Router special... Router special..,.Router special. SQ The UK's essential workshop project & technical manual er TT) wu ie Atta) Peter: get Issue 74 November 2012 Pry PROJECTS:Real Bosch! Evolutionary Performance Revolutionary Design *) NEW! GCM 12 GDL Professional Glide mitre saw (©)) \ ranism, ‘s)) Blue power tools: for trade and industry. Invented for life Re eeeorvoR “Anthony Bley rst: rthonyborneancrouncom Deputy eorror Simon Frost SenIoR DESIGNER Jan Megan STUDIOMANAGER Oliver rence aren Scot nuustearoR ‘Simon Rodway linemnecon ‘CHIEF PHOTOGRAPHER ‘Antony Salley ‘GROUP EDITOR, WOODWORKING ‘GROUP ADVERTISING MANAGER, ‘woooworxina. Rhona Boer TeeO1273400 821 fal honsborhegmeouncom ‘PRODUCTION MANAGER. Sim Bley ‘PRODUCTION CONTROLLERS. Clare Disano and Rebecca Brasby Puauisier Jonathan Grogan [ADVERTISING MANAGER Dominique Langham CIRCULATION MANAGER, Tony oveiége MARKETING Nicola Otrancesco susscniprions Sue Bennet mal svebarthegrcaroupcom PRINTED INTHEUK BY ‘Stephens and George Print Group pisrmipureD By Seymour Distribution ed woooworaina PLANS a pRovEcts (sW 1753254 published every four weeks by {GMC Publications td, ‘High tect ewes SUBSCRIPTION RATES incudes postage pacing) Toobin coy ofthsmagssine peat yourocl {She Scerpton Depron Ge Rison wwwwoodworkersinstitute.com Welcome from the Editor ello and welcome wo issue FH stein ens poets. Tis seb aher special because we hive devoted tig pat of othe subject Lam probably best iowa for~rouog There ae various profes and aes ome subject ich t hope you wil find interesting. cluding est of he i) Festool router shown on the cover, Festool are augue company uve fr ter equally unigue power tool slang and the sheer quay of thee dai and eontucton ost of ts dichards own s east one route, tnd there aot we cn do with te and for newcomers tee abo plenty ar, 0 Tien bang on about the good things tha go on in rsh inustey wth flo: ad eli that goes no inunuacuring which ul goes on Seeing hand brazing at Titman took ‘me back to my secondary school days in this country, despite the gloomy predictions. When my colleague Mark Baker ~ editor of Woodturning ‘magazine ~ got excited about his trip to see Timan Tip Tools in Clacton, Essex, my interest was stirred. My deputy Simon and I just had to pay a visit and see if it was as good as Mark had suggested. What we saw was a company refusing to drop their quality standards and doing certain things by hand, simply because they bel better and because they can therefore produce so many ‘specials’ to meet customers’ demands. Seeing tungsten carbide blanks being brazed on to ‘cutter bodies took me back to my secondary school days and my own crude efforts on the brizing hearth in the metal workshop. Titman Tip Tools was indeed a real eye-opener and the investment they have been able to ‘make bodes well for the future. By the time you read this issue the nights will have drawn in and Christmas won't be far away, how time fies... Ifyou aren't a subscriber, you could just drop an unsubtle hint to your nearest and dearest, and who sata might just pop the Christmas issue down your chimney? Happy reading, Anthony Bailey knows - Anthony Bailey, Editor Email: anthonyb@thegmegroup.com SAFETY MATTERS: Woodworking is an inherently dangerous pursuit. Readers should not attempt the procedures described herein without seeking training and information on the safe use of tools and machines, and all readers should observe current safety legislation Problem finding Woodworking Plans & Projects magazine? You can reserve a copy from your newsagent or call Tony Loveridge our circulation manager, on 01273 477374 or er im at tonyla@thegmcgroup.com. Alternatively save money and take outa subscription (see left hand panel) ISSUE 74 WOODWORKING PLANS & PROJECTS 1 YOLIGR SHLWOUS SHV TNDSYR 2012 CONTENTS ISSUE 74 This month in WOODWORKING Plans & Projects On your pull-out plans . this month... os De tured and coloured \ 25 to: miele ty 8 Power Woodworking - Yin routers & tri \ 18 Hand-built - spokeshaves & drawknives h we look at a range of frame cutters 2 WOODWORKING PLANS & PROJECTS ISSUE 74 rkersinstitute.comity 28 The covered bridges of Madison County the bridges which found global fame inthe mid'90 KIT & TOOLS well as book reviews 46 Record Power WG250 wet stone sharpening system Walter Hall takes alookat this sharpening system and sigs, 54 Craftsman’s Corner Our monthly mocure of tests and 76 Kreg Deck Jig this We pr ly designed kit which ins a No smoothing plane and a No.60 block plane REGULARS 1 From the = tor . Noticeboard ne upcoming king, and Jat you've been sharing on institute Forum 67 Next issue wwwwoodworkersinstitute.com Woo lwork on the web odworkersinsttutecom (SSUE 74 WOODWORKING PLANS & PROJECTS 3 S1N3LNOD }AW3AON bz 3NSSI 2102 ¥:: NOTICEBOM All the latest news from the world of woodworking, plus tips, letters and images from the Woodworkers Institute forum DAVID STANLEY TOOL AUCTION David Stanley Auctions, established in 1980, have become the leading antique tool auctioneers in the world. ‘They receive consignments for sale from collections worldwide and sell to around 20 different countries. Six auctions are held annually ‘wo international auctions with full colour illustrated catalogues and four general -s auctions for the more standard user tools, In their last international auction in March, Norris planes sold t0 $11,000, inley planes to 200, a magnificent carved German fruitwood brace dated 1794 fetched 82,000 and a rare gunmetal plough plane by Cowell and Chapman raised £3,200. The new internet live bidding facility, which can be found, at wwwthe-saleroom.com, has considerably increased the ‘umber of buyers and appears to have persuaded more people to consider collecting antique tools as both an alternative strategy coupled with an interesting hobby. The next General auction of 1,000 lots of antique and modern woodworking tools is to be held on 30 November at The Hermitage Leisure Centre, hire. There will be all types of modern GREEN WOODWORKING AND CRAFT FAIR This event celebrates traditional rural wood crafts inspired by discoveries underwater at the 2,500 year-old site of ‘Oakbank Crannog in Loch Tay and is part of the Perthshire oppice Project. The project aims to regenerate and ‘manage hazel coppice in Perthshire; to re-establish the use of hazel in structures, crafts and in charcoal-making; to create markets for hazel products; and to set up a network of like-minded enthusiasts ‘There will be coppice work displays and activities plus and antique demonstrations of green woodworking, walking stick ‘woodworking, ‘making, basket making, hurdle making, birch bark tar hand tools production and bronze casting using local charcoal. Many including items will be for sale and there will also be plenty of ¢ braces, planes hisels, gouges and carving tools. yy DETAILS ‘When: 30 November, 2012, 10am Where: The Hermitage Leisure Centre Silver Street, ‘Whitwick, Leicestershire, LE67 SEU Tickets: Free ‘Contact: David Stanley Auctions Tel: 01530 222 320 ‘Web: www.davidstanley.com hands-on opportunities and the chance to speak to the many craftspeople in attendance. DETAILS When: 11 November, 2012, 11am-4pm Where: The Scottish Crannog Centre, Kenmore, Loch Tay Highland, Perthshire, PH5 2HY Tickets: Adults - £9; seniors - £8.50; children —£7; families from £30 Contact: The Scottish Crannog Centre “el: 01887 830 583 Web: wwwcrannog.couk 4 WOODWORKING PLANS & PROJECTS ISSUE 74 www.woodworkersinstitute.com? Social media & competitions Ifyou're not with our Facebook and ‘Twitter pages, then do take the time to have a ook and follow us. On Facebook, ech for ‘Woodwork: Institute’ and on Twitter, we're } @woodworkers. You can keep up-to-date with everything that's happening on the website, in terms of new article uploads, the lat weblogs, as well as special features, Also, keep your eye on our From the forum: INTARSIA MICE [ f2wete route mate an intia piece, It was my first attempt, so I kept the subject matter easy 1 did, however, alter it and made it free-standing and also added a ‘lock. All the wood came from the scrap bin, known woods are beech (Fagus syluatica), ash (Fraxinus excelsion), olive (Olea europaea) and oak (Quercus robur). The wood for the mice is the only garden table. C&C most welcome as this is my first and I need to know if 1am doing anything wrong, Facebook and Twitter pages to meet other woodworkers, interact, socialise and get news of regular competitions. THE NORTH OF ENGLAND WOODWORKING & POWER TOOL SHOW Now in its 20th year the “Harrogate show as itis known, is the largest retail woodworking show in the country. Asalways, there will be a host of, i 3 F 8 H demonstrators taking part including, Woodturning magazine's editor Mark Baker who will be hosting a turning workshop, plus a Woodworking ‘Workshop sponsored by Classic Hand Tools. Also taking part are Tracy Owen, Margaret Garrard, Nick Arnull, Tony Wilson, Les Thorne, Mick Hanbury, Reg Slack, the carvers Colin Hickman and Michael Painter, pyrography from Bob Neill and Lisa Raby and the Windsor chair making ‘wizard, Tom Thackery With over 70 companies exhibiting, the ‘Harrogate’ show is excellent value and a great day out. DETAILS When: 23-25 November, 2012 Where: Hal 1, Great Yorkshire Showground, Harrogate, North Yorkshire, HG2 80Z Tickets: Adults ~ £8.50 advance or £10 on the door concessions £7.50 advance or £9 on the door Contact: Sk Promotions (now owned by Nelton) Tel: 01749813 899 Web: www.skpromotions.co.uk www.woodworkersinstitute.com Very nice! I like it Dalboy —That'sa lovely piece of work, 5 Dalboy. lke it very much : Cheers, i Claude George = ; RS PASKIN NOVEMBER SHOW RS Paskin extend a free invitation to all woodworkers, turners and tool enthusiasts for their fast approaching, show, It will include demonstrations from woodturner Mick Hanbury and other pro woodworkers, plus many leading, manufacturers including Bosch, Record Power, Makita, Charnwood, Fein, Robert Sorby, Gorilla Glue and more. There will be special deals on a wide array of machines and tools, and a large selection of wood blanks for sale including, American black walnut (Juglans nigra), cherry (Prunus spp.),jatoba (Hymenaea courbaril), spalted beech (Fagus syleatica) and the usual to attend, with free refreshments and feee parking too! RS. Paskin is situated on the A451 between Kidderminster and DETAILS When: 11 (10am-Spm) ~12 (9am-2pm) November, 2012 Where: RS Paskin & Co. id, Oldington trading estate, ‘Stourport Road, Kidderminster, Worcestershire, DYI1 7P Tickets: Free Contact: RS Paskin Tel: 01562 829 722 Web: wwwarspaskin.co.uk |SSUE 74 WOODWORKING PLANS & PROJECTS 5 G¥VOSIDUON SYVINDIREGULARS NOTICEBOARD Handmade in Britain 2012 Oe Handmade in Britain is returning for the sixth year to Chelsea Old Town Hall this November, Handmade in. Britain 2012 begins the Christmas season with more than. 90 innovative, contemporary desi inge of disciplines showcasing their hand-crafted products available for purchase or for commission. The fair will be the perfect opportunity to purchase handmade presents for you and your home, just in time for Christmas, with a host of designers reputed for both their design skills and absolute craftsmanship. nakers from a DETAILS When: 16 November, 2012 Where: Chelsea Old Town Hall, London Tickets: For one day: £6 one person entry; £10 two person entry. £12 for an inclusive weekend pass with private view invite Contact: Handmade in Britain Tel: 0207729 5704 Web: www.handmadeinbritain.co.uk BOAT BUILDING ACADEMY BOAT LAUNCH 18 students at the Boat Building Academy in Lyme Regis, will launch the boats built as part of their 38-week training on 5 December, 2012. The launch celebrates the end of, their course and the beginning of their careers as boat builders. The Academy, specialising in fulltime intensive boat building and woodworking training for adults, builds (on average eight boats per ‘long’ course across a range of mainly wooden construction types. The nine boats unching in December will feature traditional clinker, slued clinker, strip-planked, cold-moulded and stitch and glue ply construction. The largest is a 22ft slipper launch, and the smallest a 7ft 9n pram dinghy planked in sweet chestnut (Castanea sativa) on oak (Quercus robur). There re photographic diaries of the builds on the Academy website, The boats will be launched one-by-one at 10am. DETAILS When: 5 December, 2012 Where: Lyme Regis Harbour Tickets: Free Contact: The Boat Building Academy Tel:01297 445 545, Web: www.boatbuildingacademy.com 6 WOODWORKING PLANS & PROJECTS ISSUE 74 www.woodworkersinstitute.comPCRS UML Le TOP i = regPOWER WOODWORKING ~ YIN ROUTERS & TRIMMERS TECHNIQUES POWER WOODWORKING ee ain routers & trimmers One of things the Editor is best known for is his experience working with in routers, as that was how he first ‘cut his teeth’ with power tools. So we thought it was only right that he should pass on the benefit of this knowledge. He did get in a bit of a spin to begin with but he soon got a grip on the subject and here is what he has to say... Back in the ‘80s I discovered that some power tools at least could te made to do things more precisely bearing changes bet and in ways that I couldn't do using unviable, it saw service in all kinds ‘quality hand tools alone. An eaely Of situations such as working for an jon was an ELU MOF96 600W which went from the ach in my flat to the rigours of site work. home office overhe: 8 WOODWORKING PLANS & PROJECTS ISSUE 74 ‘overhead Atill-working MOF 96E belonging to ‘our F&C Editor, Derek Jones Alot of second fx trimming can be done with a small router wwwwoodworkersinstitute.coma= Ce" “Vag Allthese cutters will fit a trimmer = to re-machi ng briss door plates 10 accept new handles and everything in between. The point is that GOW was perfectly adequate then and even today using shanked cutter will work well in a lower powered router. Today we are all easily persuaded by pow' features and price. You can visit a DIY superstore and buy a router with Yin and Smm collets and a more than 1200W power motor for a low price, but what are you really getting for your money? I would suggest not all that you expected, if of course you even know what 10 look for. y smaller Yin The first important tip is to buy known’ brand not an ‘own’ brand; there isa difference, trust me, Going on recent experience inclu ‘This swap body router opens up all sorts of poss wwwwoodworkersinstitute.com A standard Trend T5 will do most tasks writing a book called Router Jigs and Templates | would suggest that for ‘most purposes, the smaller models are definitely the best place to start. What a router does AA router is a balanced high speed ‘motor mounted in protected, high speed bearings in a casing that is perpendicular to the working face, or base, as itis known. It has a switch, variable speed control, possibly ‘worklight and usually will accept a straight fence and a guide bush or bushes for template working, The cutters are mounted in a precision collet as opposed to the imprecise chuck found on a much slower speed power drill. ‘Most routers have plunge columns so the cutter is introduced vertically into the workpiece. There are lesser numbers of ‘fixed base’ routers where the router centers the work from the edge not the This Festool machine has all the facilities youneed a a The collet on the left is much more precise than the chuck face and lesser numbers still have a ‘swap body” that can be swapped between plunge and fixed bases. Routers come in three rough power groups: trimmer collet ~ usually accept 8mm also ~ and large “in collet models. ‘medium and large all have a place in the workshop |SSUE 74 WOODWORKING PLANS & PROJECTS 9 ‘SU3WWIML8 SYALNOY NI% - ONDHOMGOOM H3MOd SANDINHDALRS TECHNIQUES POWER WOODWORKING ~ IN ROUTERS & TRIMM! ‘There is an infinite choice of smaller din shank cutters Small router uses The router is the most versatile power tool there is, but it nothing without cutters which is its raison d'étre. These are currently being studied in the Router Know-how series each month so I won't go