NO.

69

NOTES FROM THE SHOP

$3.95

No. 69

EDITOR'S

June. 1990

COLUMN

Sawdust
Edilor Donold B. I'''''''hkc
De...uW' Director Ted Kralicek
MQrUJginREditor DoUjlJa.' I.. Kicks
1\.'''''''11 F.ditor> TOM)' J. SirOhmnn
James ~I.
Dolan
Project

Iksigner Ren Munkel

IllU>lrnlo" Dovid Rreylin~

ClI'l'(.~n
RodStoakes
tIlri. G
Grnphks Oi~.r Ju.Snyder
Prni<rtSuWli~ Leslie Ann ~rt

'"""cki

Customer~rvic. Mil< I.lnda Mo"""

CUSlomers.-rvIrt IJndaJ ... ,
U'I'lThu",_.
KeU) Bradford
5<'UdRllod ...

(;enelle tlran8<l"

viclOUwarcl.
Camrcllcr

MI<Smilb
PIt u1E. Gray

Ilcokk""l'ing U.da O'Rourke

Comput('rO~tfon,.
Nety,'ork AdminiCl:ln1(or

Admini'tnuiv"~-ts.

Ken ~'jne_f"
Oouglns rt,. Lidstrr

ChCf)i A. 5c<Itt

SRndy8Rum
Sourccb<>ok Jean My ers
Ken, A. RuclQon
ShuJ).\lanagcr Srece CuniA
BuUdill!!~lalnlCMll<:e Arthi. KraUS"

Sto"'~
BeJ'kcltoy. CA MichaellJel,L",en
0 es 1>loinO$.1A lien. Welsh

'Voodsmith (lSSr; Q164H 141 i. publisb.d bimonthly (Fob'u.r). April. Junc.

Augutiot.

October.
O'-:-(.'tn,ber)
b)'
Wo.d.milh
Publi.hi_!! C 22f)() Grand
Av(... D~ Moin\_~.
J,\ 50312.
\\'ood~ith is 3 rC$!"iColl'rl"d tr-adcnlark
or
Wootlsmith l'ubtishingCo.
e>Copyrighf 1990 by W()()(bmilh Publi,hil1J{

ComlWlY. All righL' n''''''''''d

SubottiptiOlL<: On< yonr (6 "lies) SIS 95.
Two years (12 illSUe.) $27,95, Canll<L,and Fnr
";gn: .ddS2,OOperyear. U.S.fuud.only. Sin,(k
copy price.$3.95.

Second ClnssP""~

P.id:tl ()",,~loino...IA

and it.ddiUo,,", offi~

PObUnas~r:
Send change of addrcb~10
1V000000milh. 80. 491.Ml MQm-..IL6105.1.

dirondack chairs art' hard not to like.

They're .asy to build. They're great
for a patio or deck. And they're certainly
classic American furnhure that's ril(ht at
home with lemonade and cam on the cob.
from a woodworking standpoint. theY'(I'
very straightforward - butt joints thai are
glued and screwed together. \~lth that kind
of joinery it should be easy to design ar
Adirondack,slylechair. right?
Well, irs more involved than l thought,
Chairs ure diflicult design proiects - no
mailer how simple the joinery might b.
The IwO critical features in these Adirondack chairs arc uie slantefthe back. and the
shape oflhe seat,
Adirondack chairs have a "lean back Wid
relax- look to them. So it's easy UI d",iJlll
them with. back Ihal has a pretty zocd slant
10 it, Irs also easy 10l!~tlOO much slant.
I've sal in some Adirondack chair Ihnt
look comfertable. bUI the back slanis a liul~
too milch. As you lean back you g~t1C)lhal
point where you feel you're I!llillg 10 10"
your balance, It happens a1lth. time when
you lean back in rocking chairs and rechners, BUl it shouldn't happen in a lawn ,'Ildjr
The angle you're looking lor i,Ih, .nRI<of the back in relation tothe sear, nlal.tngk
can be anywhere iron! 100 (lor upri~ht
reading) 10 130 (lor relaxing and snaking
up the sun). But how do you d.I,orm,n,thl
angle you wanl?
Since this type 01 chair is used for n-laxing and conver sation. we ,tarl,d ill the
middle of this range and bullt ":I"1"dl,> rol<.
types. Then we had everyone <it In rhcm to
find theanglethatlclt mostcomfortable.It's
amazinJ.l how even small dlUngl'S III the
angle (chang("" thaI don't look "cry imporlalll on the drawing board) can makl' 3 bill
difference in ho" the chair 1",1>.
Once we gOIa consen~u, Olllhe angle 01
the back. we had to d.I,'rmin,'lh. """III' 01
thl'seat. Adirondack chairs are typically d~
signed with concave (l'shaped) ><eatswith the idea tha1jf il I""ks comlortabl~. il
will probably be comfnnabk NOl so,
Ifthe scat is 100 concavl'. il may look com
lortable. but il can make you slouch Ion
much. or it will PUItoo much pr<'SSuno on
your Illilbone or right Ix-hind your kn<'(!S.
Again. very small changes in Ihe shape 01
the seat can make a big dilfcrenct
The shape that providt"l' the mosl com-

fort isa nallened-out Sshape with the fronl

of the seal curved down 10 allow relief behind your knees, As we played with thai
shape. we lound that it was most comlortGbIe when the seat was shaped SOthe
11( .... ure is distributed evenly along the
back.,Cyour legs. somewhere alonl!!.he $(:C.
end.third and fourth slats on the chair seat.
Thh.l!iV<'":oupport withoul cutting off cireulatien to your lower legs.
I'm !telling carried away with an the
dtla"~ofJlHiiding thischair. BUIilwas inter-

,."linK IUM~'lh, resultsofwhat seerned liki'

small (hang<"S.
("(.I'll' ~"'. With all this discussion about
,\dirondock chairs, you'd think it was Ill)'
lavoril" prnject Don'; get me wrong. I like
Ih, .... chairs. BUI my favorite project is one
of tht slllalll'Sl ones wcve featured -Ihe
lie.", Compass (shown on page 22).
'n,.. t,ndcncy is 10 knock OU1a project
like this ln a hurry. Grab some scrap wood.
lUll!itlogethcr. and doni worry 100much
about how it looks as loog as it works.
BUI making tools is rewarding work.
'Ibey become a part o(yourshop. So I found
anlce piece ofbardwood, [ shaped the parts
carefuUy. and [ used brass knurled finger
nuts. Thumb screws and pine would have
worked just as well. But I've found thai I
enjo)' my shop-made tools more if I pUI
more time and care into making them look

nice.too.
ICs been a long lime since
we've built a project wiUI a tambour (rolllap). Most of the time Illlinkoftamboursas
"sliding lid - as on 3 rolkop desk.
The CO Case (page 6) could have been
designed that way. bUI I wanted 10 try
making a tambour door, As with a 101of projects.the key to making ilwork wasa simple
jig. This time il was a lemplale Ihal was used
to roul!.he lambouf groov~.
ARCUf.Wood.millf is. relatively young
company. so it seems odd 10 have Our firsl
retirement Archie KrauSI' has decided to
sJ)Cndmore time with his family and do a
liltle more fishing. for Ihe past seven years
Archie has done agreat job of taking care of
our/his building. He hasalso handled most
of the shipping 01B.ck Issues. We all wish
hinlweU.
~EXT rt1AJLING. The nexi issue or
lI'oodsm.th (No, 70) will be mailed during
thewcck 01Augusl14. 1990.
'fAMBOIJ'RS.

Sul>s<-riptiO" Qu...aons? Call !lOO-oIl:Hl715

(IL r<'Sidelll>,8I)(H!92-O'IS3', 7."10am 10 ~_"liJ

pm. CenlrDlTimo. we;>kd.ys only.

\"""J.m trh

No. 69

LOOK

INSIDE

Contents
ITIps & Techniques

f41 Great

tips [rom [el ltno iooodL.:!J workers: 1. Clall~pillg IUiler Joints .

.t. Velcro Holders .. J. ,Uo1'tising Table
Stops . .$. Router Table Turning.

I f6l Walllltl tallibour

ICD Case

doors slide
(u'Ound the ends of this CD case to
conceal the 28 C D's .~loledinside.

.L-

__J ~

I Tambours

1I121ll'e
a few questiOll11about
the way t(lIllbours work. And .~how
UII$wer

...J.

L.

you hoieto make YOllrOIll'lllallWou).

IShop
_--=- Notes

11141 S01l1etipsalldideasfi'Olll
in-sidelite
~Voo(u;lnitltShop: 1.Cutting Cornel'

....1.

L.

Blocks. 2. A Thin Stock PIt.,1IBlock. 3. A

Spacing Jig. -I. ROlltillg SlItall Pieces.

Tanlbolll'S

I Adirondack

Chair

11161 Here:~olll'l!er[)'iol! ofthetrudiiional

sltltl1llmti1ne favorite. It's

/)'Idltfor

years of outdoOIIelaxatioll.

IBeam Compass
---=_"-__
L.

11221 aTilsllIal/
isshop-made rfllnpass doeswhat
CfJll1paSS can 'I - it d"aws

_J.

very IU1'gecircles.

IAdirondack

Settee

1Patio Table
L.

11241 IVelook our Adirondack

.~t
retched it to conifortably

chair (I lid
hold two.

11261 The
of this simple
tableslaiconstrnction
is a perfect ?natch
to the

_J.

Adirondack Chair

page 16

Adirondack. chairand Settee.

ITalking--==--_..:....
Shop
L...

__

I f20I Illakiligoutdool'!nrnitul'e.
special consideratiolls

-'. ~

SOllIe

for

ITools & Techniques

11301 Our sabre saw table alltno YOIIto

ISources

11311 Hardumre

control the workpiece - jusl like

when using a band sa.w01' scroll saw.
and project supptie

neededfor the prcjects in this issue.

page22

No. 69

\Voocbmirh

FRO

FELLOW

WOODWORKERS

Tips & Techniques

MITER CLAMP

VELCRO

Here's a clamping Jig I use to use a hand screw) This damp tht' clamp. will form a line
keepmitered eomerstight while appliespressureacrossthejeim.
through the center of th e joint.
gluing. IIs. method for pulling
1cutthc width otthe blocks to 111cn when the hand screw is
the pressure where it's needed match the thickness otthe hand tighlcned. pressure will bt' ap- at the Center of the joint and screw. and about 6" long. The plied dirf:clly on th, joint. see
perpendicular to uie joinl line. only tricky part is cutting' the Fig.la.
SCI? Fig. la.
angled notches in the blocks,
On a long (tall) miter rom, r.
The jig consists of two :Yt"~
To do this. I mounted a ~l" set up two pairs of blocks: 0Ot:
thick blocks Cclamped 10 th~ dado blade in the table saw and set at the top and UII<" litth. 001
IWO pieces that are being joined. tipped the blade to 45 . Cut the tom ofthe joinL
Icui an angled notch in each notch close to one end so when
It II II Ayull.
blockroaccepianotherclamp. (I the blocks are inplace. the tipsof
B" nl~III/11.\

lve round all kinds of uses (or

self-adhesive Velcro strips in my
shop. I buy."widc strips from
a hardware store forS 1.:19 a foot.
Originally Ibought the Velcro
(ur keeplngpencils within reach,
Wrap a small strip around the
p,:ndl and stick a strip in a conv"nicnl ~pot above your bench.
and th~ pencil never rolls away.
Afwr the Velcro was in my
shop. I found lots of other uses
{orit. The most obvious uscsare
{ur hulding tape measures,
rulers, and s:mallhand tools.
Bull think the most valuable
U'-4 is when a 1001 needs 10 be
close to a machine. Apush stick
on the side of a tabl e saw. Router

MIliltfO
CORN'.

o.

WITH

SPUNE

ptUSuU
APPU[O
ACaoS$
CCNTut

0.

ClAMPING

al()(1(

MORTISING

TABLE INDEXING

Afler building the Mortising

Table featured in lI"ood$lIIilll
No. 67. I made one simple addlbon thai makes it even more useful. By adding an indexing system.I can quickly reposition the
bit to cut centered mortises in

has to be ......
" :l~"or Ill" above
the table
To index 1Iil'""C positions. I
driUed holes below the router
base plate and inserted a cut-off
~"carriageboll into the desired
hole as a ,;top. "'-" ~ig.I. The

aAS!

I'lATt
ItOUTl.

ftRST:

POSH ~..."
aR,AOPOINT

DRILll,,
INOfXlNG

I' IJ

STOP HOlfS
..

3" "

STOPS

diUerenl thicknesses of stock.

Istarted by assuming that
mosr of the stock I would bemortis.ing would be Vl". :v.", or 1'~
thick. So. to cut a mortise
centered on these thicknesses.
the center of the mortising bil

the 1001and a matingstripon the

machine. The stuff holds. I've
never had it vibrate loose.

Gary Gaitlter
SO" A,,'ol,io. r

o.

tABLE

wrenches near lilt! router table.

Orachuck key on the drill pres"
All it takes is a strip "rVelcro on

' .. - CARRIAGE BOLT

(CUT OfF THAAOS)

'fl INTO
.ACKPANEl

pivoting base plate rests on the

bolt and positions the bit at the
correct location.
To locate the holes, mount a
vgroov~ bit in the router and
raise the router untilthe point of

the bit is at the desired height.

see Fig. 1a, Then, tighten down
the base plate.
Now. hold a %" brad ponu bil
underthe base plate and push on
it to mark the centerpoint of the
stop hole. Then raise the base
plate out of the way and drill
through the back of the Mortising Table.
One caution: 111is technique
works only ifthe stock iSf.>arli/l
Vi'. :\I.". or I" thick. lt's still a
good idea to work with a cornmon (front) faceofallyourworkpieces down against the table,
Do" 1':. Rulli
Keltmi>lg.OH

\VoodSffillh

N().69


ROUTER TABLE TURNING
.ly,,' lllV4..1~.I),..d "' system of
"tllnling- 011n routor ,ablt in'I{'ad "f Itllill'. My l~chl1ique
\ISt'S two 'Alll'tl!'; lilal

are

be sliUhtlyInrgc'r than III('",\(I of fence so Ihat when th,' I"rl:<- dun-, ''''''IIIU.lIy thv bil will have
the leg il', auached 10, wr ~il!.1. wheel rests again':\l the (t"ntt.
After rhe whee" are rut 10 the bit will cut a It...chamf,'r into
sise. screw them tighl to the the corner of the workpiece
ends u( th,' workpi,""e '" II~)'
I\exl. to contrel the knroh "I
f/O/'''1 tum. ~O'4'you can ~tup tbe turned section, clamp 'Ietp
the router table, see ~lg. 2.
blocks to the left and right end,
Xote: SiIKc the "'hed, mU'1 of the >JlC(',sce rig. 2.
alwray'" run on the ",utt"f t.a.blt."
To begin cutting, hold Ih,'
righl
wheel again,t the righl
and along the 11'0('", the Icn~rth

II. 111<'tnd, "fllll' work

"it,,(t'.lllt n thi...a''''nlbl)' i!', N"
.~.in'l a 'IrniJIht bit, with tbe
workpiece "'tal,i! ,lighll)' bet'At't'llIQ'''(''~r,,:C..-r to J-'ig_ 4.
'r" maki- ta..en-d Il'jl .... cy~
.nd,'r. ,ll>rt by ,'UlhnR a piec,' of of your router labie and f"ne{'
'qu'rl' stoc k 10 knj!1h Then limits the I~ngth of ''''''k)'OO ran
drill a ,maU pilul hole al the cen- "turn - \"h~n making Irg'
"'I'(",,'d

u-rpomtv 01 each ,'nd In mount

longer than 11". I matl,' a tern-

the '" h("<1<. "'t' Iill. 1 Now, if

you 'n' makillR31aPl'n-dleg.li~
taper (IIIlour ,idt, ul lh,' workpit'(-(. on lht.' l.abll" saw
The Irick h' my system comes
I1("XI - Ihe wlweb. I ('ut th",~
frolll .~," ,wck wilh an ad
juslabl(' rird,' rulll'ron lIlt'drill
they would be larger in

porary rOUI~rtabk fn,m a IClng

pr"" '"

dinnwh'r Ihan th.. end. o( the

worklllC",,"If) uu,." '1urning"
cylinder. CUi both wh""l, the
"';1l11t' 'III.'

l\uI ir) OU'I"{' "'turning-

a lap<.,.,,11l'\I, ..... h '" he'" 'huuld

[i]

ship o( pl)'Woo<1with a ,u-diJ,!ht

2x4 as a f~n<~.Then I mounted
my router under Ih,' plywulld
To set up (or"lunli1,g." mount
a ~l"strai,gtlt bit ill 011. fllul"'r

sembly 00' and trim off the next

,'orner. Conlinue around until.1I
table and posili"n th,' ...h",'1 anti four corners are ch.m(.'r~d
workpjec~ a,,,,mbl)' on Ih~ tabk' (F:,litorjf. .\Tote: TIlUi ("n'/l/rs (I ~t
so one C'Omt"for tll ...\Ii orkpil'c:t' i~ 111('rl'~/;',g1'9 (ll,d YOII "'fI!!
111(1,,1/0 $top Itpr;>, M'f 1)/11""')
against the bit, "'l' F'ill.:1.
~O\\' rai~ the rouI(."r bit until
If )'Ou"''dill 10 make th~ work
it's slightly abo'" the cenl .... nl pi""... round, move Ih,' ft-nc~
the workpi ....., at the thick end. back ~.andmak ...anoth~r'<I(lI
see Fig. 3. Thcn po,ition the cub. 8}' rePl'ating Ihi' pm.;.NOT(:

WITH

P3''''''

JIIl/eall,Ah'

HIllP'llOT
HOU

Cut WHIrLS

rut around tll(,entire race ofll1('

Yo'ctrkl>il ~I!.
Ill<' trirk t"making the workpi,'('" alnl",1 ,ll'rll'('\)} round is
patience, Rotall' the workpiece
1"1"1 ",yJ.lII between
I
and continu to lake stock oil'
,":1\'1, eorm-r .-\....you rout. you
"ill bt {r("dtin~ more corners
'lop block and push th, work- with ("3,:11 pa"". but lht"corners
pit'Ct' into the turoing n.ult'r bit. '" (1(\'1be as ,harp. 'l'l' Fill. ~
Then move the assembly from
,. ,,ntuaJl)th, workpiec e will
right to left witb both wheel-, ,Iart to I"cl -mooth and round.
against the fence.
Then remove Ihe wheels and
The first CUI will trim a ~ hand ...uld any of the -mall 11.11
chamfer offone comer. Then ro- nn'''' "'It by Ih" bit.
tnte the workpiece/wheel a,
J(,J,1I Gra"l

r
I

crNTtR(O
Of< I>IOS

r~'fljt""B j\"I(": 7'(1fN b"'ll'j.(t.

