‘A Publication of August Home PublishingSHC 4 Woodsmith ce No. 144 December, 2002 P eer ee SAWDUST | Senior Editor Jon Garbison Assistant Editors Ted Raife a I here’satelevision showIve become _As you'd expect, our Chest-on- pet cele Tate hhooked on called “Antiques Road- Chest is based on « fullsize design, Seales Meets ae ae show.” Maybe you've seen it. Fach uti takes up very litle space. (The Biever ee week, the show travels toa different _footpriatis only about 6 x 10") Yetits erlan Y. Clark city where folks bringin theirfurniture eight drawers still provide plenty of Graphic Intern Nathan Robertson and collectables to be appraised by space to keep valuables organized. experts: These experts usually provide Of course, there's more to building outbe Die een & Gor iet Dalgtne Ke the history and other backgroundinfor- a small project than just taking a fall- Nik Re Wh yan Mack, che «Sr mation on the items — 25 well asthe size plan and shrinking it down. Small me ee ea: currentvalue. Although it'snotashow projects require different solutions, Rata! about woodworking, they often feature than large ones, especially when it a ks et Dinar ae A = inieresting pieces of furniture, ‘comes to minute Joinery or "smat!” St Ga Dsner Cs Go Senta Edt: Cra Awhile back, became intrigued by assembly problems. So we kept the nee is = Govt Desens 4 auf iuan es Flt nt Cy Ton one of the furniture pieces featured joinery as Simple as possible — just cemreuLaion on the program. At firs itookeil like dates and rabbets And we cane up Suhre So int Rah » Now i Ce. Mg: a handsome bedroom dresser with with some tips on how to work with Nowe several drawers, But as the camera the smal parts safely and accurately. pulled back, I realized this piece of ew FREES, On. another note, I'm ‘urniture was less than two feet tll. pleased to announce we have a couple So what was the dresser used for? of new assistant editors here at @) A piece of children’s furniture? No, it Woodsmith: Phil Huber and Ted ‘was too small for that, And itwas to Raife, Phil has a publishing back- bigtobe considered a miniature. ground and isa devoted woodworker. ‘As usual, the appraiser hai the Ted has been a professional wood- answer — it was a salesman’s sample. worker for over twenty years, I'm Evidently, many years ago furniture looking forvard to working with both salesmen used scaled-down versions of them and tapping into their experi- Een Basing Pte TR Satta: ie Wg Se bnc of furniture pices to show what the ence and kowledge “ele Pig emia hoon sil eon/Daiver: Loa Webber ae would nego Before the show was over, I hal a new \woopsMim man oRDER i dieting DESSERT eatin: Wioadsmith project to work on —a fo Nanya etn een 2 fe Jewelry Chestonrchest, Sr yom Aa * mi aa: uty Dory 2 Gat re ae Ty chat fa i i en le Leip a a a ETA Aue Dae Lan Pt Me Tn Fike © SiS oom mente Dre tro fat No Tn Ten nen tng ta ng ag i a rr ay aren, ee rey Kan ee eee ater cae Menino lige ido vere i Saclereiea ts ae Seems CERNE = al) HSS tio oe a Race aege me 2 ee eid ; Ereoa rc i oe ie ot a peering Printedin USA, = “Avoustiione SaaS® Desk Clock .. ca CONTENTS, Features Modular File Cabinets ....... 6 Whether sou need a little storage or allot, the modular design of these file cabinets means you can build juscwwhat you need (and you can even add additional units later on). Plus, you can cus tomize the look with one of several optional dra Home Office Desk .. ‘Start by building a pair of wo- oie cabinets, connect them ith a top panel and add a shallow pencil drawer, You'll be sur prised at how easy it s to build a handsome desk. Get the Right Combination.............18 Sort through the terminology and technology of table saw blades We'll provide all the “tools” you need to make the best choice when buying your next combination blade. .20 beof woodworking that goes In spite of its small into making this clock, What's more, there's even a secret com- arimenc. Ids a great gift project that you can build ina weekend 24 ight Top 10 Router Set-up Tips... Whether the router is hand- or table-mounted, these strai forward techniques and simple jigs will shorten improve the accuracy of your cuts Jewelry Chest-on-Chest .. 