NO.

74

NOTES FROM THE SHOP

$3.95

EDITOR'S

April. 1991

COLUMN

Sawdust
Fdhor Dunald R. Pesehke
ljc-,igtlIJin -c1fJT Ted 'Krolicck
Mann.inl1f..dit", Uouglruo 1_ Hicks
Jb..">OI.iat('P'AittIT TerT)' J. S'mtl"JJm
\...~~anl
Edi1"'~J811)~;\'. Ot)lan
Rielmrd S. Pet .....
(;"nlo,) C;aippc
}Ir.)j\,'( th ....
iill\'f ~n .\lunkel
nlustr:tt~ DI1\id
K~ lin)!
Ci'I") (;hri$len....,n
RodSlDlIkee,
Chri s (:10,.,301.;
J)irlc I"or St..>ej!

"un S<ltuiV

Ut.llrC!d('Stln
~b..m,11iun
'toinagt"f ~"nd) flaus
N, ......""~"IndS.'I"-"'S l\C'nt J"\. Buckton
t. jr('um111)1lfllfNt(lr

(,r:!I)hi" ...l)irertt.r

JOI1

S~~~r

l'ruJ\'('t ~fppli\-s l.csli,~An" C(~trhurt

l.inda )0"("<

\\', ... 11<>.. "",

KollyR .. clrord.~fW.

s..,," I!hodos

bt-'T1rn as much tis J wanted a work

surface al a cornfortable height, and lOIS01
"'fUll 3

>lnrnltCbeneath it
) looked tl,n.1UJ,:h

:1 it~Wbooks

;\n(1 saw 3

Shak, r bench that cameclesc 10 whatI" as

1.,,,kinJ: lor. Shaker benches have massive
EU(1)JX.-rul-~L}It"IUJh' (\\'itll a screw vi:.(" on

cuv end and a shoulder vise on the front).

Beneath IJ11'; iup is a lat"R~('3bin(~l with
(I'HIn- ttntl drawe-rs tor 11C)lctillR all ~)rt~of

thin).:". Exa"11) whal I needed - but wilh a

~nll,lt'r ItJP. 1skctcl1('{i

(Jut m~'
vt-rsiou. but

it wasu monster. J\~I tried It) ,\'JliltJ('

it down

to a more-compact s.i1.(. ih.,' idea e)l making

"""ord) smalk-r cabim-rs 1'(lPP<'<iup.

I gOI log<,llwr with Ted. Ken and [loug

and wIr came up with all sorts.of options and

ideas. The \\hol",co"<~PI isl .. build >Iu~<
cahinets that can be ca,i1) changed
how('vt'r

you y."ant IhC'm -

l'v("n 3(_l!lil1Jt a

W~II.YQu<-ansee l'mexcitedabouiallthe
option, I,'r Ihis cabinet/bench idoa. W,""
made several cabinetste rcpIlK"'llw hudR"
pocl,).."i' of ':'>tC)J'Ugt- \\'C used to have in nur
$)IOIl here-at tI' I~"'rlll. And someday I'll
1:.110work on one lorm;~h"p al home,
Fll.F. C \Jlf'\OF.T. Ourfeaturc )lroj('Ct for this

issue is an oldfashioned 6J~cabinet, Ilow

did we choose the fik cabinet?
One fl( the Ill()Sl important factors in
ch()()~ill'::a l)mjt"C.'t (tlr l"nMl.<?""I!t ls theletIe", we g...from readers. Ifyou would lik~
to ~ a particular Vrujecl. we want 10 kJ10W
about it. Every ~uggestion we I("('t is added
to our lisl Ii ~r IJ1(>futurv,

In fact,

"'(.'''''>

even started sending' out

some surveys 10 3 Iimited number "f subscribers to get th~ir opinions on pruj<.'I~.
It's nul ~)(lICII)'a GnUup poll. but it "ill help
U~determine what proj('''CLSand techniques
to (..alur\. in "-rHxl.'t,ui'".
IlIiIJ' W""''TED.i\ lillie ever a year ;u:n I

ran u "Help \\'amed" ad io litis column

rop it you ...anl a "bcllch ..

a,king I"r IX'OI)leinlcrested in ""ingan ,di

loral lliHH!x,u,f/" A..~n
~ultO(lha' "ad"v"t~
Wl'n' (, 111111,at\' It' I'indJinl.
(j(Jrdon. 811tl Rick
whet havf._j()ini,1 \,sa~ a~i.;tanLedil()rs:.

Ja.nit.-"t' Kcrko'\'e-

111\' rlv,r.tlJ de!'iJ,.'l1 i:. sc-.mt....vl13l ...jnlilar to

lilt: minlt dnfl IJOUIt'i t.ll"if1('~bt'TI"at.h lh\.'
)ldSilakcrl)l'nch~$.Ho\\'cvcr. (_a...ll cabinC'1
I~ (It"si~nt"()ItI stand on il:- (l\\'1l. or bt- ("OIU

Jtktl~"I-'Ns:!

biltt.'(1 \\'1Ih clltlcrcabillt"'-

Gloria Sh ... htI"

(.o.~tI~St-r;ic .. ~1gt' Und.t ~lolT,,"'

C.'ustOffil1"Servh:t:

yvo or three years (U,!O I was giving

serious IhulIJ:hl In buildinR an."
bench [O,rmy <hop. Well aClually. I didn't

Jffini~EnllS

Gcn{lJ'\. Brunson
"it Snlilh
JI,:'rt).