,"t ,','

/)1 ;('(11

II'/It'li

It't

,"P "("

rl ,,'e (/IJ"lI.ifttrr .,'tt, u.. "..,"(/ it

""(/ t',"n' :trtr/lriJ>lt-J ,,';111 lilt I'f.

""11,, I" ,,1)1),,11,U I,l'" ,1,,, l'"

/,.g !tI,t,,,,,, '"

t)" /JlfOlll niHIl" (AII,f tnt If'g
h" I,t, '{,"Ix """Jf/ .. (I~t.J

I"rl,l,

t}'f tff/ ....,...tf

"

NOT(:
ItOUTU fUll
UMrTSUNGrH Of UG

sc.UW 10
wo.l(PI.(Ct

AOJUSTAW
WHIrLC","'I

1fJ,.,(

OOIIT,I

t.....

"NC(

CC
IOTt-tWHW,5
SHOULDS[ (OUAlLY'

LARGllt n-tAN
CNDSOF WORtc"(Cl

....Sl an AOOYf

CINn. OFntl(ftt.S1INO

ROUT RI(iHt

ClAMP
STOP &LOCK

10 un

f01ENCt

SIND IN YOUR

4
I.

ItOIJT Of'
CHAMI1II Of<
lA(MPASS

nps

II \ou ,. ..uld like to share a

tip

or idea, ju~t send it to

\I oo".nulh, TiP" and Tech-

niqu ......2'.!OOCrnndAve.. Des

\loint~, Iowa 50312.
\\'r
pay upon publicatiun S15 to SIOO(depending
')It th,' publisht.'Ii length ofthe
lilll. Pica", include an ex
planation and a sketch or
photo (w~1Idfllwa rtcwone).

wm

STO.
I ,.

STRAIGHT

1"... 69

an

lLOCt(

WEEKEND

PRO)

ECT

CD Case
This Compact Disc Case is a good opportuniry to try a tambour with
vertical slats. The tambour stretches around [0 form a fie.xible door that
hides the inner case, which holds 28 individual CD boxes.

've been wanting to make a project that uses a tam- canvas... (\"~ talk about tambours and how to make
bour - bllt not the l)'Ilical "breadbox" style with them in an anic!t- beginnil]R on page 12,)
horizontal slats. I wanted 10 make a vertical slat 1alII
The tricky part was routing perfectly matched
bour. This Cf) (compact disc) case gave me the perfCCl grooves in the lOP and bottom of the outer case for the
nppcrtunity to give it a try.
tambour doors to ride in. To do this, I used a templat ...
ISNBR CASE.Actually, this C I) l-ase is a case within a and a guide bushing on the router. Then, to shape the
case. The innercase is constructed first-irs simply a lOPand bottom piecesso they matched the shapeoithe
box with \IIt"-thick dividers. TIle dividers art' used to groove. I used the template 8)llIin. But this time with a
hold and separate the plastic boxes that CO's rome in. rub arm on the router table.
I made the case 10 hold 28 of these boxes,
WOoO ANI) Fl!<tSII, To set the tambour doors apart
TA)1IlO1 IRS."'hile the inner case is the heart of this
from the case, I made them from contrasting wood.
project, the most interesting part is the tambour doors The doors arc made out of walnut (same as the
on the outer case. Each tambour door is made upof29 dividers) while tile inner case, top, and bottom are
l'l"wideslats. When the doorsareclosed, theeO'sate
made from red oak.
protected and hidden from view,
Once the case was constructed, but before the tamThere's nOlhing tricky about making these doors, bours were installed, 1applied two coats of lung oil
they're JUSt wooden slats held together \\ith a piece of finish, sanding lightly between coats,

Woodsmith

No. 69

I EXPLODED
I

ViEW:._.._

-, ROUTING TEMPLATE
ItOUTINO lTMPLAn MADI

~VEllAU DIMENSIONS:
lOS." H:It 11'2" W ...1'," 0

AtOM ',,"_ THICK MASONITI

CASE

TOP/BOTTOM

'G'

""

...

6'."

TOP
PLATE

Sf00 ....

,
l'.-

DMDER.

CANVAS
BACKING
~

'"
UPRIGHT

10',

TAMBOUR
SLATS

...

OUTER

J
"'DlLI'S

FACING

f(1

;,~

BOTTOM
PLATE

HANDLE
0.0
GUllI

0)

auSI!ING

CENTER
FACING

CASE
BOTTO_:)

MATERIALS

CUnlNG

WOOD PARTS

SUPPUES

A UprigIlt.(3)
,...4 ... 9tgh
B DMdeti(52)
"- x I.? 4 liI6
C Top/BoMomPlo1es(2) 4. '2.

4 800rd F' G' 'Illick red 00Ic

31SquoteFt 0112 'nlclcw(l'"utlo: 'he
tomDoU' _
and II1edMdeIS.
.' 'hick 'edOOk plywoo(Hor!heoock
Mod.umwelgN orl1Srsconvos
" It1ickMosonIte 10:templote.
(16) No 8X~4'F'" woooscrews
" Dowel 10:stop pin$
t~ PIntof lung o~fin""

D C""'erFocllO(l)
~ 9"E Ou1erFocIngs(2)
~ x 1~. 91\
F BocIl)
V.-PIy 9\11x 13',
G Cose Top/Botlom (2) ~'X 712 1910"
H Tombour SIo'S(S8)
~. x 12 9"11.
'I.XIt, 2
I HOl'Idles(2)

Nu,69

r.~T'"O
~.

1.sW~!;L
A L_ C:

l 20 (.4 ad. ",]

)",,'"1

DIAGRAM

2.t U. 't.}

'1.4.$0

(t.S Sq. 't.)_

',Ji456

(1..5Sq.'f.

'j

UPRIGHTS
I began building the

each upright. then CUi to your layout lines.

No mauer which method you choose for
CD ease b)' making
cutting lhl' kerr.,. you11 need to mount an
the three uprigfus
auxiliary (enee 10your miter gauge. see Fig,
that are pan of the
2. This fence not only provides extra supinner case.
purl. it helps prevent chipout when the saw
t SRJGHT:,.
To
blade exits the workpiece on the back edge,
make the uprights
N~X1.llrimmediheuprights to length To
r
(A). start by cUlting 1'iJ:. ).
K~;Rl'1SG11IEI'IECES.The most accurate
do this. trim the uprights so the space betlm.'C~I"-thick blanks
to a width 01fh'.sct' Fig. l.Thentrim these way 10 cui these Vl"dl'CPkerfs is to use the lw,,<,nthe outside kerfs and the end of the
indexing method shown in Shop NOles on upris:hlS Is lrltl, making sure each upright
pieces to. rough length (,i9"
Alter the uillight pieces have been cut to l>aI(e15.Another way would be to la)'out the has thirteen kerfs, see Fig. lao (In my ease.
their rOURh k..'ngtll, the next stt!P is lc, cut .pacing for thineen kerfs 310ngan edge 01 the uprights measured 84t<"long.)

clNtta

UPRIGHTS@

UPRlGMf

kerfs in allthree pieces for the dividers 10fil

into. (The cn boxes slide on and are supported by the dividers.)
I cui kerfs equal 10 the width of the saw
blade (about W). The right and leit uprights
are kcrfedonthdrinsidelacl',oll/!I. BUL the
center upright is kerfed on both sides. see

a.

9"
ItOUGH

conu
Ul'lUGHT

L
WASlI

DIVIDERS
Alter th" uprights
are kerfed and cut to
finished length. the
next SlC1>
is 10make
the dividers that fil
into the kerfs tn suppon the CD boxes.

Making

the
dividers (8) is a
IWO-Sltp procedure, First. l.'z"lhick stock is
ripped into thin strip>. Theil the strips are
cut to their finished length.
DI\lDE(! ST1HPS.To make the divider

strips. I started by resewing two blanks to

V,t,t thickness, Next, I cut lilt, blanks in!.,
pieces that rneasure-l" wide by 16"lonl(.
Then these pieces are ripped into thin
srrips, see ~ig. 3. (This method will yield
extra dividers. buI some won't bo u,,,bll")
Since l didn't wanuhe sa....'marks to "~IOWOil
the strips, I cut them a tittle thicker than the
kerf and then sanded them to fit.
~hoJ)Note: Iused a 13rgel)U~hblock to rip
thceleveu stripSo each blank. For mon- 00
this push block. see page 14.
crrr m I.ENGTII.To cut all the dividers l(,

length.] clamped" Slop block 103U auxiliary

It'm'e on the miter "dUR~.see rig. 4. As (or
the length of the dividers. I Cut th~m 1'16'

shorter than the width of the upright< 10

allow lor expansion and contraction.
cu tSG OJ~lI)ERS.Once the dividers are
CU~thenext stepisto glue them in the kerfs.
Putadl'Ol)ofglue in each kerf, near the from
edge ofthe divider. (l)on'tsprcad the glu. in
the kerf) Then set the upright on edge and
push thedividersdown aj!ainstthe work surface to get them flush with the front edge 01
each uprighl. see rog.5.

-WAStE

,#

U~wOltK SURf
A
_.AS A STOP 10 KfE::POMQUSRU-SH
"......_ wl't'f4 FRONT (DG(
"

RIP OIVlDERSSUGHll Y
--

-THf(Kk

THANSAWKlAF,

SAND Oft PlANE

to frr

W,xx1sln1rh

No. 69

ASSEMBLING

THE INNER CASE

Aller all of the

divide" are IIh"'<Iill
!""
place. a top and bot10mplateare needed
t 11 e
10 assemble
inner casco
\~.i;.
The top/bottom
plates (Cl fil flush
with the front and
back edges of the IIl11ighlS- '" ih('Y'rc ih..
sam" width (4'V,")as the uprighl.
However, determining the length 01 the
plate... i. a bit of a problem. TIle problem Is
the uprights need In Ix'spared so a CD pl."
tic box (whith is 4;/." wide) will fit between
t)Wlll- with a Vo" space along the sides.
51'\l'E"". To get this spacing. I made four
5" x 5" spacers from ~~ItlI\i("k
scrap anti inserted them wherethe CD cases willgo, see
"ig. 6. Then Si111pl)' measure across lilt?' cutside edges 01 the end uprights 1<>
gel thrIcngih ofthe plates (121,,',).
cur PLATf.s TOSIZ.:'Afterdetcnnininl(the
size.cuuhe IWOlop/bottom ptates CCloutof
"'~"'Ihi<kstock. see Fig. 6.
An,\(1t 1lLEPLATf.S.Next. drill countersunk shank holes for No. 8 x ~." Fh woodscrews inthe platesto mounuhemto ih(' 1(1)
and bottom ends of the uprights, sec Fig. 6.
;\ole: Before screwing Lheplates in place,
drill (our 1110r~countersunk screw holes at
Ihe fourcomel'$ofthc topplate 00 the ""ide
face. see ~ig. 6a. 11,."" holes will be used
later to attach 1110 outer cast' top.
P,\ClSGS.Mer the plates are s:lued and
screwed un, I made three facing pieces 10
cover the ends of the kerfs on th.. uprights,
me two outer ral~in~
also hide the in~id('of
the tambours when the l'3S(, is open.)
To rnakethe faciogs. sian with a 2'k"wid,
by20' Iongblank. see l~g.1. Then rout a 41<"
round-over on three edges, see J'ig. 8.
CUlling off the ladog piece" L, now a
three-step process. (Before culling the
facingpieces offlhi. blank. J cui U,C blank in
half to make it easier 10work willI.)
TIll! first step is [0 trim tll(' center facing
(D) off on. edgt'. SC<: Step I in Fig. 9. The
second step is to cut the outer facings (E)
to 3 finished width of Fh". see Step 2 in I~s:
!I. The final step is 10 resaw Ihe outside
falings to a Illickm.,._
.. of .y.". sec Step 3.
Before gluing the faCingpieces in place.
trim them so they're flush with ihe 101'and
bottom of ihe inner case (!lv."). see Fig. 10.
Then glue th~ center faring CD)10the front
edge of Ill, middle upright. And gill. the
outer facings (E) 10the fronl edges of Ihe
outer uprighls. see fig. ilia
THEBACK.All that's loft to complete the
inner case is to add th~ 1,1." plywood bock
(f). CUllhe back,oi"sflu~b wit)llh~topand
bonom of the rase (91,;,",vide).bul extends
'k" beyond bolh Upris:hLS(10hide III(' tanl'
bour backing). Glue ihe back (I.) in place.

)t

Nn.69

~4~4"PI-

a.

.8

I:/

C~::;'R'
SUNK

.._,_~
~

I Z

-e,

--(.=

~..-

ClAMP

~,

:::--..

5'

t:PRlGHTS

TOGElHR

"""

.;;;

,,-~TlOM
PLAT

USEfOUR $PAaRS

I". THICK, 5"x S" SQUARE

ftOUND OVU THRlI

..!~f

RO\fJ(R
TA....
f(NCI

(DOES OF t104l BlANK

..~~~;.',. r
, . , r-

. lOP
PlA1J

~fACING

T~\
I

~-.,-'"

SHANK - ,
HOlf

e=::y :...

7:

l;."fh.

WOQOSCREW

TOP

-f -:_--j PLAT

--- . ~)9
12\ .-

2,,

~~:..
C~NTER

STEP1

~I

<UT 8lANK INTO

twOtOUAL

LENGTHS. ntfN

RIP

..~.-

STP3
RESAW
l~~-WIDII.,.._

"lW
FENCE

_1.)."

.. .!f
.
.
~[Ai
.'.c,'y.;

..

'e '

f(NQ

oun.

fACING

..~. '

........,.

..

-~.

TO A
THICKNESS
Of ~."

WA.STt

~,

,"1

STEP2

:':'

~.ROUND~
OVER an'

~P'O~
P1EC(S
la .."W1DE

CfNTtR F,,(.ING
Off ONE PIlCf

BtAN1C

fA(lNGPllC(S
~
A l.-THIC':
BLANK(20lONO)

FACING

'AQNG

I'

,@ctNTt.FAC'NG

10

CUT PlYWOOD 8ACK

111Y/1Dut THAN CASt

GlUE fACINGS IWSH
10 TOP AND 8OnOM
0' INNERCAS!

_-

OUT'"

FACING E

I (a.

"

CROSS
SECTION
(TOPV1lW)

FACING

un

"".

--

"

-AUGH

OUTERFAtiNG
FWSHWrn4
lOGE Of UPRlOHr

,~.
....,....nONO

..._

-,,--..,.
. ./

--13'/,,-

'."

9t ,-

9'."

I
,

I'

t..,
CHTfRFAONG 0

"""

ill

"""'..........

WooJsffi,rh

SLOES
Of (ASE

T""

;.-( :,.; -

.. ' '>I ~

I
0UTtR

'

r F'>i

..
f

--l..

CASElOP AND BOnOM

In order for tile tam-

ROtrr

GROOVES_

Witlt the template in

place.the '-.<"(,Irackshaped grooves can
be routed. To do this,
mount a \I," straight
bit in ihe router and

bour 10 slide prop-

erly it has 10 run between IWI) groovecl

piece'S. Hut, making
these
grooved
pit""c,> id~nlkal loan
be a problem,

The solution is [0
use a template. The template lets you roul
identicalgroows, and ilalso h,'lpsyo\l make
the case top/bottom (G) the same size.
111T"_\If'L~n:. ~lrs1.layout the Il-mpiatC.
see Fig. II and the RoutingTemplate on Jl'ij(e
7.ThC1lcut and sand it to si7.... SCt' rig. 1.2.
RIA."KS.The next Sll'l) is to make mirrored topand bouom blanks. Simply gloeup
two blank> to II width of8' and lenRlll of 19"
To keep from gcuing mixed-up. mark the
inside from edge of both blanks. and both
sides of the template. see Fig_13_Nowcenter
the template on one blank and clampit down.

.... YOUT
l<MPU1t

11

PAJ1l)tN ON
, 41HIOC
.....
",Nm

0.0. guide

7/16"

bushing

to

the
router base. \\,ith
the bil adjusted 10

cut

V."-dl)(:l)

groove.stan routing

on the back edge of

ROUGH CUT PAlT(I,N,

THeN SAND TO RNAlSHAPI

13

I-__J

TO MAKE MIJUlOR(D
IIIAN1C.RJP
TtMPIATI Ovt.

"O!~"'G
ruo

Fig. 14.

a.

TiMPtATf AND
tNrO StANK

OI-r.\'Df.

