NO.

72

NOTES FRONt THE SHOP

Plus:
Ips
For Your Radial Arm Saw

$3.95

No. 72

EDITOR'S

December, 1990

COLUMN

Sawdust
H

do you gd R pit..., 01 w,.,d 10

bend in a g(ntW.grru.'t:(uJ.,I1Ve?
It's a task thaI doesn't seem natural. Yet
lt's a 101easier than it looks - and a whole
101mc.sitr.tu<,.
One or 11,,, mO$1 popular projects 1l,.1 involves bent wood is a hall tree [or hats and
coats, The I'.,.e.1 tlung about hall I".., (.,
least (rom a woodworker', puinl of view) i.
thai it'sa progressivetessoa in how to make
bent wood laminations.
The legs are 3 simple L.bend The Coal
hoo~'S gel a linlc more complicated .. ith Sbends. Then to hold the Shooks 10the posr,
you have 10 make a complete cirrle, a ring.
And 10 mal", the ring a liule more of a challenge. it's round in cross-seetion (3 rf'fl
shaped piece fonning a ring).
The basic process for making bent laou
nations is<impl,.: rip t.hinstripsof wood. and
I)'"

Iid,t.,.. Donald B. I'... hk.

Dt-!O&D 1)"",'1... Ted ktalicek
M:tIIllIdllKlidilM Ooull)ll.< I-Ili"""
A<<!4anlf.dilo", TM'YJ. Sttoh:rrum
J"nu.')oo, ~1_DolAn

RkMr<J S.

I'."""

Cordoo GrupP<'
1'ro)o,'<'I[)egjj!ll'" I",,, \tunkcl
mW.trabH
D3\id Kr<~1inlt

Cary <''bris(enscn
RodSlookes
1..1,';H GIQ\\1K'ki
Dirk \ vIf St~
e('g
'Il\:ulation Oirodor Uz Brcd, .... o

G"'I,h&-. n....
"lor Jon Snyd.r
1"',*,~SuppliL.,. t.e..lit.\no Ck'!U'burt
CUSlulll"rSmic:e~Ij,'T Undn M(II'I'()W'
CUStOrtltr

Sevio,

l..lad. ...JQnCtf

lWlly 801dford

&all Mod",
G""'1Uc 8"",,,,,"
Vicki

Ed"lU'd.,

MR.: ~tI1itb
J'"f1nfe E~

JIm; ee lWtlwvc
Joolyn l'ro$$

J 01'1)' """dni
Robo,rto Rutoh
Co"""l1... Pa,,1. GI'I'l)'
&i>kk~
UndnOl!ourl<.
jl;ero'OrkAdminis1taIQr Oo,.gt:\.q M. );dsmr
.~mini>on'a~A.""1SCh~1')I.;\';"_

Sanily&um
Sourt",book J.anMy"",
I\ml,\. BudrtOl'
SMp !'.!>nag"r SI""" Cuni..
lluiJding ~Iainldl""'", """ Grilli'"

A",-me Krn....

SI'"'' Manage..,;:
81(\'1<),. (.A

P<:>M.~.li\
\Voodsmith-Q;

~1i<MelDena"...
KentW.l<h

ttsSX
Ml~.'j,pu~d b~
,'('l.
>.pnl, JUtll'. Au!.: O! ~.
b)'
'l-ood"mftb. PUbUllhlb, C~mJWlY.2!OO t.nnd
01

IOQothl):
.\\l'('ftut',

~e)

Dt. 'iCl'il , !L, "'-5031:! PtitltJ:i1 1ft the U.s.'-

~'oo4sm.ld:ae i~
"ft'IMl~ tndc-.trtnQ(WoocbtJuth

""lob'
' "' ' c.n"",,>:
t:('t1JI)~
1990 h)

..a~l"
..",",...,

Y,~.1'I1lIi.;J'II)lC'lfl~}"

Su.~t~)\"
__
t'JO~ ~t-5.9S.1,,'1' \'t'W'lt12
",...u,,'at: ~.9$.('.anamiff h ,p'ldd ~(IOI),".ir Us.
"";Do """ $u6.
.s-..d 0.,;, ""'!'.id~ I"" ~"""'.. lA...t "

lou.

~.m..<

l~tM5rnd(~orolddrtStCO

lIIt"'!l<-<,M
..... lA~).J.'"

~~Quc:Jrion1o;l'(~~~

lr~

On pal[<':l8 w ..n slw"ing a SlOP block

lor a mdlal lIml saw. This SlOPis actually a
damJllfut, attaches 10a fence. Irs simple.
bul,l \\o"",weaL Even if you don't have a
radial arm ...... you11find a dozen uses ror
thi~ "'"p/damp on other tools,
The otht-r damping device Is equally
~nlpl,. It'~shewnall pagl' 2:l as pan OftJ1C

miter jig Ior a radial arm saw >\gain.it would

be ca,,110 mb,. bUI take a look at lt, All it is
b pit'(;< 01wo<>d"ith a kerf io it and a
machine .....-.'" - no complicated mechank, BUI il "01ks great, \\1lh jusl a little im
agination. Ihi, damp can be PUIto use all
over 111t>.JlOP

\1'\\ f",~~Oneoflhecomment$1
hear
fn'Qu,ntl) about 1I'",,,I.,,,ilh is," Idon't
know how you g"r' do it wilhoul advertis,n~. bUIkeep upth~ gooo work. and don't
dUlI""1 Uf>wilh ad ."
glue them togl"_h~rIn a form. The1'Can'illot
The kr)' In making the whole thing work
of clamps, ctue is oozinJl 0111everywhere,
WllhbUIadVl'rtiSlnl( involvl's the business
and. in a "ford. it's a mess. Rut when the ghlt. "'d.. 01 l,uhU,hlflSl - circulaiicn manageIllt1f.l ,"t jol) (If .1 ,jl"('Ul.l1ljun director is to
dries.you 've got a beautiiul bentlaminntion
01 course, 'here a r"" delail, thrown in hri'lJ.: ill I1l'W "i.ubS(_riptiun~(\lsua1l}tby sendthere. The firsl one is how 10 rip thin. ,")II ing out din...1 mail packagcsi, and ICning
slstent strips of wood. 01 all uie problem'.
,,,.,..,111,"b,,-nll<:rs know when their subthis one appears to be the easiest. )'<1 I've ><ripllun is ~b"ut hl end (by sending out
l\'uc.,,\\111 nOlil'i"l!oo).
round it the most perplexing "'I ve,
I'V" lried 101of methods 10 np ,trip<o!
Even fur. small publicalion
like
wood. It's l)Ue of the mOM ba.....il w~k:-.in l\~l}(itt;"(ltlt. thi~lilvolves nlailing out mil
wooc1worJ..'ing. Ripping ,,'tl thin ....lfi~lis n(,t lions oj pi.....,.,.of mail earh YC:ll'.
Al l~a$l. Ihm's Ihe <;imple explanation.
100 bad. Hili rillJ)ing lots of Ihin "tri!",. an
'n\,,", ,san incrediblc3mount 01 detail. and
'()"SIsl.ih(ly the- samc.' thh,'kn~,i~
n(~t
3::l'asy B:. it $\,"t.'m~.
whnlllwl' lik.. 10 "all "numbel' crunching."
111e m~lhod I lik~ ~>I inv"lv,", Vt'ry 111<' whol,. thing depend~ a great de<ll on
simpl~ addition 10 your lable <3W.Thenddi
compulers-and
we all know how screwed
lion is a <hopomadc msert plale with a .1)ln up Ihings can gel with compuleN.
ler (sc.'C page 1). 'Illc oplill<'r ;')U,I d lillie
To handle all of this. and keepllsgrClWing
piece of wood lhal slkk, up rmm the 1,1"",. allh .. SMle lime. we arc fortunate 10 have a
bUI it m.k.-s a bigdifft'<eflcl'in the :\Cruroe) \'''')' talented person join uS as circulation
andcoflsislcnq' of ripcuh-.l1 Ii worth trying. dirt't:tor. ill Br<!deson.
Nt'w bark.., the halllr<'(..Althoulth it'~ Uz was ionnerly drculJltion direclor for
nUl a complkmed projo1:l ;1do,", lak. a 101 f'a", 1111 lIulldyt)IUIL magazine (a 1.3 mi~
of time. Bendim! th" four S.hook,. (or ('x lion circulation m(lJl'87.inc).and .4m;,rita>l
ampl . tak .., ph..,.. Oil one ruml. Ynu ba .....lo H",.Jlh. both owned by R<,ad"r'~ Dill .,.1 in
allow tim.. fur Ull'lllue 10dl)' on on.. pic"Ct! l'ewYork.
before you can move 10 nexl pie<-I'.
Liz ,..'as anxious 10 gel back 10 the mid
Even if you doo', waru. LObuild the ball west. and liked the challenge or .....orking for
In.''l tb\.'tf!'s a gr('al deal of saU$raction in a magazine lbaLwas entirely dependenl on
making onc S-hook - ,"ven if Its jusl 10 circulation. For my part, rm delighled 10
hang up )'our shop aproll.
work ",ilh someone .....ith Ill'S talent.
el" \IPS. There an'lWoc!amping devices
~V.XT (SSt t. '[,he next issue of
in this issue Ihal are easy to miss. bUI are Wood~m;/ll.No.7.!. ",11 be mailed during
well worth inve,1iJr.lling .
thewet:k OfJ3nUAry
1991.

'0

,h.,

itA,h
K..i)IJ.aw(6

5.W1!tt,. CcoJ)IIlII11lmr. -~da) "

No. 71

..~

~A~~L_O~O~K~I~N~S~I_D~E~
_

Contents
I 141./'\
L.:!J

Tipll Con/eli! alld lil'l'

gl'eCl I Iips! roll I/l'lloll'II'OI)(llIx)rJ.:f'l'S:
1) AeUllsiable Rolle)' Stand. 2) Router
Tuble PIl.~1tBlock'. J) hllpl'ol'ed Teno
Cnltillg./ig.J,) A ChipS/inge,'. i)) Sandpaper Files.

'rips & Techniques

1 Bent

Lamination

L.

_\'~IC

Be'1/1Lamiuatiou

petge6

Il(;llrr
ansu-er lots 'I}' quest lOllS Oil
belldiug thi strip of uood. EI'(,I'Y'

---1 ~

Ihi 1If1/rolll "ho: t IIirk "10 ..hou: m IIcit ".

IHall Tree

11101 Aaolnut
traditional
rorite, Ih I" sui id
Hall Treefeatures fourdisff!

---1.

L.

Iinctirr belli

lI'ood Shook~. Besides flu!

Sshook. the leg.~and the ooden 1'; IIg
/)rodde d ifferent bendi Ilg choilecqe.

1 Laminated Ring
L.

.;;.._--'.

11161 d~f!irtllt
JlIClkillfl laminated rillg is
Il.q it .~o1tlld$.AI/d tile same

/lU! (Is

(f

technique could
!lUll r OWI1

[Shop
Notes
_-.!.
L.

"I'en

11(11/Tree

pClgeJ{J

be used to mnke

uiooden )('iled" .

11181 J)Problems.
Rub 11rtll.
SUI/ding Dr"
,i) Router Elise Plutcfor
J)

1)1

_.J

CuHil19 Circles. J,) ~roodPlugs.

1

Fern Stand

11201 Fern
']'hebent ood. leg~ oj litis qruceful
Slcl/lc/ reucceuted by (( tool uu I
(I

_.J

L.

sI"ip .andu-iched beuceeu oak strips.

ITalking Shop
~_....!..

L.

11241 flatsau
If'e discuss the difference betweel(
and qututersaum l umber.

_.J

PI us, /I'e luok at calipers and

ciam ping Iill/e.

ITools & Techniques

11261 Rtldicrl A.?'I."all': A Neu: Table Top,

IFence & Stop Block

11281 ndu
A Rirop-IIIClde adjustable ao block
lIew lVood!el/('1!puilliejilli.sh-

ISouraes

11311

touches

011

OILr radial a 1'111 salc.

Harduure (Llld " roject eu pplie

neededforthe projects in ihi issue.
Fence t\:. Stop Block

No. 72

.!()

A Felice Support Ledge, A Jlitel'

Jig, And A Safell! ffa ndle.

illg

}Juge

talk about

WooJsmlth

pa.geJ8

FROM

FELLOW

WOODWORKERS

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

Tips & Tee

ques

ADJUSTABLE ROLLER STAND

.1 mad" the roller stand fea- b)" 2t1wide plywoud anchor
nired in "l't.HHI.~""111No. 70C'b' across the bouem of thc'" inner
ier 10 .dju>t by adding a Iwighl sleeve. After Irlu ;ng it in position,
adjusunem system that works drill" hole to accept the rope.
like an ('I e-vawr
Now put the inner sleeve back
The bask idea behind the sys- inside the pedestal, The rupetem is thai a rope r"st<'nedto the winds up around a :\!-t"-diamelec
bottom or the inner SIN". winds dowel CUI th e <Iowd 10" lonl!
up on a dowel suspended be- and sl;d~ it through the holes in
tween (he two sides of (he

1
CROSS SEcnON

.,_-

the pedestal,

pedestal, see r\l:.l.A"the do\\ el

T" bold the dowel in position,
is turned. theinnersleeve .Iowly I pinned il. To do this, drill It,''
rises within th~p<>GI",taI. Then. holes throul!h thl'dowd on both
once in position. itcan belocked sides 01the pedestal and insert
down with the wing IIUI.
short If." dowels. Also drill a
To add the system to my roller holclhrough the dowel 10 attach
stand. , started by removing the U,(' rope inside Ute pedestal I
roller assembly and the inner also added a handle made from a
cap front Lhe tal' of the stand. piece er scrap stock and a short
Xext. I drilled '!ft" holes in both length 01dowel. se.. Fig. I.
FinaUy. a four loot length ul
sides or llw pedestal
down
trom th~ lOP(dge and centered rope! ,vilh a knot on one end can
on it. wiolh.
Ix threaded through the hole in
To allow tlu-inner sleeve togo tho dowol and the hole ln the anupand down within Ihe pedestal, chor plate, Then Ii" it oif on Ut.
CUl a W'o",'i<Jt: b) 7ft-long Sl()1 in
bottom "fth,' anchor plate,
Now, 3S you tum the (!ow,'l
both sides of tile! inner sleeve.
Align the slut wilh the ,," holes me inner sj(,,(-'V4.will easily OIOVe
in the side ,,(the pedestal,
lor small h~ighl adjustments.
'!'hen. to provide a place to seJAAph 1'00t"
cure the rope. Igluw a:I'."-thick
Etfl-'YiI.'f ,f 1'.,rk, III, "U'~

INN"
SllIV[

',,"WJPE
SWf

..

<,
'

PO(STAL

'-..

3""'

DOW ...
PIN

<,

.~

tfANDU

.,"

-,.

31;1"

DOWEl

' ,"

DOwn

.....

-ROPI.
, ... OIA.

NOTE:
IOUll

STANDAtOM

WOOOSMITH: No. 70

ROUTER TABLE PUSH BLOCK

.1 wanted 10 roin the ends 01 moved when routing thin stock.) from the back edge of the push sandpaper along DIe front edge
101\.1{ nnrrow pleces of wood on
KeXl.allach a push handle cut block, see ~ill. I
er the push block.
Finally.to help keep the stock
my routertabl e. but the problem from a piece of 3,-l"dianll..'lt.'r
Jim limld,1I
from
slipping.
glue
a
strip
of
Loveusvitte,
\'i,yi,tin
was hulding them square dowel. Position the dowel 3" in
againSt the fence. To solve the
SC1U:W ADDmONAl STltIP
problem. I made a special push
AlONG fa0t6 fOG!
1
2
block. refer 10 Fig. 2,
~,---,,"
To make this push block. stan
\
bycuttingapicceof'l't' plywood
SI! wide and 12" lonJ{. see Fig. 1.
,
'.....
) .... PIA.
Next. to a110",me to hold a
PLYWQOO
DOWn
SlOP
workpiece firnlly against t~e
tront edge 01 the push block, I [NDNfAR -r-+--!-_~
CUI out a hand-hold, see Fig. I,
lIlT
Then. lor more control I made
the from edg<- of the push block
thicker. To do this, screw a II-:!"
"ide by 8"long strip of 31,' ply.

-+

s::::r":"

--4

."

wood flush wiLh the froat edgeuf

the block. (This piecre ....
an be re-

-l

."
,

HAND HOLD

W'1<,,,bm. rh

No. 72


IMPROVED IENON

.1

""'0("<1a ;.labl"jilt for cll(li~

tenons 311d htdf lap joints on my

table saw,

BUI

the jill'- l've seen

lend 10 drng ns they slide ale)llSt

11,(,nl) Ience.
So Icarne up "it" n jiR" that's

stable ami Illidc$ easil)' along

my metal rip tenre. """ Iill. I
""",.aabmlyco""" fmm widoninll
the jig \\;111 a I \~'!
X 1 V2" spacer
nI1ac)1t!(110 the inside (aCt',
Then 1<1 r..duc.. drag. I used
'It'!'l' round plastic furniture "fet'lor glides where the jig touches

t{NON

--..

CUnlNG

JIG

the rip fence, _l-IR. la. These the space r ~"

"I arc normally nailed inlo the above the boltom
bottom of furniture legs 10 help edge of Ihe jill. see
heavy fumiture slide over C"dJ'- Fig. Ia. This way it
I,,,,iog. nUllhe), also help my jig won't drag on the
sa",' table as jl'"
fllide a1on!! Ih~ renee.
IVhcn buildinglhcjig.1 ripped bdng used.
Ih,' '1"10"'" a bit wider than 1Ii!<~
essary $0 Icould get an exact fi;
later Then. I nailed the glides
iutoplace cn both the spacer and
th .. in~id,' of the jig where il \""'_ _"'}
touches the rip fence.
Once the jil{ is asDuring assembly. I installed
sembled, tbe fil on
u)e rip it'ncl~1J1ay be

cumNG flG

This ume, we.... looking (~r lips on how 10

organizectamps. Ctampscoru~inaJldiff~renl
shapes and sizes, and SIOring them takes lip
a tol o( ~j)ace. S" ifyou have " sp<-cialway In
keep your damps organized. tell us about it.
W.,1lpub6shthc best lips in UwApril 1991
issue o( IVrl(l(!.mdlh (No. 7.1).5.:nd Y(lur tip>
(postmartedno lal~rlbanJanuary7,l991) 10
Shop lip>; Contest, 1\'oIl(l~", 2200 Grand
Ave Des Moines. lowa 5(1312.\V,,'1t "111nnue tn publish other Tips and Techniques,
100.and pay upon publkauen $1510 $100 for
these tiPS based on Ihe published I,,"gllt.

it".

spacer and plant" a

small amount

of

wood 0(( tbe side

(If

the spacer

.-

PlASIIC

GllDU

SPACER

CHIP SLINGER

SANDPAPER

Chi"" and dusl (eU down iIlto stinger slightl)' latger Ihan the
lhe mOlor when 01)' rOul"r was hole in Ihe rouler lable so it pr()o
nl<1ulll,,1in illYmuwr lable. So I t("('t~ lIlt" mCJtor ('\'('n '\,)l(~nIh,-.
cam,' UI' \\;lh lhe idea or a chip roul~r is~h"t off."",. rig. la.
slinger to pr(H<:<:t the InOlor,
r", L. h'etlt'IXJ'
A chip sling('r is a lf1"~thid
Zel't!1,()/Jle. f'l!ll "ollyl ('t{I' IU
plywood di~k lhal
fit~on 111~'rouler bit
1
A, SIDE VIEW
shaft. sel' Fig. 1.
\
..
TMlCK
(Nole: t:or short
PlYWOOD SUN<HR LARGtR THAN

I usc ,andpal'er foks in my

shop for e,"('"thing (rom d"li

shank bit,uolfa pl.So

tic cut~out (rom a

coffee can lid.) Th.

