Display Case * Accessory Box * Detail Carving * Cookbook Rack * Half-blind Dovetails Roll-around Table Saw StandWoodsmith October, 1996 Publisher Donald, Pesehke Raitor Terry), Strohman Associate Editor Jon Garkison ‘Assistant Editor VinceatAncont ‘CREATIVE RESOURCES. ‘Cit Kise Pie Dr Ke Na = Payton Ted Wong, Je Shp Nmager Steve Cars Shap Cratsmon: Se: Johnson « Ptgrephy ‘Biretorlatciner® Sener Peg Cogent BOOKS eat tor Dough. os Aenea Ver 1 Sosiy Grape sar Chris GoWeet ‘CIRCULATION Cela Diner: Sse Bas © Satin Menage: Soy tetanus Ast ‘Diet al ie: herent Asint uenson Nar ‘ojlae *AisteGophi DesenDinctor Sse ier ‘Sr Graph Designer Chet Sion CORPORATE SERVICES Vie President of Peg and Fnac Jon Moca» Cones Rohn utchinnne Se Arto aues Toro, fete Pate Mary} Sail «Poon Dir Cees Ghniior + Herne Pligg Dongs NE ier » ‘Hoseetn Art on apis + Beye Commanleson) CGunk: Gorton Gappes Neuere Aditeub. AL Trees * Pre Drpen Dir: Joyce Monte = I.E. ‘Asstt sie Koelen me Aston: as Fah » ‘Reepronss: Jesne Juan, Sheryl Rey * Ble ‘Nant Kee eth WOODSMITH MAIL ORDER peranoesDieaor: Bo Bakers a ber-Cay Scape "Materia Manager, Nark Matas» Qudamer Sere Jenle Hes Hat Sales Manager: Kea A Buckie ruse Sup Nancy Iehesen Boer da ones 4 Sistons Operator Tana Ald + Team eader: Kara Batigers Tek Supjont Davee Cust Sere Reps Jenifer Murphy, Am Cex, Ket Andes. Man etn » Warsonse Charen, Sy Can, barry Prine, Sot Gila, Cally Sener WoopsomrH s1OKE rave Laren » Asiant Monger Pal Shader es Saf Pat Lawn, Jerome Herr» Ofte Nasager: Vie awards ember meanness See ee ei Home hog Casa Fe nectarines Baise Santee nL re SEDANS sence nina Epic Diy ‘ing, most of the projects I built ‘were small ones, That's because they didn'trequirealot of ime or material tobuild, And when [made a mistake, itwesn'ta big dealto cut another piece and try again ‘While stil continue ty make mis: takes, [find that I do make fewer of them. However, I still like to build small projects, But for different ree sons, For one thing, I don't have to ‘worry about how Tm going to get the project through the door of my shop ‘once i's finished, And because a smal project doesn't iake up much space, don't have to hunt for-a spot in the ‘house to put ‘The three small projects in thi issue have other benefits aswell They ssiveyou achanceto try outsomenew woodworking techniques without spending a lot of time or money. DISPLAY cASt, Take the display case found on page 6, for example. To give the case atraditional bokand fee, we acdedacarved draweefrontand hand cut dovetails. With @ lanier project, this might mean a lot of extra work, But because this case is small, alli needs isasinpl, understated carving and hand-eut dovetails. So if you've ever wanted to try yourhand ateither ofthese two techniques, thisisa good project to start with. ‘ACCSSORY BOX, Whenitcameto the accessory box featured on page 28, we were looking for a contemporary look. Se we used contrasting woods Woodsmith ‘The top of the box contains a panel made of birds eye maple. Foranice contest, wecould have wsed ebony for the rest of the case. But ebony is expensive and hard to come by, Not tomention beng dificult o wore wih, So instead, we experimented with 2 technique known as ebor Basically this involves staining « common wood (we used walnut) to look like ebony. Here again, because the project is small, i'sa good oppor- to ty outa new technique, COOKBOOK RACK.The cookbook rack: on page 1 isalso asmallecjct but itprobably wont preseatany dificult challenges. The nice thing about it, however, is that it can easily be com- pleted in aweckend youve exer @) built a project that takes a long time to build, I think you'll find this cook- boolerackto bea nice change of pace TALE SAW STAND, Netaltheprojcts in this issue are small. When Ted Wong, cur new project designer, came on board, we gave him atest, We asked him to design a table saw stand that would meet two criteria—itneed- ed to be rock solid, and it needed to bemebile. (vo features which don' usually work together.) Well, he essed the test with ying colors The table saw stand on page 20 uses clever cam device to mse and lower the casters. Soa you have to dois stepdown on a lever to drop the casters down and roll the stand around. Then by flipping the lever up, the stands ily planted onthe oor Tom No.107A Look INSIDE , CONTENTS Features Display Case............ 6 ‘This walnut case provides an elegant home for treasured heir- looms. And it provides « showease fora couple of interesting woodworking techniques as well. Handcut Half-blind Dovetails ........ 