NO.

49

NOTES FROM THE SHOP

$2.50

Sawdust
Number 49

February, 1987
EoIor

llhink 1\. finaD~ discovered t~ ~t ("If master rraft..._--me-n.

11'. '''~ ti"'it t1wy .drrody """" C\~ry trick
,uleit(~nIIIU(O 1~'1'\' i: to k......
" .bout woodABOL"TTIll' 1"1 t

working.

Donald a. "-'*_

11'. IMI Iht-)

them,

Oosogn Ootectcr
1W Krallcelc

Th. Iitll.

mht':ll to

.If}

thl' "U(.,\"1't\.o(
nra IlnlJI't"l 11,.\\
~'CI(Irut a
f.,1"fO()Vt'.... ,It.. t'\l"', I)' 1'('nlt'I"t"f1on t II.. t"tI~t'

SieveKroll",..
Douglas L Hieb
~M.lJdstor

u \\tJrlq))f...,'" ~)r ht,y" do )'''1 cut n ratolk'l , r,

pl:''''IAAllUltll,n;\'ClIl UK*'l .. fgr.o IIf lh'I~;':
wlXwI fron, "plinlA!n,1j.l'

o-"re.

\\'h.n"'tr I di:!cu\. r the IUIII"......to these

kind. or 'iU<'Stl<ln1< It mak .".. f 1til<cI m

IlrIvrcl Ktwy1ing

JOm_

-Horwy
~~

SIndy J. Baum

s..boa..-r AssIstants

a.ri.... Miner
J_SUOUd
PIIKoob

CompulUf Ope<IItJOI\S

t<enMiner
Adn1:~rulN8ASSL:stants

Chetyt Scotl

Kale_rna
I!litIdng Mail_roe
An:hieK_
WOOOSUITH (ISSN 01~1141 1$ po.trIisII
bin rontIiIy (Februaty. ~
.M\e Atq.lSI. 0 __
1JeoorrCo<) by Wood." ... N*stwrg Co. 2200
Grand Ave Oe$ MoO\e$. tow. 50312
WOODSI.IITH Is a ,_""ed If8IIemaI1< 01 lire
NJlislwrg Co

Su_ptlona:

One yea, (6 ISSUeS) $10. Two

yeatS (12 l"'!U8lI1$18 SongIe ocpy price, $2 50
(Canada IIrd FOforgn add 52 PI!' yeat)
CIr8nge 01 Add.... , PIeese be SUte 10inclJde
boII\ yoJI old end new ___
Secondclau poetageporcl a1 Des Morros._
Postmutor' SeRI CI\ange 01 address noIIce
Form 3579 10 __
I'I.tiisIwlg Co. 2200
Grand_ 085
50312
BACK ISSUES

clucwa (1\\' mol' till,

I'UBI.I$Hf.R>'!
S'rA1'EMt:N1'
I';ach year in
thj~ l","Ut' "to Itrt' rl~(lui}"(:'(1b~' the Post

to publil'lh t h.. Rtull!fnE-nL of Owner~hlp shown ~ti."',

1~n."icaIIYIit shows that
our circulation \\8JII up to 2f19.(N.I(las of
()Jlil'f'

()<Inl"'r

(lr

Jr.'t Y'"". That OI1ml>O\"'" to

~.OOClI h. ),.",r "'("n.

ti""""

rut:,

to l~ t; xactl~ 1111tiM Jlih(Jl.jl<Wor l'XactJ)

" ......... Ilr~ bit IS I(\>IIII! to rut. TIaat tittk

d<lat! rrent<'I.! pnrblun that (ur ~'an!I

cwkl """ r "",,v<
'lOC... an 0(. _Idt n.dic:k 1l1l'light" _
'or IUIIII d....""n .. 1 a ne:at tittle trick for
making that ....... liN' It'o ""'",.11 on P3I!<'
~,) TIrnt ,,"" 6ttJ, d il'f'I') I113de m~Ua"
\\'etl") t"ind .. I"~m:lIIJo(tlx.,..u~as
\\ ...... n In ,...... :<II, M<>Stof tJr<om aJ'\'

01_
..... are str:I_
$en(! tor hco IlooI:IM deIcnbir iQ lire 001.... lISand
10$,

SAMPI..E COPIES
-.Iej 1,,,,,10see a ocpy 01

Woodomlth jusI $O<1dllrenarneMdacldress. and

we" sorrel 8"'mpie (.1 nooostl

the article:.o., pro

Jecta. lI"d
,h()\\in in !.be -IIof 111".161,,/h publi.<lr...Jtn da\t'. Pc,
.... ml ta.t) ........
t.... u.k, ;,.dhid...J into two
pwU: the lim r!(-<tloor1i,1, ~""ra1infomlaUOII:.ndt<-clrniotiJ("'."hilethe~>tion
li>tl! all tire I,,,,j<oct.<.
''t:XT MAli I'" 11", ""Xl i","" of 11'000.
~mll (:So ;~II will be mailtod during .....
w.-e1<o(Apnl:!7.1!Jo,i,
II ('lur'J13~l

""'UI'"

In,l""

til aU
lII(or-ncllll'n

"''-ATI' 'U :-:Tltf IlW:-:t:RSHIP. M.A))IA(a:r.n:~T ,\NU ltn{ LiLATION

r.,.......bj.t,Sl

tI.x\)

I, 1lOr.t' ~
Vt-s-llh. I. J ...... 1t... s. Ql'.I"'II~.t. u.t .. oI1-'lIiat! ' ...1...........11... I ""llIIIftC'fet
..... ~Ihl)
8a-' ,rf
...aDy .. h .. ~~prkoo-:$IO.("'.
'.,,'fWtr_II""' .. II,.... r
,I~..tpubllcl\liOft,;
:;!31'~;t.,.d A\rfOI' ,
1& ......
j '. (...,,1, ,... (lfil,:!. ~ ('nmrl.-tr 1M1hf:
...1-111
.. .., U. ."..
otr.._'"' ,rtt I ,
_ .,' .-.not AYCIIIW
I,..,liI.-.I_.5(OI:!.
I_. cnmpkt.' .. lo.t~ ..rlll 10"'" r, ~jjtQf,lWI~nlt,._t
to..-:
ru~...
1IrIcM).IIcI....cfl~ 'ttI1I..c;,.,d "~t'IIIIItop.aw..._ (.,...5IIIIt. .:.ilt If
pul.io-hc-r ~~
):.chI.urltllllW' 1
(,.
, Y,
_)! I~
I
t.ruot A...... J'.)N ..... I
,ralZ;1.... 1It p, Hhb ~., (:C"MI:I "', 1"1lhr r" ..
""
I.... 4 I ,.,......",.
t\r~. '!:I1IJ('oftDdA,..- rktIW
Ino.W:;Jlt:tt
lok,...~'"'"'
... '
CIlfowtk'aU"lllbGWton........
rft8I
fll(lQiJllllllllnlvl_k,lI."" ....... '.r
WlNnu.. N " Il>..wnotappl" 0

."f"nI..,..,.,.,... t.u.._

I,..""" ..

c..,

KIIiI,." .....

tlU'M &!WI ~"'~

\~IIO.~

~....p_

AnnpftG.."pr,

~...........

" 'ftUI

."Me,'

"....

... ....
dQ

L 1W!.u-.p

AI. tree!<. _

"'(QJ "''',. amend..no

the teM. flut onthi. i.'''\k.wr had more than

we ('(lul4,1 ~\,'t in tm' J'"'Jl'Cl jo1icl~W we
",pruKll'd I"" 'l\lIkml( Sh"p "'-'Clion to in-

Although It'o fun to look at th~numbel'>'

and ...grow th. ~'TI."th4' .,..\'erbeentht
1:0"1.>1' 1I<.oodf .u. 11m
n it _-d in 197!l.
I ,k>do1<d tl>; t)nilll:(cl u( lire mag>IZinc (and
0( tho .. 11<,(,:. <Om1"'"Y (or that malt..".) wa.<
(.,.. thing: .. r.1<e 10 wu,.I"oriu.or:;.
If..P IIpI'nL koto( timt and "ffort looking
awa;.:
III tho nl\"UlaU"n and <'Oft!UOtly U')ing to
For (''''''''1'''.
tm tD rutting a Int.......'" it, we .. oukl (Vrtainly ~
.ilt o(
rat.htt ()I\ "l~... 11111111
"'theltlt
f.Jl1u,tt.nllg thi our n'al fIt11lX*,. 1 ((-It if :-i(lr"\;cvcame nn.l.
1~IR" (1'hot1~lrr)I r \ 011 " .. n th< "'""IItI.r ,"mll~I'"''
"",yb,' pn'n I)Nfi",) wool"
WWfirst tw 1UI.t kJUr.I."t I, Ute rutltt'l" 1111(I)t' I un'I)' fl,lIo,,~
""II 1>1,.1,)
"0"\ 'I.hlli. r I h. aun.1<..,..( I""
(lu, "' ...,." Y".,r whcn I have to 611out thi.
~)l)'\\'I~u(l,
I ('1"". it ',c rUI\ t.) "' ....th,' numbers .,'1'0\\' - and
But kncl",n..r l}).,t ul,."w.11"-' n\ 81',1\:\, tM' k,lt,\\ th<- fl'a'il,n lxhlM lh~ gt'O\\1h.
~)n"J1,,u t r till ,,)"llrk. the t'4,'. ,n.lJru'
1~').::< .\il.llIfI thiS lA",ue v.fI'\"eincluded

_~Co

01all bid< tsar

artYo,n

'",01

VIcI<y Robinton

Copyright 1987 by _
1\11 RIghts Reoerved

,)r

micl"l of Ih..
(f,r tht~ .'1'OJI't1.S, I'" n.re~ to ill

aWll) .. ""'." .... '" in .....

n-alI, bl>grnnll1j.l
to It;u-n _Iring And
that I'm making """'" I'~
at gtottmg
be...tl'" at .. tw. I m doing
n.: intll'\'Ot.lng 1_ 0( all tlri8 00.. tht
,k .....,,1')' ""'~"
It'o aImoot a!,,-ayt< ,.. t or
~
I). and I _h"(lot 'M v..-""",.".. nt,,'lrt

Ttrnical_

"I),." I"",.,""

ks

_SUlnl Edo1O<S

Ken_ ..

pnQI6

tn,

1>,,,,. (un L,orninl!

lu6",,)

:. MA

(. -r...r rIIIfd..t

,,_

nnw
~

....

f;IIid.~

:w1.~

....

dftubta:a ..
.Ift....,.
"'
~_
......-. ........
_,.
, .....
,,.._...--.
..........
I c~ .. 1d\'" ~
... ..w.nrrI1f'lljQnc

II

t.

Hrtll"'"

fi'l1III

.,....

t:-""

,'T hrd..,....

,.,. ""'"

'-.. ~

......
,,,.
,.,
....

II CIfIO

'SZ.t>.1t>

~ f:

~!

" r.UI,
eTJ.GS.\
~0I1
11 J h'rt,h tI~U. ......
I''fllrfll rna.,to, b)"awabo\.a.rr C'Wn'd Wllff'W!I~C' ,.."....11ftr.:onald It. "".h\1;" f\JbU.hn- t:dltnr

WOODSMITH

__

T_ips & Technigu_e_s __

ROIIftJt TAlItE MICRO ADJUSTER

r lik,~tht up in

~\;.w.. /~'t1/{.{I)' Ko . .J..j fur

rnakil'f!: "t'1")' fi'K' aUju,:o.lnlf.>JlL.~

on the router
(l1h1,' (",<inll playinJ;! card, as gauge shims).

but I <1,,,,,<1,,1 10 make a permanent micro

ndJ",ttr {ormy rout(>r t.abk>.

Then, \II chou,!:" tlk' (,........ "'lting. kr-ep

the ... Ing nut lital "'~tI,
the far end of the
(,."',. 10 lit e tahle rairly uKht (a. a pivot
P","\I .,.1 100II<'"the "in!: nut on the ,...,...
end "rull' r,'IlL'\.'.Tun."e the rence closer to
the bit. tum th~ "cijUJ'ltmontbolt eloekwise,
'II. !noV('th r- bit "WIlYfrom Ihe fence, hold
th,'
li~"'t "1I'.illl<tth, bolt with OI1~
hmKIami turn tltt Ullju.tment bolt counterclu"kwL... Illth lh~oth,r. Oil('('the fence is in

f,,,,.,

I n'C('ntl} (ound .... ~ul.Jfl (,,. thi.~prut>.

k-mas I walk.<Ithl'OUl;llthe laundry room on
tbc \\;J.~ tl. m) Ioh"p. I use a spring-type
c~>lh,,,,I'm 10 1(1'1'" the 1.,lt ""(on' puttingit
U1 the \,1," '''L< 1',,>(,.. 1> tilt' IhN>atL."",I
k''''I'' th. holl rm", turning or Nippi"K. (On
8 \\4)("1\,,. lw.'I'l'}'\'i......, it pnlll~

r:"'e~r..om th. Ih",,,Is.1

the

\\,t.KlCi

rt."l\4" JX)l(ltleln, JCl('k it do" n ti,.!hl.

'flU can 1"\"'.ilJ~..n..oak U,) 1)11acut :-oinet- a full
tum ...(IIMo W'1j'J!IO.lnK'nlt".I1l'quai.o: I>'.SS t.l:uu ..
mol ,n~nl.1 the bu.

T_.j./~
rlOjJ&fOIn4 .'n(' Hall pYr,y,.

STIIP

'II. "",1\ the moen, a<lju.'ter, bogin b;

CllltlnJ,! a 1'11"'''' ,.f 2,4 to a \\itlth or "l' alltJ
1"l1gth fir Ii" 'I""" nail lind wue a small
runner .t"I' under Olle "'HI of the block to
11,1tlu- hl,.. k !k) tu the .. II!" of the router
tJ,t,It,
Th, .<lju t"r is hdd down to my 1\\,00
.""tit router t"bl~'J""t like the fel1Ce-\\lIh
3 C"dIT1aj(l' holt. ",mil nut, ",""""r. and ..
pi>'" ,oM ".~ her th..~tfits In the J.!1'>OWe rut in
II><'''JlIoort ann under tJt<. ubIe. 'fht' dc,
tu"" frvm the n"' ....r AMp to the ~
bolt hoW t!hould ~\I the di't.aIl<e from tb<
...i", or lhe tab! to lh. {cnt'e oI<Jt.
Th k!lj1l.<ln1(nlmecbant'm '" m:otI.: (rom
unother C2I'TUj:t! bult that pre ~"', "!:lIlJl.<t
tl,.. 113fk of 100 I\II.t, rtabk' fence. 'fht' bolt
li(.,th">Ugha Tllut in the block. anrl the",',a
nt" airKl "lnJ,! nUl lllo!htt'ned ag--.ti&1. t",(iA'h
lIther ,,"~;t h.lfillll fIn tht.end fJ( the !kIlt. J

,.ltI..o. ,"OII""""on 'pnng bt-Iween Ihp nllt

antlll't' hi,,, k t(, JlUl :-.nll'le ttol\.....ion OJ' tlw lxllt
nn,1 k",I' 'I rl'<.m \'ihrntinJ;! I ,..,.

P~(SHOE

R..... nU> In", lu""," m) pbn~andmmU!d

t" kf"{Ol'lhi' C1lltln~ Mgt" and sole in W[J
t.'f"Mhtif.n S, I ,1("('1(k"(ltil. nd a fl'\\more
minut,,,,,ltl<1 n!llk"n I< .. "'en ..... (what, I call
II~Il\
n\alt'' l" J1rut.'"C't lh_ plane,
",'TIJ(SUS

lI'he" vor I cut bolt like this, lh.

thn ",l 1l1""Yl'gell:'" f,.,J up tiltle right at
tht t.'tJl IUI4.To ""'ton' thl' lhre'dlls.tum a
nut II" th.- tx,lt ~ ,"n rultln~ it nff. Then

when ~"lU Un."CI'~\\lht' nut. it -cleam:." tJt~

thl'>.,1,,1 01.1.
Stf~(llsllr

('I, ',<III,I1III'"191,t.s, ()/"u

TEMPLATE1DEAS

\\t'> n'Ct.'Jltl)

received a ('(ftl])ie 1--Y'OOC1

tips on
IIJllklnI( k. plal<
markin. p:orl>'
1.6
"('{' K nhl q <.if J )rndlt1(/'" n1T!I']"
make hi.. I< mplall'S {rom d.....

gta.... Thl d,-..r I'la<tl<' CUIl1t'S .. ith " PI'OU!C"

tl\ ," IX&JM.7"n It
I ~'(JUcal\ t' ,.,n"" (Ira.\\ tl'k
1It, mun
I"'pcr. cut "",I "mel th, I']a."ic
tlJ fih.'ltC,tu"llMIl nntO\e lh~ paper. Sint..~
It'$ ~1, it, '\,.u (',11\ ~ krln~, Oa\\:-. and grain

ror

'fht' 00.

l-< """1.1)

a k'" box ,,;,h a rouplJ'

.. -<Ie. Itfl3tl~ R"'........." th( tw~tllm.Th~cli...t.:itlt"C '1'.,11 the ("("ntf'r {If ttK' .1;t(l~
to th4
('Iltl~ or the ooXc tl}~\"lilll"(lual th(.~(Ii....lance
(nllll the' ,.,1:1(*fir the' 1,1aJll" III the rtlane iI'Y,rl.
Th'1l thl ,Iat,l'l"" bt- ~II int.()thp$hOf.' \\'ilh

th. ir..., 1'<\]''''lil1lo:

d,,,, n into the dart" \';th
ulIl .1"n"'~~1I1o:
It If UIl' 1'l:u1l' it< put into the
,I"", 'hl,"k\\~"r,:Ih,t\'' .,.,ther rIa,ltOtu

PIe",

too

pi\ltl'rn

bt)'ing

)'I'U n~a) \\~'nlll'UN' or

a\'oid ,..ht.n

utllllll'C."t ~

('),tlJ ~""'n,(III)1(',ffllr

J;'(f/f:'!o, 1011.1u.~

phu;:til lllmlJ'Ulfl f;(1'111.~ ((Ir hjj. l('m}l1at~,

l'l:L.<ltir bunill.ijtl' l:ol..~.)urful SClit clCJC:'u\ ~t't

8('C~'IJlchi' In,n.

lost :lJn('1l1,!tht \\(lOti ~rdl~. aJJd yuu aUl

Tu m;,kt U h4',ultt.!, nm'IM th.( bottom. J lah<-lill lr lnak( lit.' N\ 011it ,,;th a l't'oc,:il Th(
bo,,,1 m I"" odd,,,,",.1 <"I, "ith ,thick Iamlnat, ..... Ihm tltHt ynu """ drill a tin~
hole In n and "",k l"'udlleJtd throuKh I)a.
"",.1 '" nJW<.
\\bCOlltt's 1M'<'<'l<AAl') ttOr..rry the plandn 8 hole 10 marl< .....n'" hoI~Iocution.'.
tooIbo., ",th , ther tools. """"re the ,hoc to I----~----------_l
tht plant> ...1th rubIx I' bands.
SINO tN YOU. ,_
t; Ibm G. _"n,b<
"'!I"" __
'
C~"'"II \', J. '"'11 .~d .IO-'__
read.,.