"U""ini

RClbLtrtn ~u.qh

C.)I~tTlll~rPaul F...Gra)
Ilwk~..,p1n~ Und.O'RC)ur ....
N1.1work Adn1inl)ltattN" [)ougta..."t .\,. lJd!Uct'
..\d,fllUi ..tr.&h\'( A"''''I. Ct,cl'}l :\. St4~tt

l><J",,,,,,bwk J..... ~~,..,.,.

Sh~~t;m:.tJ{~,.
St(!\'~('urti,;
BuildlnR' ~taitlt('nanl.:4,_~Ken Grimth
i\n:ohic f\rnu.~
Sture ~11tIlilj.."'e"':
l)4':1i ~1I)1nc~
11\ Ki.....t \\'4JJsb
Iit-r' tey. CA ,\t; clt l O.II",,n

'!l

"tood-snlith.
(ISSN (Jr&.!:1It)
published
.bJmQluhly (ff"b . '\1101. Junto, t\u~ tld. 1)(..:.) b)'
WI)"",!!mlth Publlyhlnll Cl)m~hv.2~H}(;r-oIni:)
;\\'t- .1k-f; \1oinMo., L\M'Jt:!.. I'rinl ...., ill L.s.A.
\\tlJlOd~m&_b. ....., rf'Ki~l('rcd t,..dl mar-k (If
~'uoootlUitbPublistUngCc,,"qwIY.

rC"",'ril!h1 1\)91 1 W........ 1hl'ubli>hl"" C<JO.

pany . .AIl riuhtJ. A.""'C ...."t'd.

Sub-ol-ripUl)n!'l: ~hp'
"'1JI)o
"Ue'''} ~~7ij-5.
t..u)'t'ar""

~1A (~,.~ 41i~

(I:t l'i..u\"~ S,J.l.QS.
C~for..-i~:n.S2L'l'i PM'~'\':ar.l.s.
~
~"Ctmd_(.las~
P.~ Ptddal Ot:'- \fuUk"S.lt\and
.. iwldi~"m"",,.
f'OSob1~r:~d ~"tln8("hi ~IIJ~II,) It (.. -bHf,;i(.

'~l'
at}1>ical<hop>'<'ttinl1.11has

Iorl'xumplt,tl,t'

the """"h In

l>hC)llt (In

18 ,flUWS

On'<':U_'llinw~aro'l""king foredil",.". Til

q'Jaliiy. yt1U Inu!i,ll,a\'\' a ~rx."\'rtinl('nJ~1in
\\IHKiv. urkinl{.and a baC'kg-mund in \\,;ttnR_

[I you're inlt.R.""$tt."Cl. write u.;o-a letter t_)xl>1aill'

cabln(_~l~
",ilh a :"imple 141p, It'~ al~4 ~hO\l,11 ing \\'h:lt yr'u ...e ix--c:n dt")ing in tile are~of
<In Iitt OO'lailspaj!e (~e :l~'
with a larj(l' "".ooclwclrkiog and writing,
squar(_) to).) 1>lafC."d on (clur modular w1it$.
In rettJrn. \\'(1] "'t'nd you B k'lt('r dl'SCrib:\nd. il's SllO\\'O no tilt' Corltt"lll$ pa$!:\.~as just in!: the' job in more delait. (~nd your k'lIcr
,.n. (abinf._'l "ill, H ~llanto,) for Inouuljug a 10 Doug Hicks. Managing Edilor. :tlll()
two

,lngl<'l<>ol(lik,' a scroll <awl.

111er(' art oUler opUons as weD. \1'(> u;;.,d
~la"'lIlilc {or Ih~ panel", l3ulyou could use
pegboard 10 hang loob. Orrabb<>llh('('dg('S
,,11r" plpvo<,d and use it (orthe pancl<.111i~
wny you could drill holes and mounl holder;;
for ~torillgclamps an(1 ~me ji~that huve
nowhere el"" 10 RU.
A word about the heighl of ('3.ch cabinel.
'me hcightis3il." findudingthc lop).111is
is higher lhan 01051workb~nches. BUI

Gr.nd Ave ..

n,.,. Mtlinl'S. 1A5(1:~12.)