Once the
grooves are routed
in both blanks. the
nextstepistocut the
EDGES.

blanks

10

shape. To

'" '-::".
,,~

INDE.'IlNGHOUS. To keep the template in layout tne shape. I

"position when routing. f used IWOindexing made a small pencil
AND I1MPtAn
pins. Markthetrlocations (referto Template guide from posteron p.'gc 7) and drill hole. throul1h Ihe tem- board and ran it
plate and 'h" into tile blank. see Fig. 13. alongthetemplare.see fig. 15:I11"n remove
(These holes"ill be hidden bytheinnercase.)
the template and cut If&" outside the line
To locate the holes on Ihe other blank. fijp
Rlra .4.I'{~I."1"0 trim the pieces to their
the template over and use tl1<'6"t holes as a finished shape. again I used !he templatedrilling guide. sec 1:-'8_13.
bUI this lime with Ih. router tabl" and a rub

Once the hole. are drilled,

put a 114"dowel pin in each hole and trim the
pins Oushwith the (01' oflltt' remplaie.

.II. HOltS

THltOUGH
1 ) ..

MAl.K fRONl
fDGEOF&LANkS

INOf.'X PISS.

DIlIll t

_....,,~~~~Az?-=:~~

the template. see

ccr

1cOOWEt

ann clamped 10 the r.nee. see Fig. 16.

To use lite am" mounra V~ttslraigllt bit in
til. router and CIanIPtltr rub ann down ju,t
CROSS SECTION

:._- .-:::----

19"

CASE TOP
AND BOTTOM
~."TMtCKl

abovethebit.see rig. Ilia. Then. posirionthe

Ann so it touches th<vemplale and the bit

trims

~Iij"orlthe

blank, sec Fig. 16.

Now. make several passe. mOllillgihe rub

arm slighdy towards dIe bil bceween passes
Willithe workpiece iscut to the peno line,
ROl'l'ol) U\,R EDGES. rmally. I rounded
over the edges, see Fig. 17

lS

a.
POSTtR&OARD
GUIDE--

POST'
OOARO"

T1MPLATl

G1)IO[

,,"
STAJORounNG
ON BArCK rDGl

Of TtMPtAlt

81ANK

1 ... DtA.

S11tAJGHTlfT

"

DRAW LAYOUT
UNE ,t '.- (ROM
EOG( OF UMPiATf

<lAMP

CROSS
SECTION
MAKE UGHT PASSES_,
SNEAKING UP ON UNf:

' ..-THIOC x
-2,

WR>

RV&AaM

R.OUGH (\IT
..lANk ClOSE
roUNI ..THtN

1..- STRAlGKJ

81AHK

a,

..

J-S.

'10M
lOO

"

17
10111
lOGES OF
CAU10P

ROUTt ..
TAat
f(H(,

ANo&onOM

an

AOUT U9 TO UHt

10

Nil. 69

TAMBOUR SLATS
both

Ihe tambour doors

on the ell ""-'"are
'Inl"l) ...
Iat....glut*d to
a Plt.""''' ofcanvas .....,
Hg, 1S. BUI h~
Ihou!:ht of cutting
and roulong all 511
IIlmbour slll.s (n) i,
intinlldaling,
nIHI.rsn-,I'I'HO( I'". M:lking the ,Ia'~ i.
a thn
J) 1'-')<"", It-or more. >('t- JlaR'.' 1:1.)
Stnr( 'Iht ,Ittt ....arlO trimmed
the N]gt uf
d blank, Iht thifktlt''''~ (ll the blank mu ...t
t'<lu~tltilt \\ itlll) (,j the ,Iat ...(V.!"). ~ start b\
c:uttlnR Iliur \-41" 1111\k blanks --1 x 20" Then
rout a "i(' round-ov, r on all f'Mlrl-dJ.!:~
The ~'('1)nd ...1(',)i...
10 np a l~ ....
trip ()ff

,-sl,

Then ,~," II '"

18

rig,

IS, Th,'

lh" .....'A n:aark.$kitt)o

"!lain

llTTO, ..'(mi. ()nc..:)t,u\, ripptd nine

,tnp' trom "a<"h blank, ,'UI ,'oeh strip to
knJ1lh (9"11.1') I.. make a tambour ,"'I (H),
se... r;j1 HI
CANVAS aAaciNG

TAM80UR H
SLATS '

..

fINISH(O 'AMBOUR

12 5tCllONl R(OU'R(O)

15(['Aor

." ,

13)

m TAMIOUR
SLATS F1tOM
20+LONG _lANK

.;

1,.-

ItOUT (00($

_tu>P<NG

..

14'.,"

.l

~lut"d inti) h(Jlt'1loc. t nt .-n-d on the length (It in"'lrlt .,1th,'

J:TOI)\ e, 51. "C f 1R', 21

Jl('(c'r(~.ltt,IC,:bi~the top to \hl"
,,, w, fit. ,I "ul, h '" Ih" lOPfront t:dge 01 inner 4,.',1'4,', J Iinl,',('(1 all c,f the pie...-e-, with
II\\lIn,
11.... ltaodk'S (I) are <implya ,h. fi"" ,Iii' ul bolh 1,lIlIooUI" 'it) they'll close '""., t'('al ....'If tunJ,t (Iii
rOUlll('(.f~:I~x1 llic'C'\"~"f"I'ig.19.It-ULl"3Ch
Ij~hlly .ruund Ih,' !runillin, seeFig. 2t)a.
"Rr\\ 0' Jllf."w, TIll' 1.>1 'lep is to
Plt~,.~' Itlll.":111)(1
rounded over the front
<;, t 1'(. nn "">K l ,-'E L'I/PlACE. After screw 'hr "'P [I, the inner case (The top is
t'(lgc"'\and t'nt.!s wi til a fik Nexi. center the Ih(' tambours tlr,' notched you're ready 10 nul l(11I('d,,' it can be removed.)
~t"n b)' ""nlennl( Ihe IdP on the inner
pull, on 1111'1'IIJ..'Ihand \\idlh of the S4'<.'Ond ~luc'I)II' in't(' r ('n~I(llllt case bottom .
ca'
Nil", ",jill( the hok you drilled car...1011
ol ",IC:I\dour, Then, ~Iu~ them in place,
To IIl'lth,' pih"" ali!.,"l'{).mark a IiI/hi line
'''" .....
", ~1.ln
k,~'p Ihe doors from nIX-'" ".nl,r.'{) on Ih,' I"nlllh of the bottom. st.... li,ra,. !:ui<),-.rnarh and drill (our pilol holes
in~()r l'IcI~II}J:1(14)Car, I add~ a (runta:Jld ~lg. 211.TllI'n.I"",ljO" th.. innl!J'0ISC,;o Ih" for :->0. ISx I," 0.11..... <)woOOo;cn'ws. fhen
and scr(..ow
b.rk dour ,'up IIItit. I"p~n)(wr.,;eerig. 211. ('('ntt'r tll,o.:lll i~
("tnl, rt-d "n the lint:. and pullhl' l41J11\)(IU in tht ~'\'\~
Ille'
fmnl
tl(
thl'
Illf1("(
c:
~'t"
i~
1\","
from
th\..
lilt.,
1('1>
ill
1)1
:\Ct',
(
J'
iu-,
22.
fh, ... "n""kI\'!I1o -Ion~ pitXt'< .. f h do",d

han-

(Ill....Ind u(lI,lr,II'p ...b '()n"altlin~and screwinK tlu- r;t"i4,' h'~t'lJl('!

"I ,'3<'h blank -ee

Iik',-dg, OI"3,:h blankfrom the nppingstep,

(Irr

FINAL ASSEMBLY
O'K"I ".",,,!.-,,-d th, tarnbours l added

~'t:,

thinl,t.eplstOrMllC)\\

...., ' ' d'

th("("'.t~

o.

120.

'"
~."tONG

GlUl
NI'lAC(
CAS<T04'
tUPSlOf. DOWN~

_/

MAlt! HANOlfS

(Nfl. H~NOU
ON S(CONO SLAT

'ROM',_',

,,"YWOOO lACK
MUST CUA.l GItOOVI

TOP VIEW

lotOS'SlCTIOt'I

V.
Datu. I ,"

HOlU.
crNlIR'D ON
THE L(NOTH
OF THfi (,.51

StOCK

or tACH TAMIOUIt

21

O.

".,.."..

CROSS
SECTION

.,-

oowu

,
.,"
I

,..OlCH

''''SI $LAT
0. IACH
lAMIOUIt

WAX (NOS Of

NOTE:
APPlY RNlSH
1WOItI ........

..._.._.

scuw

lOP ON

WITH a 1.,,"
WOODsafWS

tl't.ACf TAMIOUR$
IN eonoM GlOOvt
aNTtI UPlt.lGHT
OH ClHTWINl -

P05.11'ION CASt
l' ," flACK 'ROM
INSIO Of' oaOOVI

THiJII ClN1U tOP

ON INNOt <ASE

11

WOODWORKING

TECHNIQUE

Tambours
T

here'. nothing magical about a tam,

bour. It"sjuSl a sliding door that's flexible, This fic-xibfilYallows she tambour 10
slide in 8 curved track.
The \\'a)' 10 make a tambour flexible is 10
join. sericsefindividualslats withsome sort
offlexible hingr- The most common method
of hinging these slats i.to glue Iltem 10 8

II

Sl!t'~)llf

tka!

mil-top d,'.s~'

"I'I'''1I1f1ty/''

that I'~!I'8{14'U lin .. II nrnll,'

to t"( t{l~),'){)"~'I~tJ,~J"t'

,<:;-~"QP;lfJ('II,,t
JQ,-

~01tlt l't{lgtlll

(/tia S,.IIUTI<'!
It has 10do with the width of these desks,
rnosrofwhich are fourto five(eel ";de.li thc
tambour were 10 angle slraight back. us
weillbl would cau se iue sag over such a long
fabric backing.
span, But, by curving the tambour it will reBut. there'. more to making tambours sistsagging,
than just gluing fabric to wood, In C3CI, ..4re there any SJlf.'CI((J ('1,(lrurtl',1I')tlr x (ij
malting th.. tambour is the """1' part - the nl' Slfhnl}('(ltltlllfH"/~!
tricky (and interesting) part is de<iWlingit.
Yes.an Sshaped tambour hasto bcnd lor l're seen tambour ll.'itJ, rertirn! .~(flt..~wardaswellasbackward.see ~Ig. I.In order
tha! 'UOl't ~Irlt-tn.side a nd ia mboure I(!iil, lor an Sshaped tambour In work. the slats
"(1_'; :(Jlt/(~l .-.:lnt:. thut ',lOI't ,i /J'(llId41o/('".
must be designed so they don't pinch together when bending forward. This can be
,. (JI.t "'411p"fe,.,', d a -er tt other!
As lar as construction It""'" both o( these done by cutting Ih~ edges 01thc slats 31 an
tambours arc made exactlyih esa meway, So angle to create a VshatJ<:between lilt' slat s.
the choice between using vertical or hori- lois allows elcarance when the tambour
zontal slats in a tambour j,; determined by bendsforward.see FiR. ta.
the design o(lhe project and the amount of
SINGICt1n'E, M3kingltingle<ul'Vc tamspace you have to work \\ ith.
boursise ..sier. (Thisisthetype I used on ll\\'
DESIGN,TIle d.si~'Il lI( the project will Cl) Casco) \\'ilh a Single CUlVe,the tambour
often determine lilt" "lay the tambour alway'S bends in the S<1nlC direction - back
moves. For example, il you're makin~ a Oil itself So the edges aren't relieved.
traditional rol~IOI)desk the lambour typl J need ttl Ifl(IJ.e (1 tnn1hollJtl'(lt J'ofltl't'x ('
cally moves upoand,down, On Ihe ulher tin"l {"II rl't" (~llt(111 IYI(I',IR). I/(),,' '/0 I ". )t~llt'
hand, il you're making a cabinel that's wide the tanlbo/t~ slots v'ill ~l;d,f tlllOUt'flb ,t
but not very tall uch as the CIl CaS<'on j/tilltOtlt ht 111tlflY?
page 6). it look. better iftheslatsare vrrtical
Atambourisa two-part .ysl~m-Ih" Illm(Ihe doors slid ide-toode).
bour slats art' 011(' ",'r1, and the gr()ov,-s Ih.
SI'A('~,Another thing 10t.'Onsider when
slals slid.. in are Ihe other part. loc lri~k i>
ot'tcnniJling which '\'a~L1l~tanlbournlC)VeS
making sure both parts work logell",r,
iSlhe amounl o( space you hav", \\llen you
111.. ~jmplt..>$l\\'a~' La do this j~I', (Im\\'
open a trunbour door il doesn't jusl disapo everything on pat)t;r fit>;t. Stan by detennin,
pear, il has to go somewhere, This means a ing how wide Ille groove nee'tis 10be. SIO('O
lossof space inside thcrabinel, eiU,eron tlw Ihe groove will mosl likely be ('ul 'vitl, a
101>,sides, on maybe even U,Cbollom. Also, roulerin on(' pa!;S,the\\idlh o(llw groov~ is
any interior dividers, shelves, or partilions limit,!(!to the size of the rouler bil, So you
have to be designed SOth(')' won'l interfere have to malch the size orthe slals to thl' mt'
with tilt' way the tanl00urOJl('rare<.
01the bit (groove).

S-SHAPtD TAMIO~

a!'NOStH 1WO

CROSS SECTION

~"~.~'CTl5"ES~9~Y
10~~:-~':"l\:~
C"":::""

I /-::__...-::;;;,~
l,~~
.~

CROSS SECTION

f/'

WIDE

'----J~
SlA" )

WORKamm

WITH A OtNnf (URvt

a.

bf

V.SHAPf AllOWS

TAMIOURTO
"NO fOAWAItO

rL~

.'t

CANVAS lACKING ~

12

/R
1:<", ~

... ~
~~

Alter determi ning the widtll of the groove,

drawthecurve thatyou need thctambourro
folkiw Now here's where Lhingsg(,l interest-

mg. To get the slat 10follow the curve, you

have three variable. 10work with - width,
thickness, and profile,
WIDTH, The first variable is the width of
th,- .Ial. \\11il" you can make a wide-slat
tambour lollow a light radius, it won't move
..,,,.,Ill])', The m'" of thumb is: II", narrower
the sial ine tighter the curve.see Ag, 2.
nnc,,'Xt;S.~, Once you've determined the
",dlh "tlh,'l'1at-,lhc ne'XlUling 10consider
is the rhicknes of the slats, First, Ole slals
need 10be slightly Ila".",'''''' than the width
01the gnxj\'t', II they're the same si?-cas the
gr'H'V\~t),toy \\un'l fit around the curve. see
Slo.'pA ill Fig. 3,
BUI,ifthe Sl31$are made 100 thin they will
raillc around in the straighl sections of the
groove I've found that iflhe thickness o(llle
<Iatb Vt6"less than the width otthe groove.
it' just about right for most tambours,
PROFILE. The final consideralion (or gelling the fanlbour to follow tile CUlVl' i:-: it~
profile. Profile refers 10 the way the sial
lookswheo viewed from the('nd, 'n,isisusu,
all)' a chamler or a roulcd round-over (like
on the Cl) CaS<'),
Wilhout the routed profile, Ihe edg(''; 01
the slals can bind against the oUlside waUof
the gr'oovc,SC<' $lcp B in fig. 3, BUI,by rout
ing a profile on the ~clg('S,lhe same size sial
..ill tracksmoolhly through the groov~, set'
Step C in rlJ{.3.
"l~ Il)or~
1work""iLh mmbc.ul"S. tJ1f' mon,'
I realize the importanrc oi carelul planning.
Becau$(' Ihe chAll~ngeis m"king a lambour
look good n lid work properly,

3
A

THOUGH SlAT WILL

FIT IN STllAtGHT SECTION
OF GAOOVE. n's TOO
WIDE ANDIOR TOO THICK
TO GO AROUND CURVE

THINf'(ER SlATS WIU

GO AROUND CURVE BUT
SHAJIP EDGES MAY CAUSE
THE SlATS TO BIND IN
GROOVE

E? SLA~~~'\
AROUND A TIGHT CURVl

Design :-Iole:Ifyou need IU use thick ..Jab

bUl don't want to make a wide groove, the
ends of the tambour can be rabbeted,

ROUND OVER OR
cHAMFER EDGES FOR
SMOOTHER nACKlNG IN
THEGROOV

No, 69

TAMBOUR CONSTRUCTION
Afler you've determined the thickness
and profil. of the tambour slats (_ pr...
vious page). Ihe next step is 10make them.
One method (theone l used 011 IheCO Case)
is 10rip the tambour ,I.ts ,,{(Ihe edge of the
board, 'nl~
advantage 10this method is thai
the profile can be routed on the edges of the
slalb.fi"" it's cut 011the board.
Since I stan with a "ide blank and then
trim the slats orflhc edge.the /lti,kll' ..x of
the blank should equal the widlh otthcstats.
(I wanted the slats \At" wide (or the Cl) Case.
so I started with a board I'z" thick.)
Note: llthe slatsaren't very long. I ri"long
strips first and then cut tile slats 10 1.Il~oth

a jointer, simply take a li~ht pass over each

Design i\:()lc:: You COdII dye the rabric to

edge. Otherwise a hand plane can be used.

Then repeat the process of routing. cutting.
and joinling until you have enough stars,
There are bound to be SOme warped or
twisted slats, so I cu120'~more than I need,

match the color of the W(""1. bUI the fabric

may shrink. So dye il before you cut it to size
CUi thr- fabric 10 fil berween the holddowns and long enough to cover the slats.
(;1.\,1':. WillIthe fabric CUIIOsise, apply an
even opaque coaling of glue 10the back of
the tambour slats. Iuseyellowwcodworkinz
glue and apply it with 3 brush.
Finally. lay the fabric over the slats.