PROTtCTlNG THETHRfADS

To lL~ LIxm Cl"O :\,lju.,tt-r, fit it intu tht>

lot 'n th<rou"'r \.lIh.. and lilZhtcn it down
righl I><hllld th" (.1\1:0. No,," bring the 8,1
J",tm"nt 1.,lt "I' lIl:hta,ainst the baok,,{the
rt"tt'i'

\VOO()"'-UTII

II hen lluu k.""" "Il'lh<' .",1ora ILlo..I0"Kbolt

nrcut ull'th,' hl .. 1. ""uaU\' e3$i""ltohultl
tht- I",ll N'(.'Uf\ly 111U mti('hlnt."'t~ \i...;e. The
p",bl<m " Ihllt Ih, lI1"UIlfa",,, on. \ow "',,"
"lIllIalll' the tht'\.'~''''OIlthe bull.

,t'.

01 Woods", th. "nd you, ode. to

WooasmJtt> r ... & TOCInques, 2200 Gland

".....o.s """"- ....... 50312

We pa~.m nltTlumof StOfor Ilp$. _S15
0<
""". for _al
!eCI>nlques (Illal"'" accept""

for publicatIOn) PIe_g." a complete explana

110<1 of ~.
Idea It a &ketch .. needed. send It

aJono. we'l! draw 8 naw one

Crystal Table Clock__

A LOOK INTO TIME

A.'a kid I a1,...Yl<.. ",,,I<-n.-I what t .. nukll ..
like to be ,,, .. dr a do<k. AU lhooP g.':1n<.
~.
hamrn<-", and hrrneo .. vrons; t...
I:Pther In perfect hannocl) Thnul:h 1
,
actmJly c-et jn, {.!hi; dork,1ookmj: In~
be thf' Ilf'xt best tIung
Tbctiodoo m.pend bm.and bral!sbob
of this tabL.. dock nn hnu.<l'(11Ilfour id<d
gJa, ....". And lhl' "", \\
Souro-s. I"'l:" l).l "b< l1(ul hand rut I.,.
,eled~~

11"'"

Th add another Ult<:n Ill! t ,tu,," ''''''

tk~itn"'<1tlx- doc:k around (our ,,~umlll
mmiat=<oltlx-t,)l",of
t.,tcl) rolurn""),,,,
"QUJd 4..'xpect to find In fruut {.f IlII t 1t nl
DWl.'<JC.tl \1)11 th I" "htno I Htoll1.l'(l ("C.'"
'lnK'tlrtl

II

the n.lllnllUl.

COlUMN BlANKS
Bt>11 \"'f'r~. I'"~ lh. (tlur l"fIJull1,,,Q (,\) 'I)
C."P.lIl11JJ.:'t"lgtlt ,)i(1.'t'S Ilf J I f'l''''k (I .1('\ Jal
thl('ktlf',NoI) ttl nttlf,!h ,lirnt'''''IIIIL' u( tl .."I,h

and l;j I""g.

Theil ,"11(' till' 11it'\'l'~ jutl! IJail'J( If. lilml

four c..,lunlll blanks, S('(' ~I)[. I. 'lry' t n 1i11t 111'

tlK pairs ~I Ihl L!'nUll 'hl"l"'llllil (:lIlli, ir
po:--.'\i}lt l"l,l,Ir) IIf lh. tJl1'1' nll\tch 'l hl'll t ht
rohtmtl." co..u. hi th'anl> I'IJutt .. l Wid i. ch
o Jlumn ""II.tl' e-ar u..~1)1,.,SCJll11 "11'( I' 4~11'.t.!
Jrl....wa-l (If ~luJnll' uf' hLtnkN. ~Cltl"',II!,1II (.
I, I sf,,I( k.) I .ll~) t')lIk tho t imo Uti" If I gill., Ut'
an l'xtrn ',latlk to two U Ofl J&: at.. t i'lt'('t tf)
set up t hi router t....
t.L
l\tl.,!,thc g!LK"ln\ .8quan l".tht, .,i;lnkl
10 1 .. squarv, . '<' Ik tail III t'~ I. "hop
:-;ote. Il<~ n- FqU;,nn~ 'II II><blanlu<. It
U1lportanl 10 pc.. I., (,," mmut
to rnak,

sure ,our np rl'1lC:\: WlII

In.

\\

bIat.k- an! '.,

labk- )

t.,

CHAMID

MATtRIAU usr

The ooIumns aImo.:;lllJlPl ..... a.< tho ul:h th.~

III'( ",undo ~iJe even UIrIl<d on 3 ~,\I><'
Tbe In{"k bcrc ~, lO Aolrt b\ m;WIlj! ,"""
blank tnlOa h<1JUtgon a"""'Il..nd .. lol> en)
nu. L'<IIl n.' rllfl....
"lt ....II ...... nd., 1><..""",, In
th ease tho. h<>p~on .' Jill .' p;t"".I1~
C<1Il1rolet<-d <J<1l1!,"OII-or
,th

.,,,alh""'I""" ..

Ih r,, ""nl('l"S ohamll'n<1 ofT

t.,\lOll To mak. the htJ~lIj("". Ii"'t
Ol3rk a l'(-nt( rltn on nt ('rd "f tlll ti t
hblnk. I-<'(' lletuollll F'j; 1. IIwn 111(", un'
,/,. ~a.lhflll"\'rtlon ("1m lhl' ('('ntt rlint' alltl

J,l:.~ a mark. '111,rli"'I.lllt, }-l(>t\\i't'n tht~,

ffiilrks (' ....
J i~t'i{ual \0 "11(' r;~('tIII' th4'

h~l)tal(lIl1.

Tht>re ~

to 11.,t.chf'n
F;r.;l. II"iI' fi'~III thl' .. \tn r..... III Ih,
11l'UtIJllt~lhlll~~

column ar~ 4,:(lual It'~ tan in"gulul' ht'l,tu

goll. 'J'hl' ot h{'r t \10 Ura4.'e:-tlrl \\'iotr. t'f\r('r t4'

I-~ig, I. Sc-coll(l. bltC,UUHtelf th( J:'.~r.n'ltr~'

CUTTING DIAGItAM

~_II
A Cok:::w .. (4)
Door s.",_.. SHIft (8)

.t,

SideIloik(4)

1 1
... ll \1, 11
.\iI.x ..", 4'

Doora.h(4)

.\

( eo..lop Ionom (2,.-

f 'JopCop(I)
G Drow.f8owIl)H Fwt (2)
I lrrOra~(I)
J Gto.. Stop

'.

7111

'&1'4.8,( II'
\, 17, 10\1)
~ a"'.-Il'.

V,... za.. - 8"'",.

"'...,'... ,.~

'11.62''1
" I,.

K Spoc.talodt(tJ

y;,.4"11._2.l,. ..

"',ad up COh"mM from two ~

01'.' ..0<1<.

Ed~fw p~ tofonn

COMTop/8ottom. TopCoP.
ond

thow., 801e.

aJp .ne! ocIgo-gl.. ,_

pi_

WOODSMITH

involved, Ih(' ,, "fI/ ",idth ofeach of the five

equal
isjust n tittle (.o;n l(lX'lder than
'I,. but for all practical IIU'1lOO1e< we ean

w-

lOUGH
-..sION

v,

refi:'rtothi:)Q:lI/:"'.

TESTcurs, To cut the

f:ttes, mount u
chamfer bit in the router table and raise
the bit about v.- above lhe table, see I"ig.
2. Now cut about I" alung nne eoi.....r of the
test blank, see Step I ill Fig. 3. Next turn

the blank eeuntercloekwise 90" and make a

J" cUIalonj! that corner; see Step 2. (I only
cut in an inth "', I didn't ruin the ..nlire
blank if the sctlin$! was 100 deep.)
'Vhen the seeond cut has been made.
measure the three faces. The tWI) chamfered faees w ill probably be less than 'h'"
wirl~and Ihe one in the middle more than
'c.4It won't quite reach the layout Iines.}
1'10\\ raise the chamfer bit ""rf/"liglltly ''''(]
re"".t the cuts, The obje<:lis to
up 011
it until the th~ faces 31"1: equal, """ E'KI
Vi.w Detail in ~'ig.2.
CtlAIIII'ER TIfE BLANKS. Once the router
hit \\"8:1 set to the correct heigh I tt) I!et
equal race<.! routed th.atlllal blank". It's
just a matter of chamferin~ the fI,.. 1 two
corn ers Iik~the te,t piece, but pu,h the
workpiece all the way through. Then tum
the blank another \)I)' and I'Uut third
chamfer. see Slep:l in Fig. a.

END

Y11iYi DETAlL

,,,.,,,k

~.
ntERtST

coo..

flUTES

\Vhcn the Iive faces we", the same width. J

l'tlUte<1 "," flutes in each face. 1'0 do this,
niOunt :. l/t't'Or'e box in the router Ulhle. and
ruisse it .1:!-abo\E' the tahle. Next, center lh e
bit on l~ width of the blank (V," from th e

fence). see Fig. I.

TEST CUT.Once the bit L,centered on lh,
blank, it will .1;;0 be centered 011 all of the
chamfered faces. To test if the bit is cellte ....d on a chamfered face. rout .bout I on
the lest piece. Now. measure the .houldel"
on either si(ie of the flute to see if lhe,~"are
uniform. If the shoulders are uniform. the
Out<!is <entered on the face. If it'. 1I0t.
move the fen<'(-~Iighll)' in or out and try
again on the test piece, (Note: There's a
good tip for micro-adjusung' [he router
tabl. f('llceon palle :3.)
ROU'l1NGTHE FI,U1 ES.After the bit w as
centered on the chamfer, [ began routing
the columns, Start by f""iug the !Kr- inside
corner
from the f.lI~e, _ Step I in
Fig. 5. Now make "ne pass th~ <"OmplPI(,
length ofthe column.
Nexl, rotal.(' the column counterclockwise
lind rout the second flute, SC(' Step 2 ill Fig.
5. C....ntinue thi!<process for lh" Ihini and
fourth flutes, S(!C Steps 3 and 4.
There's an extrn step for the fifth 0,,1<'.If
~'(Ju \\"ere t.o eonunue to turn lilt' (Jiet~
countereteckwise. the inside (90") corner
would be Irjt:unst the fence and the bit
w()ultl,r"t he eentered on the 1JI..<t face, In!ltead. turn the piece end for end ,;0 the
inside (90') corner faces away from the fenee

RUTECVU!NG

NOTE:
CEHltlCOOEIOX
III! ON O<AMIUEO
fAct TOCREAft

_-

UNI~5HOOU)fRS

RGUHS

ItOIAY<
COUNTU-

''''V'iI

again and rout the IMt Oule, see Step 5.

\VOOOSMITH

CLOCKWISE:

..

~;

COUIOX

en

,/

fIGUI

Alter the ~"OlUmJ1,5

are complete. work <all

Ix-gin on tho gl'L<'< ease that hOI'''''. Ih~

eloekworks. The ense is made from four

ftarn<!,< -two identienl side frumes lind twu
identical hillg('<Ifronuback door (r.unes,

....__'I,'

Efi,

OIIECnON Of FEU)

STWGHT

r:::>

,<;:>

RAIl

1+1

CUT OUT!>,.OCK.SL.'ll1.work

SIDE
II'

II'

~-~.,.,
(UT 10
.._ 10UGH i1HGTH

SIDE

STlLE
\

1+1

\V

til ... -_.

telti

NOTE,
toVIlNG
~EWlL1

..........nCHlPOUT

on the fOUl'

frames by ('Ulling all the stiles "lid rails

from 4/4 stock to Io/I~' sqeare. N(I\~'cut
eight .til~ (Bl to rough length uf IZ'
Then cut four side nlil~ (C) to II ruuj....f1
length of 6"' and four door rails (ill to "
multh length onr .
GI.ASS RAB8&T. Before miw"ing the
Iran,.. piece. to fin.l length. 1 routed rnb
b\'ls for the glass on the back edges wilh a
I :--trai){ht
bit. see P~ig.6.
'no k,',p the bit from chiPI)ing out the
e'I,,, sexl surjace. rout in two passes. F'TRt.
,<\ Ill.. f.oce to take II light Yo." "~kim cut"
.uid n"tIt" n backward <left l(l rightll"l..'\.'
.. ., St I. fig. 6. (Hold the wood securely
.,' tl bit tend, to pull the wood.)

To lini.h thcrabbet, move the fence to

t~lk.a (ull 1 I -w icle eut and make ;1 normal
ril(ht 1<' len I~"'" _ Step 2.
MIT.;R TO 1.f;Sc;TH.Once the rabbets arc
tilt. miu-r the piece. to final length making sure lht' rabbets are on the ;,,>'id,

,....RUS"'"
anSftlN.

lOmK(ltf-

NOTE: SAWmt1HG IS
~e SA.MI AS aNFIG.to

"f' he frnm<...

(Shop Note: The dimen"i~n.<

1,';"." lI. Fi):. 7 are "hat we nooried to hold

lilt' beveled gl:.."". It',; besr to order the glass

liM:utd "Itt the frames to fillh. gill';.,.)
ASSEMBLY. Once all the fr;.me pieces W'"
cut to length. glue aaeh frame together
eh..eking all the eerners for "'I'IlU'e.

SPUNE. To strengthen lhe milt'.". I add-

(."(1an open spline across each corner, 10 do

this, hold the frame firmly in a holding jig
and cut a single kerf at each corner, see
Fig. S. No\\ cut splines Lh('thickness oCtile
kerf and glue one into each corner, see Fig.
9. (For a complete explanation on makinl(
thisjoint.:'. II"KJ(/.,,,,i/l, No, :16.)

Next. I u.''\tally $1'\\' off the "1".lTS" of tI.e

splines d_ to the ftame and then sand ,,,.
chisel them level. Hut with 16 splines to
elesn up. I decid",lto try a new 3Pprow:h.
Firnt I sawed the can; off close as usual,
BUl then I mounted a flush trim bit in the
"'UW" table and routed lhe splines orr flush,
see Detail in Fig. 9. (Ib pre"ent chi""ut,
l"Oulfrnm the corner towartl tbe t"'nl~r.)
ASSEMBLY

Olll" the hplinllS8l>! Ou.<h with the fnunc~.

NOTE,
1'0 KEPSlOE ASSEMIQ'

RAt USE THIS

cw.ortNG "OQ<IUI

cut the oolumn.qIt.lhe same finished len~-th

as the frames (11-). Then the columns are
glu('(lto the sides of the frame s,
SPUNE';. To help line up the column" and
.ide frames, I added alignment splines. To

v.

do this. cut a -deep kerf centered on the

width of each side frame. see Fig. to.
Then. without changing the saw. CUL. kerf
in O)tt' side of each column with the inside
(9I'r) comer against, the fence. see Fig. II.
Now cut.pIU1L'Sto fit the kerfs. _ Fig. 12.

WOODSMTlli

l\~\l.lIl>-('rtthe

n,,"I'J'I.

~PIineSbe-

"IUTT

lv.t-en tht. rr4fll\'" .tlltl the eolumns, and

then glUt' R')IIl ('ian11J l(l$tl-tht'T a~'idf!a.'-~Jll..

,- .,

./
.

t,l\ ffl'M" ,.dt" (nl0'\4:" anti two columns), To

k':"" thl' 1<....... m"l~ flat. I G-damp<><l a
('I)UI'lc!o .. r J'I{"l'('8 of Kral'

tl....("""".

$<'('

.,....

./

,,

.tho\"' and below

FI):. 1:1

...

DIA.
PIlOT

,,, .. w

MOl.(

HINGlSANDCATCH

\\1"," Ih,' .. <II' ,,,,,,,",bil lin' ,Iry. IC><lItethe

dr hillk'''' .." th(, back ..f each a..,,,,,,,,bl).
I'u,il"," IheI"ok IIf th ...lunge "; from the
joint Jin4 anti mark Lhl' screw holes with an

NOTe,
MOUN11UUET

.,,1. ,...... VI~. II '1'111'11

drill ~,,"-di'lpilol
lt111t'l'OI. fh'1'" iJ)lf' t1,,-' column,
l\"" dnll a hoi... (vr u bullptcatch on thl'
batk ofll.oth,""lumn. "'... FiK. l~. Center
the hule,m IhI.- II 1IJ!th of tilt' ....>Iwnn 8",1 "

CAfe. IAItIt
SEEM l4

..