~l()RE HELP W,,"''TED. Sill"" W" had ,,,ell

good luck with this allj)roach ((lr edilors. I
thoughl I'd als" try il (or unl' "Ihe'r position
",,' ha\'l' AvailAble.
\'Te are IOtlkin,g for a Cal:,lug ~tarketinJ!
Oirt:('lur ()r "rJ(.;(I ...
Pro.lf (., Stlll!11 i~JS.
J\gtlin. the main requiren1enb
lor lhi~
job
are an intcreSl In woodworkiJlg. n back
ground in wriring. and $Om('experiencc in
the calalog or mail order bu.incss.
the~t'cabineLS ar~ nflt desi~'lled(or tht~ JUSI \\'lilt' a leiter t'~phlining)'our back
sam" kind ()f \\'ork.
gm'lnrl. and 1\\;11rt'lum a It-Iter explaining
Workbenches OJ'" usually designed al a the job in more d"~1il. (Send this leiter to
height Iha!' ctlnl(onable lor usinR hand ()Oll 1'(:'s,ltke. $c1JUeaddr(.'S!> as above.,
tools Oik~plant:s, cllist'ls. or t!'\'tn mlll~rs:).
"E~T .SSt E. Tbt' next issu~ ,)!
This t"fibirl~l/b('nlh is dctsignt.'d as a t\'IHXL""itio (Ko. 75) will bt! mailed during
counl<'r-hdgJll work surlace.
tltcw('(ko(Ma)'27.19!i1

.,,~i'"

So:.: l(7)~.lko \tlMfl\.'\I,L-\50350.

)'.;". 74

.. ~I

I \J
L_o~O~K_

.... I L) E

------1

Contents
:f41
SU'
. t.:!J

[11'1'111 III''' /,Y/l1I [ellu

/IIII'!.-e,', . I) ";"I((I'[li"[1
(I

Roll'

Table \ 'a('IIIUIl,
Not/iul Sill" 11,,1.1 f)IIII'II. ,,) Ad,

lI:!i/!{1 a /lollil
.f)

icood-

1', !)/?Ollll'l'

ju stabl .1111I' r FI'IICI',

,j)

N. Ipplllg Til i/I

page I;

Stri /1.', G).l/,>{/ '.Iil'llu SI ikil Sandi II!! Pad",

1 f6llr"
111111/ " I'/11"",r link Ji/I ("abutt'l
IISIII!I
.<11111,1 .1""111 (11111/lII,1I1

I Oak .rile Cabinet

1...

__

~.

(I

tecl: II i'lllI T/IIIII'>'llCldlTl.,,1Ii./ll1'l1.<,<hnrdt'VI/'l'

(I

IJI/.11111 1'.1',

".'0(1(111 ~J'"

er ~I;(1,s,

():"
IStub Tenon ~ Groove i 112] 1'111'1'"

.,1'11" ~1I11,,1"~/I/Yli/~
1(~j"jllll'"
IJ) II .I,YII'II I( 111/,111/11'1IS 10 11,<('II

siul) 11'1'11" 111111fln~IIY'.I"illf, Thi (111id~

take YOIII" "lIIuli IIII' I"YWI'....
x xlp/rbIJ-SII'/J,

IShop Notes
L.,

_.

_.

-':~

111611)l'p,'iIIlIII-/lIIIII"
Irlll~/I'/iI/", !) Clllill[J
('"/1/1"'/,, So TIII'!I'IY' Squore, .J) ~\

....J.

7ell',II'('1I11 ill!!.!i!!plI' /II<' Ronter.

Shop Cabinets

L....._..:..

_.l

[Draw
t:.,:Jointl>
.L-__
~__
.::..

_J

Canister

dixCII'" tt 111""(lild cou '!(

III IiI"" d d",II," 1')0;111x, Aillf

L..

':":"'

""' ".111'II ,'1"111.'; II!/ t 1111'.

11261 litAllis y""

so/ ;II'I(,k

IIl"l'd

fll)/'II/(I

[Talkin~Shop
_

__::_

11

125: di(Ji''''
\1',

...J

L..

11(lfll!

rf'Ol,\'IIIIIJI/!I'X X(OI'IIUI' ,I<'I'If" I/I't' e."

~
(l('lIy II" SIlIIII, So /I" des;gll(,l/
/11(''' enhi n I, III (lrr'/II (I "nl'lf'ty
o_t
d 1"'1"( JO (I" donr t'flll,I" II ut tuu ~..

".h((1 1(1 1II'Ik

I Kitchen

-"11111 1i'lIl111 '~(;"'/('I'I'

1"""'111 (III

t,

II

tI',pk"IIt1I()

1'(1111.,1(,1'.
Euch

hllild

lit/PI p.

11111igltl 1"11110 i 111'1',

I [28I/~IIIIIIII[1
wit

....J

11';111 " I,Y/IIII,II'I point lrlr /lVIfl/" !III( II'/1(11 is R ('(11'1;1111

II"HIC/I .\Iil." Jill" "" lit, H"t/illl AI''''

:-;,11", A 11(/ {ill" III' HIlIItHIi (ig,,.1

[ClampO~~ni;:ers
.L-_ __::__':';;"_.

11.301 fI"TIl(,11:,,'
r. ,,,1/111111 1IIIIII'Ollrcl(llil/Jfll"
("lilli, t, Hrn 111'1 the three

....J.

WI/III' r: -"I ul

'"!! "1''' HII("k. a (,.Cfrlll'll

Rark, antl n I'I/~ CI(IIIII,Nal'k

ISources
l

FRO

WOO[)WORKERS

1\1 FELLOW

Tips & Techniques

ENLARGING A HOLE

.1 neededto ~n1argl'a hole, but

precess

didn', haw a drill bil big enough

sal') logN the hok-dirunder,

h. c.lu tht' job. Sc.ll.ultt UI'with it

\10'3.)1 til "nbltW, tilt' 11,.,lt using a
router and 1'1.'0 bus.
It'~
CI lWfl-::;.t"'I> process. stan

wnnt. Rtult.ntlx'r 111i11the hCllt'

diameter will increase b)' twice
111\'siZt'or,ll(' rat)bt" bit.

