NO.

44

NOTES FROM THE SHOP

$2.50

W1.X~llli
Numbef44

April. 1986

Edilor
DonaldB. Peschke

DesIgn DorecIor
Ted Ktallcek
AssiSlant EditOrs

Steve Kroh"",r
Ooug...o L HICks
Douglas M, Udsror
Technicalllluslrators
DavId Krayllng
MlkeHeruy
SubsctipIIco Manage<
Sanely J, Saum
SWscnptioo AssisIants

CIlristel Mine,
Vicky Robinson
JacIde Stroud
Computer

0penIIJ0ns

KeoMlner

Administrative
A_t
Chetyl Scott

BuilidingMail""'""",,
Archie Kr"U5e

Sawdust

ABOll1'nils 'SSI). I ."muml,..r lh. Ii",t

time J saw burl \'pneer-I mean a ~hl""_'l"f
real burl veneer In its natural ~I:tl(' Inot
veneer on a piece or rumitul,\" tha.t Wlll\covered with I~y~.."
or yellowed ,on".h
and years of darkening}. I ,.,1\.- am"",,1 at
the swirl. of color nnd subtle l>allen .. cen.ain1~unt orth~ tna.r\eL..;of natul'\'
But a... beauuful n....thov an', J'\'t al\\"""1
had a reluctance to \\o~'k with \'t.n'l'h.
Actually the problem is trying 10 work
with burl veneers the uldrll..<hl l WRy
BUTI veneer COnIl'S in Ihin
"'1",1)'
small sheets (abou; IW to I.l "'1WU'\'1Ilw.t
are dry and incl'edibly wrinkled. ,\nd
l

the)'-'rl' b}' no mean", ['fl..... or ernek, s, 6phlt'i.

and even holes, It can be
(t can also be a I()l of work jf )'OU want to
veneer a large .una ee with burl "'I1,'<'r
using hide glue and a veneer prl':-..... Rifrtht
in the middle, up pop. a bubhle II"'t ",m.,l),
refuses to stick down,
There are two changes that make working with veneers a lot easier. F~I. 1\,
become a real fan of contact cement, It
eliminates the need (or a veneer press, and
it's especially nice when working "ith th"
unruly waves a.nd wrinkles or burl \,e".,.",
(\'{c're sho"ing a few ti~ for working with

"i""","""li"~

matter of I)()()rworkmanship in producing

lhe 1001.Dado blades are 3 good example.
\\ nether you get stack set or one of the
wobble blades. you're 8pending enough
mone~'that it should do it. job well- 'ight
.ml ofth. box.
The downfall on most or the dndo blades
we've pUl'chased is lhe qualit), of sharpenin~ - il was unacceptably poor. Although
Ihi. '" relath'cly easy to fix (just take it to a
1I00d :<harpening shop and hand over about
$:.'1)1,it tffedively adds to Ihe eost er the
blade. A ~n
isn't such a bargain ir you
1."" to add $20 JUSt to !tel it 10 work the
'"8~'
)t'~
supposed to.

I'm ,lowly beginning

change my ap"rUllfh tqwnn) bu~-!ngtools. [used to seta

hmlt on th, eest. Sut that can lead to cheap
LO

l(lC.Jll' Hilel Irustration, Now J set a limit on

I 1000kfor good. to-high quality

10010, 'I18Y more. bUI I'm much happier a.
I \\ork \I lth the tool.
.",. n r r~~\'&LOP&.
\Vc've changed the
'I"ollt)

.1. '10'"o(th"~nvelop" that's inserted in the

ce-nter of lhi... issue. \\'c,c added a few
1)o:,(~8tn chl"<'k if you're OO\'1ng a problem

w ith }'nur ...ubr!tr1"lloD.

I r \,.,r bou ... I. damaged in the mail or
hi, mi"""~ ,",).."<.<;l, we'll be bappy to send
~0"
replacement cap):
AI.". Ie you're receiving duplicate

rr.,,

veneer on page 15.)

The other change is the introduetion of
flexible veneers. These paper-backed
""IJll"'. 11 1 U" knO\\. (This is usually the
WOOOSMITH (lSSN 0164-4114) Is published
veneers are as ctese to perfect as you can l"t~ult of K(onthn!.! In t wo orders (OJ'a new
bImon1I1Iy (FeI>ruaIy. ApnI. June. August. October.
get with anything made or wood. Th,'y.... oul",,ol'lion.) We periodically cheek the
Decembe<) by WoodsmIII> I'IIbIisNng Co.. 2200
very eILSY
to work with, (Although 1hOI(' to "nllrt' lilt to try tu find duplicate copies.
GIlIS1dAve. Des MoInes. Iowa 50312.
say it, but they're even .a.ier than "orkAlthnul!h \\-ere pble to catcb mO!itof them.
WOODSMITH Is a '89_
ttadematI< of tI'1e illgwith Formica.)
It 0. h \...1.,. IlmeoC(Jnsunling proce.~.Let us.
Woodsmoth PubUsIWlg Co
If there'. a dra ....back. it'. that the' nt'- kilO", alld \\c'lI be happy to carrect your
Copyrighl 1986 by WoodsmI1h Publishing Co.
ible veneers are very, vel1' thin, Youha\'. B'Ih1i<'nJ,lJOI\ rl'(.'()m.
All Rights Reserved.
to be right on the money. becaust'thcl'I"g
On\.' Ol her 11roblem L"mis,.l~ingissues be
Subscrtptlons: One year (6 issues) 510. lWo
almost no chanc. to smooth thinl!" OUI hy '-:IU.., o( change in oddre... (\Ve get
)'OOIS (12 ossues)S18 Single copy pnce. 52.SO
planing or sanding.
!>ulld"..], uf addl'e-"S changes each month.)
(Car1ada aocf foreign: add 52 peryear.)
If you've been wanting to try a Jlroj,'<t Th" P",1 Offie<> will forward magazines for
Chang. Of Address: Please be sure ID"""OdD with veneer, Ihe small box shown in thIB 01,1>" l \\ 0 month. ... after ~~ou
mQve. Since
bolh your old aocf nt1N addtess.
i.s$ue i~
an ea.-y \\'ay to start. Afit'r ,,'ol"kinJ:
1.... ><18'"11/1~, a hi-monthly pubtication, it's
Second clasaposlage paldat Des Moones. """'"
on t.he t.~IOboxes 5hown in the phuto Qn toa."" tlJ m~ un issue.
Postma8lat: Send change of addoess I'IOIJce. page 12. I made another one out of cocobolo
If you change your address. or if we've
Form 3579. 10 Woodsm,Ih PubTfShlngCo.. 2200
with a Carpathian .Im burl. Now thai ", .., made a m...'take or misspelling on your label.
Gf8(IdAve .DesMoines, 10..... 50312.
fun - and worth the elTon to Ill't to kllu" I,t 11.' Imow. We1J OOITllCl it and send any
\'eneens a tittle better.
~U"C \,ou"'e miK.~.
DADO!:S. Over the past couple of y,-an<
One '!aatthing. From time to time we rent
we've been coUeding VarioU8 dado blad.
the 1I'"ooslIIilh ~ubi;criber Ii$l w qualified
BACK ISSUES
$.t$ to geLsome experience with each ""t. woodworking campauie. who send oUI
foJ1 back Issues of
are sIlll av_
The d[()'erenees among the sets are amaz- catnlogs or information on woodworking
Seod for a flee boo!tIet desalbmg tI'1e contenlS and ing - and somewhat depl'eS-'ing Rt th, tool' and supplies. Wescreen the .. offers w
prices of til bad< issuGs.
Mmetime.
make sure (as be.~1W~can) ""11 it is an offer
I'm coru;tantly amazed at the)lOOt '1uali- of inLereSt to \\ood\\orkers.
ty of many of the tools on Ihe market.
HO\\~fert if you (10 not ""ant to recE'i"e
Sometimes
it's
a
mntter
of
)lOOt
dCNgJ1.
thi.;
information. plea:>ccheck the box on the
SAMPl.E COPIES
This is p;U'tieularly true of th_ took fronl JI'ItlCI of the envelope and ,;end it in.
"you t\aV$8 fnend ,,!lQ would TOOl10 58& acopyof
aimed at the "sell it quick at n 10\\ pri","
N&XTII!1AILINO. The June issueofll'oodWoodomMh, joJSt send the names aocf odd<ess. mark,t. They're just not worth ha\-!ng,
smith (No. 45) will be maJled during the
and we'll send a sample (al no cost~
BUI mOl..,often than )IOOrdesign. il',
week ofJune 23. 1986.
0

_til

WOODSMITH

T_i~s& Technigue_s__

__

PLAYING CAItDS IN THE SHOP

T""" lth' dcl-lhol

u-t tum the bolt III

Ih" Tnul. J'hen to 1>1\" ,,,,t It Crom mo'inj!.
CUI,

The", are tll1~\\h< n I """" to maze a fine

adj\l"tml lit (lfthe- rl"lt.('r table fence to sneak

uv on a fin",11 dimension, RUI loo;ening the

fenee alwl Ir)'Ulg to tal' It over j~la hair
never fl.1."t'1lUW W\'l' me the control [tnt
looklnJr for.
Instead, I u playing cards as gaul!"

shims, (They'n' ,xa<:tly L lOOth of an inch

thick &0 three ut th"m equal about 101
thIckne~ s, ) Or, I use a .park plug feeler
"."go (or extremely fine 1OIiju.'rn"'n.....
~tart b) III:Iking a Ib, eut, I fit'" not qune
wirle enoul!h. hold. playiJll1:card (or more if
~)
III:lWUIt the back right end o(tlJ..> tighten a "ing nUlIn from the back until its
r.nee and damp ICI'Bp bIocl< to the table
lip Il:lUJlSt the Tnut It "ork- great f,<I'
u!lht lIj:alJIst the can!
marking and tigfl\ ."ttln;: ~h with am

aeross IlK, gnun.

CLlANINO UP .oX

JOINT SLOTS

u'"

I
II d ffcn:-nt technique to oll'an uJ' th~
ro\l~h bottoms of I"" joint .lo~" left by
.wlo", I ( ,~ \I ,,,,,I... th :-':0. 42.page :!III.I
0.) it \\ It h III, b;.UMt~\\,
SUI)t 1,) ('1.t"1I' lit( :.. l'lt-::tiJ(htt!CJ(e :ottlp to
Ih, o.lI1.I>.a\\ lahl, behind the blade. The
~leJf' hlL' te, b.. .)(*'~'l(li(
..ular to the saw
hlad.,. To do t hL' II< t til" baJ~l;a\\ miter
J!1ll1j!' [or'~
Then put lt mth .. miter gaugc,
~ (Il ';\IM. holtllt tight HilUm...t the stop while
daml' nl! the top 10 tbe table.
The ,I 101"""from the !'rom oi the .wp to
the t.....
nt cull ~ edgt' (i(!lJ..>;;aw teeth
lIhouI<l equal till' (uD rlepth vI the box .J<llllt
oW. This '" the Ihiclmt'-- o( the adjacent
pll'<'<'ln the boXJ()U1l.

JO<' I;n:JlI~
7It(,&,".A ";(', a
MASK OUT GLUE

"""nNO

11'\.'\1.'lltJ~'nl;utl"tt 11\Jm~lrf)rOO\.joinl boxes

t;1MOV'I
CAItO ANO flUSH

thl,t

,.N(t~.IH)l

tu b.: .lain."". I found on the firot

",'I"

box thotlt

STOP'tc.OCK

\\~I,.
.. quite

" Ch4)rt'lO remove an)'

C'''''~th{~
glue from Ih( inside corners o( th..
il-Wlnwould take unirOlml,~ It \\

..,_,:., IKJ

a_..

e~t)('('ltlJ~'(liffictllt to ('hilJ n\\1})' on a small

Ix" "here I rouldn\ ltd .chi..el inside,
:-;0\\ Ioo\!,n the
lIt "inlt nut on the
ThI,'11 10Wle upon tlK' ...tea ofu.,int! ma.....
kve the let\ one ti!lht). pull th, lJlg tape on th, in:<i<I~, ( each box to ...aI off
playing can! out and pcsh the fence back tht> llIu,. 110;-(...... 1.'lum;:. JU': aPl~' tht> 1"Jll'
aj!3ll1$t the b!oclc. n,;, h:I., moved the f~lX'<! dill'll with the bottom of lhe ,Iot,.. Then.
back from ItO ol"it:inal ""ttln!: a dkUUll...,

n,..

f,_ a...,.

pqualto the Ihk~

oCthe 1>Ia~'IIlI!
card.
f'inally tl&hteJl lhe wmg nUl bOIC'k '~'\\'D.
:0;0" mak, anotl",r 1"'-_. I( the ClIt b -till
I'tftl Yo kit enc,ul'!'h, l"t,ntlnuP on 'Uith lhLproc...... unlil )"u 11,'13p<'n('('l fit. I(al any
tlmf;' UII'nIl got'S lOr. (1("Cp. the proc...-e:s.... can
I", "'\'~"'l,1
b)' addinjt card, hetwecn Ihe
hlllCkand Ihv fen,..,.
Albc,1 BPO'

_Iou<"

H,
F:~I/.(l,.tJ~\(,f~ Illff"
,(mIM"
MOIt'

H'll/a",/, Pru"$!/llYIlIln

MARKING GAUGE

H ...,'. An clI','ctI,. m,,,'Iung cutunl( j{'dUl.'e 1

made (or the ro:\t o( a W\\ ,n~' wilh a
~
bolt a T-nut. a wing nut. and a ~
~
blod; of -t 4 Ilarch< 00<1.
f11'11t drill. bole throu!lh the MItt'!' of
the bIotk to 8Cfommod:tte. ~. ~ 'I'cania!re
bolt Then drill 11 <'OIIntcrbore part way
thouI.'IIth~ bln<k to aecepl the 'f.nut and tap

the 'f.nut lllto position.

:-':0\\ ~."ndI h"lup of the <:al'l"iage bolt fiat
\\,th "di",IUind,r. l'hen angl" the bolt bean
in ..datlllll to tI", dL...: .m" grind II be"elM
oogr allll ... Wll)' ""lUnd the head. finally.

sharp"n lhr I",' on lI.harpening~tone.

\VOOOS\IITH

[N"Uirri
\'*0".$0;'1

"",,#...

,1'JI,'t II'/t't

a 'Mlllds(JI#~

Ih'lf8(IU't lerJ"llq'lt' l(,tl, uS<lbrlo

1M fJ II ".1,, fl rYJlti('r tubf, (Sf't' ,\iJ,nJ.

IJo"

rfn"

\',J. l", IHltl' .1/(If (I /'1' QI'liJs/tllillg"

!MI,,.,JJ" I" CI , .. ,u/e r t(,blt), 0,. 1t.... ~(lllal'(l
1IIId Mhrr.sau
(''''/ U Zlf'Y"!IJ(lt'tlgl S.tol'
.,IIItlt

tuN 1AP'l AlONG

IHSa fOO.I Of JOt"" UNa

.\f~JI'

lOW.cOST

l)J"" lhe t0l>~' In po."ltion. hrinJ: one of

tIJto dado ,Jot.ln the \\ urkpoc.", mto the blad,
UIJtil \
the stop, Theil mo' e it liidltly
- ,,-\
( 110 you'", ju.'U tk-anlng up the
bottom of the olot Wltillt',::mooth. ilat, .....1
1IqlW1! ('onunu. on d..'aIlinJ! lip the ""'t oi
tIK'
Ih th Nl!Il(> ted>nl<lll<'.

r" , ptd O("nJUi

after Ihe !du\' IlCUup. -unpl) remo'~ th~

tape "ith th( .,,, .... j.,~\I('on il.
,. ..." .1h /{ (
H 19'tall lUll. ~\.f" 1

.tHQll b.,zt'S

(t'(ltJ.lrtd I

Ix 3' (

Ilff IIY"fJ,.Jl t t~~J.f

U ~

11IQpt. 1111'

q(rh ."b" "", hn.'~E,lh""IOI"

tl_} hit
(J Mflrp./
N~I()(Jtlblad~()II

,~:b~""u

I.d " ,\ ntt ('0 (0 t I' " goo<l

MZl fl I tZ gl It , la'1I A"
I (wi II l' U "0
.lmll.YT It, d bar 001
tO~i" 01 (/ tltt
1',,""(. JJ II

/fUdtd

S(ND IN YOU. IDEAS

you d l<e 101Nr WOGCIWotIaloglll>wiIh_

' d.rs of Wool/smith, send yOUf ildea 10
T~ & T~.
2200G..nd
Ave Des -.
Iowl 50312
w. pay a _omum 01$10 lor lops. andS1Sor
more
Sl>ldal lec:IlnlQues (!hal ate aecepted

w_.

