.

NO. 50

------

NOTES FROM THE SHOP

$2.50

Sawdust
Aprll,1987

Number SO
Edilor
Donald 8. Pesehke

Design Clue(
Te<lt<rabcek
A$SISlant

EdIlOrS

Stave t<rohll'le(
Douglas LHicks
Dougtas M. Lidster

Designer
Ken Munket
T~

ttl~talOrS
David Kn!yllng

Mi1<e li<!nry
Jim Prill
Stbsatpbon Manager
SandyJ.Baum
&Jbscnpoon

Ass<s1anIs

Christel MIn",

Vicky RobInson

JacI<le Stroud
PatKoob
Computer()petabons
Ken Miner

Assistants
Cl>e<yl Scot!

Admrostrallvo

Kat.8aumo
BtIltodlng MaWenanoe

An:Ilie Krause
(lSSN 0164-41141 is pobkshod
~Iy
(Februa!y. AI>nI. June. Allgust. Odebe<,
Oewmber) by _
PublIshing Co.. 2200
Grand Ave. OIls Mo<nes, kIwa 50312.
WOODSMmt IS a 'egiStOfed l1ademar1< 01 Ihc
WOOOSMfTH

WoodsmI1Il PublISiling Co
Copyright 1987 by Woodsmd)1 PubloShOlg Co.
All Righl5 ReseIVed.
Subscriptions: One year (6 lSSIJes) SIO. Two
years (12 ISSOOS) $18. s.-ll)Ie copy pnce. S2 SO
(canada and FtlrnIgn:addS2 per year)
cnange 01 Address: Please be SUfe 10 JOCIude
both 'fCM Old and teN-.ess
SecondCtasspostage paldaJDesMOlncs. Iowa
Posunaster: Send Change 01 addross ""',ce.
FOIlll 3579. 10 'M>odsm<th I'IJt!I.SMlg Co., 2200
Grand Ave. DesMo1es.1OWa50312
BACt< ISSUES
All bad< <SSllOS of Woodsmdh a'e $Ill! avaotable.
Send 10< a lree_tdescnblng
the oonlencsand
pclCeS 0' at back ISSUeS.
SAMPLE COPIES

II'fOAJ have a _
whowould like 10 see 8 copy of
Woodsmilh. juStsendlhc nameand addcess. and
well send a sampie (81 no COSI,

Of all the "",.llo ..L- In Th"r., "kay. It', oil iml~'rtant rroj('<t and
the shop. which "' most important? ~Iy \\'t' tlif'ln't \\ unt tu ~h(lrt changt' il.
fl ,\',.ul(1 h.t\'(" be<*neasy to ~), Wmuunt
favorite tool L' tlw h8,.1 plane but th,
IlUJ:'t 1111))()r1:tllli~
nl~' bench, A goed bench
tht (rn'll \'lst" .. tn....tea.t. we used two f)J-ig~:->
is probably the ,inJrl~most iml!Ortant tllol til tltSC'rihtt hi~ whole p1'OC~~- ont} thnt
in the sh<ll'
(.$'pec.~jal1y
ir you want til \\t r'Il1rKll() bt~a real chore. It wouldhave
ilx't_a,
..." )~(tllI~(
..l{\c1 flf mUt......nlanMlp.
nbc-, been easy to ~~', ~mf)vththe tup." But
Th'lt"!">.t 11I'\tt)' ::-.lrung :-;t.'\wm,,nt. ThIn. Vi" ,1.,\c,t.....l thr- f~J!C'-=--to thi:-.lalpi(" trn.t'~
An"n't ~'(llIIUI~hin$!'lhin~ a IittJ v l)"AA~'in}! I.""t.:,bl) th, blj!g"$l stumbling block in
AIlOlITTHIS I!:SUE.

thut :1 bench i....so important tIl;\{ it (Itlcr t}lt \\'II,.lt ,lJ'f,j('(!L

mines thl' h'\"tll)f C'raft....;man~hip?
11'ull, ws-'re Ml)'lo present the bench
\Vell.in a \I a) I ,.,allythink t"'le, tru, \1, .... \ .,1""'(1 \\ "riling t.o bu.i1<1(or ~'l~3.n\.
\\"t14.1l a 11('1)('11 fl(K':- (t.~l)Cocialtya f;Uf'QI)('an~
N. Wl.'f'S
\\',:..., also hapl', to have
style bench) is it :LlI()\\s )'OU to work ('''01n with II .. ta-w member of the 8taff. Ken
\'urll-:(I JI'IIII .. J lll> U$ ~ (l(J$ignerlcl~I1\a.r,
r"rtnbl~ with han.1tools. In effect, a bench
it' tllt' "hnl.,r,)' tlMtlltl;lt ....UI)I)()rt~your work
'"n~ lItl .. that he well "n""rve$.
anrl hultl!< It teadv so \'OU can work fin It
\\',1 tirr..l rn,,. Kon about a )'''e:l.rRI!O. At

.II'.! .\

with t 10,nun- n";Ke ,i hand tools.

ttll ttnu \'I\\"rt'llltheJ)n)("e..~()ft'('Jnc)i1alIt l,\h.at (I~c>$that mean in le~ (lr 1'11111: 1111 tllet (j,rriugt house that ~ili" I~
crufl~mll'tr>h'l.?Just beca\l~ ~'f'U \\.'llrk hi,"! our 'tffil'f.' h'lil(lin~,
with hal}(lltM.l~ .10(.....n't m.;tktoyou

hpttl'r

Cltll' t,uiI4111'fo! i~
in a part Of Des ~Ioillf.'~
th.u \\ ..... 1""'1"1,,1 in the midIXOII\<.Big
htl);,C'luls with nice vievv::-over
That'!" t nJI"'.But hand loul~are l."i>~llti:tJ tUlIft."lrttL"lI"1
I) n:fiuf'meJll luohl.. That i:;., thL' illitial tl,, ...t~ \Itllt,ugh the original mansion b
\\ urk ~)n rnt)St Pl't,jLOC(..S start. ... ,,';th IK)\\>('r J!llnl', th~ t'"mlll.!'" hhllbt' .:still remains,
tt.H,k;. B\lt u!' the ))J"()jcct continues. h:Ulit
11\"(, t h, )"';"". it had fall~ll on 1)0<11"
ll.)f,I~an" u.l'-~Ito l-crule th!!:\'ork .J I.illt:-. ;.0"\' t",,,, \\'1"," "t bought th.. 1'"",1.,t)'. i:
r<>fin
..d with chisels and pIRne~. The lim.1 \\'n.S II ...1 Itlll,\ fur ~lomg("
lhin,bP'$lhat
.lJlln;'t
nlJllrt
,In
(l(,(,Rsional
"nterin$!
!'UI-u.res"'" produced "ith plane.<. ""I"tIr,,')11'111'\ ,'I It "'II" ......
e.". ~v~nOil.,; and
\\'(,,It'(''lfll II t.1 n IWI\'aU' it, 'Ve \\tank..otllf1
111~mOl....you lind Y'"ll.,.,lfworkingwith
tIlt, nl:,jll .In. (\\h...~ ll\(.' c.-arliage."
homl tool the mo." yoU'r" refining ,I'"ur U:."oot'
work. Howev ..r. what all the"" hand t,~.1s \\ ,:1'" ,.t"II,..I) a,... It l,ht)lQ ~tudio, And lhi:
h."ck toIt ,tlll~art a v.,~cun\'erted to ~Ulol(l~
J)e\.>(1 1:-~t
p:t)CxlIwnch It, h(,I(l th( \\ I'rk.
A (.:()QIlBES(lf. Th.> n,,.\l qU,..:ltlUll i!".
ra.sIIl'lllt'fl ~IUI) a \\'Orking811ov. bUl al~(}
\,"hal rnukes a J{Otl(lben<"ll~\\ 'hil~lllf'atJ~ ttl:t :. 1"11 ,,'lItn or uhll'JUte', (The (._"(J\'crVllotu fOl'
<fuzenmore que~'tions. \Vh~ltkind of \'i~":" thiS iUU, '\ ,\5 lnk.'Jl iil this $hop area..)
should it hllvc'!Should there be IIlool tr:lyT
III the I'ro..,,,'..C6n<linll'<>caJ craft-Ill en
\\-'hIll kinel (If \\'fM'Ki i~Oel:'l to u.:'ot.~?Hu\\
l" ,\ '" k l.n t hllJ rtlth,'r la.a:g'e l)l"lJj~c.'t.\\'r' ran
aboul a eabillct Ullrlprllealh 1("
In!,. I{. II lit \\ a.~..I furnit\ll"(' dt:sig'lwr al'le]
\\~t'lril..
'tl to nJ\S\\~I
aU the~ c1tlC:~tuln~ c:a,I'IIH'tnt,k,r . '\nc1 he alot() built C:lli:ton,
\\'ith the ~nth t=-hO\\'ll in this is.su(,Tt h:"... c-It~}~,In,1 \\'if1~111\\:OO
th~olc1fashion(!(i \\'n~',
.111 t wh:ot wu "amed. Sa h~ buill ~"en
;lIllh~ iE-atur(" w. want,,1 in" l-x'lk'h
!-Old1,1,~",k t'(M'I~.<:1("\'('" multi.palle ,,'itl
partitularly the \'i......".
Over ltll' )'ear:-:. \\ l:'" C ~t4'eulnl)l:)t('cr ~.\
(j'I\\ Z"', ancl t\,'()
huge (t(l,foot SP.1ll) ;l.1.t"ch('(I
CJ,d i)ell(!hl'~ for thl" ::..111J1
F:'iU')' (UU' hli.... II
tCII_ earriagt rioun- \\'ith raiSCf1 p~lnel.:".
"Iill:htly ,UfTol'<'nt npprua<h tn th, ""', . 11",~ door> aro lhe C()<.'UIpoint of the
The ()n~ \\'(_o like he.';;l ;)'0 ~I lllJi: J ... llllpl\1 Jl".)j(~t,
":-houl{lcl'" \'iSt,., thal :<.il$.,n lh.._\ncillfth(..,
In 3drlitlon to llUttlng the fin,,' tou(,he.
bench :u\(1 lL..;,c~tl~ t(, lltlf() 3\ \\ "rkllif't',,) on the carri:l.~("h(,)\I~. K(!Jl h~l."'*en ;ll
\'"ork dl"Signing l'I'Oj(",,(t:, for (ulure i~:-l.\le::o
d"wn on !h,llf'nrh top.
There lire l\\"()
1)f"(lblf'(lbi\\;t II it. t l'~"ery
onl'{)()d.~IUIIII.\\'e have;\ 'bank- of proje<:t.
difficult to nlltk~.llrullt tt>n,L"l'"~t~1f,ut of alr<>ad~'de;;i~l"d awl built.
aoju$.lmt'nl \\ilh C'hrul~t>:"in the ~~...on." I (k",' wanl to dw..n oil it. bot w.. lU'e
tl

c:n.tt...'laan.

or

'_I'"

I:,

thumi(lil\') an(1 \\'11h ltM~.11ll' ~r,lutiC)n'\'~

~a..rPut 1....1 to "ol'k to l'Ome up "ith a
n('\\'

\'('~iun

llndaunted.

lh<tl titJI\'l'<i bc.tth r})'obl('nl:O;:~

T.d <Hn'" up \\;th the v;,;e

shuwn on thi' h<,wh. It'~ ,'11.'<)' to make.
work.like a cht....n. and d,,,,,,n't ~'OStmuch.
"H~ WllOL(:;lS$lTE. I f th~rc'sa pl'Oblem
\\ith thi" henci'l, it'jo' tl4"'l1 it require.f:. the
".hull' issue to deserioo ho," to build it.

l)(>J!innillgl(~mClk~I~tl JJroJ.,rn~....at ('1.ttchitlg

uf' on th( hedule we"" ,up(llll'ed to be on.

The c1day. in mailin!!,is.'il"".< Mould gradual.
Iy impn.v~-t" th<:gn?llt ...,Iiefof wi uf u.<.
Nl:XTMAILING. Althuugh we're m.~kjllg
j:!QOd p"oms..~, th(! nest i$Sueof '\'oods;"ifJI
1;0.10.iHI "ill still be del.yed ""mewhat. II
"ill be mailed in !be lirst purt "f AUb'U...-t.
Thank.~ [01' ~'ourpatieJll'e.

\VOODS~IITII

T_i~s & Technigu_e_s__

__

(iut that'~ nt)t 11K'l1eSt.\\'ay to ;-;ltlrl' hb..,Ifa'

A DIFFERENT GLASS STOP

,'in,..,tho t~th from"'11' bbul. mib"'t chiI'Ih.

On I)roject.<that rt'<luire a 1(1a..'frame. I use

a dilTcrent $~."tem than the typical "UlII1.~r

Ie('(h IIf anolher.

round gta..... slvl"', 'nIL<ahernative "ppn.iCb

r.,,"W -

i> to build a f...

arne within a
the
inside frame is actually Il <top that hokls t~
ill place.
'Ih make n frame \\'ilh this system, 6t.:u1.
by cutting a doubk- rabbN in the .wok ror
lh. main fnune. Cut the first ."bbl"( "id,
enough und deep enough 10 ''''''''P' the in.<i<ip
fran,.. """ Ster I in lh. (.;'"0.'-' ~ti
..n

I!'-

lAlifSAW
CAalNEI FIOM
WOQDSMJTH
NO.~l

Ot;,\\"inj! twlo\\~
DlAWfftWilL
ACCOMMODATE'

GlASS

()lIe l'I"t.llli~m1'\'(' aI\'v aysrullt with finishing a

small f.-),..,j~t i._~how to holt) tile \\ orkpieer\\llill"bn~hir)g or "ipUlg (In the finish . At
i>(.tnlt l.klint I \1~1I11~'have L.c, hohl ~.~'Uftn
thal h",' \\'&l fini,h on it 3nd ,rld up \I ith
fin1."\.rylriJlls III the fini:;.h,
R~C(~l}t))\\ hik- filli~hinK some "ictul't!
frame- I ~'aml''11",ll:lbf.tt4!r \\.3)' tu hur(llh~
frumt,~.I cut a <IC)\\'vl to l(_~nJrth ;li>mlt '/1.;
ICJII~,,'rthan the IJl!o'l(tc- width of the fl'aJn("
(ti'Om rabbet 10 ..ah bet l, Then I w,~lg,,1 the
dowel between thp rahll(>t~nnel used it :L... a
hlllllll~whit.. I brushed nn lh. fini.,h.