3'$

fiRST:

(Of .....

1:1' ""

IttSlot EOG{

many 11n1v5 3S necesOU

~ ate. Sonlt' manufacturers

b) ruuting a rabbet ;;ruund 111,1:nul' sell II rnbb,'ling sd Ihul inhl~idt' {'dgl' o( tilt.' hole u::-inga dud""OIl< mbb.:1 bitand several
robb"lillj! blt, ',. ~1J(.1. Then. different-sized b(a.rings.So it's
turn over 111(,' \\ orkpieec, and re easy to e nlarge till-hoi" in larger
nll'V(' lilt' It"Cll!t' (or Up) with 11 or smaller Increments jU~1by
changing the bearing.
flush trim bil. see 1~1I.2.
Forvxampte, I had ,,~I'
diameIe you can't jlf't to the workIc:r hoh-. and 1Ic,,(cI,'dto incn1l:oOt.' pic'C't' (r"u, th v, IX)t1oI11. U",I}'I.'I
its diametcrt, 3~ ',!,. (an increase "a~' to I"(.U)OVc
thL' Il'<fgl' is to 1.1~
or I bOO). I started by using 3 ,,~'
a>lrniglll bit with the bt'arillg on
rnbbt-lingbit and routed a rabbet Ill/I..... Fil(. :1. This ",ayyou can
around tilt' in...i(lt' (,f tht' IIC)ll' r~.UIt;(f lI,t 1,,~cJj..f{
Ir."'1 tl1t' top.
ll,at i11rr("asl'(i the- cJianl(~l('r of Tlu-se bits :irt' availabk- trem
several companie-s and art'
around 11,e bottom (.'()gt'
t11\~ f3l1t'1J template ruutiru; biu s.
hole. ~"(I:'jJ.t.lit.
This ~ml' technique \."311 be
'1'0 n-move th(ltdg(~.llurn(t1 U$(,(I to make a '.\orkpicce

a.

A(.fAns

RAB6n .(f
UOG.

--

WORICPIE<E

SECOND:
TURN WORKPIECE
oVSt AND R(MOVl
lfDG( WITHfW~

a.

RUSH tRiM
- Oil

...._ T'RlMIn

tile OPC11i'l~"'," I)Ul left II J(>(Il{tl

or

the' workpiece over and routed it

0(1with a flush 'rim bit. SCI' Fig,

",usa TlU,. In

smaller, see ng. 4, For instance.

ify,)u 1'3\'('a circulurcutour or all
irregularlyshuped piece, simply

'1. The bearilt~on 11'....flush trun

bit rnn al()nJ;! tht" just \~nlargt"(l rout.a rabbet around the outside
~tlrf'ICt!or the hole, see '-lg.:lao
edge. And then remove the

~~-::7
u:

Then IN'~at('d th"S<'stopSiO lodge with a OU$11trim bit.

increase tilt' opening another

,"lor 310131ui II:!"'. R{'lX"3tthc

/J(llll

E. ,l/;.Jblt.!1

dU~1collector fUr )'our roult"r

TKHNIQI,I( CAN
USlO
TO IAAKE PIecES SMAUElt

S" f'tl" nult, (;. ,tlryi(t

ROUTER TABLE VACUUM

Here's an easy. inexpensive
way to tum your ~lOI>\'3C into a

W1tH

BtARlNG ON TOp

RADIAL ARM SAW HOLD-DOWN

bu)' a noulc and permanently

mount it to the fence (thry COS;l
about $11.00). Ju>1 screw Ihp

labl(.... Just :llla('h :1V3('UlIln n01.7I~10 Ih(' back of Ih~ fcn("('.

R<'l'cnu)' I had III CUI a 101of

small pieces on In)' radial arm
$8\\'- J don', lik ... 10 )13\'(" Illy fin
w:rsdoS(' 10Ihe blade. so 1made
Ih is simpl .. holddown from

Ill\" workpk-cc and Ih,' riser,

Then clamp as tar in on th(, arm
a." I.ht~L-t'lrulll> v.ill r('ach_ "Illl'
ann I'ulo'" tl1t:'\\ c1rkl)i(u' ugainsl
the saw tablealld fence.
'l(J,n 11. 1,(1iiltr

uphoISlc!)' llOUk-to th~ bark of c('olcred over tlu: Op.'(lUtg.