~-pinning disk b:liu~

tI\vay an~1hing,hal
falls lhrough Ih.
hole in the table.
I mad" my chip

No. 72

DISK""

l'\otv: If you haw a wide fe-nce

likt" a llieselllc)'er. lrnil~nC\~or
Vega "'Y$ICln. you could use lhi!\

opooshe the Illides. Then screw

lh~ spacer in placeand try the fit
agruu. Continue tlli ....procedure tenon CUlling jig on your teble
until you jt~1a perfect fil.
saw. 100. Since your jig will
I maintain tltit'- perfect fil bridge. wide (cnl"'. the spacer
during all S('a~)ll~I)r planing doesn't II('l~dto be II It'wiele-.
more stock oft Iht spacer when JUSI make il wide enough 10 acit expands in humid weather, commodate the nails on the back
\I'ben tJl~w...aOwr drit's oul and of the g11de~.Illu:;, lit" exira ~
the spacer contraclS. I add " you can plane il fora perf,'C1fil
.l/(lJ'iy 1~(J')i",~()n
sllinl beNf("en the spacf'rand \Il~
Gfl'slln III. ()rt'!)Il)1
sidr D(lhe jig

,I," x ,I.,"

CLAMP ORGAHIJ:ER$

too tight. Til make il

fit. unscrew the

~~~t.__

~L1ny IVMdmith readers ba''<' gn'31 ,;olulions 10 problems, they've run into while
working in their shop, \Vp"dlike you 10share
those tips with other readers, So (or the n" xt
('W i<."U"". wr'lt ask (or tipson !1Olvinlr
differ
entshop problems.
UpIi! three ollitebe", tipsin eachcategory
will be awarded ~ I~ood.,"il},Master Try
Square. Duplkalc or very similar lips will be
considered in the order we rceceive them.

ROUTER TABU HOlf

c-o:!t(>'

~dill~
jol)!'>

ttl

FILES

shal"p\!ning

pend Is. To inake Ihe fiI~.I use

Ihe Stikil paper nOln'aUy ";;ed
on Illy palm sander. sec Fig 1
Slikil pap~r has
adh""iveon the back

and

conlt"S

in mils.

....irsl. I make 3
handl~oul of V~"ply
wood. Then, press

Ihe wood handl"

01110 Ihe adhl'>'iv,'on
th~back ofO,e Stikil
paper and cui along
Ih,' ('dge of lhe
handle \\;Ih a knife.
Woodsmlth

"(lIt ean nlake one with rf.-.....ru

Inr sandpaper. 100.Apply sand

ing di<k cemenl 10 tllC handl"
and Ihen cUllhe sandpaperto fil.
l\'"I/io.tJI (... t;I"/or,

.lJl'di~ P.f1"~'tyl'a"ia
Sll10T

SANDPAPER

TO
-THfNTJt1M
EDGWfTH

KNIFE

TECHNIQUE

WOODWORKING

Bent Lamination
B

QUESTION: WI",( ;" I}" a..1

It'ruinl! tlW'f 1/1/" .t"I".?

ent Lamination
is a
process of bending thin
strips of wood - using lots o(
)!lueand lots ofclamps. II's mESSY.
but .\."W'dI'diog to v-c a ~uny
bent piu:e of wood C!11I.1!Il' from a
glue-encrusted form.

""'I!
To

<'\II strips to a consistent

thickness, and do it safely. f Ctlt

them on the table saw using a

special shop-made insert with a
splitter. set' opposue page, ~llli~

The process starts will. ripping some thin strips of wood

insert is made so there's no

room on either side 01the blade
for the strips 10 fall into the 5101.
RIl'PtNG. To rip the strips. set
the fence so the distance between the fence and the blade
equals the deslred thickness.
Using a push block. cutasmany
strips as you11need plus several
extras. (Some may break while

and applying glue to each strip.

TIlCD it's a matter of slarking all

the strips together b'ke a sand,
wich and layiag the sandwich on
its side in a bending jig. Then
the strips are pushed around the
curves on the jig. and clamped
every few inches.
,\ CH,\u.E!<GE. The challenge
is that the wood strips don't really want to bend around the
form. So as you wrcsde them into place the
glue oozes out allover. And the strips not
only slide forward and back against themselves, they .15('want tu slide lip and down.
Tho payo!i comes when you remove the
damps and $I3r! scraping offlhe dried glue.
The sloppy mess becomes an auracnve
piece of wood - bem to the perfecl shape.
And Ole rnoreh'scleaned, the beuerh looks.
S1'RI:.'SC'n1. There's more to bent laminaLionthan just appearance. It's strong as well
as anractlvc, "1tile it would be much easier
to make a curved piece by simply cuning it
out of solid stock with a band saw or sabre
saw. it's nOI always 3 good idea. CUlling
curves frOID blanks Cr<!aI~S a 101of waste,
And there will be a weak SPOIwhere the
grain runs 3('1'OSS the narrow face (from
<><tgeto cdg~).,;ee fij!. l.
FllfPxampl .., if you cui a piece of solid oak
into a "L:" sbape. you can easily break it in
IWO. If the grain runs "erur.lly in the "U", it
will break at the bouom, If it runs horizontally. it will break on the sides.
If you laminate thin ~1ripsof oak Into the
same shap e. it's very di!ficultto break be-

beingbent)

cause the grain of each piece

nJ11~am"

tid

the bouom of the -U.

crssnoss.

ing,

bUI

Okay, this sounds interest

like any woodworking technique,

someqncsrionscomewith the process,

I'm 'W( SI<I'I'w/lalkllltl ~/

IltfxJdtl)lrse!"r nf!1 b4 .tllllllU i,ttr/lou projvcf.
II?",! .llu,lld / look/ur?
QllliSI10N:

Any wood will bend if lr's cui thin enough,

But some woods bend easier to tight curves
without breaking. Amoag the commonly
availnble hardwoods,
oak. walnut,
mallOjlllny. and ash bend the best, Hardwoods usually bend beucr 'han softwood"
but redwood. yellow pine. and cedar ron be
used in bending projcclS.
$TI(,\Ic:m'GlWN. Whalever kind or ... cod
lsused, remember thai wood with grain Ihat
runs in a falrlystraightline is best for bending around tighl curves. Highly figured
wood. or woods like maple and birch which
I,av(' unpredictable grain patterns, often
break before ,hey bend. see Fig. 2. (For
more on wood grain. see page 24.)

Shop :-/otc: Often when ripping a board. it'. dillkult to keep it tight
against the fence. This causes a variation in
the thickness of the piece. Check the piece
with a squan- and joint it. ifnecessary.
KEEP lS ORDER.. To minimize color variation in the laminated pieces, arrange the
stnps In the order they're cut off the board.
This makv, it difficult to ""'" the joint lines
when the pi('C(.'" are IIlued up. Sometimes
they will match SO wen. the lamination looks
tike a piece of solid siock.
IUP FOR~'1'R-\JGlrrGIWN. When rippiag.
the goal is 10 keep the straightest grain on
t1le.(/ytoftheslriptohclpprevenlbreakage
when bending. So if the straightest wain is
on the face of the board. just rip the strip< 10
the apprepriate thickness. see Fig. 2.
However. if the straightest grain is on the
<.'<ig(> oCthe board. cutting the strips is a two
stepprecess, first. rip. piece to the width of
the finished strips (plus Vui' 10 allow for
clean-up and shaping). TIleD turn lbat piece
on its edge and resaw the strips with the
straight grain up. sec Fig. 3, TI'is way. the
st.raightestlmlin will appear on uie 0011('of

lhe strips,

IRafGUlAA
GRAIN ON fOOf

fIRST:

RAP &lANK TO
WIDTH Of' S11UP

SECOND:
ROT"ff8lANK~'

"

ANDUSAW

W"ru,m.th

No. 72

QUESI10N: Hull' Ih,rk .tumt d th.

etripbe! (On?1 J ,'.>It ,.t(JII~f~/flll ~/"'I;~l'~"'l'"'i~/lr(!r!

You \.'3J1

UI)(:

V~1')'thin

strips, but there are

some problems. First, it can be difficulllO rip

very thin pieces 10 a consisn-nt thickm .....:"._
And, there's a 101or waste
by all the
saw kerf s, l~n.lly. it'.moreawkward 10giLle
and then wrestle II large number of r~a1Il'

",,,,".'<1

thin strips around a lorm thall a small JtUI~14

ber of "il(hU), thicker 011."..
I use the thickest strip that will bcn~
around the ''''811('st radius in the jig. II's
oflen "trial and error approach \\'hile bullding lI,e F~m Stand on P3ile' 2O,IIried 1<1bend
an \II;"thitk strip of walnut for a leg. and il
broke. Yet a ~Ihick ,tril). justlo:lt' of an
inch I""". bent ju"l fi,,<'. ~.' rna}' nol """'m
like much, but when Ihe strip i< only v." 10
begin with, 1t!tJ" is 25% or its thickness.

QUF~"ION: Tlu n .,/";,,,, on' /tal'll til

I,~((I~U"I
('tt'''~(l/tl.l/.11(111' d I((tn ~'I'(JU'it
; I(pi/'re I}'f M!/ht IJI'r~'
"i'.;'(~!

I-lt:'rt"\;a til), ~1t.~Mlreaslack

Qil}'llln, raLht*r
than onp at a till'lt".l:(>r inst.aJ1<X\ t:ight ;V32'"
Ihick Slrip$ should <,<!ual-l',".lIeiore ripping
)'our wood In iin;$ht'd tllicknc"SS. rip :;onlt~
~trips OUI 1)1 ""rap sl()~k and mea.ure Ih~
thkkJlb> orth~ Slal'k.
I also use dial calipers to a~curatcly
measut(' Ih('lhicknc%ol ,;triP"- FIlrmore nn
dial calipers, S('(' Talking Shop, page 25.

QllESflON: What

'f the

.Ilill. ""/1'1

1'iF),d n totl ~Idthrj;,,.,tl IrltltQ,,1 b,"t'O].'1 i'~/?

\I'hen J don't ",anI 10 make a Slrip any thin

ncr, and it still won't bend wilhQul breaking.
I lake advaOlag .. of Ihe rael thai moist wood
b~nd, beltcrthan dry wood Soak th~ strips
in L1pwatcr in Ih~ kitchensink. (lflheywon'l
filinlhe sink, usc the bathlub.)
Snaking time "aries with the wood and

RIPPING THIN STRIPS

One key 1(1a SUCCCl.',iul
bent lanunatlon projec t is using wood strips tllal ha... "4UIU'<'
edges .. ndare uniform in thickness. ThccasiestiIJ\d <af~'>tw.yI've found 10 cut them is
01\ a table saw with a "ZeTO clearance" insert

piece 01stock 1(1the exact thickness of the

saw blade ked. Theil ,... t ill" high (wide)
and 3"long.~nd Ih('cnd that willbecloSt'''
to the blade to a point, and then lIlue tbe
splluer imo the slot, ",(' Fig.a.

with aspllner, and a simple push block.

Filtally. bore a jOdi"",cl<'r hole in the insert to make it easier to lilt out of'thetable.

INSE.,.
The insert on mYlablesaw has .. , IilUl'~lear3Ilfe on ~a~h side of the blade ilIOn the thin
<lri]l'>C311tfall down into the bladp ,101.'1'1,..
spliner keeps the kerf open Ihe same width
., the blade <0 ilreduces ki<kI>Hckand binding on the back cdgf' of Ih., blad.,

make

insert.
first resaw or plane a hardwood blank 10 tI",
Ihklln~ of th.'
oJ)<tniug in the saw
SltAPL'IGTIW IILA,'IL To

tanksl'

this

in"".,
tIl!! new insert will lie flush

('tm'"''

Now
the "riginal insert from your
saw and trace Ih" outline of the insert onto
ti't blank, 11I"n rouJ.!h CUIIn within t ,.;"uf
Ih, oUllill<.'.sec Fig. I.
To trim Ul<' new insert to the exact shape
~rth~ original, I use the original 3, a ternplate 5tartby tapingth"original in""rt w tI",
n~w inscrt hlank wilh doublc>ided carpet
tape. Then I)lQU,Ot a flush trim bil in the
rouler table ancl, witl, the bearing riding on
the originalln$ert.
trim the new one '"
sfulpe, sec ~1g.Ia. (If ),011 don't have a flush
lrim hit. rOil l;'~n,;and or file the iose" until
il fit.snllj{ly in Ihe QP("I.inll)

The nm sWpislo cut the blade $10t.T<ldo

this. I"placl.' !he original insert in the saw
t.hlp '1exl.carcl1.UYllhgn the r~Ilt:"wilh the
e:dge 01 the original insert, ",. Fij(. 2. 11I.n
rip th. ,,101.<lopping and turning off Ih",,",,'"
31t from lilt' end o( Ihen..."W insel1.
'mE SPLl'I'ffiR. Til makl!

the ~pliuer rip"

I[AfUNG RJDS

OIUOlNAL

PUSH BLOCK
Of all lite push blocks in the lI'aCJ!/smit),
shop. the one that II:Ork, ilesrfor riJ)pinl[!bin
strips is eXIA'nwly simp"'. It suaddles the
saw blade >0 the h,'C1 on the bouom Igl' "I
I he block pushes b<JIi, the II url'pi<'('" and the
waste past the blade. see Fig,.1.
The push block is made from an 11"long
pi,= IIf 2x4. Til providl' a lip to
Ille
stock, cut or glu. a "4" heel on the bottom
.'<Ige of Ih~ block.
13~addin ..<! a heel to thellJj) 01 the block.
youcantam the bloekoverand use tlw otber
side when the fir';! heel gel' torn up b)' the

pu""

sawblade,
SHOULD YOU SAND?
After ripping the strips to thickn~ss, you
might be le.mplecllO sand the strips bef"re
YO!1glue Ihlffi' up.l>on'L lbesaw ...illC:uttll!'
.triPS!l(' the l'<lgC<are squure and th., t~irk
ness is ,,"iform. Sanding may round (he
edgl'S and create dellTl'",.ion. in the lruck
ness of Ihe ",mps.
li.H wfult il Ih.", are blade marks in IIle
fuceot tbe ,mps? USlOga combination blade
iosle'ttl o{ I( ripping blade will ~liminaw
mally 01 th,' "aw m3J'ks. Or, if you have a
Ihirkn<"" planer Ihal will planelhin stock,
rip the strips :;lightly Ihick,'!' and then run

UWOlth rough II,e planer

INSERT

l _

FlUS'H

T1tIM

orr

thickness. So check the strips every ten

minut<'S or so to _ how flexible they nre.
Takt' a SlriP"UI oftbewaterand gently try to
bend it around Ihe lighestcurveon thl' jig. If
il won'l bend .round Ihe lorm. put il back in
the ""ler and "ail a wbile longer 11Ie h2"
thick wainul ,trips lor the Hall Tree books

....

AIJGN FlNCf
WJfH tOG( 0'
ORtGINA,1. ""$t~T

\\'CJ'i" rt"a(ly to bend aftf"r soaking 20 minliles

in roonl ten1peraturl'" water.

\\ 'ET IIl'SOrNG. When lhe wood strips are
Oexibl~ pnoullh. take tI,em oul of the sink.
shake off lh<- excess ","3lt:r, afl<l put theln in
the: jig ""/1,,.,,1 gilir. Bend th~m slowly nnd
carefully. Once they're in position, (lUllhtclamps on. 3lld It-t Ihem dry.
If possible. I like 10 lei the strips dry ovorDighL It's important tllal the slrips be dry

when they'reglued up.lftlleyreslJllwel. the

moislure wiU decrease the holdin/{ power of
rhe glue and the workpi('(:c may delaminate.

No. 72

lx4 PUSH
&lOCK

SAND
fND TO A
POINT
GlUE

.PtIITt1t
SPllTTtR

CUl TO fn

SAWKUI

IN PUC{

""

GWlf ... .. mTO

aorTOM or 01.0(1(

use them with. block or a pad 10keep from forms and ih" outer forms,
marring the workpiece. see Fig. 6.
inner forms are usually anachvd to
the
base,
and Ihe strip, wrapl",d around
WEOGES. In some cases 111uSC'a wedg<' in
Let's start with the tools. Youll need only a place o( a clamp. see Fig. 7 There isn't al- them. The outer forms arc not attached,
iabh- saw to cut lite Lltinstrips. (The blad~ ways enough room to USC' wedges, since They hold th~ strips againsi ihe inner Iorms
must be square to tho' table and in tine wirh lh~y require 3notl"'r block on Ul<'jig 10 and distribute the press ure of the clamps.
To make the funns, lay nul Lh~
the fence.) 1 11<'1 a srnoorh
.hap<'son the plywocel.or glue a
enough cut with a combination
4
pauern onto the plywood with
blad e thar lh.. strips don't have
spray adhesive or rubber ccto be planed afterword s. The
ment.Then cut the plywood wiLit
onh .p,>dalill'd tool ill the
QlJE&110N:V(J} Iw(da totoJd(""p""r
~p"{'lal toots to IMr (I hpII( /nminntrol1!

'''1'

.;t----=
(l...~~=--,,\ror"'

process is a bending jig - and

that's made in tilt' shop.

Ai;. for the damp', il d..~nd.

on how cornplcx nr large the

project is, The most clamps

you'll need at anyone tim!' for

the projects in this issue is.
rwd.(' (fur 1111'U:J11 Trw ring).
and uwy can bea combination o(
Cclamps and small bar clamps.

a band saw or sabre saw, I like to

...'11 to within Vl6" of the pencil

fine, and U'M sand to the line
with a disk or drum sander. Th;,
way, I make sure the surfaces
th.ttouch the strips an' smooth,
ISSE~mLY.when all the

pieces are cut. lay them out in

posaion On the base. Check thai
the clamps are big enough to

G\lfAWAY
lASE

,-_pas.

bridgl' across the Inner (orms,

QFSTION: I rlOII" har that manu "wedge" against. BUI they're another srreng' the thickne>~ of the Strips. and the Oilier
forms, If they aren't, downsize the forms or
el mps. Aretl rc UIIUtl'ft~rllati,'ts to 11 ~;)'{I way 10hold tbe strips in place.
use larger damps Then. screw the inner
C-elo U~P$" II(II'fn r rLn l1i[l$I
QUESTION: HOII' mv- lI,p /wlldlllg jig. form. 10 thebast'
Finally, do a "dry "In" 10test the jig. Stan
Several. but I (ound that C-clamps are the it,adp! What mnlr,inl~de) the;, r"'P,ir(_?
easiest and most versatile way to do laminaby genlly ~ndillK dry strips into (he form.
tion. So ifyou don't have enough, try 10bor- I used AC(inrerior grade) plywood to build Then pu( on the damps and check. for gaps.
SCI there are no
row some from" friend.
the jiln' ShO"'" in this issue, Since lite grain Sand down allY I,igh 1.:;J>()ts
<;-mAl'S,An altemative 10using Cclamps switches direction irom lay"r UJ layer, ply W\I" between forms and the .trips.
is to use metal straps. A strap applies even wood isequally strong in alldirection . A 101
Qt "ESTlOX: I','J~U't 'lit glllr !frick '1) fhr
pressure all around th., curve and h~II)Spre- 01 clamping pressure can be I)UI an a ply
vl'lIl U'" strips (rom 'lJliuiJ,)! along !b~0111 wood (orm without breaking lt.