10 Making this traditional drawer joint i simpler them it looks. Our step-by-step instructions will show you how to cut perfect- fitting, half-blind dovetail joint quickly and accurately Detail Caninger ceric cocoon 12 Hore's a chance to try your hand at carving without having to learn any complicated techniques. All you need are a few simple tools and our complete instructions. were’s a handy, pull-out drawer for storing recipe cards. ofall, you can start and finish this project in a steckend, Table Saw Stand........ ..20 ‘There's more to this project than just sturdy construction. Ie fea tures a removable dust bin and convenient sliding racks for storing ries. Plus, it has a unique cam-activated caster system that makes it easy to move your table saw around the shop. Accessory Box : It’s the details that make this project wnic curved sides to the inset veneered panel, this project packs a lot of woodworking into a small package Table Saw Starad puy:20 Departments Tips & Techniques . Shop Notes Reader's Jig a OUICOS Te tat alate wee No.107 ‘Woodsmith a SSFROM FELLOW WOODWORKERS Tips & TECHNIQUES oe —— Crosscut Jig Itstough toget consistently square crosseuts with a cir ceular saw. So I made ple jg that guides the saw accurately, cut ater cut. ‘Thejigisawood boxthat flisaround a specificsizeof eer Size of opening deternined ‘by wietho! sock tobe cut =a Threaded Insert Installer Mosi ofthe devices I've Thethreadedinsert toot seen(orinstallingthreaded I made also uses a nut and insertsuseanutand boltto _bott—butitholdsthe insert drivetheinsertintoawork: upright atthe same time. piece. The problem with this techniqueis trying to kkeep the insert straight while screwing tin, ‘The toolisjusta block of wood with a hole drilled through one end to accept nylon spacer. The spacer A Annslon spacer and a spring help to hold the teaded Insert upright while you drive ciuo the workpiece. Woodsmith “tworby" stock. The work- piece slips through open- ings cutin the sides. Serewed to the top ata right angle to the slots are saw guides, These are spaced fo match the width, — spnce guides Bineteh wth ofsa0s shoe of your saw shoe. ‘Just position the jg over yourlayout mark and hold itin place to guide your saw during the eut Dong Thalacker Racine, Wisconsin holds theboltsirsightwhile you tighten itdown, Onthe other end of the bolt is spring, anut,and awasher. ‘The spring supplies just 1-20 hesend bore ‘enough pressure to hold the insert straight while ryoutre insallin Wally Cook Thedford, New Hampshire winx F nylon — foacer us 1D.x Fsorng Brass aiher Threaded Inert No, 107Sharp Tool Holder Tuse a number of small, sharp tools for scribing, ‘marking, and cutting work- pieces. Butitshard topro- tect the blades of these todlsifthey'te stored loose ina drawer or toolbox. To protect the sharp ceciges but sill Keep each tool close athand, [made a ‘small knife an tool holder. Angled Holes ‘The lable on my dail press doesn't have a gauge for Grilling angled holes, So instead, I use the miter gaige from my table saw. Tet the miter gaaxe to the angle Inced and place the gauge onthe drill press table so the bar passes through the opening in the fable. By visually ning up the miter geuge bar with the column of the drill press, lean setthetable top to the correct angle. Bul Pierce ElCajon, Cafoia Dust Bag Magnets ‘Trying to replace the bag use two or three small ‘nan older dust collector round magnets, Simply can be areal chore, You _ place the magnets around really need an extra set of thetop ofthe bagtoholdit hands to hold the bagin in place. Then slide the place while the fastening _ strap upto secure the bag. Srapis attached. Lee Absander ‘To solve this problem, I 1¢snothing more thana piece of dense foam insu lation (bine board). And to keep the bloc anchored to my workbench, I built a ‘wood frame to fit around the foam, see photoat right. When the foam gets too chewed up, Lust ip cover: Lee Tylneland Vintm, lowe te | ae funn No.107 Keyhole Slot Hanger ‘Keyhole slot hangers are great for hanging mirrors ‘or pictures, but locating the postion forthe wall mount ing screws can be difficult. Recently, hituponasolu- tion using pash pins. Just slidea pin into eachkeyhole ‘Nowposition the mirror or picture right where you want it on the wall. Then lightly press