10'8lA.OS

1toUA4S1~
....." IlEP1l<
Of INStOE Fl.AMl

FINISHING PICTURE FRAMES

~~~l. c"t ., :'ot'Cf'ltfJ

rabbet in....j/tllht first,
TIll!tlt'lJth of till:'- nil.l,_l Crf\tlllilu' l.ICtttl.rn or
th...fm;t ra hh..t) must "I.wl"'
th,,k
~
ofth(# f'li{'<., I,f 1!l;...ss. ~" St'1':!,

",.,,'1
tll\. muJtI rr.011\ 11"'"

NI~\\' miter
til
1t_nJrth.11l1.:n C'llt thl' thi" I" Ilk r.~..tlrhlJii' ,
(st(IJ~Jtlil fil

in lh,' n,l,lxt

By mllk,n!! one l!u"!t" d,.aw~' to ''<'I,la<'l:

the two bottom drawers. r can store Ute
bllld,,> ,e.ti""'l.\' hi", lcu ..-rs In n file cabinet.
Tht.- new drawer i$ jus.....ttt."(:l)entw,m ror J t,.1
iIiam~t~rI>la!les.
:';inct' u drawe r CUUuf blade. IS h."vy. I
11.'4!(1 ~. 'll~''''C"lICl (or t.he!drawer ~i(lt'~ ;ultl
baek, If you haH' ah....:wy built the cabinet
(ull'l\\'ing" l h" ",in;:lI plans with fotlrnrd,\\'f"r
l'1JIU)4 -rs j -neueh :-~It.'. ~")II ctUll.ut.l wn runnt:"
1-1'fl1ll'\,

in "ac-h t,f tilt-

IJITJ:(Or,lrd\\'''_lr

Ih,.\\

s~II~.
(~"ll" (Ullht~,lt()nlnlnll\'rJ.,'n)tl\'l"
_, )llt14 \\'ul,' &0 lilt, \\(IJ..ofll .,ftJle .t\\ l'1lU-)t'S

~11I1,,~':iM',>(lll.\tJ .. 'II'I....
r ,-",j,t,. )
141
k(l('St t h(, h1.wJt,~Jr-lnll'llhll~ t,,\\ ,tnll ht
back \\ hen t~ .Inlw.ri,1>U!w.1"lit.1".,\ "I
Lhcdrawer', b"cklll a litLle. Thul L,. I "ul the
tfafin for the Clr;i\\~t:r':>l~,c:l<Ie. ," fn.nl t1M:
flow}nt{_>(I~~,see (Int\\;nl!" 0010\\', ThlA cint\\'('"
~ifi~
~houJ(1 l"\.main the full lCll)!t,h tl.,l $UPI.>Ol"t
the CfI11\\'cr \\h.'n it'~
full)' oprn,:'(1.

,\nhttlf.'r till L.. tl) ,11'\('ff)t,r ~rrmll brn.(I~

I':tltt",t" 1)1' t)ack Itf t ht~f'r.tffit. \\'h ..n
fh'lnl' it- :-.t:l: flu\\ n t" (II")', Ihe bl~J...<leta...:;

111\(1 th(

lm-

..:-t",I~ft lff:-......
I{(II/,II .11'III"ll!1
1,.41(_''''~I'fnl. ,l/""'t.''j(j('r
FEELER GAUGE IN THE SHOP

I ,d\\ :l.Vs k.<" sl~u-k "Iul! fl't'l~,' l.'llU",f' in

nl~ sht)I~' I ),il'k4'fl (,111\'up ;llllll otut(J ~\.tIJI)I~'
slo,... - it lc.,k, n litll. likp 0 pucktt kn;C.
\\'ith \':ui'~ll"lt.h}('kl1(>4~:i~ofm{~t.'ll:.;tript' t llal
(;UIII\IL

I u.,,' lh(_'m('l:u :;trifJ~ to I)lll'h l!lut intu

t4.~t~IM)t..... :tll()
'Ii, a,...'ml,I. th~

mmw. Iin-L.""~'lru,t

(Jiff<!I"t'ut JnlU~

cht-'('k awl

til('

main frame. TIler} in~11 th~gla.,~and S('1't'\\

the ;,,,,ide frame in place "ith .mallllathe<K1
CVllOllOM
---GROOVE wtOE

r/fl,., "(~ (;(JIT

')'"f!l"" (',I!f.. ()I'rqtJ}1

I built the utble

ill

,:.\3\\'

l':lbil~llhal

\'~(IfId8't,,;tJ,~o, 17 llut nmde a ~lighl

.hallj(\ in th(' 1'1a.~,to indude

II

l",~

"file

lna\\'t"l'- ftlr m)' ~\\. bl,\ltlrs..

In <1t"lying the oril(inal pin,.." I dis

ro\'('T'e(1 t.h.'1l thl' dl'U\\ t'n; ,\;ere m"tk-

l;_1.1)!~

~n"ugh ttl hold 10' >8\\ bind,.,; laid d.,,, nOm.

\VOOOSMITli

T01'UVtNf

Th.

\\'iL";
~J\{)\\n

nl.iH:l1iJ't' ~,t'IIJ.....
IJ"ttll'~ B"ll(trti
Ht"'llJ(lsJ}il'~/.1\1 itt/lt'kJI

\v()(J(lsero\\':;..

SAW BLADE FILE DRAWER

fi,t;,t

litlecl \'eJl(,(_J":'.111t_'
:;tJ11"'" (,.'tUl tU)'OoI"t1'It" ll~....r( to
ululel'

lell

BlNOING

IIhide... b(,lW~ll Ihe hind ... "'""

",ud .. from '." Ma..."liw. To hl)llI the ~1a."",

niw. tilt ~."-<leel' tludoos in the fJ"Ontand
I.lck al .. illtervals. Then cUIll"high divid
N" t" fit .... lw~n th~ d",l_
Md ,li.l .. LI.. m
dt}\\" into place

1,'(1"

./n')11')(

II (tItS/I)". Tt rtf,,,

SEND IN VOUIt lDfAs

Ifyou'd ,.ke to share a woodwortc,ng np w 'hOlher

readers of WOOCfsmllh. send your Idea 10
WQOdsm,tII. Tips & TechntU4!$. 2200 Grand
Ave. Des Moones. Iowa 50312We pay a m(nimum of $10 for bp5, and $15 Of

mole for spec.al tecll,.qoos (lila! "'e accepted

roe publICation). Please gIV" a compieU! explana
lion 01 your Idea II a stcetdl is neoded. send i'
along we" draw a new ore

A
Classic
Bench
-------------------

A WOODWORKER'S BASIC TOOL

,n. r 0,, \"1)

0",\ i,,-u~ of 11', t.

",11 \\ L" jI4.'lIl out \'o,- received our fin-t
rt"'(,II(;.;.l rvr :. \\(trktlt'Jl{'h 1)luo. AIHt lh('

:-hortly

"'1l1u"1Il,s Illl\ (' JJI.ut\"f1 ill ever

~iJ14."e.

'J'h4Jw ork! It'lw'h Illall :4ht'V.11 ht.-n.' hal" been

(,'I lhf' (Inl"'ulU' 111.1:",1rtll' ~'Pa.,... rh("l)l"Ol.r(_~m
111j,.",ttln~ II (10' lh"lwJnl unci inti, til<- ~ht.l)
h;t,... Il(I(fI th;ll ""or,'I,nt J"'J~at ";IfJ,slll,IJ,
h.o...... a! hff.'.,"II,.I, '.1ut. ut \\ hat he \\ ants III.'
\\(lrkl,.:IM h: ~b,ul.1 It hoi\" ... u ~,h(1or III~
\\ eM,,1t,~",
ShcJt11d thtOn l)t.t lA",llr-4~'~ \\
lUnd, "f' "" ' H,," ""CO\ d.,g hole"o :-huulcl
II ...", be any ot<.ra~..,.... I,'r lht I"'K-h!"'"

nal

q1.~"" "tonl

flIPanrl fJO.

r II~ul\.aft, r t,lftQit'1""dl~!. (rL..;('U.';;;jon, \\'e

,1"...1.. 1 I" 1:" "",," eI ",.1 huiJ<1lhe bench,
1'lU.-<. 1,1oall~ n)(~ tlftll{' ~t('Jl\S \\ v' aR1'''\<cJ
",t...ut.1 '.'llIla J,::IIIIJlJ. ;.tunl) l.._..nch- and:--tilI
M .. I' t h. 1'11('1'oil"1 ~Ii"""~
\\ rthin reason.

_..

,\"

,.11 .1~'h~11{ilat thl' 'Tl(l::'t imI)llrtatlt

If~ltllrf' l,rlUl.\ lX"lrtl i".-I :-~thlt>.~"".11C".fLit
:-urfa..:t S..lh;II ..e whcrvl :->Uotrtf'll

THE TOP SLAB

I{f'n hllil.Jill~ t1,,l41P :-,h,b(\~h)' cuttitl~

seven tMJ.II'fI:.. {.f ~ I ..tt.k 11 I- aetual thick"t_'AA} to t' \\ Iflth uf I
,trul u n~lgh I(>,,~h
"r
;".! _(:\.It,,1h.., n~l'.'I1.:d",Ii....-t (or the- workbench L< .. n I"'I:\! 11 I Tben b-!\h' the pi-cetUJ!llhcrto (onn tl J;!I " ..\\ kll' slab.
T., 11;.'1", tho .lab. I u..... 1a belt """,It"
(t't,,, n l"t>rllpk It l',.,(;_.mlll)'1 on buiJctins:::!inti
!ltU'1Unl!II,. olah, ...,' ,ho' "tide I"'_~
I'll J~' ~,).\ftt r thot, :-131) i..
tkt,l. nit it to a
I\ni..<hro ~1l),oth.. r '~I .....' Fi~. I oat-o ,.....,
T:dklll~
si'-'l'. I"I~"~JI.

If, (,'om th~ Il,.~n.

~ntl arlll ."
!ll.ln'Il~~h.l t I): J 'rII..lhi~.clamp lhl'
nJ:t\l, see "'i~~.CNULl': Th ... JII\ I t lf~' th4 r J ttll I-"CI~I"!'>
an<1 t:ncl!" UJ"l'
"'"I-otlo.. r th h,hng block ma~ "ar; de- 11u I. a'MI til II h- It fflr ali~m"'nt~.~\,)"o.
lK"rwllnJ,:;
on th. t \ 1)I,'llf\i~ ~\,
u~t.~'1.' These n" l., p the I,it.'(,,..; fmm j:litliJI;:'
"h<lIlh. I(lu.... 111~
...d.I:'\"IC ~ ~<C'ati.. n
:;'.'1\' I ~'"2~ )
111.. n tl' rn:tn.. th., 10\":\ll"11 c,r ltw fir.-"'t
rtm
... h"J.: In1ht>Il,tail in Fijt'. I.)
(l....dl~ tlf tat! t.I,,,-". ml~;L
...tlr( 1 I- (",m
1"ht n Iu. aiM! ~ '" the pi\--et-:-. t'~lhlr.
lbl
to\\anI th .. ,J)ll.. (~ontirluc la,
( l J Ill. II \IM..... :\tf.!\l. atlll a long aux
in~ out th ,.. t (:r t~ d..,IOt.;o' a,.. :;.hf.\,"n~rl I tan r~ l th. table :-.3.\\ miter g'dUCt.
t iJ,..'1.lrt .! tXtlt. ~
'UU1II(... tJllth4!'
fix."C1 al~18n I lht u, I (Kl('k\\I:'t. tThi...1.. [I
t.ltltk,lnJ,:lt'l lht 11j.!"hl;tf'l(t lhf'-fllll":--'Ilnthl'
na,tln
of Sf.
lme J.."3U~l~.)
'fht.n "Ut
DOG BLOCK ASSEMBLY
"h(tln~ tlhl(k .tllJ,..rfl 1, t. :-t", Fi)!. 2.)
11",II~h' d,..1
II Ih,' Ih,..J "nd cor tt...
(,,14.... ll,~' ...l.llt \\.t:l ""lit, I l,uiJt a d~JgllJ(l('k )."\"1,,,,. I'IH." TOCETOER, B~r",
... I."~k.'I !'t',J 1111 I i~.
:~.
. ...IItll.luo(l(:.s. [ l:-tmillatt"f1
~tl\\ tln1t
It1l 'Iuttr J.,'1tugt'' (:(lUnlt-I'
.L.....
"('llttl' th:lt't' It.:Jrt IIf ttl'> \i...:.e a.....
..;{'IIlbl~" c:UltulJ! th,
aJ~llIl-'lht r...,nt urth~ t'M'IKh. Ik1!'i11 \\'()rk IlY (In,~flf thl' flut: ',I'N,.k 1111.C('....cII) to lhi' 11a'... t.'ll)\.'k",I I'
l lit til" I\\u c-latl~ for tht'
l'utlUl': tll''\'4' pi\'t't.I'l l(~) (If I 1 ~tt)('k(I YI.t
flf lhf' In .... '~ I., I)\_.1;lll....."C1to j.!i\t(l' it "lOre :.licl1uJ,!' 1"111 1....!'ll')':!,
actw&)thic'kl'Cl'\,." tf' "HI~h
,lill1(~r~iul\'~clf:~
'KOURI; 1
SUDING
wid, b," '~I
~'il(,l. (:-1ol~:Lat",:
DOG
lh""'IJ1t'l'\"S \\111 (1)Im.t If,n,U' "\(Aft dUJ,! l,lm'k
NOTt SU""'10 00.
BlOCK
CQHSllUC11Qto1
Of
Sl.A&
~'I"ra :-.:hul1.li'lulill~ ,11'Jr!l,hx:k. ~rf,_'rto "''''iJ!. 7 ,
nll(, H'1I .,. 1I.(nr,' IIll1illl( th. Ihffi:
11l.~ tt'}:tthtrInt'I.' hll~k.I bitl,Jut ;,,",
""Ulangte.t rl:&tlt~ arr, , .. lh(' midltl.' btranl
....
ttl ",nn !'4103'" ftltj! h_,Ic~Th(" hod)" of the
12,
,I"l!" , U!!-4..'tlas
thlf."k b\' \\ '4-1~.;;o.I, I cut
th~' .btt,"" I -llt."Cplr aDfI\\irl~r to alll'\\
"""", d,o;ar"" ....'. 1'(',' 0<'1",1 in Fit!, :$.
~'ll4:, It-'" 1M. t t'l bl\ or make tht' cl{~~
RXED
~l'"
DOG
fir.-.t ,,"-1 It'l' II C".11;A :-.;.mJ.I.. rI:.d(t ill N..'rd' tt.
BlOCK
t,
th,('k (II)' fit ..~1I1',nOl'l,.'l,n 11f~ anti \\'h)" the
rn ,It!' :'lr,f anlth ....l, .,"-(.,0 rIJ')lc: l;'j.
MAllfOOG
SCREW S'
"oat ASStMIty
fll"rflr\l;t~'ill~ c,Ullhf" 4 nn,:rJ<o;idatlOl':-- (,n
DETAIL
f.O~ tH1t11fJIKlS
till' \\'lrkll;j"(t' . \'OUh':'l\,to rletpnninc
lh ...
Of''_. c'''',., s,oc~

Tlus

to,,1.ltHIl)l

(nlll' th

"'~t.

1.,.

.".1

',,"!(, .....

-,

.'

...-

...... ,
,

thi \\'Ilo,;ll'~l'Clion bet\,'epn thr

I"n~ r",,1 hhK'k "n,1 'lip .hort sliding block.
)1K.'allfJ.lor

\I,'OODS~1lTH

DOG HEAD HOLt

There's one more step before ,t;uing the

third pi",... I)nLo lh~ Cact!of the block to
complete the "','~mbl): TIl<' anl(Ie,,1 d8dooo:
will :...,pt Lhebndy of Lhedogs. but Lhe 101'
0; each how",," to be enlal"l!<"<1t.oaccept the
rlog'~h~"". "'-'" Fig, 1.
aoursn GUlOJ-;.Tu makeIhi. CIII. Ibuilt.
a '"","ul guide for the base of my router,
The guide has n runner block that. slides
iutu the aJIj!lerl dadoes and .. ""I' pin thaI
determines the "mgth ofth" hole.
To make the guide. replace the original
router base \\'ith one made frolll 1,1," l\1tL."''"'
nite. see Fig. 5. Then cut II runner bluck
jll>t "ide enouJ:h to ,Iid. Into the .ngled
dadoes. Befo.... att.aehing the runner to the
b...<c. 'hill two ~.. -dia, Slop pin holt'< in thp
.d!:l" of the runner, Locate III.. holos 1'''from th .. centerline "rthe runner block,
:-;.xt. mount a 'I" stnUllht bit in the
router and raise it. >0 the height oftlw bit
Irom the ~hL""nit" base is equal to the
,I""th or the (lodO(ls in the workpieee

fIGURE.
RXl1I
DOG
1l0Cl<

~ II

J'"
r

,:

---------4~-------1"

US(
HAND
LJ
MITf~SCOT
10 Cur ... DO.S_,.;....._
"'" "'DING DOG IIIfXl(
r---

'.1-"11

NOTE:
US! t:lGHT HAND

MlTtI SlOr ON Rt$T

BGKTOADOES

L!

AJ('. I

II

II. I . .1.

"

,.,u....nl

("/1 .; ).1\11". screw the runner to the ]\la..~

nile so it just touches the bit and lbt bit ~

l't.'nlt'n~1b vt ween lhi' t wo~L(II)holes.
MAK.lN(; I'H!; CL'L To enlarge thp openings for th~doghe.j.I~,!oi('l the router 011 the
\\'orklli("l't' wit h t h4: ru11114'1'III the Iln-t dado
in the I<mgflM~ldOl! bl"'k "nd "rnl ... th.
hit i~11//,''(''11 th,< cl.lliu ;Ilkl t}w' oo,,'n:-.I.'
seetion. ~"CStep 1 in
t
~O\\' insert u $1C)11 pin ( .. ,1.,\\-,1) Inti'
runner htltt! ".-\" "nrt rot.t unt d I h....pill hlt.~t h,'
(l'(l~re
ofthf' \\llrkllloo" 1ni=,~huuld('Ik'n ul,:.t

AGU.,S

l .J:!

"i~.

It/':-long' ~lo\for lht! ,r'lJ! ht-ao. (Iultinll{'

"'tltillg lh~seven (Jther slots,
'fIJ t:nlull!t' the ~lnL" in the short l"liclinlt

.,,,1. tum

the router t'QIllI)"tcly1ll'O"ndtso

the hit is bel ween the runner and the
"\\'a.-nt!" sectiom, switch the :-;.Lop pin to lh(>
(Jth~I'h"l. (-B-) inthl' 11111n~r."nd "IU\ lI.ing
the ""nle proeedure. >'('{' Slell i in Fi)(. H,
CLeAN UR Since the router bit is round.
it leaves 8 dished-out 81"l'8 at the end ufthe
cut. "'"" Fill. ~. Th pl"I'vent sawdust from
bllilcling 111)in this area. 1 :lnglp<1 thp ~hO'll(Ier toward the bouom u15ing a Iwring cut

lOUT"

IW'

~".. x

with a chisel.
COMPLETING THE DOG BLOCKS

After the cloghole shoulder< .... de:",,,,1 "I'.

screw andglue the thirrl dogple<1' (B) to lb,'
front .(th~
block....~. Fij(, 1.
CUTTO SI7J_ Next, skim cut just enou~h
off the tOI) <"<I!l') of the as<"mbled hlr>ekto

ROUtE 7

dean up any chipooul len by routinjt and

ruake tlle three pie,"', fluHll. Then l'il' off
th~ botlom L'lge so the IJlock is :j'/, "ide,

l'ig. 7,
Finallr. cut out the waste ~lion from
th, :L,,,,,mblpd bltlCk so lhe Iherl hl""k i>
Uri""!! and the sti,tin!! block L'7"1011,."'"<'
rig. 7, (Note: The length of the sliding
block "my "01')' depending un the "ise
$C'I'P\\" u...;,etl. ~->eSf,un:c.-s, page 24,)
seil'

\VOODSMITH

I
/

AGUIO

_g

ENDCAPS

APRONS AND RAilS

, J'" ~2'
IAOCAPRON
.... c)

.r

All.r 11M' q('I-! bl,,<k I' cUI "part, nul. "",I

lo:l('rofL'" an- arll l.._...1 tA, t.ht- fl'\lnl an-J \tc-k ,'Cf~v":'
,o(the 1'1'
cvr ro 10.01'... startinJ! en thf' I,it"n fl'r
Il,., bat-k ..(Ih" Lult'h 101" NI an -I,".n (Ill,
[rum 4 ~ steek ano! a I"~ !nil' railIF) (".m
, I sto<i<. ..... ('rr ... :;""uon in FiK. ~. Tln-n
rula k~) 1'3.11
I c) and """Ib('r apron I n I (IIr
tl... (ronl edjIl' AU t~ 1'1('<'('" ""':1
\\idt
""'l"o raiJs, (. and ria ....cutt.. IIn.1h
J mal<h tlk 11llJtlb0( Ilk, ,lab 1I~11.:.... 1
Ilk("mt 'b;Jckaproru; I() I.II,,{,CUllu 3 "' 'lin
engtho(6i" ... ,.~, ..
H,.,I ntA\ 1t.'1I. ,\ft.'r lh~
are
(""llol.'1Igth rol.
-,,1('('1>rabll('I on the
t ,llfD~ nu1H 11o"""")'t lh~ \i:lhick1e.,1

"'O'~"

o:-,

lOOl TRAYAAa
l"-i .)

0#'

lA8IElOI'

I""

SIAlI".

tIT

p'''''''''

KEYRAIl~

', 3.,"60

--..._

tra~ l ...,tt4tDl. see .:1')11 \ I(.Y,in fI~. ~

lot \ <aUN,.to, Th' k~yra,l !('11,,01 "I'
",,, 1111 (or I he fn,nl o( Ih(, I~'ncb

'0
~t;r=

FaONT APRON
.
..... 1113'.,

(1tOUGH)
r

FlXfD DOG BlOCK

FlXfDKEYS
'

".

m-...nt.. llo II"

46

"

....

ENOVtEW

tU1 Sl'\lNm_
to'" SlOTS

-,.

..

""""

,.on

'\

flXEO

KfY .AII

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

BlOC.

floj0.YIDY

...

..

--

Kf:\'S \

GlUEen ......10

DOGIlOCI' AS~

tt. r t h., J('nKI\'4~ art! cut. cut

(~.)

I., (,t

th,~j..'tnc"'4.,,

_I,

J.t nJ,.rth t" m.tt, ht) .. IIrl}.,'1hf,rlh~

l \\ (I

IUl,l t41

JI>'t'iIIJ(J~

block ( ,*r If,ng)

lln ~. y m.I,Cllolh.,
h."k ,,(
1i",1 dO!:I~'",k with ',m' u( Ih,' kiT'
bel \\ e-e-n lh. p1t_'('(OS.
k'e fIJ.!'. 11. (Tlu' ',th('r
ke)' .I'kl r",llt l'-"'Jh Ian.: ;jIficlt"tt lalt'r.)

!Ii,," "" ...

tm-

[NDCAI'S

",1\'

,"
..Lt

Md lESi
...._ THAN '

Bo-f ...... l.. nuh "",11ipI't,""

.1 .....ho.II"
tholilih. 1m:"" ..... 1raps IGI (or _h .,,,,1,0(
t.!K. b<-ndl1'1' B(,::In """' (oil t.... ~.. I ...,''''
II) n.UUlI:l"",
~ ... co( "4 ..tu"k iUlCil"..
1_"" o( I ll!Ud: I" rw';' ,,~lth ,0(:1 ,;mel nlU';' kn~1h
,0('!7". (In("(' I""
cui, lamimte !c'l.'l'thc:1' o)Il(' 1>"'' or, '~to~'k

pI<'''' "",

:mel"')(' 1"<"<" ,0(4 t O!.",k\0, I1I3k~I.... hill"""

fi...lho- ~.nd",,"
Wbu. tho bbzlk..< M' .11'): CUI tho'm I..
"icllh I" mate h !ht. al''''"'' ancl ",ul.t:1~1

ENDCAl'

0
O'WOMaSI

"

~'i!.Ig

11,.:.1 k.\

m.1

,., Yo iflt J..""ICI\t~In th4'~('

fiXl'111UU'1 jo4li'~I"V
fllt~"',
the front rlIJI-t,n)
w ilh i. N"" ""'Jr, 1411'rIg, a",'llin.lOl lh(' (('UlOP.

...,J

TOOlTlAY.AIl

I ("lll

-j't- -.J._
1:"fi;:;;:;;==~:=:#J~~~~~;.!o.~"~;
....~":~;,~:~:,S:;,
I~:;,?;;:~J(
rr.....
"

t \\11 ~.I 3'

!l""

f'i.o('(~u.llllllo5lrt("f1 lllllo:".nt'nt kl'~'''' I f~)in

the J.!I'-",\ I see f.'i.:. 10. tTh":'t, ~Hnl('
j!"n"'v\'!! .,I~I ;M't ~LS
"',\llIlt~(clr the- k{y~lhut
holel III I hI' $hol,"~ ",,~ bloek.)
~tltt'Iu k4't'I' .111tlu.' (Ul"<:C:lnu~h ncrt'~~
th., 11'11 when lh,'y'rt' t\..'oI.~n\bll'(l.cut the
.trrt"I\I~
on t a\ h 1111...'.' (the kc~!rull, th(

~
J

, .....0

...

fJr

rl,,,1 d,,!! hlock with Ih.

and I" a fini:J",d 1e~'I.b..(:!Ii', "'.'

ri~.
II,
nil'

("Ol '1>1((10111 I) B()I,T HOI..

"11,1
""I'" are >>1 ~~u..tIII lb. ~",IH(II", .I"h.

Th"\,,, hddl" lhe

2.

NOTE,
&lW) U,

AtOM

010 CArS

ONeNel Of

4/4 {''''111 S10CK AND

!)NE "((EOf 114 (111.1 STOCK

k $~,Io'm,"'(~r 1.. I>CUllI in FiK.

"t

,'DCA.

SPLINES

COUNTtIIOlt(.

~"DEEP

.~ol.

w'lh a he.11 ,11111nUL

1:;, 'I'h~'
~y:4.~m
L~
ntatltl.:ttir. but ilQ" L.'4 ~ Jo,.'lJuClllml'
to (Inll u I t uuttnlfln-'ft hol~ in (';ach 4:1111
""I', ", I
III. F,~.11.
b...

All lh,' 1';"".< Ihat

11lI'.'

"l'<:

J"",,,I

to the (our

,.f lh~ .h,b "n' held Ou.hwilh

'(.-

~1.tit'K~.
S4.:". li"ig. X. 'Ill ("til ~lut~(tn' th~'SI)lh~l'\

\V()()n~MITII

in aUthese pieces, J used a h .lot cutter on

the router, see Fig. 12.
Sinee it's a deep cut in hard maple. rout
lhe slot in two p8..<SeS. For the fir:;! pass.
don't push the cutter all the way into the ball
betUing pilot, jU.<1hold it back and let the
cutter break the surface. On the fioal pass,
push the cutter in until the ball bearing pilot
touches the wood. see Detail in Fig. 12.
SIm'TIIE 51.A8. Begin by muting nllthe
way around the sleb wOI'king in a counter
clockwise direction. see Fig. 12.

FtGotE 12

SLOT END CAPS. !\r~)(t, rout stopped

.101$on the in.ide of the end caps,

,,"

CUToe'IH
OfSlOtS1HrwOMSStS

~lg.
II. '!'Q keep the $lOI$ from showing in th.
tool tray. stop the slots 8"," from the back
end and .r from th~ front end.
SLOTTRElIAILS.Next. rout a slot un tho
tool 11""), rail (f). Be sure it's (In the <ale
opposite the rabbet, see Detail in fig. 13.
Finally. rout a 'lot on the fixed dog block
.."""mbly. '!'c. support the router over th~
t'ntl$l"Cli(]n orthl" keyrail (that'sf')"l~'I :v,....
wide), I temporarily clamped the sliding
dog block to the key mil. sec fig. la.
SI'LIKES. After all the parts are stoned,
~('<!

SlOJ

arm.
$j'IJNtSlOJ I)flA!l

cut splines to match the slots, refer to Pig.

S. (l u~'(1'I. ~13somlefor the splines.) To
ulll'\" some ~ue space, cut the splines to
width '." ll'N- than Ihl' ",..nbm-d tll,,,th of
the

IWO

slots.
BOLT NUT BLOCK

"'lien f:~<tening lh,' .,.1 CHI'" t.. t),.. .tub,

lhey need to be puIk<1up li~"'L but Iho ~,h
$tiJI has to be ubI., to, .xpantl ",.1 ''''ntr;,,:1
with chtUlJ!'l... in humidity. '1'" aUQ" thi"
move,""nt. I dit.lnt glw' lit., cnd ''''P'' on.
Rather. I pul togelher a bolt and nut block
system that ties the end caps to the <lab. ,;ee
fig. 15.
ROL'TT8.EMORTISE.Start b~'laying out
a "'['.,haped" mortise at each end on the
bottom of the slab, _ Fig. 14. Then use a
router and straight bit to rreclland rout nul
the 'Y,,"-deep mortise and square "I' Ihe
eomers with a chisel.
TUg BI.OCK. Next cut a.small block to fil
Illoscl, ill the mortise. (Note: ('ut the block
"lrur1t;r than til" length of the mortise. R.,.
member. the slab may shrinkinwidth.FThe
drilla '//' hole through the center "flhe bl'lCk
to aeeept a 'I~"machine b<~l.see Block Detail
in Fig. I~. FiI13l)y. CUI 3 notch ill the back
edge of the block thats exaetly the same
width M tt y."." nut,

8OI1INUT

SOOINUI BlOCK MQRDSi

(lOP1IlfW)
~I
i-

BlOCK

.IV

"

tAIl

,.
.1'
...1.

5t/"

BOlllNUI BLOCKS

toOl
IllAY_""'"

RAIL
AGtIRIIS

DETAIL
(CROSS sa:TlOI<)

ASSEMBLY

bloeks ar .. made and the nuts are in

1'1.""., insert a .piine between the slab and
end cap and tempotarily bolt each ~nd eall (In
with a f,." x S" machine bolt,
Now the 1001way ...ail 31\d fixed dnll'
a,;,,~mbly can be glued and elamped tu th~
front and back edge>; of the slab. >t'O! fig, 15.
l!\r"le: 0"' ....the damps ate lillht, remove
Merlhe

the end caps so any IIlae squeeee-oei won't

g111e them

to the .,1<1$ of the slab.)

\VOODSM1TH

...-s~ ...

flGUl[ t6

BOX JOINTS

t
I

.-\n.r lhi.- .Iot! .L.........mbl~ ",to, a!tu4.. 1 ttl Uk"

,lah. I 0.1<1,<1 th. "I''''''''' ~,,'\ h,l' ctllllllR
It.. (ronl ,,",I1M .'1'''''' ,() I tn 6nall"",oth
llk...",,':. ~oth L' tht htlK'htOil\I IIh tbe
.'fl<I mil< holtro UJ I>lat.', t\ r"rto f'il1' ",
Aftl r the l.Jm.n UI'\ t'Ut. tlM..,. ('::I'll lit,
JOUk.,llo tht ,1.1 CIp\ \\ ith 00' jc.lnts - 1MJt
Ihe.,('pit'"
are ,looJ!theJOml,r:Ul\t.,'rut
the norm:d "11,) ,nth. bcv joint JII:

( l T ..., (" ....." ,.) (.' \.PS To ma~...

Ih4'
box j<Jl ts I!tArt by bY11l1:out .",1 rultin~
lhe.loIs. n tho ~",I <3p:'. O<'C J)etall onFII!'

bl."..I"'1

I" Tocuttht
1ot.s, I......t'rla<l ..
atenooJIJ: ,.,,
17 N-ttl",blllltt"th.
IhlCkllt
r th" 31'''''' (1)1an<! .1'( Ih" "I'
(enCt "" thl J
s ("'ffi tilt bl.,I"

1llGU1I1.

_CIIl

NOH:

","CUT [

WAST.
110 CUT

1101

..

SHOUlDOUNE

Of~'."FIOM
_OfSAWkAO(

-"*---

CUTOHWASt't

,,.
....

RNlSHCIIlWll>l

,-SHOUlOEl
UNE

OIO'OUT

W~SrtNTWUH
fIIHS WJTH01111(\

:\o~ JZtnclthe (Ilfl Ctl' .,n ,rwl 01).:'.1111""

the '\:t!'r1 I UPlMJrt ,II thl' tt'nnr, jlJ: ~JI,I
m:,k(! f',., I"'l! then tum thf. \~'fJrkIHt""'"
an'IJJJ.1 MIl. I~lht. tit he: r Jll(lt.
('111'11'1. 1111 I\I'HO'" PI"'S, An.,,- tl ...
:-It)L'''were nil In t)l,lh .,ntl ..urtht "IHI ('ar'''''
Ilai,1 I,Ut (,f,rr, 1"",.. III'to{ l)ln~ on th ;'I)"'ln:.,
']il cut _he lUllSI'ItrolJr:hl.~tart l))' m(.ul1t'n~

a l'l1nll'111"tltlll tli.ult' on the t~II)I..' z.a\~_