AGUlI' "
11 .."

lu~

fhtmth<'~'lnt

(lntt> thI.o build (lilth h<lIo-, are rlrilk...J. 11.c,

""'11'1, p'" .. kl the lop and b"lwm
I"~'
t"(1\."Pt"'WtJl~t\\4)

nllnluliuo IlIIltt'Jllt:ll

fItL'Ct":< 1)(

tA._U1J)'

1 J :ili.M,.~(t.1

Then

dl')'

a......
...._.m

hlllh~c;.L'(I\(t .'IJt, II;) af1 cut the tOIJand

t"'Jtl,;nl l)it"1't'ill. tl ,. ~U")!('r (in both dirnen:<01111
.....)

thtUllht'

~:llII (()\IL"ld(

column to nut-

sidl~tf"ulnn.,

IiUllkshank hili..fO

..

A.

l' ."

,
r

..

."...

~e

--1""r-.
~SS5KTlON

...-

.-

("1$")ut' mill) th(o bottom

t(IP (111).

C3$('

","to

hot...,. ("C"' near

th. cent er of IhI.- "' se 101'

for thl.- <crt''' that attam thI.o ~Iod< orks,

'O.I"""te lho, ecrre

he luI' uf th,
n.."-{

"14..'eas l'

bottom
lerh_on

011

.....

T(},. ('ro:o'..":;
:><'rlWn In f 11:. 1:,. Finally counterho", t" ',..'
....~
(a~ o(tht"

1"""''"):pilot hoI, m

_f.

--

nnur. 1101 fs. 'I'll .. Tt'W tho v'P and "'.1tum to ttl" ('1,I\IJn,\.oI.(Irill countersunk
I'
-hnnk h"I,, ,".,r ~,,,'h voruer (labck'(l - /I"
In ~ Ig If". Tht", It' Mn.'Yo n :. ll'Jl cap
tr.ftr 1(1 J iJ,:. J!.). drill ((Iur more counter

- .f ..

(f:)tut"" ........ ~Iak,blank, fUl't~p;.....",

b\

1QfV!W.

CASE TOP 'BOTTOM

PIlOTHOU

==
.......

I's...

.,.-

WOODSalW

umns dry a,''''mble the

1"ay tu eenter the tup;uM!

(0

the fnun.,.

IS

to mark ""n

1 lh the (nun,,, and Ih~"'r,,",i

ht,ll'lm. Ttl,'ll lintO UI' th~ C'E'ntt'rlinet-, :o_O('{'

FiJo':.I,;. (,\1"" "' ... Ihlkin~ :>hop. P"l 2:l. J
(J'ICt

tht ('t'ntl'.'ljll4.':;

al"t> uIiJo.,'llcd.mark

thl' Juc.'uti4)11oflht I'ilol h"lfI:oiin thl" ccJlumn..:

"jlh ,III a"'l. Thr'n drill '"-<)<><'1'
pilot hole,
into (a....h ('fllumn \\'Ith :1Y:qbit.
R01IT,..rt l'RO"II.t:~. Rl'(On- scn'\'lug
the lUI' u"cl tMlllt,nl Jlit"('I?lltl tt~\
CU1WJ1IL'.
r .t th .'(1,,- ,.r..fil. lIn t....th pil-'(.'t' ...; 'Ii)
n1..1).II PaMf'r til r,~L a r'i~_.(\:;lan(ling I,n
t"Ilh'f". J :'C'~"('1J a Iail au\iIJoaD' ft'net!' (,n t h(.i

f"'ntuflheroul"rtnloll'(~I"", ...... riK.I'

:\ov. mount a .. n>u",I~\er b,t in thl.router, Then wlth the \\orkp""", <tandinK
on l~Ij..'<'anJ hl.-klliJ[hl 8I(:U""1 lhl.- (,nn.
routthe I'n,ftl....... SI~I'I in rig. I~,IRe
~un' lhe til' fare of the t(II" an(1 bott'lm

f.'.......flhcloot"'m""'tu"""llhpf~n.,..)
~lxl.l.l\ tl,, "'.rkpl~"t' flat on the rout
I'r I.,bl"" Ilh Ih,'r"",,,I ...\'~r prum.. f.. in~

..

_'7
~
...........
~fOICI

1010UTtl
lAIIIIVICI

~C'",:;'~--l

"'",:

l~

' \~
1 ,.

I"

~. '";

_/"-"

../

jJ

'"
"':c'

AUX&WI'I

Id

"