through them alla comprehensive. It is what a router can do that matters using all those cutters. ain as those articles are quite Mortising 1Q tar zmntctions sound ing to accept tenons in furniture or joinery framework, then again mortising a door to accept a lock case. Both are mortising operations but the intention is different. Lisi com prod ‘example; the door is constructed with mortise and tenons, Edge trimming is fast and accurate with a small machine the hinges are let in using a hinge ‘mortise cutter and the lock is similarly installed and all done with straight cutters. A small router can do all of these operations, Guide bushes 1D Mir sPplcations need the use of a guide bush running against a template or jig to control the ccut path of a router. Choose a router that will definitely take a variety of different sized guide bushes or your working options can be quite limited, 13 wonaty tte js one sa jude bush, while standard Yin tachins chm in theory tke mor tspecally they met the Tend Base iigurtion (THC) requirments, a tend Scher supply wie variety oF guide bush ses e es Choose a router that will take different guide bushes 10 WOODWORKING PLANS & PROJECTS |SSUE 74 me Fr Deep mortising is best done with a ‘mortise box Edge moulding Laminate trimmers or routers TA icine Bonen pam router score at edge moulding snd trimaing 43 00 fence is required snd they re compact enough to use single handed. The cutter opening wil mit [Batis need a owoend ‘grip and mustn't be allowed to tile while they are machining, Suitable ‘work supports or clamping are needed so the overhanging bearing portion of the cutter doesn't drag on the bench top. Ail these routers have the Trend Base Configuration ‘Trimming the whole edge needs proper support www.woodworkersinstitute.comSlotting 16 Massie eso relatively shallow stots inthe face ofa ob. It could be wo accept a carcass beck panel, sliding doors for plain housing w accept a shelf tnd. AS with all routing operations the key s guidance and control. The safest option isa Fsquare witha slot to accept a guide bush, although the router base edge can be run against plain unsloted Tequare 17 err thes shea be moved against the direction of cutter rotation and towards the ‘operator so the router is pulled into the Psquare or a clamp-on fence if you use that instead, rally Jointing 1G Mesa ruterean ca various joints apart from the baste mortise and tenon. Finger jointing isa natural using a homemade setup as described in WPP 46. I doesn’t have the intrinsic strength of a dovetail joint soit suits small boxes where the lid and base sive rigidity is very neat and precise with a routing A pierce and trim cutter is being used to remove waste laminate www.woodworkersinstitute.com . —MA‘ You need to ensure that the slotisa ‘good running fit Finger jointing, made using ahhomemade setup, looks neat and attract ‘As you can see, these shelf studs are very neat and discreet A flush profile cutter shield next toit Itis important to keep the router pressed against the fence ‘You will find that the elongated slot needs extra marking out 1.9 Abit ining ees you a cheap method of slotting to take beech (Fagus syluatica) biscuits for a low cost reliable joint although you need to extend the slot length to suit each biscuit size Drilling 2O Siti: roe an dt actly perpendicular, which nobody can with a power drill, fuarantee. There are a limited series of router drill sizes available, some able to countersink and counterbore to take matching plugs. 21 studs using a jig for a neat set of regular holes inside a carcass. Trimming 2D tame simmers and smal routers can be used to trim off ‘waste veneer or laminate using a flush or bevel trim cutter DZ Ber caer should have 2 glue shield fitted to protect the bearing from getting gummed up with glue. Ht \SSUE 74 WOODWORKING PLANS & PROJECTS 11 = a 5 2 Z 2 2 a 3 5 8 8 2 g g a SUBWWIML8 SYBLNOY NIThe Rocking Horse Shop Designers, Makers & Restorers of Excellent Wooden Leena eG Penne aT e ae A iad Po con) pay loas Om coi to make! Mini-Rocky taminated Rocking Horse yor Melee) Plan & Instructions £10* Horse & Bow Timber £70* Horse & Stand Timber £85* both timber packs include full instructions www.rockinghorse.co.uk Phone 0800 7315418 UOC a OnE Offer ends 30th December 2012 Thomas Flinn & Co. The UK's fi Garlte | ea saw manufacturer Visit www.worldofwoodwork T: 0114 rderonline@flinn-garlick-saws.co.uk Pete) CT rg Plans & Projects to introduce your business to Ue mete Cee) the UK and abroad. POUT UL 01273 402821 or rhonab@thegmcgroup.comWaa I saw a programme called All The ‘Queen's Horses, It was a fascinating, intriguing programme which made ‘me look at horses ~ and the Queen ~ in a different light. It was absolutely amazing what these horses ~ from all four corners of the world ~ could do and make it look easy, to0. Equally fascinating was watching the Queen’s reaction to the horses, so that was it Thad to carve a horse! ‘Thinking practically about how could made this into a project for my Splitting the branch in two with an axe ] a ‘The basic outline of the horse head transferred onto the half-log blank wwwwoodworkersinstitute.com Inspired by the Jubilee celebrations, Paul Bignell carves this horse's head students, I settled for ca a simplified, stylised head of a horse in green wood. By chance, a short time before this I had some sycamore (Acer pseudoplatanus) tees in my garden trimmed, and had some nice lengths of approximately 100mm diameter branches ~ so that ‘was my basic material decided upon! Cut a branch into several 150mm lengths and, with an axe, split the ‘logs’ in two through the centre. Use a plane to tidy up the split edge which at the same time will remove the central pith. ‘You will now have wo potential blanks for the stylised horse's head. Next, transfer the basic outline of the head to the half log. blank, Carving fresh green wood When I frst cut logs of fresh green wood I seal the round ends with end seal or ‘sometimes paint. This slows down any rapid drying out that may lead to cracks. \When carving an item in green wood itis advisable to Keep it in aplastic bag between sessions for the same reason ~ to slow dry. When the items finished itis often hollowed out atthe back or the base, again to stop the wood drying ‘out and cracking. With wood up to about 1b in weight when cut fresh and wet, you can dry the wood inthe microwave. Place the wood in the microwave or 30 seconds on high and then allow to cool completely before the next 30- second blast. It takes six microwaving sessions to dry a piece of wood from 60% moisture down to 12%. leave 12 hours between blasts, which means two a day, ‘and so reducing moisture from 60-128 in three days. As ong as you wear gloves ‘YoU wil find i nice to carve while hot after the fnal blast. ISSUE 74 WOODWORKING PLANS & PROJECTS 13 423f0udCARVED HORSE HEAD. | cut off the surplus on the bandsaw, although this can alsobe Rough out one half of the face with a No.5, 14mm gouge, No.8, done using a handsaw ‘6mm gouge and a 45° 6mm’V' tool Cut off the surplus using a to match. Mark the ear outline with bandsaw. Alternative a pencil and then remove the outline make a series of small handsaw cuts with a‘V" tool, which are then chopped out, as demonstrated by Peter Berry many Remove the surplus with a No.5 times in Woodearving magazine. sweep gouge, which will give you the basic forward-pointing ear shape. % With the curve of the outer edge Ha of the log the main shape of the While you still have surplus wood eis taken care of, 0 with a No.5 oon the forehead mark out the ‘gouge, No.8 6mm gouge and _part of the mane that comes over the 445° 6mm ‘V’ tool, rough out one head between the ears. side of the face. = Rough out the shape with a °V" Once satisfied with the tool, at the same time removing proportions and the shape, move _the surrounding base wood of the Removing the outline of the ear using a ‘on to the second halfand rough out forehead, c= J 4 Anes Remove the surplus with a No.5 sweep _ Marking out the outline of the mane ‘gouge to create the basic shape Roughing out the mane with a ‘V'tool 14 WOODWORKING PLANS & PROJECTS |SSUE 74 www.woodworkersinstitute.comFurther detail is now added with a 1mm “V'tool bu ‘The eyes are now carved Indants above the eyes are made with No.1, Smm sweep gouge srther detail can then be added ~ F \ to the front of the mane with the Imm micro ‘V" tool The next area to tackle is the eyes; start by carving indent above the eye, below the forchead with a No.11, 5mm sweep ‘gouge, and at the same time carve the indent from the front corner of the eye to the bridge of the nose. This leaves you with the basic area in ‘Making comma-type incisions forthe The mouthlineistucked underneath, which to mark out the eye detail. You nostrils using a Imm micro’V'tool almost out of sight will note that I mark the outline of the eye surround with a series of short angular cuts and the eyeball itself with ‘curving lines as smooth as I can get. T1icemicoting ges 12 ee tp extends down to the nostrils and then flattens outa bit as it joins the nostril area. Make the comma-type nostril incisions with the Imm micro ‘V’ tool and the 2mm micro gouge LB ree inet made wn the same tools, and is tucked a bit underneath almost out of sight. Ay iorant nace working through the grits 120, 180 and 240. 1 5 Maye mane or, ‘The piece after finishing withan Abranet One completed horse's head: you nostrils and outer eyes are sander working through the grits wouldn't want towakeupnexttothis! _pyrographed and the eyes painted. wwwwoodworkersinstitute.com ISSUE 74 WOODWORKING PLANS & PROJECTS 15 W3H 3SYOH GAANWD L23fOUd‘THE’ TOOL SUPERSTORE @ #3 Your Noi choice for Hand Tools, Power Tools & Machinery D&M Tools has been family owned and managed since 1976, We have earned a reputation with our customers as a trusted partner with the personal touch, combined with expert advice from our trained stat, great value and speedy nationwide delivery service ~ FROM THE BIGGEST BRANDS! Whether you'e buying online, by phone, email post or visting us @) Bostirch PAM “ze in-store, D&M provides you with the widest range of quality hand, power tools and machinery alla the keenest pices and from stock. (DRAPER) [Ex Empiré>- Estwing >> Eto all VALU eae Visit our easy-to-use website to IWAN) « KxrcHer see what we mean aboutrange | Al KITY and value. Browse and buy with confidence 2ahrs a day from the biggest brands in the business all» ype at prices you'l find hard to beat. LSS )=S—4 awa j@macure Why not subscribe to our IRWIN. metabo regular email to keep up Marples, = with our latest deals and offers! pase L aE eso on nano 700s RUST A’spmo ESSA GE 73-81 HEATH ROAD ° TWICKENHAM » TW1 4AWait Follow us on Twitter Likes on Facebook Siete on Woaiba @DM Tools facebook comDandbtTools —YOUUT]) youtube.comiD4Tooist FESTOOL Introducing the NEW TS 55 R plunge cut saw. The distinctive features of the TS 55 remain the same, but the machine pushes the boundaries even further in every application that it is used for. « Maximum flexibility thanks to lat housing for minimum wall distance 12mm en more precise thanks to angle seting with snap-in points and indentation (-1° andlor 47°) * Guide wedge fr Sh ting joint flush and moveable ction duct thout guide rail) window pth @ 45°: 0-43 mm. Cutting depth @ 0-43/0-55 mm, Connection O dle: mm. Weight: 4.5 kg ef 101201 m. a FAIR) esc GS ==) I) Fe ES & Pd 2 Ss ee & ee The Editor’s lovely tool cabinet filled up ages ago, but only because he wanted nice things inside in the way of hand tools. One of the few gaps yet to. Ssiuen orstaping soos than be filled were those for freehand shaping tools, — bors ee which he considers essential even in a pared-dOWN do something other than creating kit of quality tools. We know his fondness for gentle curves... here’s what he uses to create them In other words, curves. ‘There is a variety of tools that a a will help you create regular and ® fe files, the Microplane fle and carving : took Ihave some ofeach of those ; « of course but incad I'm going to concentate on singe at blade : cage tools, namely pokeshave, drawknives the rare cular plane tial moulding planes wid epee 4 Dade curvature : othe {0 fashions curve efleeniy and i securely you have the metas 0 a SPOKESHAVES Freehand shaping tools come in many forms 18 WOODWORKING PLANS & PROJECTS |SSUE 74 www.woodworkersinstitute.comvarious sizes, types and prices. I still have several of the standard metal- bodied models which have been produced for many years and haven't changed much in design. well ¢ adjustable ey work In my fancy cabinet I have one with a flat sole that can work on convex surfaces and a curved sole version for concave curves. To n mind these are the least number tools you can work with. of A convex metal bodied model can shape dowels and cylinders and is handy for Windsor chair compone Ifyou meander around a flea ‘market you can probably spot a wooden bodied version for sale ‘These look more elegant and have a blade with ends upturned to ereate forks that lock the blade into the body. They need a bit more care in setting up, as you don’t have the adjustment possible with the metal but they can be worked 10 a lethal sharpness and are very efficient. Travisher These devices can either look like pokeshave or sometimes like ge thick boomerang, In fact, they cut either external or internal ‘curves ‘across the blade’ which is itself 1rved. Because their uses are more specific to chairs, I decided not to add ‘The curved base pattern is great for dowel shaping www.woodworkersinstitute.com ‘The standard spokeshave works well but you need to respect grain direction “i ‘You need both flat and curved bottom sole types ‘The wooden variety are quite slender in shape and design CChair seat shaping is done wit travisher \SSUE 74 WOODWORKING PLANS & PROJECTS 19 JING GNVH | S3NDINHDaL g z &‘SHAVES & DRAWKNIVES TECHNIQUES (AND BUILT ~ SPOK! DRAWKNIVES 1 got rid of my large traditional drawknife years ago to a willing purchaser, It was rather large and unwieldy for the kind of work 1 tended to do. It is, however, perfect for larger jobs such as shaping the unusual ‘forcoka’ or oarlock used by gondoliers ~ see WPP 68. Recently I bought a smaller — and much more pleasant to use ~ Ray Iles gentleman's drawkni Drawknives require a two-hand grip and are drawn towards the user removing a series of slices of wood. They work best on exte is quite pl > ‘The Bailey plane influence is apparentiin the circular plane design 20 WOODWORKING PLANS & PROJECTS |SSUE 74 A gentleman's drawknife ‘As you can see, the Morakniv blade hhas two bevels bur can be used on internal curvature if i isn't too tight a radius, by turning, the tool over so itis bevel side down, 1 also acquired a Morakniy, which a blade set between two inline handles. This also works really well, has a thinnish blade but does fee! rather close to the user if pulling rather than pushing it 10 ein soublebersied blade cuts easily but can flex slightly in use which may not matter ifyou are rounding over, Making some quite heavy cuts 7 CIRCULAR PLANE Tee isn't much call for a circular ‘or compass plane as there are generally better methods for large le shaping of curves. | used to own a Record version ~ no longer made Band you can sometimes find them in flea markets or antique centres, though they are not cheap to buy as they are desirable-Jooking objects for collectors. Aid eee fe rte plane is like a standard metal smoothing pl virtually stripped away. A flexible steel soleplate is hinged to the open body casting with a large winding knob that flexes the soleplate into a convex or concave shape, which can be infinitely varied within its adjustment range. Both care and effort are required to get the best from this tool, but I'm not about to add this clever bit of kit back into my set of tools, however. except the sides are www.woodworkersinstitute.comMOULDING PLANES 13 ee el lens of ‘moulding planes on the secondhand market despite many tending up decorating people's bookshelves. Lots were made and. most were intended for very specific