5 Even though this elegant jewelry case iene like afl bs este it’s actually sized to sit on top of a dresser. And basic echniques keeps the construction simple. Departments Tips & Techniques. .. Shop Notes Sources .. No. M44 WoodsmithFREE Online Tips Nypudlike even more woodwork ing tips the sol- ton Is simple dust vist usatour wed sis endsion ip to receive a {fee tpva email every ock uw wednthcon FROM FELLOW AYO NV cai.0) Dangling Drawer Stops ‘The drawer guides used in the Bedside Chest in No. 139 aresimilarto the ones Thave used on several proj ects in my home, However, my drawers are larger and heavier And Ineeded away to pre- vent them from being accidentally pulled all the ‘way out of the cabinet. So Teame up with the dan- ‘gling drawer stop that you ‘can seein Fig. 1. ‘The stop is simply a piece of hardwood that pivots up into a mortise cout in the drawer runner above it, To make the stop, Ibegan by cutting 2 mortise in the bottom of the drawer runner for the stop to fit in, as you ean see in Fig. 2. Once the mortise was complete, I cut the stop out of hardwood and rounded the upper cor ners, as Fig, 2a shows. ‘Then I rounded the front corner to make iteasier to flip out of the way when removing the drawer, ‘The stop pivots on a cut off nail. To install the stop, simply drill a hole in the runner slightly. smalle than the nail so it will sit tight, Then drill a hole in the than the diameter of the mortise to keep the stop nail soitcan dangle freely. fromrubt ally | added washers Jim Shaver between the stop and the Yukon, Oregon o “Morte for Z = \ Stop: be ye oon a ZA, oP sO iEw oN Sean Drower VIEW iP PVC Tool Storage Cork Clamping ‘Theworkbench in my shop is usually piled with tools. ‘To keep things organized, built this “honeycomb” of, PYC pipe for my most often used land tools. For my holder, Tused 114" PVC pipe cut into 7" lengths. After cutting a number of pieces, simply place them against a stop to get a square alignment ‘Then apply cement along the length of the pipe. After gluing the first row, llayered another two rows to give me a holder Woedsmith for 15 tools, see photo. I glue small squares of cork ‘The PYC cement sets very to the faces of my clamps quickly and the holder —forghting up delicate work ‘ean be used in a matter of pieces. ‘The cork protects ‘a few minutes. the wood and sill Keeps a For something so sim- firm grip on the project. ple, pretty flexible Dan Lindsey system, You can vary the Giravth Pennsylvania length of pipe and the diameters depending on the size of your tools. As an arided benefit_you ean Increase its storage capac- ‘ty by simply gluing on more pieces of PVC. Jim Kilton Mauldin, South Carolina No. 1445 Mess-Free Clea Saw Blade Storage wen J lets facet, leaning saw drain the cleaner and Having cut myself on an eee 9@ Vetsismes.Overgray water ito he reservoir epnsedsa arent, fromthecleanercanleave fordisposa orrecycing, [nowapprecate the impor. Stans on the for thet are Byer Voot ‘ance ofasafety cover. hard to lean up, Uri, Missouri Ta contain the me ought an inexpensive ol drsin pan, available at auto parts stores, It has an ‘upper pan that drains into reservoir, see photo Now Tea spray on the leaner and rinse it off When I'm done, all that’s Jef is to pull the plug to Star Knob Wrench se, Me 8 : gallon bucket cover in just afew minutes, I secured the blade to the cover using a carriage bolt, washer and wing nut, To do this, drilla'4" hole bolt and tighten it with the fn the lid and square it up washer and wing nut. with 2 utility knife. Then Jacques Paquette slip the blade over the Somerset, Massachusetts » on ‘Sometimes [just can't get Then, draw a smaller cir- of the bit contacted the ‘enough leverage with my cle that matches the diam- _ point where the outline of handsto tighten the knobs eter of the star knob. My the knob and the ianer ir on my router table fence wrench is designed for and jigs. Other times the five-point knobs, but you drilled each recess to knobs wont break loose. could just as exsily make match the thickness ofthe ‘So I built this starknob one to fit any star knob star knob (about "Aa". wrench to solve both of you have in your shop. After the points have those problems. | began With the head of the been drilled, the center by laying out the head of wrench laid out, Iset the can be cleaned out with a the wrench on a piece of knob on the workpiece 154" bit, as Fig. 3 shows _Toiva 60312, Please inchide your name, ‘Ulthick hardwood, as and traced its outline, as All tha’ left to do is cut adds, and’ daytime phone number you can see in the illustra- you can see in Fig. 1. ‘out the wrench on the case we have any questions. If you tion at the upper right. Once the arms were band saw and round off | would Hike, FAX it to us at 5152826741. First, draw a 3'4"clia. marked, Iused a %4'-dia. theedges to give ita more OF Send us ant email message at: wood circle for the head ofthe Forstner bit to drill a comfortable grip. smith@woodsmithcom. We vill pay up wrench, Next, lay out the recess for the knob arms, George Warren 10 $200 if we publish your tip. hhandle for the wrench. making sure the outside Montgomery, Alabama ui hotes for knob recess Woodsmith4 x6" - 96° Cherry (6 8.) 