""M .. tt,bt ('0 rt "lllf./f} ( IJillN

lunl,,(urttqll,n
I'r"("rtl~tlliek
111ft 01Iii, "~.#l~'1g '(l~ ("all thIYJu'f!t<a t~y
'-q It I n'l}r (l "'1 10 n 1I!1)i(J .1(/(1(.-rl rtl $( rips oJ' 'or publlc8l1011).PllaM ON.a complete explana
,nctJII.I.;'Jlg I(J/" ('.if "tYf ~stJl"f11K1 Ihe sid.f..:$COil
110ft 01your odea If I sllelch IS needed. send II
t(Jf~ ..

ttlf

'0'

I~ "ql((tltd "/1,

alOng; we'll drew a

new

one

___

R_ec_i~eCard Box

A DOUBLE-DRAWER FOOD FILE

It- Ir1te1Wtmg """ a project can ,l('\'elop
Crom a mph> id.>a. Thi.'! r't'<'l," CU'd box I:'"

good """"Vie \\" ...~" unlllllal)J lhinking

0(. SIDlpleoncdl"~"rr b.. x tohoJ,l SxSClnI.<
Rut then soree or the "<coks" on OW" oI:llI"
look look al the angu::lI
.k,~
ando:Ud
th<re .."",,\ enough room r....aD t.h<:1r
n<ape
nonIs. So" c adderIana:hct- <In,,\( r.
:-;Pxt. u..t.oad or making Ju.<t plain box
(or the -e d .. "en we dceid .. 1tod,..... u"tIItco"",,, ",th nuter and dovetail kP,"jomta
'.'lIlaiJl('(1 in .k>UW on Ill\I!'" 10-11 And
...,.., the
",..joll1 e~1thlll "aVo"1cy not
make the drawe rs with thisjOlrll'
Ry th;" time the cooks
"I of lhe
"'",.,.,..draw. r. bUlol.<",..,1 Ullklnllnboul tht
W3) th,jr ..",kbool;;o 1t,1.co, ,....-d "'ll> Oour

bo.,

"""N~

when laid out un J& t'C)unk)'\('jl. !'o \\e nddt"l'la

tilt-up frame to hold toclkbot,k .
'111.. called for a ~11(1 fnUll<' IlnlUn<lth<
bouom of!h<box to I>ollln,,'orr lhl "III. elf
anee of lhe lOP fnml:(~. t\K I M.llul, l,rujt"Cl.
designs t.,KIIO developas you !(t't mto Ihem.
But on~of the niC(>f"lIlu1'<.'"ofthi. I,n,j,'l'l
it< that yQU ran leav~orr part or II"
(the Iilt-ull cookbook bolder) un<1.till have n
us...ful proioct (lh,' ...",il'l' boxt, And
that's where 1 bel,'"Iln: lilt' b;lIIir box

",.,.j).~,

THIIOX

To build the box. I .tnrt.'Il by "","I'"

ing .nau> .to<'k 10 aboul v..' thick
for the lop Rnd bottom (A). lh' I""

... 1"" IRI, and tho dlv~"'r 'I II\"t,:

'00 can elimina.tt'! re~,a,Y..lng If ~CMJ

........

_(21

It."'."

IIj
have 110", to Iii thirk stoek.)
Y, .. 6 ,.,
.... w..121
After tilt- Mock .. I'l'Sllwn... Ill\""
'0-\ _6' 4',
C ",_")
glue one blank for the 1"1' and bottom
D .......
(ll
t.. ,.,
"', .. fit
pien.~ to rou.ch dimen.""'M or 7 ,2..
sv.
I _SIdell!
",;.to, and "!i(' 1001{ T1><:n .odl1l'"Klue
, 0....
".(2)
h ply. M .. ~,
another blank for both !'ide ,,1<'<'\ and
'.JCQ,dtoh,
00....,0..,
,,(2)
tht- eli,iIk'r 10 rough dlltl( nslons (.r
H-""21
' 2.3""
... ..id..and 1G'10fIIl
I
v.."YnS ..
Si>op!\o)k: In-t.atIo( .. h,,gluIOIt~"OUcan bortom, and ,ide piece- see Detail In fIg
J
(01
'I lY..1.'.
u..''' 'wi,k -toek, But WI' .....icr boom. I 11>e v,,'.\\ ide rabbet aDo... ,. a deeoratlvc
''''' 1 y.. ".
tend 10".rp, I think il- better I" rip tht-m .Hbatk tor tbe V.ply ...ood bsek O~
pay (\If to flt
1
(1)
down or Il.'<! naJT(J",r boanIo BJICI
cvrnse nu, MfTERS. :\",'1, <lit rrou
~ lV 12
them tOl;\'tht-r....... n aft,r tbt' Ill' dries,
mil" ....on thl.' ~nd,of ~b >ide pi.oro H ""
N s."p,Di'f.(3)
., III \l. ..011 to ",
plane tht' blanks flat and down 10..... thick.
Ihal Ih.. final length i.5" from long pomt 10
Ct'TT11,eTO ROt:OH'Il" \\'h"n 11>., wnl( ""int of the mitered encl.__(~ .... JI8g<'
CUTTING DIAGRAM
blank., lU'e Jllanl~1to V nl' Ih"m buth to.
10 for an ~xplanatiun on rullin~ theoe
unifonn "idth of6 .... :>lowrutlh. lupond
mi....... I I'ot(': Bp <\Ire to CUtlhe mi",,, ...
bollom pieee' (A) to ",ugh I.nlllh. of II" th~y'''''"n Ihl' saml.' (ace Il.' the mbbets.
from the long blank, Ami CUIorr two &',j,'
Th"n mller lhe tnd~ "f the lop alld
(rough I.nlllh. "des (HI from the' .h"rt
t.,uum I'i..",", (Abo that tht fina!lcnglh ,.
.\ ."'.S'....
;.60
blank. Sa"e Ihe .....mainlng:; pi'~'e (ruujth 13'. Note: Thi. length ;,. b.~""" on having
lenjtth) for the divider ,(;).
1\\u elm" e .... \\~lh 3,5 tani. i".itle.
RAOO",. FOR 'nn; BACK On,'<: nil Ih('
DADOPOR DIVIDER. On"" all the mite'"
pil~14 a~ cut. to rnuJ.th length. tut u ~;'''.
ha\'{l b(>~n ('ut, rout a If." by 1/." dAdo
'l,,' 3Y1.... 36' CUSAWto '.1
wide by y."d....p rnb~1 for tb. plywood
Cl'ntcrl,1 lIero.. the in.<ide(ace of the lOp
,
back on th~ in.lell' bark e,I!:(' or Ihl' l:":I':., :,,:.:":d~bo=I~lo:m~p::iec::e:,,:...:..,~e:....:.F~ig~.~2:::'_(~:-<~'o:t:e:..:
.:.1
..J
I ....

_0._(2'

~_s_,.)

,..!"u.

M.,

,1.

I .."

8::;;! ..:lmll..a_!iI
an
.:r1illEl

~=======:-

WOOOSMITH

originally built the box with stopped

dado, see photo, but changed the design to
a through dado LOmake it easier to eut.)
To make the dado for the divider. mount
a y. straighL bit on the router table. raise
it to a height of II,". and move the Ienee so
it's 6\1. from the renter of (he bit. (Note:
The 6''''"lllea8urement ishalfthe lalength.)
Now .'OUt the dado ""'""SS the inside fAee
of the top and bottom pieces, see ~ig. :t
Then rotate the workpiece 180" and make
another pass, (Thi. IWO-pa..'5 method ensures that the dado is centered. If.okay if
the dado is a little wider than Yo". The tongue
that 61., in the dado can be 3(ijusted laten)
SACK. After the dadoes arc routed in the
top and bouom, cut the
plywood back
(0) to fitin the rabbets, Then dry assemble
the box with the baek in place.
DIVIDER. To determine the lenl,othofth.
divider. measure the distance from the
bottom of the center dado in the lOP piece
to the bottom of the center dado in the
bottom piece. In my C<ISC this measured
~'I:".
see Fig. 4.
To determine the width of the divid.
measure the distance inside the box from
the plywOod back to the front edge of the
tOP and bottom pieces. 111my case thi$
measured 6"'", see Fig. -1.
Arter cutting the (lh'ider to final
rout tongups on the thickness of both ends.
see Fig. 4. I routed the.. LOngue. on the
router table. sec Fig. f>. sneaking upon the
6naJ thickness until the tOllgue just tits in
the center dado.
ASSEMBLY. Once the tongues fit snugly
into the dadoes. glue up the box. di,;(fe..
and plywood back making sure the di"lder
i$ Oush with th~ Iront edge.. Then clamp it
with a couple of band clamps.

y.

sw- --,..___

1
s:

NOTE: All S1QCIC',,' THO"

SIDE

DIVIDER

SIDE

,,'.

_,

.ize.

..~,ttAMP
(5(:[ OOAJt.RG 1)

..... &AOICEOG

DOVETAIL SLOTSAND KeYS

When the box was <ir)' I added the dovetail

keys. To do thi.. I used a Yo" dovetail router
bit raised 0/,. above the table. see Detail in
Fig. 6. (A 0/," Or v." dovetail bit would work
ju_o;t as well.) This technique is shown on

page; 10-11.

: Sl!ilAlGHlSn

DOVETAn.. SLOTS. ~'itot. position and

rout the center stot across all four corners.

Then move the fence sothe center oflhe bit

is 1Vo" from the jig and rout the next set of
slots, see slct locations in F'ig. 7.
ArLer these slots are routed. don't
change the fence but iiiI' the box so the
opposite face is against the front of the jig
and rout theslots on the other side. Finally.
move the fenee so the center of the bit is ~"
from thejig and rout the remaining slots.
DOVETAIL KEYS.After all the slots are
routed. make the dovetail key~ using the
router table (once again, see pages 10-11).
Cut the keys about I~'Iong and then glue
them into the slo!$.
J\fter the keys are dry. eut them off close
to the surface with a fine-toothed saw and
then trim them flush with a sharp chisel.
WOODSMITH

"",,"7

DfJA!L

ASL

_SlOT
~TUfD
ONWfOTH
/

eo.

.,

'Ilfl DRAWERS

Aft~rthe boxIS (,,,,,pi< te, the d=~rs tan

be built to ftl In tIK"Il(nin~. [ beIr.m work
00 thodnI.......

by ruttmgfiKht dra",-r,;ick",
lEI (rom Y. thid< n'","n stock to a Iini.""-od
width (.f21
""'gld"ngth of6v.-.
BOlTOM RA8I1t:T. lI.. for. cutting the
,"!~.
to final I(ngth. cut v..'-deep rabbets
on the bouem l'lg. of 1I111iJ.:ht
pieces just
","1" enough for th~!I. plywood drawer
bottom ,,'t' [lOll om Delail in Fig. 8.
Lt:NtlTIf OF 81Ut:S. Aner the rabbets are
cut, lh~ (Irawer .,,[(., can be cut to final
k"~'\h. Mc...~ th,' width of the drawer
"I""lIng in th,' bux. "' -e FiK. 9. (In my ease,

",,0).

lhi i'JK"nlUgmeasured r, ....) :'\lO\\cut cross

mitt'1"!! on the cnd,i of a1lelKht pi~
<0 Ihe

I ngth ITom pOUlt to point of the mite,.,.

"'I
tho ,.'idth of the opening.t Sote: The
dm....,,,, an' "'11W'f'so aU e,ghl sides an!
tht UlIl(' Imgth.)
1.1\ lI'l R OAIlO.' AIl~r aU eighl draw er
.00 hau been m't~"",1 t" length. rout
Ct'l1t......od d.1d........ "",
four of the pieees
(the 1<1, 01 the 1.. 0 drawers. to accept
n !nO, able
(G). see Divider Detail
InFJl:N
1\()l"TC)"tIt' X'\l. Mat the 1/.- plywood
1")11""" (~') (" nllll the rabbets. Then glue
I .",11'101111
Ih,1 ,In... """ with the bottoms in
. "Il,,, Sill..., II... elnl\\""" fillightly into the
4'1)('111'15::. eheek th,lt th{)'~ square.
,,,,,\',I ,'I Kt \..; \\ hen the drawers are
d~ .,Id lb. eI", etail keys u.inl( the same
tedln IU. u on th~ 1'00"....... key loeaticns
mllMoSld \1'''. hI: s.
Aft<.r tbe kr) .. are l(lued in and cut off
o h
lor plant' tbe, d(' liglltly <0 the
dra..
I."'" 11110
the """ning with about
clea.ranc n l"arh ntt'.
1'1\ III. It.. 1\0" rut removable dividers
IJ) tel ItI In the darlne1i In each drawer,
11("( t I~ s,
kI' Kt Ii' To k""11the drawer from tipI III ,I.... " ,U it'. pulled out. ! added 8
k ke r (III to t h, baek of each drawer, see
"'11( ' . 'll1l' ki('ker 81.0"0 aets as a spacer to
k''I' th" drn"~r from goillg too far back

MClCNUSOO
IOCUItClnlO

RT(SHlIlffi

,
.

0b1

.11,-1.",..

CUlTO 'n

MOIl

LBS TH.I.N

........,.

1t0000Of
H

O1'(NING

KIQ(ER

!
~

AOUIC-'O

GlUI 'A&S ~ONT 'LUSH

wrtH SMMSAND IOnOM

OOUi-.ll!

OOWll SlOPc(N'JUfO ON 0PlhlHG

kNOt((Nn.",
0t4 OUWlI FlONT

I
I

lIllo 'he bcl\,

'nh Io'nnin~ the

,~

.-

Ihielme," of the kicker

I JlU hcd the draw~r all the way into the
OOX1UJ<1
,"",,,,ured the set-back, In my case
Ih. "" . I w~nted to add a V,,thick
faL.se,I"',.er frrmt "n" have il.tick out
frum the frunt ,-dgt> ofthl bus. see Detail in
FIg. 11. Thio m....nt I he kicktorwould have
to be .thkk.
('ut I .. o kid,..." to that Iluckn< . and to
the obape
n In f Ig. ~. Then. ~ue tIK:
klcll' r to the cenl.t oflhe drawer back ~
It'.
h \\1tl'lth .. draw~r bo.t tom.

.110"

a....

FALSE ORA" f:R 'ROo,;1'8. Th compl<!tc

the dra\\I .... rut 1\\0 f81:.<drawer front$

(I) from y,- >lock. Th .. "idlh ;'~quaJ to the
h"'Khl of Ih~ drn\\~r QPI'ning minus '1,,and the length match the rron~ or the
dr.lw<'r. "ee rill. 10.
WOODSMtTH

V.

Now rout a
round-over profile with a
0/,." shoulder around the front face of the
fal"" drawer frontss, see Proftle in fig. 10.
Then glue the rronl<' to the drawer so
they're flush with the sides and bottom,
KNOBS.Wnen the d ....wer front. are dr~;
drill and then >,(,1"eW a porcelain knob to the
center of each front. see Fig. 10.
DOWELSFOPS.To keep the drawer from
pulling out too far. drill
holes through
the lOP of the box 10 accept ,>,,Iongdowel
stop'. see Detail in Fig. 11. (The"" SlOpS
catch the kiekers.) Center the holes abo,'.
each of the draw er openings,

----,

~IS
'EI'\

v.

...

flGURf

1'2

'

Q) FRONTI8ACK(II:Ju' mas1

71

SlDES_"~EC6Y1

BOTTOMF8MlJO QEIAI~

IOf fBAME PilAIl

r-

.,j ......