moulding profiles which is why so many got created and are still available for collectors to buy. The only ones that can be conside useful to a woodworker are those with a plain curvature to the base and blade, When I was an antique restorer I rebuilt many writing slopes usually ‘with the pen trays missing and this, type of moulding plane was perfect for making up new pen trays to fit, 1 Recent found ance example with a convex profile that I'm sure will come in handy som wooden-bodied planes tends to be a lot better than some of the cheaper modern plane blades, MISCELLANEOUS SHAPING TOOLS 15 Sih vaous hand tools have developed for freehand shaping of wood. The adze is one of the longest standing, examples. It has been used for centuries for flatting ~ a rel term ~ timber faces, 1e. The blade metal in ‘The adze, a tool that deserves respect www.woodworkersinstitute.com ary ‘Above: Shaping a pen tr operation 16 rates ppd fect which is pleasing and was described in WPP 67 because of its use by Windsor chair makers in anatomically shaping the elm (Ufmus procera) seats. | to be honest, I didn’t get along with it at all. It has to be swung between the user's feet and was known as ‘old shinbreaker’ with good reason, leather protective spats being essential to its use. There is also a smaller chair adze, you want to have a go at shaping chair ‘eats the travisher mentioned eaclier is a safer, more user-friendly device. -d to own one but, ‘An elegant smoker's chair ‘A simple profile that will come in handy one day 17 tisk ay on canto now full - not to bursting ~ bur certainly full. I feel I have pretty much all I need which also includes a No.90 bull nose rebate plane, a small shoulder rebate plane rebate plane completing the kit. Next time I'm going to look at the correct technique for using each of the major types of tool I now possess. I Thanks to Colin Sulivan ofTATHS (Tools and Trades History Society) for loaning several tools used in this article. Web: www.taths.org.uk ‘There's not much room left inthe Editor's tool cabinet \SSUE 74 WOODWORKING PLANS & PROJECTS 21 LING GNVH SANDINHDAL S3AINIMVEG 8 SIAVHS3NOd:SIMPLE ROUTER JIC Using a router on the lathe provides you with countless opportunities, shows you how to make your own simple router jig 22 WOODWORKING PLANS & PROJECTS |SSUE 74 sing a router on the lathe gives countless opportunities. There are several jigs, fixtures and attachments on the market to perform complex operations on the lathe with a router. You can produce single and multi-start spirals, decorative grooves, uniform depth and fading, parallel to the axis of turning or in any angle to that. The possibilities are only limited by the user's Some of these require specialist jigs, but some decorative cffects such as straight futes, reeds, incisions ~ whether full length or stopped ~ can be produced relatively a simple jig and a router, and this is what we are goit ‘make here asily with Routers, sometimes considered to be the most versatile ‘woodworking power tool, were first invented about ‘a hundred years ago to do the job of the traditional ‘moulding planes for edge decoration - moulding - of timber. These were heavy stationary machines. The router, ‘as we know it today, appeared about 50 years ago with the advance of the mass production of small light, high- speed electric motors. Routers, with an abundance of cutter shapes, opened up possibilities for the woodworker never experienced before. Using them to add follow-up decorations to turned pieces was an easy and logical step and numerous jigs and fixtures became available to provide the woodturner with this new approach. Decorations can be applied both axially - on the outside of ‘cylinder or a sphere — or radially on the face ofa platter ‘ra disc. Both types of applications can be concentric with the object, even depth cuts, or they can be offcentre, fading away at one or both ends of the router cut. www.woodworkersinstitute.com‘The bottom fillet needs to be a good fit The router is mounted on a rectangular cage which is fixed to the lathe exactly parallel with the main spindle. The 50 x 22mm fillet the bottom of the photo ~ fits between the two bed bars. A circular cut-out of 105mm diameter gives a ‘good clearance over the chuck. Just behind the circular cut-out, the hole for the M10 bolt can be seen which fixes the whole assembly to the lathe. A similar but smaller cutout ~ 80mm diameter ~ gives plenty of clearance for the revolving centre mounted in the tailstock. At the top of the c ze you can see the mounting rods of the router. The location of these two rods is very critical. The distance between the pair of them ¢ ‘Make sure the holes match the lathe centres must be identical to the distance between the two holes in the router base. This is absolutely essential for the router's free and easy movement There is something different about the two mounting blocks either end of the two rods. One tend is mounted on a good quality solid hinge the The mounting block other end is fixed wit ‘wood screws. By undoing these we can place washers on the screws which will put the router on a slope Without the washers the router will move parallel to the main axis of the lathe and it will produce parallel ‘grooves. With washers inserted the ‘The router needs to be low enough for the cutter to reach ‘grooves will fade away. The hinge at the other end allows the rods to deviate from their original plane You can ‘cage a few millimetres shorter and use washers even for the horizontal ake the serew side of the setting. This way you can fade the grooves in both directions When routing on the lathe, the spindle is obviously locked with the spindle lock. But do not forget that the chuck can work loose and introduce wobbles in your nice, straight flutes ‘Always take several small cuts and not one big cut. The finish obtained this way is always infinitely better All joints in this article are butt joints. For safety’s sake wherever itis possible, use nuts and bolts, Where this is not possible screw and glue all joints. Routing needs a strong and stable base Using a half-round router bit you can turn a cylinder like the stem of a table lamp ~ for example, into a’scalloped! shape. Ifyou are using a 6mm cutter and want 24 indents, then 6x 24 = 144mm. This divided by 3.14 = 46mm. This isthe stem diameter. f you want 2mm gaps between the indents, then 24 x 2 = 48. This, plus 144s 192, so you will need a 62mm diameter stem to start with You can do parallel or slanting grooves SUE 74 WOODWORKING PLANS & PROJECTS 23 workersinstitute.comSTRONG SII STe pe yA ANS rete) Cee aun) Se ee Eel LCR a Ue a) lec a epee CS CR eT) Telephone: +4 Email: em Website: v ‘Simple for the beginne’creates a textured and coloured rim bowl in yew like experimenting with shapes and textures Here is a very simple design that affords you the opportunity to explore ideas and play, and if you don’t like what you've done, simply re-skim the rim surface and start again. The yew (Taxus baccata) blank is initially mounted on a serew chuck and the back turned with a bowl gouge. The beading/ parting tool is used t0 create a spigot and the body shape refined. Since this is a round-bottomed bow, the spigot should be deep enough so the visual body line runs through it you eventually reverse the chuck to remove the spigot, you have ‘enough there to create that perfect, round-bottomed section. You can then refine the outside shape with a negative-rake scraper and sand down to 400 grit. So, wher ‘Once sanded, remove from the serew chuck, reverse, and mount the spigot in the chuck Using a gouge, clean up the rim section, then once done, refine the surface with the negative-rake scraper down t0 or go straight to abrasive 400 grit. Take a rotary carving with — Depending on the separate base used, round bottomed items can be displayed atvarious angles wwwwoodworkersinstitute.com Lend cutter and create the dot indents over the whole rim area, then sand and spray this surface black ‘Once dry, use your finger to apply interference paint across the flat trying to keep it out of the holes. You can then shape the inner surfac section, sand it and reverse mount the chuck, remove the spigot, sand again, and apply a lacquer coat all over. There are ma texture. | used a medium-toothed ballend rotary carbide burr to create this simple but effective pattern. Look closely and you will see the radial striations in the black sections left from the teeth. Use a finer cutter 1d these will not be ther them. The downside with grade of cutter is that it leaves some 10mm beading/ Parting tool 10mm bow! gouge Round-nosed negative-rake scraper ‘Angled negative- rake scraper ragged edges which need a lot of leaning up. Look closely, and you will see I missed some bits have been more careful when sanding, The black contrasts well with the yew and the iridescent colour adds another visual dimension, |SSUE 74 WOODWORKING PLANS & PROJECTS 25 MOS MA G3YALXSL Ee Z >150mm (6 in) s5mm (2 Yin) Top view of bow - Yew (ure) wg TEXTURED YEW BOWL Loose ring - Ebony {6mm (38in) - 8mm (74in) random 'U' dots in surface ‘of black textured rim, all (ove wuor >| fe (wie 2) wee ‘The inner section of the bowl is undercut and this creates shadow, but also when the piece is tilted, it gives the option of placing something inside the bow! such as ‘a marble, small turned ball, or an egg, and the undercut section will support the piece nicely. OF course, what you choose to do is up t0 you, but do experiment with internal form; like rims and turned feet ~ it is an important consideration that could detract of enhance the look of a piece, but done well, this can take your piece to another level. By turning the inside after the texturing has been done, you are able to remove all excess colour and create a nice crisp boundary between the inner edge of the detailed rim and the smooth, silky interior of the bowl Below: After cutting the semicircles with the rotary power unit, careful sanding is required to reduce fibrous whiskers This classic shape iseasyto makeand is wonderful to hold just love round-bottomed bowls. ‘They can be used with or without a support. They are tactile to touch and I have used a ring made from sycamore (Acer pseudoplatanus) which has been dyed black. The bowl need not have such a support and. can be left alone to wobble or tit of its own accord. However, a support allows the item to be tilted to any angle you choose to show the texture or a given feature. You can ce a small flat to create the tilt required, but [think this limits options. other wood natural Experiment with colour and texture tofind out what you lke, but don't be afraid to make mistakes Hand or power carving need not costa lot of money. Two cutters or carving tools with different profiles will give you many options for exploring texture, but so will other tools you find in your workshop. Do not be limited by thinking you hhave to do it this way or that way; you don't. It’s your piece, your rules, your time and your choices Protect your eyes, lungs and hands when texturing work. Be safe at all times and be mindful not to take any Unnecessary risks www.woodworkersinstitute.comBC Ce CE ESC) Dea CUCINA eR ge eng ae RoR eos Ls a The Quick Chuck is fitted into Sa etek Re ce Ls CEO esa Poot tics Roa bits, can ther CS Sen ig-)elo ih routing technologyo fs Eee TOVERED Simon Frost Mt us on a speedy tour of the bridges which found global fame in the mid ‘90s JY wna have heard of Madison County's covered bridges from the 1995 film The Bridges of Madison County, starring, Clint Eastwood and Meryl Streep, adapted. from the bestselling novel by Robert James Waller. In the story, the bridges provide the backdrop to a passionate illicit affair between a National Geographic photographer ~ Eastwood = on a working visit to capture the bridges, and a local, unfulfilled housewife - Streep ~ whose family are conveniently out of town for the week But in reality, the historical covered bridges of the county in Towa tell a story of their own. ‘Twenty bridges were built across the county throughout the late 19th, century t0 accommodate pedestrian, livestock and vehicle crossing. The bridges were generally built using southern pine (Pinus palustris) and northern white pine (Pinus strobus) with securing oak (Quercus robur) treenails, They were covered 10 preserve the flooring timbers and. trusses —in a time before treated timber ~ which would be far more expensive to replace than the lumber used for the sides and roof; a practical feature that also gives the bridges their distinct, pictorial quality. It is also said that the covers were painted to resemble barns and thus encourage livestock to pass. As cars and trucks .g0t bigger and heavier, stronger steel bridges were built to replace many of the wooden covered bridges, while some of the original covered bridges ‘were destroyed by flooding. By 1933, the number of covered bridges had. dropped to ten, and over the next 15 years, three more bridges were lost. The Madison County Board of Supervisors approved funding to preserve the seven remaining bridges: Working on a steel replacement to the Rose-Dunmire Bridge, around 1912 28 WOODWORKING PLANS & PROJECTS |SSUE 74 they were mostly bypassed or moved. 10 offroad locations and preserved as footbridges. The last bridige to be lost was the McBride Bridge, which was destroyed by arson in 1983 after a jilted lover attempted to burn his and his lost love's initials from the inside of the bridge The rebuilt bridge 76ft long, the original Cedar Covered, Bridge was built in 1883 over Cedar Creek, north of the county seat of Winterset, which also boasts the birthplace of the toughest man to ever be named Marion, John Wayne. Itis also known as the Casper Bridge as most of the bridges were officially The original Cedar Bridge’ by steam-powered tractor www.woodworkersinstitute.com: erat peers ‘named after the resident who lived the closest. It was moved in 1921 t0 its current location 1.3 miles east along the Creek by steam-powered tractor. ‘The bridge played a part in the 1992 novel as the mecting place of the main characters, and as a result became a famous tourist attraction. In 1993, Oprah Winfrey called The Bridges of ‘Madison County her book of the year, and invited Robert James Waller and her TV crew to film her show at the bridge, where a wooden stairway now cee PL Cedar Bridge wavoodworkersinstitute.com ely knowin as the ‘Oprah Steps’ was built beside the bridge for the filming and The brid constuction, meaning th: side has two uprights placed about one-third of the way from each bank, which are each connected across the top by a beam and have a diagonal brace from the bank floor to the points where the posts meet the beam. Italso follows the Town truss method = patented by American architect and follows aq ‘Top: The side panels in position ready to be erected ‘Middle: The underside of the new Cedar Bridge, built faithfully tothe original Bottom: Here you can see the Town truss lattice which serves most ofthe bridges civil whereby igineer Ithiel Town a lattice of small and closely placed diagonal timbers support the structure of the walls. This construction allowed the bridge to be built without requiring large stone abutments or heavy main beam timbers. The Cedar Covered Bri renovated with painstaking attention to historical accuracy in 1998 at a cost of $128,073, but sadly the huge cost and effort invested in the restoration was effectively wasted in 2002, when the bridge was destroyed by arson, Rather than allow an act of vandalism obliterate this part of their history, the Madison County Board of Supervisors set to work to rebuild theit landmark. From 2003-4, a replica of the Covered Bridge was built on site, sased on blueprints and photographs of the original, As the entirety of the ISSUE 74 WOODWORKING PLANS & PROJECTS 29 SEC Ther]RE ‘OUNTY FEA ‘THE COVERED BRIDGES OF MADISON Bere Ceaser eet ey original bridge was past the point of restoration, everything was built from scratch; new steel pilings were riven into the ground, new caissons installed and by May 2004 the under structure was complete and the side structures were assembled on the platform. In June the side structures ‘were completed and set in position ‘with cross braces connecting them, and finally work on the new Cedar Covered Bridge was completed for the official opening in October 2004. All of the six remaining bridges are now monitored by remote surveillance 10 prevent further acts of vandalism, The‘haunted bridge’ Another queen post construction which was also built in 1883, itis claimed that the Roseman Covered Bridge is haunted by the ghost of a criminal who was trapped in the bridge by two sheriffs’ posses in 1892. Legend has it that the man made a supernatural exit straight through the roof of the bridge, howling a wild cry, never to be seen again. It too was renovated in 1992, with new steel supports for the bridge piers, although the bridge itself is still supported exclusively by its wooden truss structure. The bridge was artificially iged by Warner Brothers in 1995 to make the newly restored bridge fate 4 " e look duller in colour, with peeling ‘The Roseman Bridge still stands in its original setting across the Middle River 30 WOODWORKING PLANS & PROJECTS ISSUE 74 www woodworkersinstitute.com‘An early photograph of the longest covered bridge, the Hollivell paintwork, to give an authentic look to the bridge for the film, which is set in 1965, The longest bridge ‘The Holwell Covered Brie in its original spot over the Middle River, southeast of Winterset. At 122f, itis the longest ofthe bridges, and is ‘unique among the Madison County bridges in that its inner construction is, ofthe wood bow truss type, featuring a curved beam whieh acts as an arch. Itis also the only bridge where the deck planks run on a diagonal across the width of the bridge, whereas all ofthe others are planked lengthways While the Cedar Covered Bridge played a pivotal role in the novel The Bridges of Madison County, it ‘was Holliwell that was used for these scenes in the film adaptation. e remains Film set crew at work on the Roseman Bridge, reversing the years to giveit a 1965 look wwwwoodworkersinstitute.com ‘The artificially aged Roseman Bridge, out of the make-up room and ready to make its ig-screen debut in The Bridges of Madison County The old bridge ‘The Imes Covered Bridge, built in 1870, is the oldest covered bridge still standing in Madison County. 