/)(11'(' ) ',Jit''1'!1
th~ rOllt~nablr fenc", Si'C ~il!.I.
SO"Jpand" C...-Iamp.
,I\U YI)U tll....--rl to clc, ii<- rn~tkt... a
(J/tl flu, 7'"xuJ:(
(''''1111,,(C 11,,~tl.
TI.,l'll ...
The ltoi<)'(I"wnb madl' up IIf
couple uf ~mall
twe>pariS: an arm

blnck, willi on"

and a riser block.
1
1
CUT
RAn."
TO
,"
bt:tt'd cd~('. ~('4:
'fh(:nnll is v.!',thick,
RADIAl ARM SAW tAal,l
rig.]. Tb~rabbel f--' (NO0' NOn"
i"-wide and 10111{
COUlI)!}l to go {ruin
.bould bl' dl'CP
enough tu holtl Ihe
the f.nee 10the ed)!e
'l)--en(1 of Ihe nozzle
01 tl1('lwlabk
a$!UinsL tht' f~nc:(_',
ri<l'r block is Ih('
1'<)\\' ~rtVtth('~
~n)l' tJljCkn~~Sas
lht" \\'()rkpiel'p anti
blocks 10the back of
3bOUI.,
the rQut~r lable
SCREW SlOCKS'
'" Iong-.
Jt:nCt. S('('I~g,J.
TO lACK
To use tile hold

."b-

--

\'ou ('()uld alst)

'n,,,

ROUTERtAllE fNC!

Of ftNeE

do\\'u, sel Ule amt on

\'(/ooJ,mllh

r==-=~-=.
-AWl=-_-""_

F(NeE MOV(S TO un AND ltOWT

ADJUSTABLE MITER FENCE

Ikl"

Ill"khlj( "

11111111>;'"

01

IJj,lllr<' .r,"lu ...., I Iliad, un <I(t.

ju ...",I)!tlll1nlwllC.,t h'net' fClr 11l1"
nlltC'r st,IUJ.!t'CIfIIlIY lablt' .....w, '4,_ ~
Ii,!.! 1 It lJ"I'''I\.'''' ;tr't"r<U..-,.and
.....
lhl) In ~UllJlI'Jr1IJ1J!
lht workpi~(t
riClll up, kl"4' telth .., blade.

l -aarted bv ,'utllll$: I hc' rnhlk'lt'fl

top and bouom pict't~frel1l1 n
.:;ingl, ,)ie"o,. III ,,",tllifk ..ICK'k
Xc-xt, rip it J t_t't \\iflt 111"11.rut
a rabbet

ill (Int: "d~('

Iffl

"Rl~

w"...

J purchased d convc -r..ion pad

(Clf 111) \lakit3
'luar11( ...ht,t
pain, '3ndt'r~11 (,,1ul(lll ~tlkit

clamp

I'"inltd Ihal I (11111.111'1U" lilt'

1);lrt III

\\ti'l\ cic)ubh .....j(ll,tl ("lll1k'l t~II)t

'nl('~11turn lUI tIlt ":1\\ ,tllfl
n:,l">(.,tht111:ICI,' tlll'fluL!'lllh,' ~1a
~Ilil(j.St.,.-III! Iii Illi"'('r,'alt''_
tll1J.rhl fil .111urllllncllllt hl,lflt
/>';"'1' '" \ t', h,,.

(or a

llrJ.:l nl1111D41' clf Ihlll ~lnp:-. But

l)l4t,i. It~IrI'nillc ill III} 13hl('

...;,\\ 111.... (1
I,,.. \\ idc' 1(1 "'Ilp-.
,)1'11111. Lllill ..Inl .... a.. I (lil ,hl'nl.
\I"kinu il n4\r.' ill",,rt Illa1 til
liglllc'r :.Il'lnlll(ltllC' hlatlt \~t)uld
....,1\,. lilt' .)ruh1,nl 1\111 I ,lilhl',
",1\'(' thl' liI11~'1f) lll<lkt(lnl' In
.. tl..-:td. I ,'ut tll,' 'tril)'. -.oul'l) by
IlII'

C"I\l'li"c

Ilic' ..;1\10 tab1t

"ilil ~," '1.1"1"1I1....."t J''i~.1

Cl.,AMP ott T~

Ami UT'tlNO

nm,

loibl,'ur

,,11.14:1,it

"'andpapf'r.

MlTAI.
PlAT

fiUI I \loa eli',IIl-

(lust (,(llt('elor

rt~Hlllr,

.E ...:::I!
~

nn 111\'

1)\ rlrilltllJ:

1',.],,....in

!ool"

h".(fl.ll1ltl,

",.1)

SEND IN YOU.

III

11'

,
(

-"

nps

II Villi....,.,Id lik...lo "'at{' a

11t.ark tht t't>ow ......(elt tll\' 1",1,"

OUST }
ttOlIS-.

.
--

lh .. Jl3d... altlrnirlull1
plalc (nllt Ilw

......, "

)I.r ..

1).")(1,Ii"n', h,1\'I'
Ite,ll'~ ft,r tht.., tltl"" tel Ila ......
IllrouC!h. ~ 1 olodlfi"clllll'
l~111'
\, ......
'011 pad, sc"t' Fig- 1
It', 3 Iv.e~~ttp
I'"ttf ........~.1I1
'S-f1""t'r,l1\t' nt'"

"""kin!:

-1
MASONJT1101.1'(

il II) Ihl'

/'1'1" ""Ill. l/llj,,!.I"u

c.umTAft

MITtR GA.UG

MODIFYING STIKIT PADS

To de) 1111-, -.4 , ,I't' ri,l 1.'llt'(' It.