Pl'IWOOO

THlfRAMES

0_ the drawers were complete. I added a

tUl'UII cookbook holder to the top and a
matching frame to the bottom.
crrrnxc TO ROUGH SIZE.StlU't by 1;1>ping aU eight frame piec-es from ~'.1 (1'1',.
thick) stock to a final width of 11','. Then
cut the four frontibackl- (J) to rough
length of IS" and the four side. (K) to a
rougb length of8V,". see Fig. 12.
RABBET THE TOP FRAME. After the
frame pieces .re cut to rough size, cut a ~'.".
wide rabbet in the four top frame pieces to
accept the \'<" plywood top panel (I.)....
Top Frame Detail in Pig. 12.
MITER TO LF.NGTH. Now the frame
pieces can be cut to final length. Measure
the length and depth of the box and cut
miters on the end. of the frame pieces :;0
the lini.hed point-to-point length. are IV.
longer than the box. see Fig. 12. (This
allows ,..' overhang Oneach side.) In my
...se this made the fronL'ba""" 14V,"long
and the sides 7.1II' long.
'rop PANEL Once the pieces are cut to
length. glue up the frames. Then cut the
,." top panel (L) to fit in the rabbets of the
top frame and glue it in place.
PROFILES. After the rrames arc asssembled. "fie lhe router table with a fence to
rout profiles on the top and bottom edltes of
each frame .s ec Pig. 14. First, roul an agee
profile with a 0/"," pointcutting ogee bit
(Sears No. !I HT 2S583). Then Oil) the
frame over and rout a Y','Ouncl-ovcr on the
other side, see Fig. 13.
BOOKSTOP. The next step is to add a
bookstop 1M) to the top frame. Begin by
routing a stopped \10' groove near the tOP
front edge .(the top frame. see t-i~. 15.
Next, cut. blank for the bookstcp from
,'''thick stock to 1V.. wide by 12' long. Cut
a centered tonlt\le on the bottom edge of
this piece to fit the grocve (see Detail in
fig. 17). and noteh both ends of the
tongues to match lhe length of the groove.
Finally. make a pattern from the g1;d
drawing in Fig. 1~ and trace it on the
blank. (Make sure it's lined up with the
shoulder of the rabbet. ,eo Fig. 17.) Then
cut the bookstop to finnl shape. (Since it'$
easier to continue \\ ork without the book~top in place. don't j(h... it in yet.)
\VOODSMITH

miCE

flGun 15

aoJtOP
STOmDGROO'l[

DW!(L
1 .~" _

Sl0lf'10

GtOOVf

'.

..

,.

'7

NOT04IOn. ENOS
Of TONGU: 10

STOflPDG~

ClHttR TOf'fGVON
TKlCKNESS Of- Stoc:l(

,.

--

,,~~

AGUItf ,.

0.." lhe

mlflW>. are complete, I hey can be

ut18<h.<ltothe box, Ibegan byauachingthe
buttym f.-.unt.
OOTTO" t'RAM. Start by drilling six
slight I)" oversize ('.~') shank holes and
cuunt e r s ink s for #8 x IV," Ph.
woodscrews, see Figs. 18 and 19. (Note,
TII~ bottom frame is nOI glued on. so
eversized shank hole.~allow for expansion
centracuon of'the box-l
The box sits on four W' buttons that act
as -reet. Drill "'I,"deep holes for these
buttons in the bottom frame and Itlue them
in place, see Fig. 19.
After the buttons are glued in, po"ition
the frame so it's centered on the bottom of
the box and mark and drill ""'. pilot holes.
Then screw the frame to the bottom.
SIJPPORTSYSTEM. Before the top frame
can be attached to the box. a support
system (N) is added lo the back side of the
top frame. This system hold. the frame at
about 40 for a cookbook. see Fig. 23.
$taJ't building the support system by
cutting. piece of 110' stork to I'Y' wide and
tong enough to fit~nllgly between the !'ront
and back of the frame, see Fig. 20. Then
drill a hole v.- from one end to accept a IGd
common nail for a pivot pin.
Next, make t IVO rip CUts to slice the
workpiece into thirds with each piece
measuring l4' wide, see Fig. 20. Then trim
the middle pieee down to a length ofPlt and

ROUtE. l'

,SClfW
IfOU alJTlON

""ACHING TH[ fRAMts

tOto.

"""

,..
""",

[20

COMMON

1
ORIU. HOLI ClNTlHO
ON stOCIC , .' f1tOM tHO

.-'.

..

cur MlOOU "EeE

SUPPORT SYSTM

41,o)_-lONG ANO
ItOUNDovtR

80"'''''''

NOTE: MIDDU _.
MUST rrvoT FltlR'I'

round over both ends.

~r
rounding over the middle piece, put
all three back together. line up the hole:.. and
epoxy a 1Y," piece of a IGd nail into the hole
SO the middle arm pivots.
Finally. glue the two <11ll8ill<'pieces to the
center (underside) of the top frame. (Note:
Clamp the outside pieces with enou> gap
between them so the middle piece pivots.)
MORTISES.Once the support system is
glued in plsee , locate the mortises for the
I y.,.long hinges, see Fig. 21. POSitionthe
hinge so the knuckle is centered on the
front edge of the box. see Pig. 22.
Now mortise deep eneughso the knuckle
is flush with the lop of the box. Then drill
holes for the hinge screws, and screw the
hinges to the box, (Note: I had lofileoffthe
point of the '"'Iong brass screw sinee it
came out into the box opening. see Fig. 22.)
To mount the other hinge leaf to the
frame, tum the box upside down so it'.
centered on the frame and mark the position of the hinge. (One way to do this is
,,1th locator pins. see U'oodsmillr No. ~2.
page 8.) Then drill for the hinge screw s,
SUPPORT HOJ..E.When the frame is ulted
up, the support arm fits into a shallow %'.
dia. hole centered on the length of the box
top, gee Pig. 23.
FI.NISIL Finally 1 glued the bookstop in
and finished the project with three coals of
Hope's Thog Oil Varnish.

NOTe:

00 NOT GlUE
to""" flIAM

IPOXf lIN , ,. met 0II W COMMON I'U.Il

A$" PIVOt "N

RGUU11

"""

MOITlS<SO
ICNUCICLE 15
IWSKWITH
lO'OFIOX

Mi.NGl

'0
r~~
""ucm

Ali OFFPOINT

CfHTtkfD
ONflONf
EOGl'Of lOX

OJSCRfNS

WOODS,,"UTH

__ A_djustable Holding_J!gc._____
When it came time to make the
dovetail key joint shown on
page 10. , gol out our .tandal'd
jig that rides over the tablesaw
rip fence, I figured il could be
modified for the router table.
But it wouldn't fit over the
router table rence _ and to be
quite honest. I've never been
real happy with th.'U jig. It
doom'! ride $JIlOOI.hIy along the
fence since the distance between thejig's two plates has to
be Ibe thickness of the fence
plus exact/y a $midgeon ror a
smooth ride. \\'hat 1 needed
W&8jigthat could be adjusted
to ride over either a table saw
or router table rence.
The adjustable jig shown
here seems to solve the prob-

,--

NIt

L-

lem, 1b b:WId the jig. begin by ~tting two

plates out of :v,. plywood to 6" wide by lb
long, see Fig. 2. Temporarily stick the two
plates together with double-sided carpet
tape or tack them together with "nL.h.ing
nails and retrim the bottom edges so they're

ex(J.Clly BUM.
DIULL HOLES FOR RODS. With the tWO

plates still stuck together. drill two l"dia.

by V.."deep counterbores in the front
plate, see Fig. 2. And then drill ""'"-dis.
holes the rest of the way through both
plates for threaded adjustment rods.
TENONS OR KEYS?The jig can be built
for making tenons by adding one vertical
support ann to the front plate. Or, by
adding two support anns (at a right angle

-"'......._

to eaeh other) the jig can be ~

for
rutting d(}\'et:ulkey joints.
SUPP()KT AltMs. 1b locate the support
arms, firgt determine a center bottom

point on the front of the front plate. Then

use a combination square to draw two 45'"
lines up from thiS point. see fig. 3.
After tbe reference lines are drawn, cut
two '""ide support arms to about 12"
long. I cut these out of"'.. plywood so they
would stay straight.
MOI]!.'TING TIn: SUPPORT ARMS.

Now

clamp one orthe support arms down so the

top edge lines up Bush with one of the
angled reference lines. Locate one end of
the ann <;0 it's \4" up from the bottom edge
of the plate. see Detail in Fig. 4.
I-C.OUHlU&OItE.

Afu!r the first support ann

is clamped in place. drill pilot
holes and screw it in place,
Then damp the second support ann down to the other
reference line, and check the
lecatlon of thU, second arm
\\;th a framing square, see
Fig.1. It should be exactly goo
to the firs t arm. If it'. not,
loosen the clamps and read,
just. Once it'$' in the t'OJTeCl
location. dam,> it down tight,
and then drill and screw it in
place (Note: Don' glue it In
case adjustment is needed.)
ASSEMBLY. Before assembly
could begin, I cut t wo pieCCllof
'Yo" threaded rod to 6V? long.
(Shop Note: \Vhen cutting
threaded rod put a nUL on tnt'
nxllH1.".. cutting. After it'.cut, back QITthe
nul to reform ans drunaged thresds.)
To assemble the jig. use a double nul and
washer arrangement on the fronl plate, see
Detail in Fig, L (I used IVz"-dill.fender
washers under the nut on the inside of the
front plate and under the \ling nuts on both
sides ofthe b.-.cl< plate. These lVid~rwashers
keep the plates square to the rods.)
No" straddle the two plates over the
router table or table saw fence and slide
them up light against the sides of the fent"',
""'-' Fig. 5. Then adjust the ollposing wing
nuts up against the back plate.
Finally. acljUSlthe wing nuts so the jig
slides smoothly over the fence. and check if
the front plate i.square with the table.

~H3~~~~jr--~--~-aamuMU~~~~
>PONTON

e, .."'OEE:P

EJlOHl fI\Al'!'

'.

HOU
AGUIlS

CROSS SECTIONS

.u,.o,,, .......
'\'.

'"

,.

& .,.

tAILll'SAW

WOODSMITH

Miter & Dovetail Key_Joint

A DOVETAIL THAT FOOLS YOU

Shop Now: l sneak up on
miters by "double-cutting: It
seems to gi,p a cleaner,
straighter cut that doesn't
burn, Start by making an initial
miter eut. Then make. se...'Und
cut so only half the thickness of
the blade (about V,.n it; cutting.
see Detail, Slep l.
CUT TIlt.: OTllER END.After

the first cnd of each piece is

mitered. clamp a slop block to
lhe ,uxilial'Y fence 110that the
olher end will be cut about v,..
longer than the final length
see Step 2. Cut the second
of sandpal"'T 1(1lh. l",slli"l1 (,.,,"'. \11th lid. and t hen move the stoll block to
doublesicll'<lcal'!"'ll1'I"
oI"u"I., cut the piece to liM' length (skimTESTCIIT Nexl. lilt th,' blatl"lu I:; and l1)in~t he LlJ<>t VIG" off the. miter).
make a tf:sl nat on tYo t) l'h"C't-S t,f8('rU,ko Hul1
Uc)1~rtl)'(llw~aU the pieces are mitered
thl t \\'0 test j..Il(OCt
togt tht r and f'lll,t'k
to finAlI""J(lh, cUl th~ plywood bottom to
them \\ilh a ,t;qwtrt'.
III ill I he nohh,t. or l.'I'OOves. see Step a.
(~hhl' :.;"".: If. frame is being made WllhoUI a b..ttom or top - I cut Q piece of
t.)Jl('e lh_'l'oa\\ l...
~l \I}I ut "X<t('ll)' t.a. \\t,tk
!I<''''P "Iy",,, ..d Ihnt fit.< inside the frame.
can h('gln on Ih. nutors, :;UIrt b) mlt~nllR Th", "'Tnl' h"I,,,, k('('11the whole box square
one end or each box t\li-li,', ~ ... st.p 1
dunllll ..... nlhly.)
THE Ml1tRS

s....

,
.~
"o.

IlOCI

First tip blad(' to .$.;0 (.I rId Cllt ONC <'lid

Then make a $eCOIl.d cut on that end to
ski)" off a "nih..,. 'I,." (half Iile blad thick,~e88).furucit'an Cl(l.

C10fllP U "(()II blrxk t" II ,rll,u,.v /rR('r

QIld cut 1/11' t~thl'" I lid 4/1!Jh'111 ( ,. J
/Oltg. TI'~I'ft'UdJllxt tl" 1I/IJp JNf".4 '41 tru
l('Orl:piecr f{JJ;I/~!Ii'(111'lfll),

"'"'
3.11.....
rohbrt

()II

du.tall~"

beiu"J.'ll

",,s of Ih~

8ide pieces (llld cut plyuood

1.00t"" t" fit. Cui prrciJ<dl/ ';IJU bottom

1IIIliti kf"rp box BgIUl''ll dltmlg

C-/Ot)tpillg.

.,

_SUR, FIIOMcamJ
Of' lIT 10 fRONf P\A1t Of JIG

S,u'tad gil,, OIl IIIilrrt!allJi hold pairaf

sidt pi'~tighl agai".l "'IlIlIri"g jig.
Cha "ifer rorl)tT of i.r:~
jig to aUoII' tt<CO~ lor
gt U~~qJ(erZ ":Jfll0" In~idcconl"-

10

Gille fl"" pain; together ond .lip the

bottom i"fo pia"" 10 lUfuan' lip til<' bar.
Claollp ",iUI tloo bandclamp or "rop "'ffho
c;Ol(pI~ .'r~mgnlbIxT bollds.

Mou))t III~
jig owr the router (able
fence. Drlen inr tile /<)CanOl' of the
8/ol$ by nwosuriJlg from liwf nmllact of the
jig 10 the t<'I!/<Ir of the bit.

WOODSMITH

a..~mbl~', test the

bottom for final fit by dry clamping the box
together. Once it fits. go ahead and glue up
the box.
On smaller boxes ( find it easier to glue
the sides up in I"'i",around ,I squaring jig,
see Step I. And then I gh,. lh" llairs
together, On l"'1(('r boxes, 1 find irs easier
to glue up all four at onee,
Either way, slip
bottom (or square
"crnplin place to hold tht' box square. Then
wrap a couple of hand damps "round the
whole assc mbl)' "lid u.,:hten, see
5.
DOVETAIL SLOTS

After the glu!> is dry on the miters, the

dovetail ke~' <lOIS can 00 rut aCJ'O$Seach
corner, Begin by mounting a dovetail bit on
the router table. (Note: \V. used a II,'
dovetail bit here but you could use Ya
dovetail bit as Mown in the photo or even a
"Iraight router bit for Oat keys.)
JIG. To hold the box at an angle to the
router table, I built a jig that straddles
over the router table rCIl<.'C, sec page !J.
\~'ith the jig straddling' the fence, determine the location ofthe.lot. by measuring
from the center of the bit to the side of the
jig. see Step 6.
If there's 10 be an odd number of keys,
locate the firs t slot so if.centered on the
width of the box, see Step 8. Now hold the
box tight against the jig and push it
through the bit. see Step 7.
!tOUT CYrHERSJ.OTS. Next, move the

.....

""

."""ltI

'1iPlATf
""00'

[01I00I
OI1OSITf

StO'

11 11

J::i

...

OFlrTto

H1'J<Q
(II

Hold boJ: light agoi'MI 8ide of Jig ami

down in tJlf .'tI'll(KJrl. ant(.,'i' and PUMI
'''roug'' tI", bit. ('o",~r r'} 00,.
rld(
o./o)lgsurf a," ~i"'.JIltcr tubl<.

".fAW"

flOM CfHTlIl

~!
111

I'tNa

t""

~t."

.t~1

,lila

ASSEMBLY: Before

R()/(l C'-(.)lt(tT Blot jiTf<l. Th""

8 fence"",t:e,,17;pthe
pJY

Iltr/J'rng

tI,t' ."lot

011

'le--X(

slot. S'rp

fllf! bQ.r (I""tud

th (It/1ft>' Sld('. St~/) 2.

t>I('U'(

fllf

J '\~itJll)"1
(ltrd rollt

11'ilh bit (II !1(!"" 11";9111. ro,,1 dU"floil

9 Im'gllts
10
(", both fflg'" of
pi...' of
.crop. Use o"ollter pitre 'if
hold
{I

SM'tl/1

,,,,,k/I,oce

fight Ggawsl

1<>

thfeur.

.\(uhF",,' pus.

Oil

bolhedge.,"1 011'

fort' of workpiece. 7'hl''' flip pice

il,'tV and ruut vPJI();~;tt
face. Ij-'ou!llir is fOf)
I/"e'/i. "'01'( .(t'"rp a I,d mttt OgaIU.

fence until the-next slot locRtio" i$ centered

over the bit and rout that slot. Then flip the
box (donl move the fence) so the opposite
,'<Igei,again.t theji!: and roUt the opf1<>.<ite
.Iot. Continue wit h this procedure to rotll
all remaining slots,

tlPxm; OR'
WORKftK[

THE DOVETAIL KEYS

OnC('the slots lIJ'C CUI. remove the jig but

keep the router bit at the same height to
make the dovetail keys. The key. arc mad.
by finn routing dovetail tong""" on the
edges of a pieee of scrap, see Step II.
Hold the workpiece against the fence wnh
3 piece of scrap (see Step 9) and rout, one
edge. Then Oip the workpk",e so the oppome side is against the renc:e nnd rout the
other edge, see Step 10,Now test the tongue
for fit-it.hlluld
be snug, _Step II. lfit'~
too tight. readjust the rene<> to take ofTa
tittle more (see tip on Jl<l1l'13).
After the tongues are routed, ,imply rip
the keys oerthe btriP., see Step 12.