1 has moved twice in its tife, once in. 1887 from a spot over the Middle River to Cimon Creek, and was later replaced by a concrete bridge and moved to its current location ata roadside park lover a natural ravine near the city of St: Charles in 1977. 1s location close to the interstate makes it the most accessible ofthe bridges. It unusual in that ithas a pitehed roof, where most of the bridges’ roofs are flat. The Hogback Bridge “The northernmost of the remaining bridges, the Hoghack Bridge still tands in its original location in which ithas been since 1884, and remained ‘open to traffic as late as 1993, when it was bypassed by a new concrete bridge. While most of the bridges ‘were named after the closest resident, the Hogback Bridge was named after, the ridge line at the west end of the valley, where two overlapping types of rock with different rates of erosion form a feature known in geology asa hoghack. The Hoghack Bridge ‘was also the vietim of arson in 2003, but thankfully the fire was found by tourists in time for the fire to be put ‘out with minimal damage. The retired bridge The 79ft Cutler-Donahoe Bridge ~ so named after two families made a claim to the bridge’s naming rights — was built in 1870 by Eli Cox, and originally stood over the North River in the city of Bevington. It was moved t0 its current site for p footbridge and entrance to Winterset ounty Park in 1970, in time for the first annual Covered Bridge Festival cervation as a The Covered Bridge Festival Each year, the residents of Madison. County celebrate their history on the weekend of the second full week in October with a festival which, as well as guided tours of the historic bridges, includes music, antique and craft vendors, food and historical re- ‘enactment, commemorating the are rich, though relatively short history since its inception in 1846, For more information visit ‘www: madisoncounty.com Bl ISSUE 74 WOODWORKING PLANS & PROJECTS 31 ALNNOD NOSIGWW 40 S39GIH8 G3¥3AODSHL aUNLVASCoal COSTS LESS BELT 8s" } Glarke oiscsanoen pecona rowers’ Clarke voveran sos | = €F POANERS, Bite ts tn Be R2 ROUTER ‘ACCESSORY, ‘Muuri FuNerioN Tor HARDWOOD, Clarke WorkbenchGala (fe Ds llta ts eae SPREADER Clarke ctiues MRE saw Clarke srano = curs: = fae fe & oe SS” rar Be es Kes i =) crane BexHaRNOERS BLACKS DECKER eat, PORTABLE, ‘THICKNESSER Clarke£ & likes to spend some of his idle time reading large, glossy ‘coffee table books’, but unfortunately he doesn't have a coffee table to put them on! So we suggested the solution, make one... and after a well earned caffeine boost he finally stirred himself and fashioned his own interpretation of a coffee table; now there's somewhere to put those fancy books, he doesn't feel quite such a mug. But first, we need to make this jig... Frieze and dentil moulding can ‘add interest and detail to things as diverse as a bookcase or a fire surround. They are typical of some Sar eT eS Pacnmcene ea ieaesese cece eee eee ‘The process is a bit repetitive but x eee aes \ faa ce ay coe A itworks well on our coffee table thisis the jig required to make it. The process is the same but frieze and den ‘mould need A tay is the ideal way to control movement of the router, Make the base of thin ply with fillets glued around the sides and ends. It needs to allow the router to slightly overrun the moulding underneath it so the erly formed and it ned. the stoc nd the router pushed across them to make the slots. slots are cannot get ja For dentil moulding make up the blank stock thi accurately. Glue and pin two flat fillets of wood to hold the workpieces properly: They need to be slightly higher than the stock itself nessed The tray is pinned to the fillets underneath exactly perpendicular to them and roughly halfway along, 34 WOODWORKING PLANS & PROJECTS |SSUE 74 {frieze jig on the left and dentil mould fon the right www.woodworkersinstitute.comRouter Jigs & Templates by Anthony Bailey This extr m the Editor's book Router Jigs & Templates ISBN: 978-1-8610-0¢ Price: £16,99 (Plus P&P) ublications 8 0 SEE LEI ee ey Tice ey cor) ‘The tray fixed to the dentil jig ‘Setting the width for the dentil strip, ‘The tray for the routerto slide in dworkersinstitut WOODWORKING PLANS & PROJECTS 35SMALL COFFEE TABLE & FRIEZE JIG ‘The finished dentil ‘The frieze jig uses the same principle An important feature has to be a means of registration. 1 say as each slot it made you need to be able to slide the stock along a fixed amount and cut the next slot. This hhas to happen each t ‘widths will vary and look wrong. Here a series of marks on the fillets and the piece to be machined allow the first few slots to be done by eye, while the clamp stops it slipping, 1¢ of the slot Advance the workpiece, slot ag and just keep going. At the other tend another set of marks, and in this, case a folded hinge, is used to locate the very first slot in registration slots in the fillets either side. From now on teach slot is registered in this way until you reach the end of the workpiece. The result is very consistent and looks good. The longer the Aslotis cut to accept a register plate Each successive slots registered and the next slot made workpiece the better so as to reduce the amount of starter slots you need pper job as most slots will then be registered using the drop-in strip ~ hinge as shown. Frieze uses the same method but the slots are placed closer together and you need a wider jig 10 hold the wider strip that will need slotting. I found it better to fix the tray close to the back end of the jig. Here is the rear view before the first slots have appeared, with a clamp holding the workpiece so it is held in place each time. ‘The already slotted section is 1g through and again the folded hinge does a good job registering each slot accurately. Note that with either jig in use the router ‘must move off to the side so it does 36 WOODWORKING PLANS & PROJECTS |SSUE 74 ‘A packer may be needed tolift each section up not prevent the workpiece from moving or accidentally scarring it. Ifyou need to machine thinner stock you can always insert a packer fixed in place, so the workpiece is as high as possible under the jig. This is important because it prevents it bouncing as the cutter ‘moves through the wood. www.woodworkersinstitute.comhis coffee table is simple enough in design but quite pleasing to look at. tis small enough to fit in almost a anywhere but the design could be expanded if you 2 wanted a larger version. The top is birch (Betula pendula) z= ply which is stable and resists warping and splitting and 2 therefore is easier to make and fit to the underframe 8 | Descvigtion oy ot woot i European oak (Quercus rebu) orkise bex 2 Legs 40 450000 AS Svan Frieze jig m Long frieze rails 2 450m Tsu 25m Leng (1.Siam) diameter two-flube 5 short vails 2 aoe Ten) 2see straight cutter Easing EO Lange diameter tenoning cutter Eaging 2 45000 [eve [Siu EAwin groover ama avoor 3.2mm diameter straight cutter Birch ry Medium and fne abrasives Sr Tor le T70e, AIS Bo paral sane Ply or MDF: sized strips Por leese tongues x ‘The frame and leg components Prepare the legs and rails that make up the underframe in width and thickness. Leave all components, overlength to make machining easier. ‘The rails will be tenoned at each end and the legs will be mortised close to fone end, Mark out the leg mortises on the ‘wo adjoining faces running the marks around with a square so the; line box which you have hopefully made and fit the appropriate cutter. Sit each leg in turn in the mortise box, packed up high under the router and clamped firmly, Machine each mortise to depth; for convenience the the router position over the legs only needs to be set once, 1p properly. Set up the mortise are centred in each leg so woodworkersinstitute.com www Aceylic varsish ana brush "0000" wive wool Hardening wax ‘The completed mortises with waste at the ends ‘Machining the mortises using the ‘mortise box Check all the mortises are deep enough and fully formed, they will intersect and break through into each other. Now set up the frieze jig described at the start of the article. To groove the long rails, you need to carry out this operation on all four rails and just sulficiently deep to look right without compromising the strength of the rails. Allow a blank section at each end so the tenons are not compromised by the frieze slots being too close to them. The short rails are left plain as it looks better. ISSUE 74 WOODWORKING PLANS & PROJECTS 37 | > ‘The long rails are frieze cutSMALL COFFEE TABLE & FRIEZE JIG PROJECT = ‘A4S* block used to support the ral while removing the corners Machine the faces of the tenons using a push block and check the fit in the mortises. Now machine the tenon edges, again checking the fit. Use a bevel block to trim the tenon corners off so they will fit properly into the mortises. Use a 6.4mm groover mounted on. aan arbor to slot the top edge of all the rails. Set the slot slightly away from the frieze side so it doesn’t break into them. This slot will carry a loose tongue to fix the top to the frame. ‘The frame is glued up and checked for square Bevel the tenon ends so they ‘will close together properly when fitted into the legs. Glue up the underframe and ‘lamp it carefully so the legs are square and sit the underframe on a level surface. Measure between the Close-up detail of the table frame 38 WOODWORKING PLANS & PROJECTS ISSUE 74 ‘The ends are believed to meet - note the top groove legs at top and bottom to check they are parallel. Wipe off surplus glue and leave to dry. 1 ie sented ne ‘showing the loose tongue slots clearly. Note how it is placed slightly away from the frieze detail. www.woodworkersinstitute.com,‘The solid lipping for the top is held on. with masking tape The birch ply top is cut to size minus 30mm in each di A 15mm wide fillet of prepared oak is butt glued to all edges with neat mitres at each corner. The oak should be the same thickness as the ply; sand flush once the glue has dried Now use a clamped on straightedge to machine matching slots in the underside of the top. It is important they line up with the ones in the underframe. Do this by inverting the underframe and top, mark out the underframe position once itis accurately centred and lift it off. Mark where the slots in the underframe are in relation to these marks. Now sit the router with 2 6.4mm straight cutter so the cutter is on the correct line at each end of the first slot and pin on a batten as side rail, The one-hand base grip works perfectly well ‘The top needs to be sanded to fine finish and inverted on a eady for assembly. ‘The loose tongues are glued into the table top first workersinstitute.com ‘The loose tongue slot is machined using a straightedge Cut strips of 6mm MDF or birch ply that will fit the slots in the table top. Run a little glue in the slots and push the ply strips in. Apply glue to the slots in the underframe and fit the top down on to it so the 6mm strips slip into the slots. Carefully clamp the top ‘without making surface marks and avoid using so much pressure tha top the — Finally the top is clamped down ready to apply a finish once set ISSUE 74 WOODWORKING PLANS & PROJECTS 39 ‘The tops sanded toa finish 18¥L 33440) 3a DI AzadIst ete} | 2° iz al “wU4 g s a2 8 i 5 Bi 5 Bo 8 ge a a a 2 §——~1 | it i © Your free coffee table planPlans & Projects Cutting List 1 @ 400 x 180x 18 PLY PACKER 1 400 x 75x6 BATTENS 2 @ 360x 25x30 TRAY BASE 1 @ 262x136x6 TRAY SIDES 2 @ 262x 13x15 TRAY SIDES 2 @ 110x 13x15 For table cuting list see p37WOODWORKERS INSTITUTE.COM Techniques and projects ay, Join our online woodworking With regular competitions and giveaways, community to discuss techniques, don't forget to check back in with us for projects and inspiration, your chance to win fantastic prizes! If you have a passion for working with wood, come join us at:Take a look at the tools, gadgets and gizmos that we think you will enjoy using in your workshop TREND value added router promotion Trend have recently launched a value added router promotional pack, which will make an ideal gift. The popular T4 850W router has been packed together in a practical carry box with a six piece “in shank router cutter set and the Complete Routing book written by popular ‘woodworking author, Alan Holtham. The T4EK is a 230V Yin shank portable plunge router with a variable speed from 11,500 to 32,000rpm and an impressive 850W motor, and weighs in at only 3.5kg, For on-site use there is also a THELK 115V version, Featuring a spindle lock for an easier cutter change, removable base, a three-stage turret depth stop, and exterior carbon brush accessories, the T4 packs a lot of features into a light duty router. ‘The six-piece Yin shank router cutter set includes the most popular cutter shapes and is packaged in a plastic storage case. Complete Routing is an A4 hardback book with over 300 pages full of easy to read routing techniques and step-by- step guides on how to use your router to its full potential, and is an essential read for the amateur or the experienced TREND 01923249911 www.trend-uk.com aA LY jittt www.woodworkersinstitute.com Prices are cocect at time of printing and inclusive of 20% VAT. Photographs and information courtesy of the manufacturers By the Editor (Our local DIY store stock Einhell power tools and now they have caught my attention I've got the chance ly try one! Very smart in the distinctive Finhell livery it features grey rubber overmould panels, a trigger operated worklight, 17 torque settings plus. drilling, a forward and reverse slide button and high’ and low gears. In other words, everything you expect, to find on a drill but in the newer 10.8V range. It