JfY 'x
n utiJi,n"",.
You could use a lower l!rad(' plywood
'id,' i.e,'. SC<' Fi!!.5,Slrapscan be made (rolnl
pieces o( metal plumber's strap or thin di- (sudlasCI)X). but watch out fnrvoids.They To ketp the I!luc trom sticking. rub un a
mension tn,'lal bur stoek, Buill arc avnilablc can weaken t11~form Ilr('rr:'tr a rough l'1l$.!P heavy coal 01 paraffin or paste W3.X.I rtpeat
at hardware :.tor(.s,
when' the (orm rOlllact< Ihe lamin'led
this wa.xingsttp ~rwecn cach usc.
Rub the paraffin orwnxonal!surfaccs Illat
One end 01 a strap is fixed to the base. .trips. Particleb()ard a1:;<'W()rk, well. though
Thl'n it bends around a curve and is pulled it'smore Iik.elyto break under pr",,-""'c than ..ill be in contact with the workpi",,'e.To gel
a .mootb ,'oalof J)..raffin, I U~ a hair dryer
up right on Ihe other end. A bolt go Ihe pl)'wood.
111\.<;.To 111akc.t bcndingjig. ~tar1by rut
10 melt il into lh~ iorm. 'I"is <tep isn't eS$en
through rhr free end of Ihe strap and then
Ihrough a fixed block. 'I"e ,u-al' get. pulled linl! a base. Just make il big enough to SUI>- rial. but it helps the paraffin penetrale Ih~
pnn the bendilll! piec~ and the Slrips. 11rh, 1,lywood and ~Iimlnales any ,'h,nce 01 the
up dllht with a winr;: nutor a wrench.
ba~ i!:- toO big. ~,t()lI11
v.ind up li~hleninJ! ;u1 gillt' >Iickinllln the jig'.
C.\~,~. Canl!; are anotllt!r J,!txxi, inexJ*n
:'iotC': Thcr("s ont' tim ..' J \voultll,'l rt'Colnsive allt'malivQ lO C-clamps. Th()t can bt Ihe C-clamps willi halflums ~in('t' th.> b"<e
nicely designed and carelully ron~Cl{'d or !INSin the way ofthe C-('lamphandl"s. Thl' mend waxinglhe form.llyou're n()llt"in!! to
se<'ms lik~ a .mallllOim. bUIwhfn you'", ..and or dr<ln up thl' fact'. of your fini"h~
li,e}' (.:811be a I)iect! of wuO(1 Will, .'0\"
round,-d com,'r. S('. Fig. 6, 11le impurtllnt ~!1di!111alltho<c glul11l1P.trip".round the lamination ailer gluing.c1uo' U$C'wax on Ihp
thingi<th31 thcpivOI puini bt- off.<;II1
,;()more (orms.},()uwant the daml"'lo 'to on quickly. fnrm. P"'le wax and paraffin ",ill p","'cm the
pre$$\u'e is applit...>-das the canl is tum("<I
FOR."S, 111t'forms are the pan. of u,e jig fuUsb (rom penelraLinJ.(the wood on the
If you u;.e (anl$. remember they ex~n that thcwnodstripsa .. bontaround._
FiJ!. Jinishl>dlamination. In IhlS situation. I uS('
mof<' pres.'UIl' limn you mil!ht expl-'<'1.So 4. Then:an'lwo part<ro the (umt~.lh,' inner "'axed paper III lin,' the form.

')('~I'

CAMS

ffXlD

-S"ffitIPS

,"lOaM

-Offsn

PlVOTPCNT

Woodsntim

lOO$(

IUX1C

III'NT

sm.s

, .......

'''<a>
<0111><

No.72

Ql-ESTION: Willih. wlI",/lry 11'"1""'11 nut coward each end

wrapping lhe strips
buck to its urlyitluJ ~/IU'JtaJlerpitcI llll!
around the curves.
Yes, a liul... I!you fWdthat there's 100 much AI first. just pUI
springbac:k ina laminated piece. reshapethe enough damp presforms b)' tightening the curves enough to sure on Ihe suips to
make up (or the spring back. There's 0" keep them from
formula (or how milch to ,.....hape the forms, moving. Tightening
it ill'l takes <om!' experimentation. (Nmc: comes later,
Small tamlnated proiects "ill nommlly have
When you start
very Iiltle spring back.)
bending the glued
up ,uip> around the
QUESTION: lI'Iml kimia/ylll' .'wuM/ curves. things can
gel a little tense and
Il.'il>! II(/If! (If) IjIJII !If "I -1'/III,t' *t "I)X!
lit' r,"s (III t:.(({ "I ,~/t',!(}(c,tt'l iglll {~ tl, in, ",r,-q if/Itt fffflf 11,'d ,..I np r.J_(
rushed, so II'saguoo
111",'<1 IiIL'oolld Wooo <OIue(a yell,\w glue) idea 10 have a friend If'(Jtx/ ClIft I,.. bt.'lIt. Th~'1(.Vt.:~~tlli('k1(1fl/'lll/xt,l" l('il!f Hf)(lk,d r)""r
for the projects in this issue. Other yellow near b)' 10>'UPI>I)'a Ilig/lt ",/(tp {(,yzlero 1I(/IJwll 'it.'d IfP iilit' (t prets l.
(aliphatic) glueswill also work since they fill "third hand."
small g'dPS 10 some extent and dry quickly.
Some ohhe strips "ill s1io~up above the U$ehlt!f the curve the w"ater the pressure
Ifthe projc<1has a 101o( "rips and ),ou'r(' resias you bend the stackarouud the curve s, $0 l leave the clamps on (j"<mighl.
concerned that yellow glut won't provide T 0 keeptheedgesflush,useahammertotap
When laminating a piece with more
enough ,v,)rking lime. use white glue. \\1'tit(' them down. see Fig.9,And roclose anvgaps, grndualt'llIVe>. such as the rem Sland legs.
glu._takes h)t;gcr l41 set-up. so }'{)U \\'OJ' 'I (l"el re-adjust Ihe pesiiien o! a clamp or add tht:re is less pressure 10 spring back, Itlll'i~
quite a.~rushed.
another one.
,'35<1, I'll remove the clamps a(ltr six hours,
For 3 project that will be outdoors, I usc a
\\'hen I'm sure that all the strips are in
REMOVL'IG TIlE Cl.AM1'S. \\'heo Iremove
resorcinol glue or epoxy. They're water- contact with each other. I re-lighlcil all the the damps. I do it slo\\'I)'. Walch the CUIVC'S
proof and will stand up 10 the weather. clamps and even out the pressure.
carefully. and check (or delamination. A
However. epoxies differ in how wen they fill
CU:'\.\l p.l3efore the glue starts 10set up. small amount of.pring back isuormal, BUIif
gnps and how much working lime they pro- use adrypaper towelor small piece of wood Ihe strips start 10 separate re-tighten the
viele. You'll have' to experiment to dcterrninc 10wipe offa lototthe glue that hasoozed OUI. clarupsand wauarleastacouplemore hours,
what you need.
lt's easier to remove the glue now than later,
in
then remove
Bent lamination uses lOIS ofglue. It's hard and reJno\'in~ the excess may shorten d.l)r. pixe, and stan cleaning it up,
10predict just how much you 11need. bUIit is ing time by exposing the edges ofthe strips.
usually more than you expect, The legs for Don't use a wei towel thQugh. You don 'I want
QUE!:>'TION: 11'/1(11'. 'hI! I,,., 'IVIU 109<1
the Fern Stand,tor example.took more than 10add any rnoisiurc 10the strips.
"JJnll 1//<1191
h"lf a 1201.. bottle. So make sure you have
plenty ofglue before you start,
QUESTION: Ho /(",g dOt. il IIlkf Ji.,. Ius<' a paint SCJdpef to gel the ''lOr'S{ of rut'
Al'rLYl~GruE GUrEoTu apply the glue. I tllf gl,ef' ") (/~'ll!
glu~ .,!(. Bul don'l try 10get 00\\<1110bar~
us(! au illexptn$lVe foam bnJsh and uinl Lbe"
w(lod with ~teSCralleJ'Qr you IDa), I~ar of!
tip to thcwidth of the strips. TIle (oam brush TI,;' process is very differenl from gluing up some cdg(s.
can be wash(-d Oulafi('r each use. but ildel~ a panel. \I'hen gluing up a pando Ilak~ the
To rcmov('lhe rcsl oftlw glue 1use cithc.'
damps 0 in 10 10 30 minules. BUIwb~n a low angl~ block plane or a sanding drum. If
riorates r3llidly.so have several on hand.
I'clur the glut into a $malt cupordi~h.an(1 laminating slrip'. the ....'slotsof glue and nol )'ou use block plane. make a fine ''Ill tu
spread it on cmly one side of eactt striP. see much ,..-ood In soak up tIte mois.ture.
avoid tear oul.
Mil. 8. j\:s )'OU brush the glue onto the strips.
Once the snips arein the bending jig, the
S.'lDdingh also "good way to remove the
nloislure
in
the
glue
can'l
escape
on
three
slack tllcm like you're making a sandwich.
IaSIof lh~ glue For those pit'Ccs thai have
'n,en pick up the Slack and lay il on ilSside sid~s, The base and bending (orms are l.'l'lldual curves and will fit on my drill press
in Ihe fonn.
'Yll.xed.leavlng only Ihe expo,;ed edge oftl table. I feed the workpiec~ bctVoeen a drum
strips (orthe moislure 10 gel Oul.
sander and a guide block clamlX-d 10 the
1ighl('r
curvt.
rcquin'
longer
drying
labl~. ee ~ig.IU.
QUESTION: 1I'''l!r'~ Ih' bPSI pm"f'II/II'P
for ~Ja"'l}i UtI tJ(tt :"fri~?
lim,'. The glue needs 1<1 bt' completely dl)'
tONlU s,ol'.The pmcessisinvolved. bUI
(noljust seluP) 10r('sisl the strips' desire 10 it's prel1Ylogical. 100.\\'bile il may be trickY
Slmclamping in the lDiddle.and then move spring back 10Ih.ir .ril.~lll~ shape. And the and a lillIe me"",'. it's ah;o ju.tplaiu (w
Hthings

stay

place,

the

work-

",1

10

SAND 10
UNlfORM
tHlCKNlSS

$TA(l( snIPS

AS GJ.Uf

lS APPUEO

APPL,Y THIN
lAYER Of GiVE
ONE SLOEONLY

>J". 7~

ClAMP OUfOf BlOCK

TO Orll.L PfClSS r Atlt

HEIRLOOM

PROJECT

Hall Tree
This hall tree offers three differenr bending challenges - a silnple L~bend, a
more comphcored S~bend, and to top it off, bending a full circle, All you need
a few shop,made jigs, and a linle rime,

IS

very tim. I ."" , pi'-'<X' 01 special aruclc on h<:ndinJ( nnzs

bentwood funutun-, I have on page 16,)

10 ,lUll and Iry Iv ligun' vUI how

il was mad." And whenever I
think of bending wood, a classic
proj.,,11ll1ll rye wanted 1(1 build
comesto mind- a hall treewuh
its disrmctive curled hooks.
C.~O'STRlcnox I soon 10Wld
out this project requJtt>s it bit Clf
patience 10 glue up Ih(' IlIn','
bern paris - the legs, Ih,' ~
books, and Ille ring, I'.'l'h offe",

a dlffcrt'nl bending ,'hallenj("

The k-gs require a slnglo bend
and are the simplest to make
The ~.haP<"i hook. have

I""

h<:nd, and are more l'hall,'nj('

WC)()IJ, For thl s project.

selected

walnut

b~C3USt.: It
slTt)n,g. and has 3

bends \\('JI.is
lr3onional elegance
1llRD\\ '\RJo:, Once Ill,' curved

parts are made.there's not a 101

uework toassemble the han tre"
The ~h(l(J"'"Sand ria,S!are :;.(..
''1lrt'" In Iho 110<1with brassovalhead screw s, I also used walnut
pluJ,t"-to cover l~l"" flathead
..;cr(~"",:,- ill the leg holt'S.
(~"tH'Nt~"t..,),

Prciect

Sttpplir:l.

is uffonos: L1w walnm plus:> and

Ihe patterns (urlb, bcndiug~",
"' ... Sources un ""1 31.)

iog. And the riog i, laminated

I1NLSIl, (3('QuSt: of Ille curved
using a slightly dif(ereOIIJrOCt,,;:; parts in Iht' halltree.I decided to

than the other two, (\\'e\. in, USt' a wipe-on finish. I wiped on a
eluded an article on belli lam in. couple vI coals 01rung oil to protion technique'!'>on paJr"t' 6 and ~I duct a soh luster,

MATERIALS

!BENDING JIGS

WOOD PARTS
A Leg SuI;(32)
B Hoo~ Stri; (20)

hz.1'.I>'3O
'1'.12x~.30

C POSl (I)

1'.~xI\.l!'~

o IlingStOtlerSlnp(1)
E RlngSlfI; elOl

'1'.12. :v.'"()
~x ~..24

SUPPLIES
7 6 Bel H 01.y.',the'< WO'r)tII

JC

hQodWOQd!CISWS

(llconol

.,

"".9, a.,

~..... 4',' ~60"

A

E
~ .It

i
I

"act

10

'1

3'"," ..60 {1.5 act. ".)

""

ad..

"" .. ~ .." 7fT 12

pOs!8WOX

DIAGRAM

5'."" 6O...t1.:1 Sll.'t.l

'I. COl'

(6) No 8. lit.. 110"

(' pin.) Tung 00l

~."

(1) 3"Ion9
Iiogebol1

(0) No 8 x 2' not'

heaO\'Joodscrsws

(8) WoIrnJtovolheod plugs

(8)No 6. t' !;l<<m0ll<.lh!00SCi8W1
(8) No 8 x ll',' Fn wOOd$C1eW$

CUnlNG

(nAB' ".48' $heet or

~."tnl(;l<plywood
(1) 6' length 'lI.' ,dlo
dowel

rt.l

fT: =m

!~,o~

:_g_

I
i7ZZiZdJ
J
-,-~ ,

No, 72

BENDING JIGS
I started work on the hall tree bybuildingthe
three bending jigs, (Nol~: Layillj!our these

jigs may be the most difficult pan of this

whole pruj""I, Allhou)!h we're shuwing
drawings(or tIwsejigs on this page. you may
want 10 order the jllllxi,r patterns and
detailed instn,cliun. from W""dxlllilll Prujlrl SUNlli ... ~'t'page 31.)
lEG BESI)INGJIC;.The leg bcndin)!jill consiSlsohhrec pi,,,,e.;:. base, a fixed form, and
n Ilivutinll P"""Uf(! block. sec Fig. I. The
fixed (unn is attached 10 Ihe base bUI the
pressure block piv..", on. dowel. The pressure blocknnd fixed form operate much like
a hamburger press 10squeeze the strips rogeilicr.Thecndsof till' fixed fonn also act as
<:lIl-off lines for lrimming the legs 10 their
finished lellgih once they're glued up.
CclNSTRI'cnl)S ~0'11lS.The fixed (0011
and pr.....sure block (or the leg bending jig
are made by gluinillogether a double layer
of :JI4" plywood. Afler the rwo pieces of pi)"
wood an' glued logf'lhrr. the next step is 10
draw afull-size paperpanern ofthejig shown
in Fig, I.Then glue this pattern 10 the plywood. andcut thepiecesto NJUUll shape.
N~xl. damp the pieces 10 the base and
drill ~' holes for IwO dowels - one (near
the end oj the pressure block) actsas a pivol
pin. and t11~other (near Ihe inside cdJ(,' ,,(
the pressure block) holds the pressure
block inposition uutilclampscanbe applied,
Then, clri1l11i1"ll1,,1(~and S(.'f'('\\'111f>fix~
form' 10 Ihe 00"'. see Fig. I.Afl~r the holes
are drilled. remove both pieces, sand 10 the

pattern Ii"es, and SCrewthe jig together,

SHOOK lIESDL"G JI(,. Although ihe S.
hook jig squeezes siripstogether like the leg
jig. it'sdiffcrenl in a ncmber ofways.Instead
o( relying on one pressure block il uses 5\'e
smaller curved pressure blocks. see Fig. 2.
And it uses IWO whistle-shaped bending
forms -Ihe larger one is fixed 10the base
while the smaller one acts as both a pivoting
lonn and a pressure block.
Th.. pivoting fonn swings out and allows
ihe strips 10be inserted. then pivots back so
tlte)' can hi! tij!htlyclrunped in place.
tOl'(STRl'cnON NOTES. 111e pivoting form
also uSA.'Sa pin lik"lIte leg jig. bUIthis time I
used a v," carriaze boll with the threads CUi
uUinstcad of a-l'1" dowel, sec Fig. 2.Th c, -\14"
boh located euhe center D(Ib" pivoting form
allows room 10 drill holes for C-clamps,
There are also two sets of marks on the
bendiog jig - one sel shows where the shooks will betrimmed

10 size. sec Fig.

CUT-off

LEG BENDING JIG

NOTE:

UN'

--

,,-.otA.,

,t.~

lONG

___

S(t.lOING fCNtM

ANl)PJtl$WlI
tI.O(fCAa,
11,..~ntIQt

PRUSUR
"lOCK

PtVOTDOWEL

_M

SOlOW

61,.

4-13" r-

IENOlflm

TO lASE

I
CIJI P.utS FROM
2l,AYERS OF
lI.....mt(k Pi,YWOOD

2'"

cut..", UN'

HQUS

BENDING
JIG

.o1tM

rOk
ClAMPS

HOOK

flXD

S"

...

,"

UN'

.lI....

CIJr.Qff

CUT PAftTS

'R"'"

'0"

l ..
lHlCi(

PlYWOOD
CURV(O
PJtlS5URf

BlOCKS

SCk!W;----...-

CUT"'

PlVonNG

CURVED

UNl:

PRESSURE

.0"'"

MOll LOCATION - -

'lOCKS

-----

----J6'"-

-IAS(

RING
fOltM
PII.01 HOtf
lOCA1K)N5
fOR HOOl(S

RING
BENDING
JIG

S""

'"1\.

Cut PARTS

fROM~."1MICk
PlYWOOD

13"

1, WlOIE
SlQTfOa
STARTtR STRIP

2,And

the other set shows the screw hole positions

for mountJng lite Shooks.
RlSI) ""'''I)INGJI( The ring bendingjig is
compl~lely different from the other IWO. It
doesn't have any pivotinKparts or pressure
blocks. Instead. it consists u( a simple ring
sh.Pl'" term thal'S mounted onto a square
base, see fig. 3. (For more on making this
jig. see P3II" 16.)

N\,. -,
I ...

...

S(IItEWRING

MARK fOUjt
fOUAU.YSPACIO
POINTS ON FOAM

~OAA\10 rME --

-'-1..-

fOR PIlOT MOl.(lOOATION$

""---\'(/oodsrmth

..,
II

LEGS

I After complcling !he jij('S.I sand, and check fora bj!hl fiL
began work on dIe four !logs.
:\otc: ("\ny imperfecticns on
The fir>t swp is 10 rip th< th(' jig will translate intu gap. 00
.trill'> [or the legs. To k.",p the larmnated parts. h'sbenerto
the Ic~sfrom bowing under SJ)<'IlU exira lin1<' sanding nQW,
heavy loads (such as winter than applying filler later, Once
coals). I drided 10 make you're satisfied with the fil, apply
them 1"wide, Each Ictg is a generous coal of pa-:,t~wax to
glued 1111 from eight strips, the jig, This helps prevent theeach :V12"-thick - for a lotal strips from Slicking to the forms,
thickness o[:,'.
GU ~:IPI.E(;s.Aflerthebcnd
CUT S1RII'S. The log ing jig is waxed, the I~g. "an be
strip. (A) are cut from :\ ,". glued up. I used a f031l1 brush to
thick stock in IWO SI(PS.FIrSt. rip eleven apply an even coat of gill. onto
blanks (oaNugh lenl.1h of30"3nd afinished cne stde oteach legstrip Then I
width of H~'. Then. resaw each of these Slacked ~'Cstrips and damped them 10the
blanksimo three h2"tbickstrips. see Fig. 4. straighl section of the pressure block, S<'C
(This will give you a lotal of 33 strips. You Fig, 5. n11i, helps keep the strips aligned.)
need eighl strips [or each Icg. a 10lal of 32
Now close the pressure block and lock it
strips. but vou mal want te cut extra incase in position with the dowel. see Fig. 6.111"n,
apply clamps across the form and pressure
any of the strips twist Orbend.)