GLUING UP THE TAMBOURS

:-10" it'sume IUgl"e the fabric backingto the

slats, The tricky part here is geuing all ofthe
slats to fil tightly together, The secret is 10
uSC3jigiO hold the slats flat, refer to SICP S.
The jig is made of two hold-down bats and
two end blocks screwed 10a plywood base.
ASSE~ml.\.Screw one hold-down bar (rabtromthese strips,
bet faciog down), 10 the plywood. 111.n
ROIrrnu. tJIGt:s. 011('(' you have a board <crew an end block perpendicular 10 the
the correct thickness, the lirsl step ill hold-down bar. sec Step 3.
making the slats is 10 rOUI all four edges of
:-;0\\,. slide one end of the tambour slats
the blank.see Step 1. (On the CD Case Iused (fact' dO.IIl) under the hold-down bar and
a \00" round-over bit.)
screw the remaining hold-down bar over the
C{T TI) 11IICKNl-$. After Ihf' edges are

profiled. the next step iSIOrip the slats from

both edges of tile ~IOCk.see Step 2, To do

this. firstdetermine the thickness DCthe sial,
uSinst {lit' method shown on the previous
page. (In my case this was "1<;".) Then rip a
sial off both edges ofthc board.
JOI~TORP~"E
EDGE. After the slats have
been CUIoff.there willprobably be some saw
marks on the edzes of the blank. If you have

uther ends of the slats, see Steps 4 and 5.

Then, push the tambour slats again$1the
end block. TIw slats have 10be tight enough

so tilt' glu" won't seep through. Once the

slats are in light. screw the remaining end
block down. se... Step 5.
l'AaIU(. TIle next step is 10 glu" on the
fabric barking. The matcrial l normally use
(or backing is a lighllo medium-weight artist's canvas available al art >'tlPplystores.

a.

pressing il in place and rolli'ls.! ()ul any

wrinkles. see SICP6.

KRFJ\KI"C: TIlE TA.\lIIOI R. Once the tam
bour is dry, )'ou11probably find thaI some of
the IIlue has seeped between the slats. For
this reason the back ofthe tambour needs 10
1)('"broken, "To de this. gen~y bend the tambour back at the cracks,
FINISHING

All thai's lefl is 10 apply th.. finish. I usually

spray 01\ a finish or use a wipe...on finislt such
as tung or Danish oil.

There's one final tiling I'd like 10mention

aboul finishing - sometimes you can gN
100 much of a good Ihing.ifloo much finish
is appUed 10 the tambours ends or in the
groovesin thecase.the tambours won't slide
smoothly, (I use a Q'lip 10wipe excessout of
the groove.) Then, J wax Ihe groove and the
ends onh e slats with car W<LX.

a.
scalW (NO
ILOCK 90' TO
HOIJ)..OOWN aAl:

IlUlNK

,,'

ROUT A11.
FOUItlOG"

UoK=:J

.OUND
OVIR lIT

aiJ' SlAT$'iteM
IOTHtOGU

To "laA.'... flit 'I! "'(cidf fn 'II/H)II" $I.trt~.

SVI(' ";p Ihe s/(lls 10 ,hirb'e$.("fl'")
i<11!I1,('ill! V,',""ck i>lank. R(JIII~11
from both eclge$of the blcmk. 'f/w"
,1411t I'dfJPR("~'''rh btnllk 'lSI 'lg fI 1/,'''(fJII nd p/tJlIP lit, "nm IIInrkKf>iffhehlmtkllttd ."nti
(tt'I'I-/Ilt nu 11,(,I"tJlltt1j'tllhlf~.
tilt 1)"1('('(/" ~"PtrII nl'('" (lga ; tl4

.,'

OFBlANX

0,,(,(,lIt,

Sl(r(,i (r)"(1t'f'ppl'(la~,d(,,(lit)

3J"'i$h('d
le,tgtll. I
by
t'"d

I)I(ldt' (I g/uirlg }i{J-

.'lrrp'ff"'fJ (lIt
Ix 11-4'(/II(Ii,J,I"u'JII)(I"
,\:;((111

f)(I'

hlork U lid n ntbin I'IIC'/,othrr.

...

HOlo-.OOWN

,dye. face
II/ort
o~,("r'lld (jl th ~/af rlJ,dN'
btlr.
Kp'poddillg $/e,lsu>ltil thry"'f'n/l in p/a(~

4 Witlt "'''ted

(19./al./or(nell

NIJ.69

Inmooltro/lI,p

.\jl~t.
:;C""",('

5
(/gai" .. , the

itl p<)~iti()Jl.
T/Je'lt I)ll.~hthl_811It.~tight

Mtd block nil(/ .'erI'1Viltf oilier

CD C"$~). I'Itd Mork down In /told Ihpm III p/n".

IIi.backillg IIu.ierill/ (calll'M/s"

6 Cld
it jll.~ /)(
tlt(, ht,ldoll,}((111 lKlrlt
il("1(!CII

Thf11.npp/y gill' 10 fit,s/als n>lf/11re.,./I"

Inh,.?r i), pl(l('f~. Roll Olt' (l,J'Y l(rinA ..I('.J(.

13

SO

T l P S

M E

FRO

OUR

S HOP

Shop Notes
CORNER BLOCKS
The outdoor'fumlture in this 01 the block and the way the
issue could get. 101of abuse. llrain runs on it.Hiketousethick
Kids jump 00 it. It get,; draAA<'<I blocks 10 provide the most Nlu
amuod the yard. And Ih. sun inll surface On the Adirondack
and rain cause the wood 10 eX furniture. I mad" the corner
pand and contract.
blocks (rom a 2)(1 cut 3" wide.
That's why I added comer S('(! Fig.!.
cerrrxc TIlE tIUKKS. The
blocks 10 slrenb'lhen the in.lt1.
comers and help resist racking. easiest W3)' to make a corner
Although there's nothing diffi block is 10 CIII a ~5'triangle 0(1
cult about "laking corner the. lid of the board, 1111lt',the
blocks. there are 3 couple of easiest wav, but nOlth" best.
things to consider.
The problem is the direction
STOCK.The two most impor- of the grain. When the block is
lam considerations are the .iw SCI'<.',,cdin place. D,, screws are
CUTBlOCKS

r-...!F~lO~M~:bt~.,--,
....-~--::.,<~----

t
o.

45'

_-"--,,,'<>

curs

./\.'-

almost in line ,<'ill,the direction

of the groin (see Fill. lal. This
means they can splil uff the
corners as they''''Ughtenl',
It's beucr to have Ihe grain
run (l("'"f~ the screw holes. This
is done by laying outtriangl,.,.as
sho wn to fil!_ I Thi-. way the
grain runs parallel 10 11... lung
<idcoflhc triangle. see I~}!.lb,
SCRE\\' HOU-::S. The sere,",'
holes are drilled 011 11", 10llg
<'<Igeof'the block, see fiR. lb.

To drill U,eS(' holes, I set up a

simple jigon thedrill presstable,

see FIR. 2. To make Ihis jill.li"'t

miter a piecre of scrap at 45' to
produce a SlOP block. The n,
clamp the angted ~tol) block 10
Ihe (ront of another board (or LO
a tence). rinally damp then>
bolb to the drill press tabl,'
Now "el the corner block
again,1 th(' renee and slop block
....rith the longedge up-and drill
the holes with a countersink blt,
(~I.J'E. Since the screws mighl
loosen as the furniture is racked,

I glued (he blocks

00

with con-

strnction adhesive

COUNTIUIHK

"'

t...~ '~

Cl.AM.P RNCE
TO DftfLL

PRSSTAIU

--

.____"'_

WEAK CORNU alOCK

b.

STtONG CotNER IlOCK

"an

GW"
OIRKTlON
SPlmING

POSSl8Lt IN
fHlS ARM

SCRMSRUN
ACROSS GRAIN

4S' STOP
1U0CI(

PUSH BLOCK
Typically when ripping thln

trimmed (/ff wilh a pocketkni(r block made frorn an Unlong waste Ihrough Ole blade. elimiorchlscl.Ive come up with a so- piec,' of2x4. "'~. Fig. 2. CUI out nating Ihe liulc splinter,
Fig. I.BUII've noticed a problem lution that prevents the splinter or I!luc on 3 v,n "lweI" on the
l3yaddinga heel on top onhe
with this technique.
in the flrst ptace.
bottom o(th" block. Thispushes block lOO. you can turn the block
As the push stick moves DIe
j'l SI! 1I10CK. I usc a push
001" 111l'workpiece and the over ifllw first h" ..1grts tom up.
workpiece past the blade. the
GlOCK PUSH(S
waste side of the workpiece can
1
2
WORKPIECi
AN.O WA.S1(
l;a~ PUSH
split off J".I before the Cut is
PAnllAO(
alOCK
completed. This leaves a lillie triangular SJ)linlCrof wood on Ih.
waste piece. see Fig. la,
SPUNTER. If you're making 3
series of thin strips (b'llch as (or
tambour slats), thaI splinter can
keep the workpiece from going
Illlhl againsl the fence on the
next pass. (Or silting Oat on a
jointer table if you're jointing be-

stock. Iuse athin push stick. see

tween passes.)

Though the splinter can be

14

No. 69


CUnlNG

SPACED DADOES

On Ihe CD CaS<'.I ran into a

common problem: Finding III<'
best way iocut dadoes (or kerfs)
that are III/yo"wl U spaced,
To solve the problem. I built a
jig that clamps to my table saw's

has

c(, be a uniform v~.

but the into the notch. set' Fig. 13.

kerfs are only!-\!""ide.

After the Rlue dries. use a

ALXIUARY FF."CE. To make

the jig. start by clamping a 2t-t'
wide piece of~~" stock10 your
miter gauge. see ~ig. 1.
mlter gauge. It's similar to a box
Raise the blade 10 the depth of
joinljig. bUI UII boxjointsthe dis- the kerf you want (V," fortheCD
lance between the slots is the Case), and make a pass culling
same as the width of the slots, out a notch in Ihe fence.
For the shelves in the CD case.
KEY. "'ow, unclamp Ihe lenrt
the distance between the kerfs and glue a shert ind"xing k(~'

kerfs (V1" ror tl1('CDCase). Then

make another pas.". see Fig. I

chisel to pare VI.'"off the lOP 01

I ~II'G TILEJ1G. Xcw you're
the key, This ensures that when read)' to start culling. For the
the workpiece is placed over UlC first pass. keep tile workpiece
key, it ,,;U rest nal0n the surtace nat on the table. "ilh one end
ufthe saw. nOI 011 lOP or the key, against the key, see Fig. 2.
~F.C()NO NOTCII. Now clamp
For the n"XI pass. place U,.
newly
cut kerf over the key and
the fence 10 the miter gauge
again so the distance between make another pass, S<.'C Fig, 3.
the blade and the k<'Yt'qual$lh~ This sequenc is repeated (or as
desired distance between Ih4! man)' kerfs as you want.

Q.

AUXlUMY 1tNC

~N,OE:XlNGKEY

PARE,.OFF fOP

or

WOItKPlECE

Kt-V

"-

KEY

ROUTING SMALL PIECES

When routing small pieces on

a router table, how do you keep

Ihe workpiece (rom lipping into
Ihelarge hole in the routertable?
AI'XIlJARY TOI'. I raced this

the Masonite under the fence.

Then rctighl~n the belts 10 hold

the Ma:;<uliledown on the table.
ROlrnNG. Alter the Masonite
is in place, raise the bit up
problem when rouungchamfcrs
Ihrough the hole to the desired
On th e B(,3m Compass (j)agl.' hrigh~ When rouling the small
22). To solve the problem. I chamfer. almost all of U1C bit is
added an auxiliary table lap of COVCrL"() by the Masonlte. Only
V,,' Masonite.
the pilot bearing and liI~"
of the
In the cemer otthe Masonite, culting edge is exposed.
drill a hole 1I10l'S slightly larger
When routin!! a small piece,
than Ihe exposed IlaJ'Iof the bit (like the trammel heads on the
you' .....using. (To rout the \I)"'. Beam Compass), I hold the
highchamferon the Beam Com- workpiece with a rubber-bottom
pass. I drilled a 1!1!" hole.)
woullrowel.Thisway lcanconIf your router table has a trol the cut without gelting my
fence. loosen the bolts and slide handsclose to Ihe bit.

No. 69

W''I<xismllh

NOTE:
HOLD S~ll WORKPIECE
WITHaUBN:ItaorroM
GItOUT nOWEl

'.- MASONI"

15

OUTDOOR

PROJECT

Adirondack Chair
Whether it's made from redwo()d 0'1" painled pine, chis
Adirondack chair is the pelfect summer projecL Srraightfou lard joineT)'
and a cOlllforwble design are hound Lanwke [his chair a favorite.

I was yean; ago when Ibuill my first Adlrondack

chair.The friend Igave iuo mentlons thcchalronc e
in a while. and reminds me ofits weak points. (J\t least
the friendship is holding up well.) '15 time I've made

chair looked (see back cover). I decided 10 rnake an

entire outdoor grouping USingdear nil-heart redwOIld
(,.,... from cover). To I<:t the beauty of the redwood
show. I used 11clear finish, see Talking Shop. po1ge29.
some improvements,
And 10 strengthen the I<'llic>inl$I addedcerncr block"
co~n'()RT.My fil':ll chair was designed (or someone I also used glue (actually waterproo] construction
to silOIi. When I started this newchair.I wanted itto be adhesive. see page 29) 011.11 the joints,
Th.,n'IA,..::S'\.XD P,\'lT'ER,'I," Thisis the kind of project
comfortable (or someone to sitm
that
you may want 10 duplicate in the future.So il might
The chair is designed ..iili a contoured seal and
slightly angted back. The angle We used leis you rest be worthwhile 10spend a few extra minutes 10 make
naturally in the chair. But once you do get comfortable. permanent templates out of V."tbick M"",nile (or the
contoured pieces (the back legs and arms).
it's 1101dimcult to get back out,
If you'd like a full-size pattern (I( Ihe contoured
ornER CHA.~GS-My earlier chair was made of construction-grade pim' and painted while. This time I pieces. you can order one Irum '.\'oodsI,lirh Pro]frl
started with dear pine. Bul when I saw how nice the SlIppli." see Sources on page 31.

16

N,,_ (19

EXPLODED VIEW
UPPER
BACK BRACE

OVERAll DIMENSIONS:
3134'"W x 383'4lfH x 37"0
BACK SLAT

t::::1;

-@
--

1
1"11

BACK/ ARM
BRACE

.' .~
I

10'

rARM
SUPPORT

ARM
@

S<D

FRONT LEG

@
@
FRONT
STRETCHER

(!;

@CORNER
BLOCK

BACK LEG

LOWER
BACK BRACE

LAYOUT

361 ..*

WOOOPARTS
A Bod<legs (2)

8 F.ontlegs (2)

I Seat Slots (7)

J ArmSuppOl1s(2)
K Arms (2)

~. x 2% - 2~4

CUnlNG

C f.ont Stretcher(])
.\',x4'lo22V.
o Uppe.80ckBtoceO)'I',x2-1tI9'V.
E Bod</Arm Btoce (I) 0)0',.2%24'1'.
F lOW9f Bock Btoce (I) ~, x 5v,. WI'.
G ComerBlocI<S(4)
1V,!lliCk$tock
H Bod<SIa!s(8)
.x2-1t-3S~

1"

../

1.1.-

0)0'4.6102
36V.
'1'.)( 31'>22

--,.,..,._~~
-.-LAYOUT lOWlR
IA(K DRACt ~tnoN

BACK LEG

MATERIALS

1" GRIC

"R

to." ".' -

DIAGRAM
96' :'.

''::'')~--I'''''N---------''---~:----'

"";;:';'

;~... X 5'1)*' 96* (4 U. F"t.,

f" ,

-\,... lC$1..," - 96* (4

ad. Ft.,

'"~,,,,
::

po

.:

_[

:'

"',x2~ 8
"'.)( 51.?- 28

SUPPLIES
(60)No 8x 1>,0
.. btossFhwoodsc<ews
(28) No. 8 x 2' brass Fh woodsc.ows

Nt),69

Wo<'ldsmilh

17

BACK LEGS

I'Ian"" work onthe of the lint tnr the lop edge- 01 the legs. the )ou ma~ ".ttlt to ow," a l,omplate from \'....
\dIT\lndack chair b\ radlu'on the back corner, and the .. 'edgeO<l \'"...unitt> Then you 4..-.u1 u-e the t~mplate
wuh a flu,h Inm bit in llll' router 10 roul all
makinR the base the bottom come, :-;".. -and 10Ih"""lint">.
The ba.sc~consisrs of
'(0'0 U(. \\lIh Ihe firsllegcompit-I.,
the back k'I':' In identical ,hal><."'''' ng, Ia,
ROI 'I> 1)\.N.\l'ilh a ~~. round-ov ...r bit in
Ih,' front and back It'II<t iI' OUI'",, onto th, <econd It'l! blank
the
router wblc. sofl,'n all thc cdge orllle
It-Jl'- connected by a and cut and "lind ill" match the fIN leg,
frem stretcher and a
Shop '\01,' II yoo plan III make several [rom and b,oek k'l!" ex('('pl the tops 01 the
~tt""on page 24, from It'll' and lh~ lront ends ollh~ back legs.
lower back brace. Adirondack ,'hnll>\,1Ir1111'

'dcr 10FIgUre 7.
~Ol ""l1'lI.HoS, '111('lronland back legs
call 11<' rut ['Ollllllie 11-(01)1,10111:
Ix8.1'0 do
Ihi, 61>\ll'ut twu (runlleJI' (8) 10a finished
....iLt of 3V" x t'l' Tlu-n cut two blanks (or
tlu- ba<-kI~~ (.\) 10a rough kogth 0(37"
LA\ nt'l II.\( K ttl.' Tn <napt! the back
I"R'. 6r,t clra.. dJ1l!ullil,~oltht>ieRonloaleg
blank 1\1ork from tilt> dra"ing on page 17,
0' '<'1Id (0' a lull "le pollero, see page 31.)
etTR.\(. "I,U. \Iilb Ihcoutlinc JaidOUlon
the blank, ,," ort the angled ends arthe pen.
cillil1' '. see VIII 1 TMn trim 10 within \1)0"

a,

CAAP1T TAM"
MASONITI
PAntltN
lOUG

.-. ..