stands upright on its battery pack which can only be ‘mounted in the charger one way round despite the rounded triangular base profile. The chuck will mount a 10mm maximum shank size but obviously cannot be expected to do the heaviest work that a larger deill ‘can normally cope with. It comes swith one battery and no bits supplied. Verdict ‘This is really nice to use, it feels good in your hand and it is surprisingly powerful. Good around the home or in the workshop for lighter tasks. Recommended. Einhell ‘ww w.einhelltools.co.uk ISSUE 74 WOODWORKING PLANS & PROJECTS 43 J4MIS1OH STOOL? LOIHOT STUFF KIT & TOOLS MILESCRAFT D/T Featherboard By the Editor This is another cunning gadget from those Milescraft people in the USA. For a modest outlay you can acquire a set of featherboards which can be used singly on a router table or tablesaw for horizontal or vertical pressure holding of workpieces, or using the red. spacer and longer bolts it converts to a high featherboard for deep cutting on the bandsaw, It comes with everything you need for either version although you may need a bit of adaptation for attaching to a saw or router table fence. The fingers are very springy but apply a good amount of pressure. Two sets of guide slot rails are provided and these expand when tightened so they will fit in any standard protractor slot. I tried deep cutting on a baby Record bandsaw and they worked very well but a minor note that may be worth taking into consideration — when fitted to the right o blade the lettering is upside down! BOSCH GTS 10 XC Tablesaw ‘The GTS 10 XC Professional excels due to its high cutting capacity of up to 635mm on the right and 250mm on the left of the saw blade. This means you ¢ boards or beams to the right size with ease. The integrated table extension helps you to cut longer workpieces to size. A slide carriage is integrated into the tool to facilitate precise sizing cuts at angles. With its 2,100W motor, the GTS 10 XC Professional offers a powerful motor with soft ‘onstant Electronic start, overload protection and. also has a motor brake that quickly stops the saw blade as soon as the sawing process is finished. bss: CONTACT: Bosch ‘TEL: 08447360109 WEB: www.bosch-pt.com 44 WOODWORKING PLANS & PROJECTS |SSUE 74 CONTACT: Milescraft (WEB: www.milescraft.com IRWIN GrooveLock pliers The new IRWIN VISE-GRIP GrooveLock Quick-Adjust Pliers utilise a combination of innovative features to allow them to adjust 50% faster than traditional groove joint pliers, with a new slim head design The full range features four different sizes and two different jaw types, so plumbers, HVAC specialists, builders 1d carpenters will find IRWIN have created a rang that offers a tool for their every need, Both, the new improved GrooveLock Quick-Adjust Pliers and Univers Water Pump Pliers are available in 150mm, 200mm, 255mm. 1d 305mm to suit all types of job. The range is completed by the new Quick Adjustable ‘Smooth Jaw Water Pump Pliers and means IRWIN now offer the widest generalist range of pliers (on the market, The specifically. engineered all-purpose jaw which grips around fat, hexagonal, square and round surfaces, gives this amazing new product outstanding versatility while the ProTouch Grips are moulded for comfort and to minimise hand fatigue. CONTACT: IRWIN TEL: 0844 412 1190 WEB: www.irwin.co.uk www.woodworkersinstitute.comOSMO Bangkirai decking oil Bangkirai is an exotic wood species that is fast becoming a popular material for exterior applications in residential properties. Osmo UK, the eco-friendly wood and finishes specialist, understands the importance of treating such ‘wood types with a finish that provides protection, and enhances its qualities and is therefore encouraging the use of its Bangkirai Oil, Bangkirai has a tendency to grey quickly when exposed to exterior elements and may also show pinholes. With Bangkirai Oil, the surface is protected from such changes, whilst also adding protection that will make the wood dirt, water and sta shades, and is available as a transparent satin. matt finish. Easy to apply, Bangkirai-Oil smoothes the wood's surface. Two coats are needed when applying to untreated surfaces while only one coat is required for wood that needs reviving, osmot Bangkirai-Oil resistant. It is sold in natural or dark CONTACT: Osmo ‘TEL: 01296 481 220 WEB: www.osmouk.com ULTIMATE DUCK TAPE Duck, the UK's tape specialist has just launched new ‘Ultimate’ Duck Tape, its toughest ever multipurpose cloth tape with ultimate sticking power, Now stronger, tougher and super ‘tacky’, Ultimate Duck Tape is ideal for woodworkers and DIYers working on larger projects that require the strongest possible repair option. It is very thick and strong due to its triple layer technology, with super strength adhesive, toughened fabric and. 1 secure, long-lasting hold, Duck ‘Tape is perfect for a host of applications in the woodworking workshop and can be used to clamp, splice, fix, repair, seal, patch, reinforce, protect and bundle. It will adhere to smooth, rough, uneven or wet surfaces and is 100% waterproof, so it’s perfect for both interior and exterior jobs. CONTACT: Duck ‘TEL: 01442275311 WEB: www.duckbrand.com NEW SILVERLINE Autumn/winter catalogue Check out this season’s new Silverline catalogue. Packed with over 5,000 tools, you'll find a fantastic range of products including brand new tools in automotive and mechanical engineering. At excellent value for money, all Silverline hand tools are guaranteed. forever and power tools for three years, so you're sure to find everything you need! Request your catalogue online now. CONTACT: Silverline WEB: www.silverlinetools.com/ catalogue_request.html www.woodworkersinstitute.com BOOK REVIEWS Routing for Beginners by Anthony Bailey ‘Our very own oracle ofall things router brings you the second revised and € expanded edition of ret pete become something of a set text since its first edition in 1999. At over 250 pages, it’s be ‘extended and updated, with new projects replacing most from the 1999 and 2004 editions, as well as updates to the different routers, cutters and ‘capabilities available. The first half ‘covers the basics and not-so-basics from choosing a router to jigs and dovetailing, so no matter what level you enter the book at, you'll have ‘enough information to set to work safely, with confidence. There follows 16 step-by-step, fully illustrated projects and plans which will give you practice in many aspects of routing, and furnish your home and workshop too! A thorough introduction to the ‘most versatile power tool around. ISBN: 978-1-8610-8839-0 PRICE: £16.99 (plus P&P) FROM: GMC Publications ‘TEL: 01273 488 005 (WEB: wwwr.thegmegroup.com The Complete Guide to Chair Caning by Jim Widess ‘This is a hugely rewarding creative skill with practically no limits! Beginners are welcomed in this book which has much to teach restorers, furniture designers and hobbyists alike. IF you're looking for something else to add to your woodwork, of perhaps you've an ‘ld chair in need of some repair, all in this book. The versatility and ‘endless design possibilities make ita challenging craft which will serve you for the long haul; you'll never run out ‘of ways to improve in caning, This book really is as the title suggests. 's ISBN: 978-1-4547-0384.6 PRICE: £14.99 (plus P&P) FROM: GMC Publications ‘TEL: 01273 488 005 (WEB: www-thegmegroup.com ISSUE 74 WOODWORKING PLANS & PROJECTS 45 AHMUS LOH STOOL? LOIR WET STONE SHARPENING SYSTEM KIT & TOOLS. RECORD POW! Walter Hall takes a look at this sharpening system and its jigs comparison to my normal T «pening system which consists of a 150mm dry grinder with aluminium oxide wheels, fitted with a ‘Tormek universal support arm which is mainly used for reshaping and repairing damaged tools alongside a Tormek T3 system. The use The support arm can be mounted in ‘two positions depending on whether the process is best performed with the wheel revolving towards or away from the tool. Honing on the leather wheel is always carried out with the wheel revolving away from the tool. The arm accurate alignment of the tool's bevel against the stone and is locked in place by two lock knobs. Setup and adjustment is facilitated by means of the angle finder and angle setting ‘gauge, as explained in d supplied with the machine, although found that setup was usually easy ‘enough to carry out manually. his review is made in ed with a fine adjuster to enable ‘manual WG250 wet stone sharpening system Dual Surface Stone Grader ‘The WG250/R Dual Surface Stone Grader dresses the wheel for coarse or fine sharpening. Occasional use to sharpen the grit of the stone helps ‘maintain the speed and quality of the grind. Truing of the stone can be undertaken with this tool but is better achieved with the optional WG250/K Diamond Truing Tool, Tbegan by sharpening and honing the blades of my Lie Nielsen low angle block plane and Clifton No.5 jack plane using the Straight Edge Jig. This was quick and in both ‘cases resulted in an edge capable of producing translucent shavings, as ‘good as the edge produced by hand honing on a diamond stone. The clamp mechanism of the jig is large enough to allow the Clifton plane iron to be fitted without the need to remove the split cap iron which is useful ifyou are in the middle of a job and don’t want to waste a lot of time dismantling, reassembling and resetting your plane. T wanted to see how well the machine would cope with a blade in bad condition. 1 retrieved the battered ld Stanley chisel that 1 use for rough DIY work. This was suffering from a 46 WOODWORKING PLANS & PROJECTS |SSUE 74 THE NUMBERS 250 50mm, 230x 30mm. 90-150 rpm /0.4-0.7m/sec 160W T6kg £379.98 (RRP) Inc VAT WG250 Wet Stone Sharpener WG250/C Straight Edge Jig WG250/? Support Arm (12mm diameter) WG250/R Stone Grader \WG250/T Angle Setting Gauge WG250/U Angle Finder \WG250/S Honing Compound \WG250/x Diamond Truing Tool WHERE TO BUY wwuwrecordpower.co.uk 5 STAR RATING Value for money: E Performance: Build quality: number of ‘dings’ in the edge from contact with screws and nails and the edge was anything but square. I timed this operation and was able to achieve a perfect edge in just over three ‘minutes ~ quite slow compared to the dry grinder, but a much finer edge. Verdict Liked this machine. The quality and robustness of the jigs and components compares favourably with those of my Tormek 73. It’s big and heavy and. does not move on the bench in use. The quality of the edges I was able to produce with it was as good as those Thave been able to produce using any other sharpening method either by hand or machine. At only a slightly higher cost than the Tormek T3 and considerably less than the T7 ~ this would make an ideal machine for anyone looking for a first wet grinding system or secking to upgrade. www.woodworkersinstitute.com1 makes this rack sem for vintage and plonk alike! hat time of year is creeping back up on us again, and as it's the season to be jolly, you may find yourself short of places to store your festive drinks. This wine cabinet is a possible solution and will of course serve you throughout the years to come. The unit is not too large where space is limited so it is also a good way of using up short ends, ‘The cupboard is made of the hardwood I had available, most of it has been reclaimed so there is some variation. ‘The sides and the top are made of oak (Quercus robur), the rear planking is chestnut (Castanea sativa) and the bottle supports are made from some old shelves which have a ‘grain which appears to be a type ‘of mahogany (Khaya tvorensis) apart from the colour, however — {your guess is as good as mine! laning the edges straight and ready for ing together wwwwoodworkersinstitute.com Description Sides Base Tor shelves Base vals ine bottle supports, front line bottle Supports, veaw ISSUE 74 WOODWORKING PLANS & PROJECTS 47 aly Ps — — 0 32 om Bosvam 530mm 2240 Teva Ke Lm ou ou oa to tum ou Ove 3NIM >WINE RACK PROJECT z Fe =) I wo co us I: i 3 0 +» as | rE Front Elevation ‘Seale 1108 48 WOODWORKING PLANS & PROJECTS |SSUE 74 www.woodworkersinstitute.com‘The sides, base and top are glued up to the required width and held in cramps until set Plane and thickness sufficient ‘wood to make up the width for the sides, top and base. Glue together and hold in cramps until set. I prefer to use a cascamite glue for this because it does not creep and as itis not heat sensitive itis easier to sand, unlike PVA type adhesive. Make the two sides and the top little wider so that when you cut ‘out the rebate for the back you can ‘The router is quided by ajig when taki out the housing www.woodworkersinstitute.com ‘A small piece of wood equal in width to half the router base is used to space the jig position from the centreline of the required housing ‘make it oversize and any breakout that occurs can be planed away. After moving from the cramps when the glue has set, run a belt sander over the pieces to remove surplus glue and to ensure the boards are level Housings are needed in the sides to take the shelves and base. Use a piece of wood of half the width of your router base to space the jig position from the centreline of the required housing. ‘Take these out with a hand-held outer fitted with a straight cutter guided by a jig or batten. A hous ‘The same cutter guided by a fence s used to take out the rebate for the boarded back ISSUE 74 WOODWORKING PLANS & PROJECTS 49 is also needed on the reverse of the sides at the top so that part of this cean be cut away to form th 10 fit into the housing to be formed fon the underside of the top. A housing is needed on the reverse of the sides at the top so part of this can be cut away to form the tenon to fit {nto the housing to be formed on the underside of the top. The housings to take the shelves need to be 19mm wide and 13mm deep. ‘The housing at the top is made so that a 10mm thickness of wood is left to form the correct size tenon to my 3NIM. Ove >WINE RACK Using a router guided by a batten to take ‘out the long mortise in the underside of the top ‘The housings for the bottle supports are taken out with a router fitted with a straight cutter guided by a fence the underside fit the housings cut of the top. Take out a rebate at the rear of the sides and top to accept the backing boards. Remember to stop the rebate short of the ends in the top because it overhangs the sides. You can either use a cutter guided by a fence or a self guided rebate cutter to do this, Plane and thickness sufficient ‘wood for the three 229mm wide shelves so thi the housings. Housing are also required in the three shelves and base to take the ‘wine bottle supports. Make these housings 13mm deep and the width 19mm or the thickness of the wood available. These housings can be stopped short of the ends or taken through; in which case the small length of housing not used for the supports will enter the side housing they are a good fit in and will not be visible. The bottle supports at the front and rear are identical except that the ones at the rear are 13mm less in height so that the bottles lie ata slight angle when in the rack. The cutouts on the supports are all a semicircle of 83mm diameter so their outline ‘After marking the centrelines of the cutouts, a pair of compasses are used to mark the outline of the cutouts can be easily marked with a pair of ‘compasses as shown above. Ifyou have a bandsaw you can use a 10mm wide blade to remove as much of the waste as possible. However, I found that 1 ‘could not take out all the sem because of the restricted depth of the bandsaw table but you can finish them off with a coping saw by hand. As an lused a jigsaw to make the cutouts, but ‘coping saw 50 WOODWORKING PLANS & PROJECTS |SSUE 74 ‘can also be done with a bandsaw and alternative, I used a jigsaw; this does make a more ragged edge but if your wood is a litle oversize, it is removed when thicknessing. The next step, once you have taken out all the semicircles is to sand to remove all the teeth marks; a small flap wheel fitted to an electric drill makes this