rssr rrrns, Before ,!!lwlljtthe strips to- block about every 4" to 5". and remove the
gether, there's one more important >lepdowel. see Fig. I,
test fitting the bending jig. This involves
Aflcrthc leg has dried <lv('might, remove
placing the strips in the Ix>lldillgjig. and it from the jig. Then clean up the jig by rech.ckingforgaps,
moving an)' glue with a chisel. xow, usc th,'
To check
fit. swing the pressure bl,..:k same procedure to KJUt.~the remainim; legs.
'1'1<1\11';". Once all four I"R$ ar.. Rlul'tl,
out and damp
strips 10the ('nd of the
block. see Fig. 5. Then swing the prcssore "1', thl')' need to be trimmed. Before you trim
block dosed and insert the locking dowel. 111[>,111. scrape off any excess glue and handsee rtg. 6. \It"Xl. clampacross the IOml:iUJ1(1 plane each leg loa finished widthotl". Tht-n,
mark any areas where there are gal>:;.see if there an- ~Inyvariations in thickness. UM.'a
tig. 7, Ii necessary. disassemble the jig. re- drum sander and a rub block 10 thickness

tl,,

~~"'t

ClAMP AND Glut liGHT

stlUPS TO STIAWlHf

SKtlON

aa.oc~PAST HOlt

sand Ih,' 1.:g$IOa unifonn ~,', see p.'g" 18.

Next, set each I"l( back in the Ix>ndinl!jig
and mark the locations 10trim to length. Finally. cut eath 1"1(10 its finished lellj.'th.
sovxn O''ER EllGF.S, Aflcr the legs have
been trimmed 10 length. the edges can be
rounded

QVt'T_

I routed the top ,_u!/r.rl$ of each

I(>gwith a :~t\"round-over bit in the: roult:f

wble, Sec ~il!~.Then. 1used a file to round
over tht' lOP' 11(/... of the legs 10 a ,," radius,
>rt' fig, sa. \UIC: For .Iability, don't round
over the bonum t'()ge, of lite l~g>,
ORlU.MOI~'nX(i
noiss, The linal slep in
making the I<,!(sis io drill two counterbored
lllounti"1Ihoi.., in each leg. see ~ig,
9, To do
thi" first drill a ~,"-dcepcuunterborc with a
, " drill biL Then, use a ~c"drill bit to drill
the -hank hole

'UtST. SWlNG PIt(SSUltfc

Of' PRl:SSU1U "SlOCK

a.

APP\.YC<I.AMPS NOY 4TO S AND RtMOVf DOWtL

IN t.ASt-

.J

...,.
I

THlN;.lNSlJIT DOWn
TO TEMPORARJl.Y

P1lUSURI
StoCk

LOCK IN PlACE

Non:

USE A. SCRAP a&.OC1C ,.,.,0--'

HAIMWl J01AP STRlP$ FLUSHAT
fOP BtFOIl ~GHJIN'Na.ClAMPS

a.

NOTE:
~ ROUN.D.oVER
ON lOP tDGlS ONLY

FlU (ND ro )aROUND'oOV'bt

ROUT~l"
ON ROUTt. TASU:

12

SHOOKS
,
.lust like the legs, the [our:-'

bending fig. I ,lipl>~d rubber

<- - honks are made with .\.:It'. bandsover the bent ends ofeach
"'--lL!:- thick strips, but they're only <N 10p,,v.m it from Insing ils
lint 20 STRIPS
':.' -wide. Tll.1.k~s6\1(0 strips bEolIl shape-as il dried.
J.,,"JHICJC
TE~Trrrnsc, Now that tilt's..
laminated lox,-ther I" Iorm
I
each of Ihe (otlr S-hook,. hooks are pre-bem, it's time l()
a.
lI'ilh glut bi-rwr-en Ih. ItU back and fine tune tile bendpieces.the S-hooks measure ing jig. Clamp 01,," sel or strips
about , " thick.
into thcjig and mark any gap> or
cirr STRlf's. T" rill the rough areas on the form s, Then.
book strips (B) (or tht- (our takethe jig apart and re-<'1nd as
Shooks, I b'lIan by CUlling necessary until a tight fit is
L-_--"."_-' IWO blank. 10' rouj'!h width achieved, 1'-"inaJly. reassemble
ui 3" RI\d a length of 30" TIll11,. set the rip the bending jig and apply.
Ienee to produce l-,!'thkk strips and ripthe R~ncrouscoal of paste wax to
Hili "II > O\'FR Elle ~:S.
A(Ie r the S.ho"k~. re
blanks 10 produer Iwenty .v,' -wide ,trips. the edges ofthe forms, the pressure blocks.
trimmed,
lilt'
t"dgl'~
can
be ruunded over. (
five-trips for each S-hook. ",',0 ~ig10.
and the base
el.n;II' S-HOOl\>,.
~ow !hOI the bending die! this t))' mounting a ~'l'itlround-over bit in
"""KESD' 1t(0)"S. Before tlw strips can
bcglu('(!.upin Ihe b,ndingjig.! soaked them jig is ready, the Shooks can be j!lued up. the router table and raising it 10 produce a
and pre-bern them to shape. This helps pre- Start by applying an even COal olgluelo one ~16"d,,"pcut, see Fig. 1:1. NlI'r lilt' Idges
vent the strips from brC3ing on the tight side of each strip. Then. ,t.'lCkthe strips and are routed, round tlw ends o( each S-hOtlk
damp them in the form, just as when wet- with a file. see Fig. 14. I used a quarter 10
radius bends oflh~ bending forms.
T" wet bend the <trips. place five strips at bending the Shooks, Lei the glue dry over- strike a radius on the ends. see Fig. 14a.
:1 rime in water for about 15 minutes Then,
night. remove the S-hook from Ihp jig. and
I)KIu..'lOt :o."XC 1I01S. To complete the
S-hooks. drill two hole<: one fur mounting
damp the ,trips in the bending ji!! between then glue,ol>the remaining sers ef strips.
TRJ.\I S-HOOKS. After the Shooks arc the Shook to the post, and one to attach the
Ih,' pivotarm and thefixed form, see Mit. I L
Nexi. \\'orking frorn the center out, curl the gluedup. they can be trimmed. To do this, ring. To locate the holes, place the Shooks
strips around one radius 81 a time, Clanll)iJlg begin by scrapingoffany excessglue. Then, on til<' bending jig and mark them. refer 10
the pressure blocks in plac .... v I"ig. 12. (! hand plane Ihl' Shooks to a uniform width, Fig. 2 iorthe hole locntions, Kext. use a :.~"
drill bit to drill two shank holes in each 50
used 2. /' (damp, for this.)
N~<t.
$el each S.hook back in the ""ndingjig
Let Ihe ~hook dry ovrrnil(lu. !'hen <"ak and mark Ihe ('\11-0 1000'llHon$at the ~lIds. hook. S('~ ~ig.15. Finally. counler<ink the
311d \\('t brnd 111(' r('lnaininJ,! strips in *t.., ol """ I'il(. 12. Finally. cui Ule ends orr each holes "" IIvnlhead screw. will ,it flu,h wi til
ttl"" !'ooUI;1tt:t~,.. r t),E.' s..a'(tllk. $("P fig. lSa.
:;'hook wilh a hand saw or a band saw
live_ ..\f'f'r t'l'ltl()ving a ~l of strip'" frUI'Il thr

11

CLAMP

'Ino

FOAA\

,Nt STRIP~

_- ..------\

8E1Wt[N Axro f.OR,M

AND PNOT ARM

':>_:

.;;.

"-

NOn:
SOAK STtuPS 30 MiNUTU
IN WAltR IErolt'Wn

13

.....

~IVOl

CLAMP PAUSURt _/

sa Rxr

T......

o.

CUTOfF
UN'

.. LOCKS 1M PlACE

BASt

IIOUTl

or-

SCUW 1101.(

-.

.~~
alNo.NG,

lOCA-noN

""'

1/

~oO~

/'"

(ut.Q"
UN'

a.

HOOK ..

TRACt

RAOfUS
ONTOfNOS

15

LotAn
MOUNTlNG HOW

'IOMIMAKS
ONIENOLNG JtG

111.(
ENOS TO
AAO'US
<>fA
QUARTfR

,~,.

~,.......
"":3

SHANK-

MOll

Nv. i2

WooJSllllrh

13

POST
,-------,

Once the I~ and Shooks

are completed, work can
bt.>gin,10 lh. I~~-thirkPC"1.
To make th, post, I laminated two pircesof1,"-thkk
stock tog.ther instead of

milog Ihicker stock for two

reasons. First,1"'~hkk walnut is more commonly available, And se cond. a laminat\"Cll)lJ~thas less of a tend"oey 10twist than a piece of
L-__ "!!..---' P..'.!"-Ihick stock,
To make the po.1 (C) . tart by ripping two
~""'Ihick post blanks In 3 rough width of 1%"
and a rough leogth 01 iO", Then, glue and
clamp II.. pieces t',gether face to face.
\\'hen the glue is dry. scrape off any
execs, and joint or plane the post until it's
I Ii-i" square. se,' Fig, IG.Then. trim the post
10' finished length o( 68".
R()LTSTOPI'ED t'I\'\."FF.JI. To giv. the po>t
an octagonal shape, I routed "upped
chamfers on the top two-thirds of the POSt.
The chamfer starts 24" up from the bouom
of the post and provides. square surface 10
attach tlw 1Log:,.
To indicate the beginning of the slopped
chamfer, mark reference lines around the
post 24" from the bonum end. see Fig. 17.
Then. draw a reference line on the router
table fence that's aligned with lhe center of

16

17

,,"

Q
!

POst

......

aOUttR

eorroM
lNO

rENeE

a.
"-,,"

...

POST
~

18

a:')

SAM! alT

HEIGHT AS
fIG. '70.

~."

1'0\'

the router biL

Aft~r tlw post and feDceIIJ'C marked. raise
the chamlcring bit to CUl" ~i~wid,>chamfer

on the post. see

b.

~-Ig.17a.

To rouuhcchamfer.ease the postintothe

routerbit so the line on the workpiece aligns
with the reference line on the fence. Now.
moving the post to the left. rout a chamfcron
aU fouredgesofthe~t.
SL~,.g. 17.
CIIAMfER TOP A."O BOTJ'OM_ \\11il. ihe
chamfering bit is still SCt up, rout chamfers
on both ends of the post, see I-ij(.ISa. I
placed a $OPlIOrtunder one end of the long
POSIwhile chamfering Ihp other, and useda
router table push block (sec TIps. pag~4) to
keep the post square to the fence, see rig. 18aotrr DECORAm" CROOI'F..After the

(SEt PAGE- 4)

19

14

- -, -;:-.

20

'i r

TOP0'

POst

endsare chamfered. decorative gTOO\'es can

be routed I" in from each end. To rout the

grooves. I used a ~J"-dia. core box bit set
II."-deep. see Fig. ISb.
DRIU, MOI:NT1NG IIOLES. Afler grooves
are routed in the post.the nC>tstepis LOdrill
pilol holes to mount the kgs and S-hooks.
The holes for the Shooks arc centered on
the width of the POSt12"down from the lOP
end. see Fig. 19.
The holes for the legs are alsecentered on
the post. see Fig. 20. Locate the firsl hole 7"
from the bottom of the post and the second
hole 4" iron. the firs~ Mer marking the
holes. usc a %2" drill bit 10driU the:v,"-dcep
pilot holes.

ttOUTU. fUll
PUSH 6lOCX

POST

... u.
"',,"HOlU

2.'

~"OlEP
ON AU

fOUJt fACU

_,
__.t
-, -iii! ~

1t.."..

.RlU.
~'''HOlIS
1" ....1)t(P

~I'~"

Woo,Jsmith

---

,;

.,.

,
7"

IOTTOM

ON AU
fOUltf4CS

IEiII

'2"

...

OF POST

"'I" 'I

_L.

'"
-""'''1....L

No. 72

RING
,------,

The 18$101 I he bentwood

c..

components to make i:-- the

ring. 111<' ring i,buill-UP from

:>:I:/"'Ihickstripstharare bent
around a found form. (~'Of
step-bYoSt'1)Instructions on
building the ring bendina
form, see pages Hi 10 11.)

Afler
ti
buHdmgthebendingjil1. ripa
jj ..._ IO",lonl(ring starter strip
ST\~TR STRIP.

.,./' \-

I (D)

trorn ~,"'lhick 'lock

(The starter str ip i...cut
longer than the n.~1(JIUli' strips so it'll wrap
around Owring form "omp!t'lely and ov,-rlal'
about aquarter-turn.) Soak lhe~lrip in water
L-_--"-_.J

and damp ilto the Iorm 10 pre-bend il 10

,h3I)<'.Then eut u-n 2~lonRrinl!~trip~ (E)
and pr....bend them, Let the strips dry over-

21

nighl. Then insert the starter strip in lite slot

in tilt' Jig. clamping th~ strip as you work
around me form. Nexi. apply glue where it
Q''- 1'11)~andclamp it in place.
CO)II'U'Tl'GTIIRRI\'G.
Then u's a matter
of adding the other strips one at lim..
around the form, Once the thickness is built
up to '.". the rinj! can be cleaned up and
rounded Over with a ~II round-over biL
!Again, this is explained on pagc", Into 17.)
SCREWHOI.ES.Afwr till' ring has been
made. Ihe next step i. to drill lour holes to
anach the ring 10 the S-hooks. Since the !:>-

drilling the angled hoi." I bulh a drilling jig,

see ~'tg.21. The jig is constructed frnm ~".
thick plywood and is simply an angled pial,
form. To hold the ring in place, I glu.'"
couple cleats to the plauorm, sec ~iJ:.21.
(You could drill the hol<'1;without m, jig if
your drill press has a tilting labl{-.)
llRIt.L IlOI.J;S. After the jig is m3<1,.scuhe
ring on the plaliorm.Then, position til<' platf..nn on th,' drill pres.' table until a 'l-:r!" drill
bit is centered on the thickness o( till' ring.
see Fig. Z'la. Now. adjusllht depth stop on
lite drill press to drill ~.-d('('phow. and
hooks n1('''('1the: ring atul\ angle, thc.l101('$UJ'\.' then drill thc Iour pllot holes.
drilled at 20' in fnur equally-spaced locatl~lIsH.Sinceali oftheparts ofthe hall tree
an-screwed tOR,lIter.it'srnuch easiertofin
tions. To locale the holes.place theringback
on the bending jig and mark where the four ish each pan before assembly. Su before
going Imy Iurtlwr. I rubbed on IWO coals of
hull'S "in be drilled, sec Fig. 3.
ORlWXG JIG. To position th~ring lor lung OIL
I,OCATt MOll POSfOON:$ 'ROM

ORIWNG JJG

RUDEN(.(

~-----------'Jr

MAUS ON &l:NOtNG JIG

a.

~... PlYWOOD

ORtU~
fQUAtl Y-~SpA(tD
<, MOl"

"..

DR.U. PRI~S
TA&lf

ASSEMBLY
/If'''r tht finish has dried on all tile parts,
assemblycan begin,
,\1T"\('11 LEGS.Start by placing each leg on
th. "".1 and lilting up the pilol and ~hank
holes. 111<'n.
screw the leg 10 the post with
II s"flatheadwoodscrcws, see ~ig.
23.Once
all lour I~gs were screwed on. 1):lued oval
head walnut plugs in each bole. see Fig. 233
(For more on pluK>.St.'C page 19.).
.\nAC'1I "HOOKS. After the lej!s are atiached.the m'XI step isto screw the S-hooks
to the J'O'I. Todo this, position Ollt' Shook on
the 1>O~'ancl screw it in placewirh a J" brass
ovalh ead SCI''''''. set' Fi):. 24. r.vlake sure the
large radius on thi:' Sohnok is at the bottom.)
f-Jeo!Qll" {a.~ll':'njnR
theremnining Shooks in
place, slip the laminated ringov(>rth<?~honk
yuu just mounted. (The ring won't filover all

fnur S-hook. Ol"~'IIw)"", installed.) Nnw,

"ilh th(' ring 100.. ' on ihe post, (ft'<llhe remaining S-i1<Klks thn,ugh the ring and sere'"
them to the post.
~1TA(lt RING. The final step i$ to connl'Cl
Ih,' ringtu the :-.ho"k<. To do Ihi~. >CI'eW tht'
rin!! to ... eh S-hook with. I" brussowlh.ad
~re".$t"e l-tK. 24a.

24

23

POST

"HOOK

PWG-

.Ox '"
~aRAS$
OYAlKfAD

sc.tw

a.

.'

.0.

.. OVALKlAO

1- BRASS

o.

OYAlHAO SCREW

S'HOOk

RING

PlUG

t5

WOODWORKING

TECHNIQUE

Laminated Ring
Making a laminated ring is fairly
simple. It's jusla matter of gl uil)g and \\'TIJPJ)iog strips around

pOinl of the jig. It fits into holes

drilled in a large shop- buill

router base plate, (If you have 8

trammel peint for your router,

a ring-shaped brndingjig
Okay. but i-m"t it even easier
to cut a ring oul of a solid piece?
It's easier. but not better (or 3
crouple 01 reason!'. 1;"jI'bl. there
would be rwo ",t-a k spots where

you won't u('Cd to make a new

router base.)
&\5 NATE. So I started by

re-

placi11$: the base plate on n\)'

routerwithanew one. (Formore

on this. sec P3!(e 19.) Afler it's
replaced, drill thre e !,Iu;"pivot

lh~gnin cutsdirectly eCT"" the

thickness, of the rinR .\nd second. a solid ring warp. with
changes in humidity - but a

holes in the pial!',

1'0 locate the holes, insert a

laminated nOR won't,

v,"-straij1h1 bit in the router and

measure out (rom the cUlting

Though I'm using Ille ring

irom tilt' Hall T,.,.., (shown tin

p3g"IO) asan example.thisprocedorecan beused 10 make any

,i1,(: ring or even (I wheel, Just change the ring-shaped belldingform. see photo.
,i7kohhejig andeu; shertercr longcrslrips.
The trickiest part ofthis project is making
the
round form-e-irhas to be-a perfect circle.
REI'OISGm., TIle bending jil1 I used is
made (rom Iwo pieces or l'." plywood. One To dothis, Iusedarouterand aprvotpin The
piece is a square basco The second piece is a pin is simply a brad driven into the center-

edze, The closest hole to the bit

(:W.") is used to rout the iI/sit!'
edge of the bending fonn. see
Step 1.The next hole (5") is for routing the
ol<t.<idt edgc otthe bending form. The third
hole (5'y,,,) isn't used make the form, lt's
used after the laminated ring is Jdued up to
trim the ring (0 a perfect circle

'0

,
stOT FOR
STARTtJtSrtlP
nPROUltR

art iNTO STOCK AND

ROTATEClOClCWlSt- TO ROIJI' R1NG _./

r..or(ll~r( nter ti'IPil (1111/.dm.II' ('} ...('II'~

JDY tlte rirl'I(/a. /01-/)1 Ttn:n, x("rrl(+

1)IY'rtf)(Jd 1~ln"J..'it"'f.lptllPfXO 'lit ,..rrj/t',,.UN

Ift,II, '" thr 1")19" ltd ; ',)'PI" tit~li',
WORK STAa1'I:R STRip
AR-OUND FOAM ClAMPING

tvfJtY

6-'0.

a )tPI(' IM.')f'

1>/lJtP t()tJII' mnter,

2 l1'il1l ":'.I,.",ght
hil. rottl III, ,,,.g.
3
ultiny.I.1,_.
radii,S n"d .; ri rlga nd
.4If(l(h

Remere scr(!1J's (I ltd ,~flJ(I)"nft' 1'1"9

Drc uII,," -mide slot in

(J S{~1),."~a'" .\f,}'t,
tu ""f tlie bat.e ot~rtrlldk('1'( U' r111[1 iupku
(Q/.,U (l.11d f)(lAf

~htll)fd /('1"'11

,.uditur p.t"Ut J,bl'1_(,

rllt IJ't :1/(" "'Itll

AOOGWf ON
INSIDE Of Ov(RtA.P-......_

I
HOlD SfAJITm SJRIP
IN SLOT WITH CC1.AMP

A1TDl GWlNG AOO

(-CLAMPSTO HO\.D IN.PUc(

11'11," thestorur .~tnphegm~tt)otl'r

Iret 011.'r1J>.< mId pl1,.I"."d O""III'U
Remor ony r.J~e15~
gll:ai tlte ePLdof
4 funu.
Ut t1r.v OI't!I'';Uhl.7'1'1'>.,I.,U;II 5 iap il.ll,1f. apply gill' t th~ OI'.r/<lp 6 t/"fi,..1 81rtpaJlti II",,, hutt tIlesecolfd