CUi Ih(' 'Ilin ""rip'. Fhvu l.'lAlr
lh, bbd,' .md bllullw \1.""n;I,
Up tight fI~tUI1"'IIJlt ("lIfl' ,\,,\1,

\ "'"\'I'nl pnljt'l1

GA,UG

,'XO<"llvhDIl

the Ihick","" of Ill,' 1';"'" 'rl~")

and I':"deep,
Ill, I,,I\'t+,,,,'l1.lCh()( twuinu-rX 1'\\. rut 3 fi")4,nJ! V'."" In""
-'.'" " ',"uaan
l,K'irIn.!' ~In
...
- ~t....
h nrdbbtIt't1 Ulk' end, Thi, j... 11M "'I' pk"C."C
top P I' I 111:11', "'<T,,,,t"d If. the that \\ ill be ""(.T('\\t 'fIle) till' 1IIIIt or
miter ..:~tlg' ..\nll a Itllll>!'rab- ~UJ:t The It.llll:p't'~'
i~
Ihe be,t
ben-d bc,I"'HI ,HI':t' with a tall llim oi the i. nt:f,.TIl en .ltc' the 2
SAHO 011
TMJttA.O(O IN$(U
PlANt I )," Of'
l.l\'.' ..:lll\',III.II ...11't)01 \\1,(," 01l'
pil'k'hinS! aC.:lifJn..... 11(1 .,. I11.Ut4
fACt Of
"l,kI11I1t' ""('rl"\\' .In' tl~hlt'f)l-d, I..,," ollth .. ",bbd,'<I (a... III Ih,
lO(Kf'NG Plle(
llll' flllllo: ,)It'(t' i',Hlll'ht'<l a,lt.un:-.1 h,ppiece, '(."(, <lc,t.liI illl:l~ :!
Otut fJtOHf 'ACE
1111 fat'I' ,II 111.' fI,il,'r guu'-!t:,
:Sex!. in>lalllhn.1CI,rlin"'''1TO LONG
'-,.ll1t','lllt h'nCt r ,1111)\, 1I10\ll'(l to
in the top pit't:4.'. "\ot"l' I:if.:_2. rlu ','
.. aamoPtf
li't' riJ.tll t III' It1t, iI ca 111)1'u't,'cl un arc alignt'ct with 111C' ...11.t ... or
,ill,,, ,i.k nll11l'blade
holes in the min-r~nllJ:l'rnc'c'
(\(.If"
lhl .. fc'nl't'lt- dt ...i,eTll-'<l
!\owculll,, Iront 10r , In,. 11\1'
fur u,ilt'r 1o:.111g'... wnh ..Itilled
fence Irom , I" l'lar(ly,,'cultl :!"
fAtl
1<1('1'';' It vour ... i...
n't ...lotted, drill w;rl~(high) anrl21" hlllll. 'l1wII
huh-...Ihrc)u~11L1,,,'uutcr J[dU}!t gIn.' it ", tilt Inlnl t'cI~I'Ilf tluh,r 111"n'.1t hl"'- "'o4,TI'\\" 1 .:. UI) Illnj! rabbeted I"{"C:I'....., tll)rl.:!
1)1('1; I ~I, ,,,,,,,,,
1"'10111,11"'1111'111 f'(lgt, ,
lllltl3.k, -tl ....adJlJ,lolbk'II'lk"t',
'\"tt';R(1 r, ". ~4~UAI(

RIPPING THIN STRIPS

TAIU SAW

I'IUJUt

till {)r

u-<Ih( ,;an<!p3p.,r hok pundltr

thai (Om-t ",;th the .....-nlt'lr
\"XI_ n h hol,~
Ihmul:h Ih,'
(loan! p3d ilh a hUI <lIkI"nn!:
lnJn.l- ...ingthc hQt('...in tht' alum

to..-a. ju',

1I'_.t" "til_

~t'ndit ttl

(if... an<! T,,-h-

"j'llJt~.~'(JlI(;r.uul

-\\'(1_

Dt...

\I"in.-..:-. IIl"'3 :-JlX~12.

\\'t' "ill (l"l~upon pUblit.-.w

Inulllillate~ a!'oa lerupttlt'. I}J\1I1~l

11,t'11111tip rhr4)URh Iht..~
1101(1
USJf1j.!

tIll" "I., I" "ICC) (dql<'ndinj:

tin Ih,' "ubli,h .." "'nllih ohh,'
lifl). I)J"~I"'I' in('ltld(' an ('x-

a lir,,'ular f110tion,
lol,rlll,,.,lt; 11"/~/JI"1I1 plun"l",n ;tnll 8 <k"lch ",.
1)J,(.rv (Wt'"U dru\\ a nt'''' I)nt:)
.Iln!I'I'YtI'~,,'". If' l'",.k

FEATURE

PROJECT

Oak File Cabinet

This file cabinet features [tome and panel construction and doteLaileddrawers
that ride on metal full exrenuon slides . To simplify building the cabinet, we used
s(ub tenon and groove joinery.

A:

br,;1glanc e, thiscabinet appears IIIbe 3 replica of

a classlc oak fil~cabinel with tradltional frame and

panelconsnucuon and heavy brnsshardwar(.J\ncl it ison Ih..
e. nlll whal you <"aJl'1"ff arv Ihv changes

"",,irl
we've macl .. to th~inc:itlt.