N(\t, ('I;llnl' It t I'I III"I('~ t() th ...
, nJ) 1'\.'n\,('
lu
limit thl' ""11
'111111~ut, H't" ~i)('.1~,
'n) 1ItC.".lt" h, ."1' 111IKk.11'1)' tl\t' ;lln',UI
.10\\'11 nlfl'lt:: nh 1111ilO'" 11)1',1.." 'l'htll1 ucljul'lt
th, ~tt'J) 1,II""k ~t tIn' :-h.,ulchr lil1(' il'l I '
(l'Cinllll" (rl'lIl ,If t hi' Nt\\ h1atl(, nn(ll'blml'
th",I,II.c:k 1111,111('(,MOl' "~iJ.!.I~,
~'I\~lll,lllh"
\\,'rkl'k'l'('lxI"k
nU'\'l'
th, rlJI fp,K.'t, 11'"1''''' th, hl;,rl.. :"o{Ith(' cut
\\11) ~...'nt;ul( IUIhc.',tUS'( !tn_;t, *,. J",l Cut In
Fl~ 1". (:,\,~.
('ut Jll"" ",I.ot/I/' tht ))(olH,.JI
Hre-. tht" ('113llIJI' ('IIIM,line latt'r,)
,\I\t r tIM,,,,,,, <lit. a,p IlK'1M'''''0" r ,u,,1
makl' a :;("'{'CJI1cf C,"1,\ " ltl)l~t nK" Ina ,hot- f.'Ill ..
ThtIlIJlo'\1 tht
MdIl1'll<~t""lh,,,I.,,,1
(wrtht'Ut.< .... '< ~q: I"

.",tI

r.1>n

TRI\t )"

<I"" n to
Then

net .....e)\1 ')('k

"I.nn-hlht.~"\ltJi

th, .holl~kr "1th h"n" "''''

2"" ,Ix '''0

OUl~i(ll "11..""1
..
",th alum" w and C'~n up" ith ,I
chl....t X,\t dI 1000tllw""",u'I~'I".","
lilt I' "" ISh f
~IIanrl C'U.'loltl-filth,
I'ln,' to tho
.til 'hl::! I
'-L"f: ,.. Rf .. 1t<>1" &r"", I(lu,"~th,'

!..,...,.

_UI'

."tIt

J~i("t,"t'''' lOJ!t1.t-wr.dnll a h,_!t" fr tilt \ i$t!

,;en'" tn tt... ndtl ~n"
rig, ~I.
A!'o....f. '.1.\1.) \' (j\\' t...It lh,' ",",1 ntlK t., l h'

""1'."""

- 1..- SHAI HOU

'-....
r UIG SCUW

,"'1"",,1

~I,

II, ""I'Ule<

In

"L.<". Ani'" h,

ihlt (tn,.,f. I ,....un,I", 11tht f,,'flnlt'N

(~'t'

Jo'il!_:!l (O:\t."('+J~
thl (nlnt It:ft \'i~C"I,~r.
OW!,

,"IOVIlW)

SLIDING DOG BLOCK

,-\'fil'r thl' ('t"'Iol'no. .&.i'\. ~nrll'(J. \\urk Cal'

the .tili.linJ: cll.< bluck. St.U1 by
tnnlnung .1 \\ h,,,k"r .,ff th\.thicknl:-"'ol th ..
hl'lC,'k "") It ...Iilll 1n th. lM.'I,,h OIX."lill~.
Th,l.I'J('k I~ h,I.I in thp of'M..nlng
\\ilh t"ifl
~li,rinJ! k,'~'S(1).
m'U<fJ th(, bkw..k n'mtj\f
:tlll(~rif It ,.\ I'r 11("t"(I~rcpllK'sog {Ir tlinlrninll~.
I 'ill t h,' "",,'k in hair Hndtill''' ...,\,\\"..1it
llack t'jJ!(.l~rtA, "NUlt}\\ ith" in tl1l' k4~~.fo(,,'
f.'Onlinul' fill

.Jr

'n,

MAltK POVTION
Of SQEW ltOlf ON
SUDlP<fCstOCk

SUDIHGOOGBlOCK)

\\'(X)I)SMI

nI

Fig. 22. But bfore culling it in IuIIf. drill

holes for the lag S<:r(>WS, see Step 1 in Fig.

'I'.,
IOOI.NOTCtj,

22.
Ne.'(1..cut the keys (I) to fit in thegroo\c
on the apron lind key rail. "',e Step 2. Then
t\lt Ihe block in half (St~I) :3). mount it in the
openiey. and $C!"\\' it baek to~th.r.
ENDVlSE

Once the ~lidinJ.!clog:ol"d, is in plate. mount

the '-L<e collar <0 it',; centered on the hole in
the end C'''P, see Fig. 23. Now slide the flange
onto th" end of the \;sc screw and mark the
position orthe sc....w hoi... on the eml of the
dog: block. see Detail in Fig. :?:l. Then re111<>\'0th~ .Iiding block from the bench, drill
the hull",. and replace the block.
Note: The top of the flIIngesticks above
the top onhe block. :;0 I had to file down the
Oanj(!'.see Detail in Fig. 23.

"'-OW'

TOQlTRAY

~~--~~----~~~~~~----1.BOtroM f'i'
~
',SfOCI(

2r------I~

-avo'

f. .__-

2_r

~.---------------------.T
RGUU1.5

.1. ....~4--.,.

....jf
~

TOOl HOlDER (g

-------">'-----------1

2",1 (-"'Wl : I] 111111111 Ii III! ~~LL!..u.ll_u11...u.II-----L.lI1_

r

_j___J

TOOL TRAY

Mer the end vise was installed, J began

work on the tool trd~:Th make the lAX>1
troy
bottom (.)J start by edf.!C-f(luing V," stock to
a rou' width onr and length .f62".
CUT TO WUYI'H. To determine the final
width, tun} the bench over and measure
the distanee from the inside IIf th~ back
apron (D) to the inside of the rabbet on the
tool tray rail (~'). see Fig. 27. Then subtract y." 10 allow the bench top to expand.
CUT INTOPIECS, Met the bottom is
eut to width. cut il into three pieces to
make a sawdust eleanout door. Sef' Fig. 24.
Since I wanted to add a tool holder strip
til the tuol tray. 1 hrul to cUI two Ion)!
notches Oil the back e"~,'" of the tray bI,l
tom, see Fig. 2>1.
rooi, HO~I)t:1t.N!.\\' rut the tOo,1h"ldl'r
(K) fmm ~ '4 stock t(l a "illth of 2' ."and III
Ifnl(th to tit iMide !.he tra y ((~)").,,(,~'IJ.f.
20. Then cut slots to hold diff,n.nl (,b.
An" r the slots art' CUI,chamfer the t"I'
('(I~e($~ Detail in Fig. 21 and then ghw
the toni holder to the in<ide (lr U,. back
apron SO it's y, from the bottom ,~Igp.
SCREW ON BOTTOM. :Sow screw Ihl' Ira)
bottom onto the bottom of the tool holder
arnl into the rabbet in ths- rail. see Fill".Zi.
(Note: Slot the front screw holes in the trav
bottom to allow Ior expansion.I

SAWDUSTDOOR.Once the two bottom

piece... are on. udd two I/.-thick cleats (T)
to hold in the sawdust door. see Fig. :1><.
Then cut (I notch on the bottom of UlP
tool tra~' t-ail :;CI the rloor can slide into
position.xee Fig. 29. Finally. chill a 1"-11.,.
finger hole in th...doer, see Fig. 24.
tIND RLO(.'KS.

Next.

RGUlf26

OfTJ\lL
CHAMIU
TOPftONt
lDGEOf

lOOl

..

"""'"

flGURf7,

CHtSaStOrs

TRAY END
BlOCK@

~CJ"C"'beveled end

blocks (I,) to the end_ of the tool tray to

keep sawdust from buildin~ lip in the corDeI'S. see Fig. 00.
That preuy much completes the bench',
ltlp. 'Tbenext steps are to mount the fronl
vise (pug"" 10-11). build II base (~.
12UI and build an under-beneh cabinet
Ipaj!e> 1619).

\I.'OODSMITH

Mounting The Front Vise

THE VIRTUES OF A VISE
A ", I\\orkiJlg "I.'" L. so basic liuJt J often
I.. 1n"nii<Jnit when talkinjP; about
ruodltm....ta1 shop tools. But. a )!OOd vi..~is
,.'" 0; the mO$l.essential tools in the ""1)1'.
(01')."'(

So, when we decided '" build II workbench

fQrthL....L~f.!. we g'tlvelh(l' \\ot)(l\\'orking\'i.~
bardware currently on the market a do-se
look.
TRUETO TRADITION
Altbough there' s a \\~de "ariet)' of vises
aVallable.lhey ba.,ieallyrail intu Iwo cstegories, O"e I)"., 1",-, ca81. iron ruc.;~ (1lJ'Uai1y
called a woodworkinJ( vise). The other is
renUy jU$1 the metal part., of the vise to
which yoo moun; wooden f;ICCS. (J call thls
wooden vise, even ,hough most of it i,

metal.J
AJ't.er n lot of discussion. we dt-cirled tel
equil) the U',>nd"",illt bench with thL, secood. mere traditional type ror 1\\'(11"1"
......'''''
First, there's no metal near th.. \\'"rk level Iu
mar the workpiece. knock the (..l~",.,ff a
sharp luOl. or rap knuckles.
The se<,'O'KII1!8..'<l1l
i,part uf'the ae;th. ti<':'
associated with a wooden bench. A vise g\<I.I,ru,b that I,e", through double holes
should be part of the bench. not ..,melhin~
machiued m l'ftch I'll,),',,(the carriage.
that\; auaehed to it. So. tile W""d~llfa<'e(1 Thl'r(4 i... ')Ih+ pmbh-m \\ilh the carriage
vise _flied natural.
muuntinR '\l'>lt'm. (tK,u~h. TIll! JtUidf'rods
..... ur"U!'IMU'!1 \\ lu- ..., lit.)' pas lhrou!!'''
VISE PARTS
the bc'nch'~(NII't ".,mn T., evereome this
The basic function of a wooden-faced vise is problem. th, 1.'lhr vis... '~"'lIlbliM< have
no different ;1\1111M)' other '';:'1'. It hold~an gu"Ie''O<I bu,h,"!:>. 1'<'< 1 .g. S.
objeet so you cnn work on it with two hands.
Ql'I('K ItY.I.P.ASR ()n,' part or lhe l'1tr..
But. smee the object it hnld~ is wood. it has M:lgf is an flJ.,lt 1"'0: tlu{tlit)' \'i:'t, u,.;s('mbtics
ttl grip tighlly without nmning. 1b dothis, it
offer a (luack n:1iHJ../. 'nt""" 11lf"('h1I1 nl.:o.
has some pal1$ that are unique to wood- allow lh~ face block 10 "Ii. I, "",n .u,,1el ~1
working vises and aren\ on other types of by giving lh~ hand I., partml turn to
vises,
rdelL."" the <tn'" Then you can I'u~h or
FACE OI,()(;K. A wooden vise doesn't
pullth~ ;IlCe hl.",k In when- you want u,
hllve jaw . Instead it h"" a large. mO"able
Most vise ass embli,." ar. R\ailabl.. \\;th
face block thaI clamp" th~ workpiece di and w;lhout thi. m(,<,halu,m. bUI I think
rectly against the rront 0; th~ bench. the extra $10 I" $20 it .., .. '" is worth '1.
(\Vhen tbe workpiece is pr""-"I again.l
ASSEM8lY PROCEDURE
lhe rronl of the bench. it's I""" likel)' W ,lip
lhan it would be when squcez() belween
O"'~we decided n" the ''is(! (see Sourte.,
the- nWTower r.a~of a cast iron \\'ood page 24). we had the rhul'I' "r mounting it to
\\'orking "L'"e.J
the bench. This lllnte<1 out tl, he m()1'I'of a
The rate block on m()$t wooden front chaJlenj!t'than we ,,"11<:Ipaled.
vises is IJrct.l)' ma.~i\c (OUTS L';;3~ thick).

1b attach the vC'' hanl\\IU'e unto the

The thiclmO!S:<",n', ror .trength; it'. to

pruvide :,upport (or the JlUid('.rods.
CARRIAGE, The nwtal part oflhe \'i>lE!the carri.!,,,, - perfonns lhn~ "".ential

belICh, I wo wooden parts are needed; a

'l)ilCCrblock and a fa((! block.
SPACER BLOCK. The ann on the vii'lH'oo

functions at

roJ'the "''''' a,,~embly. To pro\,id ...support

ror lhe frout "r the bench tOI), a .plIl'<'r
block ~1)i.needed. I made thi. blt>ekfrolll

nlO-"t f>\'iolL" is
holdin)!; lhe enlire ,;"" a.....
~mhly 10 the
Oltce:.

The

bench. The ._'Ond function is pNl\'iding a

tbreaded S('('tionfor the \'i~""re\\.
The third function of the c:arriaJ' is
ke<!pinglh. wooden (al.., block par.illelto
the frontofthclxtncll. [td""stlli> with two

10

of the b:\l\(' i. notched to I)rovide tlearan~

a pitt('eof '"lhick maple 18"long and 3',

wide, see Fig. 2.
Aflercutling the block lOsize. markal1d
drill , \~- hole. (Since this block i~
muunt

If,

ed right over the row or dog h,,,e.s, the ]

holes provlde clearance ror the doj!s.) Then
SC''C\\ the block in place.
~A(P.BI,()(;K. Tu make lh~ face bl"ek (N)
for the movable part or Ih~
laminate

,i.p.

two pieces of $. 4 hardwood together. ,;ee

Fig. 3. When the I(lue dries, cut the block
105" wid" and llf' lung.
fACE BLOCK HOLES. After cutting the
face block to size, holes are bored throul(h
it rur the vise SCJ'CW and guide rods,
Tu locate the hole. for the !,'Uide rods.
first measure the thickness of the bench
lOl' and scribe a line this distance down
from the top of the r.,ce block. see Fig. 3.

N,,\\~place the cast iron C3J'1;agecentered

on tbe block with it><upper <unaco alil!'1pd
with this line.
Th locate th" exact cenlers of the guide
rod bole "Ii" a '" brad p()int bit throu~h
the carriage hoi... to mark the borinj( 100"
tions on the face or the block.
Next.lhe I_tiun for the "i$e ""rew hole
is mark"'l, To do thi,. lrdce Ihe outline ~r
tbe center hole orthe corrlag.'.
BORE DOLES. Now the holes l'an be
bored on lh~ ,hill P""", """ ~'ig. 4. Sinc('
thp holes for tbe guide rods have to "'"
prtJCise. I U;;('d a .. brad point bit. The
hole for the "l", SCI'eW is ove,,,ized for
clear",",e. >0 a 1'1,- >pade bit is adequate.
Shop Note; 1'1. pre"ent chipout, ~to)J
when lbe point comeS througb and fini.h
boring fr"m lh~ other .ide.
I,()(;An O"~CH HOLES. After the holes
ar .. oorlill in the race bluck, Dllitchillg hole_

WOODSMlTH

are bored in the bench. Th do this, damp

the {Me block to the bench with its top and
end flush with the top and end orth e beneh,
_ rig. 5.
With the block damped in p''''ili~n, "'" It
",. brad point bit to mark tbe 1<1<.... tion of
tho two outside holes for the ~ide rods and
trace the outline of the midtlle hole f~r lh.
vise screw,

Then, w:ing n J'ortalign. bore I"

holes for the guide rod. and 3 l V,hole for

the vise screw, (Xote: The guide.-OOholes
are oversized to I" dia. in the bench, butl/of
in the face block. J
Shop Xote: At this pomt the out$ideedj!l!..
and outside ends of the block (except the
Pfll(('that'e e ven wiLh the lop uf the bench)
t<UI be chamfered. Ialsoband~w"'l a profilp
un both ends. refer to ~'i~.
7 and H.
ASSEMBU': Aft.er the btoek " profiled,
tlSS(:mbl.v !tID begin. First, the '"()4J(I.:u ftl(,'\."
block is mounted to the metal r,lce plnte on
the vise, Thdo (hi", fasten the guide rod, to
the metal plate with nuts. Then slide lhe
{aloe block onto the guide ",.1. No" drill
pilot hoi". for $<'1'"\\'". and screw 1he ra""
block (0 the metal plate, ""e Fi~. 7.
MOtl"r CARRIAGE, There', a trick to
mounting lh. carriag to the bottom ur the
bench. Ben by turning the bench 1"1'
upside down, Then, push the guide rod,
and ""'..,," through the holes in the bench
"nd slide the carriage too.~ely onlt) the
j!Uide rods. Now damp tbe wooden face
block tight again.t the apron, see Fig. i.
\\-ith th. \\'1>1)(1." face block clamped ill
pu~ili(}n. .::Iirle th., camag(' fOr\\,ltl'fl Ul10J
the Iront or the camujre jll!it touches tho'
dog block assembly, S'-'<' Fil!. 7.
Note: If just one end of the carriage
contacts the apron, don't try to toree th~
ather end flush, The" hoi. idea is that even
if the carriajn' it."E'lf is out of square, the
holes fa" the j!Uide rods 31... aligned with
the front of the bench,
Then drill pilot holes and screw the
carriage to the bottom of the bench,
GUIDE ROt) UtlSHIN(:S. AlWr the earriage i. screw(!(1 in place, Lhe ~id. r<KI
bU$bin),'l'are mOI1.i~1into th. Iront "f the
bench. Rellin by slipping the bushings onw
the guide rods, Then insert the ~ide rods
througb the holes in the front oCthe bench,
and trace the oulline ofLhe bushinjrs on the
apron, see Fig,lI.
T~mortise the recess for the bu.hing I
used a router "'ilh II ,;t <traight bit, o;ce
~lg. ~. Rout the recess by wo"'dng out
from the center hole to the line. Rout
pro~<i"ely
deeper until the recess is 'o.
deeper than the thickness
the bushing.
When the bushings fit the holes, drill pilot
holes and screw the b"",hings in place.
ASSBM81.&V'SE. The last step is putting
the vi.", back ltJj!ether. .JU"Lslide the ~irle
rods and vise screw through the carriage.
Then auach the washer on the end
the
vise sere" that. keeps the assembly from
pulling all the way OUl,refer 1.<, Fig. I.

fAce
1t0ClC

CAlI1AGE-

CAIl.1AGf.

I MAR" lOCAnoN
Of'GUIOi: ROD

HOUSWITH
&It

8aAO POt,."

t.-

3!/i' .,
fiGURES

fACE

6l0ClC

USE HAD proeHl an

IOMA'RKHOlE
lOCAnONS

AlONl

.'

DOIlI
lit

or

or

WOODSMITH

....,.
fAce

II

Bench Base
The ""-,,, "'r the ,",on..o.,,,,,,)!live me
au(,tltt'r ul".'rtunlt~tel use the came
... 11:....t hl.~'k "Y,lt-m C,.,., photo 81

VISF. NOTCH. There art' a COUIII!!

more .lep" o.'fore (he arms and f4?('(

are ccrnplete. Fi,,,,t, cut a lonjr notch

on the tOI' of tl)t~"is' ann tn make

ri~hl. that 1 "",,,I to attach the end

c"I" I.. lb. 10!,slah o(lbe hench,
The baseeonsist....of'two ellti fl'rull~
conneeted by two stretchers, ),,(,f(rW
fig, 10, 1'h e two ~nd from... flM' ,1I,

enough

Mttl'

fil(, I.

CHAMFERS. Now cut J" ('llunlr{ll":!off the bottom ends uf both arm" "",I
the top ends of'boih feet. see l'ij(S. :l

ARMS AND FEET

Eaeharm and (0(11i,1ll:"I" from three

pic-ct'S or 14stock lami,,,,u-d tIlg<'ther,

and 4.
f'OOT CtJToU't The 1a:;1step i., tu
cut out an area 011 the bouom of each
foot, see Fig. I, To make Ihi' CU10IlI,

see Filt. 2, I began work on the arms

a1\4'1 (N'l b~' l"Ulting twelve pie cres of
.wc:k 10:l ".ugh width ot 2" wide.
Then CUI nine of the pieees to a rough
length of2:f' and the othe.. thr<.... pieces [for
the long vi... arm) 10 a rough length 0[2'1',
CtJT NOT(',":S' Allerculting the stock to

I temporarily cI:lml't't1 tile two fe,,1

IOg<'the,' and drill"d a '"dio. hole so there
thll('hl'~ .1I'C("III, dl,e UI' lIlt (Itlr blanks in
would be a ~,. aI'(: in each leg. see Fig. :i.
:-'1'1:- (11 lhr.'t with ,..-,1,httllMl;lm if I tht~ The" unelamp the pi('('''~ aile! cUI a s truight
lui,ltlll.6t"t. 1'1":. ~
line between the an:'>',
ClUf'tthc'l,tanks .tl~ cJ~.lh,~ ''.IUt be lout
I.AMI"A:H AND(T't .\1\(,,.111,, I'.-,deep

t'CluJ,!h$i.z.t.. 13)' out notches on the ('f "I,,.

boanl for each arm and fOOL (\' .... n th,
th",,,, pit...res W1l laminated IO)!'ether, the tn Il'nJ,!th 1;, (I~tt'nnlnl tht "flIt I""ull,! (,tInotch~ in rho C(!llt~tblAaI,-t("rm nlflrtt.-:.~., t'ut t 111~. nwn....
UI"t' out I ,-frrllrl th,' "'It(ht~
f",' th. I.p: lenons,)
lin ttw n),:'ht ann "ntl l"t, fet-L, tiol;' Is~. ;
::;tart hy la~;np:nut a 2",,,;<1.. nQlth 2" {".m !'llk"_lh(, \ J:..(' :\nn Ii' l'lllJ,(,r. th. fr"tJnt ttl(ll~
I r,....m I hi fltltch. :-'\'1! }<",: ~ 'rhu\ nUlk. !Ii
lb~ br,ck eml or """h ~hterJli""",'*" Fil!. 2,
Th"n hl~ oUt" ,.,...,n<l2',\\;,1. ""tch I~ fn:lm lh. (,'tot :lJl(I.'I)(ht I,rnl I() :!:.!, lt1l1~ .,1)(1
111<' fina.
th.._ \'L'!t_ w'n\ (f*J 2:. 'IIr1I-:,.
!GUn.
l-
-tt",,
TO!'
~"

~C(

VlUAOM
Q
@

- )

;:

IV

'0'

'"

tclGHtAlM

VIEW

,..

LEGS

An.,)' the arms and (eOl were complete, I

t.. "r.m w .. rkon the four 1"1:"(Q), The Il'ngth
f.f Ih" leI!" fl('I~"mi""" the overall lIei!(hl of
II.. \\ utkb<""'h. (&~
'r.dking :':hup, p:)j(e 23,
f'lr Uti f"Jtbulation 'Ut ho\\ tu rlt:'t.er1nU1E" tl)t'

"''''II .."",h height.)

,,, -~
C .
"

~lol

1IftOUGfI HOU

...

11FTEN!)

G
(i ..-~

lOth'

...

, ;~

R'GHTENO
0

IOlTHQUfOl

SfRRCHElt

"'1'

1D

;)

"_NO~ lOAvt$(

wAStt

~ ~)2~.
~

,:_t.

1 COUNTER.&Oitf. '"..- DEP

, ;~

GW!roGllli[1
THREf "EeES Of

4!4 SlOCl(fOt
EACKFOOT

APPIOX&MAJEO'
't.WAST'fON

c
.J_

~~ l"r~i(:::-:.:-~Jj,(=::!:===--=====,::,--:,-::'~Ji'
NOTE:
FW
"'-"_

'~'

12

25'.,"

;,

IfG-

for the vise hardware,

,'('10m

Fig, :1.

MOCNTINC HOLES, Next.. dl'iI!

counterbered hole> un ~"rh arm til
muon! the to), 10 the base, see ~'ij(.
:i_
OJ) the- vise urm. center the hole :!',.'
FromIhe r...",t cnd. ()"the ril(ht arm,
center th" hole en lhe lelll,'th.

most identicul, except the arm :It the

lo!, 0( the Jt,ll. .. nd is IWlch.d and :;
I(ln_g{'r Ltl ht.')11rlUlllMirt lh~ vise,

IOTlt
THESAME SIlli

MAI(f

\VOODSMITH

fIGURE 6

ClIITlNGTHE PIEOES,Thbuild the l~~,

first cut twelve pieces of 44 stock til a
rough width of2Y." and rough length of3C)',
Then laminate the pieces tog~thcr in sets
of three to make four leI(blanks,
After the glue dries, trim the leI!blanks
to a finished width of 2'/, anti length of
28'" see Fig, 6, (This measurement can
be increased or decreased for a hiJ(hel' 01'
lower bench.)
'rENONS,""xl cui P ,'Ion!! tenon. on
the en. Is of each leg to tit into the mortise>
in the
and feet, see Fig. 6.
DRILL 1I0LES.Tu altach th~ stretchers
to th" k'j(>',y"u nee<1to drill two hole. in
lh" I.!!S, First, drill u 'i';-dia, counterbored through bolt hole 191/,"down from
the tenon shoulder; >*.'" f'il(. 6. Then drill u
-deep hole for a dowel pin on the inside
of the II!!(I'/.- above th~ bolt hole.
ASSt:~UlI.Y,Pillldly !(Iue the It'll" to the
:I1'm,' u",1 fe~l. "h,ocking fOI' square.

@LEG (fOU' ..,.,1U0)

,..-CACIUS

8J'I1I"

'f,

fRONIYlEW

STRETCHERS

--; --,..

STRETCHER

To make the IW'~stretchers eRI. eut fOUl'

Jli,,<'('Sf I I stock to a l'(lul(hwidth of ~...'
andfini<hedlength "f,~~I1"".
DADOES.B~fore lamin:tling the pieces
imo pairs to make tile stretchers. I cut 1"
I\'itl~dadoes 011 the inside face of each
I)ict'\', see "'ig. 7. When the pieces are
laminated, these matching dadees form
morrises that accept the boll nut blocks
(H). see Fi~.
S.

11tf.r_~;I

::

..,.___
AGUR!9

AGUl.a

BOLTISUT BLOCKS. A lier the dadoes are

CUl. CUll "0 ~'.IQnj.!boll nut blocks tl) fil in
lhe mortise e, Then j.!ilJeIhe 1'';1'< together

NOTE:

DRIllHOlES

1.<, Iorm lh~ stretchers. (The block, act ...

temporary "Ii~.,'mpnl keys nnel should be
removed before the glue ><et~.}
Onc~th .. ~Iue dries, trim both th~ lop

WIllI

i'

OU>CI(

IN PlACE

and b<lltom 'Jf the stretcher Ilush until It's

I'/i wide. Then put t he bolt/nut block bark

into plar, and tfnll n " ,"dia. 1)(011h..le in

(".m the en.1 of th~ stretcher through lh~
block, ~ Fij.!. 9.

,
(,

Next. insert II ~' boll into the hole.

mark the block with pencil. and cUI it off
flush with the 101' and bottom of the
stretchor; Then. cut u nOLChin the baek ttJ
lightly hold a ." nut.
DOWEL PL~.
Tu prevent the stretchers
f''(Imlwi,lillg as the bolts are tll{hlell."I. I
l.dded ~""dowel pin to the ..nds lOr th.
stretcher, Drill 3 hole [' z" above thv IK,It
hole 311dglue in a I"-long .10"el, se Fig. !I,
IIQUND OVt:R .:OOES,B.rore .." "nlblinj!
the base. I rounded over all Ih~ ",Il!~ 011
the stretchers and end frames with a 'A.~
round-over bit.

~
USE-8OtLNIJT

aLOCk

Dati t/tHOl,.
31,~-1)(lPfOR

MA.CHlNEIOU'

NOTE: IEMOVf 8l00t

AS ltMPOtAl't'

IDORE GWE:stTS

AUGNMENT KY

_AIM

_...>~

__

."

"-.,,"00_,

'-......

...J;:

,/

:J
~

;),

J"'"

mm;Htl

:1 r"(1:-..:L-~

.. "'-

.:;~

i 't.

~==~==========
~~~~