the pins into thewall The pinsleave tiny hholesso that you knowjust where to install the mount ing screws slot and then use Scotch David Zeidler Shabepee, tape to hold itin place. ta BUT C0 Sty Ifyou would like to sharean original shopested tip, ‘send it to: Woodsmith, Tips and Techniques, 2200 Grand Avenue, Des Moines, lowa50@12, Orifitseas ier, FAX itto us at: 915-282-6741. Or use our E-Mail: 75830.2301@compuservecor, pubished, you'll receive $20 to$150, depending ‘on the published length. includea briefexplanation and sketch orphoto, And don't worry, yell rewrite the tipand redraw the art, ifaecessary, Also please Include a daytime plone number. Woodsmitt Quick Tip A To make a peg- board clip for Ihanging notes, just Atl ahole trough a clthespinand hein a shor length of dowel Loyal Huson Gasslle, ArkansasHs taIa PROJECT DISPLAY CASE Half-blind dovetails and a carved medallion make this case worthy of displaying your most treasured possessions. News Thappened to be visting ahistory museum. Ofall the objects in the place, my eye was ‘somehow drawn to some artifacts that were displayed in a handsome wood case with a beveled glass top. That case was the inspiration for this scaled-down version. Ourcaseis ‘small enough tositon top ofa coffee table or deskandis designed to hold afew of your favorite keepsakes. A #= MDFtofitsaugbetween the posts. But allowed a'/a’ gap oneach side so it can be adjusted easily, soe Fig. 7a. Next, added a strip of edging (1) to the shell. This "wide edging is cutshorierthen the witthofthesk ye . YD ancl see Fig 7, This automatice- wens Hae Iy creates a notch that vill allow the shelfto fit around the corner posts, No. 107 Woedsmitn 2%Sliding Rack Assembly ‘There's one last option to add to the inside ofthe base. Iwanted some stor. age space for hanging saw blades, insert plates, and wrenches, so 1 designed a pair of vertical sliding racks, see photo below. TRACKS, The sliding racks are simply Yt pegboard panels that slidein MDF ‘tracks. These upperand lower tracks: (U) are 1014!" long and fit between the vertical panels, see Figs. 8 and Ba. (Mine were 94" wide.) GING. Next, I added hardwood -eciging (V) tocover the sront edge of the tracks, see Figs. 8 and a. But this. /'-wide edging doesn't cover the entire edge; it's cut short to create a notch that fits around the post. With the front edging glued in place, I cut two 4!" x 1" grooves: through the track and front edging, ‘see Fig. 8a, These grooves will guide the racks as they slide in and out. ‘Thento create a stop for the racks, [added another piece of edging to the back of each track, see Fig fa, InstAMLaTiOn, Nov’ that the tracks are complete they can be installed in the base. The lower track is easy to install. It'ssimply screwed to the outer bottom panel (1), see Fig. 8. Butat this point, there's nothing to ‘screw the upper track to. So T added a pair of track cleats (W), see Figs. 8 and 8, These are 1'4"-wide (tall) hardwood strips that are cut to fit between the stretchers (B) and screwed to the rails (D). Now, the upper track can be screwed in place. StiDNG RACKS, Now thatthe tacks are complete, I cut two sliding racks 0 from 14" pegboard, see Fig. 9. A These siding racks ae designed beep your able saw accessories close at hand. To bul the simple storage hooks that the accessories hhang on, see page 19, ‘grooves are aut “These racks are cut to size s0 they slide smoothly inthe tracks. (Mine were 1414" x 1948) MaNDUS. Then 1 added a 3"hick ‘hardwood handle (X) 0 the trontof ‘each rack, see Figs. 9and 9a. To attach the handles to the racks, Tut a centered groove % deep on provide stop for race tad beck odeing afer ‘each handle, see Fig. 9a. Then [glued them to the racks so there was a ‘atboth the top and bottom so thehan- dlevould clear the track, see Fig. 9. Finally, to hold the accessories on the racks, I designed some hangers. For more on building these simple angers, see page 19.Top All tha’s left for this standis toputa op on, sce drawing stright lupe an NDF panel forthe opand added hard- wood edging. ‘TOP PANEL. To make the top (Z), the first thing Idid was fo cut an MDF panel to finish size (41423, see drawing at right. With thetop ct. aid out and cut the opening over the dust bin, see detail ‘by. ‘Todo this, (hoisted my table saw: in place. 