,('itl,
Jftnyt~r
it /litlgMt<}. TllQr"
thecla."tps
glued stri; 10 tht ftr.1. ee a V;tllick

(l!l'll)I
tile
ktn/I, ;tlse-rtlt({1
j)'lto t Iu: ';;/(11 (Inc/ r}all1pltlg I!Ier!16 it} d"

16

tel'll.J~'t

11.eOytl'f:

$Iut. m'erlap lite strip, ami ,.,,t!OIllP,

1]

.m1P blo<k to damp the butt jointtig,.t

:-Jo.72

ro cut the slot. first unscrew the oc'nding

plate is complete. work can begin on Ih, 10m.from the base, Then. draw an ,,"'-wid ..
ring-shaped bending fom. it,;elf.Sian bycut- curved slot on the form. see Stl!1'3. (I U5(.'(i a
ling OUIa plywood blank and laying out cen- large coffee can lid to ~ellhe desired curve.)
ter lines on it, see Step I Then, draw the :-Iex1. use a sabre <;;JW 10 cut the slot,
(ann eirclesfor reference during Toutinl(
ASSElIUL\', Once the slol is tilt, re-nsThe ring (ann is cut from this blank by semblerhe jig by 1l1PIlingthCbase overtoget
making repeal passes with (h. roUIPT until u clean surface (no grOO\'~~
from routing)
the bit CUIS Ihrough Ihe blank. To ke('11the and ""rew th,' rill.'lshaped Conn onto tht
blank in place during routing.] screwed iliO ba."l'. :,\tlxt. If) keep the ~IUl.lofrom l:'uckin~,
rut' top ()f a second pit..'-':( nt' plywood. "t'(' apply a generous coat of pasn- wax 10 the jig.
L'MIN,\TE RING.\\lth the jil( complete.
Seep 1. toe.. lethe ""!'I'W"so tht'Y wont be in
the path of thc' bit, Then. drive a Ii gauge work can begin on the laminated ring ilSi'lI.
bra(1 U)ivol pin) into 111(..-emerpcin; and snip Bcfore the stripscan be glued together, they
need 10 be WN bent, To do this, "Oak a ,trip
off the brad II,' above the surface.
Rf)l T 8.~S'r)fNGF()R.\I. Once the pivot pill
in water for 15minutes and clamp it to thrlsinplace, thetormcan be routed. To do this, form without glue. Keep the strip on the
sci tile routerbit IU make a VII~et.'1Jcut and
(IJnn for 15 minutes, remove it, and wei
make apasswiih the base plate firsttewered
bend the remaining strips, 'Own allow all the
over lhc 3'\1," pivot hole.Then make a pa,,, ring strips to dry ovemigltL
with the base plate lowered over Ihe 5" pivol
Once the strips are pre-bent tile gluing
hoi,'. NO".lowerth"bit t I"atatim~until ti,e process loanstart. sec Step 4. B<-gi n by inse ningthe ~IY'lonl(starter strip into Ihe slot and
bilCUIS through the top layer, sec St~p 2.
cvr SLOT, After tile top layer is routed clamp the strip 10 the form as you work
through.lhe next step lstocut a slot into ihe around the (onn. When you reach the point
ring-shaped lann for thl! first strip of the where tbe strip overlaps, apply glut 10 Iht
lanllna1ed ri~.
'Int!-startt1T strip is an ~xlra- overlap and damp it in pia'.... ~ Step 5.
As tilt! renlainjn~ 24"\ong strips ar~
long strip tll~ll
acts as a foundation layt-r for
additional strips.
wrapped around the (onn. tbe) aTi' bUII,'
~L\KJXGrue FUR'IS. Once

the router base

together at the end" sec Step 6. Make sure

the strips are flush at the top, And continue
wrapping until the ring is at least :jI."thkk.
see Step 7.
Once the ring is laminated. the top and

bol1001 edges are planed Ou,h. st'(' Slep 8.

TRL'I RINC,lll4.-" next step is (0 usc a router
to trim the ring to a circle. To do this, ~';n
by mounting a scrap block insid. the bending ((1mt.~""t" SIt."p9, Then, UF.t'Iht' rc.'((.l'rc:nfi"
lincsou thc ring (ami 10 10<"0103
centerpoint

on the block and install a pivot pin,

\\ilh the pivotpin in position.the ""t,.it!e
OftllC'

ring can be trimmed to aperfoct circle.

Usc the Ilivol hole that's fanhest from the

router bit (5-V.") and a t ."straight bit.Then.
slowly rout counterclockwise around the
ringru llT<'\,cnttlwla.l strip (rom learing out.

=Swp9.
Then. to trim the In~/(14 of tile ring. remove the WllSI~ section of the starter strfp

with a hand saw. see Step 10.Next. feather

the inside of the starter strip to 10m! a
smooth Cirri".
ROt ND O"ER E1)(;ES.To complete the
ring. use a 3rjf' round-over bil un the router
table and a rub arm 10round over the edges.
see Sleps 11 and 12. (For more on u~ a
rub amI, SCt' Shop Notcs on pagc IS.)

Rf.M.OVl:OCfSS CWf"WTTH

StaAPat

TK(N

PLANE staR'S

RUP4 WffM IJING JORM

ADD ADDmoHAL
SlRtPS CLAMPING

MAY 2" TO3"

\\'ork Ol.(t~(l~trip.~
around lit, J(lrll~.
,4ff, r t/l(;. !1tll~ rlrlrA. ~r'l'1J1~('(ltlU
$rrt,'ll' ;-;I/t, blurk l)l:tid(
bp)l(i;}(g
('111lpingas ltftt' tt Q~))t'C"IiS(l toy it) gf'f
.(n,.,'i"
1111
d"(I',
(J
bl'(lt1
il110
tI,t.:
Cl'uft r.
t ..~~S$
{111lt: .frtJ)'t I'te to}' uf '''te ring
(r(ipqltalt gillt' Sqllf I :e-()Itt bt'IU'~'ll'~
:o:-trilk>;, It'itlt tl ~rra.JH!r,Ti't Ii. pltl 'tl! btJtJt t;(igtIR t~r/Ilt' Lr~(pr~'l)t},oll' /rlll, .iII.. dt.ff. tl) I,i.". IltL
(',))11 i )ltlf uutil I'; U!! is (tt It'(f $:t J/ .." f I,jrk.
Slr'llpt_n II1'h ~{'itl1tilt he-udi."g[()I'ln.
1(11111 )fated ri ug If} it M''fi'rl
('';r'('U,

faQNTOf
lOUT

fAflll

cur

wrT14 HAND SAW

TO REMOVE: WAS'rf

SANDOff
WEOCE

rt~(!J}ro", l>eudt,'g for'11

r"ut n/fl'),l'(!$.f\ f{to ''(t'r str,p u'ilJt
Jlll,ild
~(/)ulIJ'''liISidf'' (if/ht
ri"9 (( Itt II it njttltes ltlstlll t)u IJ,t ,torn).

1
0
Uli
o
s(1.'. TJ,eJt.
Ilf~t}10."f

tl

No. 72

RUa,tJtM

DlR(CnON OF f(0)

11

C'/n)}'I'

(l

"Ilb

(1J')"

fo fh" IYJlftrr

((I bit

RQJllld ()ly~r
tile t"ifldt

12 ";)10 u';lh

f(lye.,; oft/t.

aUfl tY1/411d ()tp,./ltt Q;IIP,id,

('rigj's ojlJ", ri Ilg 'f.~;tlg(J.J/~.7'()}( tid .f)I'er bil.

117.,,, l'Oltl;l!g lite inside edgfJl of lite rill!!.

S" lit .. billll rlll~"ab",'i! lit .. loblt.

rollt III a r/CKk(('i&

WU(ldsmith

tJtf' "lib Ur/)1 i), (1/(1('.('.

(l,r('('1101'

17

FRO

TIPS

SOME

Nt

SHOP

OUR

Shop Notes
RUBARM
When making L1w laminated
ring for the HallTree shown on
paJ!~ 10. I wanted to llUl a '1'."
round-over 011 all (our tdges.
However, I ran Into a problem

terpoirn of the workl'irrt

i\rXI. to gt:1 lh<- rub nrm

aligned wirh the bearing un ,ht'
problem was that the bearing
bit, tum on the router. Then,
surface would be removed
CO!loSJ'RVCI10". To make a slide the rub arm imo the router
during the fi~trouter' pc1K:> and rub arm. cui a notch ,1iKh!ly bit until the end "(the rub ann i...
using thr ~x"round-over bit in the bit would cui a shoulder on larger Ihan the diameter of the flush with 111" bearing. see Fig. 2
router bit bearing in a pi('('t' of 1\0\(. turn off the power and
the router table
Ihe second pass. see fig. I.
The problem is the location cif
ISIXG A RI'B ARM. To solve 11,' Masonite. Then. glue. base damp the rub ann to the router
the IlearinK - it's too far above this problem. I made a rub ann piece under the arm. see Fig. 3. labl".rd~rluStcp 11,,"page 17
Note: For Ihe Hall Tree ring. I
Once the rub arm is installed,
IJlt' cUlling <'fig!' on some bits, [rom a piece of I,r," Masonite,
Nonnally. illls isn't a problem The rub arm acts as a substinne cut an arc Oil the end of the rub matching round-overs can be
since the bearing has pICJlt)of bearing surface and when it's in- ann 10 allow till' ring to rotate routed without creating an un
wanted shoulder.
surface 10 rid" awUns~
<tailed. it rubs ~t
the cen- smoothly during routing.
In UNO~rurSSfNCf

&lA.ING ,1:10(5 .AlO~

W!1)lST PAin Of RlNO

BUI, on the ring I wanted to

rollt a Inating round-over The

1--'

RUe AJtM PROVIDES

SUtFAa

TO

~ot,AGAtNST

S('(.'

Fig. 2.Thisprevent the bil from

removing 100 much stock,

DUllING 'KONO cIIJ

CUT8LANK
INlWS

UA,Vf ROOM to
tlAMPTO
~ ItOU'IU TUU

CUTNOTCH
SUGHnY

IARG THA""

IIOtII'IJO ."

IKARlHG

AlC
MAT(H(S
AAOIOS Of RSNO

OVULAPAND

GlUtINIU.Q

SANDING DRUM PROBLEMS

I came across a problem when

pand, locking lh. sleeve in posi. SC'(' F'?

lion.
,g. _.
11llClUESS SA,,(OI'C:. During
press 10 thickness saud pan> of used 10 press the workpiece into
the Hall Tree. I noticed the the drum sander, see fig 1.
normal sanding. Lilt' drum and
edges I sanded ....'(:reot 0.11ORI'''' COrr\STRl CT1()!\. To un- its sh""l tum at the same speed,
thcy were concave, sec rig, I
derstand why this causes the ilul when you thickness sand.
lI'hen I examined the drum drum 10 bow. you have to look at the workpiece is inserted besander. I discovered the top and how the drum hold, L1>e"'Ulding tween the drum and a rub block.
bottom of the drum were bowed sleeve in place. When the nul on 1l1i~can cause the drum to slow
out. (Note.Thisonlyseemste be the drum shafl is lighl('ll('d. It down. even ",op if ennugh presa problem ",th Ihe larg,' hollow pulls th, bouom Rangt' up. 'Ibis .u,, i,apptlcd - bUI tlu- ,haft
drums and nOI the S01aIJ<>r solid causes Ih,' rubber drum 10ex- will still be rotating since it's
using a sanding drum on the drill

O'RUM SANDER
lOWS OUT

rubber drums.) This problem

arises whenever 3 rub block is

tightened iruo the drill press

chuck. This over-tightens the
drum, causing it to bow
I'\C I"SERT.The problem is
eliminated b)' slidin!: a piece (I[
PVC pipe insid the rubber
drum. This allows the drum to

tighten. bUI keeps it irOn!

bowing. For my :1" drum. I CUI a
piece of IVJ"dia. I've pipe to 8
length 01 2ltl" It" exactly the
right size to til inside the drum.

-,

I',.,"
PVC PiJ'
INS:EmD IN

DaUM

18

Np.72


ROUTER BASE PLATE FOR CUnlNG
To '"UI the round ,h,I,,, for
Ill!' Fern Sianeland Wm'k~ II",
ring bending jilt for the Hall
free. I replaced 11... base plate
on m)' rout"'rj\'itll a 1ar:g\.r~11ol)buill bast'. The n...w base pl31<'

acts 3$ a trammel auachment ior

t"Ultingand roulingdrd~s.
li.bE I'L\TL Iused a tlit> of
"," Plexigl., (or ),ou could use
Maserute) tor the new base. To
curcircles I"orthr projf!Cl~in lhi~
issue.the new b;1~ needs It' be
extra long. To make the base
plate large enougb for tho ring
on the Hall Tree. rul lilt' PI,,.;'
gla<In a \\;,l1h lIi7" and a ltonRih

CIRCLES
"our ex

the plywood 10 my bench .

To auach Illi..;.piece of Plexi- ample, on the fern Stand I
To rout a circle, $t~t111(,'bit \/.1'"
Rlas to yuurrouter, I)OS11100your needed 7"dia. shelves so I deep and drop the base plate
router's original base plate over drilled a hole 31-," (rom the edge over the pivot pin. then, lip tilt
tit,, n("\' platt!and use it as a tern- ,,(tJ1C bit. ~'C Fig. 2.
router nt a sligh, angle sc the bil
plateto locate and drillthe screw
For the pivol pin I used a 17 is s)igbtly above the surface and
holt." and large center hole
gauge brad and drove it imc the tum on lite router. sec Fig. 2.
PIVOT nOIE. The n('XI step is workpiec e. snipping it 011 ~4" (Nole: If you're u.ing a plun~
II) drill a VUi"-diamt'ler hole in above the surface.
router. you won't have to tip h.)
Ihe new base plate In fil oyer a
ROL'TISG ('IRCUS. Once the
Now, ,Iowl), plunge the bit
pivot pin. see rig. 2.
pin is in place, you' re ready to into the blank. Then pivot the
To locale the pivOIhole. firsl start routing. To keep thl' bil router rlm'kll'i" around the
mount a slr'tiight bitin the router
(rom cutting InW the bench circle until you reach tile stan
(I use a v,,"-srraighl bit). Then. when roulinR all th e wa)
point. Repeat this process.
measure from the cutting edge through thr- blank. I screwed il lowfring th. bitli," (or less) be01 the bit 10 the hulc. This dis- (in the wasl~'iCctionl 10 a piec..,
tween passes until the bit cuts
tance isequalto th{radiu~ of the of piywood and then clamped l1,rough the blank. S<'t' Fig. 3.
circle you want 1o cut,

of9V~tI, S<'t.l-lg. 1.

lIP ftOl.ltlR AND

LOWt "
"'_-"'_"'NTO WORKPLKl
<,

SCRiW .LANK TO

BASil,..
WASlt S((;TION

...,.
PIVOt PIN
PLYWOOD aASE

WOOD PLUGS
Wood plugs are commonly
available in three styl es: flat-

head. ovalhead, and burton. see

Free, I needed a simple way to

install the plugs without flatten-

piece, Ovalhcad plugs have a

rounded lOPihal protrudes from
the workpiece.And buuon plugs
have a shoulder that keeps the
head evenhighero{fth~surface.

ing the IUpS. So I made a plu![

seller that matches the plug's
rounded lop. see Fig. 2.
C(ISSTRl.'t'TIOS. To make the
plug seller. first Cui a :]f." dowel.
11a'long. Then. drill a shallow
hole in nne end of the dowel with
a 7/t6" twi,t drill bh, see Fig. 2.
SETrue ru'cs. To use the
plug seuer, position an ovalhead

Flathead and bunon plugs arc

simple 10 insJaIlsince either the
top or $houlder of the plug i<
nush with the work surface.
Ovalheadplugs.however. can

plug in a hole and place the Sel'

ler over Ihe plug. Then. tap lb.
sctterjustuntil it boUoms ou' on
the workpiece. see Fig, 30.
Notl.': Don'l continue tapping

be driven inion fur. And il'~easy

10Dallen their rounded lOp.
Since [ used :}s" ovalhe.d

you'D leave a doughnutshaped

dent ill the work ."UriBe.

fig. 1. And they're available in

~
..
'!.~.
and 1.1" diameters.
I~STAWNG pu'cs.

Flathea d

plug:; arc installed so the lOP of

the plug is nush writh the work

plog,;fonhc FcmStandand Hall

No. 72

WOOl> PLUGS

BUlTON

OVALHEAO

FLATHEAD

/--....

t.

1
'\

the SE!tterafter it bottonlS (Jut or

WooJsnll[h

\-{

I
1
DON'T

OAJU
PAST

..

1'~l71

1iV[l
ON I" ,,~

.IT
ORW. HOll

~7~,
...
lW&ST
ORW.8ITroa ~."
OVAlHEAD PUJG.S

PWO
SmtR

19
I

WEEKEND

PROJECT

Fern Stand
There are two challenges to bUikling Ihisfern stand. The first is bending
the legs with a gentle curve on both ends. The second is eLLCting the shelves into
/Je7iect circles, Fortuna tel) , sinlple figs lnake both tasks a snap.

wnuld

that
makinll bent legs - CSI>oall)' legs with a bend on '",rh
OU

t h ink

ends - ,"'"uld require a -':cI111plt.

cared jig and maybe a special

technique Iha. involves steamillg tht ..wood.

Actually the bent k'j!Son this

stand

arc

bent lumivatume.

They're made o( thin Strips ,,(

oak with two strips of walnut in
lilt' \'t"nt-..r fnr accent. These
strips are laminated (glued) l()o
gether and shaped on a bending
jig. (For more on beut laminalion. sec page In
Rf-:N')iS"G JI(;. 10 bend the

curves on both ends of the legs.

all you need are ten damps Ihal

w(lod can be benl to shape

without steaming, soaking. or
an)' 'lled.1 preparation.
$IIH.\'E. The bent legs are
(If

attached to three round shelves.

I sized the shelves 10 hold a medium sired (6"o(]i3.) flower pol.

bUI the shelf diameter can be
varied to almost an)' size.
Cutting the shelves into perfetl cird," i~
the second chalknl!'" on this proJed. But again.
it'scasier than it might seem. All
I used is a router filled with a
shop-made base plate thaI bas a
piVC)1 hult drilled in il. When thl'
hole is SCI over a pivot pin. the
router swings around it to cut
perfect circle s.

open I(J allt;"d~t -1", and a ~illll11t"

"l~lStl.A-:.

for the-fini~ll. lh~

bending jig that's made out or

primaryrequirement isthat it re-

plywood, 111e jig is designed

with gentle curves sn ttu- strips

coats or salin Jl<,lyun-thane.

sists moisture

r applied

1\\'0

MATERIALS

3;,..

A OokLegBlon1<&m
I , M
(Each bioI''' YieldsItvee Sl~ Minimum of 18stopsneeded)
8 Wo "ulleg BIon1<&(3)
'1-. x 1\II. XM
(Each btank Y aids lrJeesll\ps. Minimum 01$ill stnpsneeded)

C WolnuISheIves(3)

~A.8.8

(Edge-gllJe these rreee blankSfrom sll( 4' .8

cseces )

~." x st.," . 48" I.' 14. f,. 001(1

{TT'T!'T~lEl
c
:1." .. 3',,-

z,z

c
.aa.

{1.2 ad. Ft. Wolnul}

.. ',,'

8 ..... " ..... ::tfl';%l

Also requ.ed for bena.ngjlg

(I) 10'.<1<1 piece

'. thlCkpl)lwood

(I) 14' .2"",. p.ece ~'.fthIc~ply\VOOO

(I) 14' .~1~ piece
-InlC~MosonlteorP!ywOOd

I'.

20

N,l. 72

BENDING JIG
The first slc pin building the (em sland i> 10 1V1 1de \yilh 1) ~1"
space between them,
make the legs. Bill before you can even start which "ill be the thickness of the legs.)
on the Ic~. you have to make a bending-jig.
'\fter drawing the half-circles. CUIthe blank
Ilegin making 1I1Ojigby cuninga base irom in half. sec Fig. 3. Then cui out the quarter:\I," plywood, see Fig. I.
circle forms with a sabre saw.