WOODSMLTH

lEG

ASSE~IBLY.
Next, fil a nut inlo the notch
in .ach bolUnUl block and lnsert the blocks
into the mortises. see Fij(. ) O.
Then, push a 'K"x S' boiLthrough Ihe I"g
and into 1II. end nflhl'~lrelcher. The nowel'
pin in the end oftheg\relcher should owtch
the hole on lh. inside of lhe leg. riooUy.
~li~l!:hW~n~up~t~h~e~bo~l~t.

" lONG

,@
lOOT
11

r"""f

II

'17

1<

'~;;;~~~1)
'...
b
MACHINE
8011

.... /

....
VlSf

'0

1"

"

MATERiAlS LIST

MOUNTING THE TOP

til(' 101' ,,:In bt>

udded. 1'" du tbis. ( found it C<I."(,><ltoII,".
the tOl' up>idc down :0.1 tht-n (Jo:;itiull the
base Oil top of it. see Filt. l l.

Ovtrull Oitnemion.-: 29'1.." die 65.,."lx.34"

On(.'<1th. b&e i>< assembled,

LOC,\T.: THE BASE. Position the base

$0

the \'i.'~ann (the IOllger arm) i.over the

fl'llnt vise, Then gu 10 the other end and
position the fYOlltend of the right arm (tb.
shorter arm) "" it's flush with the back of
the opening for the end vise. sec fig. 12.
No\\' measure the distance Irom the back
end of the right arm w the back edy:eof the
back apron (0,. (11 should 1)('about YO),
Then make sure the vise arm is the S,'lilltl
distance from th.. back <'<II:".
Tn position the b..se 011 the length of the
table. lin. UI' the righ; arm 5',~' from the
end with the end vise, see ~ig.12. This
should position the vise ann (al the other
end) between the dolt holes.
MAKK THE l'<>SI'l10N. Now use a ','

ATa~TopSlob(l)
(!Iu;!d

11( 12'/.60

up"""' ...... board. 01814 ..odc.l

8 Dog 610ctcP~es (3)

C Key-RoiI(I)
o FronI/BocJcAptoM(2)
Fixed Key' (2)
f TootTmyAoit(l'
G End Copt (2)
(Build"'P from 8/4 and
H SoIt/NuI8Jodcs(6)
I Sliding Keys (2)
J 1001Troy 8oHom (1'

k 1ooIHokfer(1)

'3f,. Ie 3-'1. 60

rough

V 3'/'6O
"/ x3'h6S.".
11. J(. '1.44
0/.. x 3Vt60
2~1.
Jt3~.26
4/4.tO<k.)
'Y, .. ,,14~
%.1
'h)l; 861 rough

'I."

'IV,.. x1'h-60
1
1roug:h

V."

l TroyEnd 8&odu (2)

"l ..

Wodt:ing Surfo(e': 18" d x 65''-'"

MYIWSpo~8Jock(')
lx3'h'8
("",wn to ",hkl<",,", 814 ..odc.)
N Front V'M Foco 810de (1) 3'/')I S - 18
(auikfupfromlwop~of8/"'-lloclit.)
0 fH,/RI.Atm(3)
2"/1I,x2'h22'/,
(8uild \lp from thfH plt<o~of 4/41itock.)
, ViiOArm(l)
2~',.x2'1t2SV,
(B\lild up from th,... ptt<.OJof 4/4 ttodL)
0 Legs (4)
2'/,. x 2',s 28'/\
(8uildvpfron,th,"~of4/4stodc.)
R St"'~ (2)
15ft .4'h 48'/1.
(8uiJd up from two ptoc:osor 4/4 $todt:.)
S Movnting6bk(1)
1l(.~I7f
. 2'/1.
T SowdV$tOooor ~
(2) 'It JC lllJ. 874

CUTTING DIAGRAM

brad

point bit to mark through Ihe hole in each

arm into the bottom of tbe bench top.
MOUNTING
BLOCK. Abo. while the b..se
is in position, [measured th~di>","ce from
the bottom of the tOP slab 10 the top <Ifth(
ri~hl ann. """ Fig. 12.(}Iy measurement
W3.< ['I.", I Then J cut a mounting block (S)
to

fill thi~
space,

Now drill. 1/," hole thl'll"lt" the center of

the mounting block. (Not", To allow (or
expansion, I drill",1 ,. holes through tho
mounting block and the ann s, but u-ed 0/"
0011.< to hold th~ t.oprlu\\'n to the b:ISC.)
THREADED INSEIITS, Next. remove the
base from the top and dnll '. ".<*p hole.
(0" threaded inserts, S4c'(' n,tail in ri~.
iz,
FINISH AND ASSElII81.\'. After the insert.'
were in place. I finished the benchund base
with two coat. oftunj(.,iL Then mount the
lOP 10 the ba.,e with machine boil.

