUI iI', trade-off. and 10', but typically it', 10'
10'_
NfGU
Since tlll'r,- are This angle cuts the wood rather
('"Wet' Il'CthJl'r r inch,
than <craping il like a 0' rake
)'''u '3<"lificequalily, angle looth, This mean, a h"ok
"OOK ro')'1"II. In tooth blad e ,,;U cut more a)OO't'Saddition 10 these siv,,'1)'. pulling the workpiccrtocth
patlt:rn,. into the blade.

,,',II,nJ'l/llIl,IMJ1'
.If a.If 1Itl, (;"""9la
There an' 1"0 RIal" looth pal
terns ..umdJn:I (also ,'alk-d reg'
ular) and 'kip On a ,tandan:l

there's

..nollwr

tooth d.sigll avnila,

ble on band saw
blades - Ih,' hook
100lh, <t~.pholO. A
blad, Ih, "'<'lh and the gullets
(valk"),) between each tooth are
th~same 5"('. "'-l"t" photo. On a
-kip tooth blade, every other

hook tooth i< u'uall),

Tln-re' another important

difference. The guu,t~ bct ... -en
the teeth o( a hook tooth blade

are rounded. p""iding a p<rf('u

pock e t (or "hips as they curl vII
the ..ood. The po~ilive rake
angl,' and rounded guOe 1make
for a ra." ,'UI...ith Ies, I~ J>R"-

porona skippancrn, Thall" th,'

gullel is large
But tbere's an imporrant cu....and "", heal build-up.
I ""-,Okav, which is the bt>o,t
dilfel'l.'lltt wilh a hook loolh(wlh in the pattl'f11 i~
mi ...~.
the tooth rake angle 111;, i,Ih. blade 10 u"",,i Just like ~b'" saw
''TA.''''R11 TIX7Ilf. Th~ Sland- angle belween Ih., I.... 01 lh,' blade'. th,1'e iSO'1 a blad.. thaI

JIG RUNNERS
Ev"ry ",.",n th~ hUlllidil:),in
our shop dIOllg,S - and th~
wood in our '11(111 charlRes with
iL On, allhe 1i.. 1pla('('s I notice
Ihi, i,,,11<'11PIl,hillg a 'ho~buill
jig aeru" th, table ,"w. \lany 01
lht"~jiR:' have.'"'em runn("r'Son
th. bull"m Ih.t 'Iid~ in the tablt'
~'oIr', mitl"1' RJuge fl:)oL
111<' problem i.lhatl\e mad~
the<5<'
runners (orar.irty tighlfiL

HOOK

..ill do ."F)1h,"~ perfectly You

should <witch blades dcpending
on what kind of curs you're
rwOOnl( TIll'probk-rn with band
~a" bladev i...
thev're inconvcnicat tochange.
I k.-ep a """dart! tooth ~>.
or
~,' wld~ blade on m)' band saw

rue ....
1 oCthe time: For crosscuts
andcurvesa ,tandan:l bladewith
12 to H " -eth per inch results in
a "'"'00111 surface in most wood.
" I'm rippingthick stock. re'~Iwin"wid..> stock, or cuuing

1'1)'wo(l1l or particleboard. I
",itch 1"0 hwide hook tooth

wilh 3 I.. r. I.~th per inch. The

,"wdll'I ..I<'ar;ClUll'aSiIyand the
blad. i-n't as likely 10 heat up

and .1<-11,'0(Orbreak,
:-... matter which blade you
U,t'o it'...best to OJt at a ~w.
"''3.1\ nil, n...n'l SlOp,but allow
1M 1('(Ih In do Iltdr job by feedinR at a con"'lant ralt'.

OILY RAGS
Plexiglas can be CUI011n lobI.,
saw'U1dsanded like wood. (I ust
4()().gril wct-or-dry !l3l1dJXlpcr
(or final sanding.) 'llI"n <imply
countersink and ""....w il 10 Ih,'
bonom orth~ jig.
OTIIER OI'TlO',. Th.", .,,'

R,T, Lamoureux. a reader

from Hawthorne. CA olkr~d

the following on shop fires:
"'SpontaneOlls comb\l~li()n
n<ed.s three things 10 o<.'CUr.
,",UI'Cl' of heal. something

1(""

hoI('n"ugh. material, do,,' to tlw ..'atl could ignite.