81ANKFORFOK."S.The next tepin build)'01 ~"NG11IEFOR~1S.
}\fter-all the form
ing the jig is to add sections 01~lr.iiJ:ht and pieces are CUI.the bending jig ran be ascurved forms lU bend the uiin strips 10 sem bled. Start by screwing thr inside
shape. Since the strips are )I/u1' wide.these
(smaller) curved pieces 10 the base.
To align the ends of the IW(. curved
forms should Ill!at least 1" thickl made the
forms by gluing a piece of III" plywcod to a pieces, drdW a line down the length of the
piece ofv," plywood 10 produce a blank 1-1" base. li"'2"from one edge. sec Iig.. 1. 11''''1
by ~J1"1.". set rig. 2.
mark reference lines 18" to each side of Ih...
STR,\ICtrr Fo')R'IS.::-'1.x
pieces are cut out ot centerline. sec Fig. 4. Now screw down Ihe
this blank 10 make the bending form: four curved pieces SO the outside of the curve
curved pieces and 1\\'0 ~traighl pieces, To touches the tS" reference rnarks atthe ends
make the straight sections. just rip two and the line down the center.
pieces I \r!' wide b)' 21"'2" long, S<'(' fig. 2.
Ne:l.1.screw one of the straight pieces un
ct K\!~'Of()R~I"'.To make tilE' curved ~.
the line down the center so it's aligned will'
lions. scribe ("ur half circles on the remain- the ends tlf the C\U"Y~ jit..'(es.
iug pan of lilt' blank. sec F11>!.
2. (1b"",
Note: The other straight piece and curved
curves are spaced to produce curved forms piece.. are not screwed 10the base.They're
M ....

BNDING JIG

__-""'1

fRST: RIP rwo

used 10clamp IIw strips 10 the fixed form>.

Finally .10 prevent the stripsfromsiicking
10 the base and bending forms, rub paraffin

(orpasiewax) '10 thesurfacesthat willcorne

in contact with the $trips during gluing.
ci i'TTh'G nlE S1"'RJrs.Now vou can start
cutting' the strips for th~ leRs.. Fi""1cut S('VeIl
blanks of:V,"thickoak and thn.'t' blanks of
:!;,"lhkk walnut 10 widths of lVItI' and
lengths oj 41". Now. resaw the blanks into
thin <trips by sctting the rip fence '.r/" from
the saw blade.see 1-1,1(.5.
(Fcrmoreinfcrrna
tion on ripping IIUDstrips, see page 7.)
1'0 be sure your saw Is set correcdy. test
it bycutting eillhl.tripSO(S<.T3PSlOCk.Then
Slack the strips and measure the thickness.
see Hg. 6. Ifthe :;CIting iscorr e'CI.lIte stack
will b. :y,"thick.
When the ","Uing was correct. I resawed
IOIaI of 20 oak strips (A) and S walnut
strips (8). (I cut two extra strips of each in
case some broke while bending.)

II~~

WlOE STRIPS FROM .A;-v_.......

\4" x 211,,"

SECOND;

.LANK

CUTOUAftft.
CIR(USwtTH
eA.NOSAW

ORSAA~SA.W

5(1.11f HA.t.F
aRC';I.B ON
ItEMAINJNG

aOANlC

1--' STRAIGHT

'oM f

1 l
a.

..

211.,.

"

3."
I"

lI".. PlYWOOO

eA,$f

[
CUTl.),"lNKK
STRW$tROM\

IliANI<

\~
4

A~D

FOR.M

,
No.71

.......
lOO~

'ORM
10"

"

_f
-.

...____. 4

_.J

1\i.ICKNfSS OF SlACK,
$ttOULD fOUAL"',,-

21

LEGS
After riPPinll alithe oak and walnul strips,
Ihl.'next step is 10glue-up the k'1!S.
GI..l.'ING TIlE ~"ffiIPS.Sian by spreading
the ~IIICon on" side 01each strip. Then. a.
LJu, glue is applied. slack Ille .trill" like a
sandwich: Ihl'{',' oak. IWtIwalnut, and thrC<'
oak strips. Now pick up this stack and lay il
on its 5i(I<' aj-'llinstthe straight (~mlon the
bending jill.
C!.>\,\1PING. Nnw. add the other straight
(orm and clamp everything together.
starting in the center and working toward
the ends. see l'il(. 7. Then. align the top
edges of the strips flush by gently tapping
them down with a hammer.
8~!'oDIN(; TIle ST'Rll'S.Nex~ the ends o(
til" strips can be bent around the fixed
curved pieces To do Ibis. use the loose
curved piece to press the strips against the
curved lorms. When they're bent a.' fur as
they can be bent by hand, piu lin a clamp.
centered on the curved section and tiRblen
it down. see ~ig7.
Ihen add twomoreclampstoeachcurved
section, Now. tightco all the damps ;;0 the
pressure is even along the entire leg.
CLEANt". After waiting about six hours
(or the glu(to dry. l\'mQ""lh~ leg from the
bt'ndingjig. Then, scrape off theworsi of the
dried Jduc witha paint scraper. Begenllethe paint scraper is " rough 1001and can
easily tear CJr gouJ,:C the strips,
Now the legs can be planed to their 6nal
width of 1". To avoid tear-out. Iused a low
angle block plal1~.
cerro IF.NGTIt.I\s It comesout ufth~jig.
the leg is too lon,l(and must be cut to length.
You11 need 10 mark Ihc lOPand Ih(' bottom
endsot each leg. and then rutofftheexc~
To keep all three legs a uniform length. I
marked rhe cut-offlocations on the jill. Use
acombination square to mark the locatlon o(
the top of th.. leg 1"in (rom the cod or th..
flXt>d curved (onn.$Cc Fig.S. Then mark the
location of the leg bouom 2. from the end
o(the other fixed curved form, see Fig. 9.
xow. put theleg' back in the bending fonn
and transfer the cut-off'locations from the jil(
10 the leg. Then, cut offthe extra stock with
a band saw or hand saw.
~Hi\PINC'l'Hl'. ESI)!;. When the exun !\lock

11

~
ClA,MP Sl1tAIGW'f SKnON

SECOND:

1--'

MAIIlno.

END OF LIe

IWI~
BOnOM

IN.
W1rH

--

SQUARE

c,...,_

V'_""
.: r="

.. ~

o.

a.

ROUNOOvtl np
WI'fH'IU

CUT0" STRAlGlif
wmtlANOSAW
OR. SABAl SAW

ROUNO ()VI:R
ND WITH HU!
OR OlSK SANJ)ER

--.-

DttAWUNE
PERPlNDtCUt,A1t TO
ENOIOFORM
nAT fOOT-

10

UG

,.W

ItOUTlR.

ROUTmG(S 'N A stAllS

oF UGt-iT PASSU

',.

ROUNDoOvtR
Sir

is removed. round overthe lOPend o( lh.lt'g

with a file, see Fig. Sa. The bottom end requires a secondcuuecreate aflat (001. To do
this. use the combination square to drnw a
line on the bottom ofthe legcentered on the
squared end. sec Ftg. 9a. CUIoff tht' CXc<"'"
and then shape the lip with a file.
SH.t\I~INGTI.F.SIOES.To soften the comers
01 the leg s. I used a ~t<" round-ever bit
mounted in the roult-rlabl.- and tt,tllc a klriVS

12

ollighl P3s.""s, see Fig. 10.

SCREWHOUS. Aflcr rouodinK "II"r the
IPIIS. mark the localions 10 drill the holes (or
the screws that attach the legs to the
shelves, Here "Ilain I used the jig 10 lay oul
the screw hote locanons, see Fig. 11.
Finally, drill a ."..tJlameter counterborc
V,"-deepat each oClhemarked locations. see
Fig. 12. Then, drill uie shank hole with a
:!ltG" drill bit.
) ... COUNTIRIORf

....

/' ' ....~DQP

~." COUNTtUORf
ClNTlRtO IN UG
\

CROSS SEcnON

22

Wood~mith

-,
N0.1_

SHELVES
\\11t!l1all three tells at" complete, work can tractor and mark every 120'. see 1~1g.14.

begin on th" shelves, The circular shelves

(C)areculfroUl '4" thickwalnutblankswith
a router, To make them. start by gluing up
three 8'1K~" :,qUatl.-:-.coc,,"fiR. I:{.
IIQl'TCIf{( U:S. To ou the blanks Into perr.~t 7"-diamewr circles, I used my router
filled with a 'J1('('ialbase plate. l'his bast' is
slighII)'largerthan the original baseto accomodate a piv(JIhole 3t'tl! frt,nl the router 1,jL
For more 011 cuuing circles, SCf.' 1>3Kt."
19.
1.J.;c. SI7Tt"IIf-".11w I,'gl\ an' screwed int"
notchescut into Ihecdl!e.oflhc ~hdllt,- 'J"
mark the centers ofthese notches, usc a pro-

13

_'""'"

...... ...__

..............'

r~3"'"
(f

"

i~

INro

~.

~
ATTACH lU.ANJt

120\

.....

- I~" ROUND<WU
arr

r
/

-,

"'.

./

ROUT aUI,I.NOSl: lEFOR[

18

~-_;;
.,
"

'."':

C,"~

OANJ).AW

......

"

..

,.

SMoOTH NOTCH

wt'n4 ' ....OIA

....

e-, "3

.r

QHltRUHI:

}.;,~

17 ~

\.

ctlmNG HOTCHtS

-e,

~)

'y

ROM [OGl

$HIll'

aoUTtHG SHQI"

J!j.~.,..

IN'."

Tl.MPLArt

sn TtMPlATl

~~

-..~

UG
NOTCH

lAY our ctNtUS

""NOfCl<6
fOR1.toS

TO SCJt.All8AU
wmt CAI.PT TAIIi

(a,

tJ

",'/
/j}
\J._ .
. .;z:,
~.

lUOR(

r:~

'/

...

: /'

...

16

"\".~=

15

~'/

GUJI: UP
T'HRU :I: ..".JH1Cl(stttLl at.ANtCS

..

~SMELfC

.~.

14

tlUIUIOSE Et)()ES. Before cut ling the

:<01'(;11
TE.'tPI.ATE.Each notch js cut to fit notches. I routed a bullnose edge on each
the side of. leg. It'< easiest to lay them out ~helf. see fiR. 16.To do this. mount a l':!"
by first making a template that's the same round-over bit in the router table,adjust ltso
shape as the lew;. see Flg, 15. To do this. iI's "'Ib" above the table. and rout both the
round over the edges of a scrap piece of I" top and bottom edges, see fiR. 100.
thick b) I"wide stock, u>ing a :Vtt" roundOT OtT NOTCHES.Now the notches can
over blt. Use scrap that's long enough to be be Cui OUI.see Fig 17 I used a band saw to
safply handled on th, router table,
R'OlOV!! Ih.<lock, bUlajigsaworcopingsaw
Now, 10mark the notches on the shelves. would also work.
center the k'g template over the 120 marks
Then, to smooth the inside surface or lhe
011a sheIL Sct il :11." in from ~ICedge. and notch. usc a :!t." -dlameter sanding drum on
draw a line around the template onto the Ihe drill pres>see ">g. 18.N"w.l<.''SIthe legs
in the notches 10be sure they fit,
shelt.sec FIg. 15.

ORU.M SANDEll
,

fo-

<,

ASSEMBLY
legs.into tho shelf notches with No.lix P.'2"
Oathead wood screws, see Hg. 20. Once the
rem stand is as sembled, check to see thaune
shelves are perpendicular 10the legs. lf tlte
stand is twisted. loosen the screws- adjust
the stand and then rc-tighlcn Ihe screws.
I'U'Csc'R.,,\,, 1I01.t:s.Finall) . fiUthe screw

To assemble the legs and shelves. "Ian by

drilling a pilot hole centered in cad' notrl .
To do this. damp the shelf lnto a large hand
screw or between two piece~ of scrap sl<lck
<0 the slwl(j~ held securely 0190' II>LI",drill
press table, sec Fig. 19.
SCR",\'U:C'TOSHEL\'El;. Next, screw the

~1

PIlOt HOU
(N NorCH

;} "

aH'11.a .),,"

19

(T

'1

f"

~'

20

'c,

cu....

.w.
...

A~~

TO IU. ... USfA.1l

j
\~ood;nl1th

CJirac THAT $TAND

ts STRAIGHT effORE
GI.V1NG"PlUGS fN
SCIlf;WHOW

...

ItG-O

,~

Nott:

a,

AU. SCREW
HOlESwnH
OVAlHtAD PlUGS

ClAMPSf<Rf
P(JtPfN ..

.17
N". i2

//

IX~
J~
;::'

SCUWLtGS
TO Sft{lV($

l.

"It.

~
~
fl~

holes with oVlIlheadwalrun wood plugs. see

Fig. 2Oa.(Formoreon inscrtinglheseplogs.
see Shop xoies, page 19.)
11111ISII.
To pmtect the rem stand from
moisture and water stains, I applied IWO
coats 01 dear satin polyurethane, sanding
Iightl)' between coats.

.ax

SHW

11'1"

fhWOODSCREW
~

23

COM

}vI E N T S

QUESTIONS

AND

Talkillg Shop
FLAT OR QUARTERSAWN?
I IIlll''_' tt n oi(1 tabl,
Ihltt'l(
1}1(~itl)I!lnIrafnnd ! lllf,nt to rl
11(1)1";"t. {Jut /",1 "n~'tn!laIJm/~.

1,," ,tt.,d,ltg tl" ,;tJltl "";"d

'('Clod. "l't t"t'lt (Ollillc(lt
1(IfH/II/ IX "'Iltllrlt"r"nu'il
-

r'f';

GROWTH RINGS ARf

ltSS THAN 4.i TO TK

fAa or- TH' 80,"0

vI"

.OAltO SHAJNKS

tIlt

AS IT DalU

"

~'(il; f,'11 "ft'

"'1,,,,'.;;
nut qtl(,,.t",~au)j!"'}I,t ..
due " r",llt '''ti''l '! .l'lud ,,./,IlI'x
lllf

bi,

tIlt adr Ilta!I" tfIU.'fill!l,t)

J"illi' .II

"roo,.I!

Bill ;ttY8, "[ol,lll.llll

First oi all your problem i~o'l

tindinzthe right kiud ofwoodirs finding the right rltt of...""d.
lis you said. your table top W'<iS
made u$ing qucrtereov lumber. Today. the type of lumber
that is typically available in most
lumber )"ards(llldbuilding cent-

FLATSAWN

[:::

ers is,j1(lli)II'CJt.

quantity of u.:ablt' lumber with

the fewest detects.

..

.I

,, , , , 4, , , t , , ,

('lTl1~(, U)(;S.The difference

between them is in the wav

they're cutat the saw mill When

log$ar~rut into lumber.the "oaJ
is usually to produce the larg<sl

...

QUARTERSAWN

FLATSAWN
80th of these methods produce

SUGMT MOViMfNT
IN TH)(~HtSS

FACE (;R.-\IS~However. the

direction of th~end grain isn't

111~
only dii{~""n<'ebetween flatmostly flatsawn (11r plainsawn) sawn and quarter-aw II lumber.
lumber-> the mosicommon cut The face grain also changes. In
01 lumber available,
woods with pronounced grain
1I0lUZO~"AL .'''D GRAIJoi.To pauems (lik(' red oak), quarter
determine if a board is flUIS3\l{n. sawing produces aJIIIOsl iridesstart by Io<'kingat the end grain, cent rays or flakes on the face of
SA\\'ISG ARO~IN1) nil-: LO(~_ Ifthe growth rings arc I~ than the board, see photo.
WOO]) \fO\'F.Mt:;~T. Another
One way 10 avoid Lh,' I~,~
45 10 the face oi the board, ii's
desirable area in the center is to flaisawn.s~edrawing above. diifercllcc is tllC' way quartersawraround the 10g:To do this, Another sign that a board is 03t- sawn lumber resists dimena sawyer (the person who cut sawn is an 0\131 nrllshaped face sional changes (shrinking and
log. into lumber) starts with the {.trainpattern, see photo above
sw~lIinl:) and cupping with
b("iltlooklngsick' ,,!the log, cutt:han$ltS. in ..:ea-sonal humidit}'.
QUARTERSAWN
All boards expand and conting offboards until he COUll'S to
a defective area, Then the log is Another method forCUtting log tract along Iheir growth rings,
turned 90' and sawn again. This imo board. is called quartersaw- On a IlatsaWtlboard thi s ca use.
leaves the center portion intact. ing. With this method the log is the board 10 move and possibly
which can then be made into CUtin half and then quartered, cup across its width, see drawposts or lower gradl' lumber,
see drawing. Then boards are ing. On the other hand, on a
TIIRfJllGII ANn TIIROl ell. If cui from each one of the quar- quartersawn board there's very
the log is rather small. or has tered sections.
ijU]~movemcntacrossthewidth
\'t."R1lCAL ENn (;RAI:'. Cutting oi the board and virtually no
many defects. the sawyer may
decide it'stoo time consuming 10 the hoards Iising this method chance (If cupping.
RIfT, In both iJatsawing and
sa... around the log. Instead, treates a difierenl pattern on uw
end.
The
growth
rings
....
ill
be
a~
quan~rsawing.
a certain amount
board$ arc cut one after another.
'Ibis is sometimes referred to a. mo.t pr:rpr:ndicularto the (ace of of lurubrtr will be r(fl.'O.Il'/f, The
t"Utting-througb and through:
lhe boord, see drdwing,
growth rings on this lumber will

Typically.the clearest lumber

comes from just beneath th~
bark, And the least desirable
art-a is the vt''1' center (or pith)
01 the tree. This renter area is
weaker and prone 10 cracking
and checking.

24

QIlARTERSAWN I''ACE GRAIN

run approximntely

15 to I)",

face clthe board, Here again the

easiest ~rayto determine thi~is
by looking at the end grain,
Riftsawn boards usually have
a >lIaigln grained appearance
without a strong pattern or rays.

So it makes an excellam choice

if you want 10 "'play down" the
grain on a projt":~
AVAJIAl!II.m'. II quartersawn
lumber is so gr~at, why isn't it
readily availabJe? The problem
with quartersawn lumber is thai
il'o;:_time C011!\Uming
t() mill and
lt's wasteful

It take ....a large

diameter log to get boards ofan)'

si1.~liticanlwidth. so many oithe
pieces are toe, narrow to be uSW'"
ful. TIle end result is that quarrersawn lumber is expensive
and hard to find in large pieces,
Finally, don't be discouraged

if your local lumber dealer

doesn't list quartersawn lumber.
~:ycn Om""wn log will have a
few Quartersawn and riftsawn
boards, So sorl Ihrough the
boards carefully - you might
just findwhal you're looking for.

No, 72

CALIPERS
ltow fie. ),CIU art"unlttly rncasure
clampnut Then 'h~''3IiJ)<'''' can
thin ~Iril)'" of Yrux1?'11'1... C)Ut'~ be- u ...cd 10 make rt'p"lilivt,.,
ti(nll"III1'(' up ,1",,1\\ ,l't-Ultjng We' IUt.~asur\m('n1' ~lirlr. ca1ipt'r...
,uil" (or til\' Irll1llll.kd prnj{'<'ts are- available in c. ithcr II1c'I1 er
rh('('k the depth of hulc )'011
in ,hi, io:... ut \'e'tl could 11)' to metric j!1':ldu;Jllon...
1)1\1. c.. U.D'Fft:"o..I\ dlalc. ~1I1)l I'"l'I jU!'1 drilk-d, Or (,"\'1.' lht.depth ul
hal.11l\ l".~
1111"'1111<urvor a ruler
on L1II' t'dl.::l' ell 1),4, thin ~triP""- difl.", from a 'hdr car I" rs in a cUd(, or groov.
bUllhi ...rna, tic 1 vlcld VI rv accu
that w." ,1idt I'" i..'Onnertl"ft tet a
\10'1 dial calipers have ,liat,
rd.l, "-,\IllS Or you t00111d do diahndi<'3h r. "'" UPflt'Tl'llliJ)< '" that art.' graduated In Ih"u
inph to.A,lh,,lid mo\(.,.,th~ ...andth .. of an inch. which i..
"ha, I do - u~ a ealll".,...
'1J1lF ( 'UI'I It'- Th. ,lid<l-a). dial prnvid ,a d reet I't'3,Jout pk-nty 3CCW'3le (or mo-t ,,00<1