RIp tI,p /(IIIg ,I",~tail k.. ,. ,,0

,(ll]il.
11 illT,.,'lh,dOl~ailtollu"elo""
12
Ih,
r",<I.d i" litt/lOr. I( il'
,rvrkpic(-c
they.lall u !JII""JI tl,,'
b{IZ(i,. Leove a ~'igllt sJ,ould,,. to IH'
tIl"

II",

.,[oIs

SO

)'''' 'I litlle 100 thick, slightly su,,'; mr

tQlI!1"'ll to pmti-l,tt' a govd ~""g.fit,

UV.l

;!tun'"

k<'!lJ$

aro

Ifidl'

t'nofqJI1.

~lm

FINISHING THEJOINT

Now CUt the keyg into I'f! lengths, apply a

lillIe glue to each key. and "Iide it into the
slot. AJ\erthe glue-dries, trim off the ""000<'
with a .6n...toothed >QW, see Step 1:1.
To muk. the kuy. pericetly Dw;hwith the
!\ideorthe box. ,lulV~thtm orr"ilb a;;harp
chisel, see Strp 14. Then you can .how off
your "do,'etail" jOint.
WOODSMITH

13 the-", ;ntn

CuI /tPIIRab(lIItl'/,'

Itnlg allll gl""

flIt> ~1(Jllt.O,tc"~
tIlt:.keutJarr.

drl/- rill Ihe," "(f r/o.'C Itl Ilu' .id, oftl,e ,",,.
t~';tli.a.(i"p.tot,tllt'd

$011:

.t:;/la,'e erres (~/fJI'lsl, "'illl 11~Jlalp

14
eJlt8el.
rei

liork fro",

tnrh

l't'rlll'(' It)-

tl,f ceufpr 0.( tIle bo.r [!idt' tl.) IIY1:ty", tllf'

,1(J(t(tuil keys,fro"1 ("/ti,l/lillfl IJ 'f.
jl"U

11

Decorative Boxes

I uk" to make tittle boxes - they let me be

t~tra'''~'lI1It "'ith exotic woods and veneers
that I OOIlldn't aITord on larger projects.
And. unlCtl!; I'm trying to be tricky, boxes
don\ 1"l'<luire complicated joinery - just
...",ful fitling.

THEVINURfD I'ANlLS

The square box shown in the photo has

walnut sides and a tid panel made with
Carpathian elm burl veneer. 'I1,e hexagonal
box has zebrawood sides and the lid panel is
veneered with maple burl. (See Sources on
page 24.)
Note: The rest of this rutiele and the
artWork deals with making the square box.
The procedure (or the hexagonal box is the
same. except wheN noted.
THE PANELS. I started by making the
veneered top panel (forthe lid) and the (e1ttined bottom panel. (You need to have
these panels firsl in order to size the rabbets that are used to mount the panels in
the side pieces, refer to Fig. 3.)
Start by catting
plywood panels to a
rough site of 4~" square, "eo Fig. 1. (Note:
V."bircb plywood works well as a sub-has.
for veneez) Then I laminated Carpathian
elm burl veneer 10 both sides of the top
panel. (For more on t.bi.~veneering technique, see page 15.)
The plywood bottom panel is also eat to a
rougb size of 4~" square, but the fell isn't
added until later (so it doesn't gel tilled
with sawdust).

V.

THf SIDES

After the panel. are made. the stock ror the

sid"" is rut to size. Begin with two pieces of
4148tQCk (~, .. thick) at least B"wide by IS"
long. This length is longer than needed to

allow extrafor test pieces. Now. resawthese

pieces to get two pieces '110" thid< and plane
the surfaces smooth, see Fig. 2. Then rip the
two pieces to 8 final width of2"K.
ROur RABBETS. The rabbets that hold
the top and bottom panels in place can be
cat on a router table. To rout the rabbets
for the top panel, fil'St set the bit to cut V.
deep. Then adjuat the fence so the width of
the rabbet equals the thickness of the
veneered lap panel, see Fig. 3.
\Vhen routing this rabbet, reed the
workpiece fI'oom left to right (instead of the
normal direction ofright to len). see Fig. 4.
This "bad< (coeding"le$.."'ns chip-out on the
shoulder that "ill be the top edge of the

side piece.
Shop Note: "'hen backfeeding, the router bit wiD try to pull the workpiece. Hold
onto the workpiece tightly.

12

BOTI'OM HADD!.'. To ...,UI

.h" "",tlnm

rabbet, :ldjU'1 Ih. ("n'~'thenlhhcl .'

a hair dN'""r thall tIcombinedth'ck
ness of the subbaJ ( ply" ood and on,'
thickness ofl ... I4rl><"""l.(Th. f"lt (ur IIx

JUSt

bottom pan~1 b- ",OUI1I<'<I

tu a
posterboanl. set> [IN:ul, Fill. :1.1
OVERt..APPING RAII81ITS.The

pi.-," ,,(

n,-" 61('"

Involves u~inJ.tit llltl" lngC'J"Jll)< tC'.t 6t"ot llu

lid to lit onto tbe ba se, Th. lx.. 1way tu It'"
a. good fit 115to n.... semble thrR.!l ft. , .. hl,It.
unit. then eut the 101'"rr to fnrm the lid.
There's also mny t",,11I1I'1""that ",ok, ...
an overlapping rabbet JUIUI "h~"" Ihe 11<1
and base meet, see l'ij1 II.
To make lhese on rillI'!''''!: 1.hb.I~,I" II

Ix."

).,-roo\t1lattCUl-on\!. is rut on lh<tinsid(tof

tho '1'''' I"' -eo ' 1K,1in the 00)(is assembled.

""lei tho !'I(.,,~t~I..rroo\e
is cut 011 the 01ttsitieof
th" box aJ\er it's assembled, refer to Fig. :1.

MOIH (;ROOYES- ikgin by routing' a +.'wide Il1'00' e, . down fi'Om the tOP edge of
"a"h workpiece, see Fig. 5. Note: The
dl'P' h o( tho groove is important - It
should I
' close 10 balf the thickness of
Ih, O!".. k , possible,

cur

SlOES TO LENGTH.

An.er the

~roo\'(" art! routed, the sides can be cut to

I"nllth. Rtart by cutting the two workfJ1\"('_'!'Into six pieces- approximately 5"
10llN (Ssve two of the pieces to use aa test
l,,,,,e.later.) Now selthe saw blade to. 45-

.tOUR.'

tiSAlNfNOUGH

44

SlOCI (2 PlfC6l TO J
JOlt SIDESANO

rtSr"EaS
I

r
",
NOTE,
cUlw~mEca

iWRtVfNnR

NOTE: cut IOTtOM 1'ANfl1O

ROUGfolSfl!"\'t;'"

.'IJ

SIDES

TO lfNGUt
AFT.. I!OIITlNO
UBUTSAND GAOOVt

~'OODSMITH

angle to cut eros. miter>; on both ends of

each piece. (On the hexagonal box 'leI lhe
blade to 80" and cut the workpieees into 3"
lengths.)
We"'e found thul the best way to cut
miters like Ihi$ i. to u a double-em
procedure on each mitered end. Sec page
10for details.
\Vben mitering these Jlil:."~to final
length, clamp step block 10 the auxiliary
fence on the miter pUJte 80 the point-topoint measurement 011 the aide!' is llAr(2'+''' on the hexagonal box), see Fig. 6.
CUT PANEJ..STO Sl2.. After the sides
have been cut to length, dry assemble the
box with band clamps. Thencul the top and
bottom panet. to lit in the rabbets, Sneak
up on these cuts untO the panels fit snugl)'
in the rabbets, bUI don't "spring" the
mitered corners, see Fig. 7.
GLUETIlE SIDES. When the lop and bottom panels fit, the sides can be glueod
together, Use the panels to keep the sides
square. bot don't glue them in place yet. (I
followed the gluing procedure shown in the
article on page 10,)

HGUI)

-TOPPANtl
FOIGItOOV'f
_1'IAC.tMa<I
SnAGS 5&1

- CUTIOnOM RAIUT
SO 'tu' lS SUGHlty

," 1---

aecBsfO

I.
>

.--

D.UAll

, ..

10....0,.

,10""'"
......PAN"

SEPARATE IlASE AND LID

r
I

Now comes the fun part - separating the

base and lid. Before cutting intO the box, J
used a test piece to set the bit height and
renee position on the router table,
POSITlON THE FENCE. The fence is SOLto
rout a groove on the outside of the box thai
overlaps the groove already cut on the
inside of the box. '!'he overlap should be
about Y,,,-, whicb means setting (he fence
"i',," from the bit, see Fig. S.
Since these two grooves overlap, they
will form the two overlapping rabbets on
the lid and base, see Fig. 3.
ADJUST BIT BEIGH' The critical part of
this cut is adjll8ting the height of the bit so
the groove on the outside of the box is
slightly deeper than the groove ab-eady cut
on the inside. (This sets the clearance
between the two rabbets. r f the groove is
too deep the lid will be loose. If the groove
is too shallow, the lid will be tight.)
Use one of the pieces left over all.er
cutting the sides as a test piece. Set the
depth of cut until the second groove is just
a hair deeper than the finn groove. see
Detail in Fig. 8.
CUT GROOVES. When the set-up works
on the test piece cut grooves on two opposite sides of the box. see Fig, 9. (Togive you
something to hold outo, press the top and
bottom panels in place in the box.)
MAKEFILLERSTRIPS. 'lb keep the box
from collapsing when the next two grooves
are routed, cut two 61lerstrips to tit in the
grooves and tape them in place, see Fig .
10. With the strip" in place, cut the two
grooves on the remaining sides of the box.
Remove the strips. and the overlapping
rabbets on the lid and base should slide
together, see fig. 11.

\VOOOS~1ITH

l-"-i-""";J'"
,

POmo

...,

OOUU1
TQf
"",,,

GUHNG
PRocrouJlf

ONPG 10

NO~

tOUT ~'W9OE

G~""lWO
CJffIOS(T[

.,

SflAlGKT

an

SlOS

-:- ..

"SfRAfGHl SIT

AGUIte. 11

NOTe,
ROt4t&

.ox 10

ct.rrGltQOvt
ON Of'POSIfE SlOE

13

API'lY INLAY $TlIIP

An .... r.ho okIcs ""' _mb1ed.

the box is

rc..I<1\ (or tht> lilU h,n~ touches, I began by

~l'ply\nj(un Inlny .tnp 10 the top panel (See
Siwl' l\.~.~
1"'1:" 23.) This strip is rabbeted
,nto the t'Cigc o( r.ho' lop panel
RAII8.'"!: To rout th(' rabbet, adjust the
b,t hi cut hair shallower than the thickn .. of the strip, see ~'jg. 13. (The strip i.
",nd,-d Ou.h "ilh the lOp later,)
:-It,.. t ~u.
st the fence to cut a rabbet
C<jual to the width of the srrip, To prevent
thh< thin piece from sliding-into the opening

VttC.111O l'Of'
I'IUCtil'Atl
IIDIlOOWH

RGUlE- ,,-

in the (.~, Iclamped a plywood faciJlg tt,

the fence, see Fig. 12.
MITER THE STRIPS. Alter the rabbets
are eut, giue the panel into the box', lid.
Then the ends of the inlay snips are
mitered with a sharp chisel 10 fit in the
rabbets. To guide the chisel. I made a
mitering bJoek from a scrap of2~4 cut off at

a 45 angle, see Fig. 14.

Begin by mitering one end of the .trip.

Then. position the strip with the point in
one corner of the rabbet and mark the
position of the opposite point with a chisel.
see Fig. 15. Now cut this miter on the
block. Alter the strips have been mitered.
giue them into the rabbets.

fIIlAa MITlUO END

1NlO ..........

COlNEJ:

4S~MfTrRm
GlUED

IlDCI(

10......
~

I.

CIIAMffR LIDfOGfS

I chamfered the edges where the lid and

base meet. This tan be done by holding the
box together and against. the renee while
ma1;ing8 single pass over a V'i(roOve bit on
the router table. see Fig. 16.
Note: The top edge. on this box are
square. For a softer profile. the top edg<>
could be eased with.
round-over bit on
the router table.

set'

HDtDUD AND .... Y

JOO.r.'fMl1 WH4I

C'KAHIf'I~.c;

V.

Fig. 17.

'.' lOUNo.ovtll &IT

AGURl1.

MAKE TilE flLT PADS

The box has a felt liner inside and a relt pad

011 the bolWm. The trick to making the felt
fit properly is applying it 10 a posterboard
backing. see Fig. 18.
GLUE FEI.T TO POSTERBOAJID.
1)) glue
the felt, I used spray adhesive. (See
Sources. page 24.) Spray the adhesive on a
piece of (e1t large enough 10 make both the
bottom pad and the Urter Then mount it to
the posterboard, see Fig. 18.
TRACEPATTE.RNS.Now trace the bolo
torn panel on the posterboard for the bot-

CROSS SECTlON
USEIOTlCM
PANtl AS A

'rlMPUJEm
TlAUBASa ....
OUl\INE

fJ$(

INSIDE

OfIOXro
TRACI

Ot.iTUNOf
f<U~~_
~

..
HU

_,

FtIT G<OO>
IOPOmI

I'

su

....

11

"

. ...,.

fBfUNE.R

8OARO-

NOTE: ,..., .... O\fWlUl) "" _

tom pad. see Fig. IS. Then turn the box

up.id. down to trace the outline (or the

linm-.see Cross Section, t"ig. 18.
Alter the patterns are traced. cut out
the pad and the liner with an XActo knife
see Fig. 19.

MOUl
WITH

.....

.... 00

DETAil

FINAL ASSEMBLY

Alter ~ing the box. Iapplied three COOlS

of Delt Clear \Vood Fin;"b (Mro.oll. When
tbe finish "'lIS dry. I glue.. tbe bottom panel
into the box. Then I glued OK'felt insert and
pad to the bottom panel, see Fig. 20,

14

NOTE,
flU Pt\O __

DONOtSTOtt(
toN IONS IN "lOX

WOODS~UTH

Veneers

DE CURL DE BURL
I WOrkM with two different kind.>
of veneer> when making the prqj.
eets {OJ' this issue, TIw hn.f...". is
covered with pap"....backed C~xibko
veneer. The tops of th,' b\tl~deeorative boxes an" CO\'t'n."C:J with

surface, The secret to a l-'1lO<1 bond

is making sure there's enough ce
ment on both surfaces.

old-fashioned veneer, (It'. 'litT.

wrinkled, and asdr)' as an autumn
leaf.) Gluing these two t),I"''' of
veneers to a sub-ba.-..e i....~'1lnilar.
but the preparation is ditTo","\,
Ftexible veneer requires no
preparation before gluing, II'" as
_y to apply Ill> plastic lruninnw.
That'. because tne thin !a"...,r of
veneer i. laminated to a sheet of
tuugh paper, The paper keep.' the
veneer Oatand prevents splitting.
Old-fashioned veneer requil'el'
special preparation, This is because it', rarely Oat. 10 eornpound
the problem, iigun.'<Iveneers such
as burls don't have any real grain

"ill soak ul' the first coat of een-

StrllctUl'C - it 1(00$ every which

way. I call this "nervO\ls' grain, It'. under
.t;re,;o and tendo to crack under

Since figurt~1 veneer j~I)rftdominantly end grain, it's \'(''1'

absorbent. The open wood 1""'<'

tnct cement. Let this first coat

d.,)' thoroulthly. then apply Q sec-

nnelcoal.
When the see nnd coat drie s.
the surface should look glossy. If
......any (lull t;1)()t~ remain, apply
another coat.
rontnrt C.'(l'mt,~nl
ha~ to be "dry"
on both surfaces beirur joined beCore it can he used, When the
~mCI1\ no longel" rcelt>
.tick>', the ven.. r ean be applied.
To apply the veneer, lay a piece
eomaet

To nallen the dampened ven ee r. place it

pressure. 10

betw ,.. n the sheers of paper and the pieces

lessse n the chances of cracking, it should he

Oattened before 1L'I6.

of part ,."oi)llard. see Fill. 1.Then place the

bricks on top and let it sit 2-1hours.
011 lh. """"nel day, remoisten the veneer,
put in dry paper, then .'Cpla ee the bricks.
(In the third d8); change the paper. but
drm'l "",!.ten the veneer. By this time the
will btl almost Oat, but it should be
allowed tn ory thoroughly before use.

fLArnNING

The secret to Ilattening veneer is dampeninj;

it to make it flexible, then p.-...;ing it Oat.
The process takes about three days in a
simple flattening press.
DA~IPENlN(l.Dampen the veneer with
water sprayed from a hand mister, Dol,'t
soak it. Just lightly spray each side without
forming droplets. With ju.st a little moisture it's ready to go into the Oattcninj!
press.
.'LATTENING PRESS. The flat tening

press isn't fane)'. It's just two pieces or ..-

p'""tiele board or plywood ix or eight

bricks. and ,;orne absorbent paper (like
brown paper groeel'Y bags),
~INGPRSS

"e_,'

GLUING

Chung ,,",ul pieces of veneer to a sub-base

can be c1('))4'with contact cement or vellow
glue, I prefer a plywood (birch or' Baltic
bi...h) sub-base beeausse the glue sticks to it
well. If M."'>nite t, used, it should be roughenod with """,,paper to help the glue form a
stronger be,nd.
CONTACT CEMENl: ContaCI e<>ment j,
the e~iesl \\'8)'to glue \'eneer to another

NOTE:

of pape. on the top of the subbase, Then, pa~.itklnLht.veneer.