<'all il""1(

"'Il,c.' r('lllainillJ,l c)ption is lO

climill[l' IIII' 11I'atsource. The

chemic-ell reac
tion",c.:au~.odby thc' painLc;orvarni-h," in Ihe rail'. (Soh'ffil<.. ill
IU..'al (CUll.....rrum

10bum
Heat '"001<'"
some othe-r opti('n~ for nlnnc.""", (rom the oxidation of '<actin' ii.~nite.at I()\\' It>mperatUJ't>S. but
as well. Sleo-I bar .. ould be'id,<II. milteriab in finishing rag,;. Fud, dvn'l prodUl'C heal them_....Iv.s.'
but il mighl be diftkult 10 find a are rags. so)\'C1IlS. or <awdu'l
"OIlC\' h....1 accumulateS. the
piece that 61..; pc-r(.....1I} in II" ,r ,\nd 0ll}'gefIis in the air,
tI11"lfJt-ntUn- ri.~to igniS(' the solBUI ",h .. n th .. wood 510dIs or miler g3ug<' <101,If Ih" "l~'1 bar
"Remo''lI1 o( anyone 01 th,' ""h III!ho.' "",,,Iur \-arni;.h. 111<'
<hrink'.the 61,,100 uJ(h' or too doesn'l fiL it wC'- a "', ..( .. ork th"'" ingredients can stop lhe trk'k i,10not It-! the lk>algatht'r.
loc}sco in lhf" ...tot
10 make il fiL
JlI'OCe'" Since fuel ..;11 ht' pre1 hanll my rags on the
AnOlher pos-ibilily i, \1. -.enL you need 10 renl0\t' oX) d"th"hn. (away from the kidsl
PI.,,<;T(C RI "EllS. Rtocently
I've b~tn replacing th& wood sonite.ll's ~nble, and c;all ('asily g.'n or the heat sour' 10pr"""nt untillhl' rl'ac.1JVC nlat('1ial, hav-~
runner- wilh 'Irip' of h' Plexi- be worked "ilh woodworking a fire. To exclude oX)'gen. pla<'" had a ..han",lo ""'-.Iel and Ibe <oj.
glasliCmp I buy al a loc.1 plastics tools. Though it dOl',n'I 'lillld up oily rags in a sealed can, A fire v('nl~ ('vnpt'.rate. Onl'l" the) are
disUibulor, (I'J(>k under "PlatY to abrasion a. well ", I'lexiKI"". mighl stan, bUI would run oUlllf dry and ,Ii(f Ihey can b,' di",
Iks" in Ihe Yellow Pages.)
irs an allernative 10 solid ,lock. oxygen Md stop, Howt'ver. ifth,' curd.oc]\\ ithout lear o( 6....."

30

(fuel), and Ox)'l:=

W".."hnlllh

Nu.68

PROJECT

Sources
CHA'RSIDE CHEST.
DaAWER KNoaS

Sineewedesigned the Chairside

Chest 10 look like an antique
spool cabinet. we wanted 10 add
the right drawer knobs for that
style cabinet, The classic design
is a brass. Outed spool cabinet
knob. sec photo at right,
\1'<, also found IWO other
styles that look good on the
Chairs ide Chesl - a simple
while porcelain knob and. more
slylish brass teardrop knob.
We're offering all three styles
through Woodsmilh Project
Supplies. Each. knob comes
with mounting hardware.

Fluted Spool Cabinet Knob

7611-101Fh6"Dia. Brass
$3.75 ea: 10or more: S3.50ea.

CHAIRSIDE CHEST.
NYLON GUDE STRIP

To resist wear on the drawer

guidesand drawersof the-Chair- Porcelain Knob
slde Chest, Wl' added self adhe- 753-1311"0;a. Porcelain
$1.501.'3.:10or more: $1.25 ea.
sive nylon glide <trips to the top
of each of the drawer guides.
The nylon sirip. help the
drawers glide cagilyin and out of
ihe chest,
This tape is available through
Woodsmith Project Supplies,
For !he Cbairsidc Chest. you will
need about 14feet,
Nylon Glide Strips
753-109 \-'z" \Vide ($pe(-ify
Teardrop Knob
the number of feet you need.
14f<'i'lrecommended for
768-102 IVl'Solid Brass
Chest) ..................$.50 per (001
$4.25 ea: 10or more: $3.9S ea.

ORDER INFORMAIION
ay PHONE
To order by mail. use the form For roSier service use our Toll
enclosed with a cumml issue Free order line. Phone orders
or wril~)'our order on a piece can be placed Monday through
of paper, and send it "i!h your friday. 8:00 ~I to 5:00 PM
check or money order. (Please Central St:mdard Time.
'include 83.50 handling and
Beiore calling. hav.. your
shipping charge with each VISAor Master Card ready.
order.) IA residents add 4' 1-800-444-7002
sales (ax. St'lId order 10:
Wooc:I!!mithProj<><:tSuppljes
All", ~ ie) t; 1' t. .rpr dt liJ.:fry.
P.O. Box 10350
.\'ott, Pri.N1f )rltbjM II) ('Jr(III{)I'
De. Moin~s. IA 50006
aftcrJNI'f'.lfJOO.
aYMAIL

SUPPLIES

N(I.6S

PLANT STAND
The only piece of hardware
Bail Pull
needed for the Plant Stand is a 768-201 2" Bore. 2%" \\r,de
small pull for the drawer. We
I V4" High OveralL..... $3.95 ea.
found many Iypes we liked bUI
narrowed it down to two - a
small bail pull and a round knob
(see photos at right), Both arc
solid brass.
\\'oodsmilb
Project Supplies is oft't'ring the brass bail
pull and round brass knob. The
nCCCS!<3J')'
mounting hardware Round Brass Knob
i.also included ror each of these 768-202 1"DiamelcrSolid
items,

Brass ............."" ......... $.1.95ea.