~
"="J) ,

r-:iJ .:.
I o:::r: \
.~.
'''COVlIIT
~tc~II:I'~"~"~II~.~'I~I'~"~"~I~'''~~~(:''~I~O~l~h~~~~1~u~ln~n~'~'
~~~~i~'~~~:::::::::~:::~~==::::::~==::::::::::::~:::::::::
111""111
nlUI a

,,,,,polltheol'p""it;eedK",

"". Sh'p 2 Imally. >'(:rcw 'don'l J:lu~) lh.

WOODSMITII

/'"

I~

..A [.1 I~.:.

'.'_

'..

OY<I'"

TOP CAP

a,.'......

10 ..~

oJ..,.

--....

1 :

,~

Aft.~r tht_ ntaU} case i.."l

-mhk-d, tht> ttll'
cal'. 11ra",'r ba...... and [.,,( arv ,"~I,.I
CIIT TO MZ~. su.rt b~ ,t!Kl'gluinK "
blank (~r tn. t"I' <,'1' (t'J [N,m I I .I, ...k.
Then eut It .- ~n\:llI...r (In both (Ilolt.n~l('ns)
lhatlt}wl'"'J:;~lI,(I:-~).!It'I,,' "I).!.I~1
t..O<:ATESCRE" II()' .., St\t,o-nu-r th"
lOPcap ( t'J on lht' tl'l' f f~),.(thl case Thet
reach in.,t<I~the .....'" _I mark tlt ......~h II...
",le-tO!.ht. tor (El 1IItO tbe 1 It..m ..( Ih<,
tol'dip (t) ",.1Ilnll ".1:. 1,11
u1t.~"""

''''~'I'

ROl'Ti'G TNt: PKOHIJ-. Tit,

ortl ...
tOt' (""oll'~ routed In t \\0 t4:J
0 ,1(.'(", .r"I:MJnd ~,\'('r
antI'l
" t......\\. -, M"t.
:!tJ. Hut
I ran 11\1" v"-hlem "tK"1 J"Outllll: tt\{,

"~lJC.

--r

.....

_..

........
......0IlIll'"
--..

~~

....

-:'~!l _
O!

THIOlJGH

r-----..,

/'

thf" hit "-'C.UItIII't III"O~'

J''<"t high .noul!h 81>,.... < In,- rouu-r labl,.
r"4JODlI--<I\t"rb4.""l,",u~

Ir),.'rl.'1

\\,11"'fr/II'"'Jl,<1 hi~h'".J~'"
It':\...t 'Df lht' ~h~,nkIn tht'
\."OlJ.el). n.u\ tbe nJurtd4'I\'t"r In .. ,t.:.(ri(~
11I3.
....~~ a~~hll'\ II inSt ..p lin Fig. 211,
11)(' aI14"'1.:&tl\'l' ill Ii' UM' U tuu~Jh(kl
I"IM.ltA'r. J 'ut the ""utt'r h4L;",lA)
run on t h. to(l~l'
of thl" \\{,rkl))(_'(,'(' - r}4)l a '""11' :4:ttllt sur ..
(a('l~.Trl kt'f'l) th. nlut"r (roln lil"l)in~. r
('-daml ... 1 ., hl""k 10 lit, router "" lit,
IKt-,(,,)II1)! at

t,r

\\'r))'kl)iE'C(>\\ a....."ttntl\\'i('ht.o h(ot\\ ltl1t hl.' l,it

and II", blo('k",.I ...",l,-d the munrl'II""J' in;,
series of I~n to l'iJ.(hl1."""'_', "' -r- I-'i);. 21.
(Notl): ", flN\'(nt. clUllOUl. n.l4.ll lht ('ncll'

MIa" fh

wooosc.uw

1~1t20

finn. )
Next, rout lh~ cove with II... 1"1'(";11'
nal
on the rullll'r labl~. :we Sl~p 2 IIIrill. 21.

DRAWER BASE AND fIn

' ..~COY'(

When the l(tl) (111)I~ (.'1Hllph:k'. l,Ij(\....~I:IIII

drawer ha.". blank II;) rrom I l.t ...k,,,.1 <lit
it to the ~.
t'llA' ....
..; lh.. ("~L"'"1)1ltt'lm. :..('(
"i~ItJ al'wl 22
IlI{AWER RECl;;"" T" h"I,llh,' duck W 11.1
int! ~)'. IIl,a41~.. drawer lll;atfit:. Inti' a' ;.tl\:(.,1 n-n-~...routed inthl' jlr"'~t'rt);.....'. tIf't.
fi~.
~ anct ~~. Thi.. n,\'l"s"~ t.'4IIJ1tw ".1114.1
r,.....-rumd "lth a ""'.Ih..!tI n,ul<ru".1 U.....

1iI1-'~-

-"
.~==::_--0AAWt=~'~~' ~~aA~-.sE:-===:"::'-:;
f1
1I

,.....

~._

,.....
l...

"<\..

l't...UlM UI) \\ ith ~ ",}u.",,I.

t-EE"l:
li, ooml,l<:l< th~ boll"m I<lrt ..flh,
ca....... cut 1\\:0 (t"fJt 4II) (rum 1 I gtcl(k t ,\\,<1<. and .. longpr than IItt' "idlh ,,( Ih,'
dra"-,tr ba,t,G). :o'o(."\.'
I~. Th('n "'Ut a

.~
..

.'It.

!i

,,. --'

~.

r--.;,;;:

.....

Y.-rwM)..f'\'f>r \\Jth a !(hnulfkr lin b,lh

ft.'t't. 8(~}'oot Prolilt'ln fo'ig. :!:!.
A~E.M8U
!\,'" the (t-(t .&011,lf1I'\l'r
ba.....can "" alta<h...ll .. th,
n..."'.....
is :w~'Iledfiu.'h "Jlh lit, ._._. I.,n ..m ,,,.1
lhe .,,1 V....j....
l "I",~,,"dthe (",nt. ha...k,
anll ~i(l4.'Sufthc lla.'"t'. M"'t" "Ig-. l!J.
(In....lh. I>iu Ill"\' """il'''I1l~1.d"'IlI'
them (ogl,\h"r '''''' unlll""nll"l'"uJlk "hallk
anti pil.. l h.. lps. Tlwn ."Cre" 111., (l1'1 a",1
drawer ba.," IIIth~ ooll!)",. INul<; Th ,tll,,\\
for \\'00<1 mU\'l'ml'nl :U1fl nl,Uctit ({t~I,'r tu
filli.h. don\ glu(' Ih.,", 11art.11I1I('lhl'r.)

.".<e.

KEY DRAWER
Once lhl' ~jt(.'C~
aJ'\' ~'I"(\\'(_>(I
t(1j.(Ithlr. 1('ut a
key drdw",' (J) to fillhc J"'~'''-'."'1' ~'ij(.
2:1.

WOOOSMITH

Wh~ndoing this, wtlhe drawer so that side

grain, not.end grain. will show on the Imntnf
the clock. see Pig. 2:3h'-()P $CI~"'"!W,
Since lht' drawer isn'L as
deep as the 1"eC<Hl$. I aclde<!a roundhead
,;('1"(''' (I.' an adjustable "top on the bark of
the drawer, By turning the screw in or out.
Ute drawer front, can be ali~""'" flush with
the front uf the drawer base, "I'e Fig. 2:l.

KEYRECESS.Next, drill a series of holes

(~". 'I,", and 1''''.. diumeters) lo form a

recess for the key. see ~ig. 2-1. Then

freehand rout out the wllSle between the

holes. (Shop Note: Hold the drawer 10 the
bench with carpet tape while routing.)
To nti;;e up lhe key so you can I.'et
Gnger under it, glue two ",,;.Iong hy Y,.
di a, dowels inw the Yo'-dia, holes.
TAPt:R. ~'inally, sand n slight taper toward the hack of the drawer to keep the
drawer from sticking ifit swells or cups.

HINGE

DTA!L

DOORS

Once the drawer

i,< complete.

1"

continue work

ON

CINTt. 000
PUll
DOOI

on the doors. first, trim 1/",off aU four sides

of each door UI fit the opening. see ~ig.2-1.
(See 1lill<ingShuJI, vage

22,)

HINGES.Now screw the hinges into the

hoi... already drilled in the columns and

slide the door into plsee. Then plat"! a shim
under the door SO there's a unifurm gap
above "",I below. I_Ie the hinge s, and
chisel out the morti, es in the door frames.
cxrcu PLATF_ Once the mortises 'U"('
cut. center the catch plate for the buliN
catch on the opposite door stile and drill the
SCI";\\' holes.

S('I!

II.

CENTtR
PlAtt ON
lfNGlH

Detail in fil!. 24.

YlNISIi. Before ),'Oinj( uny further

OfDOOl

I 100,"-"-11+'

CENmI

2.

CLASSSTOP.AnerfinL<hingtheca-.e, the
gl ass i. mounted in the frames with 'I," x
h" quarter-round SLO,,,,(,I). To make the"
stops. round ever all rouredges of. piece of
4/~stock. see Step 1 ill Fig. 2.;, Then make
four ~"I"- -deep kerfs to form an o!l.f.~h\.lnN'I"
""1"-bloek, see Step 2. Finally rotate the block
on its side and trim off the quarter-round
stops. Me Step 3. Now mite,' the .IOP" to
GUn lb. rabbets, and apply tung oilfinish,
lnstead of tll;in" br-dd. Ul mount the

.. method. Glue 1.long

sUlI)S,I used another

brown paper strips (from a paper sack)

bel ween the swp, and the rabbets, see
Fig. 26. I r the gla:;.< 1I1:1.'(1~
replacing. simply inser l a thin knife blade between the
stop and frame and gently t wist. The pape:
will split and the .LOI)Scan be pulled out.
SPACER.'Ib support the eloekworks, and
act as a stop [01' both doors. cut a chamfered spacer block CK)to width to fit between the doors, see Fig. 27. Now center
lh~ block under the case top (E), drill
through lhe IIilUI holes fOTthe mounting
screws. and gfue the block in place.
CIVE IT THE WORKS.The last, step is t,)
SC,""W tbe pieces together and mount the
clockworks and hardware, see Fig. 24.
WOODSMITH

PUU )

.,~~~i=~::~~~ON~~~~_/~~===jIl~~~===

thu ease oompletely apart :tnrl "mohed all

thl) piece... with two .Olll$oflungQil.

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FIG Rt

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_

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GlASS
SlOP

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~

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AU.fOUR fDC?ES

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W01!XS

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Bookends

SUPPORT YOUR LOCAL LIBRARY

I started stocking my new
bookesse (_ P31.>e 12)with books
on woodworking. I realized I
needed some bookend, tomaintain
order. That, when it dawned on

bookend. 1b make it functional, a

plate is added lo the bottom orthe
base to complete the -1'" shape.
One end of this plate is covered by
the books. The IIlhel' end is recessed into the base.
MATER 1",1.. The trick.
of
course. is l<J make the plate Lhin
enough to Slil) under the book".
After trying several materials, I
settled on two: plastic laminate

....F

me how scarce really good

bookends are.

rye

_11 lot.s of

good"JI)okiIlIJ
bookends, But. there's more to a
good bookend than good looks. It
has a hro\')' '..,;ponsibiUL),and has
to bE' desiJmed to hold up.

and I-l-gauge sheet brass, see

Solll'<lc page 24.

NOT A MATTEROF MASS

RECESS BASE.

No mauer how big the books are. a

bookend doesn't have to be mnssive to do it>;job. Design. not bulk.
is the key. The trick is \0 let the
books supply the weight to hold
themselves up.
The easiest w~IY to make a
bookend that work.~ is t.o evaluate
why typical bookends - both
heavyweight.< and lightweight>;falldown 011 the job.
HEAVYWEICHT. Bookends lhat
rely 011 weij,oillhave to be huge to work. If
you take a book out. even .he heaviest
bookends \\;0 slide when the library leans.
LlGHTWEIGHT. The moot common ti!(htweight bookends are Lshaped, see Fig. I.
They can be scaled to look great and have
surfaces thal invite decoration. But Ir
shaped bookend. are nothing more than It
block with most of the mass removed.
Ooe common sohition to make up for the
missing mass is to add 11 non-slip surface to
the bottom of the booke.nd.But this doesn't
help. Sinet! friction is (UI't.,<,Uy related to
weight. no matter how much "grab" the
bottom of a bookend M.,. the L-shape still
slides or till& because it's not heavy enough
to bear down for a good grip.
T-SHAPEI) BOOKENDS. The bookend de~ign that does the trick is a modified version of the L-shape. If you extend the base
with a base plate to give the bookend the

No matter

\\'hi~_hmaterial is used, it tlj easier

locullhe recess first and then cut
the plate to fit the recess.
S.I:."I'OEPTH. To do this, use aVo
(or 13I'J1;er) straight. or mortising
bit in th~ ",uter table. Adju5lthe
router so the bil sticks up above
the table the thickness of the
plate. see Fig. 4.
Then to rout the ''
x 3" recess. I set up the router
table using th e fence and two stop
blocks. 1b establish the length of the ....cessset the fence2" awa~'f,'Omthe far sid~
of the bit, see Fig. 5.
S""'!' STOPS. Then stops are used to control the width, I elampedplywoodscraps to
the router table so their edges were4" front
either side of lhe bit.. Then. I routed the
recess, w;ing the fence and stops to c(J1I1.r01
the limits of the cuts ee ~'ig. 6.
CU'.AN UP CORNER s. AlWr the ree '(!S.< if;
routed, square the corners with a chisel.
S~"I' FENCE.

ofan upside down 4"'. you have the

shape. sec Fig. 2.
The T-shnpe works because part of the
base plate is under the books. This turns
the h<j()kelldand the books into one solid
mass, "" the books rest on the plate and
actually support themselves.
BASICBOOKEND
All hasit T-shaped bonk('nd< .tart out about
the same. To make the one shown in the
photo. I cut the base ruld hack fn'l11114oak.
_ Fig. 3.
Then to dJ't'SSit up n litUe, I ","-,I n 'II. "
Romanogeebit on therootrr tablr In Im.fi)e
the edges. see DeWI A. Finallj; I glUt'" and
screwed the two vit>cesw~lhvr.
Now: To provide clearance for the rtlut~r
bit when routinJ1;a base plate recess, ccunterbore the screw holes %., see LklaiIIJ.
BASE Pl.ATE. This produces " b~,,;c

r.RG~U~nn'--------~------Q5-~-------~-4-$--~--------------'

..
2

&ASEPWt
COMIlNU BOOKS

MAJ(E THE PLATE

N"w the plate can be installed This takes

two lMps: CUlting the plate to size and
ra.lenmg it in position.
('IJT1'1NG 'nth" MATERIAl. Cutting thin
mattrial on a table saw is tricky. The
problem is the edge that overhangs the slot
1Il lh,' table Insert vibrates as the blade
cut" and the edge ends up ragged.

BClOKENQ5 WI1'l'I BASE !'LATE

.AND IOOKENO

lN1Oi'UN'T

10

WOODSMITH

MASONITE BACKING. To support

the
plate all the way lO ~he edge during sawing, [ backed it with I,j.' Masonite. 'Ib do
this. I used a couple strips of carpet tape to
stick the plate to the Masolute. see ~1g. 7.
CUT TO SIZE. Now eut the plate and
Ma.""nite to .i7.e on the table saw. Begin by
lIawing off one side to make sure one edge
of lhe plate and Masonite is even.
Shop Nole: Bra", is very soft and is easy
to cut with. carbide-tipped saw blade. see
Sources. page 24.
Next. set the fence to the width of th~
recess in the base, With the (n,shly-(;ut
edge against the fence, rip the plate 10
width. Theneut it to a length of6".
END PROFILE- Alter the plate is cut to
si7.e. the end th81.mps under the books ;.
cut to" semicircle with a sabre saw. First,
draw the arc on the Ma..'Onite backing.
Then, clamp the piece with the Mnsonite
side up and CUt the curve LUshape with a
sabre saw and file it smooth. see FigS.
CUAM."EIIEDGEll. The last step before
installing the plate ii\ chamfering the edges
en the router tabl e. To do this set the
height of the chamfer bit so it lakes just 8
tiny eut orf the edge, see Fig. 10. Then,
with the plate against the table, guide it
pastlh~ bit with the ~l.a!<oniteriding on the
bearing.
FiJJally, smooth the chamfer with 220grit silicon carbide paper. Then separate
the "late from the Masonite and knock 011'
the other 'harp edges with the sandpaper,
MOUNT THE PLATt

After the edges are ><IIIOOth.

the plate can be
mounted to the base, This Is ",he~ toe
method differs depending on whether the
plate is plastic laminate or brass.
PLASTIC LAMINATE.A plastic laminate
plate can be glued to the base with epoxy
Begin by roughing up the surface that will
00 mounted in th.. recess \\~th 6O-1,'lit.and
paper, Then glue the plate in place.
BRASS.Tomount the brass plate. I used 3
trick that dates back to the days when
gunmakers inlaid decorative brass patchboxes on the SWC~ of Ointlock riOes. The
trick involves fastening the plate with
brass screws, then filing 01Tthe screw
heads flush with the ptate.
INSTALLSCREWS, 'Ib install the screws.
position the plate in the base recess, Then.
dnll pilot holes through the plate and into
the base.
COta.'TERSlNK. AIte, drilling the pilot
holes, ceuntersink just deep enough ,;0 the
:;<'~II' head is just part way into the plate.
see Fig. I L (The SCrew stot should be a
little higher than the plate surfaee.)
FILE fll.USa AIler the screws are li~tened, fiI. the heads off flush with the plate.
This gets rid of lhe screw slot. leaving a
solid brass "rivet" holding the plate to the
b.", e. Then sand and polish the bot tom of
the plate smooth,

WOOOSMITH

1'IGUItI.

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TESTfIT PlAJ1IN IfCUS

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II

Bookcase
A FRAME AND PANEL HOME FOR TOMES
The prublem with horne hbraries L<lhaL they
k~p J(I'Owing.F;ncyclopediasare adeled to
:-Iational C'o<>ographies.and soon a new bookcase is n<leek"'.Allhw~h 3 bookcase doesn't
have to ~ faJ1<.~to do it..<job,il ought to f(Ct
more respect than the (,)(1"Jx~I~ and
bricks" approach.
The traditional bookcase shown here has
relatively ~traighl.fon\'"rd joinery. The
sides and back are fram,,"nd 1""",1construelion. And nll parts are interloeked with

vuriations of a tongue and groove joint,

MAJ<E THE FRAMES

[ started constructicn b)' making the two

side frames and lh. OOckfi'llJ'OO. Begin by
ripping I!~stork I''Y,. thick actual) for an
the bottom raiL.IC and Gl 10 2Yi' wide. "'-'<'
Fig. I. Then adjust the fence to rip the tol)
r;lil~IS and F) and all the .tiles (A lu,d E) 2'"
"ide. Now eut the rail. and "til"" to final
length. 3.< shown ill ~ig. I.
JOIN THE FRAMES.

After all the pieces arc eut to size, the)"re

ready for the tongue and gI'OOvejoints that

hold them together,
&1)(:1,; GROOVES. Th. ~'TOO\'esare cut so
rle;>pk.rfth~ le~h oftheworkpiece, Now
nip it end for end and make a second pass,

thpy..., centered on the ill"ide edge of all

the frame pieces. (These grooves accept
V.'II.m[u'lXld plywood which is ,,.wllly thinner than y,', S() cut the grooves to fit the
actual thickness of the pl~wood.)
POSITION FENCE. 11, order to cut the
grooves centered on the edge of the workpiece, posttion the rip fence so the blade iii

This pnxtUCl's, a centered groove.

SIDE GROOV~;S. Arter cutting
the
gI"OO\'(>S on the inside edges, another ~et or
grooves is eut to join the back frame to the
side frames. These gn>O\'CS arc cut on the
inside fill:eof the real' stiles IA I on the 1\\0

slightly off teltl,.,., see Fig. 2. Then cut a ,/,'.

side fram es. see Fig. 4.

oro 1.H,:<.lt 1tl'I t hc~(' I.-'T()o\e~.begiu by

Itx'ating the- f('fltt- I '110":1.\V"~y from the

"f ttK~t.latll'. t'''1S la.r measuren...111i-, "lUll) 10 IIw thirknE* of th~ hack
frumc. ,til...",f"r 10 )C>tail ill Fig . .l,) Now
cut a t/'..-decp I:rf .'n the fact! of lh(: rear
~I,.for til\' ,;<),. frllnw. Next. move the
r~Jlt""Ii)lhl I, d_r \ft Ihe, bl.,t. to widen Ihe
(lillIS/Iff

groo\'~to 1/,-.

TOP RAIL

,-

,.

-. 2"1 I-

1'-

cEN1tUO

011 SfOCI(

,I
r

6ACIC
FlIAM

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I

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AU.GIOOVES
Ih"OfEP

1;"]
ST1l.E

- --- -

I'

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. '.'.'
I(

-- ------

14''I;

..

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I
I

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:'*~'J

WOODSMlTH

CUT THE TONGUES

Aner the grooves are cemplete. CUlth~

tonJ1l1e.<
that tie the parts logether.
STUBn:NON. The tongues that connect
the end, of the rails to the ~tile. art'
actually stub tenons that fit inlQ the panel
gl()oV(~. see Jo'ig.3.
These stub tenons are cul by making
multi vie passes over the saw blade to cut
rabbets on both f8ce~orthe rail-Ieavingu
longue that fits the groove. (See WIl(Hi
,,,,ill, No. 2Il for a complete article Oil this
l(,dlll ique.)
ClTT PI.YWOOO PANELS. After the stub
l~non. are cut. dry-assemble the frames
and take measurements (or the plywood
Illlnru8.Then cut the psnels lo, $",'" mukinz
sun' the grain runs tho height of the ease.
see ~'ig. I. (1 cut the pan4)ls'1" undersized
so there's some "pace at the bouorn of the
groove for a glue relief.)
BACK "'lAME TONClIES. Before gluing
up the frames. I nlso rahbeued the back
frame stile. to form the tongues thnt join
the back frame LO the sid. rram~>. CUI
these rabbets on the edge o( the stiles S(1
1M tongues will lit the groove><already cut
on the side frames, see Detail in Pig. -I.

AGUU'2

AGU....

HmCUT
!JUGHlrt Off

cut TlHONlO
AT GIOOVE "

c...,...

1/

.r~

,f...'

==>I
fFi"::::

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TO!'

RAIL

<:

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y.~J.

I'l'IWOOO
","8.

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I.PfATPlOCESS

!L

.... "'

'-

GROOVE EQUAL$.
tHtClCHESS Of

PANEl WDIP
tINTml> 01< sroqt

10 WIOfN OItOOYt

SIDE

FRAME
SACK

FRAME

SACICCORNER

IleAIl

LAST STEPS

Nowtile framesand panelsare almost ready

for ""-"",,bly.There are just two more steps
to 00 now tbat make :L<semblyeasier.
OOVt:TA'LCROOVtlS.The first step is to
rout " dovetail JmlOve to accept the top
apron (1). (TIIi., apron
the frontofth,

'P""S

case between the side Irames.) I routed a

stopped dovetail groove on the inside face I"""'"
of each from stile, see }j'ig. ;),
To make this groove. .(ljuM th., ~
dovetail bit so it's '.' hi~"'. MId >et lh,'
fence .~. from the center of the bit, ~'C
,
Detail in ~'ig.7. Then clamp a stop block
II>(,"tu lh(' leli of the center of the bit. :md

CUI the
in the leli Irame. see Fig. 7.
Afte, cutting the groove 011 the 1~1\
frame. move the block to the other side of
the bit and repeat the cut from the opposite
'W'
<liJ't-}(!tionon the light frame.
Shop Note: Alier making these cuts,
i
don'l change the setting on the bit, You
need it to CUl the do\'ctailLOngues on lhe
ends of tile front apron later,
$HW' HOLES.1\, complete the frames ' ....... 7
befure assembly. J drilled holes for the
sheJfpins that support the eentersbelr, see
~'ig. 6. (For more on shelf hardware and
tecbnlques. see page Ill.)
These holes are spaced every 2" Harting
7W up from the bouom of the frame. and
are centered v,,' from the insid edge ofthe
.ule, see ~"iIJS.4 :mrl6.
ASSEMBLE PANELS. Finally. the three
frame and panel assemblies call be glued
up. A$ I was gluing up the frames, I glued
the plywOOdpanels into the frame grooves
(or maximum ,tability.

..l

)!TOO".

,I

:''''''2..

WOOOSMITH

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)

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13

t-

LL,,.>-----------..""-------------tir-~~After

ROUtE'

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.,

THl FRONT APRON

the plywood panel.' were glued into

the (names, I started work on ~hefrol1~
apron (I) that runs across the WI' of th"
bookcase, refer to Fig. 12.
CIJ]' TO SIZE. 'fu make the apron, begin
by cutting 3 piece o( 414stock 2' wide. see
Fig. S. The length of this piece equals the
sboulder-to-shoulder length of the back
frame (>101 including the tongues). plus %"
(for the two y,,-<leepdovetail grooves) .
DOVETAIL TENONS. The apron ls held Lo
lhe side frames with dovetail t..-nons that
til into tbe dovetail grooves already routed
on the side panels. Th hold the apron
securely while forming the dovetail. I
clamped it in'. JOl')Wnsen hand screw, see
Fig, 9. Then 1 adjusted the fence W lake
jU.'"8 little off each face of the tenon at both
ends of the apron.
Th bring the tenon to final thickness.
move the rence and repeat the process until
the tenon" fit the do\'etailgruoves.
TR'M TNONS. Next. trim obout
off
the bottom of the tenon so when it slide~
into the gl'OO"c, the top ofthe apron is n""h
with the LOpof the frame, see Fig. 10.
CIJT PROPILE. When the dovetail joint
tiL the curved profile on the bottom edge
of the apron can be eut, Th do thi. draw a
I"r.tdius curve centered 2%' from each
shoulder of the apron, see Fig. 8. Then cut
out the shape. Now straighten and smooth
the [lIlished edge on the router table. (For
more on this technique. see ThIking Sbop,

.::J

V,

_-

,IDE
FUME

page 2'2.)
FASTENER GI.lDOVS. Now it', time to
plan ahead for fa~LeninJ.:the wp. The book

<, NOTCH

TENON
WI,"
CHiSEl

,n

\ I'
iO

,
I

I'

) I

BACKFRAMf

'~1.

, 1"11--"/

....... ..:.'

~
BUUNOSf

DETAIL

,f

,If..-
,

14

1 '

c..se's top is secured to the front apron and

the hack frame with table tOI) fasteners
(see Sources, page 2-1). These stamped
mOLOIfasteners fit into I(I'OO\'OS and are
screwed to the underside of the wI'.
To make the grooves for the fasteners.
cut a v..".wide kerf V,. down from the top
edges of the apron and the top rail of the
back frame, see Fig. I I.
SOFTN EDGES.The last step before assembling the C'dS(! is softenin~ the edges
with a bullnose profile. Th do this, use a v,'
round-over bit set II,." hi~h on the router
table, see Detail in Fig. 12. Rout the front
edges of the side frames and the bottom
edge of the apron,
ASSEMBt... After the edges have been
bullnosed, the case can finally be ..'<SCm
bled. First sand all the port s, Then glue the
side frames W the back frame, and add the
front apron. see Fig. 12.
TOP AND BOTTOM

Once the case is assembled, the top and

bottom ean be made. Both of theoo are 'Y'
plywood panels with a mitered frame on the
Cront and sides, see Fig. la. I sW.~1 by
cutlingthe two plywood panel!. and 0) to

WOODSMlTH

Shop NOle:The (01) frame hangs over the

esse Yo 0 onthe sides and front. so i(should be
built :y, deeper and 11/2' wider than the
outside dimensions of the assembled esse,
The boItolll frame hanj(Sover 1". so it $hooId
be 10 deeper by 'Z' wider than the ease.
EDGING STRIP. Before making the
mitered frame, the grain on the back edge
of the plywood i~ covered with a YoNthick
trim strip. Rip this strip from"tl~stock and
(WIlenit la lit<:back edge of the plywood
with small brads and glue. \\'hen the glue is
dry, carefully plane lhe strip flush with the
urface of the plywood.
MJTRO FRAMt:S. Next, the mitered
frames can be made. Begin by ripping 4 ~
stock 1V,' wide, see Pig. la. These from.
pieces are joined to the plywood with

tongue and

gt'OO\le

joints. So,

CUt

r-

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j.

to!'

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EDGING

PANEl.

", .,.

13'

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.-owooD)

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BOTTOM

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PANS.

1C Iv."O"
13"
1!''O()''ecentered on lhe in~ide edge of 311
~ .
(
~.H
lIO<JCH
the pieces, Then fonn a matehing tongue
liNG'"
~'
on the front and sides of the plywood
panels by cutting rabbets on the top and
~
bottom faces, see Fig. 14.
1'\1-'''Shop Note: To cut this tongue with minimum surface tearoui, score the c:ul line
first. See 'I'.llking Shop, page 22.
SlOE / ~
4/f'~H~
EDGING
(cutlOR1)
~IITERS. When cUlting the mitered cor
lien; on the frame, J eoncentrated onshaving the end$ of the frame's front pieces (K AGUItE }4
.--and Nl unlil the inside eorners fit the
lONGUE
~'A'I'
~
ItA&IiJ
.....
ItNa
corners of the panel. see Fig. 15. Then I
I'I:IWOO!D
1'0<'_
EIIGING
mitered the ends of the Irame sides (J and
~
IE.
L
0Nrt
RO. 16
M),le8yingthe back end a liltl~ long.
sa
'nNY RA8Bf:.'T. There's one more step
cut .. ,...
fIG 17
before the frames are j!'lued to the pi>"
1---STWGK1
_~OM~ EOGE_
wood. CUl a tiny rabbet on the inside edge
lit
r
WITH ComR
t
_'f
of lhe top frame pieces.
Fig. 14. (This
'
.L.
"'ONTEDGING
01_
~~ i'
''''.
adds an accent line and makes the joint
i ~'~~T",,~
more forgiving than a butt joint. l
~o,,~ ..l ~'I.
ASSEM8,-V. Now glue the mitered
to the plywood panels, \\'hen the ~u. i.
.,.
dry. trim the back ends of the frame's "id('
t
pieces flush with the back of'the panels.
J ~'?:.

l~/

--::-::-=:~

rm:~'i"":~=fiKjNt~
..

,.'.-

'I. rtlM STltIP~

1Vl'

""I'

-p';/;'

\ ..

I""""'"

--.

_J

--

.,

r,.....".,.

"~"-C ~

mGE PROFILE

~
To dre.'I!\up the edf!C" IIf th,.;e frames. I
wanted to make " fancy profile with a v
round-over bit and a
core box bit, "Ct'
Fig. 14. However. I ron into problems when
trying thi:; on the router table because the
shankof'the bit.harltobepuDed too faroulof
the coD~tto gel the depth of CUL net>ded.
~~
A safer alternative is to make the profil!'
with the router in hand so the collet can get a
AOUHt7
full-shank grip on the bit. The only problem
here is that when the bit pl'tljects fulldepth,
there iim\ anything for the pilot (0 ride on.
1b solve this problem. I cut teml)hlLe;;
from y.o Masonite 811(1 fastened them with
carpet tape to the underside of the frame
flush with the edge.', see Fig. 16. When the ~
bit reaches full depth. (he pilo; will ride
along the Masonite. see Detail in Fig. 16.
~ w )
.'I1'AL TOUCH. 1b complete the profile. J
COU8()'
routed a small COve on the shoulder of the
lin

'I.

r'-.

,;Y~

.J~

round-over using a V,' core box bit in the

~ 1'--

<,

/'

MAK
MUIJIPII
~~
I'ASSES

/'

"

RHCt

.;

'
~.~~

."

.t

~x>(J'

~~

GUlO

-- -

CENllIt
'''''''- SHOIIlJ)fI

K~~
- ---ON lit

.,,~~

,-,'

~,/

,I

.::
>~

-I

']

. .,

.....

T ,I

~~

router table. see ~'ig. 17.

WOODSMITH

15

=
"'.

Cl.EAT

\__~

BASE
FAAME

'0'.

_r-1lA0(
,FItONT

'

to:r

f~~:=""11~."

SIDE.......

'Y,'

IUUHOSl

Sl'UNE

CWll

1""""" :zo

I
-.,,- -----..,//
~

FlGUlltE21

aNltJt

Fh:;;:~of",,,,o;:i80~mlM~~F"'
:
:::~~:~~~
-

WOODSCItW

". X 'ft-

MITER &NDS.After the rabbets are complete, cut a 45 miter on each end of the
workpieees so the finished measurement of
the base is
Ie...., than the bottom frame on
the fnmt and sides and i$ flush 011 the baek,
see Fig. 22.
SPI.JNS.To strengthen the corners and
hell' keep them aligned while gluing. the
mitered joints are splined with sirlps or Y,'
M_nile. 1cut the kerfs for these splines
on lh.l"bl~ .aw. see Fig. 19.
U:-e the rip fente 8.< a slop and make
adjustments in lhe blade height and dislance betwe(>nlhe bl~de and fence until the
kerf L, a litlle more than 'it deep and
located about 1.4." in from the inside comer
orthe miter. see Filr. 19. Then cut the kerfs
on the end" of all the pieces.
BOTTOM PROPILt. After all the spline
kerfs are cut. the eurved profile can be
made on the fronl and back pieces. 1b do
this, strike a J yt" radius centered :;v." in
f.'Om the long ends of the fronl and back.
Fig. 20. Then draw a sll'3ij!ht line
betw~n the tops of the radii. remove the
waste. and sll'3ighten the edge on the
routcrt.abl~ using the same technique u,. on
the apron, see Talking :;h0l>.page 22.
CL&ATS. Now dry-clamp lh~ b!llW to-

I,.

BASEFAAME

FRONTIBA~\

see Detail in Fig. lB.

AS... OII

'IMASON1TE
FiGU.Rf t9

cl.,."L,

.L
_...,...-

With the basic cabinet complete. J wus ready

to make the base. The base i~a fMIIIW
jeined
with splined miter joinl->!.
curro SIZt:.To begin making the base,
rip 414stock
wide (or the front, back.
and sides. Then cut the sides (Ql to a rough
length o( 12'h" and the front, and back
pieces (I'Ho. rough length 0(38\<'".
CLKATS.The base is attached In the case
by three plywood
mounted In the
base. I found the easiest way to mount
these cleats was to cut a'll" x .y.' rabbet on
lh" inside top edge of all lhe base pieces,

-.