C()"~"l'R1'rn()~.ln the o~inall'abin"l$.lh~ Irame and

panel sides were buill u:;ing mortise and tenonjoints and
""till w"nd panels. The Irnmes had 10 be extra .lrang
because the wood panels were d(>siglled 10 "floar" in

50 a simpler version o!-tht" mortise and tenon, a ...tub

tenon and groove. could be used, (\\',o'v\'indtlded n tech-

nique article Onthis ioiru 011'''1:'''' 12to 15.)

Il<\Rl)\\T .\R.E.

The second change is the drawer ...lides

Older file cabinets usually used wuode.. or nWl,ll-dide...

which limikd how far the drawer could be pulled C)UL
Forthls cabiner.I used high qualily Accuride metal full
t'Xtens.ion slides, Full extension .:;)irif's allow th(.~fi)(
drawers to be pulled all the way out - which means no

l(rQ(",es in the frame. This allowed the wood panels 10 mere groping 'nth" back or a half-open drawer w find a
nU1Ve with CllWlgl"S in humidity
filt, f 'tf'HK/~lli)'II fJm.1f 1'1 ."/f "IH ''-/\ i~
(lffC.ril\g a ("tllnplc'I('
The!' fir~ ('11UJ1g~'
"'3~ 1(1 replace tIle solid w()(xl pane-l hardw are kil rur the file cabinet, see Sources, page :ll.)
with one made from vt" oak pl)'wood. Sin,,, plywood
FL'ISII. To finish the file cabinet, I started by.taiuiol(
doesn't 01('\'(.>' with humidity changes. I (.."Ou)<1glue the with. ('Qal of General Finishes s..-;J~K'<111
(P,...
zan).Then,
panel in Ih. solid oak frame. Gluin!! the panel in place 10 provide a durable surface, I applied IWo coal> of
strengthens Ill< frame so much that deep mortise and Gt'n~ral Finishes Ruyal Flnish.
tenon joints aren't needed to hold it together.

Nn.74

MATERIALS

EXPLODED VIEW
OVERALL DIMENSIONS:
151 l'W :. 3()3....H l( '223411D

__- iiJ

-A

---_"-

MOLDING

"loP
RAIL
~
~

TOP
RAIL

'J
"-'

C~RD

MIDDLE
RAll-

A .ron' SIIIe$ (2)

8 IlQck SIIIe$(2)

'.x2~x28!',
~.x2 x28~

C MiddieSliles(2J

~~ x2 )X25.t.

D Boflom Ilo<I (2)

E TopRod(2)

~.x3xl<>~
~.x2\ 22'100

'.0IY.7I.x2~<

Ponel(<I)

BACK
G SlileGl)
H Bo"omflo6(l)
I TOI)Ro,I(I)

'-

.Y

TOP
RAIL

(j\

.-

DRAWER
SUDE

'.:(J

BACK
ClEAT

SIDE
ClEAT

HOLDER

SIDE PANELS

TOP
PANEL

PANEL

Molding ( I)

-@
SIDE
ClEAT

R~ll

-../

-@

"" ply. 14 x IO\?

Q KiCkboord< 1)

"':;:x3x 151.'l
3.,: K t A x 19~
I(

12

STILE

SUPPLIES

'/4"'" 12'". I<i'n

14\-:1

IJ 8 Bd rt of . tnlck Red Ook

<>Bd Ftcr ~. thlo~PopIm (fo,drawe's)
(I) '. sheel 01 'hicl<OOIcptvwood
(1) 1"sI'leel 01 .-th!Ck Ookplywood

(2 POI') 2()" Accuflde D!ower $lide$

a)ll'O$$Orower P\JII$
GI) &ossCord HOlde,s
(I pjnl)GeneJoi FinishesPecO<' $Io,n
(l p;n!)~rolFI_IlovoIFInI$l)

fALSE FRONT

PLYWOOD

,~ .. x- "'" 96.:.;(3.7
....... d...,....):--~

-;;"

-,~

__

.."...__

Nil. 14

~.IX12.

Eo

-r~ __ ......

.
W

,',

'N

6" 71"(Two 8oc:ttdsPop$o' .3 ad.._:_ft::.' """;;:;:",) __

tiT

V Bouom(2)
W fOl>efront (2)

CUnlNG DIAGRAM

.),04)[

BACK

BOTTOM
RAil

FRONT/BACK

JI:

' 1\4.14

P BoUomPonel(l)

MIDDlE
STilE

fRONT
STilE

2OL'oII

-2.5"4. ,~~
\-:Ix5 13

-@

BOTTOM

y.

T SIde (4)
U ftonilBoCl< (4)

'

..

.. ply ld

DRAWERS
BOTTOM
RAil

1,..

"xH.xl~
.xlx 14\7
3'1'. x 14 \-:>

~ Side Cleol (<iI>

S 8ocl< eloot (I)

BOTTOM
PANEL

101<~'

, 4 ply

TOP/BOTTOM
N Top Ponel( 1)

<,

-.<

2)( 14

FRONT

It)

L._:'

4)(

K TopRo~(1)
l MiddleRo,1
(I)
M Boaam Ro (11

~.x3xM~

J Ponel(1)

DRAWER
PULL

l<. 2\'.>x2~.