'positoned my sew so the ‘motor cleared the back edge, and cen- tered the saw side-to-side.) Thea I traced along the inside of the saw. Next, Iremoved the table saw and drilled holes in each corner ofthe lay- ing 14" wide, so it’s alittle wider than ing pieces can be mitered to length. out. These holes allowed me to the thickness of the MDF, see draw- When the edgingisattached, | rout- | remove the waste with # sabre saw, ing and detail ‘a’ above, eda'4" chamfer around both the top EDGING. To protect the edges of the ‘Tohelp align theedgingtothetop, and botiom edges. Then I centered | top, I decided to add %4" hardwood I cut a %4"'deep rabbet on each piece the top on the base and screwed it to edging (AA, BB). I made thisedg- _ofedging, see detail’a/ Then the edg- the upper rails (D).. MATERIALS A Comer Posts (4) Wax -23% B Upr. Stretchers (2) Wax We 40% | © Le Stretchers (2) Wax2¥e- 40% | D Upc Rails 4) Wax 18-20% E wr. Rails (4) WWax2- 20%, F Vert, Panels (4) YoMOF - 15% x 20% G Vert. Pal Edging (4) Yax'h- 14% H Ctr Bim. Panel (1) Yansor - 13% x20% 1 Ott Bim, Panels (2) YaNOF - 994 x 20% J. Cams (a) 1%4x3%4-9 K Toe Bars (2) XM 19% L Corriage Pane's (2) —YaMiot - 1446 19% Mi Caster Supports (2) YaMOF- Ye x 19% N Bin FLsBK. (2) YBMOE - 1396 x 19% © Bin Cleas (4) Yarn 1M P. Bin Sides (2) Yattdoa ~ 18% x 193% Q Bin Bim. (1) YaMOE - 13% x 19% R Bin Stop (1) Wx Shelf Pane: (1) YBMDE- Ya x 19% T Shelf Edging (2) exh - OH U Tracks (2) YeMDF - 36 x 19% + (4) Yetdia. dowels "etlong + (4) 47x 3%" Hex Bolts Y Track Edging (4) 8x%-8A + (@) 3° Swivel Castors + (12847 Flat Washers WTiack Cleats (2) Axe 19% + (16% 1" Lag Screws * (@) 34” Hex Lock Nuts X Siding Racks (2) YaPeatd - 14¥ax19% | | « (16)34" Flat Weshers + (16)#8 « 1% Fh woodscrews Y Rack Handles 2) ax tte- 13% + (2) 3° Butt Hinges wiscrevis + (4) Yé Spoon-stye Shelf Pins Z Top(i) Yor -23%x41% | | + (12)832x1"FhMachne Screws + (12)48.x 1" Fhwoodscrevs D | saree. exsing ey YX 5-4 + (12}#10 Split Lock Washers « (20)H6 x34" Fh woodscraws BBSide Edging (2) Vax We 245 + (12)8-32 Hex Nuts +B) #8x 1K" Fh woedscrens No. 107 Woodsmnith aCia PROJECT ACCESSORY BOX For a small project, this accessory box is full of mteresting features, like curved sides, a figured panel, leather lining, and.a unique, ebonized finish. too. There are ever for organizing jewelry. But that's novall. The techniques that go into buiiding this box male for an interesting project. For one thing, this isn'ta traditional, square box; there are quite a few curves inte ‘grated into the design, Also, the lid pivots open on small pins, not metal folding hinges. And there's even a ‘special procedure for finishing, But even so, there isn't anything {to building this accessory box that makesit especially difficult. Box ‘To build the box, I started with the 34!-thick sides (A), see Fig. 1. After cauting these pieces to size, the first thing I eid was to carpet tape them his unique accessory box com- been ‘ebonized”—stained black. together. This simple step makes a bines several interesting design The inside of the box isas attrac- _lotof sense for a number of reasons. features.Onthe top ofthelid, there's tiveas the outside. There’s amirror _Frstoff, when drilingthe 4" holes a panel with feared maple veneer, on the inside of the lid, and i's _forthelid’shinge pin, havingthe sides ‘And for contrast the rest ofthe box “framee!"with eather: Plus,leatheris carpettaped together ensures that thas been builtoutofwalnitthat has used to line the bottom of the box, the holes automatically end up per side pcos exact raring sod cating | ‘SECOND: orl hole ferhinge pin Woodsmithfecty aligned, see Figs. 2 and 2a cvs Then when youre tving autthe curves on these pices ha ing them taped together creates a Jarger surfece to work with, The 1" radius on exch end ofthe side piccos can be dravn at the same time, see Fig. 2 And its easier to lay out the Jong curves, to, seo Fig. 2 ‘To draw the long curves on the sides, Imadea simple template, see ig. 3. ut Lintentcnally cut the tem- plate longer than the side pices, This the template can be use ter o draw the curves on the front, bac, andlid eer tothe exploded view on page and the pattern above right. When laying out the long curves, poston the template soit connects withthe curves on the ends see Fis, 3 anv 3s, Then cut all he curves on the band sawand send them smoot, see Figs and 5, Here again, [ound thathaving those pieces carpeted together helped to stabilize te cut JOINERY. Now, the two sie pieces can beseparitd so the oinery can be cat