~~~

BASE

MAM'- <,
OHCASf \

,
-

_;:

iJt

"'*'

r-

CROSSSecnON

gether and me ure the distance bel ween

Ole rabbets lo determine the length of the

cleats (R). Then out lh. cleats to size. see
Fig. ll!.
ASSEMBLE BASE.

16

The base frame is as-

sembled by gluing the corners together

with the splines in place. Then clamp the
base \lith a band chimp. \Vhile the glue is
still wet, glue the cleats in place. (The
cl~ah' help pull the bas e frn_ square
befol'e the glue dries.)
MOm-'T BO'l'l'OM FRAlIIE. While the base
isrlrying, the bottom plywood frame can be
fastened to the case, To clo this, turn the
case upside down and align the bottom
frame on it, see Fig. 21. Mru'k eenterlines
on the frame and on the ease to align the
two. (For more on this technique. see
Talking Shop. page 22.)
Now drill pilot hole,; IIlId counterbores
through the bottom frame (0.' six No.8 x
1'1.," woodscrews. and glue and <crew the
bottom frame and ease together,

WOOOSMITH

NO" the base

MOUNT BASE .'RAME.

frame can he mounted. To do this, drill

pilot holes and drive No. S x 11,."
weodscrews through lhe cleats into lh~
plywood bottom. see Fig. 22.
~IOUNT TOP. Next. the top frame can be
fastened on. This i~
made ea.o;y by the metal
table top fasteners. To use the fasteners.
lay the lop WdffiC upside d,)\, n. and place
the case upside down on it.
C:ll'efuUy center tho ease on the toll
Cram". CU se centerlines w ulign the 1"0.
seC ThllclngShOI" page 22.) Then slip the
fasteners into the
and fa-<tenthe
lOp with roundhead screws, _ Fig. 25.

WOO'''''

_n
~!
..'

_::

- -_~-'-:._==

PlYWOOD

I.

...

RGURf26

"_'h;'

CBOSSSECTION

10'

~;.,""

',
',_.
-;:

J. ~\(

INSlOE DIMENSION U5S '1..

1""~"",

[rOlltedge ,mil bottom surface of the shelf.

see Fig. 2:~.Then rip rwide $trips and cut
rabbets to produce a tongue (Inone edge to
match lhe width 31.d depth of tI", g1"<)<J\'c.>.
see Step I in ~'ig. 24.
To complete these strips, rout a bullnose
1)'Vllleon the other edge, t with. If:" roundover bil >'<It.>\,; high). :'('" St('I' 2. Finally.
glue the strip" into position,
FlNlsH.l.taine<1 thi$ bookcase with two
c..'UaL"'Qr~tin"'axEarl)' American stain, and
then applied two coats of tung oil.

IV,,,, .....

+<?

SliflF

BUu.... OSEPIECES. B.fOl" making these

lhJ"et pieces. cut ~." x Y." grooves en the

With the bookcase essentially complete, all

lh.,t'S needed is a shelf. I wanted a trimlooking ,heif that
dy to ...u-ry the
h.,... viest h"brary.
PLYWOOD SI":I"~ '1'" make the "heir. I
started \\;th a piece or ',' Illywood and
added reinforcement on the front ed~ and
the bottom surface, see Fig. 2:3.
REII'IFORCEM'F.NT. Ocncl'aUy, I would
havejust addeda bullnose st rip to the front
ofthe ~helfto make it stiffer; But this time
II)really beef up Ih~ shelf. ) made duplieate
bullnose strips to serve as stiffeners on the

-,-

r-'----

bottom of lh~ shelf.

MAKE THE SHELF

i--,_..

It.-__.

r ""

.....__

~ IT

fD<~

,..;.

'r r:.-;,

RHC

'/

VwUNOSE
D.JAII,

[1

_...-

STRlPS

t:~.,.t:;~'~-.

0"""

11..0'.'

r',

~J-

y;

\ \

MATERIALS LIST

jv..... r ..24%'a;' "

I:

r ..
r

'\." 1( 2. 'I,' ..r

V."x8".21

')/"
.r ..
24Y,
'0/,,".

x: ..32'"

IV. 2'"'' 32

v,,"

32" ..21'V,.". 2'" .. 3S 11.."

1(

tv." -1~
10/,. x 10/'.' .. 40"
",,"x let ..34V,"
10/,," x 1~." .. 13"
1......
40"
'0/

I"",~.

0801_""",,1(1)
0/'.".10'1." ..351f,"
P &0.. ftome """.11ad< (2) ',,;.".3" ..37'"''
Q 80... Frome Sk18 (2)
',," 3" . 11,,,."
R Cleab(3)
Vol"x 2" .. levii"

5 SheIf(I)
T RoInl_ng

0/." lit 9'/." ..34.

Strip (31

\VOODSMITH

I'"

CUTTING DIAGRAM

Ovetoll Dimensions: 37lft" "" x 11. d x 21V."' h

A Side Fra~ 5tH. (4)

a Sid. Frome fop $IoU (2)
c Sido Fro~ Botrom Roil fl.)
O Ski.f=n. Po".1(2)
E 8Gdt _
Stile (2)
F Bodt ftome Top Roil (1)
G Bode fta",. 8ot1om Ron (1)
H Bod< ftome "".,.1 (1)
I Apron (1)
J Topfto"", S;d<t Edging (2)
K Top_hEdging(I)
.. Tophome ""nol (1)
M 80. F",..,. s;do Edging (2)
N Bot fTome> &Oint Edsi~(1)

~-,

.... IENU

"' ...

l7

AU ME

,1"

)1".,

SlTlII'S

~~
.~

~,r-~EW
\

APitOH

"- ...

1OP"""'~

m<a

~_,_

HGUltE25

f- _-,r

:. I'

~
....,..

..

"

PiN

~ .==1
..... ,_~~ Sloe!/JEW
~\8 , ;.
~- - . . os. '~t"" ;_~-,~
@
....
[i:~
~.",.
'I"~:--1~
.~
i_t.
RBNfOI!C1NG

....,..
"'"

914.

_'t."

-"J

'~i.".
,"-34""-

,\1;.".

7'l,,; _96~

6.=; -n-,. I. ,E:, , , J

..

.'"fI .... 5'",

t .

Xi

0'2i:
.rr

t)StIIJ~t

'VI.... 7Y. ..

J ;

e:

!:t1-2J

ttt . f2l

iJ,S,~
'4" P'D'WOOO 4t'" )C 41"

~ PO"WOOD ........

D
~

'~
W./7///.:

H~

% W3;/;/~
17

Hardware For Shelves

SHELF SUPPORTING STANDARDS
-1t-"'-"-'m-'-I-ik-I-.-,-e-l')-l-in-I(!-'-I-f,O--in-t.-.-t-h-,,----"',"I";on' Mun' tl",,,,', ""Ill<' new piett uf
h:.tnl"~u'Ct" r'L.'~t(J'sh4l1\'t~tC';l , ....1Uor into a
,~,hmd. M... I (If thl' hartlwa,, foe hokhnl(
~ht.'l\=tr;
in D el,tlirMt rull~inl(, two general
lat"j.!flr1ttl!thi~' \\Ith l"i.arul:tnJs and t.h(JM~
\\itht,ut f.t;t.uflanl" (".,uc:h~ pin ~upVO~"l.t.;;
or
,Ic,"(-I:I IJu,t fit lute) h~,k:1'Odrilled inlcl thtSlt I,,,,,,.( l... t.itk ts)

;;;;---;;:::;--;;;;;;;;;;;;;;;:-~~n:.;.t",i:.~11 tt

Ic...ute th .... thtr thn..'(. ~t.andanl,~

U>ingth" ml'lh,.I. all of the h"lo, ,hoJUkIbe
i:I uniform til...t alk'(' (nlr,' tht..hottom.
RllRIIPt:AN II.A"II(' MrANUARDS.
ll~
c'\nll~' "t' ('is{,(I\'''rt~) a 1'(.hali\ll~'new shelf
~t:t1,dnl'~1uu llla"'l nt'\\ ttl tl1(. U.R.> that's
math rn)ln:1 )oIlril) flf plastic. S{>(" ~un:4.;'l".
1J.:'l.!t, 2-1 It'" II,Nt l~rl\.ll
..i\~
than a metal
..t;'II~I;I"
1UII(I t'ltlL'4idt'raI11)'cleaner loclking.
(It's th"I)lll'I'Jl the nxht111ths- phuto.I This
~lnll fi{1; lllttl JI ).,'1""'1\'(' In the ~}{'I: or the
('1IOill(t. but ,1(1(1fIt 0.'('41 an,' nail...Ctt
KY'1'\\ ~ tll )l.;Jltl u III 1113<.. ' I ",i.'act it ha...
1a1~r-alI<"lhon 11M.
filde of the .lnp to .mp
lll< .,d.'lI oflht
see f ll!. I.
To hold th. ~,",h"'" III pi""" Ihere a....
m311 1>I.a..U<<hpo< Ihat 1,,,,1 nit., p~.,
-e.
Th(, 'n) Ill-at, dl-alt. Sllwt 11l ~ t,b, iou.. ~...
Ih. mNru dIp"

SHELF STANDARDS

'file ",""I .. ,Inmon I'Wl<lanl ..re ."..ta1

,tnl" made uf oold roll,,1 t.....L",..,.., <t:1ll
Il:tn:ls are
til'
"ide. 801131'\"('II.mmonI) ...'lliIabko frnm two to
feet long. 'file)'
have B Ii<"I"k'1'I 01 Nou (,,\t'f.\ - that acct"11t
11ll-taJclll" I" hold the ,bth C'"

I.-

N'

~Im ... 1\18ll1!;lnl

an' Cll,.,iJCltt'il fi,r surfa c'e

meHII\tIIIK. tlut nl'~t flU\ Iw- recessed tOu:-;h
Inc.Ul1l4 r ,I) irlte, a J,.,Tt"OfI"Pcut Ullo the ~I(I+!Il(
th'lal,ill4t, ~(t
I, Lthink it':, \\~f.rthit

'..hI' 'tthtr

rn.IIII mt,th(wl (or supporting

:-hll,t.~'~wuh "In itUI'J""'1.:oi " .. dowel- ... thal
;,r, Itto'lnt.'('1 Intil Ih. ht;lt!" ,ltillt."C1 in the
:-Klt~uf t hi' 4,:,.lllfllt.
PIN Sll\I'()tC I'S., Pm ~UIIJX.rt~are availItl.lt" in I..tth nU'Llu ~Tu\:ktl. bf'll.."'.:-.ancl \\aJ-

tn 1,lk,th. lin1<' 10,<CO"" Ihp standards, If

)'U\I <It))\'t rc....
("~:;....,,,
Lhl'01, ;\'0\1 have to cut the
:-.ht'I\'t""hurt l<.allow fur the thicknes,....f,f
thl! gal'

I)r(ol\~t-Jlt

('1'(',.:1111] \\'ht_'n )"IU cut a shelf

111)IA,'}U lntlwfl'n(loftlK~.helftofit

short.

aI'YJ\III~1
thl" r\laJ)rt .. n~.)

nut ('(I)u1') u,u.1 ,.la.'i:tl(, (Utll Wld clc:ar ;b.'Tfatt((Ir ~13!ot lih,I"l"). Tbt,) (,,"'f)QW if~.a

!\otf'l'T"'f; ST"SI')ARt>~, ~ITJ1t" J...'{....,J)lt

rul c:o><bo h~ ('Ullml! the ,Ialldartb .borter

,tr.U~hl "poon
or an I.

liOl,,("ul

u""""
,n.1

lhan Ihp ,..wnwI ... 1.,. I a!\\'lIY' ..........

thalll ..", lInp<lrtanllhal tJw b"am
of lhe otan.lanl n hod finnly on a ,.,lid
~uVJJOrt 11th n.'" t .....hot tom (.(tbe ('3.......~
-(l's hIlt n...tll~llJ lh:..t Im~)II'1"t411t. I'X,
J)I:UI~I Ithh ~rt'I'UI.ln Clr Ktktflt" & \'ogt, a
m.lJI.r nl:tllut:lltUnr nr mf'lal !'O.h,plr~tandanl<. "11'$ In,.. Ih:ll all th. wpi~ht "
EUI111llIrl\elll., tl11' Itil,I:--. fi\ll (ur mf~t.:lJ)JJlic,':ttilll~ hl' lIall", t'hl,uIJ hold. \\"hat i..,.
iml~lrt:lnl "Ihallll."t. ifnot nil, fifth" nail
hull" ~n' flII<',1wilh nuih<.
In tht> nlt-tul ttt,;ulrJum:- then:>'~ nl:;.o tl
:o:;.("n" .. Ilf \','rv flnall Jl"le~ (l"'o ~irlf"--h,'
...,tl\) l'\ 4,.'r\ a;,j'x IlK'h,-sth4t \\'erl~a)"o\'~' it
n* 1<'1')'I~ III,, ~ rhoto B"b ""id
Ih..... hoI..,. ...... fur" ""'I'~ 'hal', u.~,,1on

ih:,1

ohdf

'''''1'' lhat

l,rOfluctl(,n 1I11Ilalll'n., Anal"" :tnct \'~

St'lisasbl"{ glln lo hoot the~ ~tal,l(":into
t h"hc)I,~. lWt !"W)\Irt't~. llaj.!e:!.t.
\ICJl ''''11\(. Ttl' Tht" mairL vrubl\.m \\ ith
Inounlil g tite l1lt'taJf.tun.larrl~ i::- j!ctlin~ all
(IJur >t:tlltlanl. If! tht.\.':Ublnetalj~
l'ra)",
('rl)~ If the.'hul,'t' ,1'IIl't hn~ up tln the.sun ...
"1,,,11'. Ih,' eli"" ""n't he 1"",1, ,UlUth. "l... if
\\ill l,tl4:k Ill' ..lant tu onto sidt". There's a
"impl,' lilt I. lrock to 10" .ure the hole..-are
nll.llii(lw,l.

rirst,

il\t'('rl .l

rhl.

Jtp,"tlJ(

(/(11""

in

II

!'O.t~oltlat'll, ."t I'IJ!.:! Tht:'Ja.~

n ~r
hlu,,~ 1"1'<I't n Ihe dip 1Il.llhe c-..mnct00.",.
and .t Uk'h u.., llond"nllO lhe ""binct
1'"" the sUI.' .I." ....r bl<><k and the ,.am('

,.1.

"'" p"'.lu

fil-' un<ler lh,'

h:11~.1hra<ko-t

lhat hook.t~ ~ht4(.

II<' ""ppurt< an- Ir

an.ulMI th( "nel urNI lh.