1\0" move the paper tn expose a
_.strip alon)!'one edge where the
t\"0 !'UrfAl"CScan come toget her,
\Vhen the two surfaces are joined along
on. edge, slowly slip the paper from bet'\\~een the surfaces while pressing then)
together. Then 1',,11the ven er fiat with 3
roller, st.., Fig. 2.
YELLOW GLUE. YeUow wood glut! i.safer
to use than contact eementespecially in
areas with poor ventilation. To j!luc veneer
with )'eUo'" glue, :t small press is needed,
For the .mall veneered panel on the deeorative box, I made a press with $oCl'QI}~of
particle board and C-elamp!'.
To lise the P""_', apply glue to both sides
of the sub-base and to the veneer. Then

sandwich the sub-base between two pi""e.

of waxed paper to keep the Illu. f''I)11I
.tickinl: to the press and clamp it tight.
Since no air can get to the glue. it dries
~lowly.Allow 8t lea~t 21 hlluY>before reo
mo\~jng the c1tlml)S,

""""'"

If',APU mCK$

10aM9lt_
ADOITIONIU
DftYlNG liME

DWL

ViHifJt PANEllS

\
RfMOVf STIFFPAfiIt
AS_EEl

lS lOlLED DO-WN

WOODSMITH

SANDWKHlO

arrwt:t..,

PAJrllClf IOARO
A,NOWAXED MPat

15

Briefcase
A CASE FOR THE YUPPIES
..(~r \'CW'\I I've wanted to build a wooden
bri 1<'M<l. hut one thing stood in the way: a
""11"<1 Cor tho hard w are. This problem has
1..~'1lIOlvlod by the folks ...ho put out '!'he
Woodworken;' Store catAlog - they now
Iui,c kit of the hardware (loch. hinges.

W1da liner) .. s well :IS ~ leather ~

for
brlclca.'te5. see Sources, page 24,
Note: All of the dimensions of this briefcase are based on fitting it with the liner
CromThe "'oodworkers' Store catalog. This
meiIJ1S a ease that measures U y," by l5Y,'
i,l8idc. (The liner is okay in quality. but it's
not a nice leather one. You could leave it out,
and build the case any me you want.)
10 make the case B>1llghlweightas possible, J made tbe frame out of Va"-thick stock
and the panels out of v." hardwood plywood.
(Using hardwood plywood provides a lightweight panel that's also sturdy and stable.)
There'. also another option for the panels,
rr you want 10 get a little fancier, the panels
can be <overed with veneer - which isn't as
dillicult as it might sound, The new flexible
veneers are SO eai>J'to work wilh it almost
takes ali lhe fun out of it. Those veneers
cemein sheets with a paper backing and can
I be applied to a sub-base (birch plywood
works well) ",ith eontae; cement.
VENEERED PANELS

if you want to use 1'.' hardwood plywood

(",ithout ve_r) for the panels, begin by
cutting them to a size of 121'. wide by IllY.
long. !fyou want to apply a flexible veneer to
the panels, begin by cutting the 1',"plywood
sub-bases about 18" wide by 14" long. see
Fig. 1. (These ove~
sub-base panel. are
trimmed 10 fit after the veneer is applied.)
Note: The sub-base panels for the veneer
are cut so the grain runs in the l4' direction,
sec Fig. 1. This is because veneer is nlw8,Y&
applied cross-grain (perpendicular) to the
sub-base grain.
After the sub-bases al'e cut 10 rou,gh size,
abo rot four pieces of Gexible veneer 10 lhe
same rough size. (The panels are veneered
on both sides.)
COi''TACI' CEMENT.10 mount the veneer,
apply contact eement te the sub-bases and
to the paper side or the veneer,
'Vben the cement is dry to the touch, the
veneer can be applied. Support the veneer
over the sub-base \11th several dowels, see
Fig. I. Remove the dowel on one edge and
press down the veneer with a roller. Then
eentinue to remove dowels and press the
,'eneer down ~
lhe sub-ba..<:e.
TRIM TO Slzt. Alter lhe panels are
wneered on both sides. trim them to IinIlI
dimen..<i= of 121'. wide by 161'.lonl:.

16

THI CASf FRAMI

Xext, work can

bt_'gUl on

th.

~t tit. C"'K'" 011 th~ table saw so the

the out.ine of'the blade is equal
to th, thicknc>,. of the veneered p8Il~1.
TI....n <lIt .1;''1''0\>". en both edges of all four
1''''<00;" !IN' Fig. 2. tThese grooves are JUSt
di

1..'iI.'*.

RatJlt:'J

than makin~ it lid lint) a ba.......' t"'OIl<"...,.h

pieces. tbe l4.'<'lm''Ilw h .'I\- Is to mak.- th~
ease as 01 '" wut alld th." cut th~ titl ocr

So. I.<l mal", th, .'lk'<'. cut th.- rour 'kk", 10

.ize. All (llur JlI,""'" ...,. t" thick wid "1'1".1

1'''..h.

1111(1.,

kerf -,,qual lothewidth of the saw

)11atl.

After the grooves are

to a fin:11 width .,r:~8- 'l'IIlf)nK~irl{~
t ..\. tbe
cut tl ... ponti. are rabbeted to form
top and bottom 1'".....,,) .re cut 10 " rr.,~h 1<1111.'11, 1<1fit in the grooves. I did this on
lenj,>1hof I" ru.1 U. ,11C1I'l.1~''S
CHI a.... rul
tho ruuhrt"ble.;ee Fig. 3.
to a roul.'illcngth ..f II...,.,
f 11(. :!
~'ILh~ f.nce so the width of the rabbet i.
GROO\'-ES "'0", 1).\Nt.I",,~, StoXl. 1,'11"")\1"
"Illal ttl the depth of the groove (0/, ..").
are cut on the i~lrtt.
fam flf t::lrh l)it~'t'l4' "h~1I rai se the height of the bit So the
thkkll""" IIf Ihe remaining tongue Ilu, in
hold the p"nol", 11.. trl.'k),
IJIIC.-tlllll!
the groove ...in l'Xllctl~the "gilt 1)c~11il,n. th rroeve. (It helps to sneak up On this
The distanee Inlln the .<fK( IIItho work- ''lII, le,tinl( it on a piece ofthe scrap cut off
piece to the (a:rthl'~' l..II{. clf tht gnK)~t fr..m the veneered panel. Raise the bit a
must be equal to the thick'..... IIf tl u- lilli. at 8time to get a good fit.)
veneered panel,
10 tij(. I elf tlli'
Nnw: ''>'hen the rabbets are cut on the
groove is cut too clo.,,10 lh" ... I~c. Ih, J>IUII'I
s, make S~ the face you want to
panel will stick UJ1. Anti "UK-'C th. v, n",''"'t i" .ho\l on the outside of the ease is d<mm on
$0 thin, it can't be >\andtod<1,.\\ n,)
ll,.. router table.
Il \11"F.T PANEL.

'''1'\

nr,,.

AGOIt! I

RNISHEO!)lMENSIOtIS
NOTE, GMI"''''tenON

"'-

01

SUI-P.ANlt ntl'lNoiCUlAt

I"

t----'16v.----l-1

WOODSMITH

FlGUH2

JOINING THE CASE

_-----ROUGI< I!HGTK , ..

After the panels are rabbeted, the four sides

of the case call bejoiIled. Here I u:-eelmiter
jOints that are strengthened and deeerated
with dovetail keys, (See the article starting
on page 10.)
To join the ease with thb joint, begin by
mitering one end of all four frame pieces.
Then in order to miter the opJlO"iteends w
final length, slide the panel into tt,e groove"
in one long side and one short side, see Fijl.
5. Now mark the point.<where It..> rabbeted
shoukler of the panel I'M- on the frame
pieces. see f'ig. 6. '!'hen miU'rth. end. of the

: iLl,

:l

= ".

~I

PW

i----IOUGoH

LfNGrH 14'

p"""'...... --

..L.....

pieces at these marks.

Shop Note: When mitering II",,,,, end

attach a fence to the miter gauge and clamp

on a stop block. AdjU$t the stop so the cut io.
made right on the mark on the long pll-eee.
Then miter bot" lung pieces at the NUll~
setting. Move the stop block and miter th~
short pieces to length.
ASSEMBLY. Afte,' all four piee es are
mitered W length, the ease can be assembled. Apply glue to both mitered ends and
the grooves for the panels. Then slide the
panels in place and clamp lhe ease together
with band clamps.

AGUItE 6
LAY OUT 45 MIfU uPftS
fROM PENCil MAlKUSI:NG

DOVETAIL KEY JOINTS

COMIINAI>ON
_M'

When the glue is dry, the dovetail slots can

be cut on the comers ofthe case. Icut three
slots with a %" dovetail bit using the layout
shown in Figure 7. (Note: YO or 0/," dovetail
bits can also be U$Od. but use the same
spacing to the center of the bit as shown in
~Iig.7.)
DOVE'l'AD. SLOTS. To CUt the slots. URe
the jig shown on page 9 to hold the case on
the router table. Set the height of the
_7
dovetail bit to 0/." and position the jig 'h"
from the center of the bit, ,... Fig. 8.
(Note: By setting the bit '1'." high, il \\~II
produce slots YI" deep as measured on the
side of the case, see Fig. 7.)
Now rout dovetail slots on all four corne r softhe CMC. Then turn the case around
(so the other side is against the jig) nd
rout four more slots.
The middle SlOI is routed off-center l<J.
ward the bottom of the <"-"C. This is be,
cause when the box is cut apart to form the
lid, there will be an y" kerf removed. To
allow for this kerf, the middle slot i. shifted
\4>"lowardthe bottom of the ease - which
means it's centered 1%" from the bottom.
see Fig. 7. This way, after the kerf is cut,
the dO"elai! keys will be evenly spaced.
DOVETAU. KEYs. After all three slots are
routed on each comer. dovetail keys arc
cut W fil in the slots. (See the article on
page 10.) Glue the dovetail keys in the
slots, trim them off. and sand them flush
with the sides of the case.
ROUNDEIlCES. Finally, round-over the
mitered corners and all edges with a
round-over bit, see Fig. 9.

_.

ROO ...

,.

,-;.L-_--.Jt......_~........
"_l

UOPANEt
CROSS

StcTlOti
BOTTOMPANfl

Y'

WOODS~l1TH

17

AGtnitt2

CUTOFF LID

:<;ow the cuts can be made to separate the lid

from the base But before making !.hese
cuts, fm;1 make IWO 'l"<hnped spacers, see
Fig. 11, (Thes.c spacers ,u-e used to prevent
the lid from collapsin~on !.heb.ase M the final

---1tAD(

cuts are made.)

Th make the spacers, eut rabbets em two
edges of a piece of scrap (about 12"long by 2"
wide), A(lju.st the size of these rabbets to
1eA\'"a tongue equal to the width of !.heke,-f

ssr JUST

HlGHEaJKAN
lHQNUS Of f1tAMI

..'.~-/,~--

-SAW KIItf

__

made by the saw bL~dp.Then him off the

edge ofthis piece and tulil in halrto produce

two T-shaped Spac(>l'b

OUT 0'-.' I.ID. Now bet up the AAWby

-M.

raising the blade high pnough to cut

!.hrouW>the thickness of one side of the
ClI.'c,..ce Fig. 10. Then adjust the fence so
lh,' eut is made 1
from the renee.
1\ll'tll otI Ihe lid. make a cut on one end
"f Ih,' e4!1<'. Then rotate the ease 180' and
,n.,k. IIJIOthercut (In the opposite end .
wpe Ihe T~h8ped ~pacel'''in these
l "II cul~ArMlmake the final two cut." on the
"'mammg .id~. 0.'<1 Fig. L2.

y,.

ftGUltt 11

-.

.'I,,"

MOUNT THl HINGES

N,," the 1i,1und base are ready for all the

hard Will"" Fil"l. moem hinges tojC)inthe lid
.,,~I 1_. Th,,>,In' two z- brass hinges
n.,rt'!I<.1 into the ,odll'''' of the lid and bas".
",. FI~.1:1 I tilt lhemort~for!.hehinges
Clll th .. rout('T t"abtl.
HINGh MOMflHES. ~t"UJII a yo~traight

RGUltfI<

MASUUIO

AGOt"5

INSIDE Of 81T

...

.'Of'"

MfASU.E 1'0
OUTSIOE

' ..

51~GHt

&II

AGVI! '7

""_I

18

hil n,.1 .<'( .t 10 height equal to half the

thll'kn. 'of lh, knuckle ufthe hinge. Then
.<-1 tit ..
2" from the i>l6ide of the bit
c",, hK 11l.n"drnakcatlltatbothendsof
II .. lid :m,1 thv ba-e, 1<00 Fig. 15.
I{,",'t th( (elK'(,'::'() it's.J'" from the outsid
~.ftht, hJt (t,c. make a 2"' ..wide mortise), ~""C
n~I C. Then make another set Qf cuts and
('I, :tn l.Itlllhe waste between the euts.
'I10UI\'T ItlNGES, Mounting these hinges
.,ItHk u'ic!Q: 1 had some trouble getting
Ih<hi nil"" lined up so the lid was perfectly
.hj!ll,-d with the base (when it was closed.)
()Ilt '\a~, to (10 it is to mount the center
O<'n'l\ in the leaf that attache. to tbe base.
Th"11 mount "locator pins' in the outside
I"" holes of the other leaf (that mounts to
till' lidl. (Locator pins are described in

f."o<

U'"",IHlllilh No, 42. pagt'8,1

\\'i!.h the locator pins mounted, hold the

lid in position over the base and press down
so !.hepins mark the location of the screws in
lhe hinge mortise in the lid, Then mount
these screws. This should help alij!ll the lid
and base, And continue by mounting the rest
"fthe screws.
If the lid Is off a tittle from ulij!lling with
the base, fiddlo with the hinges to Il"t the
alignment as close .. s, possible. Then clamp
the case closed and plane the sides so the lid
and base aliJ:n.
BRASS FEET. After the hinges are
mounted. drill four hole> for the screws

WOODSMlTH

used to mount the brass feet, see I"ljt. 1!3LlDSI1PPQRT. N~xt,lhe lid supports are
mounted in.ide the ease. Drill pilot holes
for the supports as shown ill Fig. 17. Then
screw the lid sUPI'OI'l.>'
ill place,

fIGWI

lOCk MORTISEPOSmON

LOCK AND HANDLE

The hardware ldtal",conuul1s two eombinalion locks that are morused into lhe base.
(While mortising in th,'lock., Inomo\'t'<) tIM?
hinges, feet and supports Cromthe ether end
of the case.)
~IORTISE, The mertises ror the locks an'
y..0 wide by 2"10119:and .n' 1"e"t,'tI MI"Crum
the top edge oftheba.-e, R'< f'R. IK To cut
the mortises. mark their location' 8nd drill
out the waste with a ~"4"Ferstner bit. see
Fig. 19. (Since the mortl_ go all th...way
through the sides , <lamp on a backin)!l.i"" ..
to prevent chip-out.) Then use a ""if",1 to
P""" the ~ide,of the mortise square, "''(.
Fig. 20.
Now, slide the lock into the mortise and
mark the location of the four holes in th,'
corners. Then drill V," holes through the
ease sides for the brass posts, see }'-"ig. 21.
(These brass posts are pins that are split at
the end and work something like couer
pins.)
MOUNT CATCH. Before mounting the
lock, the catch must be positioned. Remount the hinges and place the lock in the
mortise (with the posts in place, but not
spread) and close the lid,
Then insert the catch into the lock, and
mark the location of the two brass posts
that hold lhe catch to the lid, see rig, 22,
Remove the catch and drill II.' holes for the
brass posts.
llANDLE. There's one mere set orholes to
drill [or the handle. Locate the bra ss
swivel plates on (he handle so they're
centered on the width and height of the
ease twith the lid closed), see Cross Secdcn
in Fig. 21. Then drill pilot holes ror the
screws u...>d to mount the handle,
."INISH Tin: CAS." Before the final
mounting of all this hardware, sand the
ease and al)ply the finish. (I used Sutherland Welles Polymerized Tung Oil, see
Sources, page 24,) Let the finish dry thor
oughly before mounting the liner,
INSTALLHAROWA'RE,\Vhcn the finish is
dry, remount the hinges. the brass feet. the
lid support, and the handle to the case.
Then secure the locks and catches with the

brass

~I"

=:j

lOCI<

/
F<>tO_fOWI1
IN1OPADTO
,1t01'ta SUltFACE

CRQSS SfCIIQtj

CHTfI HANOU

,,'

ONLlNGfHOfJUK

POSts.

fIItor

To do this, insert the posts and use

screwdriver to spread the split end. Then
use a C"'L~mpto tighten the ends down,
see Fig. 2!l, (Fold up a pieee of paper towel

and place it on the head or the post so it

lI_n't Rt't scratched by tIM? C..,lamp,)
INSTALLUNR. The last stepis to install
the Uner, ~Q."ten the line,.', panels inside
the case with doublesided carpet tape, see
Fig. 24. Then tack the end OI\j)Sto the sides
or the case with small brass brads.
WOODSM1TH

HOu:

CAi!KT1Ali

19

Tools of the Trade

DADO BLADES
I'm nola Kkcptical PCI'S<ln. Since 1 assume a
tool
t\q the job it's Intended to do. I'm
1"1'rit<cd when it doesn't. Before blaming

ally. all of these components

",II

U,, "",I I ask myself t'WIl questions: Am I

'L<inl( it properly? Am Iexpecting too much
rr..m It! For the past four month. ('\'(' been
.IL<;,kingthese questions over and over
,bIdo blades.

about

~I:;eoneern \\~th the performance of

,ubocriber. He expressed hi. di&....arisfaclion with the Sears It'rWOlh ruijustable
,Iado blade. He had purcha.'l(>(1the dado
blade and found that the bottoms oCthe

bo,tto,m of the groove t1at.