rout hens onthe outer table, When working with small () _dieces, 1 ke using the router table \ instead of the table saw. The router makes rice, lean cuts that result in dadoes and grooves with perfect fat, square bottoms, ‘The firs thing todo is rabbet the back, inside face ofeach site piece, see Fig. 6. Whatyouend up withhere Js a wide rabbet that provides clea nce forthe lid to open 9 cut this rabbet, [used a 14" straight it rane see Figs. band fa, Buthefore you begin therearea couple things you need to do to nour safe square cit First the bit eperingon the Fence needs tobe cor- CURVE TEMPLATE une femplate NOTE: Curve telat used (7 box sides front back ard id font ake template and celges ose preces Position template 3 curves on fedgosimeet tunes on ens ered with an auxiliary fence so the riece doesn’ tip into the openi Also, | squared up a sorap piece and useditto push thesides through the bit, see Fig. 6 This serap piece holds the sides square to the fence, butitalso back up the eu, so there’. Jess chance of chipout, ‘When routing the rabbet, estab- lished the shoulder with the fist pass, see Figs. 6 and Ga. Then made muk tiple passes to remove the waste, With the wide rabbet cut on the back end, next cuta smaller rabbet along the top edge ofthe sides. This rabbet will support the lid ofthe box. ‘To cut this rabbet, the height of the bit doesnt change, but you'lineed to remove theaunillary fence and reset therouter fence, see Fi No. 107 Woadsmith 29Box CONTINUED. To complete the sides of the box, there are just two more steps. First, dadoes are routed to hold the front and back pieces. Then a groove is cut for the bottom of the box. ‘DADOES, To rout the dadoes for the front and back of the box. used a 14” straight bitin the router tableand the ‘same scrap push block [ had made ‘earlier, see Fig. 8. The only odd thing about this procedure is that these -dadoesaren'tthe same distance from each end, The dado in front is 1%" from the end, while the one in back is 194" from the end because of the wide rabbet in back, see Fig, fa. GROOVES. Finally to complete the ‘sides, routed a '4"x '" groove in each side pieve for the bottom of the ‘box, see Fig. 9. 1 didn’t want these _grooves to be visible from the front, so [ “stopped” them — the groove rans from the dado in front to the dado in back, see Fig. 9a. (For more ‘on setting up a router table to cut a ‘stopped groove, sce page 18.) FRONT & BACK. Now that the sides are ‘complete, | worked on the front and badk ofthe box, see the exploded view below. These pieces are thinner than the side pieces; they're only Y4"-thick. T started by cutting the front and back (B) to finished size (24" x 914"). ‘Next, a groove is routed to hold the bottom, see details’ below. Then I rotted a tongue on each end to fit in the dadoes in the sides, see detail ‘The laststep isto lay out acurve on the bottom ofthese pieces, see detail ’e, Usethe template you made for the curves on the sides, referto page 2.) ‘The curves on the front and back pieces end at the shoulders of the tongues on the ends, see detail ‘c. ‘And they're cut and sanded just like the curves on the sides. Just make ‘sure the top of the curve is slightly below the groove forthe bottom, ASSEMMLY, After cutting the curves, dry assembled the box and cut a sthick hardboard bottom (C) to fitin the grooves in the box. Thenthe Doxcan be glued together.lid ‘Now that the box is complete, work can begin on the veneered frame and panel lid see drawing at right. ‘RAME. To begin, Leutall the frame riecesto size, see drawing. The front (@), back ©), and sides (F) are all ‘cut from thick stock. Butthe front isa litte wider (14) so that a curve ‘can be cuton the front ofthe lid. “The next stepis to cut grooves for holding the 4" hardboard panel, see detail‘ at right. These grooves are cat lightly off center to allow forboth the veneer on the outside and the leather trim and mirror on theinside. With the grooves cut, stub tenons ‘can be ext on the lid’s side pieces to fit the grooves inthe front and back pieces, see detail b'at right, ‘urea Paut. Now the frame is resdy fora center panel (G), see drawing. ‘This isjust a pice of 1" hardboard that the veneered panel, leather, and iirror willbe atiached to later, ‘Todetermine the panels size, ry assemble the lid and cut the panel to fitin the grooves. Notes It’s nota bad lea todrilla finger hole in the panel. @)_ ten when estating