AGU,( I

TIlt'

1'' '

II until.'r

~hHpL'd. !HIt ha\: e an nocllll na) :;'Ul)pt'rt

"rack,lunder Ih,' rool (.r the "I..

'Incre Ul"f' t \\(' mt tht"l' (or m(runllng tht~
[....hal",1 m.utlliuPIr1., ,..f'ig.:I. Irlh,'
C'VC" I';'" ,If th,' -I." fac."f;"sup in nf}rmW
filtO)'I(,n. It ~tll~IMli'l';
till' :.-h,..lf" hilE' lhto 4.'11.1

"r thl' .1lI'lfk..I ..

Ih~ 1'1I111..... ;eri ""curel~

jn t lu' hlllt" 11\11ifl thi.-; l'ituallOJ'l the ~h('l(

hll" In I", "Ill .hm'l tn aUO" Co,,the thickfUI~!'<j,Ilfth., :oIUl"'4.)rl".'I'hi~

mean!'> there ,\~i11
LI".Ii~hl(' " 11'("1'IwI", ...'n th nd u((h~
sh"I( nll,llh,' al(ll:> (,rthp t:'lllintl
'rh .. met~tJ I ,..t'hallt ...1 tlnl~.'kt:L' can al:'O ht..
U!'of"" "lIJr.o..UIt .1,1"'1," ~.t.'~1J!'.:'l. In thi...
1.... 1".' . Ih. ,h,lf ..111 fit right uJltu the

fIGOIl)

rep

.....
StM.a

"""""

SUt:FACl MOUNT

,-

....

-c-.c

R'_

MOtJm

18

PIN SUPPORTS

.i~.

()'Il' \\'H)'to

~~.'e.

SI Rt,\{ t Mill vr v s. FLI'SH '>IOL'T.

thl' jl;t..II1<tanl~.(Neltl':

Sf'

EUROPEAN
I"lASTlC StANDAiD

)
SCIt(W ICIlPS
SHW IN "-'IC<

WOODSMITH

It '.. aJ:-oo a \\8 V of~ttinr

a httl<"".". "I""" for ~I books or ...... ni10..1
.." th'
t The bottom of Ow ,"'If
n"''-'' "bo. !Ix "'''' m t1w""b .... t. nul bMo"

"""f.

pi,'(_"(_' (If

M ,.,'1. Ju

t rut a ~tnpto fit into r.ht.~

anf' clrill tht h(lle:- \\ herever
w~"",nC"'t"ft .. t
J1Ko llnlllOrt.anl thlnJ! i....that )'00 u.....e th~
il.) nut th,. U,... ',,,,,,,, II arr_nent
L<Ill .,,, .... lnll I!',.I. for all the ""Ie:- and that the>
drill l.'I1i<!<.a1"a~.be ...... I...IIIu.<b with Ih,
a.< secure _"
the,, 1:<111
p~""""fr,.,m tho~,.I"flh,obi.lfpu.<hm;:tIwpminwth. hoie. he.ttOJ'n (I(ttwratllflf't ~uklllr bt'ltom :Jte!(.
DRIU. SIl.: II', 1..~';"a1 Ihat if you're
'Ii. '."" "'....". tIw ,Ii> If. me,,! m..t..J lr
(ItiI1U1Jt'hul('ti. to Itlr,\III\ (I I 11)lt1 support or
"""I~.I bl11<k<"l.
have a ,..."'\\ hole in them.
Scl\",in).! lll~' hnu ..kl~lSto Ow ::-htM:o:t.ab.il.iu._~ J." ft~I\\t'I. ~'UU \1.;(141141u...v nil- drill bit.
it, 10111 u' m..,, .lifficult I"
Ill<' ,h,lf Loj.!lciil, but rl4,t prnetieal. I've round that
lhe pin !'tUI.I)4'I1,~
unci If A- dowels range m
I......
iti(llt
l'iiz
..c
fn)m
.~U)"lll
,2!',!"," thick ('//' is .2.:;0").
UOW.;I_' '\11 ulternative 10 using pili
1'hf thit'k('r IUI\S ,\Iul ,II,,,,t.I:-.can ~ fOn.'ltI
:-IUI'lJe1rt" i:. dowel ,)111:4:. llisuall)' UJ'!(" it VI"
mtu a t hllh' but ~(~ttlllg them back out
tI"'H'1.1"1 1'''"I((~
into Ih~ side u!the
a~Mifl can he (I,fril'tlit - RI,d lhat':-; tht'
t"'dl.lntl and n- tlutl"r the ~l'(IO. I've also
\, bolo (I)r h'llt) ul,:a (,f udju ..'abilit~.
U~"ft t,,,,nlA' "l'111111Jlft.1 k pln.~.
\\ h.lt atx,ut (InJIIII~ H lilli, bi}!g.:r hull'1
:-Iflt' (,f tilt- ('31.1"1'1

eabine

01""......

DRILLING fOil PINS

4'11... 'o){a:;(_'r

0""'.

\lAK.: Y(lt It
I d(-ad,'"
1Il$tm) ,1\1. II Yolnt t.1JJ'poru and

to try mak
bought a 3-

t""

".1

foot "'n)!lll or .."

from
hardWlIN'
f..tort for ,~. f't ntll. ..\ft ..r C'Uttirnt the rod
Into I"
hs, I bent .. at .ach "00 \0
:!IJ. Then 1.lnll ...It"" lb"I(',inlh",iJ~
of tho railm<l'

To mCIU'll thl tLhcl\ e-, rout a I -" me

sl(>t in tht lncl1'litlf th. ..ht'I\'~:4 "'itll a ~14Jl
Cllttl:r (or 1". ... l'lrai)!hl hit) to a'-c."(~ptlh(~
~NI I~)' l"t.'I'lun}! 1Il4' slul I'>hort o( t h," front
of the .hdf. il won't Ix' seen, Another
method to ('IUlt't'Jilthl' ~lul would be Lf.,"'Out
.11 Ih. \\,lIy thr"u~h and then cover lhe
rrunt t"'CtJ.:'~ wuh n rUt", ~trill, see t'il{. 5.
t ,\ 'hen U"IIIK ply" Ix)Cl. 1ell! this anvwav. )

',,!I

,oart

" HYIRID SYSTI:M

th(, tfll"ralK't! fJlC&lchbt-lU:~

Aft"r l1.''''I':!h<. "",. :<1111- ,}"",m "",I I""

fic.J\\tIIJtn ~\")ittrn.I t~dI1 'II tl'Iink "fa \\~\
or clo\\ebo\~r lht'lfI(_~ :-.t..UlfJ.a.nb ~ t..bt_.t.r
to romtCll(' thc_t t"., (lJl"an tn('\IKn..;i,'" and
atlmd'\t
t',)i tl.'In \\Ith th .. t'ocl:-. (,f tht I
i.IJ""I to11\ ''''' "'" .. mln~"",,,,"1l~ ho"
IT\;ln)' tdt~\"OlI "<iItIl IJ)It '" hi-T{> )'OU \\ ant
heh '''' tlj,>!It (,.> ".1') 3Ir.Ull.<I tho- cabinet.
tlk m. ",.1 Voo ",II od<lII...... ho"'-' bl<'r.
~
tI>'i'tt.11l WC":'l (It,""L, and he:.::.Iikf'
U)(;ATIN(. n ...: 11()l.S. ~f) rnattA:r hoy.
"m f)...um. but tll<
are
huk .t,IT. ,., nl Tht: hatk ,~Ij!t' of the :;belf
mall} }.. ,1"8 )uu U.l', It':- lmr"J~lnl th::tl the
hul,~ tKlul('(1 UI. u(t,:ural('I~'~Il lh~ ~h{_ol,~(':, rnaChUlil'ol~ l" 1~1 .lrill bit, ~ $oun ...:-;. ha,...a f ....,,\trutl :j(b,)lC.ovt'r a pin (hk~ lht!
l\!iJ!t> ~ I, \o"f-" I,il 1:-. .tM)'f lar~er
in \\ It\" ul'flll,rul. 'I"hL"" :.It.tt i.,-. :-;tol}J~ a ('fJUI11~
ftc;n'( "I"nt e.r nJl'k
(lIlt ortht ,,clJo.l(!to!t y.a~'~
tQ align the h(lh./'i .Iianltt(r lhull It .- hil,
IIwh.,.fnoll Ih. I~,"k.On thp hc.tt"m ,i<1..
Tht nl(t.,1 Pi" I'iUJ1})()rtl" I'\'e tK~n U:OOln~ ,...... In. (" .. I "f tilt' ,helf lhe"," a p.."kel
L' It> milk, a "nlhnl( ~'I1idc (",m " pit'<.~of
,,"twgl\();lJ"(I. ~tlt I"ilt, -I, "I'he holes ill nlf)"l
a)'t' a lot I:u:o<i,'" tfl ICl't il\ anti out Ilf an .. ~~.. th.lt (ltd .1.1\\ It I.n R I .- rlt,\\"el, ~ Fix: ),
.;o.;i.1Allnl",.Allrl II,ave'n', Ihltii"t..t an~' pn,b1lt.gbt.u,lllIx "K'lIl,,1 1llllart.
1;. ~.t110."""If inlu "I.",. fit Ihe ,101 in
10 mak a 11I'1(1",,,nI,Irill J.,'llidl!.cUI. 5 1(,1lU' \\itl, l,r)'II1~III"l(,.,r fIUI.
th.__l'<h"l{ t'I"1....0' (or th.: l){lckcl(.Y;el pin." ancl
,,,"~ .tnl)
1.'IMgboanllo Ih(' I~ngth of
t""n -1.11-I Ill''''''Ifl"w"nlthe back unlillh~
WIR[ SUPPORTS
tht' c.tl,tlltt ,(ll. ):,;,u clt.'l' ha\'(t to ~ 3)] (,f
IWl(kt.tsf'lll nl:hl fIVt.rthe f.n'llt l)lt1..~.
The,,' nne .('" r I""'" .., ,,11<'1f h:ml",,,,,
n,.. "'' Ihlnl( .bUIII Ihi, "y,wm i>; that
th,' h"I". ", lhe I" "1.",,,1. In .0000"",t ,,"h
n'" n,,<ltli helf "'~\ lhe nuddl< three or that's ~I rth fllt111'f.'lIltg. Thl')"n. \L...u.all)' tht f"Jllt 1'lllS }JI'l'VCTltthe sheltfnJln slirling
fc)ur h.,le$ nf't'll to tJ.. u5e'lJ Th~ l'l'tJblt.omL' ralk,1 S" 1<II Ivie ",,,. '"UJ!i"rt.-.' tl (ronl to bac:l(."hll" tl,.. hark pili' """" tht'
loc:aUIlj( 1m:.. hoI< III reb" ..n to the hoI
J:lK.... tIM mwnal ideltcrune from :;weden.)
helf f"on upI'm!: up if" ,,!(ht i> a,>pIit.-d tn
lum "tlhe rolJinet or the butt ..m ,""If
It..'T 'AIR. l1M.* 8~...temron.~~of a lhe fno't .. I~
bf.rlt pll."l,\ , f Win" l}w fiL'" into ~
CJf
1" clclthi~.tigun.- out the i-J" (-:-.t pcr.;ltum
fiNAL THOUGHTS
ul' (nlm th( bc)ttom ),c'U might \\-ant lilt' hoi""
the hul,.,. for Ih" pin ,tyl~ ""1>poN) .lnll,,1 Inl.. th< .ide of the> rabin~l. """" ) hr.1 ...,' helf ",~iJd",,1 d.,wn
Iir,I I)ustahY,.helf 'On our "'.,kca.. "c
y"antt ..1 th,lf,y,,st hc,....7 - frum r.ife bot ~ f a~.:i. Th. ht'lf ~It.:-f.n lQI'0rlh~ y.;rt- wlth hf k:, ,IIKI ~UI.'''lrtt'(t t),) 'Ul~ CJf ~
te,m flllht" t'30IJl.t 1"1,1t'.:-;eep:lge 13.) ~oy.
"r th, ct.1 uf Ih. ,h.lf ....
.u\ be .lotl<:<1 311<1 1,111, :.h,l( ,.Ul'I)()rt,.... It "l,ukllw
ea...). t., l:te
C\lt th .. 1)t'),ftM,arcll'>othe clil'lance &rIm lh~
Ih,' ,1",lf ,Itt! in "v....r Ih. w~.
l",'''~m..,111111.11,,(th .,.. .helf "Y"lcm;an:
1'h('l1". hUlh "n advlInt311'P and a di<ad
1>;.".1 on ,h,ar ,1"'llj.oth. KnaP<' & \'01(1
bullom "I' Ihe ollil' I.. Ihe ,..,nwr of on~ of
th .. hell,... l'tll1U)J4thuo. In~~W'emcnt,
Th~'n vnnt:tRl' tl' t hi:o<"'~'titeJn. SinCf! the $11~Jr11"0 ('l1gln('('lin~ !-Ilutlwl'i t(h4J\\ lhat tfwir metll1
OUl'Ioh116r.lirl-ht
t lUI illl'ticl, ral.'4,' of the cabill(.t,
.(Jmd:u.b. r"n,mnple. "ill hold!i(KJIlls.per
11'11f.11lill Illllrker lucircle lh~ hol~ that
th('rlt~
ru.
gal'
tM.-'t
\\"t'tU
lht'
~Itclf
an(1
the
IIc"cllu Ilt.'drillld. andla""" lhp holtom"
""UlU"" lUI ull n I \\'0 foot "".If.
C",itlin4'l 1011(',liut j(tht \\'irc~ nJ'c slill (,\,cr a
(,lu_1uf \hl ~tril.
It. nnt
likelv Ihal any of the",'
.1t.1
in
II....
h,lf
(II>
i.
usulIJly
.Ion,,).
th~
""1)1",.1.,
"illl;n,,,k.
iI', much ~~'''' likely
."Olty ,,1 '('I(. If )'"'' "ani lV.pa',.. lh.
In., ,tl\'lf iu..-1f ,,111"'It. So l'I>ou>JnI(lhe
helli' l,1'll'4'r f.r fl-trthtr :tJJ.ar\ than tht 1 ,helf won't huhl II. mud, wei!(l't 1J<,(aUS<>
"1)J,l'iJ\~ j," 1)t'gIMJ.,nl. an aJtt'rn:tti\-~ 31)th~.... ,...Iy Ih, ,mall h" aho\'p the ,1,,1 l'On...'Ct fi.:u'''.IJ1t-\",.tt:m i"'Ill4,re Hl,ue~tioll4}f
I,n-,a,('h '" If) m..kt R -.t_.t()r_)' ~ti('k" from a -UI'Irtln~th~~h,lf.
\\ hat """b I"M-'f.C
:w-tet i.....t'Ok'l~'~1 t4:) lMiju..4..
0"" o!th<:' lJi~t .. h .."t.:lj1l'" of using vill.'

lhe ,17..' "f lhe l'ln antllh, , ..... ofth, holp.

lhe gn"iIk,. th, In n)!lh: ~xplained Bob
Sonn.~lu.-If ')'IU allc)" an)' ~13(k.lh{ Vin
$hlfuo",~IandWuU I.. ijt",...l1y 1'1")" ~r t~ar
out thi- "1(,(,(' flf "fJlJfJ."
IJut to nlak. t tIt l'In.... a little ea..otiftrttl
n'm(I\"", 1'\" "t.tr'14.. 1 Ul'>lng ;.n "F- It'llt"r

t"'

""'h""

,natI,.

nr

a'k....

"'r,'

_.

,ru.,

SlOT AND POCJ(ET

an "'"
IN"""......

SlSTVo\

I'OCIII1

o ..-r$0Vt1

oowu ....

WOODSMITIi

19

___

M_a_ki_ng Shelves
MATERIALS AND DESIGN

"'hen we started working nn the bookcase

(~h"\\n on ptll.'l! 12). the fin;t 'jue.luln was
whether th.. center shelf would be .t.rvog
enough to bold a fullset ..Cbooks- without
sauUlj!.
Books OIre he"".\' - h~a\ i~r than th~y
look. A !'E"lof ~n("ycloJledia. for example.
weizhs ill at about IOU 100. \\'h~n you're
dealing with lhal much weight. lhe shelves
in a bookcase have to 1)4l(ko;;igned10 hold up.
'!'he materials )'OU \L~ for the shelves and
any method of rCln(orcmg the shelves beeeme important, or tIl(> sbelves willsag.
SHElf MATERIAl.