14

~" " .- 72 crouRlOAaosJ

CO

fI

t
i "i'

WOOOSMITH

Bench DQg_s
CHOOSING THE RIGHT BREED

Although a bench dog looks like a simple

:;quare peg, it has a complexjob. In addition
to holding the workpiece down on the bend.,
it sbould hold its position (heilt) while
you're gelting the workpiece in plat.., (wben
there's no pressure on the dog ai, :ill).
Also, when the dog isn't being used, it.
should drop just below the surface of the
bench to be out of'the W3):

PEG PROBLEMS.But why go to all the

trouble to make the anj!'led square holes in
the bench (or square do!!,,? Why not just

bore round boles and use dowels for do"rs?

Dowels aren't ~uiu,ble for ""veral reasons. One of the problems is the boles. If
the holes aren't bored all the way through
the beneh top. the) fill with sawdust.
!flhey're bored 11I1the W3)' through. lhe
pegs fall throul. Putting' n heat! 011 Lh.
peg stops it from dropping. But, Ihis
means

M"ing to find a place to put the peg

when it':; not being used bf.cau~e it t,.\gn't be

pushed belowthe surface of the bench.
NO BITE. But the biggest problem with
dowel peg. is the.v can't get a good bite on
the workpiece. This is because peg holes
are usually bored perpendicular to th~
bench surface and a little oversized so the
dowels won't bind. When pressure is applied, the dowels lip backward, So. in.,tead
of gripping the workpiece. they actually
spit it lip and out. see I"ilt_1.
ANGLE HOLf:. Angling the hole for the
dowel would seem to hell" Then when
pressure is applied, the dowel would
straighten up. Bul the round dowel doesn't
provide much gripping <urfa~ and tend,.
to spin, see Detail, Fig. 1.
SQUA.REDOGS

Using square dogs selves the problems.

They wip tightly, stay put, and slide clown
out of the way when oot needed.

WOOOENDOGS

AlthOUgh the dog holes in the W"",/'.m;II,

bench are de;;igned for a set of steel d~

<_Source,;, 1~24),lhel'('are Lion""when

the ;;teel makes me ne",'O\.s about nicking a
plane blade. So. I decided to m.1kE'a pair of
wooden dogs.
I ""J}eCiaIlylike wooden dolll' when working M' thin stock. Then, if a plane blade u,'
edjre "fa chisel runs into one. the dog WOn't
lllk. a bite out of tile edge.
DOG1100\: '1'0 make the clo",>;,begin by
rippin!! blanks from hardwood. (I used
maple, 8.< on the beneh.) The thickness of
th~ blank h..uld be about y,," Ies.' than
the width Qf the hole (",- thick for our
bench). Tho width nf lh~ blank i. I" about .".. I"", than the length of the hill".
These blank- are cut to I;long, see Fig. 2.
I)(}(; HEAn. The next ste" is fanning the
head on one end of the dog. To 110 thi"
SMART"NGLf:. The secret to getting a begin b) euuing a ".<)l""P kerf across the
dog to grip is makin)! sure the dog's head is front, ;t. down from the tup. Then usc a
baud.saw or handsaw to rip the waste piece
angled .tabout2 to1 toth."urfa~lIflhe
(rom the (runt, see Step 1.
bench, sE!<!photn. This \\8Y, th~dogaetll"lIy forces the workpiece down onto the
SI'llING. To make the wooden spring. ti})
a strip Y"thick by... wide.
bench surface "" Ill'~<ure", applied.
To huln lh~ dolll' at this angl~. 1 eut the
'rhi, strip is mounted to a chamfer thaL's
rlog 1101(>$ in the b<-nehat I - <0 they're
planed on the dog's body. see Rtel' 2. To
angled toward the end vise of the bench. make this angled surface, clam I'the dog in
Then 1 angled the dog holes in the .lidillJ! a vise and rest a hand plane 011 it so its sole
block in the opposite direction.
contacts the dog's head anrlend ofthe body.
TENSION SPRINGS. Another problem is see Detail, Fig. 2. Then plane the end until
getting the dog to stand up in the hole the surface is about 2" long,
while you're gelling the workpiece in )JO>'i.
ATfA,CH SPRING. The last step is to atU\(:hthe $pring to the bOOy. Apply glue and
tion and tighlt'ninJ: the vise. A tension
spring SOh'CKthi. problem by pressing use No. J brasa screws, If \'OU want to be
again<t the inside waU of the hole to hold fanc.v, don't countersink the screws. Instead, let them slick out a IitLleand 61ethe
the dog at whatever helghl i,set.
Tcnsion springs ..ange from fiat springs
screw head.' Ou~h until the screw slots
to bullet cat <hes, Th me the most sensible disappear, (This makes them look like
brass rivets instead of screws.)
is a fuu spring on the fT<llltofthe dog.

FIGIJ.. ,

--"'~;r'
-I""'~~.,_,
1

QlTNOrCK
...... IANOSAW

2~~/---------------r7.~'
SPIlHG

DETAIL

!lOG

HEAD

r
----

-- ---

!lOG

IOCY

SSOE PRES$UH

CAWS OOWQ 10
ROTATEAlLOWING
WOI'tO'IEa 10 SHin

WOOOSMITH

15

Workbench Cabinet

STORAGE PLUS STABILITY

\\ hUI Ilk La.~c"OUt uCtuna' oil was still rI!,)'in)!

I." nl) 'M'" tllIH.'h. I started huildingm)' first

on u a t(NII8--((JI"aJ..'l' cahinet to mount

1."....11h th~ "'nth.
1'11,'"n,lorlItnch t"hlllci acLUailyi$(rv.~
I wo I'Ul1"... s, Of ...."I'!'. it k"""" lool. withpI'IJj(_'(1

in rt':Il,h "nil t'ruoy t4' IKlt \I\\"a~;The tlt.hl:r

I.,.fit b< ... 11 of" windfall. \\11<'nthe eabiIlf-t i.~
lO.(w.:kl'(t \\ ith t ,b\. it a.1fJ!oO \\'(-j.eht and
<I.I.hl,
Th nlN'I('1 l" lI'lUJ.1(ll.rn11It J)l~"'\\'noribox

"11"'I.,.h.

Th..
kft rotnll3l1f1l<'nlL' for ,<t'orinl! bulky n.,m.
Ii..... JWJMJttdl' 1.1....t r Ifw.L..., 'Jbe:;.c are ~
....aled I><-h".1 ILI"_ r ,,,-- The ri.>rtIt ,~ompo.t1.Int nt 113..il Ii\..,Ira" (or.-. (.,... a la.r'1.!e assort"",nt ..("""'I t...1.s,
lNat:-.. tll\ tcl."llrlltl 1\\0 compartmenl$

CUT STOCK TO SIZE

TilII",,,, th. 'huwl. 'tnlt by tUltinlt slllh ..

pl~\\(IC
..IIJi ..'4':- to t'17~.-ee ~i~.
I. Tlw top
""ultm (AI ,,,~I baek (H) are wt to 161/,"1""1[. (\\'h.n IL~nl1.lrill>'are added Inl~'.

'f,

th,' 1"nL'I1>'.1' Ih, '1,1,111<'1 "ill be 1/.."1...$$ than

th< ''',I'''''''I''(\\I,'n Ih" 1,'j!Snrthe bench.)
:\",,":1'1~'
,h,i<l"r till i., eut to til(' ""'""

strip'~"'wc,,111'"
,~ll[e, (J(th~ plywood and are cut
t'i1A. )._"nH'\"(:- :11"(.> routed in all
art' also 1"" IIf Ih, mNh,,1 of joining the four (..IJ{~.'/'i.(If ull thtI'ly\\(}4J{II.)icce~<t!X~I)t
corners ..flhl."hIlWI. re("rlo Fig. 5.
Ih. rli""I"r) f..r M'L'lInilt >1');'1"$. (The
~i.7
... 'L'" tlu' C:11htot J\),ko$ .) to lwgin with t
Ttl tw'J.,.,l cut th{'~' ~lrilJ."
about ', '1,linl" ""~'11till' t~I~"'"1:
.Irill> with th~
motkf' It t a: I(>r to "late}1 t be :-.pat-inc- flf tlx ,,"I"r than Ih,' Ihl"kl)(>,,-'of the plywood.
I)J~'"01.)(1.)1).cut tht'14. L,'1"(KJ'~,:.;.. I uM'd all,.'"
,tar~"_"S(')J' tru draw , r ).~k:-" "I1lc1) later. rn... otnl" .In i,I.IfI(d OIL,h attrr lhe{", ,,101,1Jll,r n th, ",ultr table, see Fig. a.
"",...iaIkey." lin! .. kkd 10 III(' ",II!\" .. f tht JUlIk"tlllftbP I"~v..c i.]TIlt nrut the ~tri~
1(1
GR()()\'t;" ron UX;I'(:. The ""-,\1.1.,, i.,
(ii\ .. It r to n13k .. UI' (VI" tbe ditrt"J"t"flC'l' In
".,,:-h k"'l:lh
nl~.. 1 I' ~.n~.r
than lhe makir't" ".. It("hlllj: Jrf'ftf,\ (_'" in the ....dj!\n).t"
kngth ofllltld,,,, I,,Ij1t thP~1111(' j<Jinori :-otrip- -:-0" ."ie.:!. (4\lll"'fI.n'1;:' stnp-, ex..
dimen.<l6IIS ...... hlt. I
tlll:.t("r:
:1)(;1'(. ~TRI""" ~f"'rt. edJ,!'ing :':triJ'"
Ct'rt tl><.... un tilt f"onl ..f tbe ,... bil",l. an(.HC)c)\ ..... , Itl.\'\\()('O \fl.,r the ~11iJ"'" ..,...)()\, ...1, ,n '"(' I'let........)
(t.(i.JO :11,\'
1 r",m I I ,I.",k. Th.....
o

"1.,...

MATERIALS LIST
~tto.fMfI~

CUTTING DIAGRAM

16'.'h,,4-8"'WJl21"d

'. "ywoocf
A Top ao'tom(2)

19',,) x. 46'1,

8 1odt(1'
C S"'(2)

'''''1
46',,, ..~ 19'h

,."' 19',1)

I);vi"'(l)

E 000t'(1)

,. 109
G

.... Hardwood
IoItoft\Edg .... S'hpS( .. )

s.cs. u..f'II S.npttl,

13't'.J(22).,

1', "',.-41

I,". ,,,..,
..21

H OMcI.fEOg.,..Sftt9(I,

'~aX "1,-16

I ~""'("

~.a_".-21

J
K

_._(101

s... Drw,.,.."

.... (6)
l SmDrw Sidft (61
lot l'9 Drwmnl _
(0)
N l'9DrwS,d..(O,
00.0,,(2)

\..~.,.t9'"
'1.. 2' 22".

\.112.191.,
11).31. .... 221..

'"," .. 3.1,. 19"1.'..

'ta2.'S\,.

',,'" MoJ(H1I"t.
P Orower80ltom, (5)
CVI To Fit

16

\VOOOSMITH

DADOES

Ik'Col'('thp cabinet, can be joioc'(l toj!cth.r.

three differellt width." of dadoes are cut in
the plywood pieces,
ShQI>Now: It', iJl'IJOr\aJlL to cut the

AGCIlt.,

dn<l_ in the plywood nll,... cutting the

_plioe j!TO(}ves.If the dadoes are eut fin;t.
the plywood will begin to warp and make it
impo:.;ible lu keep th e s plio~ grooves paral-

Y'

-- -

RIGHTSlDE

I,'." X-l'4'"XEYSON
lOP,lOnoMrIACIC
OfOlYlOU

yo.... WIO X

,tSlOTcumt:

&IT

EDGING

~JAII.f

v._

flHCl

~111J

I~

1 i

I)I\rIDt:R KE\'S.

_.

11

-,

11...

Yo'

OM'"

There's one more S.t(!l~

before the cabinet <all be assembled. Keys

arc neeeded to (..<ten the divider into the
lop. bottom, and back panels.
'Ib make these keys, rip litriP' 1(1 the
exact "~dth and depth of'the dadoes forthe
divider. see Fig. 1. Then. )rlue them to the
101'. bottom, and back erlges of the divider.
With all the lodging strips in pla... the
eabinet is read~'10dry-as ..sembleto fit the
oomparl",ent door.
\VOODSMITH

,....,..

\\;(1~. t'1'hi:;s:; v","'l(>~

..~ lruln

sitle panels first, see Fisr. 5. Miter.n the

edging strips 10 length 10 fit around lhe
pl~'w"",1. Next dry-fit the ;Irip; to cheek
the accuracy of the eorners. Then apply
J!lueand clamp the edging strips on.
TOP AND sorrow. The front ami back
l>oge> "C Ih. top and bottom paIIek are
next. Glue the edging strips to the plywood
(with the Sl,lints in plate). Then saw the
ends flush with the end. of the plywood.

......
1m

CUTSPI.IN"s.Il"gin by rip"in!!' - MlI>lt~

vide ~Iu" r.,Ii"f.)

Then eUI all the .plioo.' to 1."!!Ih ""
they're '1;- tess lhall the lenf.!l.h"f Ihp tlly
wood ,'fig<- thl'Y'U be .it,"",,1 1<1.(f'ht" bIt,
aUow ". "I .ath ~nd ,., th(' >1'"11.,; WQn~
inteti(-re \lith """ another at the eorners
durin!; l(iuin!t.)
sros PANEl.STRIPS. Af\~r cutting all the
<plin"". I mounted Ihe ('(Iginj($trip.<to the

ON

JOP,-~8ACK

the ,...."'bined cl~lllh of th( !!''QOV('' III pr...

OEEP

I -

OADOamtR1D

Now the edging ~lri""

can be lIPl'li." to the
edges of thl! Illywuod panels,
-;/1....

,.. 1

APPLY EDGING STRIPS

niw splines

lOP

a .

lff1' SIDE

1.1to (00 pl~~vood

edj(l:.
!)IVIDER I)A00. The first dadoes to make
arc used to join the center divider to the
top and bottom . see Fig. I. These ;lTC " ..
wide by ,/, deep. centered on the wp.
bock. and bottom panels.
Gl.IDE PIN I)AOO. The next dadoes .,..,
channels for the
dowels (glide "ins) that
arc part of'the flipper doora .sembly,These
(la(loe~ are 'I." wide 311(1 positioned y,."
down from the top m"ide edge" of the
divider nnc-IJ(_~flside panel. ~(' ~'ig.
-I.
DRAwt:R DADOES. And finally. cut five
pairs (If dadoes ;~"\\i(I("by II,".. deep (OJ' the
drr..wer runners on the right side )):-In(>1and
divider; see Fig.j.
DRAWER(lUIDES. \\'I1on the daou." lire
finished. rip ten drawer guiries. l(, y,." X 1~:"
to fit in the dadoes ,melI(lu" them in place
before the plywood panel begins to warp.
see (;''OS-'' Seetion in risr. ~.

CROSS
SE(J!QN

,,7. ,
,

17

I' ..

.'::

lUI

_7

KEY

OEI'IH

:1

t
. .'

t
,Q'

--

bI).

'1,"0lP

','

.s GIIOOV

;t/

.....OTHOf.E--

(OUN1'fft1OR1:

''''''1)(1''

OfTAil Sff AGUH 7

t-,
ftOHT
IIlGlNG

~
~

---

STIIP

...," .,._
:->

.. VlIlO

ROUKe_'

. ~ -.

<; -

..".

,
~--f
-,
~.

.,

.~

""ing rn...,ly. aDel" for a '/,."gap at the 101'.:}

~',.: gap at the bottom,and a 'N" g"JPon both

.i,ll,:,. Then, subtract an udditienal "J from

tl,.. "idth ",~I hciJthI rur th. 'I.-thick trim
,tlip'" IMt will he on
edges of the door.
TRIM$TRI PS. After cutting the plywood

U,.

MINUS .',.

door- to

t-l1A:.

ril' It,"tltick trim striJ..lK and

ths-m onto the ...O(lgL~.see Fig. 9.

GLIDE PINS. Th,>d"nr rides on glide pin.
Ihat.U,Ie 10 th" ...,u~-d lITOOv"".These pin.
ure I ,"""",1,, muunted in the side edge. of
Ihe ,1",,1' n..ar tlI"lu". ,..,..Fig. 9. The holes
[or the~ pins un.' pesitioned to allow v.....
elear.lll\'1 ;"\llh~ lfl)l nrthe door, To (10 this,
measu rv %.
n from the top and V; in
frnm Ihe back. Then bore hole; V: dee"
alMIinsert ".Ion~ dowlb. (Don't j!luethe
dowels -Ihey migb~ have to be removed if
gillt)

-__ :

,I""

DOOR
Y.PO'WOOO

l
~~I
__
~I~~
PUll'"

~.~.L_

Cj

:)

_
__J

I
J
,,'---':....~~,;,;;;;_----~""'=

the (IOflr needs trimming.)

OUJ'l1OE
fAG

RGUItE 10

INGtOOVES

II j

AGUI( 11

.....,

l8

Aller the cabinet is a.,...mbled. measure the

opening to gel the dim.... ioJl" needed to
make th~ tinaI'. see Fig. 8. for the door to

.i

_9
L

Before the cabinet can be glued together, the

lell side and the divider have tCl be prepared
for in.,tallinj! the door.
SUI'P()IIT VOWELHOLES. The lirsl step
i. to locate hole" {or the ,,/ dowels that
huld the door uv when iI" open. M"d.~u,.e
IY,"down and y," in from the edge:; of the
plywood (nolthe edging strips), see Fig. 7.
Then bore 3 ''''" hole \,,' deep for the end
of the support dowel. AI",., drill a 'l!o "pilot
hole (in th<! boUom of the \1;( hole) for lhe
screw that ,,;11 hold the dowel in place,
refC!r10 Fig. 11.
EXTEND GROOVES.The door actuallv
hnnl:l' on two glide pins (y," dowels) th,;l
slide in Ihe grooves that were already
rnuled on the inside top edges of lh.
jJIll1els, These {(l'OQ''''' have to be extended
into the front edJ1ingstrip by notching OUI
a small section with ~chisel, see Fig, 7.
ASS&~lljLE CASE. :010'" the cabinet ('8"
lx, assembled by j!.iniug the corners witb
the edging strips and splines. (A detail of
rhis.eorner is Mown in Fig. a.)
DOOR

...;~

-r
1

-,

-c

SUPPORT DOWElS

CHtSElIOS_

l~.

DMOI

SIDf

NOTCH OUT W'IJM

KEY

INSTAI.L I){)()II. To hang the door, hej!in

by chl,mfelinjr off the fronl upper comer,
see Fig. II 1'10""install the door pull.
\Vhil. h"Iding the door in the Cblllilaftment "1 an angle 1_ Fig. 10), align the
glidp I.in. with the ~'TOO\'esand twist the
door p"r.U,,1 with the front of the cabinet.
SlIPI'ORT HOIIEL.''' The last. >llkp in instaUinj( th e door i. pUlting in th.. dowels
th~t hold it horizontal when if.open, see
Fig. U. Bel-tinby .ullongt"'o W' dowel. ~""
long. Nl,t drill a shank hole through the
center, Then ~wing the door up and .,,"""
Ihe dowels in plate.
:-111'; Don't 9:lue the support dowels ill
the hole". The idea i;; to make them remov
ubi.so tlw door can be taken oul iCthe glide
pins need replaeem~nL

\VOODSMITH

AGU.RE 12.

DRAWERS

SMAU DRAwat SIDE

(6 "<CIS!