particular part both quick and easy. ‘A flap wheel is used to remove the teeth ‘marks from the cutouts www.woodworkersinstitute.com‘The bottle supports are glued into their housings before assembling the cabinet 1 removed all the semicircles before thicknessing the wood to size, so that when light cuts were taken on the thicknesser any slight breakout is removed. Finally, take off the sharp edges by hand with some abrasive paper. Make sure the supports are thicknessed to enter the housing made for them on the shelves. The bottle supports can either be glued in their shelf housings before gluing the shelves in position or afterwards because it is a simple matter to cut them to the correct length. The shelves and base will ‘ced a small cutout taken out at theit front comer so that they fit, flush with the sides. ‘The bottom strips are glued at the front and rear and are held until set www.woodworkersinstitute.com YDVe 3NIM ‘Small cutouts are removed at the front corners to allow the shelf ends to fins! ‘The shelves are glued into the stopped housings made for them. Apply glue to the housings in the sides only, then fix the shelves and base in position and hold in cramps until set. Check to make sure things are square. There are two lengths glued below the base: the front one is either flush with the front edge of the base of set back slightly. The one at the rear is positioned so that it forms a rebate to take the lower edge of the backing boards. ‘The joint between the side and base can be reinforced with short lengths of glue blocks. ‘The cabinet is glued together and held in cramps until set Short lengths of glue block reinforce the bottom joint ISSUE 74 WOODWORKING PLANS & PROJECTS 51 | >WINE RACK ‘A3.2mm radius self-guided rounding over bits used to round, lover the top edges The top overhangs the sides and front of the sides by about 19mm. When the sides and shelves are removed from the eramps, the top housing should be sawn through if you did not do it earlier, to leave a long tenon 10mm thick and 13mm high. Rather than mark ‘out the position of the housings in the top by measurement itis safer to invert the cabinet so that it rests fon the underside of the top and it is possible to draw around the tenon so that their exact position is located. Remember that these housings have stopped ends so that the long tenon is trimmed short at the front and rear. Have a trial run by dry fitting the top in place, mark out where it needs to be trimmed to leave the 19mm ‘overhang at the sides and front, also ‘make sure the top is flush with the SF Applying a coat of Danish oil ‘A rebating set is useful to make a 3mm deep rebate sothe backing boards overlay rear of the side so that the rebate for the back is in the correct position. You may find that a litle squaring up of the comers of the rebate is required by hand with a paring chisel. Use a 3mm radius self-guided rounding over bit to round the top edges MDF could be used for the back but I had been given some chestnut, which I cut into. random widths and thicknessed to fit nicely into the rebate. A small rebate {is worked half way through along the sides of the backing boards alternating at the front and rear, so that they fit together without any visible gaps. Do ‘not make the backing boards too ‘wide so that any movement is small and taken up by more joints. To fix the backing I use No.f screws towards one side of each board into the rear of the shelves and top and bottom rebates, in this way the upper part of the rebate holds the lower one in position. If you leave the fixing of the backing boards until after the finishing process it will make things a lot easier. Do not use th of wide boards because due t0 the opposing grain direction. They are more likely to split if shrinkage occurs Three coats of Danish oil were applied to the outside of the cabinet and one coat as a sealer to the inside with a brush before removing 52 WOODWORKING PLANS & PROJECTS |SSUE 74 surplus with a lint free cloth. Sand lightly between each coat and after, the final coat has had Apply wax polish with a Scotch: pad and burnish with a soft cloth. ‘The backing boards were also given a sealing coat of the Danish oil before fixing. This unit was made to fit onto a shelf but if it is placed on the floor you may want to raise it slightly by turning some small ball feet with a top pin, so that they can be glued into holes drilled in the base. Your finished wine rack should look like this, now time to fill her up! The finished rack, in need of something ‘else, can't think what! www.woodworkersinstitute.comce WAX -OLISH BLACK BISON, Give your furniture classic Black Bi Why buy anything else? For a free guide email liberon. quoting WPP and your call 017 5 of visit wwwiiberon.co.uk for details Pee eae Pe eae Paes sea Re ua eRe ET . No of adult tickets £3600 @ £8.50 N ckets 6900 @ £7.50 Cheque / PO. to SK Promotions Ld £- m CRAFTSMAN'S CORNER KIT & TOOLS scsi oy pi oft wich no wood Srorshop should be witout El a glee te so ro Pa are toed Theend rill and ‘turning tool dispenser raftsman’ s omer Simon Frost takes us on a tour of the Titman factory in Essex to see how their esteemed tip tools are made Above: An ROCB special for Titman GmbH Right: Martin Newnham and Paul Stevens on shop floor Clacton-on-Sea to get a first-hand look at what goes into a Titman cutter, Shaking itup "When | cantare ago, there was stagnarl the business Copleins PodMMMRe Dicecor and Head of Sales, Matti Newnham ~ could be sald yal recent years Titman had solsewhat dropped ander the rodaMaTaman never stopped producing cutters ofthe highest qualleand with Newnham tthe hcl, aay a rebuilding their presence agilleading ‘manufacturer. “We want péople 10 ds qualified carpenter with ten years’ experience in the trade before ‘moving on to posts in management, and his passion and knowledge are ar from the start. “The guy running the company should know everything, 54 WOODWORKING PLANS & PROJECTS ISSUE 74 about the produet™ he says, and as {We moved from machine to machine his comprehensive knowledge of the"process confirmed his hands-on ‘mentality We donned our safety goggles and made our way to the factory floor, where Martin pointed out impressively that of the 43 employees which still includes one member of the Titman family ~ the average te of a current Titman employee s at 20 years. Tough stuff The high-carbon British steel used for the cutter shanks isa tough yet ductile alloy, which allows a level of flexibility and of heavy use by the day-to-day user above that of solid carbide. It is cut to length and put into loaders before the body shape is turned, and then moved on to the mulling machine to have the slots putin. A brand new www.woodworkersinstitute.comthe tool holder in the Colchester lathe Biglia CNC machine ~ a $300,000 investment which has 165 Fanue= coded programs written into i, using 46 different tool turrets ~ is capable of turning, milling, drilling and tip. cutting for many of Titman's eutters. ‘There are 6,000 different cutters in the Titman eatalogue, and of those Sold), Titman has a 0.001% rate of returns, the sort of figure which is practically unheard of in manufacture, and speaks volumes of their attention to perfection — each model of cutter is tested on 2,500 metres of wood. The variation of old and new machines is invaluable as ivallows them flexibility of manufactureyspecial cutters ‘currently a€count for 10% of Titman’s business, and they gladly make spec cutters to order in any quantity. The capabilities link in strongly with the cating technology that goes into all ‘Titman cutters, old and new. Brazed by hand ‘Titman source the highest PBRBbIe sade of tungsten carbide from ‘otal Carbide, and they can use this source to try new combinations of metals. Tungsten carbide tis must be cexremely clean before bgigilBrazed to the cutter, so the next gear the tip has been turned i sandblasting ‘The tungsten carbide tips and steel cutters are then heated and brazed together by hand using atr-metal alloy with a lower melting point. Once cooled, the resultant edtess bonding agent is removed by another bout of sandblasting, before re-polishing. www.woodworkersinstitute.com YINYOD SNYWSIAVED STOOL? LOI Dave Yetton putting con the cutter bearings ‘Steve Goode milling the special cutters ‘The next stage is to grind thertip, standard cutters are sharpened in. Jarge numbers in a CNG machine, which is also used for eutters sent back for resharpening = the signature slot in Titman cutter shanks is present for this reason, with the slot being used to line the cutter up precisely for sharpening, After more sandblasting, the flute of each cutter is hand ‘painted in Titman’s signature red, and the electrochemical painted logo ‘added to the shank. The reason the flute is pa oiL-based coolant used in the grinding process, which would strip the paint from the rest of the eutter if they were painted in a dipping process. The finished cutvers af then packaged and ready t0 go. ‘The aim of Titmaft now is to return to its former size and prominence in the industry, and having seen the expertise and passion that goes into the manufacture, it's plain to see that ‘Titman is a company on the up. nted by hand is due to the DVaBloks hand reine the specials WHERE TO BUY Titmaafh» Pe ‘Stewart Ware adding the Titman red by handin the finishing shop. ISSUE 74 WOODWORKING PLANS & PROJECTS 55CRAFTSMAN'S. a ire a / Paso ceUUILDiT We unleashed Anthony Bailey on the high and mighty Festool OF 2200 EB. Is it, we ask, a beast or a beauty... or both? time I have handled this machine, despite having worked with ay routers, so I am coming at this without any preconceptions. It's big, there’s no getting away from that, and powerful too, at a class leading 2,200W of input power ~ about as much as you can use freehand and without blowing fuses all the time. The desi engineering hallmarks: solid, carefully considered construction, attention to detail and system compatibility It can be inverted safely for cutter changing, then a paddle lever is pressed to engage a ratchet as you turn the collet nut, so that you don't have to keep © spanner off the nut ~ very natty: The collet itself is the standard large Trend, DeWalt, E type held in firmly with an O-ring and is available in a range of shank sizes, ‘The plunge columns run in bushes, one being phosphor bronze, completely waggle-free and smooth in operation, the lock being a unique rubber twist knob on the left handgrip. ‘The large round base has two ‘chopped’ faces to allow various operations and a clear plastic upstand to help contain dust, while on the right handgrip is a lever to launch a sprung clear shield that slides inside the base upstand giving full dust shrouding. This is important because there is a large integrated dust spout at the rear of the machine. The switch trigger is at the top of the right handgrip and is heavily sprung and can be locked on, The body has a variable speed thumbwheel and a speed guide 10 show which setting Depth [= confess that this is the first n has all Festool’s setting consists of two methods, one: the depth rod can be raised or lowered and locked by a large lever for coarse adjustment wit adjustable pointer against a se Two: with the locking lever on, a click-stopped rubber covered knob on top with a green increment scale can raise of lower the depth rod very precisely. In both cases the rod presses against one of three depth stops on the click-stopped turret below. The depth rod is a lite wagely but settings are accurate. ‘The base is something els With the router inverted a sprung, lever is pressed to make the phenolic resin facing pop up. Then a guide bush can be inserted and one of several base facings installed: an ‘extension base, standard base, small aperture base, flush tri base and one with dust slots. A standard fence with long fence rods and a dust bowl is supplied and a fiting to work with a guide rail, all stored in an precise machine that will last a 56 WOODWORKING PLANS & PROJECTS |SSUE 74 THE NUMBERS Festool OF 2200 68. 22000 10,000-22,000 min-1 6-127mm, £744 (inc VAT) WHERE TO BUY wwwwfestool.co.uk FESTOOL lifetime this is it, but at a price of course. A variety of accessor are available and helpful free downloadable PDFs for a number of joinery operations can be found on the Festool website. i www.woodworkersinstitute.comCutting:down iteB eT Anew study investigates the link cesearchers at Leeds University and the NERC Centre for Ecology & Hydrology have found that the destruction of tropical forests is dramatically reducing the amount of rain that falls in and beyond these ar Analysis confirmed that air passing over vegetation produces at least twice as much n as that blowing. across sparsely covered ground, In some instances, it had an effect on rainfall thousands of kilometres away. It i a subject which scientists have debated for some time; most agreed that plants put moisture back Of the forest could be lost by 2050. between deforestation and drought eee eae Ancings show the importance An estimated 1.5 acres of rainforest of initiatives to protect tropical are lost every second to logging rainforests. Dr Dominick Spracklen, companies, and whereas rainforests also of Leeds University sad, “Brazil fonce covered 14% of the Earth, they has recently made progress in now cover less than half that amount, slowing the historically high rates 6% of deforestation across the Amazon On top of the long:proven and our study emphasises that this environmental problems which progress must be maintained if a4ise from deforestation; such as the impacts on rainfall are to be avoided.” toss ofan estimated 50,000 species As well as supplying water t0 per year, and the rapid decrease Brazil's vital hydro-electric Meet Of wibal inhabitants; drought the Amazon rainforest also acts caused by deforestation could have as.a carbon sink ~ which removes severe implications for the mostly C03 from the atmosphere ~ but subsistence farmers who Occupy the some researchers believe that rising surrounding areas in southern Brazil temperatures and drought are limiting nd southern Afeica its ability 10 perform this function. into the air through their leaves, but the scale and geographical reach has never been fully understood. Researcher Dr Stephen Arnold said, “This has significant implications for how policy makers should consider the environmental impacts Of deforestation since its effects on rainfall patterns may be felt not only locally, but on a continental scale, workersinstitute.com The researchers modelled the observations against predictions for future deforestation and warn that rainfall could be reduced in the Amazon basin by up to 21% in the dry | yaww.ceh.aeiuk season by 2050. Over 600,000 square More information kilometres of Amazon rainforest have Oe been lost since 1970, and current wwwillegal-togging.info trends predict that as much as 40: 4 WOODWORKING PLANS & PROJECTS 57 ISSUE 74AVAILABLE ON YOUR IPHONE or SUBSCRIBE > DISCOVER pain. Woodcarving ctnnaig our other woodworking magazine apps and get the first issue for NTS WAC fala! — ALSO AVAILABLE FROM POCKET MAGS wal aeFresh from carving a large decorative bowl in WAP 72, suggested another idea for using ‘found timber, in this case a small diameter log of yew, to make some natural edge coasters. To our surprise this was done very successfully on our small Record bandsaw with a pleasing result. Here is how Mark achieved it his narrow branch of ye (Faxus baccata) had been cut down and left to dry quite some time ago with the ends sealed to prevent splitting, Being roughly round in shape demanded a safe way Of cutting the log into slices. The simplest is to place a wedge under the leading edge of the log before feeding it through the bandsaw which 1g and snatching on the blade dangerously. We went one beter and made a cradle to hold it more securely. www.woodworkersinstitute.com [20d SYALSWOD 39G3 WYNN - dOHSHOM 13D [es )-@ a | i ~ y= ‘The blocks are glued and clamped up in ‘two packs of three Cut six blocks of 50mm wide prepared softwood with a 45° bevel