\I'I>'t stack sets come with five chippers;
rour l\J't' v." thick and one is v.." thick. The

grooves it all ",(U'('.n'l square with the

.ut-.;. Sears happily exchanged the dado
blade with another. assuming the fin;t
blade might be faulty. The sccollli dado
blade produced the same angled groove

meet my expeetatiens,
HOW '10 JUDGE A DADO BLADE

Judging a ne"" dado blade seems easy

elll)Ugh.Just take it out ofthc box and make

a fCIt cuts aoross the grain (ndado) and \\ith
the)!nlin (a groove) ina=pofwood.
Then.
may"," try it on a piece of plywood. If it
phnte"". it'. 00 goOri. If the cut 1001<.<
smoot.h. the dado blade is perfonning prop.l'll\ \VoU.there's more to it than t.hat.
'TKK DAllQ BLADE'S JOB. The dado blade
,lIould cut a wide kerf with dean edges, a
Oat boUom, and the corners where the
bottom mt"ta the .ides should be sharp
and "<1u~. It .hould abo make II partial
cut on t.he edge of 3 boa.'d to make a rabbet
or tonl(Ue. It should be able to make mult.ipie pas._ 8Cl't1!1S the Volin on the end of a
board to form a tenon. And. it should be

20

Th~y look like small circular saw blades.

Tll& CIJIPPR$. The chippers are twotoothed blades that fil between the cutt"'~.The chippers control the width of the
Ill'(IOVe,remove lbe waste, and plane the

,bIdo blades beglu. with a letter from a

bottmns.
Before jumping to conclusions. we bought
similar dado blade from Sears. It had the
same problem. SO I had to conclude there
"11$ a b3.<ieproblem with these blades.
About this same time we were buJldinp:
the box joint project.> for !:,sue.J2. Another
problem with dado blades cropped up. The
bottoms of the notches for the box joints
were unacceptable when cut by most of the
dado blades we have in the shop. We.mtched to the router table to make the small box
joints. But this wasn't an alternative for the
\argel- join!:> 011 the cabinet because of the
amoum of waste thaL had to be removed in
one pass, So we used dano blane and
cleaned up the groove bottoms by hand.
That was the last straw, Instead of
,"""",bing [or more alternatives for mAking
grooves. I asked myself what I reall)' expected of a dado blade. Then I wanted to
know why tbe dado blade Oi() ofien failed to

5t into two

categories - a pair of outside eutters ant! a

collection of chippers,
TH CU1"I'RS.The euuers are the precision components of the stack dado set.
Their job is to define the edges and make
the straight, viical side. on the grooves

'\ldlh "rth~ groove being-cut is controlled

by til<' number of chippers added to the

"lack.~in~ eachof the cutters cuts a YI!"

j!T'1"".~,tht .t"ok oct can cut grooves from

,-to' , \\'lrl~in

'1(1"

increments.

STEll STACK SETS

\\,I,-I .. II",th hi!lh-.pood steel and carbide-

"1'1"'" ."""k .. u<, evalu.1ting two different

able Iu cUI through t.ho ,,.1 of. b"",,1 tn

Inakl"a notch rl'r box jeint ....,
t:VAI.UAl'l"(;CIUAI.ITY In "v3Iu"lilll: Ih,'
qualit~ of a dildo bllttlc"I"rfonnant't 10

"n

o[t.h,,,,, applieation, thtI!TOO'~be,lwm ..

equally (or morv) imr.II~1II\1than th,' t""

edge.'. So I""kat the buttam nr>t. It ~hould
be Oat and .qw.r, \\,tlt th,' >id,,,,. Th"11look
at the~"
lh"y should be .harp \\lth no
splintering. (Mak, thi. ,,,t aero:.., Ih,

I,rrain "'here It'unnf:,! hs ntf.toIl likt'ly to oeeur

Even the lower quality bl1d,.. 1,.,"
edge. when PloughinR with th. grain.l

,tw,.

A VARIETY OF DADO BlAD(S

t),I>11within l'tlch "1Wj(OlJ'

:-:01<'. 1'""", quoted in this article arc
."~
11 nlail. M,,"t.d,tdo sets go on sale
fn:~fnlim,' tel time, S(_>(' SouJ"eeS, page 24.
II .\T Sf ..xt, ~tm! Vial .teel stack sets
lin' t.h"II'lt""ftt"n.he. The Sears 8" set (9

liT 3'~175)j. t.ypical n(thi~ type, we Detail

I 11'8priced 3\ S:~1.99in the Sears 1985.'

II""; ('"W(t Md Hand Thol Catalog.

Th. cUIl~'" on this Sears set have a
'1"IJ,l(> tooth eenfignration that consists of
fi,, cutting teeth, a deep gullet. then a
.-. kt-r tooth to remove lb. sawdust,
Th, cuulng teeth arc ground and ,..t in
J(rrmp.< of five. That is. 1\". teeth are
\),",Iec! and set (bent) in onc direction,
Thi group is followed by an unset raker

to<.11Iwith a nat top. Then the next group

"!'here are two basic t)'J.M.~01 dtul(~l"'I:"h."S- "f fiv~ cutting teeth is beveled nn<lset in
the stack set IIlIdthe wljw.t.lbl. elMo bble. the op~it.e direction.
Thc purpose ofalternating the bevel and
Both type., pe.fonn the
thl'C( 1'11'1 Job.
That is, to cut. gl'OO"C lb,' d...\,J blu,I,mIL.t ..,t of groups of t.eelh is to provide clearpare the sides ImlOOthand
th. l'<1~
...'" Mt" bel ween the sides oC the groove being
clean. It mu.:,t. JlblIlC the bull....., Oat 8l~1 CUl and the blade plate. There's a negative
square to the groove "d"", And. il h"" t.(1 .eet. though. Because the poinL.. of the
cutting teeth extend beyond the path onhe
remove lbe W8.,te from lhl- groo"" It""I(.
'Ve saw no purpose in Irying to teI<t ."'1")' points ofth. raker teeth. the conler oCthe
dado blade on the market - thCl'l'" 100 groove bottom i.nol sharp and squnre, see
much overlap \\;thin the bm;ir t)ope;<. So we o"Laiis IAand lB.
The Sears 8" Oat stack sel lell. a groove
selected some re'.dily availabl. models. that
\\'c're already familiar with in our..hop. \\'e bottom that was unacceptable at the corDer$. And it tended to tcar the grain on the
checked out the .tack seto tir&.
edges. The problem ~th the edges c'Ould
STACK DADO SETS
be corrected with sharpening. But. the
A $tack dado gets its name becaUJ;C a ,;et. problem with the corners of the bottom is a
eon.';"<t6ofsl, "rscvcn individual pieces that. design Oa\\' - it could be Je5!;eJled. but. not
are stacked togcthcron the sa\\' arbor. Actl.. eliminated. \Vhile this sel might be attrac-

""'1('

k-,,,','

WOODSM111i

tive because it's so inexpensive, it's really

only suitable (or framing and construction,
not Cor <abinel-qualily joinery.
HOLI,.OW-GROUNUSTt;EJ. sers, Another

an alternate top bevel, The Sears has a

raker tooth between the beveled teeth: the
Oldham does not.
The teeth on both sets have a steep hook
angle like a rip blade. This Sleep hook angle
helps pull th,' workplct~into the blade and
down apinsl the sa" table. lt Ceed.smoothly. And. burning isn't a problem
with either of'thesc dado set a.
Both the Oldham and the Scars perform
better than the steel sets, but there is a
marked ditTerence between them. The Oklham.hea..,.thewondfibe.",cleanlywithout
learingthe edges on cross-grain cuts, BUI.
because there's no raker tooth to clean UI>
between the bevel leeth. a tiny ridge "' left
in the bottom n.rar each comer. see Details,
3'\ and 3B. While this tiny ,;dge doesn't

Sears dado, the tr 'Smooth-cut" (9 HT

3:!53~4.99J. I, rel'""vnt3liY, u( hollow~ound dado,'" ,ee netail 2. Hollowground .'('1 >('1.- gel their IUI_ lx_use
the cutter. plate rim i. ground !\O il'.
thin",'r w"sru the plat. '~'Il\('r. Thl, Nliof
allow,. the teeth ttl be !!Tuuml",thout any
SCl and (in theory) leav ... 1,.,."...", beOBSERVATIONS
tWeen the plate and lhe ,I~. oflhe J.,'l'U'Jve,
The CUll.."" on a hollow ground. tl'k <<-I
Aftl!l' pUlting the stack .Iano sets through
cut smoother ann cleaner than the cutters
their pares. [ made several observations
on a fiat set, And. becau .. ' I he h",th a.....
that would iniluenee my buying decisions.
unset and have a fiatt"I). the <OrI ... r ....h,rc
srset, V8. CARBIDE. The .tccl.tack sets
the groove side and bouem meet '" "4uart'
don't perform as well as the carbide-tipped
and sharp. BUI, while this r----------":---.."-:=,.,--.....,===---.....,,,.-:,,,,---,
sets. The problem isn't
set euts smoolhel" than the
2 ::
3 ~1t
4
matter or ~harpn(!~ (~teel
nat set. it has two distinct
can be made sharper than
problems.
CU1'TER 8IAI)
carbide - it just doesn't
The first problem is it
TOOI'M DESIGN
hold an edge as long).
burns badly, especially
let
The problem seems 10 he
when ploughing with the
,II
design. The steel btades are
grain in dense woods [ike
economy tools, They've
cherry and maple. This
'/.....WIDE~OO\l
I
I
1
been designed with the

l'::TH

~7~~".:"
~ryrru;s;::~ c;'.:'.;t.

The gullets between the

teeth fill with sawdust, The
accumulated sawdust in-

creases

fric-tion,

which

....
-WtDE,~OOVE
v

me ~...

I
1,
Y' _;;

.~

'1

wood,
The second problem becomes apparent
when the two cutters are used without
chippers to CUl a Il." groove. Because
there's. space between the euuers.n small
sliver of wood is left [n the bottom o( the
groove.see Detail2A. Thl$ sliver has to be
removed either with a chise 1 or by making
another flll$.
Sharpening the hoUow'g1'Ouudstack SCI
does tittle to improve its performance. Its
teeth oontinue to fill, ." burning .-email.. a
problem. And the sliver left in the groove
bottom bec-omes,,;dcr each lime the dado
set is sharpened.
Although hollow.grinding improves the
pel-formance of regular saw blades (and
gives them a higher quality image). in the
case o( darlo sets hollowgrinding is aClual
Iy detriment.
The price jump from ~teel to carbid.,..tipped
<t.'lCkdado scts is a big one. But. ,;0 i. the
improvement in performance.
CONVENTIONAl. CARI)I.o&.TlPPED SETS.

The 6' Oldham (f,oo.CCD.$119.00) and the

S" Sear. (9 HT 3264 ~.99) are typical
repre..<entative.. of t'Onventional carbide
lipped .tack ""I~. The rotte'''' on both set.
are ';milar to carbide-tipped combination
blad~$,>1lC Detail ~. Th. tutters on the
Oldham set have 11>teeth: there are 22 011
the Sears culters. The teeth on both h"'e
WOODSMlTIi

. _~

~!~~[:!~~
not the end

~_~n
_n ~

t1----=.Q
-_.

'A

--_

..

18 --

2'8

makes the blade bum the

CARBIDETlPPED STACK sns

tracts from the smoothness of the bottom.

On th c premium blade~ there's just A
score line on the outer ed~e er each groove.
With a correctly sharpened set. this results in a very nat bottom.
The Freud and Dell' sets wit h the single-angle grind produce ,-er y clean
groo, -es, Both fulfill all dado application s,
including rabbets. tenons, and box join",.
Since they're priced about the same. it's
hard to give the nod to one 0" the other.

errec t Ih,' quality oCdadoes. groove s, rabbets, .ut( tenous, it would rt'SUll in lessthan 'Ik'n,"'t bo" joints.
The );"""" blade's performance is sort of
a 1(0<.1now. bad nt'wsstory. It makes very
~\Uln.gr.H"'lbouems, but tears the wood
fiben- ""dly Oil cross-grain cuts. Both of
these ImIt. re.. ult from inoolTCCt.harpen
inlt. Th" mkcr (t..ll>are exactly the .. me
len~>ttt," Ih(' ""'vel leeth. If the blade"
were ,;harpened ".jth the rakers honed
slightly lo"('r than the be"el teeth. th.
tearout w,.old .-IQJl.
PRE'''l'! CARIltD.TlPPIill St.'Ts. One
slep up art the industriaJ-quality dado
",t,. "'''' J)H2i1 .1. The 6 Fl'('ud (D53oo
SI41;.~1and th~ 6" Delta (35550'$165.00)
are repl"'l'~nl"ljve of this category.
On both sets the CUllers are unique they hav~ rightllnd left .ides. The teeth on
one ruthr.I'\: all ground at one an)tle and
the t<'t?thon th~ olh ..r cutt"r are ground 3t
the Ol'posit" angle.
Thl' point of ca"h It>!ithis actually .eoring the ,,000, '1'(' Detalhi..:.!.A
and 4B. The
srore line '" ju.t a hair deeper than lhe full
"epttt o( the rak('r tooth and the chipp"n..
Thu.line kw"" the .'(!ge of the groo"e clean
by pre"t'nting lhe wood fibers from tearing
out J)a"tth(' line a, they're removed by lhe
raker:, and lhe .ttipper-,;.
Thi. _ring action i. charactelistic of
tutU>ts with a1Lernate bevel leeth. too.
BUl, the inner $Core mark they le""e de

SUARPeNING. As (or the

carbide-upped sets, proper

sharpcning is the keytc the

set's performance. Out.-,i.)f

lhe box performance problem. all could be traced back to e"""Il'SS

_

factory.harpening.
Careful sharpening mean!'. more than
getting the carbide tips sharp. It means
gelting the tip, uniform and making sure
the relationship of the Leeth is correct.
The correct relauonship mean. the raker teeth and the chipper teeth are exactly
th. ""m.length. Th. be"el teeth should be
jUl!! a hair longer. A <'lU"bidetippcd.tack
dado sharpened to thc>respecifications will
perform all of it.,jobs well.
SIZE. One of the other oonsidcraUon. in
buying a dado :>et i" size. Dado >eLS are
generall~' available in 6", 7 and 8" diame
tOTh. t. bigger better? I donllhinktio.
To begin "~th, the 6"dado blade "ill cut a
H:deep g1'OOveon the Sc<u" table ,ow.
Thi;; l, mol'(' than adequate for any projecl
imaginable.
Considering that and the fart Ihnlthe6"
dado ~lS cost les.~.\,'e see no sense in
buying an If dado set.
CONCLUSIONS

So. which set is best'! The Oldham set is

l(OO<I value. II 0061.5con:;iderably 1_ than
the premium set", yet perform. all functions
adequately cxrept for making box joinU;.
BUIfor all'around use, it's hard to beat the
Freud or Delta. Both peliorm \'et)' well out
ofth.. bo~. Their plic'CSare high - bUIboth
are often hea\;ly di!<oounled.They should
perform excellently for a Ufetime.