the veneered | panel ate, it willbe easier to remove itfrom the frame to apply the giue. “Afier the panelis cut to size,thelid ccan be assembled. But the frame of the lid is not complete quite yet. Its frontedge stil needs to be shaped. First, @ curve needs to be cit, see Fig. 10, To lay out this curve, you'l need to set the lid in the box. The back ofthelid shouldbe fush with the backs ofthe sidepieces, see Fig. 108, ‘Then the template used earlier can ‘be positioned so the curve ends up flush with the front of the box. After the curve has been cut out, I rounded over the four top edges of he frame slightly, see Fig. 1, To do this, used 4" round over bit sotto makea ("deep cut, see Mg. 11. Finally, ladded a finger gripto the front edge ofthe ld, see Fig. 12 This ‘can be done easily with a hand-held routerand a'i"'cove bt, see Fig. 12a, ‘The cove stops 244" from each end, And it ean be routed safely with the dclamped tothe edgeotthe bench. Atthis point, the frame ofthe lids ‘complete, and now isa gocd time to sand it smooth. Butthelid stil needs tobe attached to the box, so Iturned my attention to adding the hinge bar, No.107 ‘Woodsmith 31Lid conTINUED ‘The next step in building the lid isto attach it to the box. What's a bit unusual here is that the lid doesa't use atypical metal hinge. Instead, it pivots open and closed on a pair of Ypl-dia, brass pins, see drawing at into asmall hinge bar, which is attached to the lid. HINGE BAR, The hinge bar (H) is justa%4"x 4" piece witha roundover routed along the edge, sec drawing: But to cut the piece safely, I started see detail ‘a f roundover bit toshape the edge, [rippeda4”-wide (al) hinge bar from the blank. FILER STRIP. But the hinge bar can't be glued to the id quite yet. First, @ filler strip (1) needs to be added to support the hinge bar, see drawing right ‘These pi with a 2"wide blank, ‘Thenafterusinga and detail b'at right ‘Thethicknessoithis stripiswhat's ‘important. should match the shou! ide the frame so that when the siripiseiued in place, itwill be flush with the face of the id and provide a level surface to glue thehingebarto, er see detail: ATIACHING nNGe BAR, With the filler strip glued in place, the hinge bar is ,utits position is important. With the lid in place, the ‘bar should be ‘fa fromthe back (E) simply giuedto te ‘of the box see detail'b run srr oa w |S the wood, see box below. Then | applied afew coats ofawipeon ATIAGHING THE LID. Now, you can NOTE: cut hinge bar fom ovenized blak ‘choss Section ‘SECOND: insert rasp Dowel lug inthe box sides wo guide the bit. The ‘goal is to drill aholein the bar that’s Sf ee, see Fig, 13a. ish, FINISHING. Inordorto get into allthe recesses of the box and lid, [finished thom before the lid is attached, This isa twostep process, First I stained altach the lidto thebox. Thefirstsiep is to dill 14" hole in the hinge bar forthe pin, ee Fig, 13. To do this, I set the id in place and used the hole ‘The ldpivots ontwo 3a brass pins cut 1" long, see Fig. 18 Then the holes plugged with a short length of ‘ptelia. dowel, But ifyou cut and trim { wanted this boxto took like ebony with- out actually using eliony to build it. For ‘onething, ebony is an exotic wond that's not readily available, But i's also exper- sive and difficult to wore with. So 1 did ‘what many woodworkers have tradition ally done— | “ebonized” the box. ‘When I'm geingte ebonize a project, start with a dark-colored wood, (used walnut) You ean ebonize any wood, but darker wood gets black more quickly. “The process of ebpnizing isas easy a ‘applyingsa stain. miup a fairly concen- trated black aniline dye. | like to use @ bt al ea lly waterbased dye because i's the caiest to work with and the most lightiast But because you're putting water onthe wood, ‘you need to raise the graia first. This is done by wetting the strface of the-woor! ‘and then when it’s éry, lightly sending back the raised “whiskers.” Tmixed three teaspoons of dye in a quactofliot waterThen Lbrushied aewy ‘coat on the wood and lett set, Since the {dea i 10 get the wood! a dark as poss bie, !donit bother to wipe off tie excess In fact, you may want to apply a couple ‘coats, When i's dry, simply apply afinish, Woodsmnith twas mae oacof ebony. Sofist | ised ‘walt to mathe the box: Then | applied caccciple outs of ¢ weter-bosed, eon cenerated, black aniine dye.A After slung the leather into the box, 1 bull this opional divider ail