BASE ASSEMBLY
The base assembly
('on~i~tsof two mirror-irnage
sides.
Each side has aback
leg (A) and a ('001
I"R (B). The sides
are connected by a

Ironl stretcher (Cl

which is installed

complcte.thr ",'xl su-p is ) make th(' front

rrercber (C) Ihal connects the IWI)sides.
To do thi 6"'t cui tit, piece- III lenj!lh
(22\1~")from a Ix6. see Fig. 3. l1'1l'nrip it to
finnl width (H',"). Nnw drill
countersunk shank hok-s ''''31' each end ofthc from

I""

..- ,

nO\l .and a I",,,,,, back brace (instilled laler),

N.. TRI,{EIJ' .....Ilt-Ioreas""",blingth e
1<'11',mark rt kl'l'nn'li",-", on both I'ronll<'gs
II!inrtkale" herr the back It-,poareau.ached,
....~.~IK2.,\1so, mark~
linesonlh<'
back k'lt' 10 indll.le ",hcrt' the Io"~r back
brnn'" ill "', .Iwl'l,ed "' .......~ Fig. 2b and
th, Rrid dra"ing on pag~17
SCRt."'"11()I~,~o .. , 10join th" legs, drill
Ihr.....('(lunl.'I>\lInk ,hank holt'S on Ihe ill'
.. d. [",'I,.,II'arh ba"k leg, see Fig, 28.
'n,.n drilllhr ... '<1,ank holes forth" lower
hack bran', "',. Fill 2b. Not~: Orillthe coun,
Ict>ink, (0' Ill,..,. hole, on Ihe " ..t,.ide face
of ";rch b'l'k 1,'lC
JOI~I~t.~'1l()N'1 '-'IlIL\(l(LEGS, Jk>gin as
<~mbling Ih, ,,,1(,, one al a time, !-irsl
~pna.(t-.cUll\ ron"'IRk.'liun adJ-.esive wh(.rt"
II", ('onll"1! "''''' Ill<'back 1<11.(~Talking
Silop. PIll" 29, (or ntOl'l' on u<ing conAAlCIi"n adh."" .)
P.. ,ilion lb, back l<jc again'" lbe pencil
mark~ and "In\,' tn one or the ~(Tey.s.~
Fi.: 2 TIII'1I ,,-,nd the monl leg upri!(hl on a
Oal lei",, and adju!)l the leg members so
lh" (,,'101 <""h a'" I'hIing- pn:f<rtlyflal on
,h('tabk' Nuwdnv<in Ih~olher"''() SO'I:w,;.
,\[1('1' the fin-I .,jde "a.,;embled, join the
olhvr IwuleJI' in Ih,' <ante way, so the S<'C'
uod ~d\'",;ril/'"1lh(' fintt side.
~'ltONT~''R''I'(_H~:R.
Once Ihe sides a,c

18

.. ,1,._
~

FRONTUG

.'

, f

la.

~~

\'/1-

..

'"
I

(&

,s....

)1.-

1_.J.-

'\

f
I
IACX 110

S,t orrAU,h.

~-

~
lACK llG

STRETCHER

-S

,-

f)

t1

fb.~

1((1' UG
sauAJl1
10 FlOOR

FRONT

.,-

,- - -

WOOD SCIIIWS

IHStOl fACI

rlONruo

~"\

1tUUU.HCf ..... 1IN ntOM ntOHT mGt

15'

n"

!\i"XI. "r.pl} ....

adh""iv~ III the {ronl
"lid;, 01 II", b;II'k It'l(' (A). and damp the
(ron I ,,,.'Iritt" bt:twI','nllw I('g assemblies,
"' ....Fig. 3. 1111'11'14''1'''' the stretcher in place
10the front end ..of IIII'b..ck lel('O.

LAYOUT

$tn'rh~r."'1' l i)( :~

,IACKUO

~I

,ltCHT

,"

uo

USE ClAMP TO
HOlD fRONTmnCKl.

CLUlAND

SCltlWWlTK
"

Jl

2" WOOO

SCREWS

fH POSITION
WHlU SCRlWING

,,..

...
No, 69

BACK BRACES
The

la~t piece

needed for !bt. ba",

j,

th. lower bark

b ........ (F). see Fig i

\1 this ume 1abo cut

"''0

the otherbracetll31support the back

'~'b. rck'l' 10~ig.
10.
I~t'f{inby cutting

111l'upper hll,'k hm<'e (I)) 2:\'," wid" and

l~)'\/~"ICing,~'\IiR.1,
'11(1, 11<\1IIRICF..

"exl.
cut the
hlldVllml bru.( (E) 10 a rough "idth nf
2\ .' .lIlti fini,h.-d k'nglh of2lh'. '<"'111. 1
'>inn' I ".IIIIt-d the bark ,1ill' 10 be ""Ilk'll.
,hi ...pn-ce has be bc.,\'( l{"Cialong its trout

'0

t:dR'" to 'lJl'flt'r1lh,'

lilt pie<:,' ...... r~1l 5. Then.to determine th. ..quare 10lran,I"r thlint '
po-auon of 111t'l-ds::~sol the 1'1 iddte t\\o ~l~.
...cRru 11m'" ',xl. m;u:k th< position of
dr4" Iint-, W' on "tllt'r ,ide of the center- the "T,,, huk' centered on the slat positint-. ~O't\ nwt t.hc:'pt:l!Wklft,oftht: TJ 11'(lOU' ~I tion.. en each pit,(l'.!"ot't Fig. 5. :'\ow drill
countersunk pilol hul., in th" Io"cr back
211<"" ,de st;.b. alJo",ng 10. bet" ec" th<'ITI.
b,..:k bra..e aube marks.
TRA."ffR r.worr uxe- The n"XIstep I< brae and IllI' UI>ll\1'
10 tran-Ier all the line-. from me lower bark
ROI~l)n\'lRfI)(.f' Wilhlhescrewhol.brace 10 Ih,' uPP<'rback brace, To do Ihi s, drilled, O)llt U ~~" round -overon allthe edges
mark a t'lnttrlin." en Ih,," upper back brace ollh,lh", bnJl'I<.
except the beveled edge
(Il) and align il "illl lit" centerline on Ih, on 11ll'back/ann bruce eE) and the top edge
lower back br;\('(! (F). v-e rill. 6. Then usc a and l'ncb IIIIllI' lower back brae" (F).

UPP~R~~------~==::~:::=~::~--1B~A~C~KJ~A~RUM~1
BACKBRACE
- -,." BRACE

.'

tat... Til C1111hi...bc..,..,l.

lihlh, so"bLwdo25 .andriplh,back

brae" (El _ ,,1<1 v, "'" ~ Ig. 4a.
11)\\.1( K\lk.liH,\(t

:\'0" ,""\It

"

-<Y

19".

ann

the IO\\"CT

LOWEll
BACK
BRACE

back hnlcr (I) In n .. idlh of 51#.' 10del...

milK" Its wns,.'1h. fll(a'Urt~Ih' distance beI"'~ n tlw bark i<'l.... at Ih, front or the a<...-mbled base (2(~~"'),
n'lt'rlo FiK.I.

o.
s.n SAW ..
.lAD(
TOU'

I.." ",,. 'I~\T IJ'I-", Afl..,.the If)\I,C1'back

hl':1"";' ..ut In "nlllh.lay

OUI

th, position

FtNCI

.... CKA .....

.... ct

01

Ih" bark ,Ial, nil it. "" Fig.5.

liNI. tiro" ahnvcentercd OJIlit .. lenmh o(

NOTE:

."

COUNT'. SINK 11.- SHANK

HOUi ON OPPOSJT( SlOt

,."

UPPER
lACK .. RAel

,"

_2'...
_

_21..
' _ .. 21,-_ 2....

r-------~------------~--------~--~.~
I-

\-;';

TIIANSmt
LAYOUTUHES

~,.-y-o~UJ~.-.~~-.c~u~~-----------------~~~~--------------~T
loa
....~...

.ITW[tN SLATS

MAAK aNJtltS

SCItCW

_.

.ROM lowtR

..

1J,A(l(

OAC( TO UPPEI
lACKIUCE

HOLESON fACH SlAT LAYOUt

LOWER BACK BRACE

AI"'r "lIlh,,'" oj th, back brace pieces are
round,,1 ",.,.lh,llIw,r backbract' (~1can
be ;n'I"II"d lx'IW"'1I th, back 1t1r3 on the
"''< mbk-d base-.... .., Iill 7.
To cI" lit,,, forst 1'1l1).!wad o[conSlnt('
Ililn ar1h(osj\, I(J tilt fll(l ... of tht Joy,er back
br1k~c 11lt~ ~lJl)n
thr bra('(' q) the C4)UJ}o
",,,unk h"l"" an' Cannl(toward 'he ironl 01
Ihedellr
lamp tht~IJIt't"(o in po...l1J.on bt.:'t\;Cf'n
Ih~pt 1M" mark, un Ih"(nsid", 01 th< back
klI' n", In"'l edl(e of Ihelol'ier bark brace

NOT:
COUNt(R.SINKS

ON'10m III)(

PUt fOP SCRtw IN FfRST,

THENWOttK DOWN

AL.IoCN ,JtOHT EOGl

0' I!tACIwnH
,~

lOG Of LlG

usr Cl..AM1J

'0
HOlOaRACI
IN PlACt

'f1"" (:

,hollld n....llh, I"P "dg, of ea"h back 10il.

.......
Fi~73
111l"l u"-t ~n X x 2" bra~..,Fb woodscrcv.-s
tu ""ft''''' lIlt. 'li( ...c111plart' thrClu_gh the hol~
al" acly,hill.-d in Ih, b.lck leg. ~ Fig. 7.
N" 69

f005II1ON
ALONe LAYOUT

UNI

GlUIAN. '---

...~

SCRlWWflH II 1"
WOODSCltrwS

19

CORNER BLOCKS
Imade cc>(llt'r hk,<,k,
10ht o(p ~"
Iht
<'liar ba- l'ul the

Illakt

Glut

AI)

scuw

WfTH II)C 2WOODSC.EWS

h-~

It'lir cnrner blc)rkb

CGI [rum a 2. t
block. 1'Ir-,1. rip Ih,'
2);.1 to a ""'lCltll tIl :,"'

Then

,."'"

$TR.lTCHr.

conE. CORN"
8lOCKON
'RONT $TRfTCHER

'\
)'

a '( tit.....

4)1~5c.'Ul,atro......the
(for more on comer blod<
.. S<'<' p:lgl'

Ill""
t I ) ~'"I. drill I"'" ('OtlnlcI"'unk l'I ,I","k

h(,I, ...",r ""(nw....m t-ach block, St"(~"110:. ,.,

,t()t \THIJ"KK.' Tht"IlRlul' and ~r,\\ the
bIOl'k~ t(' the inside comers or lht' b~I'"'t..
see
"'11-~,.(~inr~ the lower bark bnln';' anlll('(1.
tlu- bark corner blocks will lib.. bl' anllkd.)

OACKLlG

,
"

,
"

CORNER
aLOCK

(,I.,'"THICK}

J1,.* $HANk

rRONT
STRETCHER

HO"
'1-

BACK ASSEMBLY
:\0" it', tune to
REFER'<- I IJ"" \:e:XI. draw two line-,
make 1111.'bock ,tal'
on each QUL,idl' ,Ltt II' fldif.'att>th1,.' location
.,
1I -r ro '1Zi:. F1t'SI, 01 Ib.. other ,.... back brace--. -ee Fig. 10.
rut Ih., dllhl beck Draw'h~ fil"l bn.31ll~ UJI lrom lilt' bottom
slats (H) ~W'..ide of each slat 10indi,'ah' the top edge of the
and 3S , long.' n...n upper back br:oc.(I),....,. !-ill. 1I
soften all lour ro~' Then dra~ the "'t'(,nel hilt, 17 .,."up in)1"
u~i"g .1 \Is" round- the bottom of each .Ial to ",dit-arl tlle lOP
overbh in Ih,'n)llh'r
edge of tile back/arm brace (E). M'~Fig. I I
1)i~,"1J (ll T"IIlE ~IA"'. 1'''lall thv IWII (This refert'II"" li,lt' ,hllulll I", Ic\'d ..rith Ih~
lIuhid,',lal' fi"'t see Fig. 10.Todo thi-, r,"'1 top of the fronl I,g.)
ill'I~Yadl ...-ave 10the back >ide oIlh. 10""r
I~SL\lJ.. l I'I'..-NI' \t t\ tlK.\l.~. :\0"", glue
back brace I~l. lllt-n align tll. ,~'h 10Ih,' and screw lilt UI~"
r b;o..kbra.... lUI 10Lhe
r(;{t'rt'rK:t: Olark$ on lhi~brace, nnd nu ...h back of th~
t'AO (KlI"'lde'" "al. uliJ(l11fl1:il wilh
"ilh Ib, bcollomedl!".
tlle ,..,fer...n('(' bOt,. "'" I'll. 10
\1tt"r (11(" ~t!'are in po:,ition. "I(.'1'l'"'\

Then glu< and

lht111

in ,,1'Kl' from the Ironl. SC'e~ig II

10

SECOND:
AnACH UPPEa
1ACt( lRACE

"'.J'(....

,h........ 1of Ih.,back

,lab to boll, bra...,. "Ir~lIinlllhm' ..itll tlle

THIRD:

BACK SLATS
H)

~
aAtk SlAlS
.tJt( 21.- .))'.-

'NS1AU. RlMAINiNC SLAt'S

~.._,..,.

"" .~

n(t"ftf)('. nw-k ...on the braces, ~"'I'is:' IC)

lI\'1\. \It'l IJR\(E. Then the ba.:k/arm

,I.",

b rae, (E)" sere.. ,'<1 to the back

driv
jnl-:Illt'S(Tl'\\,fr()m thefront oi the-chair Te

I~K""':lI\
the po-uion or~SCI'("'"

hc,lt .....li,...,1

ll'lU"lorll,,' rd.rt'J'(,(, lines from til. ba,'k (lr

Ih,1....'\t IUJl sid..slats around to the (runt \lrilh
a -qu.m- ",,'1-111. I ia.
'1111'11make a second I\'.lrrenc~ mark '1'1,,"
dllwn irom Ih,' lines you jusl transfern-d,

:"0....connect Ih('~l'A:'Cond re(erl"n.., mark ..

with it pt'm'illinC'across the front C.(tlll' ..JOtI....,
~.xt,frum the frnnt of I!", chair. drill ,I
......
.,;( ...o( .....
(JUntt."f'Unk -mank ho1t, 'tn l}l.'"
lint". t"t'ntl nngtht' holt."on th .......idlh of ("3('}1
,Iat FinaUl. altach the back farm b",,,, IE)
bc-hind Ih,' ,Ial" -c.......ing lrum tll., I....nl

11
lACK
SLAT

--'"""'>I
\

301,.
tACK/AAM

IRACI

(0
LOWER
\ &Act(

_!tAo.

fiRST:
A""eH oursm

IAOC stATS-

NOTt:
fOURTH:
AnA-CH &ltrK/ AlM
UAct(Sllnc;.11,

!)

20

OW1ANOSCUW
AlL su,TS 10 IAACU
WfTK " ._

NtH'.
1.1.0<1(

WOOOSC~

No. (>\)

SEAT SLATS
Now it's time for the.'
scat slats (I). First,

12

fRONT

rill six ~lal~2~"

wide, and one slat
2\.'1" wide. O~11this

','

SEAT SLATS

II x 11~WOOD SC:It.EWS

SPACtH

.G\

last sial 10 fil later.)

To determine

UG
SECOND
$1.Al

the

length of Ihe slats.

add 1 \.':!"IO the width
of the base, for a:>r" overhang at ,'adl end.
ROtl1 3 ~/~"round-over-on ahe' rdg('$.. (A t,:!"
round-over on the frnnt edgcofthe first slat.)
seRE\\

'AC~
UG

HOI..ES.New drill countersunk

shank holes centered on the "idtl. 01each

slat.and l ~'t ITOln the ends, see Fig. 12.
Also drill countersunk shank holt's alonl!
the (ront edge of the firsl sIal where il attache 10the lront sm-rchcr, M~ Fig. 12::1,

InwtIH
fRONTUGS

,"aOUNOo

GWEAND SCREW SEAT

SlAJS re BACK UGS WITH
fa \'.- rho WOOD SCJlWS

l'

2~i~~

16- aMi.
BACK LtG

ARM ASSEMBLY
'The last step is to
add the arms and

arm supports. First

cut the two ann
supports (1) to final

13

_2':_J

angle on the suppons. see 11g.13.Now round OVerflll1il the

outsideandbottomedgesof the supports,
Next, center the ann supports 011 U\(:!outside of the trent legs and drill countersunk
"bank hole, from the inside. see Fig. l:l.
111~nIllu" and screw the suupcrts in pl1CC.
AJ{)IS. Cui the IWo arms (I<) 10 shape as
shown in the drawing on page 17.l'ext chill
countersunk shank holes forlh(' S('l'{'\\"S Ihal
attach the arms 10the legs. see Fig. II. Then
round over all [he edg~of both arms.
To attach the arms, first spread adhesive
on the [Oi' of lite front te~, arm support. and
back/arm brace. Theil screw the arm to the
front leg and arm SUI>porI.. see Fig. 16.
Now adjust the "tilt" of rhe back slats se
the back end of the arm is nush with the rear
edge' o( the back/am! b race. Clamp the ann
in place. thendrill and screw ltto the bark/ann
support from undemeaih.see F,g. 15.
Hi\1)I1 '5 8.\CKsuers, Finally. lay out and
cut the 16"radius arc on the lOPends olthe

bock SI31$.see Explod<'d view on page 17. I

used a beam compass (set' page 22) 10 lay
out the arc. and a sabre saw 10make the cut

14

f
I'

. ,.