rp 'f'. (If c,"3.hpn rul. ha.. been that', "'d,it'1' to n-:ad than a .!ide 1IIori<.f" The) can also ,,",Iouod
",th "tI" II1"lduan,IO' \I'hil. u
tl......
-rl bv m:k'hlnl't ...10r(I nrune-. ,-etlipt."T ...
a idllM'r small inen-ment
to mt"3o;,urt'in I.rnaland I xterna]
In .lddiIion 10 m<ltk and out ~'! i...
<ide mt axurc rnent ..., all Ilia! fat on a ruIcrora slid, calipers, it"
dimen ...ic}n.. ........ IIIYO'r calilltr-.
In 1)11(111, ()nl J 1'4' Ilf the-calipers
i')I"~can be u.....d to measure ('3.''-)' to read on a dial calipc rs,
i...
tix('(1 te) ,hi' main pan or till' depth, \11,.'0 Ih"l"3lil''''Ja'' ,an' "or more information en wht-n
((-,ell. J\II" tlu- ,,,Itllt ~lW j" pan of optnr:d. t metal rod thllt'" ,tt
In fintl rJial calipers, sev Sourern ...li(I,' tl,;" nlu"'('" in or Ilut until t3cl't'cl to lht' ~11(lf"prtJtnlfit s nn I"l!!'c 31.
1'~lXG CAUPF.R.O;. '1~()u...t t:ulboth jaw, 'oUdl Ill<'workl'i.ct.
rn)m
bonom ..I thl' <
()n(~I' in l1Cl..iliflU, thr' "lith-can
and isa coov('ni('l1t rit'flth t:;ttlJ.t"_ iIM.'r-..slidl~ tIle jav.--s "lclMd fln ;j
h. d:UlllWd with .1 kourl(od ~ phOlf. 1111' (',an I,t ,1.....,1 tel "nrkpil"' ....TIleD. if Ih(' "ali""r,

'h"

"Ii,.,.,.

hasa '.~'k nrclamp ynu can lock

Ih. lidi in l')()Qti{'nand remove
lh. <'.Ihp"'" toread it, Oryou can
n d t be dial with th. .:alipe'"
Ilgh,unlh ... orkl'''C(' rlu-ethe
....''('('nd method b-cau-e thl'''C'~
:1

"'MOtl of error v. ben mo vinR

tIl",OlI'lo rs,,
onltR t'l'. I rind my,elf
r. 3d11nl: lor the dial calipe ....
ml,n' allel more I iI~'t
p on...nex.
tel lilt 1'~Ultr (I)' ch('\.king the

",r ~t()(;:k bet ........Cn

thickm- ......

1'.1'''''. It', uJ"'I1l"at

for check-

illS{in ...jclc.' cibll1:n":on~. such as

'h, w,oth (II"dado, Orth. actulil
,tianll'll'f of a hoI(_" you jU~l
f1rilh"flln "v.','rkpil't'l',

CLAMPING TIME
,'"" 'tl'
hll 'f' I

rhflK"

.!r

(l1tJ!

lal ps (

cniltt""(lt(.1tht \rio 00.1 )our~"., Ir}:.

ItUJlutC-:.whrn tht- tempt r:a~urt'

1111l1Uh"'!1onnd~C. rilo!hl to work.

nt2"Mlh ~if\Cttltl,;\il n'3~tltl) ,..,.nh j.5 d<'gl'(~

(~tlt'!.A'Tlding 3. 'lo;.'--krfUt-C up
bt>lit"\"t"
thai
\
our
\\ood
m!t)
nc~
pand
Ihroullh
a planer is
''''liP
I ol'dded:o lJ)" an "xP<'rilll< III
f,r1-.. ,I.( IO"p$ol/"ONJc
"I"
bencarth(,"o;~lrnum
11101" lhat would cl=k ,,\lI)"U', In(ror ).:tI.W("f" ~or) r \, ,I.!t at ka.....t (Qur
le,I" '.I rorl:'
tun'" \."'Ontc'n~U ... a J:IXld id(""3 \1,) matton about the rt.>Lltion,hlp h.tuf"". anellh,lf ...( nf)' i( rnl in a
Jvl, r ':'1"rcld lea\'( tht 4,~lamJ)'" I,n u Ii lIt; belW{'t>l1 tIw dryin2 tino" "I )"\- bll! hllrr),. '"nnaD,.1 prl'k..-to
lOngt.':r th.aI1 Jc tf... g<'nl'ra] ruj~
10\\ glu(' and air ((m.,. rc:l.1Ur~
wast e)\, rlligilt
,\t "q"./".,Yl
!-TT, Th, ... '\.ol1rJ r,ln"'ldrrdtlon
I p\ll dolloJ)5 f)1 yen ..", gh., "n
t'nl III"64,'(10<'"(mt'd thallh~
ll.lmplnJ: llnlt' dt'llt'l1rJ, on a lot
of thlnj.l....ill~ludinl.:the kind of is tht' Vwa}lllt I ....t' IJit't"C"... f)j .1 I"". pia't.'::,o(wood, lind Ih,'n lX11 ~'i01 "ill r"ll Ih, pmblem is that
Ilt.'IAlv..:ll't.-djellUl'!'>"Vo(.'U up,
glut
) 011 U"(', ''If'r~ al joinl cf,m"'I"~I-'h,'r,1l1t' bt."tt~r Ont~ pi~t" in th .. n(rigtrattlr
"""111."'111111, y,.'(' u"llall~ .. USt" lh~ fil. II", I,'" dJmpIII" ,im, b n,..o J watched the difl<fl'nl ralt
Wh, n )'Utl )II.." '" 0 pieers of
Frankton 111t'iHl1ld11' 1<1Glu~ (a II<'CCS.sal")' J\ g(u.ttl i.,jnt \toill t( ... at which th~f.~uedollop, dn ...1 YI'()od l(j~l'lllI,r, lll(, nloisture in
AIl,,:r ;\n Jlollr. Ih,' tliCf")'('llfl' tilt Rlu(' i....
nb'ScJlbcd into lhe
Y"l1f1w Jlh...). ," I culkd J<ff qui~ Ic~s gltlt, .tl.d l('..~ s.rIUt'
.....ij!oo
ubvl()us.
~fhl'
glut
11131
s
al
"I
('.Itrr:t,
elf
11,e'
wnod along lhe
Shuc'rntlkt'l". d h'C,'I)lurru !'I)I"('"ial
mt'an$lt ...,dryill~ li'IlI' 1\ colnl)!)\"
j,t In lilt, \\'cHKI i\rJhl'~i\t~
l)i\i~ joint n'<t11irt .... nlurc s..rI\U te. iiI) (Imnl h,:mpcraturt" hat) ski111ll'd Jllint. 11tt \\'()ud eXpoI.I.lds 'Aim
tht'gapsand Ih., ,\tr.l~h"'tlk, ~ O\t. r f..,,(nplt"tt'l)' and ha,l.t J.!~joIlfl LI,,' tI(ldiljc)naJ Iltoi!'lUfl"
...leul l,f i' rtlnklin Intl'm~lionaL
(c,r lli ....t(l\'irt'"
nlort'tinlt'loeir')
(..\ntlrt
ull""n
gt1l' (.n a lOtllltlJit'k ~tanelinJ.:UI'
If ) UII ",'re 10 t>lan~ or ,:and
in Iht. mJdd1c.: e,f it. Tht RlUt, 10 tht., V.CMxtI..f1uncdi.4h....
ly. the joinl
1111' J!\ fl' 'r.tJ rult, Ilt,lll'w 1:-45 a Q, <"ak('"r~)lnl.)
TE.\IPI-.A\l1 Nt 1111'It11IP'.:r:.
the ((rijlerator.
",hjl ....... Ullt
'....lllllei lLppt"dr fine at ~
But
IninUlt.. h,r~~' ~lulnli!,and5 i:(.
what
thicker
from
th.
,old.
had
runor
tht'
air.
'.'ood.
IlJUI
t:lul"
1(' ,IUllutt ..
a :-ot n)bl~'JOinl~.
a.I1. , til. " .. 1<1 """ a cbaoc~ 10
lik. tOllgUt' and groCtvt'... f'''~ a}sc, ha... an affl'(1 011 ('lampiJljt 110 <;;kirl and the tt,H,ll'Ipi("'k pJit dr) out. \ou'd v.ind up ~;lh a
plain,-d ).H. H~ qUK'k1) pumled timC" the ""M.lt r they U<", Iht t1tlfll)<d 0'1.'1'.
sunkenJOml r3>'iJ:h, d<'J>l't"'<it.n
....
llU:i.S~I'"G
nlF J()l''', The aJ,'llJIth. JOlnlh".)
out \hal thl' I'" a RC"nera)ru..Ie and mort' cialltplng
'lOW'S n<'CC'"
dcx....n' :lPl)I~'ln
f\,~
....
itualion.
final I.'on~id('ration on d"'lns:cm.t1t t,.'T1c" .... Ont' more
53l'l' 1111'rulthen: 53)' )df
umc
(and
the
ont,.
l)n~~
ou
have
to d()ubk lb,' fLI:nPII1j:!tlnlt
thong If p,u,, '" big hurty.
\1')""" Rl l fl,n 'T Th('11" "i~
an' rl~ur main th.&ng"'lo Cftn...i<k,-r fi,rt."\ef) Ie)to l5 (It J{Tt't' dr. tp in much control O\'t:~rJi-:o hov. ...oon Y'~In.t\ v.anllt) con!oider using
YOIIcan pul s)lllt ...{rt~S.
.. Cln a .1"",.J"ori<IOI:
....h ...n s:luillR. tnc fir ...t ;:-. tbe temp(.'raturt JlIu~ or a
For t'xanlplt, il ~ou ~I)ulrl glut' j()inl alter rrmoving th,' (i'...minul' "poxy, Tb.)'r~
moi~'un .. ()nl 'nl (It tht- ""M)d.
1\loi..t ....'l)Url nl"")' In'Jrt.: 1('ave tht, clamJ,." CJn a 1)'1nt l hlr clamps. If I plan to do <nnw In(lrt' ('xpt'nsi\,t" than yello\\<
l"Janl,)ing tilllt. btlt Yl.U fila), nOt 45 minutts wh\'n it'..7(ldt'Wt"t'~. handwork on a glu.dup pand.1
I:hl<'. bUI the damping limcs are
alway 1\ kn()w lilt' c..);a<:lllloi~lurt" k... p th~damp;, ,,0 lor "ltmll !KI will !'('mov~Ih., damps In 30 "xtfl'mdy shun.
I, a/leag.oor
",ltor! IIIJ 1Wf.J" (aN I

'I'

"'Ill"

,,,),

~,
I ...

TOOLS

&

TECHNIQUE.S

Radial Arm Sa",

T

he radial ann saw is tit...

perlect 1001 lor cUlling
kmg pieces oC stuck t(, Ill.nag...
able lengths. But the problem is.

FINCIi

Ih~ tables on most radial arm

~\\'Sare too short. Il becomes a

real balancing art to cut a ~root

1<'I1I."hIrom an 8-h)ot board.
To "",1,,(this problem. I re
placed the particleboard table
Chal carne on my $3\\' v. nh a new,
lunl(l'r table (Bl'Si""" the uld
table had zouen pretty chewed
UI) over

the y('ar.;.)
PROTfCTtVf
SOIJIJH)Rl)()(lR.I iound the
SORFACt
perfC'('l replacement table at the
SPACUtS
OF ' ....
local home center, It's a wUd
OF I."
MASONnt
MASONm
core door that measures :10"
~
wide and ~O"lung. (Slight I),
blemished. these doors arc
SlcnON
often available for about $25.)
QtlAaI.l
n,CS<' doors are usually H'."
thickwith a solid con- ui panicleboard. They're heaw and stable
-guOO for saw tables. TIn-races
01solid-cen- doors are tYI)j(all~ chipout on th~ bouom side since
hardwood \'I.'"('('J. ruul even if 111t:r~':-.no :-,uPJX,rt where" the
the lace i. blemished, il still blade exits,
works fioC:" for a saw table
To help keep the new table in
:-'ote: Instead \)1IIsinl! a solid- good shape. I screwed down a
cure door yoU could build uptwo protective surface of V." Malayers 01 ~," plywood lor a 111- sonite to the topofthe table. with
ptacernent table.
a replaceable middle section,
PROTEL'1TI'ESUlFACE.i\Jlother drawing above. Now. when
thing that's always bothered me the Masonite becomes 100 cut
about working on the radial arm up. Ireplace the middle section
saw is the way the table g~t. and start fresh with a smooth
chewed up with repeated cut surface.
ting.!ls the kerfs in the table gel
"PACERS. As a further precauwider. sawdust builds up in the tion against sawdust build-up. I
kerfs. And the workpiece can added another feature 10 the

_NT

'I'"

SOUDCORl DOOR'-......

SPACERS

{1,S....THlCKl

(GlUe TO fRONT

SI<\'lON OF TAlLIJ

new table, This is simply a rowof

~pac("r~attached between i.he

fenccandthc front sectiononhe

table. see drawing.

These spacers produce a ser-

ness 01 your table and any protective surface. Poshlon the

spacers at 7" to 8"' intervals, and
glu(, them to the inside edge of
the from sectlcn 01 the table.

ies 01 l(3)lS between the fence

and the CUllingsurface 01 the

Shop Note: 1101meh glucworks

table, The gaps allow sawdust to

fallthrough thetableratherthan
accumulate on top of the table
and keep. workpiece (rom but
tinlltight against the fence,
Icut the spacers oUloIV." Masonite 10 a length 01 2". The
width of the spacers is determined by the combined thick-

SIJPPORT. Finally. if you position the longer table very Car 011
renter (It'1l.()orighl Onthe base)
you may want to support the

best Ior this,

heavy end with a cabinet. or

simply a 2x4 brace. This keeps

the table 1I10re stable when
you're cutting a long piece of
heavystock.

FENCE SUPPORT LEDGE

It's nOInecessary 10PUIa 101lg
table on your radial arm saw ju~t
because you wam a long fen."e.
BUIifyou do add a long replacement fence (like th~ one shown
On pag~ 3/), you may want 10
consider adding a ledge to support 10D$!workpieces, see !'ill'. I.
A ledge that extends from the
end of th. tablv 10the end of the
fence keeps a long workpiece
from drooping over the end 01
the table. The ledge also lets you
use a stop block beyond the end

26

onhe table.

_.

MAI<II<G
1l1~ IIX:". Icut the
support ledge Irani IV!"tJlick
stock to a width 012". To attach
It, flJ'Sl bUll the end 01the ledge
10the end of the saw table. keeping the top surfaces 01 the saw
table and ledge (lush. Then
screw the ledge in place from the
backside ofthe fence.
If you ever remove the fence,
}'OU

11",-

COUNT'UtSUNK
Fh WOOOS(If"WS

FINe>
I

can return it to its original

position by simply bUIUn)tthe

ledge UPIOthe end oftbe.able.

\Voodsmlth

No. 72.

MilER JIG
AhhoUJ(hI use the radial ann
saw mostly (or cross-cutung.

there III'(' umeswhcn I USC it for

cutting miters. But the problem
is moving the saw ann from 90
to 45' and back allain. It lakes a
lot of 6ddlingaround 10 gel il reSCI to CUI a perfect 90' aner cut-

comer 011 the centerline. After

it's screwed down. rut ilofLOush
with rhe odf'(e of the base

tH TSIIl~; I'E:o.(F crmes.

for

Nt'Xi. screw two outside fence

I{uides (e) parallel to the edges
of the inside fence !(Uide. see
loig. I Screw these in place with
temporary spacers of +'4" stock
(the same thickness as rhe

The jig consists of a base and

fence) sandwiched betwffll the

inside and outside guid(_"".

ling miters,
My sclution was h) build a
miter jig. Then the saw arm can
nlwaysbe k~ptat90' whilethejJg

is damped

10 the

saw

ta bk-

c:ulljng miters,
fence RUides (ail cut (rom less
than a quarter sheet Of;~/~"ply.

wood). and a pair "r removable

hardwood fences. The base
damps 10 the mdial arm table.
and the guides fomt channels lor
the remcvabl .. fenc,'l'.
I1<ISE.1le1lin making the jig b)'
cuttingthe base (A) to a width of
I<lW' and a length oi 21". set'
Fig. I. Then draw a n(trenee

one edge, see Fill. I, Align the

comers of the guide with one
edge of tht base. and a third

the RUide<
screwed in place. work can
begin on Ih,> two fences (D).
TIleS(!lengths of 1'4' hardwood
fit in channels formed by the
FE.'1CES. 'l'ilh all

f~n<:"guidl-s, (The fencescan ""

removed when milt'ring a wid.

workpiece on the opposite side
of the jig.) Once in posidon. the
fencescan be lock~ in plac e,
I rut lite (encc' from a 1\"!"
line (that will .Iilln with the "ide >I1ip of'harrlwood. ~'CFig.
blade) centered on the lenl,'lh.
2. The knP,thot the fenct'S isn't
rl\Sllj~"'-UC~(,tI'). '\')'4'("Ul
criucru-!.hcY''3n be cui long to
a square (16" x 11;") inside 3l'l'OTnmoda", ""-"',lIkpi<'Ccs.
fence j!U:ide (8) and screw it
The system for locking the
down to the base so itoverhangs fences in place is a simph- one.

INSIDE
h)FENCE
GUIDE

16"

WASJ

First drill a '." countersunk

conterhne on Ihe base aligned

with the saw blade
1'" avoid CUlling Ihrough the
jill. raise the blad( 1:V""above

~ '-wide by ~."-d~epslot, also

the table. Then cut a ,h.llowkerf

tontop of 1111'inside f''''''e guide.
T" CUI 11 miter. first hold or

screw

hole for a machine screw

centered on the bouom "dg e of
the fence. see Fig. 2. Then rip a

centered on the bouom "dlle.

lightening a wing nul on Ih,
end of the screw causes the
screw head II> slide up into the
coumersink.As Itslides up.the
$lot opens and locks the fence in
ltschannel,
USINGT8EJIG. Tt) use this jig.
butt il again", Ihe fence on Ihe
radial ann saw. Then clamp the
jig down tothe saw table with the

,."

COuNTU:SUNK
SCUWHOU
CfNT'RfO ON
fHfO(NU5

16"

.,~

"."
NOTE:

(UlIO
DUIIlfl) llNG'ffi

damp the workpiece against the

fcuce (This keeps the workpiece from creeping.) Then pull
the saw t1u'ougb the workpiece.
Shop Nolo, Bl damping a

stop block 1t) the fenre at U\()end

of the workpiece. multiple
pieces (like frame sides) can be
cut to a unifonn length.

FENCE

)J

0 ..

WING
NUl

t,".W1Ot )(
~4"DrP
lXPANsJoN
SlOT (tHftftto
ONTHKKNfSS

SAFETY HANDLE

I get uneomfortable when I short section (3") hold, the

cross-cur short pieces on lhe workpiece lightl)' a~aillst the
r"dial ann saw. I jusl don 'I like felice. (I'lle short and lonll S<.'C'
my fingers that close to the tions (om, a 60' angie.)
blade. So I made a safety handle
fly placing !.hecod of the long
It)hold small pieces,
section against the radial ann
The boomerang-shaped saw fence. you can apply a lot of
handle is cut from a 12"lonll leverage on the workpiece
piece of 1W.lhick stock, ,ee

Finally. glue a <trip of sand-

Fig. I. The long section (about

9") of the bandle keeps your
hand away from the blade The

paper on each end (If the handle

to keep it from sliding on the
fence or the workpiece,

No. 72

Wo"J"Ttlith

27

RADIAL

ARM

SAW

Fence & Stop Block

hen rulling on tl...
radial arm >'II'" the re 's
of len a 101of measuring and
marking of a workpiece before

place at any point along the

renee. Then, to t-tinlinalt' meas-

cuulng it to length. But this,

"measure, mark. and cut"
method leaves room Ior error.
1'0 vliminau- l11('~ gu~No~-urkI

the

added this fen..", and Slop ,)'Stem.

11ICf('arc IWO partslO thissystcm: a high renee and a stop
block that locks onlO Ih, renee,
seepboto, Oncethe stop block is
tighlen('<i down. vou can cut p;.c.,
after piece to uniform length
without measuring or marking.
FL"CE.The new f<onc~i<1aIt~r
than the one that comes with
most radial arm saws Thisextra
hcightgiv,,,,you more suriacelo
support the back edge or a work,
piece. Plus, it It:'t:o; )'OU stack workpieees and

the

SLOP

rate

10 keep

uring before each cut, I added a

self-adheslvc measuring taj)(' to
(('_'11t"(>.

111(' measuromcrn is

read throur,h a P1exil!la.<"hair-

line' indicator,
"Ole: The hardware 10 bllilrl

cut t hem in a ~inStlepa_"

As lonlt as I was replaeinz the fence, I de-

cided to make illof1!(er,too. ITo support Ihe

longer stock this rente can now handle, you
mal' warn to adrl a longer table or support
ledge,
page ~6.)

block is available at
or
through
Woods,,,,'}! ['raJert
SIlI'pri....."'~ page 31
"mRS, One thing needsto Ixsaid here about this system II
you ~ng the radial ann to cut
miters, you'lI cui lhmuJlh the
metal measuring tape on (h."
new Ience. Ithinku'smore aecu-

many hardware stores.

the radial arm per-

mrull'lItly ~I at 90' anyway, To

CUI miters, I use a separate jilt.