1 x6" -96" Cherry (4 Oe Fe) MOopULAR FILE CABINETS _ This hame office solution is straight- forward to build and can be adapted easily to meet your storage needs. one ofthe mostversaile is 've ever made, Built in single drawer units, they can be put together as a stack of two, three or four. Add abase anda similar cap,and you have acassiclooke ing file cabinet. Or you can make two stacks of two, con nect them witha desk top and a pencil drawer, and you've gotathandsome desk. (Desktop plans are shown on page 14) So yaucan buildjust whatyou need to fitthe “office” spaceyou have. Flus,as your storageneeds grow, you can ceasily build another unitand add i to your cabinet. ‘This modular design has another benesit— you dont have to bea seasoned woodworker or have alarge shop to build the project. Since it's modular, you're basically building a number of fairly small plywood boxes. The joinery is simple (tongue and dado construction), and there are no large assemblies to wrestle with. Plus, the ‘units go together (and comeapart) quickly and securely with « few machine serews and threaded inserts. (One final note. Since these drawers are large enough toholda lot of 4!" 11" hanging file folders, I wanted to make sure they were plenty strong, so they're joined ‘with routed haleblind dovetails and open on heavy-duty slides, But don't worry. You'll have all the information you need to build and install them successfully. 1 na mae. # SE TLL 7 x6" 48" Cherry (2 Bd Ft) ‘5" x6" -60" Maple (2.5 Sa. Ft) uv 0 Wil B ° e Uy Yi, Ji x5" -96" Maple (4 Sa. Ft) ° istie for one dawer unt, base end cop, WoodsmithOVERALL DIMENSIONS: 16°W x 24D x 30°H (Two-Drawer Unit) 16"W x 24"D x 43"H (Thrae-Drawer Unit) False front Joned with Stub tenon and groove ply 2x 14 a ly = 22/4x 12% 248-15 1h, py ~14/0% 11% UU AG Ux Ve 28 Ya rly - 1Alex 22% Uyx2-15)2 Vly ANE K2e UX VWa-1500 Ux Wa 23 Vox 2-14 irowiock 2) Gx 144-16 Oo Capen es @) UX A 24 No. 144 Woodsmith UX2-23% CP PANEL Tim has -bulrose Ypretie Cae ijoines With eanguce ‘ond dadoss P Drawer FronvBack (2) 4x 9%- 13 Q Draner Sides (2) 14x97 -21% R Drawer Bottom (1) Yap. 12% 21% False Front Stiles (2) x 2-126 T False Front Rais (2) 54x 2-12 U False Front Pane! (1) ax 12-8% + (1 p1)22” Overiravel Slides w/Screns + (8) 4"-20 Brass Threaded Inserts * (8) %"-20 x2" Machine Screws + (@) 4" Flot Washers + (20) #8 x 1%" Fh Woodscrews + (8) #81" Rh Woodscrews + (@) #8 Flat Washers *+ (1) Bin-Style Drawer Pull w/Screws “its for ee craver unit, bse and cap.As with any project, this dling: eabi net takes a bit of planning: Before buying the materials, youll want to decide exactiy how many case units you are going fo build. Each ease is just a" plywood box with a7" plywood back, as you can see in Fig. 1 above. (For these cases, Lused cherry, but they would also look good in oak or mahexany.) ‘And in addition to the box, there's also a small, hardwood “frame” of ‘rim that’s attached to the bottom of ‘each case (and the cap later). TOF, EOTTOM & SIDES. For each case, the firs thing to do is cut a cave top (A), bottom (A), and two sides (B) to size. All these panels are wider than they are long so the grain direction runs vertically on the sides of the ease. Also, since these panels are close to the same size, its goo idea to label them carefully, EDGING. With the plywood panels in hand, the first thing to do iseover the front and back edges. To do thi Tadded 4" hantwood edging in Fig. 1. ripped '/"ide strips from "thick stock) Then after ‘gluing the edging to the plywood, 1 trimmed it Mush using ahand saw, 3 hand plane and a sanding block, ‘The case pieces are joined with tongues and dadoes, Since i's easier to sneak up on the size of @ tongue to match a dado, I cut the dadocs ve SIDE SECTION VIEW across the ends of the two sides first, asin Fig 2 I used the rip fence to.guide these pieces and avoided chipout by backing up the panel ‘with an auxiliary miter gauge fence, Now that the dadoes are cut, the tongues on the top and bottom pan- «ls can be-created, As you can seein Fig. 3, this is done by cutting a sim- ple rabbet. Just sneak up on the cut, checking the fit of the tongue in the daxloes on the sides. ‘The next step isto cut grooves for the back panel, To size these to hold the if" plywood panels Tused a rege whi blade, sneaking up on the final wiih of the groove, asin Fig, 4. (4" plywood is closer to jy! thick)The sides are complete at this point, but you still need to drill four A] & stia.nokes on each top and bot fom panel, as in Fig. 1. These holes are located in the same spot in each corner, soyou can drill themall with 4 single setup at the drill press, as shown in the right margin photo. ack & ASSEMBLY. All that’s left now is todryassomble the easeand euta Yt plywood back (D) to fit the grooves. (Its grain runs up and down, like the side panels) Then you ean glue the case together, as shown in Fig. 5.Just make sure the good face of the back panel is facing out TRUM, While the glue on the case is