".

length (S") and

widih (2711<"). Then
lay out and cut till'

OvtRON
FIRST SLAT

NOTE:

OACK SUoT

CUT 1.A$T
StATfO fIT
\
'." SPACtR
NOTCHSKOND
SlAT ATANOl! ~
,
....
TO FIT AltOUND "l
i j....._~'
fRONTltG
$ATSlAT1.1
.t

~ ,,; cer re rn

f1{O'T1WO ~I,\TS. CUI Ih(' first <laI 10 fil

between the front legs, Then cut 8 notch in

the second sial where il IIW(iIS the (roolleg.

~"1! tig. 12.
5P,\CRSsnuf'S. Now installthe slats, sepalflling them with 11..'* spacers, Bevel rip the
last sial so it fltsflush against the lower-edge
oitht back slats, see Fig. 12b.

_,..

:.-{b.

..... \1..,"

....

'"
ARM

-~

I,'

0'

ROVND-OVPt

ARM
SUPPORT

FRONTlfG
I

....

ROUNO"()VfR

fRO,," UG

T'
\

a8 x 2"
WOOD
SCREWS

15

;/

C-CLAMP

UCk S1.AT
~~

fiRST,

"

GLUEAND StREW

l\aMA'FRONT
SCAlWS

~~

"-

SECOND:

ClAMP SACK NO RUSH

W1l1i aACt(/.A..RM BRACE

(refer to Fig. 8 onpaze 28).

W,,(ldsmtth

11

S II lJ

PR()JECT

Beam Compass
T

I ,:-;,,11 tht grain directlon 1111'blank r-,

SIll<

II"

of hardwood. And to dress il up. I used bra"

wid.,rthan il is long,)
I),U,O. Af\t'r the blank i~
fut In ...j/. rout a
t ',dt~,p dado '!LTt'" tlu- blank. \\lten lit.

machine

blank ., cut 10"il~and 11u.'t""c, 1laC'l$of lbl

Ilit",'" ,uf ..... ick t'\\o 11lnh,;tlinJ: Ilil"\'("'S to~l tilt r I -mp -rarilywith dlJuhlt,j(il-d carpel

tm.01111')point art' xrt"\\l"Ci

L'Ipt.

ot,ra\\' thearrxfur Ihe .\llirund.u:k fur

niture in thi .. j.....U(. I made an Ilcl
ju...l~lbl(:'beam ('onlJ)a~, nul r,r some scrops
~fP\\-~and

knurk-d finger nut ...

(n""...outs are a\-ailab({,III many hardware

"00

I""

t('R~ther, the

"1(lrf'S..
can at..., order them through
1\ o"'/Jmlltit Pro)ect,~.'lpllr ,"'"
31 )
\10'" of the work on Ih~ bt-amcompass j ....
In lIlilkinllthe tw.)tr;unmd heads Oneofthv
trammel heads hold, n ,h"I1H.'nl"rpoim (a
CIII"rrnail), and IhNltllI'r hlll.ba I'('ncillt'ad

dad"," r.. no motti", Ihal pulCh", around

.",'hit'k beam, ro rout th., dado.Lu-a-d
a I ,lr3ighl bit, ,...., f'lI: la
1'1'(.111'(; ACTIO' .1\) cr ..atl' tht 1}lnt'hulI:
ac:ljcln.till' top in..id(_ portion r t'd~'htram-

tor marltil1g.

biltt/lill part. So I trimmed I~" on the

widt, ~-'Clic'l1 of the blank. ~., ~I,t! :!

"""e

CITOlT 111,\.'1(.Allor Ih., pit"'''' lor

both

trammel hf"ads an- rut (ruin one blank. 't

t"

mel head has 10 be" lilll"lhinn.'r

than lilt

,,"

( , 'llU 'lZE. ~(Xt.tUIIht blank Into tour

~i~,
I To make th., blank. rc-aw a pia:. of .-quaI-.izt' (1 ;4" ""i<l<') I_t" on tht Llb1c
<lock to ~. thick 111n1rut .t to a ~".
"''',t('t: ~i!!,3.Shopnp:loS3fel) "",blh,
width of 6" and final length of2t'z", see ~i~,
'111111PIl't'."i thrnUl(h Iltl blade, 1 made a

block trom a :~,I

<

(I'(;r

I... I)ush block, "'t'I"I('

In"re on

1U

~11(I< IIMVF,ST(Wf11I1~, \\,ilh lilt' four

1-1 .$, This

S("(

n.-J1:,h(":!l"sen \\ hcle-,

mllC"'N an bolll

pN-c._'C""!!o

"",.1( "neue..

k t ...}'OU n11

finger

lilt>

and d(,,(,1 )rali\l.'l.""OfTk'f'

at Ih(" ....ame tune.

:\0" you can drill the

~1-nt-!'llaPt--d fu12t rnt;llll\.":-._10 hold th~
1"<"('''; .. hil.' drilling, I buill a ,i01I'I.'jill, S('('

('1',

I'IK.S, 11u-JiJlconsislsoftour:v,",lhirkdeals
n,I.I"'cll(, OJ IJi),":oOO base,
()'Il"l IJ't'jig is buill. "-t" Ih"I,llk'd 'I'J.L!t"ll1tr
lrd.fllnK"1ht'adsinlolh('jig and 'L~.11"ForstRI'I' blr te dnll the ung''T'HlICh"
lhe fioj!<'r
l1Q({hl"S ~ OW}",~" ....id( (:at the bottom ot
thccurve), <;,Q position tht" \ I nterpomt 01 the

C::::;::IP "NCt

A,

<

av.o.
I.IMI~:I

or, fOP
TOO'

hot

PU'S)f

Iloa:

~~~h-

POWnON
Of llANO
'-

1--' I.......I.

..

"

CUT BlANK
INfO FOUR

1'.-W1M

Net$

CARPrJ

''''''

lOCfmta..
mtN Tlltt.'\

''''''

'lU~

'u
THROU(j:H

DRIll
HOtt

...

10THPlKU

, ..

..

"

WA$lt

',"

drill bil %" from the edge of the workpiece,

see Fig. S.While the pieces are in th~j~.also
drill two ~ holes for the machine screws,
refer to Fig. 4
MrrER E!<IJS. To dress up the trammel
heads.Ilaid 011145'miters at all four corners,
see l'i~. 4. and cUIthem off with n band saw,

1- FORSTNER alT

SECOND:
ORIU "211-

DRIUING JIG

S(ItW

HOU:S

NAIl. CLEAtS
TO lASl

sec Fig. 6. (file pieces are 100 small to CUI

safely on a table saw.) Cui a lillie outside the

layout lines, and sand or file up to the lines.
CIIA"t"F.R. '<ow pull the pieces apan and
rout a slighl chamfer around the uutside

PLYWOOD
""Sf

edzes, seel:'ig. 7. (Formorecn routing small

pieces, see page 15.)
ENlARGE SCREW HOLES.

Before reassem-

bling the trammel head with screws. enlarge

lite holes in Ihe/runt pier, only so the machine screws slide easily Uu'Oughthe holes.
<CC fIR. 7. (Nole:The holes in the back piece
are smaller SO the threads will catch and the
screw won't spin when the knurled linller
nut is tightened}
~\SSE\{BL'. Now tile pieces can be assembled with No. 6-32 x 1" roundhead machine screws, washers. and knurled r.ng~r
nuts, (Youcould also use wing nuts.)
POLVTAND LEAll. Allerthe trammel head.
are screwed together. drill a "so" hole on the

bottom oreach head

10 accept

tOP

~l.

HOLt-

THROUGH
fJtONT
PJECONl'l'

COttNtw,S

WASH[t

ROUT \"6-

CARPlt tAM-

CHAMf[RON
OUTSlM lOGES

You can cut off a 4(t box nail :L~

a centerpoint. see I-ig. 9, or we can supply a chrome

mel head I stuck a short pice e of 6U drafling

pencillead thai Igot from an art supply store.
Once the trammel heads are
complete.cut the beam to width from a piece
of hardwood so il slidessmoothlyln the mertises, see Fig. 9. Finally. I cut the beam to a
length "f 18" so I could strike the 16" arc I
needed for Ihe Adirondack furniture.
Before finishing the compass with lung
oil, you may want to drill a hole alone end of
UIC beam. see fig. 9. This
hole
lets you Ilang

BAC)( Paret

.s
..nt.

a centerpoim

centerpoint, see pallt' 31. In the other tram-

"'AW>
.,,32)( .MACHINE:
KIU'W INTO

RtDRIll

or pencit lead.see ~lg.S.

lAC)( PIlel

"'NDSAW

-DRlUPAtSS

HI"''''.

CUT HAM TO

SlJO( FRERY

SECOND:
DRUl " ....
HOI.[ fOR

lfAD AND
(ENJERPO(NT

FIRST:
T~~'"

o~=':~=y

~~~~~

tUl 4d lOX NAJl

~=============~~=========:'0='.:LON=G==~L,

the beam compass on thcwaIlOfYOU~r:slt:o:p~.

USING A BEAM COMPASS

AitcrthcBeam Compass isbuilt,

if. ready to be used for dmwin,(l
arcs and circles, On the Adirl)ndack furniture, I wanted the arc
to have a 16"radius.
SP.I'111E CO\!PASS. To set the
Beam Compass, ftr<1 mark two
lines 16" apart on a scrap board.
Nov.' move the rent erpoi 11' trammel head III one end o(thelleam
and pesition the point on one
tint'. Then lighten it in place.
Next. move the l11nrkin!1 trammel head until the lead point
aligns with the other line and
light~ il in place.

No. 69

the compassset, place the cemerpeintin

positlonon Uleworkpiece, Then.
$\\ing !he marking head to draw
ORAWAl~ARC. \\lth

SWING MARKINO

HAD TO DRAW AN ARC

an arc.
only
one problem when doing this on
the Adirondack furniture -the
centerpoint of the net: falls in a
j,rap between IWO Qfthe slats,
To solve Ihe problem. I made
a "bridge" to push the centerpoint into. The bridge is just a
thin piece of scrap held in place
over the gap with double-sided
MAKE A RRII)(;E. There's

carpet tape, see rig. lao

W<l(xl:;mnh

S[fCOMPASS
TO DISIANCl,
'1

OESlRto

112.i

CARPET
tAPt

ClNTIRPOtNT

HlAO

23

OUT

0 0 R

PROJECT

Adirondack Settee
T

hi~ ~lll't. i~II oj,l\ version of thv

I\dironda~k .-1",1( -hown on p<Ig< !Ii,
On many proje('I' "hl'lI you 'Ian chan).';og
till' ~I/'(' of one or two parts, it 1111'Sa dir(l('l
I'f"~ton other part, l',in~' 'Ian I""kin!:
CI\II

,.f proportionorpieces\\

11n',

fill~th('r

lIul Ibi, s<'ll<'"i, diff.'r<nt By adding

,~ht more back '~'I' and a c< nter suppon.
and nlakinga few pk"Ct S)4,ng"'f'.lht'\itair(t>r
one can become 8 ~tlc"tlclr1\\0

10 build the

,,tI,'. jU,t

folio.. the av
"'n,bly mstrucuon-, lor Ih. Adirondack
r hair (pagt~16lu21I. amI milk" Il,. (ollow
inJ,Cchanges,
{E'TER 5l PPOHT, rhe only additional

,,,n "",-cicci tor the ....11"' (tha!', not on th~

chair) is the center ,uppon (L).....fer 10

hI! 3. It's ju,;t a <hoJJll(-d<>ff
.(I",ion of on e
,,( the back I~ ~...)

I "lade the center "UpJ1(lr1 ri,Rhtafter cut

linfo(nul Ihe back 1'"1:' h~'Ji:.18). SIan by
rutlillJ[ a blank Irom a 1.1\ '" a lenJi:\hof 18",
Then lay one o(lIw back I,'gs 00 the blallk
'" III<'bottom t'dJ:('" an' flush. see fifo(,I
.,\,,,, trace the curved lop ~dl!~ and th~
unzled from end from Ih,' back kt: onto th, ter Ji.U)lpon{lJ. The bat k (-d~of the cc !III"' 'nlnl oj the from stretcher leI and Ih.. back
blank (CUIthe lop and fronl..!g" 00". bUI "U~Ir1 i~rul at a ~1.) nngl(" fI, fit :u,,'3.ln...t the ollin I"" er back b,.",c" (1)...." hR.:1 Then
wa '1 I', mark and CUi on Ihl' back end until 10".... back brae e el)
glUt nod -crew the center ""t1Itl)()rt In pIact. .
all~r the base is as....mbled.)
I odothi -. lay out n nutrk (. Ir lh. bot<.:kc11J.!" \:->0'.': when lbe scat ,I~I' III', dddl-d. make
I , 1 tor" tmm the fronl bt,ttllnl f,'CJnll'r,'\('\'I-Ij.
W:O<GERPI~:C~:S.All (,r the P'CCCSthat run
~Urt tu screw them rothe 1111'I" tlll.)t."K,,,,,,J
horizontally have 10 ~ made longer than on 2, UUIIdidn't cut ilon Ih" lilli' "I first (111il tIll' lop enhe center S1l1l'~jn.)
Ill(' Adirundack chair, bUI they're still the alitll. 1(111~ancltt ..t lit In till' 1);,,,,, If jt ~ IUllf.{,
nacx, A~S('mbletill' r~<II'( tl\(' settee the
trim elff a lillJ~,sn\-..;tkin.: up 1.11thvfinal fit.
<:l"'t thickn e " and ";el1h, Wh e n cutlin,c! the
-..un(' "ay as til<: Chair TIk' onl)' Illanlll' is 10
\\ lit. n tllf center ~Ur)l"lrtIii mount it by Ctl, a doubl. an: on the oo.'k.... ,' I""', \ -k'" I
trent """leher (C). b.Kk braee, <D.E.Fl.
and ,cal sIal' tI) -"("r 10 Ihe long ..r dnlr II)! t\\(,.._""tKJntt: ,....\Ulk 111.1, tbroU~'1 IlK- u-.cda"3l>r..:;awIO('U1 b"lh It;" rddiIDoa,rc,.
mt"3~uremeo(~
in
Ih~ malcrials Ii", un
3
~o
1 uS( 1AC1CUG "
III\,' clpposite pal(c
IACJCJAL'4
UHlI ... CIC
l~'AnfJtH
(illt a~ alwa)s. ('til
....a
'.ACt

II... "i",("\ lU fil.)

Sine .. tlt~seliN'
ha ... twice as ntany
bark ,tats (16) OL'th,'

chair. )'tlU ..ill n,,,-d

10 Ulark and drill
nlt.rt!' holes in thc"
upper and low.r
bill'k bra(:'cs. -t{""
delaildra\\ingon th,
OWO"tC pug ..

CENTER
SUPPORT..

BLANK

ItO

AUGN stATS
wrTH LAYOUT

UHES ON

aut(

II
oms Of
lRACI

2J

A"t'mble the ba'

(olio" 1011lbe sam.

TO'" IETW'U.N
fOOHI STltfrCHU

24

f.&~W
i:I'

l!>

fRONT

(QUAl

r "an CUT SUGKnY

Chaor (page. I ~ 10
19), After the ba ... i,
asS(mblt'd. you can
11"1 bllck to th.. cen

...(jJ

ovtIIW<G
OHIO'"

liT ,\~ I) MOl ST

l ~'ITER Sl:PPORT.

lmx ..'tIure3'()n Iht'

..;j

@
lACK
llG

OV(IUl1[O, THIN ftUt\

fOOHT

SltCTCHU

IoHO LowtJt
aAocau.Q
SIT 1(Vf(
OAUG(

,G

AT.S

COI:NfI

'LOCK

:':".69

PLAN VIEW

OVERAll

52'/4" W " 38~'4"H

DIMENSIONS:

SACK
SLAT

fRONT VIEW

SIDE VIEW
(CROSSS[CTION,

~nr~~~~nl~~"~~nL/
I.'~l'-i~rt

I.".

~~ "~1,&,.
-@
-@
1-- BACK LEG
-'-_-;- __

@
BACK

l CENTER SUPPORT

CORNER
.J._ ."-"" BLOCKS

,,

CD

LOWER
BACK BRACE

BACK
1." SPAa
anwtEN SlATS
SLAT
.2:11," ,..,..
__

II

r.-~'
:---===~9~
-I- "

I,....

17'.....

41.1.-

LOWER
BACK BRACE

LEG

ARM

LEG

CD

FRONT

BACK/ARM
BRACE

@-

SEAT
SLAT

ARM

i.5i==;:>'-r

II -"t--....r.... ~FRONT~STRETCHER,....

~~'--".

<D

SUPPORT

ARM

<!. LOWER

, .I

.I

SKAN"t-tOLES
COUNTERSUNK
"." DfEP

BACK BRACE

--

.
"i
-,

CINTER
SHANKHOUS
ON SLATS

CUnlNG DIAGRAM

MATERIALS
WOOD PARTS
A. BockLflQ$(2)
B F.onlLflQ$(2)

'1'. x6~36t;.
l'3~" 22

C FronIStrefcheI)

-\0' ,111,43'-','

D UPP8rBockBtoce(I)~.x2~"'.'
E Bock/ArmBroce(l) ~.x2~"454<.'
f Lowe<Bock8toce(1)~x5~41.
G Comet Blocks (4)
H:!"tnlck stOCk
H BockSlofs(16)
~ x2~35~

I 5801SIolsO}
J Arm SupportS(2)

..