STOPBLOC! The stop block is Oleheart oi see page 2T
this SI'SI.m, Itrideson uie new feuce several
'L\KISG 11U, FlXfI'R.E, Since this is a fix,
inche to the le(t of Ihe saw blade , there's ture for the- radial ann saw (though you
no interference> with the motor housing.
could adapt itfor a power mlter saw), I made
I made the SIOI)block from J 12"tluck it entirely on the radial ann saw, BUI if you
stf)(:k ~I()Ucan U~ a eomruon zxtt _Tht,,rc:-. havea table saw.you might find Ir easler and
a win,!!nut on top of Ih. block 10 lock il in sater to rip uic pieces on it,

BODY BLOCK & PINCH BLOCK

The stop block consists or lWO main parts:

Then cut a notch for the-pinch block OUIof

pinch blork. 11l<'SC one ~ndo(lh" blank, se....Fig. 1.Tomake this
pieces act together to make the btock "stop" notch, ,"I tilt! radial sa" blade Id' above lho:
along the fence.
table and make a series of ,,'.rlawing kens
until yc,u've formed a 2,,"\\~dl!notch. "'Ole..ll
III order to make cutting these parts with
tilt: radial arm saw easier (and safer). l smooth offany ridgt.'S lut b)' the sawblack-with
started out with an oversize piece of 1Vi'- a chisel, and cut the body block 13,."long,
Pl:':CIlBLOCK.After the notcb is ttlt in the
thick stock for each of ~ICblocks.
DOD"mAX To male" the bod" block body block, the next step is to make the
(A). start with a 21'2".wide by9"longblank. pinch block (11), refer to lrolt.3. To d" this,
the body block and

BODYBLOCK)

NOlt:

cui an oversize blank to width to match III"

hl'ighl ofthpDol!'h in the body block (2"),

To determine the length of Ihe pinch

block. position it in the notch or the body
block with tbe:\'t",thkk stOl'kym,11brusinl(
(or the fenre sandwiched in between. S('('
Fig, 2,Add a match book cover between the
fence stock and thc pinch block 10 aCI as a
spacer for clearance. No" mark th~ pinch
block and cut u tu length. """ fig. 2.

PINCH III.OC1<

t..

I~'

CUfF.OM

looy
&l,OC1(

11,,-

,_,-..._

2" q.

BiANJ(

2'

.....,
4)4"

NOlt:
CUT BODY BLOCK

' .....

JaQM 9"- lONG ,LANK

28

..

)..
'J1iROATOf ~
STOP.lOCK
frTS TKIOCNESS-

"

OFnNCrpws
1'MfCkNW OF SPAC(1t

W"",,!smlth

....
PINOi
-BLOCK

No,72

ASSEMBLY
With the body block (A) and pinch block (8)
cuuo size, you're ready to begin assembling
the ,lop block. The pinch block i.auached
10 the body block with carriage IMJh and
wing nut, sec Fig.!.tighl~ning the winRnut
pinches the block against the fenc!. To
erealf the 'pinching" action.the pinch block
is b..'Vdt>dalong ils upper end.anu hinged III
the body block with a spline 0(11." Masonite.
see ~-Ig.4 a,
CI.TSPUNE "F.RI'S. TIlt' spline fits in kerfs
nil in both blocks. see Fig. ~. To rut these

,"

,~.
SPUN

NOTE:
I(\I(l

fXlIND,

ONlY to

$l'u."

kerfs the saute distance from the ends of

both pic"",. I buued the block. agaim,l a

stopclamped 10the radial ann saw fence, see
Fig. 5. Position Ibis SlOP It.J" from the saw
bladeand (-ut a It."-<!(-epkerf across the end
onhe bod)' bkx:k (AI. see Fig. 5. Then raise
the saw blade and ('IIIa h"-<!eep kerf on the
pinch block (8). see ~ig.
6.
j\t.-U<.e ntE SI)U.~E.\\'ith the D),ating kerfs
cut. the next step is \(. cut a spline to fu the
kerfs, see Fig. 4. I Cui the spline from \oS"
~1asonil" to awidth of"'!' and length of I vi'.
Then temporarily assemble the body block
(A) and the Ilinch block (B) with !be spline
in place.
11RIIJ. HOLTHOI"'~ Next, 10 recess the

head of the bolt. drill a ;,.~.counterbore OJl

ihe bottom of the pinch bl,,,..k, '>t't' Fig. 1
Then drill an oversize (~,.") shank hoie
through the bod) block and pinch block for
Ihe It,"x:r' carriage boll. see ~Jg. 7a.
'-\.~DnlF.}Jf.:\'EI.s. Now,tocreaiethepinching action sand 3bevelon the-topedgeofthe
pinch block. ,." Fig. 4a. Finally. 10 keep
built-upsawdust from affecting the accuracy
01 the SLOp. sand another bevel on the lower
inside edge ofthe bod)' block. see Fig. 4.

ASStMaLE ~N04IUXK

AND IIOOY BlOCK WITH

SPUN! IH KtRIS

--~
~

=<:
~l

IlVR
fOll

SAWEMJ

o. }.-

DRJU.OY(lSlH

.-1".-'

COlJNTER80JtE...

HOl.[FOA

1". CAaRlAGE 8011

.--~~

IODY
PINCH
StoCK

"lOCK

RWE'

DRlll A '-',"
COONTtHOlE

' OEI'P

INDICATOR BLOCK
Atu-r the stop block is assembled, a triangular indicator block is glue"<l10 the side. This
holds the hairline indio...,.torIhal shows the
position ofthe stop block on the fence.
SUlCK ,\,"[J IS'OICATOR.
To make the lndicator block (C). CUi 3 triangle from 102"
stock, refer to fig. 9. Then. to make the
hairline indicator (D). CIII a piece of ~..'
P1exil!las I V.' wide and 2 W'long. see Fig. 8.

Next, scribe 11 'iairline mark

centered on the width of the Plexiglas using
an XActoknife. To make il readable,fillthe
scribe linewithblack inkfrom a feltup marker.
SCtlW "OLE.To anach the PIC'Xlgias.
drill
a 1t4" screw hole centered on its width and
IV." down from the top, Note: This hole is
larger than the screw to allow for adjusting
the SLOp 10the measuring tape later.

UP. To prevent il from twisting as irs

tightened, the hairline indicator rests on a
lip (E) of \oS" Masonite. see rig. 9.
~'lSE"'H"'Y. Once the lip is CUI10 size. glue
it to the front of the indicator block. Then
glue the indicator block (C) 1'0 the leltsideof
the body block (A). see Fig. lO. Finally,
loosely screw the hairline indicator marked side down -10 the indicator block.

IWR.UNE.

O. INDICATOR

10

BLOCK

UP

No. 72

WouJsmirh

29

FENCE
\Vilh 111.-stop block complete. work can

begin on We radialarm saw (cocc.I,.,,1 Ultfence (rum ~~"~hil:kmaple and chamfered

11

12

CROSS SECTION
ISL.. VIEW)

WI" IO~(nlllt edge 10providv a mur,' dire....1

line o( sight when rl'adinR th~ta~ measure,
re (er It> Fig, 11

VAaN&SH
eHAMfOt

,
FENCE

fHa.OATOF
STOPIUXI(

CD

RlI' TO \\ urm. 111determine tilt' width

(height) oflhe (eoct' (~), measurcthetbickness o( ynnr tabh- and add th,' height of We
Ihroal opening in lh,' SlOpblock (2"), see
Fig. II. -.:,,'" rip the f,,"('1' 10Ihh combined
widlh, <l,'I~~
12.

0,

,.

Cl TTO I..NG'I11.Jlt'[urc.' ('tIlling 111(- fence

'0 length, thC.'fl' ure S(IOlt' dt.lision~ 1)(

,u

WIDtH VARJU
WfUI THtCKNESS
OFT~

mad,' Silln' I wanted Ihe m"lurity "r the

(rnet to th,' r~r} nl th,' blade, th. fir.;1 d.-.:i
sion was 110\1 tar to go to tile left, 'This i.
u.!1iUaJl)" determined b)' the amount of room
there i, in the shop 10 thl" leCl ul Ih" radial
arm saw (before a W'.u\ or another machine).
or Ill~siz(' ollhe saw tabk ,10 myshop. wen'
\V3S enough room for a ~~'I f,1nrt on rn.;-ll.'ft
Then I had to d cc ide thl' le'ngth of f.. nc..
lhal will fil til thl' rl!l'" of the
blade flO
my C3S<;,30), This or...de Ihe IIllallt'Ogth O(

J ... WIM

CHAMfEIl

flN((

CH.AMfUl

all

13

saw

Illy fvnev KO" ("ot,,: I'ar mo re 011adding a

larger table to your "''' or adding a support
ledRe (orth~ fence,'C'C pag,' 26.)

,.

CI"\~ffER.
,\ll<-r the tence ;UIIO tinishro
size, Ihe next step is to cut a ~Jtwid~
chamfer alon~ thetcp edge for th(' measuring tape, see I~ll, 12, To do Ihis, I used a
chamfering bit on Ole router table, see Fig.

.....

(RUfATO P. 26,

12a, butYQU <"uld !wvelrip Ihis on the radial

arm saw or table-saw (Shop '01'" lfyou saw
the chamfer, plane or sand out any saw
"larks so the self-adhesive measuring tape

chamfer.",

bas a snloolh surface III ,tick cu"

1i:1\:lllng tht> sel(adh~jvtmeasuring

MEASURING

~(,XI.I
3

applied a coat (.f varnish to

Ihl'

edge of LIlt!fence. This provide>

non-porous surface (or permanently al

UJpt>

tNSf,\lL fENC..Once the varnish dries,

you (30 install the fcnre on tI", table. see Fig,
13,With the fence locked in place, cut a kt'rl
Iltrough lhe [(,IIC('to the depth ol the table,

TAPE

AfI~r the fence i~

installed in the I.bl". the
next step is 10attach the me,,-<urillj(tape and

"zero" the SlOPblock.

AlTACU T.\P":,

NOTE:
SUPPOI2T LDQt MAY
a( AODD Hllt

To do this, firs!

fil

the stop

llS(NG TIlt:: STOI' UI.DCK. ~Ow comes th<"

We hairline for MY measurement and cut off a piece 01 scrap Then

re al test. Set

measure the tess piece' against th~measur-

block ontc the (eli" e.11t~1lbutt the righl side ing tape - il should be exactly the same
of th, SLOPblock to th,' It'ft ~id~ of th. s<,w leogth a, illdkatcd by the haIrline,
b1ad.'. S<'C Fig, II. Now. ";Ih Ih~ "Oil block
c1nmp<'d in this posilion.lX'eJ back a couple
14
inches o( th,' paper bal'king Irom the rem
eod 01 the measurU1J! ta~
I.UTf Qt.GHT SlDt-Of STOP
1'0 L(Ft Slot Of &lADE
Thelllhrt'ad th~ Lapeund.>r lht' rlexiJ!!as
TH[N
lOCI( STOP tN PLACE
indicator and position the -7ro point undt'l'
the hairlinv, sec ~lg, 14 No'" r~IlI"vc th~
resl of the backing and prK' we tap<' 01111>
the (ence. (You olay h:J\'t: to cut the 111(.'asur
iog lape to the lengw or your fence.)
~11\~
'1. 'N~,Nexi. d1(....k till' hairline in
dicalor closdy. If the hairline docs ol)l read
exacLly wro wben the <lOPis louching th,'

There's om' more thinll to keep in mind

Any time you remove th~ ne, or replace
the saw blade with one Ih31's a different
thickness (such as a thin kerf blade) re-adjust the hairline so it s&:e~anaccurate- "zero"
reading (or th(' new blade.

15

PO$ITIOH
HAlRUN OvtR

~\

/'

liIlO MARKAND
T'IGH1'lN SCAm
.J

~
,"

30

-..,

~CAt()"

.LOCK

...

left side of the blad,', 100,.,0 the screw thai

Iiolds th.. PII.'Xigl3sin pl:tet,. 111"n slide the

Plcxigl .., unlll the hairline is Over Ow ""ro
and r"'u~hl("" the S('f('w, see Fig, 15,

.A;~
SAW

al.ADl

'"

No,72

SUPPLIES

PROJECT

Sources
HALLTaEEPATTEaNS
\Voodsmith ProjectSuppIJesis
off..,ing fuJ~siJ..epaltems with in-

structions formaking'the Ix'nding

jigs forthe Hall Tree (featured on

page 10). Indudcd are plans {or
the leg jig, the Shook jig' and the
ringjig.
HaJJ Tree Jig Patterns
772-200 HallTn!f Paut!lllS

s.~.95

OVALHEAD PLUGS
\Ve used woodovalhead plugs to

cover the counterbored screws

on the lIall Tree (page 10) and
the Fern Stand (page 20).

Woodsmith

Project

chined from reinforced fiberglass so they're lightweight but

strong. Included are a metal rod
for measuring' hoi,' depth and
jaws for both inside and outside
measurements. The IY'!"long
jaws open 6" widt.
The feature Ilike most about
these calipers is the easy-te-read
dial. Most of the calipers found
in catalogs and sreres have adial
lhal m'''''''I'1."$ in hundredths of
an inch (set' Alternate Sources.
below). Some of'these abo have
an Inside dial that reads in Standard inch inerements of ~".

Sup-

plies is offering these plu,tr,<in

four different types ur wood.

111ey will fit 8 'l'ij"..!ia. hole and

are only sold inpack$of25.
0va1bead Pluj!.~
772 100 \\'aInut Plugs $1.65
772110 Oak Plugs
$1.55
772120 Cherry Plugs $ 1.6S
772-130 Birch Plugs., ..".$L25
The dial calipers offered here
are divided by \.tI" increments.
but have another feature that's
especiallyuseful. Marked on the
I use dial calipers. They're also inner dial are divisions of
handy for measuring stock as it eighths, quarters, and half inch.
comes out of the planer and the There are also bold hash marks
depth and width of holes. (For at VIS'I intervals.
more on calipers. see page 25.)
These marks and Increments
\Voodsmith Project Sup- I find the mosl useful. \Vhen
plies is offering the same dial working with wood. I don't usucalipers that we use in the ally measurcin hundredths ofan
1V,J<Xk<mith shop. They're rna- inch. And I can't always recall

To accurately measure the

thickness of thin strips of wood
used inbent lamination projects.

ORDER INFORMATION

MEASURING TAPE

There ate a varicty of uses for a

self-adhesive measuring tape.
(We're induding one in the
Radial Arm Saw Stop Kil above.l
Theycan bemounted on benches.
row tables, and lathe beds.
The \.'t'wide selfadhesive
steel tape has black numbers
and hash marks against a white

background. \Voodsmith Project Supplies is offering tapes

RADIAL ARM SAW STOP that read from righl 10 lefl and
Woodsmith Project Supplies
lefl to right. (NOte: The right to
is offering a hardware kit for Iht' left tape is 6 feet long and the left
Radial Ann Saw Slop shown on 10 right tape
(eel 10nl1.)
MeasuringTItpt.>:;
page 28. The kit includes a clear
Plexiglas hairline indkator. a 772~J 0 Right To Left ~1,a..
large plastic wing nut. a self- uring Tape, 6 fLlong .........S6.95
adhesive measuring tape, and 772-450 left To RighI Meas-

i.,

uringTape (Reads righl 10left)

(I) 11.<' x I V." x ZI-!I" Clear

uring Tape. 1fLloog

$5.95

LAROE WING NUTS

To secure the fences on the
Miter Jig shown on ~e 27. we
u~ la~epla~tif winK nuts with
merallnserts, Youcan bwld this
jig with standard metal wing
nuts, bUI we find these 3"wide
wing nuts easier to tighten.
They're the same wing nuts we

Plrxigl ... Hairline lndicator.

(Hairline on the back side is
etched and inked)
use on other jigs in our shop,
\Voodsmith Project Sup (1) 'I." x 3" Carriage Bolt
(I) Larg~ Plastic \\jnfr NUL plies is offering these wing nuts

\\itll Metal Insert. 3" Across

to fit 111'(/ different bolt sizes,

\\ingl<.Threaded To '\rCCllt
Large \\ling Nuts
772-403 V4"20
$L65ea.
Standard ","Bolt
(I) 'I." LD. \Vasher
766211 .. 1<;.18
$1.65 ea.
770110 W'LS
$1.65 ea,
(I) #6 x :V," Rh Screw
(l) R6 washer
10 or more til one-size: $1.50 ca.

ALTERNATE CATALOG SOURCES

BY "HONE
To order byl1L1iI,use the form For CaSlin' service use our ToU
enclosed Voith a curreat Issue Free order line. Phone orders
or wrire )'our order on a Pl~o:c cal) 1xlp1~edMolldaylhrough
o(paper. andsendwith a check Friday, 1j:()O k\1 to &:00 PM
or money order. (lncl\lde$:l.50 Central Standard'Tlme.
handlilJg and sh'JlI)ing ch3rl:e
Before calling, have your
with each order.) IA r<:Sl<,ents VISA "rMaster Card ready.
add 4f, sales tax: CA residents
'-800-444-7002
add 6.2511. sales UIX. Send In:
WoodsmithProject.Supp~ Allo"~",6",,"')J/.. d~I;'''rJ/.
~'f'f}(~,
PnCCIf Insfbj(tct to clla"l/('
P.O.Bo" 10350
ojJ.~
F;"""_'V.I$~
Oes !\I.oines, lA 50300
'"

No. 72

read a measurement that's ea.")'

to ...'Ork with.
The accuracyofthcsecahpers
is plus or minus .0015" and the
bezel is adjuSlable. Also. there's
a drill and tap cbart on the back.
FinaU)' .ihecalipers are held in a
protective case.
Dial c..Jipers
772300 DialCalipers ...$26.95

ihectherhardwarenecessarvtc
build tbe Slop. (Note: Wood is
not Included.)
Radial Arm Saw Stop
772-400 Radial Arm Saw Slop
lIardw-",,' Kit
"
$12.95
(I) Y'!"x6h.SclJ:ildlleSiveMea ..

DIAL CAUPERS

8YMAIL

that "4'~"
L...thesameas~". But
by using this dial. I can quickly

S,n,ilw' Iiamu'Urt al/d $llpplie.mag be /oulld ill the/ol/(1Iuwg

calalogs. Please call <=1. company/ora t%/og orin/(frmoliml.

Meisel Hardware Specialties

800-441-9870
PIII.IJ~
Trendlines

The Woodm>rkers' Store

612-128-2199
Dial ClIlipi"fS. PII<!JII.Top"
\Voodm>rker's Supply of NM

800-767-9999

~S-9292

Dia! C(1/ip"I"IJ. PIII.g s, Tape

Dial CO/ipn'd. Plllgs, Talle

Woodcraft
800-225-1153
Ow.! Calipers. Tape

WooJsmirh

Cherry Tree Toys

611-484-13113
PIU9S

31

LAS

LOOI(

Final Details
Stop Block

FemStand

<to
..Iliaci, tI" s shop",,,d, .rfJp bllJCkIt) !{qllr
mdiai anll $QW tQgt t QI".'CUtut C~Ii3 t'l'ery f, "(~ \11
tjQ,(

"{tc/ 'i$a l.t!, nltl/olrltlf

bit Uj'/l(ttr/ IVln

Hall Tree

Bent Lamination

.. r"i~ Halt Tree i.I(

Yf,/(r

/,(t.

ft'g u

I,'llrt

I/IU" a. pl.'C'1 ro l,flU!!

')t br:ltl {",i"aliUlt

1..-ljIIUjJf!(llegJi. f:i-s/,(lJJed J,t)Ok~,u ,/~l r;/f9.

32

.._ The grnrrJu/ ("(1'.," ...."u tltl~ Fin, Stalld art

hig" li!lhr.'l( by (I "If,t Ulll ,..I MJn Tll,':driJk. "" iI.4\ Ii"
If!1lgl'r oJ',(,th It 9/t j~tll'llltC'}'f's lilt a'Ui II lit slu:J l'''';'t.

('(lJ("~(.

1.

,I",t

}~')'t1/',,, " fll'pd tl {(Il ul:fu"C'J! rtHJ/X ") II( 11,1

.<I(nIJ~ fJ/ 1'Q(";d. ()nrr fhl "1/ ,'" ,"",1. ttll III'" ~
IIf ~ ,If ,/ (J re rinl1'p-,<, gll/f. ",((! KOIIII J~Jt.II' "