After lhe door is installed, the five drawers

can be made. I dt>cidc'<!to use box joints to
assemble th~ drawers and started by cutting
the pieces lO~i7.efrom v,. stock.
Note: The boxjoints have %"\\ide finge'"
and slots, The drawer dimensiens are multipies of W' so there'" ,I full finger and slet at
the top and beuom of each drawer,
RIP TO WIDTH. Before cutting the slock
to finul width, make practice cuts on oversized pieces The idea is to get tightfitting
joints, ~pac"d $(I the small draw.", have
three full finger. and slots . Old the large

$1OCK

SMAU DRAWERFRONTI8Ac!(

,.,lHtCIC

(6 PlECtSI

22')".,. ,\"lSS THAN DIAWD' OII"NING)

lARGE DRAWER SIDE

(. Plras,

lAllGE DRAWERFRONTI8ACK

('''<CIS!

-OIAWEt

8AQC

WGE

drawers have five. (For procedures 011

making box joints. see IV(J()/L'lI1ill, issues

NtI, 35 and No,

JIIQTE:: AILettAW"

SID.

42.)

CUTTO l.NCTH. After the joints are laid

out. rip the 1"-'. (K.l M,N)to width.
Then eut them to leng! h so lbe fmnL back
pieces are If,.." C~I,I.'"on each side) less than

lhe wiellh of the opening,,;ee Pig. 12.

GKOOVS, Next. t \\'0 sets of ).'1"00"1'8 are
needed. 1'hp IIIOsl critical part of l)(lsi
lianing these g...>(we. is making Sure they
remain invisible from the front when the
box Ioims are assembled.
R\fNNR l'ROOVES, Start by cutling WO
wid~ grooves on the outside of the draw-

All VOIDWI1'H

WOODPVTTY
lOMAJCIl

"""0......
RaUl! IS

BAc!(

SIDE

er's side pieces to fit over the drawer

To posiuon these groove s, ali!,'"

Ihe rlrawer$ide with the darlo blade so the
blade exaetly lines up with the second ~Iol
from the bottom. "ell Fig. 1:3.
Then slide the fence 1lsr.U1lS\ th~ drawer
side and cutlhe dado. \\'h.n th~ rlra".'r i
~mbl~". the box jnint finger on Ih.
drawer front \\'111eonceal the jm)()\'"
BOrrOAI GROOVE, The secend .~t"f
grooves are \l4"\\i(l~groo\'l"~or, llltlfL~irlt
runners

of aJI pieces for the V, )1a......nit. ,lmY-'t'r

bottom. To make sure these
are

JITU'' '""

not visible from the front, ahf!ll Ih, dado

blade with the boltom ,>dge "flhe bottom

\!.
BOTTOM

.~m

(QlTlORTl

UNTil
PUUOO<
DItAW..
fIONT

slot, see fig. la. This way the groove in the

front pieces will be thl'oullh a finger that's
'1Il1y visible trom the side . ..., t'ig. 14.

fIGURE 17

Cf!QSS SECTIQN

ASSP.MIII.Y. After euulng

,''''1

the grooves.
be assembled. 1b make

lhe drawers
sure the box joints were clamped liJIhtly. J
used finger blocks. see Detail in Fig. 15.
('1100" CIANI'P. s.,rol'e the drawers
can be mounted to the cabinet. there are
two ).'1'oo"e cleanup operations. Pirst,
chisel out the tin!:er that blocks the rear of
th" runner groove . ...., Fig. 14.
Next. fill the void in the sides (created
by the bottom groove) with wood putty
thal matches the end grain color. Then
mount the drawers in the cabinet.
CI.EATS. The last step before mounting
the cabinet on the bench is mounting two
cleats to the bottom of the cabinet to
prevent it from sliding off the S! retehers,
M.'e Fig. 17.
!'INISH. As on the bench. I IinL.hcd the
cabinet with two eoats uf lung oil.
\VOODSMITH

,f.' 1""./

WOOOSCRW

--

19

Building the Slab

STEP-BY-STEPTO A FLAT WORK SURFACE

~I"lht"

s.,'\, ~1I1kat each

fJl-i t l" (Onl) ~ f..'0I1"'l'"

"'ttltei'k'1" hk..._ 'k.. t",'l'" been lIlt' flf

piece (rum

tIll' , 'It/

(411' .ut,'

1hi' mt t IUt~lulat furniture

I'-t~I,.~
It\',liLtt,I,,, Tht' Ilt"lll11~mit,
1,"i1dllljt hllt"h"r hl,.k furni-

.1.,\\ II

4.~tllf'(ll'I")"

lUM' tor the IHlkhtrhl... k slah

1('11 (i)r
\\f.rk'"'tlch 111lh_i$
i.'''''t'j i1< J.!,ltIUj,! .11("-lab per-

ltU.' 1)1\01'11"..:\\ lfl

IKI\\ II.

tm-

!!luing JIj( and then ,;;u~s..10;.1

00 a ...ilk belt l""od"'1I< sur-

gt.'t ('\. ~

.,t:ul' ttl il.altt 'II tltt :-1,,1)- 01tU1:

on thL'" lut"i',1 R~ lakillJr your
lim,'. th(!xnth t""ran he n.lri~
a,.. Ilat ,an(1:.-nlfMJtha.... lhou~ 11t"3J11Cfrum a
fuctu,,' in lhl' lilack 1'lJl.....st,
RIPPING THESTRIPS

t",.

T" t.1II~1lI. "url;htn<h

1 ,lWt,..1 b)
nJ','"ig1 \\ "tt 4nf~ fr'lun' I ~l,'Ck 1 ,e

)loa k~l:'hthaI"...-"Ix"'t iI

r,.>1 ~ Ij!t ... Ii(..-11than "hat

""'" _~..J
(S"t.. ('UI It. ''''"'''''' Ion!: tu ail",. ro... an)
.... 1 "",,,,Ie< Iml.or(l'<t.'".. ..... ,>bner 'ml~
"".,rkhlonrb

'lfK"t"

L'"

I:.!

the

mam

""ko.

Ok,,,. 1 "now.

a IlIwkm. ",i,l) can't

I'll...........
h,,r\'" it'...sup,lo'JRod t.. be. \\h.. n you put all
tht 411~ln't; 00":"0 tl~t:lthr.
t Ilf ("fI'''' lIS w on ~t
(I"i)(_):-< each
t,ltHt' Ctr th\'n--'~~.n1"'chipout
"I' .j kill It tiltht 11\t h() mifldlc of
th, tll}J

In a honK- hop lIs llII<.u...r

it <'lII1 I. ,lone. Y.",
fM.-e"CIa little Ilratkfl<'I',:. numht-r
of clunl"" ."MI h"rnl"'M helt
NU"'er. II .10.1,,\ """ a 11.",,1

l,h(. z1tll(k

tt ('I"}\\~ (S<.i~J

thtn

-10". but

In

('1"4'\\

\ I'K()III.t.'1

....m.-.

0l11"d th,d".

n or crook,

~"t( tf tht h.lO'ln)!o I\:l\'(.o :t

'''t'n" ~'n,y,n. ~'C)Uma~' want to
c.'" III::l(I('r U.:-Ul,l! 'I,hr ...:-.t" kt'\'I)
the 1'''1''1, .u'c", ... I. ,.....th. Ro"
M the no,t """~.

f,..,Ll) n,,1 .,.,.. ... II>- ,...Ith .,.1

rif,,,,. It.~ 1''\).,'1h ln a (3(.11111'
this i v; \
11;;1(111<..1UI' In a
t.k'(o

\~at'JJup 31\(1

u~.liJI.1)1.'(.'\tl\( fJi('("(~!lot)
It (In Inll' r3c..'(~up ami

()tlt't

tht

part f,(

I rippl1I

",,,,,,I, "'" hg I.
POSITIONING THE BOARDS

tIk

:o-t"\l'fl

IllUI'U!<o into a 11UUJC. usual-

another 'X';I:-(In fnJ' tlippinJ,!the

1>""",1. (;"""1'1.11),. hutch"r block
hll\"lhl"'''~'' ..",.in (ucilll! up. I(th~ t-<llte
J(I'-ain fat ,'!( UI). thvn- ':0' tl',"~:-ohriltk~l" ami
mcl\'('m~'lll ,t\,I'tI:-o.
.. th,, \\ itlt h tlftht' slab ,,;it)'
t"rn.'lj!t .. if I hurnldtt \.
~'tll( II ""OE' t .....
Z\II\\, takl" a cJo.....t. IllflJ..;
at, a{h 1111;1,,1 tIMI,ll"(,t-cI(' \, hicbofth4,: :t'8,'\"""
urf,.,.
b. Ulfl (.1(,(' til' f or t~ ~t
tht ""rr.... to
up
th:.1
tht!'lll
t.
~oWI, th. k_
clu,.", m !t'<1 ,," tho:
t'dJ,.'t' .. 'hen
tQlll~}.Anli """.
1m1.-rftrt"Jft..'t
'rht'I'c"s

.'"h,

"'... :'n,"'" ,....

r......

"',Il'<I'

( Jlt 4 k flU It('~

\n"r nJ'l'lllJt

tb-

1'1"0 "III u """) ha" 11,b~bl 00\\ 0\. r

UI' lh .. huanb l~) ((,Inna ~li(l I ht'lr 1.ngt h Sl)tht 1111\\11' h"I"!lL.."h "f e"'4t h
hulc:llt'l' bt'K'k ~hlll, thl~J""'~it numbcr (It o.~'l,1 uIMI Ilito-'k 1l11t tht' t,,u :-ll""dightl ...'
thil\h~ 1., l'ull....ic1f'I- - C:-'IJl'\'.u'II~'\\'h~n IJI)..,j lW);lnl~,N,t thl:-ot .. t\\'I' :t....iflt! fl)1' tlu.' (Juts-ltl,,
li.".i.l)! lh,,: uwli\ i(luall~Irtl:-..
~dJt(~ (If I ht 1"'11(.'11\tIl'.
MAT{'I1IN(:l'I.ANt;U SllRPA(,;S. Aft"I'
r\,'xt, hlu' uJllhl' l'\'lll;:tlJlinsrI)iec~ ~othe
ril)lllnc. I\\'f) "Url;l(~.1'1flf (';,lChbo~nl t'ttnlain
hu\\' III IlIli' ltc,nrcl t'11fKJ!'l'''; the IN)\\ in
Jt.t.iill'e ~Iuill):

IK't'f\'t.:t sohruon, Y(,Uha\, ttl

lind U I"I,Jutic,f) that has thl) "IIIXI (1('-$inu,lll
fl'lIt urv-, ()IIC."" )'11\1 fiJIII the solution llult
"'04.",'Ill'"
h,' 1-11>!IO.t. mark t hl' t"I' with a c.--.dJ1M!U
t"r...tri:U\}.!j.'",1 ttu' \\h"tl' a.....
..;(mlll) ean be
I)' without

put I..",k

;J

Jutl I 1",II1'1.lltr.

ClAMPING

Onn tll<I''''''O.,

i"'llIM

- dH~nnl"'.I.tho claml"

'M...... -mu.."lab
('3JI

k lairl out

~~Olt'" :\11'"
t~ llllll' to J;:l' out a1JCI bt.'C'.
or n: I I t'11IlUl1hd:unl'" to(~,the joh.
1 ........1 Idnt '",
t. I!I", up lhe ,,, .,
~r tho ",
Ikh.
"'1<.IITI'I: 1'0 "",II,,
B tla .lab. lh,

"')fT(~
mu:.t

""I.

,-1:l1l'i'"

IUll"lrtilnt

:\tl'll

1.1'>":-j~hling"

lht.~

lI:lnll~.
:-;l trt 11,\n,uhll,l.! thl' tlalc.:-l~urfa('ft
;1\ aila111t. t fl 4.'lilI1l114)II, 'rhL'; mil!ht be a la]"gt"

lubl('. a t1;\t :.f(tifln I,f D(Mlr

11\ th(l

:;hOll. elY U
C"UII1~1(
~l\\'llt Ir:-t'/'i.. !'>('\' ~i~.
!l. ~O\\t la)'
(In\\ n t \\ u 17ftt ~: 1nK t\...
!o ~itl~ 11.\' :-iClt"

h3...... booJ'd~.)
plalll,t !'<n\f,,'th.II,rl '\\'fl "iU hu\'~ ~,\\'Ublfl. :Ulflliu'r \\ ht 'II \ il'\\ ",I f',,('ln the ItIJ., :i('i! l-"'i~, .Iw,ut" (,.,1.1,",,1. (J ,.dllh.,,,,
nl<'r~, "Ii, ("!'t'.lti' thl' tl(:-.t juint (or gluing,
:!.. (hK'(' tilt, 'n' W\lt11 Ull. the fo1\'\."':"i' ...ill 1'~'11
lll~ tlu\\11 t'" u ~'11~~.'r ku-) claml-1:-"
0111 tht' ''''1.0,1'1:1... SCI th\ 1,lane<i :,urfa('(_'_:O;
:-In.' J"ulraJI7~ fliK Itl)l,lht" w)!) mII' ki..-c:p .ht ;\('rtl.'~tlu' I....~ ht~lnl", 1' .......'\.'t~llttlk-> ~1}lil'oflf
3.l.....

in...' t I\h thtr...

~'II!'1

tlltin t.'I' p.ll":tJj!'ht,

fOGUI( I

-,

1t." \\ I 'I-hl III'C'\"J(.

'S1OQ

LAYOUt SO

l.....MNID
GlUE TOGTKfJ.
SUR,FAClS
20

IK)WS

IN IOAtOS

~_AHO'''LO
\\'OODSMITH

B.fo ....plating the ri :." 10.... wuMlonto

the cllulll>S. SlruKI back about five' "t. I!<'t
downuntilyoureyes ar even with Ih" topof
th. clamps. and look for an)' twist from one
clarJl11 ie lht? (Jth~r. :ot.~~Fur. :1. (ThL... 11'1
~ighlinjr- the elmnps,l Bulh clump" ,J",ukl
be aligoocl with each olh~r.If lh~).... nut,
shim under the tm.~hO.1.t'flat the 1,,\\' ('{Inl('r
until Lhv claml'" "'" uligm-tl.

POSITIONINC; THE CLAMPS

Aft'"

the

t"'I. end ("latnllS are :tliglle<t. ),Inct> more

pipe clamps acrn:-~.; tile lm..,t:> Dt,3J"fI:-.llM)tlt
l.'vt..~
If,", Till'n ~l!l lilt: \\urkl'IC'C,'. ...

liltl)

011 ttiJ1 of the clamps. l\fl'\ .,Iat.',

n101'(" pipe clamps ()llll~/) f)f thto \\ t1rk'J1''('

positlon
:-:0

lllt..~r'n in-between lh(~ !)Ilt."::.'

fin tl14'I.,l

tem, (Thu.. VOl..... JI~W"1:

UIKtllt t,.'\"(.'f1o' ., .)
Shop Not~: Puttinz wax pape" ht\\\',,'11

the wood und the piJl<" (or b:U'>i' ho-ll"

(l"'vrul bl:u.k mill'k!" f1"(10\apPt'ctrillj!, "h.'11
l.he met:ll in lile ci:1mlts I,".lets \\'ith lilt, t.. Hi
in the \\'()(Jll:ltm(llhe \\I:1tt'" hltht! I!iUt.
GLAMJ'ING IlLOCK.'Il> k""p ovcn pr<
~Un>OIl thl! ar:s('nlbl~' and t(l I)I,,(Jt~lt t ht
"ut."j<l(1' lOflgt':o fl"Un) tll'itlj! (Irlllt"fl. f pl;lt.11
V.-\\idc. ~' lonl( ciampinI( bloek '(nlI".1
un tbt l)ut~i<le(!(J}t(_~of til....&~ITlhl.\. ~ ..
phUlll. Th. dllmpillJ( block> k~~I' Ih,' I"~'"
$\IJ'E"C"('nt~rt~Jon t 11('thiekull$$ uf th, :.1.11,.
ShOl' Not~: Ke.pinll a dampml( hl,.k
(Cnlen"t vn I;;!ache<lgt' i~
just Clnt' nl.II ...
thiltg 14:,\\'(In'~' Ul'HIUL \\ 1'(;11 clccnlllil1~ ul'.
(\'011 h:t\'p ytllir han(l~ full a$>it is.' 1\J kt,t'l'
the blook. in pO$ition, I $tiek thorn to Ih.
edgl: hctaros "'ith (lo1Iblc:-.-iclt:clcarlx'( "'tl~'

nn Iheir sides so th
Thvl'e'. on" IlI><t .1,,1'. fh.",Jc to I.... u ....
gtuing surfaces are exposed . Because of thlll all the pieces ;lIOP:::eatoo (lf~\\n ;1g'aif1~t
the time involved in spreading the glue and the bottom "'W IIf clamps. If ther re not
clamping up the a.,"ernbly. it.:-o E'a....,)' to gel a 0\.1\\n n~lo all the Qriginal "sightilljl!" \\ ,L~
dry joint, For lhat. r\.~a:-OJ1.be ge.np.tt)\l.... wasted, 1\, get "II the pi~c('> <10\\ n nHt.
with tho glue and don't worry so much
place a wood block on lr>p ofall~'
hi~h 1J()int:-;I
about squeeze out. I usually apply It thick and pound them (I~
..wn with a hammer,
uniform coal to (JUt-side nnl)'. It should be
REMOVING EXCESS GLUE
thick enollJ,!h $1) thE' \\'tIKI isn't visihl,
A, long as til. wood i, "1)\'1\. the ~"u<, Once th.$ktbdri es,lVemtghl. remove aU th e
won't dry \'~ryfast. Rut once you tip the c1a.mftoi-. I USlU:lU~'scrape tjff lhl~ beads lIf
flU""'" inv) position and pullthom to!!"th~", drie<! glue \\;th a paint ~raJl<": But on lh~
dryin!!, begins, (It's alw.y" guu" idea to w or kbenehslab I clmnjt'<'C1rny proeedure,
1ul\"'-"a fri!'rJd an)ulltJ nt this stage to htll)
}:.illCC the workbench slab was m~lc e)(
IIrl,\r(!.'t panic.)
hard maple, and maple tends to chill. I was
I f(:H1't:NI.NG TH: CI..A~'.)$.AfiE'1" thp
afraid llmt if I hooked the scraper <In" head
1)1,t:t.~
3rt> in rMJsition. start tiKhtcnin~ the
of glu,' it mij!ht pull (out" small 6""1' or chip
l'hlnll)~_ I)~tn' overtighten. The clamps with it. ""'I<wl. I :<W!1.c(1 by paring utT any
:-;hlll,I.IIJt.
tj~hl (~n~}ll~Sf) lhere'~ a unir()rnl
Ifil1(e bear(s wit h a ShOll' chi",,!. 'I'h.n I
-r.cIIU"t (.'tlt" alflillt the:- jniJ\t~. hut ~'(lll HUlIcke<!tll~
'Yol \\;th belt "UlIII."
h(.lllfllM 14t""l(1 IfNJ.~tl tbl: chtnll) \\'ith (,nl!'
I k,"'" ,,1<1 SO J..~itblI\.. ;"'lIlnd jll'l f....this
f..:tnll If ~ "II l'an't. )'OU'I"t! lil!ht(.'oinJ! l~)(J
purJlO'lC. (Th(' jrlllc J,.'Ums III' (1 belt,) To
mil h '" III("h "..til "tol;uo\'(!"lhE>joint f.r erush
t"(lo)llO\'e fM p;I\l~l N})l(1 'r("/'fl.....
'j th(' ~,lin.
Itlt "'Mlfl (tIL, to thl! ,)Oint '\'h~rt" lh(')' \\"ol'king ju~'t (10\\'1\If' tl'tV\\f)t,cl.ut lh(!jtlinl~.
Iklll\ ~ntl tt, lh\. (,(lsre:ot (Ir t Ittsl.'lh,1
\\ l1l ",11Lotl:knUl.
I tip UI' all the piece

SPLINES when and how?

mt

"I""...
"h.'n
1.10,

buildinl!:up a

bill Ifill rll-" :otrl'ogth.

J,","'(I ~u,,~
",tJllt..,j,1t'Opl"rt).