STIKIT SANDPAPER

On page 28 (Tools oi the Trade)

Stikit Sandpaper
we lidked oOOuI31\1'sadhesive- 4.!,,\\rtde. 10YardLonl( Rolls.
barked sandpaper called Stikit, Spcdfy Grit When Ordering:
II's sold in 'W' wide. 10 yard 768-310 SOGrit..............S13.95
long roUs.
768-320 tOOOril............$13.95
To u>t Stikil sandpaper on 768-3:10 120 GriL .......... S13.95
your sander you need 10 replace 768-340 ISO Gril............$13.95
the fell pad with a replacement 768-350 220 Gril............$13.95
pad (unless it's a new Porter- Two or more rolls: S 12.95 ea.
Cable sander) or add 8 converReplacement Pad
ion facing. (See the article on
For QuarteroSheel Sanders
page 28.)
.768400 For All Makila (Qrtr.
\Voodsmilb Project SupSheet) Sanders ................$5.95
plies i"offering Ihe replacement 768-500 for All Porter Cable
pads (or IWO of the most com(Qrtr. Sheet) Sanders .....$5.95
men orbital sanders as well as
Conversion Pacing
thecenversion facing thatcan be 768-000 4 Vi' x 11". Can Be CUI
CUIIOfil any size sander.
To All),Smaller Sizc........$3.95

ALIERNAIE CAIALOG SOURCES

Similar i,ardllYJ''f'(Wd $upJllies "IlIIJ be/",...d ill lAP/011(1"';.'9
(alullJ(l8. P/t'Me rail
compallyfm'a ,atalOf} tJr j,,/oY'l'I<ltiQtI.

,,,,</,

lI1eLo;clHardware Specialties

li()()...441-9870
Glldl Sln1)
Shop!illlitb, lnc.

800-..>43-1586
Stiki! Sa1uipII/J('r
Trendlines

800-767-9999
Stikit .'ilwl/paper

\\'oodcnlft
800-225-1153
Stikil Salll/papar
The \\'oodworkers'

Store

612-123-2199
Kllobo.PlIll~.
Sti~il f'atu/poI)1!r

\Vood,,'Orker's Supply orml

800-645-9292
Slikil Sa"dpa"..,.

11

LAST

LOOK

Final Details
Chairside Chest

... A ,,,itt "'(I (WI,d , ,I, l~l/r""It' "1""",,

plY''(HIlI/HJ."r/
'" ,}w,. r"f"1) tln ('h'llt..

tlll.~{t (II u re, IJ"

l1lsfdr, flgl

I, "U"

OJ t',~
tI'(,

,Id (1" u~t

r'f

h,,(hlI71,t

chn "HI I,,,; c It (,",,,, ,I th,

rlutJru"rl
f. III

In i/rd J't/tnt 1l/ n t'l/ tt.... '~rcJttSIt/Hit" rttl,l,r; (

A'It(Jlnc"""uft 1"iftllflt#9(1"ld~tu t"uJtltll'iC'hr~t Til,
ha rd. til(11,1. dnl.u'It'T IJJd,_~Ct .... "(11 IJIII!I (/l(n.lb/~. tb'l'
<'IJllt ''(lsi "rCt I II .""" tlJ, "vII I. ut Nltl, 1J(l'l'111I

.. Ttv ,fljl-'

Plant Stand

.l As is typical oftkl8 style offiln,iorre. tJlelegs I'l!'"

slightly ahot-e tile tlJp ofthl! P/{J>1'SWlllt Til ~Iighl
1'lIra"" id ohtlpe ou lop of ca ell leg soft.<m$1II. end oftJw
leg cmdprovid"" a notker .ubtle point of i111""""1.

32

.. 1'Ile simpl, 14 ~,('/llt""'td '!iolll{~nf tiu: stn tid en 11 IIf>

in th~prtMoo;e ttf"'!1 o/tl" tf,.""v:r "Ottltillllil
fJpt II i Ity. T11~Uo to bl'lghtt " ltp I}'t' fron! cfttu dru If" r,
Me,;

lilt! addd

\Voodsmlrh

a .olid bro.. bull plllI.