on each, Line them up in two sets of three and glue and clamp in a pack Apply glue to each pack and rub into position on a piece of 12mm MDF aligned along one edge CCheck the log will sit down properly between the blocks bevelled pieces to set. (SSUE 74 WOODWORKING PLANS & PROJECTS 59 | >XGE COASTERS POCKET WORKSHOP ~ NATURAL E! Log Cutting ig Fitting a hardwood strip to fit the mitre protractor slot bet Several experimental slices were made before the frst really clean cut We also tried some larger wet log slicing ‘ona bigger bandsaw Now turn the board over and drill ‘and screw the blocks so they are properly secure. Small panel pins are then tapped into the bevelled slopes and the heads nipped off with pliers to lock the log in posi turn while you are working, Most bandsaw tables have a slot for a mitre protractor. We made a as After several goes we were starting to get consistent parallel slices ail Use a small amount of hot-melt glue on a block asa safe hand grip device 60 WOODWORKING PLANS & PROJECTS |SSUE 74 hardwood strip to fit the slot on the Record and screwed it in a position that allowed the cradle to just clear the bandsaw blade, ‘A wedge is needed under the outer end of the log and can be pushed underneath until it sits nicely in the cradle. Several experimental slices were made which removed any minor splitting and the end seal. This is the first really clean cut, Several goes later and we were -nding up with consistent parallel slices that were showing defi promise. There was plenty of log left so we could easily afford to waste a few that weren't so good, Our raw slices are on the left here, we also tried some larger wet log slicing on a bigger bandsaw and you can do the same within the capacity of your machine. You could also try making a slanted cradle for oval slices if you wish. Use a dab of hotmelt glue on a small block as a safe hand grip device ready for sanding, www.woodworkersinstitute.comPress the block down firmly while the glues still hot Spray a coat of cellulose sanding sealer on both faces Press it down firmly while the glue is still hor. It can be pulled apart later. sander, the faces sanded smooth, Do both faces and check they stay fairly parallel or your drinks will be on the skew! For a finer finish you can orbital www.woodworkersinstitute.com Sand the faces smooth with a standard belt sander, check both faces are parallel sander quite safely and get bare finish ready for sealing, Spray a coat of cellulose sanding sealer on both faces allowing to dry between coats. Do this in a well ventilated area with no naked lights! a piece of Webrax sanding grid sady for the finish coat, You off and denib usi Finally, press some small self-adh to prevent movement Fora finer finish before sealing, take the coaster to an orbital sander Flat off and denib using a piece of Webrax sanding grid 1¢ abrasive if you do not have any Webrax available This time apply a satin lacquer finish, again with good ventilation for your safety Press small selFadhesive rubber pads on to the undersides so the coasters stay put and do not rock at all. Now it’s time to put the coasters to good use! ‘rubber pads onto the undersides of the coasters |SSUE 74 WOODWORKING PLANS & PROJECTS 61 } Od 4 = 8 £ SWALSWOD 3903 WHNLWN - 4SUBSCRIBE Ne ee BEV t) Furniture -* cabinetmaking Design and inspiration for furniture makers Frit & Cabinet Making isthe UK's only magazine dedicated tothe finer aspects of Contemporary ani cawie woodwork, With an emphasis on quality the magazine aims ce in faritare making by modern and cli funicae design thn, Tel ae und hand tools that makes F&C an Furitare maker Emr Omen The best-loved woodturning magazine eden he works bs-slng magazine foe woodturners. Read by tursing ent in over 60 countries workdwde, 1 pls well-ltat techniques, news, reader feedback, detailed t a wppealing to iy Corer £40.50 TODAY ye al VO EN e Oa ie CARVING THE RESULTS Guidance and inspiration for ambitious carvers Wooing sa truly iecenatonal de that focuses on the art and techniques of carving ctised all over the word The magazine WOODCARVING ORDER CODE: A3229 £20.25, i UK £12.66 UK UK UK DIRECT BESTT 318 ‘UK (DIRECT OEBIT) #3150, UK DIRECT BEB) 215.75 $53.35 EUROPE £50.65, EUROPE 225.32 5 ‘OVERSEAS, £59.72 (OVERSEAS, £56.70 (OVERSEAS, £28.35. f YES! | would like fo subscribe to: 1 vais (A32329 Py By: Cheque or debiieredt card SAVE 10% 1 UK pice 1 Rest of World price Europe price © vais (A3230) Py By: Diret Debit SAVE 305 UK pice © emma A822) easy ways PORT rail y +44 (0) 1273 488005 Men ett Post the form to: GMC Publications Ltd, Rsageaiey foestoeFrame and pane] cutters Framed at last! We've finally MON YaLNOY SANDINHIAL got the better of him as 2 we remind our Editor z of what it was really like = when he made doors and Zz panels for a living. Now he is z going to give us the lowdown a on the cutters that are almost g exclusively the province of the > 3 large in router — frame and panel sets 7) nets in one form or cut that needed to well as styl be framed and panelled, from carcass The one sides to doors, required suitable to favour m ‘cutters to do the job and not being years ago w in possession of a spindle moulder, reversible type where you the router table was the logical machine the scribing cuts answer. By acquiring several different first, then swap cutter components, frame and panel cutters I could cater and do the profile cuts second. for most requirements and produce decent quality frames and panels Since then it has been possible to ‘quickly and easily. buy one-piece cutters which are “ abit taller and are simply wound up Profile and scribe cutters or down in the router table to select either the scribing or profiling section of the cutter. Atypical frame anda matching panel for sutterhas tobe reassembled when These cutters are moved up and down to quick and easy construction changing from profile to scribe change cuts www.woodworkersinstitute.com ISSUE 74 WOODWORKING PLANS & PROJECTS 63 >ROUTER KNOW-HOW ~ FRAME AND PANEL CUTTERS TECHNIQUES ‘There are also separate scribing, and profiling cutters; you just swap one for the other, of if you have the luxury of two router tables, both could be set up for repeat runs ‘without changing cutters or settings. Styleavise you can choose between a plain bevel, ogee ~ shallow reverse curve ~ Roman ogee — fa steeper reverse curve — and classical = two opposing curves broken in the middle with a narrow quirk or step. Which one you choose is dictated by the situation the frame will be used in and how many sets you feel like investing in. Frame cutters ‘The plain, square frame router catter is actually very versatile both for hidden panel, eg. back oF side panels, but will look good if you want either modern, clean-lined doors, painted to suit an earlier farmhouse or Shaker syle. It can be used with flat of raised centre panels as can the profile and scribe sets. Panel raisers Since all the frame producing crtters usually have a 6mm panel slot you can use a flat ply or MDF ppanel which can save cutter cost and look good. However, ifyou want traditional raised solid wood panels Flat panels can look good in the right situation With two separate cutters ith have two routers then you need to acquire at least one panel raising cutter. These are large diameter cutters and in some cutters fairly massive, Ic must be noted that these cutters ‘must be used in a router table and all frame cutters should be used similarly, even if there appears to be no manufacturer's restriction on freehand use. Horizontal type TO restiscates come in a variety of styles which are intended to complement the frame styles. So you can choose from Roman ‘ogee, hevel, bevel with a swept edge, classical and dished profiles. They may also be available in different sizes with the smaller ones suitable for drawer An arch top door can be used to suggest a specific‘look’ 64 WOODWORKING PLANS & PROJECTS ISSUE 74 CARN RS Examples of various different moulding styles fronts, ifused with care in setting out the sizes ‘Whereas frame cutters always come with bearings, not all panel raisers do, but you need a decent fence to run against in any case, unless you are ‘making arch top doors in which case Sorby i ss ‘There are panel raisers to match all frame sets www.woodworkersinstitute.com,Tim cen eansccrt back cutter which creates an even tongue so you know the panel the frame slot without ar adjustment. It gives a slight sweep fon the panel rear face which looks deliberate and adds to the appearance of the door panel. Vertical type Dee caters end a couple of distinct advantages to panel raising operations, Firstly, they aren't 4s scary 10 use because they are much smaller in diameter. Secondly, they can be used with a small router, as tong as it will take an 8mm collet and has sufficient motor power to run it LB moms hat you cannot do arch top panels, only square ones, and the scribing ‘cuts will tear grain out so you need to take steps to prevent this. TOP TIPS é@ ‘The through-fence on the router will prevent breakout Itis advisable to always start with a proper cutting list www.woodworkersinstitute.com Right: The small back cutter creates perfect, tongue Vertical panel raisers are available in all shank sizes . = ‘The WPP router table that | made works really well Precise measurements are essential when using a router “~ 5 Na&A A stack of raw components, ready to machine ‘Tearout can result with the vertical type of cutter iste ble win a heh through-fence fitted is essential as isa fine height adjuster. Apart from vertical panel raisers all cutters will need a preferably with at least an 1,800W ‘motor input. Check all cutters will fit through the opening in the table. Always make the frames first as these define the actual size of the door or cabinet panel you are creating. Measure the openings for each one so they will be a correct light trimming is needed after, assembly. Inset doors and drawers should have no more than a 2mm gap on all edges when fit and aim for Do a carefully calculated cutting list expressing the sizes of stiles ~ vertical components = rails ~ horizontal components - and muntins = vertical intersecting components. The stiles should be left overlength and ‘horns’ cut off later All other components must be Jexact length and take into account the width of the stiles - or rails in the case of muntins ~ plus an amount that the scribing joints plug into the other components ~ usually 2 x 9.5mm, 19mm with most sets, \SSUE 74 WOODWORKING PLANS & PROJECTS 65 |OH-MONM YaLNOY SANDINHIL JLLND TaN¥d ONY 3W¥es - suaROUTER KNOW-HOW ~ FRAME AND PANEL CUTTERS TECHNIQUES ‘test piece for panel raising Prepare all stock plus some spare sections for test cuts as accurately as possible. A planerithicknesser will help assure this, but if you don’t have that facility pick carefully through prepared stock at your timber yard, In particular all frame components ‘must be the same thickness, since the process of scribing and profile cutting involves turning everything over for the second operation. Work methodically by stacking ‘components like with like, Mark which component is which, e.g, stile, rail or muntin, In addition, mark the opposite face which will be face down when machining, for example if component ends are being scribed. ‘mark the component's ‘seen’ face. When scribing is finished they will be turned over and all components can then be profiled. GBs ae cent bore you start; get the seribe cut right, ‘machine all those then do a test cut before profiling, Panels, if they are made from solid timber, need to be flat and true on the edges where they are joined in the middle. If you use biscuits to add edge strength you risk Even downward pressure is needed for consistent results 66 WOODWORKING PLANS & PROJECTS ISSUE 74 Scribing cuts need a through-fence for ‘good support them showing at the ends when the panel raising takes place. It is better to make a good butt joint and avoid the biscuits ‘grinning’ through. 10 regia checked against the dry.assembled frames. Measure for panel size by working from the flat frame section excluding the moulding as this is the same depth as the groove underneath it, Now subtract no more than 2mm in length and width to obtain panel size. 1 Dizzee pant ise in ‘more than one pass to depth; don’t be too ambitious as it means removing more wood than is safe Ifyou have a back cutter fitted, do the multiple passes by moving the fence back until you reach the correct cut width, Itis important that the mitres meet at the corners ‘end ~not good! You should always check panel ft before assembly 1D Serie sering cus so any tendency to tearout is, removed when you do the lengthwise profile cuts. Use even, downward pressure so the cuts are consistent and the mitres meet at the panel corners. A light final pass will help when making cut alignment correct. Manufacturers & suppliers Wealden wawavealdentoolcom ‘Trend www.trend-ukcom CMT wwwemttools.co.uk Titman wwwcitrman.co.uk ‘Makita woewmakitaukccom ‘Axcaliber worwaxminsterco.uk Whiteside wweroutercutterco.uk Infinity wwwnfinitytools.co.uk www.woodworkersinstitute.com,In the December issue of Mer S w | combination workbench at HAND-BUILT: Hand sawing Titman technique router Safe working practice: cutter test Keeping all your joints loose! PLUS: @ power WOODWORKING: Multi-tools @ FEATURE: The Forestry Commission — a walk in the woods @ CRAFTSMAN’S CORNER: Workshop extraction Christmas scrollsaw project wwwwoodworkersinstitute.com ISSUE 74 WOODWORKING PLANS & PROJECTS 67 3NSSiLX3N SYVINDaYIVE A MAGAZINE S SAVE 30% WHEN YO * The perfect present Om cli E-Iu (| UK cover price Seria is there’s something for everyone @ Aunique present that lasts the whole Nels CODE s3714x CARVING Naw Forest pony ~~ "e) i) CODE $3716x CODE $3717x Aa eAGe tires @ Saves you time avoiding the crowds @ FREE GIFTCARD for you to give for fescue DIGITAL EDITIONS OF ALL OUR MAGAZINES ARE NOV cyL TArd rd oe Gees | ean oe [east ent Toes | es e0 Teor [ ne | es work fim and pin, Oven nas ese wt ea esba8 CODE $3718X CODE $3719X DallsHoase (pte ea Fucks Whte Paneer fens ieee oe Sgt on aco wn era ez Me we) nat nae CODE $3720x CODE $3721X Y AVAILABLE TO DOWNLOAD! ies SOMO Onn nooo s coer Go through to the purchase page, select the gift option, and onc« eae eat eet ead poelipalires eae blar tela ioeny Fron iar ila dg ehehoardeollet sed a Cat eu eoicnr ann) pos oee et ed eee aesFROM THE SCRAP BOX ~ KEY CUPBOARD makes % a handy cupboard for you to store your keys y its very nature your scrap box is. bound to contain a lot of small offcuts, ‘and here is a project that needs only ‘a small amount of timber and a piece of plywood. It is a small key cupboard, though obviously it could be used to store other things, to0. Its construction involves a fair amount of routing, and to make the panelled door you will need a dedicated cutter set. However, itis all pretty straightforward. Use any timbers that you have and, ideally, try to find an attractively figured piece for the door panel which contrasts with the frame. > Sow Plane + Reuter table ‘Straight cutter Rail ana stile cutter set Panel raising cutter Frame clamp Component ty L w Th + Baw lames side 2 300mm 0mm 2m Glue Ena 2 20000 0mm V2 Abrasive paper Back 1 PA Pome Ans, Hinges Stile a 276m AO eam 20mm neo Rail 2 120m A000 20mm Catch Panel 1 200.0 ent Simm Hock battens 2 180.0 0mm Go You will need some suitable B offcuts for the project, similar to these shown here. When cutting up small offeuts, a bandsaw is useful as its thin blade tvastes less timber than a tablesaw, leaving more for you to work with, » You can now plane and thickness your timber to suit. This piece of = cherry Prunus spp.) will become the Youwwillneed some simple offutsfor _M possible, use a bandsaw to cut your door frame, this project similar to these offeuts as it has a thin blade 70 WOODWORKING PLANS & PROJECTS |SSUE 74 www.woodworkersinstitute.comKey Cabinet e and thickness apiece of cherry, which will become the door frame Fityour router table with a 4mm. diameter straight cutter for the back ‘The cupboard frame is simply made from four boards jointed ‘with mitres. Set your tablesaw or mitre saw to 45° and cut to length. The completed sides should look like these, The cupboard back is a piece of ply that is held in a groove cut into the sides. 