ASSJ>MHLY.To a";l!lI\hl< the Sl:ID wilh

;pline;. I >larl by t.ack !!'Iuinj( (apilly

.,,,,l1;

u( J!lul!~ in thc::JulS on f/tl. Fhlp.of ('auh JliL'1:C:.

I 'M .. \ ariel
.t ....n).oth.1 I Ifklu<l~
111<.n.IWe a '1,lioe imo each pieee. Al\.cr aU
ltM.'ln \\}" n
J
111.Hl 1ht.llv (on"\ n.(.>(1 the bcxtnt~M"e :I -:-plirM!in (HIe si(IE'. (try
,lunll th, boards to lind wt h,," th~yuJI fit
1,1'IlIld ."'Wh Ill: I opt no. (Oil' the
tog,tJ,(r.
nlto dlgr
I t "I..,It)l \: ~ ,obJIIINocJ
GLUING
1ft, 81
I.} ,Id 11111(' U.J1 J}'f rrllJt
rf tl", "pli"", a,'I! Clll for a tight fit. Ihe
.rfnC1 \\lth.,
ph.. , io \he fu.,.t ""ani might not fil ea.<iJy
Irs3 ~I id."10 J!l' th",ugh allthi. chlllll~ In Ilr II .. tllf.'1 Il(tnl
I t tlf r II
... /111notlu
I..t ,IK' inll) lhi' .f'lclt in lh. :,Cl'fIOd lxK&T't'J. To h~~lp
ill)!1)~l"'(lure iu a rI.tJ' tc:-;ta..'.....lnbl~b..'f(.~
~~,icI~
lho .."li,w into
I ,lightly chamfer
net"ally :'ppl)~nlt the glue. It hell" Y"U,..,> l\t,.ol,Ul 1 f
,\~h('}"(l'pmblE'n\s tnifhl 3Ji~3nfi}tt.ak ... !'oout't,
SIll P N l I ~In
l t"tJl till' lot \Vllt, lh. "I~,' ufth. ""lin~"ith a hloek planp, _
\ h~tllllhl'!(1
<In,,, illl! hol"", I HI.., s~)..-blly cllwnfc'r lhe
,,)1the "PI.",inl'("'Il1><'-Obl>ar(L, ....tIl tlt' flull" I l"lll~ "' ~r I ,roultrt.jtl,l
,..,ut('1
Will
r,lll
\\
hh.)'"ftht
("Iolflt,.un;t,(tht+
nl)('tlillg of Ihl\ :-;tot.s..
tUgI!th.r tight. nut il dfJt,ml help 1"11h,,"
1",-",", il I kM: 1. th. It t I I {tIn" lll.>.;whl't.
\\'hpn it ehl-cl<.< ""I. glu, UI' lh~ hllal'!>.
mll"h tlw pk...-e:< will ",Iidv" ol\e" th., "lil'l"'"
I
t'sonly
n~
to 3.1d a unili>nn ]a)'erof
",rtue is aplllie<l. )(.11 ell1 Ollr~'n4) t11:11II.\' (n In tiM! t. p \ I .'
clr:,\\ IlIg 1...1,1\\,
giuing it up.
T". ~"II~.S
tOI 1,11IH':'f 11.-.e 1 ~ta ,;uc to the <odJ(t' "rthe Ilk""","ilh th~ slut><.
l)Qn't try In 1l"1 glll~
dnwn in all the slot, or
Itt:)tO\'-p, THE CI..A~'PS. ..\ft,,'!' tC:ll elan I).
r nl) IUlnl"'''1II1 tnp~
thick.
mg. l''nlO\lc al1the clalnJ)~t'Xt"'-'pt lht! I.il)l '11 , hUulcIfll ughl!) IIIlh.>.loL." but Itol <'Overilll tho >']>lines. 0,,,,. the glue i. uni
llamp.t.;.c>nthe oottoln. Ke('I' the J't':,t \\-llhiri
"" t, I that y..u "'101 """ily "licl~th~m in formly 'l'l'"ad on all (Or the picees. clamp
an arnl't' reat'h :\1)(1lighlclte<1 dt)\\"IIl'I!,St(u
out It' 1M l to .."I Ihem to fit, and lhcm togeLher.
110
II
If t 10,\ n too lIll"t. saiki",' plant' "ff
A1Lh'IIlgil till' >IJlin~ wfln'l Ju.~p Lbp tOI'
Ih~ir final pc",iti'lII.
C:'.trE ROLl.!:H. '1\. 1'(11,,ul' the w, ...,
'fl~thitk 11(11
anti boltom l,e'1"'//!/ilal (there'. still.llme
\.it
(01
\I
,,]tho
lilt
lh.
'plillP,
about
'h"
snncling ,,-oqllil'\.-<I). they "ill k...p the <..J)<eS
beneh slab. I useel .velle", wood\\'ork~r'"
of WUl'J""II.IW'(I. d,,,,,,r in line.
glu.. (1ileboncll in "glue ,,,lIer bcJlUe. "' I. th.;,t,n th(" ('1ln11)II,... 1~It'r'th or tbe. -:o:toL"-.
SoUI'~P,';, page 2 J '''ou ~c,\J)d;l1sc)USf a ~ln:,11
IIOUlH fOlLOW'S
)l:cinl ",.lIer. P.ith~, I~l. you gel a 'luwk.
COftlTOUR Of
wAaPEO 8OAIIOS
uniform film of glue.
TO KEEP SlOT
TAKE A MTmITF.. Ont .. c\' .. r~'1 hinl( u;
U_OISTAN<f
_1OI'll>Gf
rPJuly to glul' up, .it t,II.k. wkc II ,h"'I'
nt

II

1'''''''

",S,.

I,l"".

(,1"4

&-I.,lIt,

I.-

",.1

IJrl:tth, an(1 !oipcn(1 a CQUI>lc Ininute~ to

double check cvc,ylhiug. Are the cl..,nl"

0108(>at hand'! Do I h.\e" mallet Q" ham
mpr for adjustment.,t" 1$ Ihp",' enoul(h
in th~ boltl~?Alld moi't important of
all. \\'ho L..:;gcing tll ~Ult'\\l'r the phone for
the nex't half hour'!
SPREADING THE (;1..U~:, OnC'f' all th_

CHAMfft EDGE
Of SPUWE WITH
aLOCK flANE

b"".

quC~liol\"_~art: an.....,;:\\'eredto m)' sall ...factiOJl.

"'lOOOSMITH

'. StOT
CUTmI

21

two or tho baartl, who" <ruldinJ!with the

gr.tin. The sander tend~ to ride on I~ lOl'of
~fl\\' th~ nonl \\"r~11("J,.,'\I\.""13kin,z lh~ Ih. high b"arel" ,,,,d then ran orr and I!',ug<'
:'>IJrlltt'(4 0;" ~III(Itrue. 1r'.idlliotl:tll~. thL"
the 10'\' niles. B~' first ~}flillg across the
\\,,,.1,11"'1" Ii
Ior a plane, And if ltlt" ~l:.tl. gmin, aJl(l then (mi.!ffiulg with the grain, you
\\('n' IliaCI,~Ir oak. J'tf l."n!'iclcr it. H,\ll tKlt tOmiUI) \\ uh a lU~ltcrsurface.
1\,11,,1n"lIII ...-, '11~ J!M'in :t\\;tch~ dim'ti()t'I:>u
'I" start sanding. IMd a fr h 80 wit Jx.ll
l'OUfll(_~
tlnlt~ over the 1cnhrthof each boar{l. on the s",tle" Then sand perpendicular (!l(r I
lf1f1 .;(llTM,"'htr\ i\tlJ~ tile \\as. tbe r1ao.: i... 10 the p:lue Jilll':; I"c"",-, the W'.unl. When
hk...: 10 ,lItrt Iiftinj!chil~<'
ron!(h :::t,"linJ(. w.....k in an eUi~Ik-1II
pattern
BE!:I'SA,~J)I;:R. Instead, I n'~ch for my
and never make 3 ttal si4i(>\\'n~':",movement.
bell sander, Som,thinj!sh"uld I",said he' ... SCl'Fig, 1. t\l"1t~':::' move tht sutClet' fol'\\'ID'd
:t~""Ut btill sanders. , ,I'JI'l think lht.,1"l""~:t (ur t\:.-t(.'k\\'anl, fJ"f/l-li~ll,\ :-.i(le\\':t)~
at O,t\
\1-"'( In thtl shopthat tan ttl!~ll'rl~"
a fJJ"(,ject :-:amP time,
(fuiekf'r. Out of control. a bell sander (.",tI1
I start :11the 0'1","", n)!hl hand (.. 1or
bitu. f.,.1'f'Ub.il11(1J.!CUIJ:!f! \\'fM'lf1 tik(>.t shark in a
the slab :.11)(1"ork to th.._ltf\ %'411run :-4-:C wh.u
("cdillJ! r,N1ZY. The trick is k<>f'pinj! .1 J'\,t~ju-t c.~lnlr,k'l("(1. lt)1k,ntr;,t"enun an'.t
under control.
tIl' :Ill",u\ Olll' ~Iuart f.1t ,t lUlcl lr)' te, rcrno\1.'
Mb<\ o( th~ Um('" h~n I \\ urk \I ith a bdl
ull 'he rul..",,' in that an',. !J<,n't o\'e,,,,,,1d
:-.ancil'r I"m t:fln::;cinusl~' thinkitlR abclut A::-:;.Qt)nu..->- lht: ri<1~ ill"(' )!QJK'. mo\'c on to
ho1ding it back .L"; it~
t.'llttinl!. It'~ Jike a Ihp n<\1.ar<'a\(, the left.
routel' ,\,itht,ut cl 1J:i."(.'- It jusl kt'e(':-.
STAI AWAI't'I{()~1 E.1X't:S. The bij!j((?$l
diggUl.~ 111 if II'" nol held b"ok. ~Iosl twit
I',,,blpm i> ""nnin!! th. nut;:icle ,>tip.", If
SUl(len- :U'~he;I\",)'; th",,)' (Ion'l ne{"(1 :tn)' thcy..., nut k."l <)1;01> and :;u,';~ht. Lhe
mfUV rlo\\"n\\'urd Ilre ....t\111X'
t h.tn tht,.\\'('iltht
~lab "'onft r-tI,(Wa,' tel hH._\'P 11.unifum. thi"i\vi the ~ncll"'r it~lf. U$"t."OUlO halld:o. :'lJIc1 no,,-,.. \nd if you ,III"" lh. p,ul or Ihe !wIt
tl:rm~I)nly lo hillel it back Il,;d J.,l'Uicleit-lUll
AA"~I("I'to \\'clrk all the \\'aj! (.llt l~)th(' eclgt>~.
In pro", clo\\ n. The (eelinJ( i,to 11II1I11"r~'on the engC'}; 4tr~'l JikC'I~'ttJ taJ)(I.' (,0" cu' ('\,('11
Ih. ",u"l~r.nlll pu,h down.
J~.,unclu\'C'r.
Th~r"'s,,"p othPr thin!! 1\'. nt)liooOaooul
I t1')' tu SllJp m)' ~ul(linJ! :;tl'()ke...;abc:,ut
Jx.)l sUl<I,",.\\'h.",,"er I u,.,nne it WML-Itl
'..!- {rum ('~Ich(cadge unlet'.... il'~
nfi!c~"'<\r.\to
,lig In OIl'.U lcft :-;WC I thhlk lh:..-tl...bt.'(,-;ill~ I'"("n\o\'(>:-t nd&:!:t>. The prolllr.>mi~
dt.~lcnninrm ,,!(hl hand,,]. )1)' n!!hl h,,,.1 ",!turally
inJ! \\hl't'( thr p;jcl of the St'lildel' Stol~, :<c
..'c
\\'tlIlt~t':1 l\\1st t(1thl' le.ft.. 0\( tJw f.am(1' tlnle
t'ig. ij. 'I'hal ('t,m~~\\'lth prnctic<-. 01' t)
my tl":'i't hnnrl n:>_;;,.L
...on th~fr.lnl klll.h \vith th,'
u~inl{ rl{.l'lnct" PCI,tll:;.')0 lhe-~nfl('r.
\\'"i1!ht ,If m~'Jcfthl1'll fI" ttlt' Ilft :oI1(Jttlf t ....
('n nl~' ~.lrl-ohtolL Nl'lrt(r. ror 1',:,n1Illf".
$tU)tll.r. ...\llllfthis make~tJ~NiI1derm"in lila "\t .Ittlnlliru''I'l th.lt I( I :-;,itl1ft (clr'\\.,rrl un111
Ihe It>t\. Sol CO'!l;Ci"u.,ly put "ubtle P"'-',<Ul'<' the lla&:k1'1' tht!' 11"'111 k.lul, i:- ,tll't.oc:ll,'.,\('r
"n th. n!!llt haM.ide "rt!w (11)1l1 kllob.
Lh~ far (rlJ!.\ "( tht' \\c)rkl'u~t. tht lrflul Ilf
SANI)'ACROSS TH~: GRAIN. M""t b<t<ok, lht. NUKlinj;! l)Jul \\111 .... !'.I4.Ut
fl'llnl thl~
\\'al'11 l
s.::U1tl act'Os."the ~'Tain~Dut
l-dgt. t)nth{' bal'k. ~tl
..
,k'-,l)lt ("",11t..'r (1t,I,,)
lllllt'.exactly wh:tt r do \I h"11I.t<trt "nling of lhe Il,;u,'k \\h("(1~hl'IIJ,1 tH ctin-ell)._ I,\",,'r
off a :-UW likt> I h... }x'lk'J, tOI', Tl1('I"I'~ a lhi" b'1CkNI~e if I "nnt l,. 24tl'll '.l,u.ling
.lurnlJ,crofrt'a ....'w: to :4t:lI't b~' :;anflinJ!; .. crn.....
" fJ"om thf' 1II~t
lh~ j!l'lIin.
SAl<OIN(: WITH rllEtaUIN.OIIC( tJllh~
MI. u 1,..11sallder will ~"'"cl1dly ('ul ~h.lrj) rl(t~(',:o. nrc r(.nlc.\'c(1 b!- :41.Tl{ling
(... ll.!!'acl'<",' Ih~ gr.un Will \\;lh lhe j!rnin. .\t"r"\.I~"t ht gt11In. ~"ilcl) .'llft Sln(1 ,\'ith the
Sh,,. Ih...,Jab n11'UJ:-e,. a greal d",J) santl- W'din,,,ill)! lIw l'Il will ....lt. \\1Jel1 >'an<ling
ing 10~l il tlnt, ",,,,,U"J! ill bolh din.",tioll; wilh Ih. j!ruin. w"rk ,:Ughll)'J;!rj(~I' m'e3.<.
I fin-I ;t"1"Or\..~. tJu:.n\\;th tile- min, 1p'$..~I'U'tIll' i)Ul OJ11\' :l.._" fu.r ..t." ,'f/ur ~Irm~ ,\ill mlJ\"('-.
t"hatl(''\.c,r fll..ll gtlUI,,'l'Sthat t'nmt~rlV,n, ~U\(l- :-;.\.~,.i'1' In w;llk aJ"'n~id(' th~ WO"~lli"t~
jllg III I,ntclil"l-"C:lion.
"nd
,\1....,. 1IDll'e lh(~ AAndn1~ptl(1 i....c)nly thl"\>(>ttr
Th(! basjc m()v('mcnl c,f lhf! ~(Ier ,\ith
((JIlT incht;o.\\;(1(" it ,,,ill Olll~' ride (In Ol\~ or
th~ J!'rain is " liltle ,Hifel'(:nt thun \ ht
SANDING THE SURFACE fLAT

,tt".

,It,.. ,-

"r

,,""d.

ellilltical P.'t\~11Ifollo",ed when ""nding

across thE' jtr'd.in. ll':; In(lre j,r :\11 up and
back movement, Keep the sander parallel
10 the plu(' lines (and Lhe etl~$,,(Ihe ,.jab)
hUI move the sander up a'MIbuck!ll" :;light
angle -like making a long. t.all"\\,'" ::-h:ll*'.
~.~
~"i~.
G. (l\tlt(': ~1ill kf!'f'Jl ~~,"3"-U}' fn"n

the edges.

Continue """,)jnl( with the ~, wit sanding belt. but the goul now is l<I eliminate all
"rth e e ross grain scratches, W'alchcarefull~'what YOl)'\'e Ju~t completed :111(1once .,11
th,, C~ !,,'n\in scratches, :m- .c:one, :.t(IP
",mdinj!. Thai ur...u "e the l"hl. i> Ilat . If
lh"",s a slighl 10'" spot in the middle
whert- the eruss gr.tin ~J':lt\'he. .. are ~lill
visible, C,or,utilllJet(, work the ar",:-t ar{lUnfl
lh(' ~l"nltt'h(*~
and stop as f(olJn :-t~ lht'
M'l1Itcll(..~(liAAI'I>l'ar.
""NAL :.01\1001lllSC. ()nce the te'I' i...., fl'll.

;,>\\itcll t~1a 120 grit .;"'~ul(lingl;clt llllUl'tJU

tinu' wflrking \\ith the gl'tti'I, (1)01"\ ~tf
buck ".,,,"" Ih! Im.in ;';''1Iill.) Follol\ lh,
~'nll11a:;it'tall"\\'" Jlattcm a....h"rol"'c". 'J'Jl~
{,,""ll no\" i~to n~rno\'''' all of the $("I'tt~ht':-krl by Ih.. XO ~"';t~Il and I~av. fin...
:::'CMllchc:" lhut C"dn lw 1"(mo\'f'(1\\;th n 11l..lii
!<:ulrlr"lwilh Ir~1 J!"il 1';11""" tI,' han<1 ,:;,n<ling \\~itll :1 I,h)l"k.
SANOINCTIIBo-rrOM
~'A('K H(lWlIb"ul
~l(tiJtg the I)()\tclnl fact' oft hc' $Iao';' II nl~ ...
1['~ t"\(4).-.(lfi. it':,> ()I'(;11nhl)'not "(Il'th it. 1
u~uall~' jt~~t
renl(,\'C llic gllll' ~tlltJ1h"'n :-;:l11U
3('1'0..'''' th~ grail\ Ullt il it'.:-;.fu.i,.I~ nUl. (!'l Oft,:

It's a iZ"JOlI
id...". lholll!h.

to '1'1'1)' finish I

th .. hl1t t Il,n fllt'4! t jJ :-.10\\,10\\"1 nO,' nl(li~ul'l'

imll:tla,'t'l"';; ill tllP ~l:lh('all~1 b~cl1an)!e~
in

rd:t1i,, humid.ly.)
CONCLUSION

In thil1kiJ\~ La~k at.,ut thi.....\\'Imlt,

111"Jt.'l~

lure.. J' \ ~ t'Om(' to the e.)nch.-wir,n tru.-lt. thr;

ffiO.'I,mport.wl "'''I' ;,. 1!I"Qably the fi,.,;1
:-t.art \\ith aj!llU<r 0a.t~IU1n4.'\..
J l:" cntil'""'.u.lhat lht' rhtm)lS are rlfJ\\'ll {)1\ ;:1.
Oat :<tnia." and all t!w pi<'C<'s;u-" '("dlro
do\\'ll l1at hl1 tht (.hu1'll~\\ htc'1lJriuing. ()\C(."
t.h.. toilab i~
fir')' anci tht-' c.'hln,,"*,;U'\' rt'lllC}\"('("I.
\11('..... h"ul<ln\ lx m"~ lluu, '/,.~ off""l
l)(t\\('t,n piN,(,":-; that nt......
""'(J~ t(1 be:- ~-tf)(ietl
(In\\ IL if WI' 11fl."'i(ll is .111)' runl",,' tJUlll t}t.ill. U.\"
th;.' tinll' it':-; ~an(I(o(1tI0'\1. th .. :;.lab '\ull', h4'
Ilat. Anti ,,110\\un~ u \\e.rkl>enth lrnlt Il)()k.~
like ~ ,.olhng 31'"' liekJ'!
f

RGU",

4'

,I

GIAIN tJlRiCnON

r-.=::
;=
~~- _, .. __

..