~,

,I .

II

~.-~~~------~--------------------~".----------

I'

UPPER
BACK
BRACE

BACK
SLAT

UPPER BACK
BRACE

'vi"

37" D

~ X2~ 44'1',"
% .2" 8

F..

tS~3".".'

A
"' 3"

l.....x 5t," 96- {4 Bd.Fl.'

:1;

_-:;>7,>

.:nZltt,..-/~zz,-.pn?Zitt>lil

K Arms(2}
-\o'.x5~28
l Center$vpport(l)
6~18rgh.
'loogerlhon AdirondackChelr

~ .5",-96'" (4 Bd.A.)

sUPPUEs

~." x 51, 72" (four 6oord.e 3 lei. ft. loch.)

'

"

(102)No.8x l'/' bross Fh1lIQOdscr8WS.

(32)No. 8.2' blossFhwoodsclews.
(1) lube woterptool construcuon
adheslve (see
(I)

quon

spot

page 29).

varnish/lung 011 combl,

nalion, 01 paint (see

No. 69

page 29)

\'iloodsmifh

25

OUTDOOR

PROJECT

Patio Table

Az

building th" ,\dirondack Chrur

and Settee, I decided to complete th.
M't by building a -mall patio table, Lik~the
Chair and Seuee, th,' tabl~ i~
built using
,iml.lr glue and screw jOim'ry.
111e assembly pmc.-du re for the slats and
the cutting procedure lor the arcs is aI,.,., the
<arne as on the oth~ t,,"11 "",j!:;..
Uk". The actual buildin~ III !hi. table is
WirI) ('asy. The tricky part '''C' making the
1<:11'look right, I "ant"" them to appear
,turdy - ...ithout u>ingthick stock, (All o(
the' stock (or the Chair, So>!t"",and Table b
N," thick. except for the comer blocks,)
To do this, ] cut the It,'g, 3~'lwide and
-crew ,'<1 them to the out,ide 01the apron",
Because they're thiv wide, wben they'",
,", .. ed from the sidt' )'00 gt!theimpres,ion
tltatthey're made lrom thi<k stock-maybe
from a 4x4 Of COUl"", when the tab]" is
viewed from the end you can seethey're not
Il,at thick. But when ,1rerchers are added

between the 1.8s, tlw)"re strong enough to once 3l(ain, you could u$<'I.in<,and
ea,iI, support the tabl,' without any racking. paint the tableto match tl...oth,'r IWO pieces.
\\0()0 AND SCRf\\,.] built the table from
To avoid rust stains on tIlt' table. I used
d"..,. all heart redwood (not construction bra", screws and ceunu rsunk them >li~htl)'
grade) to match the Chair and Settee. But bdo .. tile <urface.

MATERIALS

~l"'fI.Finally. r fini'h,'d tl1l' redwood

lable with two coats 01. rIO/50 mixture 01
lunll oil and spar varnish (For more on finj,hif1ll and painting outdoor furniture. see
Talkon~ShOP.page 29.)

EXPLODED VIEW

WOOD PARTS
A leg>(4)

00

OVERAll DIMENSIONS:

'lo, x3~ 15\1.

bx3\;31
~'x3l?17~.
~.x3\;17"',

B SodeApfons(2)
C End Al)tons (2)

SlrelcN!B (2)
E lopSials(8)
F CIeots(2)
G Comer 8Ioc1a (41

203."W"46'."l,,

TOP

16"H~

SLATS

CLEAT

~ 2l>47

~.x219h

,0

I'll' StOCl<

CORNER

SUPPLIES
(32) No 8 x 1'I,' bloss Fhwoodscrews
(2A) No. 8 x 2' oross Fnwoodscr"""

BLOCKS

CLEAT

CUnlNG DIAGRAM
.I

71......

(2.614.

".J

."

LEG

,I'
StOE
APRON
'c'

I,...41(1.., ...,

~.... S

E..
26

.::~'"'

2 Id. ft. (~1

-@
STltETCHER

Woochmllh

LEG

1'0.69

LEGS & SIDE APRONS

Istarted building the
labl~ by making two

aprons (B) 31rl" wide and 31" long.

SCR.EWHOLES.After all of the edges are

rounded over. the next step is to drill counside units, Each side !'i7.c. I sanded a Jt2" radius on the bottom tersunk t6"-diametcr shank holes 011 the
unit consists of two comers of the legs to belp prevent the inside foce of the side aprons (B) near the
legs connected with comers from chipping i( the lable is dragged ends. see ~;g.
3.
a side apron. see fiR along a rough surface, (Shop Tap: To mark
ASSEMBLY. Now. the side unils can be as1. Later. tbe side
the !'z0' radius. trace around aquarterheld at sembled. I glued and screwed them tounits are connected the bottom comer of the leg. SEe Fig. 2.)
gether using construction adhesive and No.
with end aprons to
ROtrNDO\"ER Ef)Gf.s.
.. Next, rout a ~'.
S xlV, flathead brass woodscrews. see
fonn the base ofthe table. refer 10Fig. 5.
round-over on all four edges 01the legs and TalkingShop. page 29. Position the topedge
CL'TI'IECESTOSIZE.To make a side unit, aprons, and un the bottom end 01 the legs. onhe apron Dush 10the top of each leg. and
start bycuUing the (our!egs (A) toa width of sec ~;g.
23. (Xote: Don't round over D." lops keep the ends 01 the apron I" from the our3W' and length 0(15\1,". Then cui two side of the legs or the ends of the apron s.)
side edge of each leg. see Fig. I.

SIDE
APRON

AUOH Slot APStON

fLUSHWITHTOll,

RAOll'S t.E(.iS. Aft(:r the pieces Y..ere cut to

3'-

2
UG

"

(NOSOf/

aonoNi
\

_ ~

~~..__;i'

ONI01K'

J t

QUARTtR
(I,..RADIUS)

SOUAlt.
UGSfO
...... 010

OfFSET

O.

(N,DS~
......

8)(11/...
BRASS

1,._

A"ONSOR
TOPS OF-LG$

rh.

WOOOSc.REW

OVLRlNOSOf

Once the side units

are completed. they
ca n be connected
with end aprons and
stretchers.
ClJIT()slzE.8cgjn
by CUlling two end
aprons (e) and two
stretcher.l(D) 10the
same size. 3Vz" x 1'At.". see Figs. 4 and 6.
Next. round over the edges (but nOIthe
ends) of the aprons and stretchers with a \Is"
round-over bit,
SCREWON API\ONS. Now the end aprons

APRON

DONO'.OUNO

@
LG-

1,.,-

..ROUND-

NOTE:
J~t,.

$WE

OVER an

....

COUNTtRStNK

can be glued and screwed to the ends of the

side aprons. To do this. first drill two countersunk shank boles ncar each end of the
end aprons (C). see I;g. ,Ia.
Then begin assembly by laying one of'the
side units on its side. see Fig. 4. S<'l'CW One
end apron (e) to the end of Ille side apron
with No.8 x 2" brass woodscrews and conslruclionadhesive.eh'..,kth"tthepi~'Cesare
Hushacrossthetop. Then screw another end
apron 10 the opposite end of the side unit
Nowstand up both side units. apply adhesive. and clamp them together. sec Fig. 5.
Check thai the aprons are Hush across tlie

lop. and that the base of the table is square.

Then theserewscan be tighlened into place.
,\DDSTItP.l'CHER.After
the legs and apron,
are screwed together, the stretchers (0) can
be added. Start by drilling countersunk
shank holes I V!' and 7" up from the bottom
of each leg. see Fig. 6. Center the holes on
die width ot the leg.
Then glue and clamp the stretchers between the legs so the bono", edge is 4" up
from the bouom of the legs. and the
stretcher is centered on the width of the
legs. Finally. screw the legs to the stretchers
with No. 8x 2" nathead brass wood screws.

o.

END

AP~ON

IND
_ON

, J: .t
/~
.u-"""""""
(

."

.a Jt 2'" auss
fh.WOOOKJtfWS

No. 69

APItON

'1,-

afI'WUHUGs
SCltOWS

COUNttRSUNtC

~SH.ANK

_).
{. J

CI..AMP"INO

HOUS

"-

STRETCHER

NOTE:
APRONS SHOULD

t.l-fLUSM ACROSS TOP

Woodsrnuh

27

TOP
AIt.'r tho table base H~II". -ce Fig. 7. Then, round over all ofthc
i,complete. the top ,d~.'s o[these with a LI<"round ...ver as w ell.
(.mlx- mad" 1061on
Ill" dra'" are screwed hi OICbouom of
Ih,' ba,,. The rop tht' ...L.ll'!'o_ To do thi-, fa r-,, drill ' JII' counterlCNl~~~ of eight top
'\Jnk..;.hankho~ ceutered on the \\idlh oi
,lals (E) held 1<>- the ck-al'" al 1m- Iocati"n ... -hown U\ rig. ;
llNh<'f by two c1,-ah (111,.... hok location' "ill ,','nt, r the ><.-re\\"
(~) la""n~ under- on the ,lab.)
nt'il1h.
t.1l"- "~C'n''EE'\s'-,'!'. 'Ill<' -lats an: posi.
ti4)nl'(1
with Vii' gal)s bvtwr-cn them. To
'1;\1'. Start by l'UttJl1Il'til., "'lIhl top slats
(~:) from :1-\,"llIkk't<>rk to a width 01~ ,_"
Ul(J 1('I1R(hof47"."-t'C flu i
1'0 "-(}ft{"fl the edges (,f tile ...Iat .., I rounded
all Sflured~c."$~irha~ round-ovc rbitonthc
TOUkr

Llble.

"eXI.<'UII"o .-1(>3('1') from ~,.

thit:~ ,to..-k 1(1a .. idlh lIt 2' and length oi
(I.I-_\l'.

[7J ~)

centered on the length of II", l"bll'IOp. refer

10Fill. 10.Then position II",
~(I,.
(Jill.
.'flt th" J(.g.., onboth ('I,d,
.>.lIuth~clealsareC<n ... n-d on the k-11JIih
ot the llIbk-IQP. center them on the .. idth of
Ih.lnp..., there's an ",,'nu"'rhanR on both
"ici,",. ~ Fig. 7.
'iCR.l'\' TOc.ETHER. \I'htn lilt location of
the dl'al, is determined, wn-w II", ch-ats 10
crvau- unlfenn gal)S clurin)t ~t...~mbl). I tlu- ,lab with No.8 xlV, flmlwad brass
placvd ~Ithick SIl:I<:<'I'"bt I"''''n the slats ,"CMKI""l're~'~,see "'~ig,7n.
and clamped the ....:heJI,a' .....IT1bl)together
I<.'UII , EXDS.Once the lup i,.'.....
mbled,
\\ ilh ;XI>t"clamps, ~. l:i.:.7
Ia~(Ill! .11ti '-radius an: on ,a'11 "od. centered
I'<hmo' <.1\'1'.. '0" Ih, d. ill>. can Ix- un 111, '. idth of the Llbl,' 111,11rut the am;
p)siliont-d on top oJ th, lat....~ ..Fig 7. '1'0 ..ith a -ab re ""''''. see Fig x, ~"",Uy.souen
determine where (0 po ili()l1 the cleats, $("1 Ihe ,'tl~c","
the ends o! lh. ,''", with a filt.

11,.-

TOP
~
SLATS :-<;<~_~

....._A-e
-,

e
CLEAT

'\

..

ill

CUA'

~
4

.69,."
19:1..-

........

NOTE:
lOCAl( ....

.,. 10'.-

CINnR

UHrON
llHGTH
OI'TOI'

><

>0>,'

O.

d.."

l_

SPAcm

...
2' ....

1."',,*,,

"

...

.. -

11 '

,.a,.

IIII' ba.... upside down on the slats so it's

NOTE!

2"

.nucvnINO ..
SOfltH TOPAND

aono.lOGfS
WI'TH .....

.,. I'.
.!tASS Ib.

1"'" I.-

WOOOSCAWS

r_2),-_ ...

----

,,SPACD.

CORNER BLOCKS
final step in (lssrmblinj! Ihl' Illble is 10
add the four comt'r bl",k,. '1,<'<e blocks
I'TeVt'ntthc ba<c frum r.,kinR and pnMd~ a
m,'an, (or~inlt
th, trop10the base.
(I T TO SiZE. TIlt lrian~larshapto;j
<'t,mer blocks (G) an: cui from a kngth 01
2. t. ,~.. Fig. 9. (!'\uIC. For more aboul
making Ihe com"r bkx:k, .... .., Shop )\;01",.

II'r~unk 'IIII'!
~hnnkhlJl('~in c.'arhblock. sec.'
1';1(. !Ja. 'Ille firsllwo hoi,, are drillt'd in the
l<log,-dR. of the rom ..r bl""k and arc uSt'd
tu "",,"w the bltJ<:
k 10Ih. ubi.. b."._.
Ill, "Ih"r hoI.. i<drilktl thn.ulth the fac..
ollh. <-urnerblock for mounlinR Ih.. top.
'TTI{II BI.Ot.K;' Aft"r Ih .. hole. are
drillt-rl. Ih. block. can bt Illued C"ilh ron-

1"1)(" 14.)

~tnlt'tionadll~si\'t")and ;(.:r(iv.t;'dit~place to
tht insi(lc of Olt' lab),' ba!'.(with No.8 x 2"
nalh"ad brass woodscn:w s, .. ~. l'iJl. \I.

TIle

blocks are
l'UIIOsU:c.lllenext swpis todrilllhreecoun
UI<IIJ.HOI.S, Afl"r Iht'l'urner

til. lOp. I
fini<lwdit "ith a lung oil/'I",r varnish (om
binalion. (For mon' on fini,hinll. S('CTalk
inJl Shop. page 29.)
\TTIOITOP.Qncethcfini,h dri.., Ihetop
(3Il1x- mountt'd 10the ba,,. Tn d.. thi'.lum
Ihe IUP up-ide daViDand IM.-.i!i''''Ihe base
P'N'SII.

Bdore' atlat'hing

iklWt"'fo thl'clt*als

0;0 lh('

ba~' i..l't'nt('Tl>don

Ihe w,dlh of Ihe lOp. S('t. Fi,lt'.to. l1,en dri\'~

~:()()(l~'r(.'w~
Ihrough ear), ,"(.n'(:r b10ckand

inlo the lOp.S('(' fig. lOa.

SCIUWCORN8

CORNER
SLOCKS

ROCKS RUSH
wrTK lOP Of

UCS ......

I(UTROM.

APRONS

NOTE:
aN1'(1 IA.SI
OM WIDTH OJ
TAIUTOP

a-

CROSS SECTION
'1

lit

I.ASS rh.

WOODSCUW

.1.,..

.-

UAS.s nt.
.WOOOo

\!._C1tIWS

11,"

Iu..-~~I

~1.

SHANItHOli

~ il

..

~~

28

Nu.69

COMMENTS

AND

QUESTIONS

Talking Shop
S

ince the Adirondack Furniture in this issue will su outside in thesun and rain.thereare

Once the spar varnish and

lU11R

some special considerations

when building and finishing

these proj<'Ct'.
WOOD
TI',e first thing to consider
is the
choice of wood. Ibuilt the furni-

ture shown on the Caver from

redwood, It's naturally resistant
10

decay. dimensionally stable.

and the heartwood is a beautiful

red-brown color. (I used a "Clear
All Heart" grade redwood.)
But I .I$<) made one chair in the traditional
Adirondack style - built from pine and
painted white (seephotoon the backcover).
There are a number of other good (k",a)"resistanl choices for outdoor furniture including cedar. teak.mahogany .cypress.and
whit. oak. (For more On Ih e se outdoor
woods and screws for outdoor proj,.'cls, sec
II'ood_~",itlrNo. 45.)

GLUE

out. lei it dry overnight and nil it off with a

utility knife or chisel The stulf is incredibly
strong. even on an end grain joinl4
SCRh'~>i.The adhesive is probably strong

enough to use without screws, but it'seasier

to assemble many projects with screws as
well as adhesive. I assembled the redwood
furniture with brass screws and countersunk allof the screw VI." below tI,C surface.
The brass and redwood colors seem to work
welltogether,

In 1I'()(I(/,mil/, 1'(0.45 we also talked about

FILLER
outdoor glues. At that poim we recommended using plastic resin. epoxy. or yellow Since I waspaintingthe pincchalr.I counterglll(' based upon the kind of wood you're bored the screws l;g" deep on this chair and
usulg and theweatherconditions tll(" project filk'<i the holes with Minwax's High Perwill be exposedro,
formance Wood Filler, see Sources. page 31.
COSSTRIICTtON AfllI!;SIVE. 111is time I It's specially-made (or outdoor use so it's
tried something different and was surprised water and rOI resistant and won't shrink or
by th( results. I used standard exterior con- rail 0111. It also lakes paint easily and can bt
struction adhesive that comes in a tube. It's planed or sanded after it has dried 30
used inthe building indu>uyforgluingdt't"k minutes,
ing to floor joists and paneling 10 walls.
This filler "ames in two pans: a beigeThis adhesive is sold in tubes thlll fit a colored polyester resin in a can and a small
standard caulking gun. I buy it at a local lube o(while hardener, When you mix the
horne center for S2.2!1 a tube. and one tube IWO parts toge,ther (in tile plastic tid prowas enough 10 do nil of tile Adirondack fur- vided) you hav(' about 10 minutes working
niture in this issue. There an: 3 number of time, so don"( mix up any more than you will
different hrandsavailable, but look for aiube need. (Follow the directions t.ractly.)
of adhesive that's both warerproot and deFINISHES
signed [or wood.
JOI"l\TllN"E. '\'00" construction adhe-sive For the redwood fumiture Iwas looking (or
leave a thick joint liRe? No. and you don't a satin finish that wouldn't build up, but
have IIIspread it outas you would ",h.1I using would still offer protection outdoors. I also
yellow glue. Usc a new tube and cut a W' wanted something that would soak into the
hole in the nozzle of the lube. The adhesive soft redwood and be easy to apply LO the
should be creamy. about like toothpaste. small spaces between the slats,
Run a small bead ordots on one of 111('pil'CCS CO~fBL'IATlON "tSISIl. To get what r
10be joined, sUlyingabout l/4" from the lodge. wamed, I made a mixture of sor.McCloskcys
Then. when (he pieces are Squeezed to- Man O' \Var Satin Spar Varnish and SIn.
gether, the glue will spread OUIover the en- McCloskey's Slain Controller & Wood
tire joint area leaving a nice. thin ioint line.
Sealer. CTbisisa thinned down tungoi!.) For
If some of the adhesive should squeeze a source ofthese finishes,see page 31.