and sein place the phigsaiter you give them in, you wvillmar the nish already on the box. ‘So instead, simply cut the plug so you can push itin lush with the sur face. Thea sand the end smooth and ppust it in place, Finally, alittle “spot finishing” is all tha’snceded. LVINEERED PANEL. Now the ldisready for the veneer, see drawing at right, I ‘ghied apiece of bird's eye maple to a 5" hareboard backing (), with con- tact cement, see deta ‘a (Both the veneer and backing are oversize at thispoiat, Then aftertheveneer was stlued on, I trimmed the pane! to fit the openingzin the lid finished it, and used yellow ghie to hold itin place. LATHER £ itiROR.The next thing to addis the leathertining, see drawing above. [lined the inside of the box and id with tether, Pls, | covered the hardboard underside ofthe box with leather, too ‘The leather pieces forthe box are simply cut to size and glued in place, (For more on cutting and gluing the deaths, see page 18) Butfor the lecther thats glued into the id, Ieutan openinggin the center 20 it looks like a Iovide frame, see drawing. That's because Iacded a5" xT" mirror and wanted to attach the mirror directly to the center panel (©). used slicone sealant to dothis) DIVERS. Th las thing todo is add dividersinsie the box for organizing, your aocessories, see photo above, ‘There are four interlocking pieces heres two short dividers (1) and two ong dividers (L), see Fig. 1d These pieces are all 14" thick and 114" tal. Only their lengths are citferent. ‘To join the dividers, cut a pair noiches in each piece, see Figs. Ma and, Thea, [finished them the same as the box, “locked! them together, andl set them in the box. No. 107 MATERIALS & SUPPLIES Box 1 Filler Strip (1) Wx%-8 A Sides (2) Sax tha 4 Vereer Backing (1), % Hebd. = 5% x8 B FronvBack (2) Wx2%-9% Divers Bottom (i) Ya Hebd. a 9k K Short Dividers (2) Yox 1%4- 6 ‘Lp L Long Dividers (2) ¥xI%-9 D Front (1) Bx E Back (1) Yx% - * (3)7* x 10" Leather (igh), F Sides (2) Yex%-7 © (5° x7" Miror G Center Panel(1) Ye Hdbd. - 7x 8% ‘+ (1) 8* x9" Figured Veneer (rgh) H Hinge far(t) x2 (gH). ——» (1) %"-dla. x3" veh. Brass Rod CUTTING DIAGRAM 25" 48" Walnut (1.67 BFL) SoS Woodsmith 23PANEL RIPPING JIG ( utting a full sheet of plywood down to size with a circular saw is always achore, But thisjig, sen’ by Ken Heck ofSanJose, CA, makes ita whole lot easier to rip a straight line down an & footlong panel. tase. The base of the jigisa “track” that clamps ontoyour panel and accu- rately guides your circular saw through the cut. made thisbase out ‘ofmedium density fiberboard (MDF). Inprderto make the figlong enough to use on 8 foot-long sheet goods, ‘you'll have to splice pieces together ‘with lap joints forthe base and guide nails. see detail‘. Atbott ends fhe basearesimple clamps to attach thejig to your panel ‘Theseare connected tothejig witha carriage bolt, a washer, and a large wing nut. To make the clamps adjustable for cutting any length of Fete hace 10a" 34 woxr Miveodseons {postion spor) panel, cut a series ofslots inthe base of the jig, see detail b’ SHOE. To enable your saw to slide along the jig, make a “shoe” out of ’qMthickshardboard thatis sized to fit between the rails ofthe base. Attach the shoe to the bottom of your saw with machine screws. (Youmay have Woodsmith to drill and tap serew holes on the bottom of your saw) Then use your sawto trim off both edges ofthe base, see detail'c. ‘Tose the jg simply align the edge ofthejig with yourlayout line adjust and tighten the clamps, and slide the sew down the track, see photo.e@ SOURCES Woodsmith Project Supplies offers hardware kits and supplies for some of the projects shown in this Issue. Supplies for these projects are also available at your local hardware store or through the mail- thick plywood that was ‘wrapped with polyester bat ting and fabric. (To secure the fabric, we used staples) PROFLE ROUTER BIT. To rout the decorativeedge around the frames of the display ‘case, weused a special pro- order sources at right. file bit. I's made by Freud and is called a "Table Top DISPLAY CASE Classical Bol BE” 9-011), Thedisplaycase on page6 see the source at ight doesn't require much hard ware. A'!ia, knob isthe only brass hardware you ced, and you should be able to find one at a hard- ware store, (Note: As an option to the carved medal- lion on the drawer front, ‘you can substituiea drawer pull. The one shown on ‘ARVING TOOIS. To