12

\I,'OODSMITH

____~T:~a~lk~j~ngSho~
__

AN OPEN FORUM FOR COfvV\AENTSAND QUESTIONS

swirl riU'\JIUIJ'k,;. Keel' fe(."'in~ th...saw '

fast '''' it will CUI,\;lhoul LolQring clown.
After the slab (01' I hr' workbench was !(Iu",1
NOI'1':R. Anllllll'r way tu cut the slab to
1,nl.'1l1
1 with .. mUler anti a straight bit.
up and lInt(.,.., 1Il1icl~on the previous I"'!{el.
1'* n~"XIstep was (IIeut it 10f~ngth. At thi It'",:t lilt)" "'tln.lim(.' consuming, but "ill
point, it "(Lot SO IOJllt and beavy that it \\.,L" I!IVta ~Jn(M.th ..'nli \'"It h u cle...n ::.hcl'ulder.
awkward to wOlic with
Thet'e \\'8.,,'" 00 \\!n,~'J would ever be ._lhhlIJ
cut it (sn the tahJp ~t."'.even with ;t pam-l
futLingjig. AIHImy radial arm saw's C',..-('.;....
CUlTING THE SlAB TO LENGTH

CUllU1J,!tall3cily \""3."' just a lilllt M)' o(

rutting all the \\'U~.acnlS$ without ~LlttJrav
from oo(b directions.
POlITABI,E CIIICULAR SAW.That

""mlthin", like I hick. hard maple. thv,,' :tn'

If YI>U'I" going to take the tune to build your

U" n workbench, it might a.~well be a custom
fit. That ts.rhe hci~ht of I"e bench ought to

4m

fit you

b(.ncl\(!t\

the way you work. On most

the \\"()rkjn~ surface is somewhere

II.,l"''''11
3!l" lind :3(;" higjt. If you',,,, .I~I~.
hl'igi>l (""mewh~I'" between 5'\)" and 1;'I)"l.

that's tl<uaUy a{"nUOltab'" height. But even

a f'ltanJ:\. I.e 1- lip l,r down can make a hiJ:t
fJifft'l'\n('t.' in 1\0\\" (;U..;;;~' it is lu work at the
bench.
\\'e'\'eu~"'{1 a fot of methods to determine
the bt,,\ heighl fol'a bench, But one simple

It'll th.

pon..t'f. circular saw. Tu be honest, m~

circular saw and I h:l\'(>never grlttC*U .1"~nJ.!
vety well when working on fin"," " ..rk
The saw doe. II good job "hen r1lugh
eut ting plywood and ~hot)ping off ~,I',.
But any I ime I tty to m:lk. Hstraij!ht <III III

BENCH HEIGHT

KOIII (VY -_"'

lINt to
".V1hl

""""".

NIII \'111 I~('tit lh. I~il,

llli).~htl~( ....)
~ fi, t" thn('In.'1I~&rR:i\\
tl\.llh(t1l

11\'"

Iltf,tho<fseems to gil'~th~ best ,'(>:;ufts.. )U.'l

messun- the distance from th, 110"1' to the
crease en the in:;ic1e of your wri.,~.""',," I
dill t";';.Iftt. mC&;Ul't!nlc,lI was :;H So tl1;lt.
the fwighl 11_1 on my ilf'nch. (I(.)'(,ur ",,";',t
C~
.. measurement i-: shorter tU' taller;
in""","" or dl'C"""se' U~ length of'the I~ a'
I"plai,.,,1 on l~'lt\'s 1213.)
I( you're u'ur or taller; you may find that

problems
('"I'l1h I , h "",,Il. In, It ~ II1I =an.nlt"y '.ut 1
Even ",iUI " carbide-tipped ..,w"I",I,. 111,1." fi,K! t Iw.i\ 1'\ 1"NIar)':
the cut makes rough, heavy :;3\\' mark....aJ,,1
1i, 'll.lk, tlli c It "'Ih 1''1''.(1'1', t ..trt l,\
burns, And th~ exposed shoulder isn't ~, 1;'.\1f1' ._ul 'l,lt IlIh ul~l" r,,'\t'(' 11"'-, Ii(o~. lhi~ wri,.... l'J"('1u:;{' mt..'3..""UI'l'1ll!nl io:. :~ .. to 3r.
Iln1\\1I1
I hI ,II t: ,w:, '",'1\\';'11 lhc!o ("lIt nIL,
niel' .f.mI. stl'aightlin .
S{,(m t ., high ((II' a ilf'nch Inlt ul,d tit (Ilk 11111 I 1'(111 tIl tht, j> ,~-c.;:tll~t'\lrL"id,~riJI~
"Irt :-.t...'Ul<"1:ml.... BUl
11,"'t ,,,.,,
tilt t "I fIle .,(thl' tilt t" tilt Ih."". <l.u.lont> I\'ere "alid whell (he fJ'ljIIlla
fltll I,t, o(thc ... utcr t
I,latc' )
(ljJfl III ~l'Jk'f1il \\-1l..' n\ut'h sma1Ilr.

IIU',

rr.""

.\ft('r nu,,",,-III tl

la\ "lit the

,lRnllkl to It 'I ~"'II '1 11 fl'U'n.'

~'nltt
tilt (i nt"'t II'" W"IUnd tll( l.t.

(,'IM."e
ttJ

"f'

(,I,t hlk

PRMNTlNG

VISE RACK

()Ut

t)( tilt>

,l>,'lI'

l)hlhJ{m.~ \\1th

\\"UC'KI\\(lrkillJ(

t"',1 th~y .......k. If ~"uligjtlen dO\\11a

nt rhll..cMlt ,.tlll1 ",,,,III(the
I.it'(.,\, ,.r" '''I(I in unttl'Il<1 "fthe: \i~.
the OtJleT
('lat. I6('1llt til ('ut hne' J~ I}u ''1I;.:t ,tlfti",
\,... 1 f,r \lu,,' \ i...tltM..~in,
"hit, (lr ('Itf-ITIIII' lO,1 1)( I iii_ to ttlt l-d~l':-',
11,t'Ul I.ffltll
t 11041
\\ Ill,,, ...IIlt'r. I nH}Uut
(,fl.', tn. htIlit \\llh. I nutt 11'IJttln~)
.
II Ul::tl, Intf. thi rlllll, r UI"I rl.lll~I't,1 :t
If yuu glued UI' lh~ ~lall a fool IOIl~er :t-trullr{httII~" tIl thl.: r(!II\'t IURI, ~11l1:.' lht.'
~IIJt

CJlllJC.,lh tlk If 11,\,wllloll\(flln llrfull'

~,"t.11.lln

\t

"_

than ne('"f>$S8:_r;Io',~'()U\\"ill

lla\'(! ~)JJle ,,'":\In,

m;\lcl;allc) '11tH, J)(JI14bit!circular .$:\\\' t(, ~t>f'

if you call get a slnli!(lll. ""'''',th cut, To rI..
thi. first tum th,
Ihe f(0<Xl ,una'
(the top) r~(I(lI('n, Thi..-\ mi.)jm17.t>5 {'hiJ..)()lJl
(In the face sirle sirK.'C;,t circulal' Nt\\ CUL....UI)
from the bollom.
No\\' clamp :l fence (~)rciJ"cullu' Nt\\ tUl..u.r
jig as showu in the drJ",ifll( above) tn the
workri_ (!JO" to the cd_) for the shoc of
lIl<',;aw to run along, Sel up th~ clll 8(, III,
hca...;e,,'t (motor) part of the
L, (fl' th.

.w.. ",.

III~ ....IIIlg_lllltlli ~ .1\.'l'''I~ 'jn,' ~icll-u'ltil

tlll'll' \\ a I cit"~fl~l'IJCI\t
Th"11 n.p Ih. 10" 0\ pr. "art'(ully cL'Ullp
I hi I r:'I~hl.~IJ.!'I' nght tt, lh" lalu,*(,Ill tllt.'
ulhlr ,..'11, ,l1ut l.art l"ulang. :-:lot (lra"~ng
1,{'lCI\\,

\(\t'"

:a1,uUlthl'('\'

I)US$[>:"

"'1111'(:til ,,"al.

S"i(icun a few others..)

\\'OODSMITH

lh('

:::.1
rlu~hl t'Clut,'r Int ,uts thrtluj..rh and the-

workpie: in.,l(-ad uf on the "lliW. (Nut.:

This is the left ,ide un mrn;t"""s. the ti!!ht

......

t'~,I, \\ aut ,
tillt k. J lu...
I. n ~n,'~
of four
I"~ , (. I h ,,1.1'11 f- tll"t'I:M'r thUJI t}U;!

""w

Shop NOle:1b prevent ebiroUl :n the end

nfthe cut. clamp an "drlitiuna) pi""" of ~'';ip
!lithe Car ed~ of the sl.1b.
\\lMD making th.. cut. think about plL,h.
ing the saw all the "Or througjt. Don't slow
down or the cut will burn ,mel create h"""r

MAla MUUIPll

PIUSfS us.,..; A
t ..' STlAtGtn 1ft"

CUT
lINE

.... Cf

UNE

ThL ....J'aCklns: n'c..'11~ l)t"('SSUt'C \\iU De Up"

rlim only to Oil\' edge of Ihe wOI'k"k'Co
('1I'I~llg lhl~ \'ol'k-pi(1.."'eto pivoL()I'~J)il':1$)o'olt

",ork on it. ThaI rlef,>.!., !1Il! whole IlUl1"'''''

of a. \'i~.
til'S :d.."Cll~I1..3.tjllR"a ~1,-ain that't'
likely 10 enJarJ(~ thp j.,.... irl. 1-00 hoi ... in lht
(aec block.)
1b p,'(!venl "ICkinl(. I t"l & slep"",1 "fock
lhat offers a ,ruicly of Ilo.'<,il>l"thi<okn<"
...."'
Then I chlxt:<e lh~ Ihickul"" cI"...,~tto my
workpie' and slip il uno the ,Jl.bel"nd ofth"
,ire. Olll,(!it's ti~htened down. th" vi,;" f''''1$
;u't' parallel and the wm'kpi""e is held tight.

23

Sources
WORKBENCH
\\1"," '''' "I'SI ' ....rtro designing the work,

'" ",h.

,<t. discovered that

th~re is quite a
.f vises available. Ami since vises

',,",'1>
.U'\> ht.~l\t)'to

ship.

w prices varied quit(' a

bit f""" one 00Ul'<'" to another. even for Ute

grunt' vise,

rno~,. VISE. \Ve ended UI' using hardware made by the Cambridge Tool Company inCanada Cor the Crontvise. The best
priee we Cound for this vise was from,
WOOI)("RA.,. ~I.1PI'I.Y
COM. 41 Allanlic
Ave.. Dept. \VS, Box 4000. \Vobul"ll, MA
Ol!!; 800225-115.3 (Catalogt Free). Quirk
ReJ,o.-' Fm1l1 V"'f. l!r screw lenf!(h. 2ZY,'
overall length. 10"" wide. Order No. 17AII,
$1()!l.50 ppd.
\Vood<TIlil and other sources offer other

clamps slip inl.<>the dog holes and the upper

Jl'Il'( oCthe body has an ru-m that swings out
beyond the ~<lgcof the bench,
On the other end of the ann there's a
swiveling vise pad wilh two faces at !JC)' tJ.
each olilet When pressure appU!'tlon tho
j!lipping
face of the pad. the other f.'lOO is
the dowel. counterbore the back rllce of 1>J",,""'lli~t1~ag-dim,"llhe";'Icofthe bench.
'hI' wbeel and screw 'Th,,, kw!l<' the f~ parallel for a fum grip
I'
down thrQul!h th. on th,~\\or~"Plf'("E'.
C0UNTEI8ORf. ~~
rront ,,;th a Ntl. S x
::;hol' Nolc: These vise clamps have a
\i"DE9
~
/'
I Fh I,r;t.."'s l'oo4,,'l'\'''', n,III.I <fu'll\ that tersls to deC0I111lbesquare
dOl! h.. k .... 1\, ,1t1lIwith this problem. I mad e
o.JNG
~
TI... toy
t" CMA .....
U. fod l"1t.n be onJ(_'n"tl
"<loti"" il.... rts lhal :dip between the dO!!
DOW[I
L-..=;:=:...... ........-.I--' (ron"
botl)' ,",llhe willi or the hole. see dra"ing.
THE WOOI)",ORKt;HS' SlOIt. :!ISCII In,
_..... AD5W1VBS
d""trild B"ul~'Hnl. 1II1.1{'r.;. MN ;,r~Ii~:
ONQNII' AAJIo
(612)1~21~ll Nt.tl-':.\1inlmun1 cash order
"
-~,
")
$i.W. Cutal,'I(: $2.(10). 11', 11."7l'!lI\''', ,,,.
'The knob. on the ends of'the handles can
be tum(od on a lathe or a orill pre S". But we
Io u nd t h a t ~oy
wheels worked just
as well. Tc>attach 8
wheel U> the end of

w",,J, " .

~_:--==::::;"'/~
.

types of front vise hardware that are a littl,'

less expensive (they dOIl'1 Im\C a qui"k
release mecluln;"llI). but we diseevered that
the guide rods on some of'
are metric,
It's importam that the hoIes drilled throu~
the fa"" blork he "ror' (see !Il'(idt' on I~'~"
lO-ll). St, you )11"., U> IlO UI tht trouble of
finding a special metric dnll bit just to drill
the guide rod holes. (Note: Our plan. will
have to be IlIlcl'\...,l ~Iightly if you u"" one of
these other vise . J
t:Nl) VISt;. On our beneh, w~...I... used an
end vise made by CambJidg~. This piece of

(Il. I , db.
$11~(or",,t

hard\vare lS ~omclime~called a "\'i~e

Til .. WO{)I)W()ltKI:HS'
SIUIU; t
add"". ailnvp). S,>I"I (}I,I; 1',,11. llll. I'"

t""...

screw" Youcan order it from,

GARRETI' WADE COMPAIOo''I'.INC.. 11)1 Av.

enue of the Amelicas. New York. NY

10013: 80()2212912 (Catalo~: $4.00).
Shollider Vi.....Sm'U\ PI. dia. x II" long
SCl"!'w. Ord.r No. 7000'Z.CX!. $41;.70.
ANOTHER VlSR SCREW. Alter we had
con."tructed our bench. we 'h'l'tWerOO an
almosl identic:al. bUlle,,~expensive ($:32.90
I'pd.). end vi.... ,",reI" from \Voodcralt Supplyc_ address abo\e). It'~ painted black
(in.tead of blue). and the ,;o..,w I~ngth i< 1"
.horler. If you do buy this ,;erew. make the
,Iidin~ clog hlock s:' long;in'te:td ofT. Add
che I" to lhe right ...,dofthe bloekoothe fir:;l
anw"" dildo ....mains Iy, from lh. waste
area. ",f~r to Fi~. 2 on page 5. Srundi1ll)
lic.t'l BNtl'1ISrrru; I 'I," ~.
diameter, 10"
"",""W I~nf!(h. I:~ .. overull length. Order
No. 17F71, $32.90 ppd.
UANDLS. 'The vL<e> lisl.<'d above don't
<'OrneWilh bandit.... W. mad. handles from
12"long piect'l' of I"-ilia. dowel. On tho
ends we ooded a knoh and a n,bbel' I",
inside diameter Oring to soften thl' blow
on the knob when dropping the handle. O
ringl' can be found at a plumbing .ml)ply
house or lhe plumbing section of mo.t
hardwlIJ.., sUlres. The ones we fc>undcost
$.59eaclJ.

24

thick, Om"r :0;0. Ill~(;:l.

"f('Hl'

THRf:ADKO INS~K1'S. '1), altu('h lh~ bU.."",1

th(' to) ).'I.u tweri ly"ll threaded in.~rt..,

( , ,- internal l.hn.u:1 :-tl.\). These t>-'-l" u;.:uat
tel

COVE

I~' lit (t,Uf,,1 It",-..II)', If

"tIl. ~(,uean

lhem f"..n TIl, \\'oodwtlrk"I'" Store (,;<".

add",,,,, "bo,,). rh",,,ti'd 1"~"1. 0/,,", lIl"
der No. n:!!lIII. $.:t! eaeh.
WORI<8ENCH CABINET
,'c)U can

"rotr th; V'lll~filr lhf" ,ll'U\\-('Mi :ulfl

door on the

CUI

(,m"r

l'l(lnl,'h C"lltlll'K'l fl'Olll!

,
WOOO(N INS(1l

'uta can 'tnkt' a pair of bench edgE!: vise

rIItJ"p:- ,"'111:
"onll(',IAF'r
SUPPI.Y COIlP .. ("ee
ntJci~~~
;tllll\ t',. lIt IIl'll Edy(' , 'i.-u' ('In 1)1p.~.
O,.,I.r Nil. 1:1(~1l. $:..>li50pair I)pd.

SPECIAL TOOLS

BENCHOOGS

can order steel

"'S....

-..asIOOES
OfOOGIIOI6

tli".. :fY, bon'. $1 70",,,,h

.1,').: tt,
fit the \rurkoo.ll'h :;.ht,\\ n UllhUl 1."-"\"- (nlO'_
\'O\J

WOOOEN

01' \\'fMJrWfllj('ltth

11M'''.'' " 1I1,,"bt'r "f 'l"",ia] tools we found

h.ll.ful II' huilding lhe workbench.
1.1.l!. IU)I.I.IlK

\\'c used a CI'11ftmurk

GARRETT WADECOJ\t,';\N,'. I~( (...,t' 1;11,,T,.,I "h"n building up the "lab 1.011.
nddre;:.s abovel. Sfu/ 8,,,,/1 1),,,,.,, If loooly It.. , ,,1... 11<bo,nlc "ith a little rolle,' whc('1
!ell).'1.h.&Y," ove....ullcn~h. ~ . "'I,",n' ,hlmk. h.lel in " Yllk .. on tht lop of tit .. bottle. A.<
to x I" head. Order No. (JI(~'1.Ul.$:!;1.2.". )'('\1 J'ojlth"'7A'" thl~ bot~le.glu....c.."'Onle~out on
t>''lir. l"(J(JriruIJ,."r), Dt~$. (~lt'}'ojl'(_'~'":-.t ... l Ihe "h ....I.",,1i,unifOl'1lllyapplied onto the

dogs). O,-der No. OIGOLO'l. $12.;,0 I"'"

BENCH EDGEVISE CLAMPS

",,,Illmt'< important when gluing

ul,l I... ""IWIt LOI).
1'h, ('ruftmark Glue Tool i~
availahle for
nl~Iul $!I tn SIO (rom stores and "atalog,;
indu,hn!: ;111..f the 5OUree.< Iisled above. .
ORIW,. lilTS. ffince the bench indu(]""
thICk 11I(~, lher" are !\Ome 1aJ1(e bit$
n...'Io<lto dnll many oCthe hole$.
Th,' mil'! critical bit;' " Y"dia. b'"ad
I>ointbit fur drilling the clean. tighl holes
for the ~'lJide rods through the :jy""-Ihick
f'ront \.;." face, see page 10. One >OUI'\."C for
lhil\ bit L"
LICIITUNG. INC.. ~9.j,jCommc"," Park,
way. Cle\~I3.nd. OR 44128; 800321-6840.
'I.":Dia. iJ",d Point Bit. 7% long, Orde,'
No. 760. $11.95.
["".,.

Rench dUll" .,... J(l'Cal for holding A W(,rk

pie' tighlly Oil Ihe bell('hlOP surf"c.,. But.
there are times when it Ita:; to be bel~ (!l.Tthl:

cd&l' of the bench. Thl:; WOll; ('onvenit'nt

when trimming the bux joint pin, on the
drawers COl' the undcrbeJl<:hcablll.t.

_DOG ..oCiCAss_~.-\
~
.))

8Urf~\(,l It ,r.u\'("~ tim(.' "'hen ll")'"ing to

'jUl'~]Y.I"elul ~ue on a numbel' or SUI'

_Wfl

'lb hokl the drawe,; ] 11.00 "specilll .. 1 of

dogs c:allcd'bench edge vise clamps." 'The;;e

WOOOS~nTH