21

AOJU5TAall DADO BLADES

A" uht-rnall\. 1'1th,' Mack,.,t is the n<ljust.

Ihlt 1!;Wlololwll It loa> a lot of a appeal

he'<1lI

-muk tool, rather than a

It..

'I,

<Olil-dion ..( "'ml)Onen~, It can IX' adju.ted

t" nit ,I(1't1O\t" lrom
"ide to C)',,' wide
" til !"fin"e adjustments within this range.
.\nd tht.... "'lju.'<tmllntscall be made without
n'n." jill: the dado blade from the saw;
11<.
.. the adjustable dado blade measure
"1'10 tbese claims? 'Ve have live models and
'Olr l"oclu,';()n L' "yell, hUI , .- The "but-ill

of the gl'OOvecan\ be improved.

The groove bottom cut by an .dju.<tabl"
dado j_, gen(-r:tlly ""'ooth. Ane! th e mon'
teeth it has, the smoother the bottom. This
is b<'C81lS<' each toolh cleans up th~ ('<lu''''of
the path cut by tit" adjacent teeth.
This smooth groove bottom k'a\t, the
impressionthat tho! dadois perfonnilljl better than it "':tUy ;_, What', "'"010 roo",
important is the bottom profil.,
THE IOnoM

flallen.a coneave bottom. it's almost impossible to keep the groove depth uniform on
both sides,
DOUBLE-CONCAVE, Tb~ Sears -Ex
calibur" lelt a doubleconca,! bouom profile. This is because both of the blades are
sharpened like saw blades, so side-by-side
ares are lell behind,
\\'e fclt the double-coneave bottom Was
the most difficlllt prom. to Ilatten.

PROFILf

PROPER SH~RPlNING

The bottom l'roiile <U1 hy om:ltlju tnbh'dado To pruperly sharpen an adju,;table dado. as
th;lt it doe"ll\ produce a Ji.rsst-rate groove.
blade is ,..0-;,1)' Oal. l'.'WII1y, Il'~ 1<1'111,..1. much (or more) auention must be paid to
MODELSTESTED. OM of the fi\'e models concave, or 0011'<". The,,", prom ... "..wt
j!('()me~' as to edge sharpness,
we have is the dado blade ""uu,
"".,..,
FACTORY SUARJ'ENING.
that generated this a''liele
~,
Poor factory sharpening
- the IS-tooth Sears (!i HT
'~4\'>
was the cause of all the
:1263c$34.99).Three olhe r:;
MIlAI>E
problems we experienced
are the Delta l2-tooth "Mi lACH
OOUNOT woa."
w it h a dj u$lable dado
TOOlM FClUOWS
ere-Set" (34959/$3G.10),
n'OWNI'AlH
blades. The quality of the
the Acu-Edgt>8-toolh Jlhl_
'. G.oovE
cut is almest totally depenCIlI" ($49,951, and the S"
AU''(1"0l10III<010
dent on the attention the
Freud 2~-tooth (AD800
IOUAlW<G'H'IOMClHn.
blade get. on the sharpen$62.90), The firth dado
ing machine. To prove this
blnd( is one we just 1(01in:
-,
to myself. I had our poorest
the Sears "Excalibur" (9
performer - the 16-tooth
HT321081$99,991,
NOfE,,nmOf
::;ear. blade - custom
WHAT DO THEY LOOK lOOlHONIACH_
-harpened.
UK~'?All of these adjustCUSTOM SHARPENING.
able or "wobble" dado
'Y,OROOVE
GROOv{ \\'hl'n I took the Scars 16blades IO(lklike ~ carbidetooth adjust.ble dado blade

~':="'~

tipped

S3V.

blade that's

mounted to a thick hub. L

,,'!utt make. them unique b that the hub
can be turned .0 the blade tilt. at an angle
to the arbor. Adju.LiIlI( this nn!!le ,-arie"
the v.idlh of the groove cut.
HOW DO TH . V \\10RK1 You can go

__J

'!~~'Z~':'-'
_:_.:..:.__:_

!h,m thl' )..~~.. -try oflh" r{;.I" hl"de .... 1 hy

the way it'- l<hal'('llL.I,
AS(.Lf;U 1101'0'1_

n,~

s"ur.; I,;'l<.,th

adju,;t.'hl" blad(, 1'".lu(' ..",,,,, anl(l<'1 hot

torn. 'rhl~

IJ'

th~ t.<.,th "" 1111.' ""I" or th, "lad" an>

ground lon~er l""n II", ol'I.""t. t'11>,'UI

works . But the secret is that it doesn't

ling the utllt'r side urtht

realty wobble,

)!1'tJO\

e,

It"'' ,,,,

I ,,'uti

""M,,,.

i$ thi~: The blade i~ Hdjustabl., dado

1",,,., "
mounted between two lUll:led disk$ that j(I'oo,'c bouom, ..... F'Il, ~
arc paI'l of the hub, The&' disk;, lUt the
The conca'~ -lu'I" l'\",,,lIs (rum _ 1"",,
blnde 80 each tooth is sJufted out from the blutllt ~h"'1~'nl,.llik,' a j!8" bInd,. Th,.t to,
\'ertical axis. Although it appem,; to \\'ob- th>dh-tanc(: fnlm tht I,.,nttr
teJ tIn' lil't' I~
1>1",in reality each tooth stays B $peclfic the ... me on 81tl<'cth, 'Vb"II" bl.d. ,"III
di:,t.nnce OUl from the axis a.,_, it I",()t.at.e~ ('(IUlll-Jellgth tecth i..IIn~'h'(ltn Ilr,,,,lut.,(, ,I
arQund the arbor. >leurill, I.
\\,id.,' cut, the gr'OO' ~ ho,U"", ",.11 MH' "
Note: The Sear.!"Excalibur" is unique in cur"e that'. the same IU,\,'" lhe lila".'
that it has two 2-1-toolh blades, The blades
PLAT HOTl'OM The ,\<11-ErI~..t ..d ..
are mounted on a ~inglc hub at opposite blade mak,,~" natbottom,,1 j!1'OO\-~ lI' th,
angle, to thearboJ. iJ, "fft-<:t, it's two dado oy.' $('lling, """ Fig, a. A t1atl...ttolU <un bo_,
bl:odcs l'\Inning on the same arbor,
produced at a "P"'ifi, ....dlll If th., <1:<d
..
QU~llTYOF THECUT
blade is 'P' dallu ~und_ !.lut!hc, bouom
NQ m"tt~r

h<Jw it wurK>-, the quality tlf the

eul is still the ptimary concern. The side

wall. of a groove cut by an a<ljustable dado
l,lmll' ;O'\~\trtlC'.t1. I)Ul lhl' ed~ aren't a.\;.
d~an .. those <-ut by " .wok set. This is 8
I"(",-ullof ~ach tooth havmg ita own path.
g""h tim" lh~ d;IClobblde re,"I.es, the
OUI<!nno,ttooth 011each !<ideis the tlnly one
<!Uttin!(th"L~lgeufthe
So. no matter
how mllny teeth the daoo blade II"", the edgt

grtJ().".

22

w""I<II,,,,\'., II ant bottom at "".

(1 could

.I"I! "lIh th~ eemer "dge that would be

An. r .harpt'nillll,

CONCAVERO'FIU\l,Th.lkol",anoi

'Vhat happen,

,I

,.n

the "'~lalll)( ('4trt."1",

...~ f.."Iilu.lln~ I~I\nt nam)\\.\'r "-Ullul~.)

to figure out how a wobble dado blade

through a lot of mental gymnastics t"ying

l~' uur local sbarpening

$hnl', I explained that it

""' 1t'll\'UW
Imilled bouom, Then I
u.-k.. III,1' ,h"'1 ..',wr tOI'l'gnnd the blade 80
.J

",11 be Ilat nnl)' at that ",'t!l1lg TIn. IS

be<'ausethe'p<.'Cjalgrindin~ 1<'8.'''' the( ....th
10n!(eSlon the teeth in thp out~r palh,
CONVEX BOTTOM "'hon tht ..h'llgdg.
clado blade i.adju.ted to mok. a naml\\"'r
groov~,aeon"ex (ridged) bottom .o,'\Ilt._.
The eonvex bottom is le~ ObJt->('"lit)n.ablc
than the conca,'~ botttlnl. It', easy tu Oatten \\;Ih a chisel. Basically, what y~u'r.

doing i.planing duwn Ute center ridge to

lhe depth at the e<>mers,'Vhen trying to

cut

or

"n..t

the Sean; dado blade

bottomed jrt'OOveat 'Yo". The CO~t

re:-har] Jt:'nlD{! was $22.00.
THE fiNAl CHOICE

'n~,,\<-u,Ed!(e adjustable

dado is the only

11I<.1tI tl"""" that perfonlle'" properly light

o<,t (If the blll(. Thl.<is be<'au,*,the ,nanuf.1Co
IU1'<'r undel'"tands sharpening geomelr),
(Th,y ('\"en include detailed sharpening inu-uctiUIl8 ,,;th the blade,)

Based on (lllJ' e,,-perienoo, I prefer the

A('II,Edge of ali the adjustable dado bl.d ....
Hut, any of the other blades will perform us
wdllll\er _tom .ttarpenillg.
Caution: \Ve f.. l the Freud 8" AD800 is
lIot safe for use on table saws. This is
bc'C3lL"C the hub is too thick to allow the nut
to be runy threaded on the arbor shalt,
ADoIUS1'AOt..E
VS,S1'ACKSE'C "'hen mak
ing the thoioo between aclju$table dadoes
and c:urbide-tippel! .tack sets, I prefer
.tack sets. They cllt smoother edges lhan
adjustable sets, And by placing cardboard
spaoerslX'lween the chippers, it's not hard
to finetune the groOve \\idth.
I'm willing to pay more for a tool tMt
produces the quality 1 expect - and ",ill
probably outlasl me.
WOODS~lITH

___

S_h_opNotes
C~ITt~(. rH. ,TR.P" On..., th e

lHINWOOD

in.....,rt 15

in pl3,lhe

V.

All of the proj('cl,. in Iht, i~_ use thin stock

- ~". ." and even
thick. Although ~:.
thick stock h ."metim;, available at hard
wood lumber ya,,". anything thinner than
that i.< difficult to flnd 'otTthe shelf,"
Th~""Iution i. III "IR"e it down yourself.

.nlaYl can be cut on tbe edge uf

Up''''' IIf II( '.'1' with a tine-tooth"" blade. I

CUTnNG
WIDtH

nf tho \\'OJ~\since it penetrates ~ far

dew n al,,1 eontain
hi""h percentage of
"0'14'

11-.- "If((

1',.\1''''" IJACK}:: v t:.NJ-;.t;H.One solution is

to U:-:.t R '''',)I'r hackt(1Ilexible veneer since

thl'

It', [(".Han

eve ~

aIIlhe

WA)

the I l-a:).
On!iJIWI pl''<'I.'8.I', "orth makinj1a simp ...
jig to guld. th, IIL,r,eto the proper th",k
Ill...
s. Jll"it rota pi"Ce of plywood as a bar-e
and I,lar~ the rvsawn workpiece on thl'

.,:r \\.-

\_

"
'7

THICKNESS

over the guide >11;1". AI; the planing progI'I'''''{''. d. n<>1 plAll\' the bl.ripol. They will
st0l' Ihll phm.whcn th~ workpiece is planed
down to th.ir thlcknlljl
CUllING INLAYSTRIPS

OIL ON VENEER?

The pl'u.:.:dul'\' I u..... for making thin (~'.

thick b)'
Ie) Inlay otoipo; i., ,-imilar to
the metfuwls "t'" C prt"\;ou..I~ ~ho""'ll(or
cutting .mall .trips. aut there ;. 0"" dill'e".
onee - t~ inla) 'trip" are ,; T'JI narro"
and thin. They're the kind of piereHhat MJI

\\'. re(t!nlly ",,,,I\,,IIIl'll1l from a .ub>rcribtr

Nowjust "Iun.thl' workpiece down, angling the pl.~ .Iightly i'O the heel and toe are

III the >II"", in.,ert plale.

ha,~to dit:' tluwctt the """Uuot
WId .. tOO "",. to ftnd the lIInJ'S.
., .... Hl "I..AII: .toe v.--a) to _...())\e the
prob)"m 10 make "ood.n Ill!ert ",th a

down

And

O('('

pi"".

V."..

Into tOO &lot

)00

<maU bind 01.1 So

1\,.. ",. 1.Ih ;\0. a.'i,

pagt"2:i for JOt.n l'l(lll1lllilWJL)
Cut the """'11 (I. """"" and damp ,I IIllo
lh.. I'\.'\"CSA III tt"." tahl(~" nU'nral~ th,
bladc toctll,ulc.1 u~wloI< u- the billd

\\o'()OO~M'TH

"'1<''

\,1l....plannillg to vCflC\--'ra
pn.j<d and tint,h It ,nth \\atoo Danish Oil.
But h,' .....< """,.""",
thHt th" oil nnght

y ft4:'n the C'Ontact ~m-nt lim Jill the 'clll"(';r.

!'lJl(e"C\\ eft Jan" ~~l~'eneer
ona
coupl,' pro)l'ds 10 th ' '" ..... I ",..JCaI Bob

or Rob "

\\,

JWooidna:

Supp1ies. if he h:taI 11<=.. (..n.o I.rob!< fIlS

\lith oillinbhes on ,",nee.
..\\ on):. ~'{ta C'OfDI,!;t.1ntor t\\O t:\t.-r">
"""pie month; about
hllill;! as
~u1t or fln
llob .... 01 U,u;.lIy th,
"""'I,lainl Ian m11l(l<klltal ",th ~
If u..n ".". 1018o( problem...... I
\\ n'llrln'\ 1)l'1n 'lll 1Ilt'68.-

h:

."""j(t'''-

'''IX''''''

KY 40'21101;

"""" 11'< ad~\ e, -I I"dn\ ""Y it', totally

'"'mu .... 10 anything: he says. 'but it',;
I"""'t
rou. II \( Kt I)\ "l:.R \\p also tallu.:d to
Glenn I~.h.rty al Albert Constantine and
s.:Ul. InC', Hr- foUt:Jtt..;t(-d a nell' product
C:l1)\,(1 S:lnllJ),.. t It consists of veneer
backed With .lllIy,r "f,'""l'r, then a lay"rof
foil. and lillllll." alloth"r 111;I"rof paper. The
foil uets at' a barJ1t'" tv the fini ..-h.
Thv ollly di.'"""anta~. "e,;eo ",ith San
PI)' ..' i.~
thut tht' '" ()lKI ta~
...r i~
\:(ll",)'. \"1.'1")'
thin. You han' tu II. careful >0 "oU don't
::-afI() thrlluch 1t

S;onrl) I ... va.,.h't III nine

and
t"" '17.c~ I:!I .910 , .~. ,!)Ii"') (rom Albert
(o."tantme and :<On. Inc . 21.;0 Ea;.u:h~,
ter Road, ll,,,,,,.:\\ 11)161.
NJI).Z!:l-,.,...".
OIJ"t'ERE" GLt ..... o\noth('l' ;.(llution ""

.,Jeci....

to u>t' a J:lu., oth~r than mnta ...t cement.

Yello" I!:llIe (a1'I'Mtlc ,...,.in) I"el'bt< oil
fim.hcs belter I han ""ntact remont. Oel-

K." lI'lI. will" (Irk on a ,mall project when

tht \ ,lu,,'4.'r ."an lx.' tJi....ll~
clamJ*<I, but i:m'practlraJ fl)l" lar).!\' ht,,'l \,'ork \\;thout 3
\"cn.'t'r 1'1'\ '" ,l
A....l.nl'(.

lilt

HNIIi"

Th. type

or

\"{"n.'t'r IIr gltl" U (10(1i!\ only half the ~tor).

.Ju"'t

in .0000'1:)n.Ohio \\ M

\\,bh. ""."....

LouL-ville.