carve the medallion on the draw- €r front, you'll need a few carving tools. The ones we found most helpful were « skew chisel, around nose chisel, anda Vagroove chi el. Many woodworking cat alogssellthese chise'sinl- vidually or in sets, sce the @ vxes'5a3'ratsyepuiy sources atricht Besides the knob, you asoneed afew othersup- COOKBOOK RACK plies. For the (op, wesed To build the cookbook rack 'A'-thick glass with a 1". on page 14,allyou need are wide bevel. Ourpiece was the following: 1274! x 124! overall) You'l (2) -dia, Wood Knob, need to order this froma w/screw local glass shop. Note: Its (4) Y-dia. Button Plugs Agoadidea to getthe glass (4) ‘4"-dia. End Grain ‘before making the case, Plugs Also, toline the insideof (15) #6 x 144" Fh the drawer, we used 14! Woodscrews: Un tam ary To order a hardware kit from Woodsnith Project Supplies or fora copy of our WoodsntithShop catalog, use our TollFree orderline. Ifsopen Monday through Friday, from 7 AM 107 PM Central Time. Before calling, please have your VISA, MasterCard, or Discover Card ready, Ifyou would like to mail your order in, call the ‘number below for:more information concerning ship- ping charges as well as any applicable sales tax, 1-800-444-7527 ‘Note: Prices subject to change after December 1996 ‘This orsimilarhardwareis available locally or through Dox, lused two ‘Ata. pins thatwere cut "Mong. (And thesources listed atright. I plugged the pin holes with 2A! dowels) TABLE SAW STAND Forthe outside ofthe i ‘Thetablesawstandonpage 1 started with an 8" x 9) 20 requires quite a bit of piece of figured veneer. (I hardware And eventhough used bird's eye maple,) This is available from the sources listed aright, ‘Then onthe inside of tho lid and the inside and underside ofthe box, lused suede leather as lining. (oul need three pieces?” x 10!) To find the leather, you'll need to look for a none ofthehardwareistoo ‘unusual, rounding it all up canbeatask. So Wondsmith Project Supplicsiscurrently offering akit or this stand. Included in the kit are all the woodserews, washers, ‘nuts, and bolts you need to build the project, plus: @) 3" Swivel Brake leather store or possibly a Casters @701b.load fabric store near you, capacity) Note: To attach the @pait)3"x3" Hinges leather, I found that liquid ()'A"Shelf Pins hide glue worked better 7O107-100TableSaw Stand than yellow glue, sce the Hardware Kit.....$7795 sources at right. Note: Similar hardware is On the inside of the id, 1 available at most hardware also addeda 3x7" micron, stores, See page 27 for a Its secured to the lid with complete hardwarelist. silicone sealant, And finally, to ebonize the lid and box, Tused @ water-soluble black aniline dye, (1 oz, will make one quart, which is more than enough for this project.) See the sources atright. ACCESSORY BOX ‘The supplies you'l need to build the accessory boxon page 23 aren't what Iwould ‘all "Tracitonal” hardware. To attach the lid to the Wood Net wow on re wer -¢ 50 Woodworking Tips Online -* Woodworking Techniques — Stepby-Step # Project Plans You Can Download + WoodNet Forum — Woodworkers’ Q&A ‘¢ Power'Tool Reviews ‘* Links to Other Woodworking Sites *# Coming Soon; Online Back Issue Database Point your browser to: http: //www.augusthome.com Select Woodworking” from the Weleome Page ment. ‘Woodsmith ORDE SOURCES Similar project supplies and hardware may be ordered from the following companies: Woodend 800.225:1163 Diplaycue ad and Aap Crsirg toe, Contech rock abr Hid he, vile i ‘Woadeith Store ‘800.895-5084 Diol bend nitty pl, Cavng ‘oe, Creo Aad, Tel sv stand hate, Mile gs, Woodworker’ Store 100-270-4441 Dipl each ond riltsept Corng bal, Cert erere,Vower, ie i: Adio se Woodworkers Supply 800-645-0202 caring eter< Table Saw Stand. This mobile saw xand features a nique com- activated caster system. So 301 can cost rll out of the way. And there's plenty of storage for allof sour saw accessories. Fo sep by-step insiretions, see page 20, Accessory Box. Ebonized walnue and Teather trim are just wo of the emique details that sale up this small ‘accessory box. For more on building this project, see page 28. ‘A Cookbook Rack. This easy-to-buld, weekend project features two storage ercas for cookbooks, Pls a drawer to hold recipe cards. See page 14 for sep-by sp plan Display Case. A hand-carved drawer front and « beveled lass top make tis ra- digionel welrua display case areal hesioom. Plans begin om page 6.