4mm thick ply was ‘used here, so fi the router table with a 4mm diameter straight cutter. Set the fence about 6mm back and set the cutter depth to 4mm. Carefully rout the groove on the inside face of each of the sides. You can then cut a piece of ply to fit. www.woodworkersinstitute.com Set your tablesaw or mitre saw to 45° to ‘ut the four boards to length Carefully rout the groove on the inside face of each of the sides ‘Support the frame with a frame clamp and ensure the assembly is square The frame can now be assembled. Apply a little glue to each of the joints and you can also run some glue into the groove for the back. You ean now fit the parts together. Support the frame with a frame clamp and ensure that the The completed sides of the cupboard frame should look like these Itis now time to assemble the frame, applying glue to each of the joints Tomake the door, use the assembled frame to mark off the length of the stiles assembly is square by measuring the diagonals to confirm that they match. The next job is to make the door. Use the assembled frame to mark off the length of the stiles. ISSUE 74 WOODWORKING PLANS & PROJECTS 71 GYVORdND ABN - XO8 d¥eDS 3HLWOUS >FROM THE SCRAP BOX ~ KEY CUPBOARD lamp the stiles in position and measure the gap between them Use the ral joint to line up the cutter then makea test cut ‘Cut the stiles to length; they should be a tight ft at this stage. Clamp them in position and measure the gap between them to gauge the length of the ral Remember that you will need to allow extra length for the joints. A combination rail and stile moulding ‘cutter is ideal for this job. It euts a joint 9.5mm deep. So you can round this up to 10mm and therefore add 20mm to the length of your rails. Install your cutter in the router table and set it according to the manufacturer's instructions. Normally you cut the joints on the ends of the rails first In this case the rails are very short, so set up a mitre guide ‘with a sacrificial support board at the rear and then clamp a stop block to it to hold the rail up against the cutter. Now cut the joints on both ends of the rails. The cutter must be re-set to cut the grooves in the door frame. Use the rail joint to line up the ‘cutter, then make a test cut using a piece of scrap to make sure that the settings are correct. Again, the short rails need to be treated carefully: Fit a satherboard to the router table so Install your cutter in the router according to manufacturer's instructions Fita featherboard to the router table so that the workpiece is held tightly [Atthis stage, the frame should look something like this that the workpiece is held tightly against the fence and also cut a length Of scrap to use as a push stick. Fix the relevant cutter guards, start the router, and using the push stick, guide the two short rai ppast the cutter. Repeat with the stiles. At this stage, the finished. frame should look like this. Try to find an interesting, piece for the panel. This is bird's eye maple (Acer saccharum), You now need to cut it to the correct dimensions to fit the door frame. Use a panel raising cutter to mould the edge of the panel so that it fits the groove in the door 72 WOODWORKING PLANS & PROJECTS |SSUE 74 fA Set up a mitre gauge with a sacrificial support for the rails Guide the two short rails past the cutter, using the push stick Find an interesting piece of timber for the panel Use a panel raising cutter to mould the edge of the panel frame, Some of these cutters have a bearing to guide the workpiece. ‘This one does not, which can cause problems, especially with small panels, www.woodworkersinstitute.comClamp a false face onto the main fence and raise the cutter to bite into it ‘Mark the positions of the hinges on the door of the key cupboard Place the door on the cupboard frame and mark the hinge positions clamp a false fence onto =U the main fence and raise the cutter to bite into it When moulding panels, you must take a number of shallow passes until you reach the desired thickness. Test the fit in one of the stiles after each pass until you get a perfect fit ‘To assemble, apply glue to the joints on the end of the rails. Be careful not to get any glue onto the panel or in its groove. Clamp it up and leave to dry. Because the back of the cupboard is rather thin, fit pair of battens across it to hold the key hooks. Cut them to length, glue in position and then screw the hooks in. Mark the position of the hinges = Don the door. Line them up with the edge of the frame moulding, wwwwoodworkersinstitute.com Test the fitin one of the stiles after each pass until you get a perfect fit ‘Screw the hinges in position, again with flush hinges as they don’t need to be recessed into the door or frame. EE Dill pilot holes and fit the hinges with one screw each. Place the door in the cupboard € Oframe and mark the hinge positions. Adjust the fit of the door with a plane if necessary. Screw the hinges in position, again with one screw and check the fit. Make any adjustments, and finally instal all the screws. Fit some kind of catch to hold Dthe door shut and fit a suitable handle. You can turn or buy one. the completed key cupboard. ‘7 Now simply apply some oil or lacquer and itis ready for use. ISSUE 74 WOODWORKING PLANS & PROJECTS 73 Toassemble, apply glue tothe joints on the end of the rails, then clamp up = ii Drill pilot holes and fit the hinges with fone screw each 7 | ie Fita catch to hold the door shut -lused amagnetic hinge ‘The completed key cupboard now just needs a coat of ol and it's ready for use GUYORdND AB — XO8 d¥UDS IHL WOUSIRWIN. Marples. STANLEY IRWIN. Peete >) 7 4\ your,Essential Ghristmes Gift Guide For details of these and other fantastic offers please visit www.realdealsforyou.com to find your nearest stockistWe asked the to try out a rather nice set of smaller planes which would make a handy Christmas present for someone (hint, hint). So do you need to spend a lot of money, or can you still make good shavings with budget tools like these? ben as ofered this it WV ee ets the Not smoother i soitwas intresting ose is Simple was othe sume standard and hese ne uy ot the No 0 block pane, which hat had ago th before Both tools ave spp in 2 proentton oe of eee lly Baritdos Keep hem st No.4 smoothing plane Starting withthe smoothing plan 4 copy ofthe standard Stanley Ba pattern which isa very tried and tested design, being approximately 150 years old since Leonard Bailey started making them. The body yet www.woodworkersinstitute.com casting was slightly thicker on one side but otherwise well turned out with finely ground soleplate and ook good and are highly lacquered. Everything you would expect to be right is; the brass knobs are good, ustment is perfectly possible {the machining to rest the blade sticks up too far and as when I reviewed the No.4, 1 The general appearance and build is good. I spent 10 minutes flatting the sole as I do with any plane, then flatting the back of the blade and sharpening to a good ed diamond plate. The resu Tcould tune in the plane to get a thin ribbon of shavings. Time and experience will show how good the blade metal is at edge keeping but I ‘was impressed this time around. No.60 block plane ‘This is another well-trod design, again THE NUMBERS £29.99 (RRP) Inc VAT WHERE TO BUY wwwrealdealsforyou.com 5 STAR RATING Value for money: Performance: Build quality well cast and machined tool with a low cutangle. The blade adjustment and mouth adjustment mechanisms are well made and operate nicely. It all looks very crisp and appealing and it its the hand nicely: thumb on front knob, fingers in body recesses and the blade cap casting comfortable in the palm. The blade has a large cutout which limits the amount of metal lining after repeated sharpenings. Verdict ‘The sole needed flatting like the No.4 because of slight hollowing in the grind. That done, the blade got the flatting and sharpening treatment and I got a gratifying wire edge to knock off on the bench and, although using a strop would have got a cleaner edge, the No.60 nevertheless took so ‘grain mahogany (Khaya ivorensis) its stride cutting cleanly and rather covet this little plane with its various adjustments. i ISSUE 74 WOODWORKING PLANS & PROJECTS 75 4135 3NVId OMLTINSHLVS STOOLS LDKREG DECK JIG KIT & TOOLS Summer's gone, so it seems like the perfect time for to lay decking ready for next summer! And what better way to do it than using a specially designed kit to help you with this onerous task. We present the Kreg Deck Jig and show you its clever tricks for laying that decking Teri bomen coe pat ad to crs dais Stops ape measure and pencil Te tnt pointe make that as it only contains a sample pack. In use ‘The first task is to create a suitable, level framework for the decking from ‘treated framing timber with plenty of crossbracing, Once that is dot can consider laying the de: surface and as far as Iam aware, you can use any decking boards with the Kreg, Deck Jig setup. The theory give you an nothing. Watch and learn as I did before you try using the kit, it will pay dividends to do so. ‘The jig is precise. The screws are angle driven so they don't penetrate the top surface and there are no unsightly split boards or dangerous ‘metal on the surface. Boards are spaced evenly using either of the wo spacer sets and you can drive screws home on hard to reach areas, Itis cost effective and the jig with its hardened steel inserts should be long lasting. Verdi An effective low cost solution that is not only good for Divers but would, suit tradesmen, too. The downside is you have to use only Kreg deck serews and you can't use the jig fon the last wo boards up against a vertical surface such as a wall screwing down is required here. 76 WOODWORKING PLANS & PROJECTS |SSUE 74 THE NUMBERS £75.98 (13-piece kit) Deck screws - Protec-Kote pan head ~ coarse thread: No. 8x 50mm - 100pk - £4.45 No. 8 x 50mm ~ 700pk ~ £29.60 Deck screws - stainless steel pan head - coarse thread: No. 8x 50mm ~ 100pk ~ £10.66 No. 8x 50mm ~ 700pk ~ £65 WHERE TO BUY wwnwkregtooleu 5 STAR RATING Value for money: Performance: Build quality wwwawoodworkersinstitute.comwww.woodworkersinstitute. COURSES/TIMBER STORES 2mm Thick Real Wood Edging Supplied Un-Giued ready to apply We meg gay PAR & Saw ais, with PVA or ContactAdhesive. tenant wi | PCE Sa e. a Doe om or eat: 01923 249911 “email: enquiry@trendm.co.uk Woodworking Plans & Projects UOMO eC Pra CE Lee deliver cost-effective promotion Ps Ue tL For a builder, a carpet fitter, an antique restorer or a tree surgeon... 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Parts & Kits a = www.toylander.com 01767 319080 Advertise in Woodworking Plans & Projects to De ee Ru Re ed Te En een erred ae kur ae ae eo Distributors of the original RELAX workshop stoves , Cleat oey Treg geome pAUneociclotxe Weng + Range Sono Prices held for 2012 eS eoCae Ee ‘on the market REL Seer | BE BK] co Dovefields Industrial Estate ve ee Oy aRanch kent os ore a 78 WOODWORKING PLANS & PROJECTS ISS en oo ree | Interior joinery + Osmo Topol is cal oll and wax ith natural plant ols and wax + Offers highest cove ite ge of any oll on the market prox 12m A TRADESMAN Nee eA eka The Guild of Master Craftsmen has just launched its new and improved website to help you find a tradesperson you can rely on to give you a quality service with complete peace of mind, www/findacraftsman.com Members have to pass our strict entry requirements before we will accept them into the Guild S0 for any kind of work around the home visit wwwfindacraftsman.com and ‘we will ind you a tradesman to trust in your local area, ‘And now you can leave your comments on the website about the work they have done - helping to keep our standards high findacraftsman. com www.woodwor ersinstitute.comF a. = Jet woodturning lathes, Henry Taylor chisels, Full range of native and exotic blanks Flexcut handearving tools and Tormek sharpening Are you looking for a quality hardware store in Lisburn?” DIY PRODUCTS, EQUIPMEN’ 15 Graham Gardens. Excellent adhesives, abrasives and finishes lwww.thecarpentrystore.com| |Lisburn 8728 1xt ow The Ad Tool ere by Here and Kieninger Dial, Brasmare ct (QUARTZ MOVEMENTS ‘Tel 01469 540901 ‘Whichaven Farm, Boston Road Peeper ea teaen cee Tel: 01726 844100} ob: 07760748882| email sales@sww.con [Chamwood & Jet products www.swwwm.com eee | ere Hse fnctame | | "Geta eee” nes easa (45) 883088 small rayldtotidpa.cok anh LincolshiteD SW Woodworking Machinery Treespanner Timber ber Merchants ey Feast Cottage Dey Hill Fam, Mooi Lane D Email: te tiscali. cosk matenacierras ar WH. Raitt & Son Liq” CSSD D B KEIGHLEY MACHINERY LTD ‘New/Secondhand Woodworking Machinery Service & Spares Vickers Place, Staningley Pudsey, Leeds, West Yorkshire L$28 6L2 (01192874796 Fax: 01192 574299 www.dbkeighley.couk TET EICS| makitauk.com Satistying the professionals needs. TILAKLEL 4 Rieter Ge www.stanleyworks.co.uk Spindle tooling Pre Gees STANLEY BOSTITCH www.woodworkersinstitute.com EVOLUTION Teen ee loynt Gen je P recresonws Rene eueku) SSUE 74 WOODWORKING PLANS & PROJECTS 79 CITE] 4 ° > 5 Es FA EY FI Fy Fa k Fy Fd ra ry FY Fe Fa - FS FA ° = 2 FS c= z $ Fy § Py 3 Fa 8 PY i &BOOT RACK PROJECT Simon Rodway creates a useful rack for you to store your shoes, boots and wellies Cutting list Boot vack re 1 @ 854 x 150% 22mm Sides 2@ 160 x 150 x 22mm “er brace 1 @ 854 x150 x 22mm Botton pieces 2E#10x 150x220 Scvew blecks 2@ 150% 50 x SOmm Long dowels 8 557 x 250m dia. Short dewels 10 @ 220 x 22mm dia Ply back (optional) | @ 42 x E54 x Grom et and muddy boots are always a bit of problem in the house, and this boot ‘ack will go some way towards solving it, Storage is provided for two types of boot: the longer, Wellington ones on the vertical dowels, and shorter boots ‘on the horizontal rack above, soles "upwards in both cases, with room for four pairs of welles, and four pairs of ‘walking of other boots Construction is really simple, with zo tricky jointing at all, although if you wanted to make a more crafted version you could dovetail the corner joints. The lower rack is formed from a pair of horizontal pieces with matching holes, the lower holes stopped 10mm into the timber, with 4 spacer serew block at either end, ‘When you are making this, clamp both pieces together and drill atleast pilot hole through the top into the ower piece to ensure the holes match up. Screw the top and bottom pieces into the serew blocks and insert the vertical dowels into the holes, gluing into the base, having first rounded over the tops of the dowels. Cut the side uprights to length and ‘cut out a notch in each atthe top for the horizontal rack. Mark out the centres for the dowels and drill holes through the backing piece to match. A the same time, mark and drill two screw holes in the top corners, 0 tenable the rack to be secured 0 a wall. have shown different diameter dowels forthe top and bottom racks, but you can use the same diameter, as long as it’s sufficiently robust for both. Round over the end of the dowels and glue into the holes, and then assemble the rack, screwing the top rack into the side pieces from the back, and for extra strength, through the top into the top edge as well. The bottom rack is just screwed in through the sides into the screw blocks. As the rack will be heavy on the top, it will need to be secured to a wall Thave shown an optional addition in the section of a ply back, just screwed, (on, to protect the wall from mud and scuffing, if necessary. ll prorat bak ot ait Section 80 WOODWORKING PLANS & PROJECTS ISSUE 74 SEOs en 210 Hee Front Elevation www.woodworkersinstitute.com,HITACHI Inspire the Next HITACHI YEAR WIN ne ae ay NET ti) Son eer renee For further information visit www.hitachi-powertools.co.ukWHEN DIcene AM) DESIGN|MEET, RESULTS - ARE GUARANTEED - TE Te cea omen ma LLL) TF