\\ebb .L....n'C<>mrnl'tlll,anoth"r 1)'Pt' u(

veneer It\!.,.,.", that u...e;. a pressure-

.r'

,""

11",,,1.

;"J2 I;;';' 2S.11j.)

U~('(I n !o'hort )11('('4' f to ) lei limit the problems ir tht'Jit ill bowed 01" twisted.
TI' rut the ,"Iuyo, ol..rt by settiOj1 the
dL,tan.,o 1,..1w'~'n th. f"n"" :ond the blade
to '~lual th,' Ih"'.n,' w,dth of the inla): In
m,} etl. I !let It to cut a ;'&"-\nde strip.
Then t the bl",!.- h"l~ht to about 'hr.
:0;0" make a I...... and then mp the
around ... the ( J>posIt.> ( ..., i,agoin." thp
(,~a.xI makeanoth~r pa<s. > Sl<~P1.
Rl""'t the "" .. 110 the lhiekne....< cut is
taJuonon th,ouliide ()ef\) ,ide ,.(theblade.
",e !'tC}.2 The Ilritkne-- ,bould be a little
moJ'C than the thick"" ..., or the veIl""r
yuun uclng 110It can be sanded down flu,h
aft~1' It'.gI".", m.
th. I!eC<Ind <'lit made. the thin
~lnl)S lall (,n thl' "8sl(,fO ~i(le "'here the)
ran\ kirk l\lIek. A nd th~ .maU .Iot in Ih<
woodell in'~rt P"",(nt.<the .ltip,; f)'om
.lipping d"wlI ""In" Ih~ .IIW.

piece C!<.unlt,"';nkinl!: the brads.

IJr,.vlttt.. somev vhat (If a barrier

BanI'tO" n

CUTTING

plywood.f11t..n rip two l~"",\ide strips to

th. finalthiclo,c ..., ycu want (or the werkpiece. Thek lhcS('I,,,,.tril'" beside the WOI'k,

,loaf)o')"

between the "m.h and the adhesive, (Bob

~lur)!"ill'l"It.rl1(l'!'\ t-t'\'t'raJ tlexihle veneers:
Bob )I"r, ..'"n\\'uo.l"urking ~upplie:-, I J:!:l

V,.
,ure

,l

w)"t'nl

Of ('OU""', I( you have a thickne ess planer.

that'" an t.~H") la.-ck. 'f'heo alternative is to
resaw the .tock to .. thickness that's I!.z' to
0\"1'th., final thickness, Then use a hand
plalll' to ,"" ...th It the re!!t of the ""A):
The probk-m Ifind" hen <loin!!:this is th,
ha.ss le or ronstanll~ checlcing the thicknei-or the pi..' .. Iillc al I ,came time making

I'Rom . 'h wrru OIL BUI Bob admitted

lh1t the re L. a JI'""ibilit> of pcn"trati~
ells tiOakln): thrtlUgh 1l thin veneer antI
attackl"!: the adhesive, And \\'ateo Oil "

R" 11ItIM)rtUJ1t ....

ho\\' the finish i~

"",,",,1.
Th rc'~
,.wmptatiun to continual
I) '!.:llI c I"~" 11.. add to th" ,h,,,,n. But

Ih all \\S th, .,I,,'nts to ""netrote th.,

\lent :T &l'MI attack tht. adhe;:;.i,,e.
It b< t t.. let the adhe,i, ...CUI'('(or at
I,
I' hOIl... b< fore appl);ng the finish.
'I1t<>nPUI on a couple li~ht ,...a1ing <O:d, ~r
and let them dry llaorougltly (a couple
da) before .pp!)i:... addltJOnalcoat.>.
One oth.r CIlution: I( you're lini.-hinjt
'ellftr ..,th lacqu"r (including Deft Clear
\\'aod ~ lO",h,. don\ I'UI on. h<-a,,)' coal of
h,l(hJ) thm" ..d Inl.''1ul'r ,ina: '""'" contact
""mlnl. d..... I.., in IAcqu.. r ~r. Seal"
.. ith a V'I') lil(hl ",.at (If ~qcqu~r sanding
""aiel' "I' th(' III....u('r it';(>lf.1"en when it's
dl'Y. apIII)' light tnl) ,"HI,.

23

Sources
'<lIni
00 ranbox oro.
the hamwlITe for the recipe
rrum
I'

Illr. \\OODWORKt:RS' STORE. 21lSOi In-

du.lnul Boulevard. Rogcn;. Mol' 55371;

flit 1:!>I219!I
tNute: $7.5U mimmum cash
Cut.loll: $2.1101.I'nrrtloul KilO'" (2).
I' dill.. Om.r No. 1::1702.$1.IQeath.lfill!/f'1<
tl "~lr}............ 1Y,lnnl(."'openwidth.!Ii
1<Tt'..... mdu<led. Onl,'r No. DI22I. $1.60
JNUI' S"rro: 11,,1,HIlIt"'.~ 14t. Yo'. Oak. Order
;0.;0 BIIII8. $1.70 ,"'I'm.
01'.11'1'

SMAll lOX IURl VINEEllS

Rut! ,'enet'rsroTl1e m odll,haped piecesanrt

are a\-ai1abI(ltfrom a vanetv of ~":>_
l'ht'Ck the ratalo!:& I sted belOw for spt.ocifito
I'P"CI~, w...... and pn ces , You can
r the
hurt, anrt ".",,, I' tdu<! w, U--e<1 on the

boxe.. (nlfl1:

dccidrd to make our o....n ;tn,,,, oot

of tlCl"Rl'.""" Sbop Not .... paj{t' :!:!.
DE(:OR"TI\ Il t"I.AY" :O;tiUanother pes:;0...e

IttCIPt CARl) lOX

0""".man

!<tibilil)' \\ culd he to UM a tlt'Cf_lMl.ti\l' inla):.

They're av,.. "'1>1.In a wide variety uf ffi!.
:-i~..fr(Jn~Itll of th4' 6Oun:I'S lio;t(..'(1 above,
FEI.T ANI) AI)III:."IVt;. WI' PUI'\h.k'<ithe

f.'ll (or th. I,.." HII~r a,"1 I"~

Onl,r No. 12\(.jr, f.4.IS.

Albtrt Constantine and Son al.;o om,n; a
Hurl 1
ITt"'''''t Itincludeo<2 "'I. fl.
o( !l('\COdlfl"'''''I\1 bur',. om.r Spt>cia1;o.;o.
C\'S 2:11.~1I.2.'>
(lthcr m ul on"r ~
o( burl ","""",
include
TIIF. "'OODIIORKF.RS
STORE. <ec
addre.-..: ab.,\C').
1'101.

n..."".\....

BOB MORGA:' WOODWORKING St;P

IUF.S. 1123 Bant,town Road. Loub\ille.

3 loea!

.],,0 available (nlln'

Youcom onl"r th~ hanlwarc for the bricl''''''<e

from:
Tilt: WOOIlWOIIKEKS' STORE.(add re,"
above), 11";,fN.. ' IInrdll'Ort Kit. incl\ldl'!'

locl<.s, lIn~r. hing , 8"loUI'I)OI1.$.Order

1'(0

A9J90. $:l9.tm. Gr",,;nc Lrot/ler H~"dlr.

s]Xod(y Dark Bmwn (Onl('r No. D!IlAAIt or
Lighl Bmwn (Order Ko_ D!tioOll. $9.95.
You n,-cd "K'CCof O.xible \'enet'r thaI
l11t'1I.'u .... ' .1wI II', i2" for the briefcr.-
bncfca....,..out o(t.u and
rift <Ill II hlle oak anrt c.tnIm.od the Y'_
f~m;

\\'" """'" """"Ie

"t'.
I"", ~-,

AL8t:RTCO"STA."i'E A''D SOS

Sp.'<'() Trak(OnlerNo.llrVI5Ifor$:J.l.liO

or \\ n'te 0:\1<, rift rul. (Ord<.>rNo. I!FYI'1I

(or $:.'7_()(j. l:-it", lhe ao.talou for other $peO.'S
Qyail"bll.)

11:15W Corthmd ('t . Addisol1. IL 60101:

312-62\1:1100 (C"18101(: $1.(0).

\VC1orlwo"kin~Suppll.,. CraI\$man \\'oocI

Servi<'t' Company. and Arti<try in Venee'"
Inc. tSM>Q<kln.......above).
"RTlSTIIY IN VENEERS. INC. 450 Oak
\\e onlon'<l th. lung 011Jirllih for lhe
'nw A\'e . Soulh Plainfield. NJ 070b0: 21)166t>-I~:SO (C[\lalol(: $1 !;Ill.
bn('("""" (rum:
(,Allllt::TT WADE COMP",,,,, 161 Av~nu.
ISLAY SIll'" \\"'tn It ramt> time to lind
o( Ihe Am< rieal', ;o.;~\l York. :-.,. IIM113.
(.M _. Yo,"'" X 16 lunJZ"inJa)' ~lrip rC)f W
box, \\ e mn int.u a l)rohlem. Alben ColIn. "'l().2:!129~2 IC.. talOI( $3.001 S"I/ ...rl<lI d
tantlne and Son Ita- a m'nImum onkr of a \I..ll PollI~
TU'19OilSNJ1IT.Onkr
d07..n , .long plc<es (.\"al~rol \1'00d :\0.WROI.('I. ~u
nperquart.~lIIl!n1a,ut
S"pI let' ~
for 'jJ("""". OnIer :\ o. \I({ ",,"'olll" mud n.'go.lrLoICLtUt"
OnIer!\o WRIl;!01, $1~90 ....r qaar'~
OOVOA'L _OUTERlilT
\\e " .... 1. Ilu\ ctall nJUter bit to make the
nulered rI.,..etad kf?)JOUlI on the "--cit'" CIIrd
I." and rlra" .... _(&...articleaMuI thisJomt
on
10). \\t' h"VI'II'tlx-en able to locate a
y,' car/"," -I'II,Ht! dovetail bit. They'", aU
high.""," ",,"'!.

"'Ij(~

m the art:i.:lc on dado blade,;

"". n ....."""
ntail prices. Fortunately.
nl(llll ..r
ran be purchased on sale
,IT "I 1< ,I ~.lInlthrough mail ()rdercatalogs.
"".tU ~ IA('K DAJ)()SET.The industrial
'I,...hl) /0',.,.",1" ,"rl"drtippedStack Dado
S. t (Ord"r IS... 117:lJ\2. $99.(0) is available
J'ri<,

1.'UCASt

laddms abo,,~). f'l.'zibl.I"",.,..

"ould.oo..-

DADO .I.ADEs

.hould ""t 00 u",-,I.)

FI~xibk ""ntO(>" arc 01<0available from

CRAf"n;MAN WOOl) ~ERV'C COMPANY. Th~ 'Voodwork.r.; Store. Bob Morgan

24

dealers, A v.: l'oI1,...Cable dovetail bit is

-e '''''''''JOb

K\. IIr.!tJ.l.r,(r~I~.(j2045(Catalog: $1.(0).

!to\ II ~ ()O per 12.'.

The \\ .. .m.otittrs'St,......(~abo\e),
...
illaeIl one 3G'-long OlI'lPbut they ha'e a
minllnum $7 60 total .... h 0"""1' ~'allm/
1100<1Sln/l.
th,d<,'
,,'de x 3J,-long:
\\nit. ~lal'lc, Onl"r :\ o. As12:l. $.3-1each
HInck, (lrd.r ;0.;0. A~120. $.50 each;
R,,,,,,,ood. Onl.r ;0.;0. A);121. $.52 each;
:;'It'I1,,, I. Onl(], No. A8122. $..52 each).

t~ appticallon.

fabric.' l\t(Jr,,, SliMlY 3(lhc!'oi\'~ are .\.t~Ila.bl(

ALBERT C(lSN1'M"INE AND SON. INC.
at art l"UP1,1)' stores. l~()l"~:
J )o,l', lr)' to Ul44> (acIr1",'~'.00\1". Dn"'lllil Hit. If,'. Order
"'.
to,_"JoIl."
'J"
\\1)0(1 glut' or (.vlllact (.'(_ml,nl TIl<-y ~rak
.'(1. -i1)I{lo)i7,
~).~,
into th. (I'll.)
line eauuon: For lh .. project. don't use a
Two """10 tn"'" of. rayad!," ves are ~ -JtiuIIIg' do' .WIbit - the kind with the
.:xtra Cutes that creal. an .,,,...,.ic>n .101 for
.~ailablc adhffi' "" (or ,,""nam'nt mount
"x..,..
!due. _ IIOnd.mritJ. No. 31. ~
in~ and t"- (or t.mporary mounung. A
p._nnanent a<Ihe"'lf' fhould be ~(_-d to bila are ",..nabl( (rom a-b and \'ennonl
mounl th., fdt \\'c used 3M :,pray.Menl
,\II1l'rI<IUI). Th.
,lot
3~1Photo-~Iount "wid al", ..'Ork. (3)1 on U",JOInt
Spl"8~.~lount 15 al<mporvy a.lhe,,,e and

ALBERT (;OSSTAl>'T1NEAND SON. INC..

2050 EIL'lehc"tel' Road. Bronx. NY lQ4tH

2:..'97: !ltJ().22:~0!I7(Note: $10.00 minimum
ca.h ~rd(r.Cmalog: $1.(0). B."/l't>IIeer.
npproK. 10"x Hr. :1 sq, fl. minimum order.
(\Ve u"",' ('al118thian Elm Burl for the
~bo,.
()nI,,1' No. V16. :Sl.20persq. fl.,
an<! Maple Rurl (or the h"x8$lOn box. Order
Nt" V5:!. $1.2.; 1"'1' "'I. fl.'. \~. <w Gi,,,.

"I

lu.R'h.speed i!leel
_mo to lIurk fine. \\ u.se'" the Yo do\et.ail
bit (:-10.9 HT 2.",...~I.
$4.1'9) from the 1!l8i>'86
Stoan\ Power .",1 Hand Thol Catalog. Black
and Deeker tds<> ,,(fera a ~,' dovetail hit (N~.
59078. $<1.07)At local Rinck and Decker
But (or

(j~

,.I<d

I""'" .."

f""ln \\'OOCI"llrktr's

Sllllf,l)'

or Ne"'

Mexico.

I~)'I \\ ~I. r~~'1.\lanK,! NE. Albuquer

~Ul, ;0.;101Bill:l.

I'I.MI-r~;,.!l'192 (Catalog:

t n,,)

111(' IIldustrial qua!i.

t) ll<llo"Carb k.t Pl.ro Slo'* Dodo Sri
tOnk.,. So ar,q)), $11".50) and the INlto.
Ad ,ufnbk IJcdI'I()nI<rNo.~.
$36.10)
are both oh.", n Ih lit< Dclta AOCl'SS01'}' Sale
III ItA 1)1'11>0~E"-'

e,;ataloi: ., .. ,bbte from "-ood"orker. Su~

I~)

r :\'''''

\1,1"'0. addres., above.

.\1 l oca; I R~.ctJT_TheAn.Edg. 1M,.

( t A4j tabl, [)ado (Order No. 09T31
Hf ~I"., N"l.) u. available from \Vood

.",1\ SUI'I,ly. 1)<1'1. WSI. -II Atlanlic A,e ..

1'0 ]lo, \IlOO. \\"bun,. MA 01ll88;800-'>'2.';.
II~'I (('ltwl'lj(: F",'t').
OI.OIlAM

ell RHIDETIPPED

STACK

S.,

DADo. Till Oldlwm b"('arbidetiPl~ Stark

lOrd<r :-10.600-C(.'O. $S9.(0);"Il\wlable

Ino" B.mlilll!ham Saw \\'orlul, n..PL WS4.
910 North:!llth St., Binrungham. AL35201:

~)04'U11316 (Calal ..... Fn",).

Seant dado ""I
pn ....'$ """ onler numb.." I!>ted \:do" are
from the Sears 19"~ Po...er and Hand
'IbolC.taI"!:. \\at<h for;ale pri ... ,.
-tandard-cut Stade !J<.d" Sri. 8", Oat
atcel, Order No ~ HT 3'l-17S. $34.99.
~moollt<ltt Slack {Judo
8", bollow
IlJ'Oll"d 1It,...,I.Onl.r :\0. !l HT 325:1. $.I~.99.
('arb,d,..li"",,1 Stllck [",do Srf. 8". Order
No.9 HT:l:lI>1.$'<9.!I!l. Adjll.taoltdado,l6tooth. Ord~r No. II HT 3'263, S34.!l9. Er
,,,bbllr' f:Z Ad}".t Dodu. t\\in blacle, Or
St;AR.~DADO SETS. ",.,

"'I,

del' No.9 HT827!J!!.$lJI1.00WOODSMITH