There ace three materials c"Ommonly

used

PLYWOOD.
What about making shelves
Particle board 8n.1 pl~'w()(J()are ""1>1>out of plywood? Plywood doom'. u.uaJly dally suseeptible to creep because of the
wurp like solid wood and it's dimen8iollally g11l~used to bond the material together,
stable. The se chara eteristies arc impelr The glue stretch es over time. The particle
tam in II book..helf where you W3111IUIt board shelves that Y"u put up illlhe $h,,1'to
shelves that won'. expand anti ('1)1111'8<:1
hold paint. ~II'
might not sa)r at first, hili
with changes in humidity. Rut plywood will
mlly look like a sway-back ho rs e I"ady for
<31( more than solid wood.
th~ glue WCW1')' aft"r a couple vears,
I n solin wood the individual wood fib..rs
1'hp"is anolhe,thing 800Ut C~I" In all
run along the length vi a board. Th"~
"" .. I materials creep inereases ifth. t.m
fibers resist stretching (.agging) along perdlUI'I'or hmnidity increases, AI." green
their length :;0 n board of solid wO(J() is wood CI'ee(.18: milch more than dried wood.
stiffer along its length than il. width. tTIll<t', anolher re ..'on to use kiln-dried
Plywood is constructed so thal.i<"u, of th~ luml",r.)
fibers (ev~ry other layer) run along the
SOLIDWOOD.If your only >,,,,alin buildlellJ1;th.Thi$ keeps " 1'1)'\\00<1.helf dimen ill1,!shelves i$lO prevent sag, &IUd wood it'
sionally stable but the "h~Jfwon'l be 1IS.'ti1T th~ 1",.1 d"",... All Lhefibers in solid wood
as
of,;ojidwood.
run al"nll' the length, and as long as the
.helf JS put mto the cabinet lengthwise, sag

(or shelves: particle bo:,rtl. plywood, and

""lid wood. Each
ndvantages and dLsad
vantages, ,mel each ~'S differently.
PAR'1C'LE OOARO. Fur most $ituation.o;
th.. worst material fOl' shelv,", is particle
board. The wood fibers in particle board
run every which \\'ay. This helps keep
'I.'OAKPQ'WOO()
particle board dimell$ionaUy <Iable. hut
do,,. little to prevent sag.
% (''Y , WHITEOAK
However. particle boar d nu,.\' be lhe best
choice in t \VO cases, Finst. if C()St i~
8 factor.
pru1.icle board i. vel;' inexpensive. That's
why mnst knock-downshelves you""" at
diSl."Ount
arc partide board (",m
plet. \\ ith fake wood Imlin). A S<1<:ond Another factor colltlibuting to th~ weak
reason tl) use particle boa,,1 is it'. 3 good """" in 1)I),woodi.thut it's """ally built up of
flat ba,,,,, for venoor.
dilTerenl.ploci".ofw",.I. The fa"" pli~smn)'
The key thing here i. that there', " he a .irong hardwood slIch as oak. but the
lll....
iclc plip$. could be M)1hi.ng, even t'oft..
number of diffe",1l1 kinds of p:u1.icleoo3rd
available. Some Mg lIlore lh,UI OIhel'<. For light b:..<swOOtI. And lhere might be \'oids
".ample. low density. class 1. particle
tbat weaken it further.
boanl ha.'\a Ininimurn 8\'r..nlge -E" rfictor of
CREEP. There's something el;;e I should
only .15. (The .~" factor reien; tr> the mPIlUon aboul 1,1)'Woodand particle ooard.
"modulus of ~1'L,Ucity"or .tiffn"". of th.
When YOll fir<tload bo<>k. on a book.shelf,
board. The hij!ber the "E" factor, the Ie,," the sh~lf lIIay Sll)( slightly. 13111O"~I' a
the board will SIIg.) Medium density. class period of time lhe ... 's an additional sag
I. particle hoIml hAAan "E" (aclor of .:1.~. called "creep.'
Ann high riel\.<1ty.cla.,,-, I, particle bunrd
has an "E" factor of .:!-5.(That compiJrt'. to
1.24 for Ba.<tem white pine. one C)f lhe
weake.<t pines.)
[( you dc'Cide to 11."" particle hoam for
shelving. Ir{q}, d"lIflit!l particle board ($I,ml'tim"" ca.Ued'robiMtmaker'slmlde" rather
than "underlayment") would be the b,,,t
cboice .inc... it'. :UighUy stiffer (but aJso
oonsiderably hea\';er).

ru"

,1.'''1'.

20

b""

will be k(_~I.1tel u.minim-um.

If till' WIKMI i,particularly den.<e. such Ill'
.,,,k ur bll-eh. th., wood ceil walls arc thick.
there are mort' of them, and they tend to
resist the eomprcsslon a11(1 tension forces
(lu.l take plac~ within shelf under load.
What this aJl moon' is that as a rough rule
ef thumb. it's usually better to make
shelves out of a denser wood . As an example, yellow birch has an -EO factor of2.01,
northern I...
od oak I.t<'Z.black cherry 1.49,
and ponderosa pine 1,21;.

SAGGING
Ho\\'

sa)t is too nm('h'! )'OUI" c)'e \\'il1

.l3I1. to _ a deOection (sa)r) of niJ(lut ~
l1l'r running (""I. For e,ample. if" .hvlf b
:!Ii' long, it sh",dllll'l >ag mort' tmu, ' !'.t
the C'C.llte)~That meal)!$. a I/H~"sag ,,'ould 00
acceptable. but a >/,.sag would become very
Ilaticeable.
SOME TESTS. Before building lh~ book
ca.e for this i"sue. I did S<)me$irnilip tests
to compare the ,;ag of different .IIelfInate
rial.. I te,ted pieces of ". high a.wity
llartid. board. 'ii' oak plywood. Mid 1/1
(. Y.,," actual tbickl\~ssl while oak - ~.ch
piece Wa.' Cllt I if wide by ;j6"long.
To "et up the t.. ls. r.UPIKlr!ed the piece
at ~eh end and mea:rured lhe cli><tance
from the bollom of the piece to the tOI)of
the bench. Nex't I pl~ed six bricks (4:1.
poundR totall at the center of the shelf and
measured the sag. _ photo.
Inuch

\VOODSMITH

RESULTS. The particle board "ugg"d

about hi', see the chart on the opposite
page. The oak plywood !!a!!:lted3 IitUe I"",
than', ". lind the solid oak only sagged
....... L',ing th" 1(,,' per foot rule (01' 'f,,,,'
over throe f""t). onlv the <",lid wo<KIis
acceptable,
.
RfDUCING SAG

Does this mean YOII"hot~dn't use I'lywood or

particle bool~1for shehing? No. A. a matter
of f""t, tht<yntis:ht "" 11<'1.
te r choi"" $in:

,e

they aren't ;1._ likely to warp or "'parKI Mt!

",.,tr.;(1 "ithchlmge><in hunudity. But whr-n
u,;jllg them (n.; wdl "" ""lid wood), Ih(lre a",
N1Jn4,.'H1.clJ~~tlU cam lake t,t) n..odUi.~,1the $lj!.
OISTANC.:. Fin-t. cl~t"rmiJI~ if tht"n' is
some \\'3~'to design the cabinet to decrease
the span of the .helf. If you reduce the
span. )'OU can l"C(iuct:lht, :,ug. A rull' of
thumb is if you cut the span in half, the sa((
will lII'one eis:hth as much us the oriqinal,
Pur example. a M.1f that'" :11; long InIIY
~g 'I,..'! at Lht c."f!l,te~ If it'l' ~UPpo.J"t("'lso
each h.->1fi, I,,' I"nl(. the sali( on e~ch half
"ill "" n><lu~ to .,....
I!'<CIIEASE'THICKNES:>. Anoth.r solution
is tv intl'lill.'Wth~ thiekne>:.,"I' thl! 'hdf. A
lhitker ~helf\\ ill Ih1U1l3Li("~lJyinert'us. th"
"hell''' rigiclil~',If~'o\l double th~ thickn""'.
fot examplf', }IOUC31' 1"(.I(lu(etile ~'\g to OllC
eighth of the t>l'iginal.
To test thi. I cut a piece (If Go t (It,
thi~k) \\'hite oa.k t.o the Slml' dimen~l(,n:;<a...
Ih. other tpst "heh~$.When th.. brick.,
\\'eJ't' pil!'C:1 on. th~dcl1L'clion \\'W onl~' a
little 0\'01' r ,.1"', \\'hich ('ompares to a::;.:lij!of
1,.'(' .. )fo~44,;tock.
REINFORCING MfTHODS

SUPII(lI'lil\~th. <xn.....r of" shelf. or dnubliOlr

til<> lhicJme",. mn), not "" realistic ""Iu(ion.<.

A lII'tl"r 3Ilpr.."ch to n><lucin!!AAj!'i. to 0"

,UJlJlUrt to th, ,,11ll'"or unde!' the .hclf.'lr.
(.'(immOT' t() SC<! ~hcl\'('s \\"ith a ll\c~ strip
addecl LD the front edl!"_ Thi. i., not jU"1
det.'Or.ltioJl or a \\'U.)' tu l"flVCr the l>dge tlf
plywood or particle b<mrd. I"ucing!<trips 8re
a functional addition to the sh"lf- the slril'"
at't" tb4!'re lQ ac:lrl ~tiffne.s.'i.
A "helf is Iii," Ii ix1 laid flllt on iii< ,i<1,'_ if
you lay a 2x1 Oat b.,LW('('n two end .uPI)>l1.>
and ad" weight. it w(illl" d"finitely AAj!. But
if )'(lU tiPIll'Ci thl! SWlll! 2x4 "I'
l'ug. ,Old
added Lh~" eight. there \\'ould be '~r~littl.

hi'

PER 36-

edge I'liC$ ancl d"e,"'! decrease the ,helf

paee. l tested tN.' arrangement byac).Unl:
a I'4"wide strip howlIltaUy to the mont of
the plywood. The plywood ~cd
.. lillie
more than .t!._ That's an improvement
H""r (hl' plywt.oo without f_ strip but
nnt as good 3.,< the strip on ~dg
e.
l!I':OERSHEI..F !'lIPPOR'T

Sometimes "

"el1i<111.(ril' i, nr('(I('(1 for 'ilr<'nJl!h hilt

deesn't fit the desij!'fl of Ih. pruj<'i!t. Oil.
'\'a~'-to hid,~th( SQPIM1rt. is to put it nvder
the shdf. The >UPI~,rt tak,'S up Melf SI"",(:,
but it ,'JUt lw fit int.-, ~I ~rroo\',("01 in the
bottom (I( the .helL
I ltie<1('I)I)~\)in~a '/ItI"rLhiCk lly l"~\\;(lc
l'eiIU()rcing-strip of alwniuum ililo U gl'OO\ e
routed illth~ ""I tOni oftil<' plywood. Adding
thi, Ulin ,1.Iip of aluminum u"o('r the sheli
was col'llp.1t3bl(> tn nddin~the l I wooden

WOOOSMJTH

stnp v,,'rtU;all) to the facu - sal! \\ (L_, re....

<ilt"","I) tc, t/a.
) alSh

uet.dod

t.ry udding ;on'" """']

f'\IinifJn.ih~ strips 111Id(" tht'" ~helr \\h\1~

th~y "oultln'! .00\\. I cut a cnUljl~piec..." of
1 \\'id~ hnrc)\,ood strips (with a tonl!\w nnd
bullnos--d fnce).nnci giuetllhom into ~'1'tJCJvc!'
''Ilt into the bottom or th. 1>lywoorl.hplf. It
N~f"(l :1b.:\11t 1,.1: which was riJ..,rill:IL the I .

J)Cor fUlL nil...

.
BOOhC ...
\St: StfELP. ThL.. method of rei It..
furecm-nt was the ".3\' 1 decided t build

til" ,hI If ,in the hook,.._. Th. shelf i.

I,J) wood (:-;CJ il \\ on'l be a....likely Ltlwarp ur
expand nr eoutract), and there's a bullnose
rntthlulg :olnlt (In the front l'(lge - nlnsll~,
tn
,oI tlw plywood layer,. !-'Qr .tirf
Of',' I ".IeI,,1 lwa bulln"~p rpinforctn,:
strip" to til<'unck>rsid(>
of the ~h(>lr.

'~tIl,
...

RECOMMENDED
SPANS
I----------------------------------l
If

)'<H.ll1!(It-signing

;l t'li"Ulel.

\\'bat's the

f,.~."atl'ffi.lp.nJ:th("pHil) a "h.lfca" Iw \lith""l

an "b.itti"llabl~.-ag?TheN are (Jur facto'"

Rr.lI'i~(lIUt.~tt:N1:
FirWl~.lfyou "anttu

Intn>W\(" tl'e :..pan. ~'I'U(1tn aflclrvinroh. ....m"nt to I'NiUCl thtl' ;ut1(.iuntor .!:.tljlt.

COlfll":!.lI'iES. Thking all four rncto", Into

to """,.ider: 11ho\\ the 10lld",di..<tribllt.."'. 2)
the eXIXoctedload. :l1th, $heJfrrotenlu. al1<l cc-lll~111lnltion.the chart !"Jlfl\\b-t!Qm{!~n
11 the mothorl of ",info~menL
,..1,..1 ....,Jlflllil\C~fur lhi: mJl:\imum ~Jnlnror
LOAD DISTRIBUTION. For thl" t.>-t., d. !'tl...lv(>S.to a\ oid an objoCtioriable-~.
I>Cn'bed in this article. I W8Jlt,'(I to dCl<:rThe mns( pr:)cticaJ approach to "",,-114
mine the "'\vo~t rw.s,,,iblc :::;ituation'" (Qrthe :,t'JCk. or ply\\'ood \\'ith tl!inCorcemettl.
di.itribution arth" loon. So I u."<,<1 ,ix lorick- j' TN.- \\ill I'rodun' $hel",o< \\ith ntiniruwlI
O:! ""unds). and 1'1",,""thorn right'" the l'al( and the best "isu,,1 9JlIll'ar:lIIct'

I.

c,"ler ,,(the
shelf.

Ho,,~\"er. in a nomw mlu:J.ucln tilt", ~l

\\'~ukl "" db1ribut.'lluver tbt- ~/llin .helf.
This '" the 3."-<umption ...,,1 to d,\ dol' lhe
thart 1111i,:bt.
t:XI'I!C'TEDLOAD.Anothermd'Jru. ...-d w
de....rnull<l maximum >pan L, th, (01<1] ex
ilIlj!'.
pected load - the lon~r Ih,' "hdf. tbe
ItAC~ STRIP ON EDGE. 'rile $o1me tlri1lci
mol'll oo.,ks (and \\eil(ht) it has (" hule!.
pip "1'i>Ii.~if you acid" faL'" strip on edge 10
A runnio!! foot of avenlg("- lu,,1 hook,
the fronl of a "h~lf. To lest now much this
weighs about 20 pound . So a th,....,.f""l
h~lp" a ,,1),w 1 shelf, I add(>d a P/'wide
shdf rilled "ilh nver: .".";7..tI 1>00)<'< would
v.rtical ,"lnp of4,4 aak.tock to the front of haveto,uPI'0rtabout
00 ""un.h\. IRl'Wni:s
th. plywood ."elf and m"",,ured the ""g.
and .I'~yclopedi"" \\ould ".igh more,:1nd
Without (hI' sttil> the plywood liIIggc.'C! ')!".
paperback books less.)
SHELl' MA'TRtAI_ The third ractnr Ui!e<1
Dut "ith the "ertit-al fadnl(.lIip. itSlljOi!'od
un))'.,... , ~e chartUbc:I\'('-.
to detcnni'le maximunl ~fXmi~
the type of
ROftlZO!'<'TALt'ACt; STRtR \\'hat "bout
material u><,<1- particle board, l,lyw()Od.
lIt1ding a hOlvJlntal ""lid (ace strip to the
or ""Ud woocL Each ha. a different 'E"
front of the plywood .h.lr. It ('Overs the
factor. as discu.."&'<1 in the article above.

(I"

A\IlSI8lYACaPTAlIlE.SAG

r---------------,

MAXIMUM SPAN RKOtNoIENOAJlON

FOR 10" WIDE SHElf FUll OF BOOf(S
'!fA" PARnCLf BOARD

'1.PIYWOOO

24"

% (,'1,.,5000 STOCI(

30"
36"

,~(l'f'.")5OOOSTOOC

6(j'

'to" PlYWOOD RBNFORCm

WITH:

t 'I," WlOf FACE STRIP ON SIDE

36"
32"

AlUMINUM STRIP UNDERNEATH

3f>'

MOlDING STlUPSUNOERI\IATH

36"

1 V.WIDE FAa STRIP ON EDGE

21

___

'E~a~l~king
Sho~

SOME TIPS FROM OUR SHOP

Thf n.,,\.,,~~ u. nXltt-'ff to leave a
lip
To trim
11)',,"0<1 tI,, nUll<idll.ll(\". 'I'JlI.'uniy re,;i.<tanct- start hy
l, ."

CUPI'ING BOARDS

Hy Ih., um 11~lg"l(lu,'<llllld then planed"

blank fur 1111't"I' 1111'"n thl' table dock ($(..,
paK" !( I, it Wll.. ""tling late in the day. s., t

ju,1 "'I th. blank 011th. cu. 1(11'to see what

It ","11<1 l<.,~.lik, IUloI then len. it tlu.t WlIY
f.\,tmight
\\'''''n I n\un>t<1 tht ""\t momllll( bolh

tilt- blank (",. th. 101'<01,,,,0<1th.ca._,<,WJ' had

C'Ul-'IIt'(llfi f'.'J.MJSlt.. clirt"'f1l(tn... 1'here \\1:L' .1
V." 1(31.1x1\\.'eIII"" I"(ore<at the fronl lIlId

10 rlU1lin~ Ih. two )!it...,,, Oat 100000tho<ri;> Ihi,

n"n" .... lip. Aut! it
puUed dU\\lI <'l<'iJ),
with ""'x'\\" I" ,Iinllllat .. Ih~ ll"P and pro(tUi-~'a tlVll' jellul.
111Inak, n,, .. tikl thi s, <tart hy iayinK
It out \\ nh .1 114l1c'.1
lr3vlnp: a V..--wjde Iii'
l1"u"IIII IIw ,MII I,. 'I'JlI.'n f""ten tho<boanl t"

,,.11""

th,Ix.kh II

1 ,~.llbl"'KI,'t).,..".,t

tilt (..Iur t-l(I..~

p11... hins: f)IH-'

fJr a ooor frame,

sltlt., of the frame

throul!il I~' hil k"'I"n~ the frame lighl

'lI(auIIIIlhl' f''K'I.- jll>1 ",1,, il I~k"->;(>.the bit.

=-

t ,.WCI:

"'I''''

(or larc\r) strdit!ht (or

morwinl!) hlllll the rouler.
J\nct """Jilt;.

b3<k.
1'h<- <U1'IKIIg de\{'~1oed bet ........., I d.ln\
a11v" t!k. rn..ldv-pbn<.,1 poere-; 10 MIlI!a,mlg
adJu"\ to

tI,,- ilry en''''''1UT1<"1I1in tht! ;Mr.

The air <"u~1 .....i1) dry the out.;id" o( tht!