Nn.69

Woodsmlth

oil are- mixed, liberally

brush the mixture on One seetion o( the proja:t and I"t it soak
into the wood. The sohredwood
will probably drink up most of
the finish. bUI will<'any excess
smooth alter abcur tcn minutes.
After it dries overnight. apply
a second coat in the same maonero Once you wipe this coat
smooth you should begin noticing a slight sheen building up. If
you want more gloss. apply a
third coal.
One of the advantages of this
finish is that YOII can tell when it needs renewing. and it's easy to do. If next year the
finish is dead nal. it's a sure sign that the
furniture could use another coat, The color
of th. wood may change, but if you periodically apply a new coat. the satin smooth
finish will be maintained.
PAl~T.
As (or the chair made with pin,', I
decided to paint it white. If you used 3 construction grade pine with large knots, it's a
good idea to seal all of tile knots with a coat
of shellac before painting. The shellac will
seal the resin in the knots and keep il from
bleeding tllrough the coats of paint,
T(I paint the pine chair, I used RustOleumsnew"WoodSavcrcname!.Stan
by
brushing on a coat of RustOleum's light
gray \V ood Saver Primer with a 1"'!,-wide
bri$ll" brush. The primer dries quickly. so
brush out any drips 8$ you go and paint the
pan that will show the most last_
I waited 18 hours to be sure the primer
was completely dry, and then sanded it with
32().gril sandpaper. You probably won't be
able to sand OUIall of the brush marks. but
sand it fairly smooth before "wlying the top
coal c.Cenamel
Thetopcoat can be brushedoncrsprayed
on. Brushing is considerably ksscxpensive.
bur it's more umc-consumlng since it takes
time to brush between all the slats, (Shop
Nole: It may be easiest 10 paint the edges of
the slats before assembly)
I sprayed on IWOcoats of Rust-Oleum's
bin:h white \I'ood Saver enamel (rom aerosol cans. It took one can for each coaton the
chair. but the finish W"dS perfectly smooth,
without brush marks.
No maucrwhich way you choose 10 apply
the paint. you may want to pUIan extra coat
on the mostuscdereas- the topofthechair
anns and seat.the fronl of the back slats. the
table top. and the bouom endsof all the legs.

29

TOO

L S _A_N_D_T_

E C H N I Q:::.._U_E_S

---1

Sabre Saw Table

O

L11')!"r
than the base ofthe sab... end of Ih.. arm i,;\ plastic canissnw, ,t'(' Fig. 2 The rcce ...... ter (a plastic brad container or
10(11<Oik~a roetcr or",br,' saw)
"l.AOF .,1.111".
CUI3 slol for ho"ld be deep cnou!!h '" the pill boule) which acts as a blade
I, thaI they'r~ awkw:,nllu COII- t1w blade. I drilled. series of ('dll"s of the base pnltrudc just guard, see "lSI.3.
trol, ~spcciall)' wh"n you're overlappinz
IISlSCnIETAIIU'_ Youwilldisholes centered .bov, the surface of Ih,' lOP It
.. orking with """II ~."." I'm on the width of thl'lop, s<'<.' Fill "'If This wa)' the sabre sa '" can CO\'('I' Ihal the trick 10 using the
",u..-hmorecclmforwl,k'(:QOCl'f)o 2. Then I c1.."n,-d up the ho..... be """,,Urt'CI "ith four turn bUI sabre saw is k."pinll the work
Iraling on moving the .. ork u.<inl[ a fin(' ,",bn: saw blade.
lon, thai hold the base tJghlly.n piece from jumping upand down
pito..c.So I buill a tabk- thaI hold,
Rt)l11_'_G\ Rl(:F~ TIle sabn- u",hile you're ... WI OJI.
rtg.2a
a .....
bre SlW and tt..l~nx' u-e it saw mount, in :I n,\'ft~see fiR
IIvlllF Gl,\RD. To k~'p Ihi'
lthelps 10hold the w orkpij;cl'
lik.. a band saw or ",1'\.11s.'lVo
2. To mark the' r....j;"'. hold the t"'hnique safe as w "'1", useful, tightly. and 10u,, a sharp blade.
1ll'ILOINC TlIF TIIlLf.. ro sabr e saw on the underside of I made 3 guard that fOY('" the Also, don't uy 10 sawworkpiec
l1Iakethe table, sian with nquar- the table lOPwilh the blade stick- "xll()s~d Icelh of the moy,"!! that are tOO thick (over about
tvr "'eel (2 II." t h.) "P'." ply inglhn."~h the <lot.Then trace bladc' 11ie guard cnn<isls of a 1").11,ey may "catch" on the tip
,,",cOO. CUI on,' pil,' tor Ih,' lOP the outline elf the ,",W base.
2x I "'WOn and an arm mad" of of the blade and cause the workand IWO piec('$ for Ih" "d,,. see
:\""1. rout the recess sligluJ)' r'('xi~"'" (or :\Iasonil~).At 111<' pi,'CeIO bounce upand down.
ne of the pfnbl<1Il' with
u:.o.ing portable power

F"II!- 1.1110'"(~ ,aJ\',1n'ogthl'lled

ll)'o'O",vbnk",,,;n """land back.

"0

~II'"

'"t-....~

........
""AI.

1
,~

""'AIM
'"""""
)

',"SOUARf

... w ......

uass-

".

'8"

Of T.ut.I TOP

~".
~

II

0,

.r

'''''''

1UTT0H

'"
caosslltAQ

=4

.>-

',.

...

""'"

aUTTON

STOP SABRE SAW SPLINTERING

PWlIOIASOI

"0
mailer what bl_d,' you're
u5lnll. or ",'hal material you'....

MASONJrt M

e:Ji,>--

cutting, you11 almosl al... ys

have 'J)linlerinll along Ihe rdg""

Ypus~

of a freehand ",bn: .,,,. CUI

ro Pl'l'veIll thi~I marl" a plale

..... CAN,mllt

~
~

(If ~i<"Masonite rn.1Iauache-, to

Ih(' base of the sabre ",v. with

double-sided carpet tapo,

A slOI in the :\1."Onil, fils
tillhtlr agaiOSl the ,ides of tbe
bJad(' 10 prev~ '(JliOl~nng. A
notch 31 the fronl of the p1ak

hd"" you foUo..- a pc'll<il liM

and 1t.I~
you see the ,plinh,.'r.rec

........
GUIOf
NOTCH

SPUHTDlNG
PlAT(

II." MASONfTI)

l_<~~:I~lh:e~~:::re:~:=,,~c:.:n~ll~rod::u:c:~
__ ~::~
__ ::::::::::::~
30

~o.69

PR(.1)ECT

SUPPLIES

Sources
BIAM COMPASS

A1llhd,a,dwun' ,,,', <1,.. 11.. build

the Beam C"OI," 11""" 2"~)I,
available
\\'c.ld.milh
Project SUl'JlIi,, :-;hh Fhe
wood j ... ,,,,1 in..lud. u

1,,,,,,

The brass screws aU have a

l'hillipsdrive. \\'~rel)ff.rinlllhe
zmc-plated 'Crews In Phillips "r
Retex drive. The Recex screws
can be driven with either 3 I'hlllips or a square drive bil or
screwdriver. (Note: For driving

PILOT DRILL KITS

To drill the screw holes for Ihl' Ihal adds the bits needed for No.
Adirondack furnlturc, we're 6scrt'ws (!<I','photobclow).1l1is
offering a kit of our favorite bits kit includes every thing prefor pilot holes. shank holes. and vioosly listed (lor No.8 screws)
countersink or counierberes (or /11,,0 all of the following bits
Recex screws, it's be,1 10u.....a standard and Lo-Root (deep- needed 10 drill holes lor No.6
square drive bit So ""',,. 31", thrroded) screws (For a discus standard and f.o.Rool screws,
offering a S<luarr drive bit to be sion of screws and pilot bil ".., s. 750420 Pllol Drill Kit lor
used ...-ith an ek'Clric drill Thi-, see lI'ood.'<1lUfh "0.56.)
:"\0.6& No. (I So.-rew._._S26.95
bit is lor 110"''1' c!ri,;ng otllyl
(II t..' Brad Poinl Bil (For
\\'e're off~ring the screws in
:"\0. 6 ~hank holes.)
bags 01 25 and no. I.a.;h bill{
(I) %' CounldSinklCounlercontain ...<Ir,(1'("'t\

...

bore (fju;0\..".~... brad poinL)

or on part.icu--

larSlyleand~Zl'\,'erannIJtmix
screw t)-pe~or ..11e......in a baR
BJ1I!.S Phillip &1'(",.,.

(I) 'tI;,"

standard

'/o.S" IV. . FlaU".td

769-215!R3!C 012,,)
~2.95
Hard",ln . .
. ,S.~.9S 769-210 (Bag of 1IXI) ..... S!I \15
(4) N""lc'd II",,, Fin!!.. r Nut< !':".lIx 2. ~"lth",1(1
(.1) .11-:12. I" II. MIld.."'-n.....
" 1G9-2"l5 (Ha~ "12.,,
!\:19;,
(I) Hr".... W
7(,c).2:!OII\'IR"I tiKI) S 12
III I" Ch,,,,,,, 11.,,,,1I',,illl
:0.0. 8 Pilol Drill Kit
ZincI'L"cd ""IIUI'" Str,,,,.
7~-'&-'101'1101Drill Kit lor
(I )'1"",, J "" ,,. "Uhf! b-ad
8,1
~1.,IJ> I
~I ,., ,,,.I!Scrt> w s
.,~ .....
~ (It
1)
SI5.95
PAmaHS
52.."';; Ill" kil includes (see photo):
f' JO (lias! of II~JI
full ...It...~11('m5('Jr I)lt \dw i" , ~'2",11ath.1Id
(I) 1I.;c" Brad Poinl Bil (Illi'i,
d""kcruir'sback~ ," ...nn
.II .,
I..r
drilling the shank hole lora
.~ IIIog0f25)
SI25
ann -..uppt,n...&ft. iI\ ,Iil.tbk tn-If
.!
40 elias! of 1(0)
83...'15 ,,,s~. Though a '1',,' bit
"'oodsmith Project ~ppli<."
work>. this is ~ perlen size.)
Imt I'Llll-d K.. '1", "'"R"",,"
AI", in<'iud,-d" a pattern fur the
(I) ." Coumersink/Counler114" Fl:IlI.1Id
cenl~r support on the Settee. i69-25.~(11oIs: of .:..)
bon(This 6.lS O\"ef ~ I ~",'
SI 15
Thl~l.aa't...m ...(~NIIIinclud~the 769-250II~ 01100
$3.2S
hr.td IIClIIIl bit.)
part, ij..t,-d aooV('
(I) ~. Slop Collar
:\0.~, 2". Fl,,'h, ad
Adirondllck Panem
(I) Allen \\"l"l'tlCh
'~26!;(I\aJ! pI~~.l
110
,
.,
769-200 Adirondack Chair
,
(I) ~~.Twist Bil (For No. II
i69-2tiO (Bas! 01 11M))
and Settee Pauern
S3.50
, ta ndard SCT!'\\' pilol hole s.)
Square Ori,,' lIil
(I) 7,." 'J\I,;st Bit (For ~o.8
756-31" Squar..llrivo- Bil lor
WOODSCalWS
I,.R"," Sfft'w pilol holes.)
Reccx Scn'ws
~
II you' ... Illanning on building all
thrt~, Adirondack Cumiture proORDER INFORMAIION
~t' ~ho"n in thi, i.,;u~. you1l
be U,inll almost 300 Oathead
BY PHONE
B"MAlL
,,:r~'" (Chrck the supplies list
To order by mail. u~ the lonn hlr I.b.t,.,. ............ U"" our Toll
.."h ~a<h PfO/l'CI for the exact
num)).r and ,il" needed. ;\1 c:ndosed .,.;th a CUlTrnt '''11('' Ffl'(- orel line Phone ordcl'
or ,.-rile ~our order on a pttre can be pIamI \londaylhrough
wa~
..,bu} t'xtnl~~,)
ofpaper.and ",1MI .. ilhacheck
f rida), 11:00A.\I 10 5:00 P\I
\\'ood.mith
Project
upormoncyonler (Ind"d~S3.50 C""tral5cancIard T 1I'Ill'.
plit"l i, oll"rilll( both bra" and
handling and ,hippoOll charwc
Bdore calling. ba ..~ your
UIl\:1' ""od nalh, .. d '<1'''''<. If
.,.;th each order.) lA ""idenls
\ 1SAor ~1aSlerCard rt1ldy.
lhe "Cf("1l\ ... ;mlountt"f'qlnkand
add
~
"aJe,.
laX;
CA
re,idl'nb
kfi l'XflU""'" Oik, "'" did on the
1800 444 7002
add 6.25 'ilks laX. Sc'nd 10:
rl-"Ci"uoc:l furniturl'). v.t n"l'om~

,oJ",,

'J\I,iSl Bil (FOf :-<0. 6

,;('1\-w

pilot boles.)

Bit (For ~o. 6

Lo-Root screw pilol holes.)
(I) :>Cd'1";st

Be...m (. UlllJllI"'''' Illlrd\\Ute

74:~"1(.)J\t.IJU (_(Jfllpa"',

No.6 & 8 Pilol Drill Kib!

\V,,'I'(>also ClICeringanother set

'I"

'0

'0 ~.

..

1.(.'

nll'nd bra'~

S('r~'~'" th.lt ;on'l

ru., If you plan (In wunl, rbor

Inj( Ihe' ,,'r<'w' and filling Ih,
1101(.'~,
U~ ti,u,,"plalt'il S4."1\'\4'S,.

No.6Q

\\'oodsmith Projed Suppllee

P.O. Box 10350

Des 1I1oinC8, IA 60300

Alru ( ,

to 6" It'tVl~.,.,,,.tk~
.\otn:Pr(~ /fHb}ttu ('Ito Pl/'('
(1~tr AU9lUt\

19f1u.

FILLEa AND 'INISH ,oa

OUTDOOa 'UUUTUH
As rnemioned in Talking Shop
on pagt' 29.1 used Mm..",,s High

Performance \\'ood Filler (or

filling the coumerbored boles

belor~ paiming lJ,epine version
01 the Adirondack Chair shown
on Ihe back cover. This 61lcr is
availabl. at man)' local home
cen ... rs, and painl and hardware
SlO,..". If you can'l find illocally.
il ran be ordered through Ihe
mail from The Woodworkers'
Store. 21801 Industrial Blvd.
Rogers. M~ 55374-9514: pbo""
(612) 428-2199.
For finishing Iht' redwood
Adirondack lurniture. I used a
mixturt of 50'- McCloskey's
:\Ian O \ror Satin Spar \'amish
and 501 \IcCloske)"sSlainCon!tUller & \\'000 Sc.oaler(for more
infonnalion, seefl'llle29). These
product. orc available' al some
localrelailstothandhomecenl

ers. and can also be' ordered

(rom The Woodworkers' Store
1M.. address above).

31

I. ,\ S 1

I.

0 K

Final Details
Beam Compass

Adirondack Chair

... ThlAtradttj"'UJlpa.'tdrxr$lo.oJt~ Id m"Ind.:C~IIITI.tl .. ... To" O"&a" rompaololdtA <

II( ,!tr' l"'nr~ fur lJIl" II , ,i, ",l re/aJ"IH!1 To ark,PIt. a elrn Ir",Ik, lerpol,t! and 6 n"g I/;I' " ark Hyt 1m"
1ft ('(IttIII, rbcJml I tu 'l',r''rll' Iiolts (l tJd1,llffl th con "IJ:r#XJTtIf II'" I,
lI(ad :I 0, 1/ ""'I' hMo/Y" tJ. l1"P
"'MIII/rlltr. For ii,juP"lllf,t jolt ()tl fi II illY 'f lid IHI ruti ny. 81ft' 1)f((It'.!!J. tilt bark ,/"/1( I,n ttu ..Wi ('(II ,I,,('J./u" II"".

"'t

CnCase

"

TI,. , I III 'I IttII buffr tiQl)nf. prot",(/,

t ,.flJol/ulfh tlit; oo/,. f)n

,"

IX (.

t1

Mtn_k'HYf"".

ta ",J/(Il/rlf gi.If' tto: C(lIH (I rli'IIn. ((urJlttt;"",llti()/"

3Z

fJJ~' 1"1 ,}I, 'T'tIlramll~d

D {(l~f.
Tllf ~( r, ,'1I('nl.~/al aI' I, n, r rtl.", t/'fJI/'QI,bt lilt
f~'lfrJ,(1) /ift.f'

"

lei

fftJ/,OOI.{rdlJ(lf1l r't"'tTdili
to

JiUJ'ul"J by

l~

,1,,.,"'.).1" ~

CQ)il].KIrt
l1Vlltllli (/,I"(/f

r~.