I"t"<,~. tlllit f)f( tt....~JL_o;ict~wbere the tv..,
I,i."(,~laiCI t(~I"(lwr.
Th'n'

,.00 or the fin<l,"U1 tht-l"C mav be a

.tiJ;!l1 "h'I"UI III tlK mill'" on tht! ""xi ;:jd~.
At

a'" ~ c..ml)le ~~UllljJ1ti.to lh.i:$111"o..

IIm. First, "1,,"),, stan......orkpieccson edl'

as ~ (.\1 work un ...JJl"ttjloct J )nn\ la~'
pil;r('\.";"10 full
OVtll'nis:ht(Ill Jt bI'rM'h, ttHl table saw, or on
(tleh other
If a JII,.... "huu1<l\\"U"I' (<UP>.Iry Oil>pingil
ovr-r tU141 10..v it lULLI,n the
~cle. It JNl\'
1.tJ,~ Oillllll;1!II 1.1tk ani! forth a number ,;,
lim to "'lIllI4. tt'ly Oalt~nthe I'~.
\\1 0 l.wung ~ blank 1Ial. plane both

'If, ('k',1I1 1111 thl; l'Jllr~uut. move the frame

lVUllt. nlciC.k\\ i: ~uwl .'.lll the next gicl(i.
111ltl\\"rkll fin,. 'Itltd Yf)UR~l to tOO last ~i(fe
- a firnllla;lAAh..n "'Iulel Milt out tI.e fin;.l

,,,,,,.r

s.It

If you JU; liIanP one "ide.

)0',....

OJ.,m~ UI' th. '\lxvl <t'll.,.., the bWtk IIn.-.I'astt r "n tlu.t Id, and at", mak"" 1Ibkcly \b
<up m that din.'Ct......
A HIDDIN _(CESS

Ilkaj: \\ hllt do I do if I I'Iln\ gct 3''''1' or

ho",

(lUt elf a b,.lll"l'l or ll)ert!'! ~ JJiJ;!ht cn.\\:n in It

from ()\'(>n':q.r,r lI.lOr1I1la'. ;meI I,,"ant to ilL.....
tfon It ttl' tl.,\vn (jl ;ut(,(lM'r htxml?
Th,. I. "elu~lIy wlult h:lPJ)(ont.'<i,,;th tbt,
to ... luul tlll' t(,P t.OUf.t tnt our clocl<.. Tht
1"..,I>I,m " .. ' 11"ltillg th, Iwo pi....". 10 fil
t"II.tlwr ti~hl "" 111<',,\\'ouldn't be 0 gal'
"h,,\\ Ulg nrI11ll\(1 t ht' out I/h todites.
l-a.'l4,,_

~1C14.

10takp 8 '" -d<"'p<llland

f~'h:u~1 rout ,.,11"" .... nler nfthp
n."('(~" l)tlt Lt, the 11('1tC11 [lilt'

Xo ....""tt""lxl

lOIJ'\fllll),

TlIMMING

OFF

I ,

\\ 'ht'll I" h"ndu'!! tlx <Io"k. I """""'I to

lnrn a UI-ili,"' ," ~,tTthe :--D-S, top. and
t,.,ttc'.lmo( t.2l"h ,I'.,r mtme' ~ the fr..U1le
\11,111111,1fil Int lht (*"...~ I fin.t ron:-id"'n""(l
1~'llIgit 01\the table saw, but that In\'(,J'l'_S a
Ilunl'.'r elf IW..t UI~
.. rlC'llt)l$ flf ""l.._~ibiliti~
i(lf l'mll'S. I\''KI \I, n.n .}OU':l'l done m.'lkin.1.C
thl' cut.d yo, .f.lill havf' to nomove un).. :<;u"
n~Irk.'.
'1'1",,I ,,m,ml,,n<1 " IiI' thaI we I)rinwl
in l'flf.IMIII,II, Ne" .a!) fnr tumiJl~a rtJult'r
t"hl, inl.) a j"III1~r tlu.1 ....iU trim urr a
uJufonn 'Ao a,,,llloaf,\l,!", l'Imuolh :--uriace. TC,

rni'"k.>lb, I'JtJtC'rlauk "Je,intRr." ~ue a l-.i(w

..r (>last., I.m""'te ~~'''rmica\ to tht kft
II,ut(('f'd I
I. fl1th~ (~nct":;;.0 t.hat 00(>,..00
ti_ up "'1th the WI OI"'IIi"l( m the (enre.
'Then file " lIlight be, d (,n tht! ed~ of tOe1aminaI,' 1)("'" IIw o""",rog "'" tlu.t il ""n\
catch" IIw L.':IIi.ng '... nIlr o(the workpit.-co-.

:,\,.,.: 'I,oetrommon pbstk 1aminat~(For-

n, ""I,. tho

1.",l>lern. I routl't) 001 a ..

tlt,,(f' f\'t't~ on lh( OOtt.)m of the top cap.

(Thill;' .. ,nlllIm.:.,. call"d undemJtting>. TIw

1"'.""", or Ih, I~

acre!Jl. m ... t "f

the ,lighl =\\,11<.,)
of Ihe ~ 101'. It
also n\m()v,,1 ,tI.(Jnlt' uf lh~dillon the boltom
"ftl,.. 1"1"'(1".

22

W,,"" 10

,uri".."

I""

Thi.i tlU,K.r ('hIIWlllt nUl)' not be objectionahlt! -It Ilt'J""ttf!' lin "'J\\ tivhtlhe ~
of
th,' " ,JOd L'" 'Thkea ~",k aliI><' chlJl<lUI "" yuu
n..t tM Ii"" lion", ",,",,'1'>'. If il"s Ml ""jt..:....... bIe. rout Ih~ n m:.. wlll." ~1d< mo"in", tht!
ji3Jll(" lilft"t.1.ion

Iftht '"

~ !arJ."'<!u,.. ut.tht- .....'a W;lY to

I'"'ent It.. 1\m, tlw er"I11(' \1.,..01<> .Iown and
roul "", .. t an ""'" mh, t.... fourth ~idelhal', the f\n;tl """""'r of the d"". frame
'lb; n t'Jm " tKlt,'k u\t'r d~ nnSl the ~ll,i
lh4' ,t.; l Ir14'
SCORING fOR A SMOOTH RABBET

",hlx'l " ..n"" lhl- grain on "Iy"'(xxi (H....\\ h('u ('Irmillg lhl' ton(...'\Jl~ on the
lUJ' :lntl lIClttAnn flf ltll' \xxlkc:.\..."'<."
on ~
12)

("UIlInK "

;llm",t ,~""~~ ''\'lIullJ! III I_an,ut along tilt,...tgl' lhltt [Ull'\.'" the tx.tlkl("'f. The Y.1.)o' l'-'
t')inlllttl('
th(' t~",.rotlt l.._4to ~'Ol'V thE" edJ,!\'
b(r(ln' !"Ol1*.JIl!:,

saAr
WOOD

.._

nunl) '" II btlle undi-r ,. thick (i"~

about
....l Rut t,y the lUOO )'ou .. k1the thi"kn ....
()( tht J!hlf' t., ntt ..""Ja It to tht-" (c.tll."'e, it;-. elf1:'*'

Pnt,u,.,rh (II

If!

ft.r tl,"'mihK thP. noon..

8'

n1C,unt a naigitl bit in the router

ta')lil ;uttl n)C,v\' tht rtn,-,\,,:'(.lh~ oULSid~ I)f
Ih"IIIIniluI(" aiil,'1'" wilh t1w out~"n<l$l Ij(e
IIf (h.' hil.
!':f'\\

STUlGHT

'"

1'h<. l,robll'hI \\;\h ..,,,nlll! "' locatinl( Ih~

<,(,(,'x' IiI., .. "rlllI wh ,\ thl' 001:" of til(>
mbi)('\ ....i11 Ix'.. I ...,lv1 Ihi. problem by
\VOODSMITH

"

routing an identical rabbet in a strip of sanp

on the router table. The suip was then used
as It guid~for' the knife when scoring the
plywood.

Then, measure the length of the C:L<e Md

make a pencil mark at the eemer
Now it's just matter of lining up the
c('nteriine marks to get an even o\~E!"rhangon
both sides.
STRAIGHTENING INSIDE EDGES

WlOlH
'-Of

ItAlIan

After the rabbet is routed in the strip. ju..<\

fit the "trip over the end of the plywood to
guide an XA<1o knife while making n seorin){cut. Then,llip Ihe plywood over and rout
lhe ra bbet, The muted edge will Ix> etean
witholll any torn fibers,
CENTERING

When tut.t.ing out an inside profile (like on

the bottom edge of the bookcase apron and
base on page 12). there's a problem "ith
keeping the bouom edj(~slr.ug!lt. It'~ impos$ible to aaw this profile on a table S!lII,
diffieutJ.W >1.raighten "ith a hand plane, ruld
you get a ragged edge with a ..abre saw or
bandsaw,
One l.e<:hniqueto get a smooth Mil" L- tn
start by drilling out the radiused end. of the
profile. Then draw 8 pencil line between Ih~
nulii and clean out most (If the ",,<tt' b<~

INSIDE CHAMFERS

The inside ed,::ellofthe frame around a panel

Oikc oil the bookcase sides on page 12)

usually look nicer if tlt<!y'r<' liJlhUy chamfc1'(.o(i.
But if the panel is already assembled
this is diflkult to no because the pilot on the
chatnfcringbit run. into the JllIneland keep;
it from cutting the edge.
'lb deal with this I)roblem, 1 used a -
IlJ'ClOve'router bit instead. And W guide the
bit, J made an au.'ciliarybase for the router
and allMhed a guid~ (hat does two job< at
the same time.

Y,

tw'een lI1(" ends with a sabre saw, nltlin~

about

outside the pencil line,

'fu str.ligilten the rnl().."-,,Ied~... 111'''!.- by
the sail: Iuse the I'tJUtel'labk>\I;lh" ,tn<lllht
bit and a JonI'( uultiliary fenl'(' d"mpt.<1 to t"',
router table fe.nc.'(!, Thi.~ o.l)~ilUU) (..-ne...
~houl(1be t,,'ict- 3.'" ft)llg :~ thl) ()\~Ir..tllt'nJ!lh
of lht \\clrkpu"'Clt.

Ccnt..ring one part (If" project (such ..' a

top) onlo aootb.r part (such as R ease or
frame) when they're dilrerenl sizes ruwllY'
I.IC<""" like a challenge. The problem is gel
ting un even overhang QIl both sides, Thi!<i"
usually matter of measure and adjust,
measure and adju..<. That l<. measure the
overhang on one side and then tit<! .oU,,r.
then tal' the top over II Iill.h. then b:ocl<. ",1<1
so forth. and so on. until they are '''lIW- or
-d_ enouJlh.'
Sometim"" II plan will call (or a "pecifu' I
measurement for an Ilverhanl(!'" h sides,
The only way to gel that overh~ t; ifboth
the toll and case are marie to the e1I<1
STlJUGHf
dimc;ru;i.)os ""Ued for on the plan, But if
an
these part" arc a little off. you will never get
the overhang specific'll. Usually it's more
The "'By this sctul' \\Iork.~j.g the -:feet"on
important that the pieces be centered on the ends of the workpiece sUdc alool'( the
each oil,er so there', t!'IlUll overhllng on auxiliary fence while the biLtrims the inside
opposite sides,
profile in " .traigilL, smooth line.
Position the (enee so the distanee to the
outside edge of the bit;,_ a lillie Ie>.'than the
finished dimension you want from the -(eet"
to the ifl8idv Mg(t Qfthe pl'<1fiko.
Then. with
the feet re<ting agaio.<t the <lU.'iliary(ent~ .
. .,
roul
from right to len.. Move the (ence
,1'
.lighlly :mel .... peat ulltilllw l,l!!c is SlraiJlht
I.
and ~ooth. lind lin<",up 'nth tho nuliu.'lCd

The primary function o( this guide i~ the

.<:llne:L<that of the pil!)t on a chwnferinl! bit.
II keeps the bit a uniform di.,;1.8OC'C from the
edge being chamfered. Then rather than
trying W cut the chamfer aIlll.e way illw the
corners, the guide is also used to swp Ihe
chamfer a uniform distance (Yo;" in thi. easel
from the corners,
'lb make the guide. repJw.:ethe original
router base wuh one mad~from v." Masonite. Then, (or the gulli. it""lf, cut out
another piece of V: Ml.l.'iOnite I 'Ia"wieleby
about S' long. Align the edge of the. I'(llide
with the center of th~ bit and screw it to the
base.

l'Omeno.

UNEW

aNnlUH.

To center tbe t<>1> and bottom un the clock

case and the bookr-.ISI', (or example, I u..<ed
an easier. (UK) more accurate, IDf'thod tharl
lrial.and-el11)r. (I 81,;0use this method for
m05t oCthe tabt~ I build. see th~ dra,';ng.)
J-'irst. m_ure the length of the top and
make a pencil mark right at the center.
WOOOSMITH

U... only a> much 1'''<'''''''''''' 1<.' ",,,,led to

MId lh. I,'I!' :l(I;uo.,t th,' (rJlC('. 'full mueh
1Jf1'~..un l't,n t.,:;"u...;(' th J,i['(,'(> lA. 1'ilJtingin
wurd. whi"h lIill ,""suit in IIfini,he<1 profile
that'~
Ct'-leaVe,
Of... IIQrd tor caul ion:""'1't'.lIl~mptation
lu tum thl' v,orkPItl('(>MJul1<1;.t,m rout ,\lith
the WOrkpll'Ce))elW(... nthe fenc.",lUldthe bit.
<So the 1')01'(
. .tralJlht tol>o( the workpie<'e
ricll.gagaio.<t the (e"'.....) Don't do it. It'. elL<y
'lb make the stopped ehamfer. just !I(lju.st
to lose oontrol uil" set up thi:; way:<iooetbe the depth o( ~'\It.The end of the guide will
bit will tend w grab the wood and puU il maintain a unifonn chamfer and will $lOp it
quickly through the CUL.
:V." froo} the COmcl~.

23

Sources
CRYSTALTABLECLOCK
\ ~""I \111.),Cltll.

r the fI}I.\('mtnt, h~.rcl"1f,"~UlI'J

11(" 1f'C'lgla........for the Lithlto c-l. '" k fn 1f11

\t.\'iooi()'" !-olW\'A.' ('O.. Ih:I,l .~r,!'lJ.r..,,;
I

11'1:1:10. Crn ..... U I:,""", \\e.<t 'armouth.

1\'.-\ (r.!fl.':::, fi I j) rrso \7.)

MJl140n&: :<u1lWan h:c put tClj(' her a
1.'031packaj[{"that indu.l, lht halfhOlir
lJe11 1 rik... movement t :\fJ ~,X J '" It h
tl .1 II(ndulnm, kp~.serlll'l1tl,,* hanll be
( ~pt'(~I.

\'j

-lo l M'la_~.~tlill all th hOlrtl" art O"t"lt\'tt IIt

build t h.en stal Tubh{ I",k .h"" 111111h"

~If\\III.KlS"Jill,. fXolt: SUM'" (hi", IS a

'"'<'tal 11<{'kaJ!l'llUl t'I).!l'lJur till' '\;II(I'{ " tIl,

&g:O;Ut

., "t, n;,

It

Nlt,Y.,.

1)I,t

111

the "ason ,\;

Stlll"...n mu"ug
f lOrkr. r forma""" ,htd "l.JIj lh I"
('l;t11"1''''''~~
and 8 in-<- "",n (}rt~ M..._ &:
SUUl\1Inl'ata],Jg. "' ....11.'
19'.!9 K th
.. klrt
b"c

' '1'(.

metal -e .,tlinl( hh,tltl"j.'''t a .u"",lh ed)!('. A

I\ootl",uUinj! bh.I., "ill fl" the job. but it
lc.~.a\es 8 l"lJUrh l...I~, 011 th("hrdl'.... -just. a:- it
,,r.ulrl Ill) 4t thin I~h
ce cd\\ IlotM).
PQUs""(. HIIA~'TIll.' secret to flOl.,,,,
UlJtbra .......
L"the tOle as ~( lttnJ! a :\mooth
nm ...JJ un ,,-,. II;' a matter of ,,""'tdullI:
IlK ourf'an "'th lint'" and finer abra",\,es
To d.. this, I """,I thr bro." with three
$JT."ul.-:-(I( silicon l'1lnlld, Il..-qxar
2:!1',3".!II,
and 4'~r J(111.
ABRA..
...I'r. (,t"I(,I .. 111polish lhl." brJ.5.'\
t.J u nurror finl:..h. I \1.....a (i ~t)fihuffin~
wheel (In tht' bench grinder The \\b"1.1
It~t!lfis 1CIOl!1lt\to J",Ji"JI.l;u~1.blngit hi,"
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24

&-".,...'

\\'OO[)SMITH

Index of Contents No. 1...48

This _.

co v..,. IIlI 0( thP lI11lo1e8

Culduding proj........ d k'CbNq_I .....
Wood in tho lin ..a il<;",-~.f W""_
",",th.
\\\>\.~dividoo

""~

index into two

'l'be Jin..'t Jied.ion i:s g('llCml

molog of
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juina-y, jij,lo. and
fini.<i1eo. Tho "" ... _
;..Iist 0( oil
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III' "'OL<:nIM.

~l&.

The

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I111I'II""'"

r"u"wing

,,ror 10 the i_ MIl _

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lim'llI<

wbee )'OIl

can find Infonnatlon 011 tJuo Ii-"<d su 1>Jt'd. Por ell;M\pie, 4114-9rerers to in(or~
m.tJ.ion in '''br.ltl.~ir.h~" No. 41 on
_.1-9
GNBlAlINDU

WOOOSMITH


r
l

WOODSMITH

PROJ(CT INDEX

f.
~

WOODSMITH

\VOOOSMITIi