-;

"T

.1

-,.

,.

QGRAIN

D'''C11ON

vr

VI

r
r

-."'"

=~.

pj
7

SIDES
I bezan work on lh~

To determine the width (heighl) of the

Fil,> Cablnet bv
b",ldingtlll' two,idl'

bottom rails, subrractthe leolM oi a middk

(ram'!.....The sides
an- "'ilTvrinl:1~'Sof
each other Each
j)ril~ consists CoI( IWt'
f11)....~t,.idpanels *1>n't,'r'.tIl1l-...:;arc' buihb) j4~inIn't.J'rl'-~lil('

(a [rnnt. middl~. and back). and two rai" (3

lonJ(er top and short er bottom) with srub
tenousand

RT(1()\'r,.., see- I'ig.

1.1'or detallson
makinJ( thisjoiru, refer tn pag,' 12.
FRJ\)IES. To make the two side Iramcs,

Iw"",, by ripping enough .\ ,"thkk stock for

stilt,,,, to a fini~ht'(1 width el' 2l!~ "1O,,n.
rut tv..,., rronl (A) Rnri two back (11) ~Iilo.tn
;1 iiui_:.;htdl(:ngth of 281/.l'. And. cue '\I,U
middle ~tile$ (C) 2 I' ,hon~r (25'1,").
;\llllOUgh Iht"'IOI)anel be.lttlnl rail~ art' a]$iC)
l'tll (rcun ~ln'llick ~l~k. 111{_'~~
(liffcr ill botll
"idlh and kllglh. Sl'(' Fil!. I. 'nw <hon"r
I~)llfnn rail fit..; ffl'll'" t'll tll4.~fn-'ll1 anti b:u:k
,Iih .... :\nd if...(Out Voider li13n II't r()I) filii (t)r
aill)O":U".'U'~.'Ole I(JJ>rail is ~UI1011.1('1' Jnd
....IX

cxl"'I1C'I:.11"141 tl\e {runt stilt' 10rreatv a clL"(.'Or"'dli\J~('nfl. S\'(' f'j~.

I.

2' ,.

..

fi,..,

25l1,,').
r. Ko\\" the- side frames can be

ran-ly ~,', make test ruts in scrap wood and

use the plywood as a guidc to check the fil.

71

'nll'(\' are also l.Tt't:K)veS cut 011the inside

lit I',," III '1It~
fmlll Hndback ~lilt~
(,.r assem-

assembled. Note: Sine, the r c'san inside and

clul:iidt to t,.it'l, rrame, il', a .$ttKHIidea hi
dry-assemble both frames :In(J rnak sun
the WOf'\'es CuI in tht: stiles are facillg' each
olher fOf n fllirr(,)n!cl set. n'fl'f to f-ig. ttl
Theil glue 3Jld ('hUllI}III)('<It'h :-.;(Il'(nlnlt'.
AI~I.ER STRW. After th(" ~j(I.._"~
art' :to;.

lht j...JTC'(iVt>!:'- J,.'I"(rOlll

the Itt;,,' t-dgl;' uf

Ulf'

(ronl ~tilt' CA) ;111(111,~ frOlll tilt: /}(rt'J.- l'tlj('l" of

Ihe ba~k SIll" (Ill. S('(' )ij!.~.
CtT IR()rltl~.()Ttl"t" lhl' gnX}\'l'-:- arlO cut.
Illl' nt'xl ~ll'Jl is to ..."11a (l{'t~lIrati\'('prell11t'()ll
Ihe Il)p rail, (hI. Tod"lllis.lr-.."s{,rlllc I>......

lht: part arli, ...RruO\'('~ tllal an'vi:;.ibh,' (ut lll.'

(roms "Itht"lop rail. ",,Fig. 5. 1'<, do Ihi"
CUll\\'O ~lrips to (it ill tlle Jlrt)t)\'("~and ~Iu('
tlK'111 in. ~ F'I,I(. G.TheD. trim ru1(1sand lilt'

~trij)Sttl ftlatcb tJlt' pr(JfiI~on tJl~lUPrail~.

$"

":-

'tG,3

rOR

\!)

BACK
STILE

FRONT
STILE

'h-

CUT STUll TtNONS

TO FI1'GROOVE _./

4
PANEL

'.-

S.- R

ft:fICICN{S$Of! flL'rWOOD

PROJ'l(

.,s,-\.;..
I

'1

,J

CUTGROOVlOFIT

lOP RAft PltOffl

CROSS SECTION

~~~

s<mbl(~I.IIlf'r~sOIl(> mOri'lhinj( to cI,,- fill

lile shown in rig.:1 to Ih~.r""111t'nd "I ('ad\

mil. TIlOII, CUIalUls,nd lh" rail. 10"bat"'.

,jl'l

\.>;SI"'tRI

hling tht' c'a,r, rt~f('r 1()IIj,!.l(~,~t1t(':These

W()Ovc.~c.,Cln
bt~;;1full! 'J"wid("sillce lh('-~'will
Itule} $of.Jlid\\'oo<ltt>nons.and tonl{lles.l.oC.-1tl

, TOP RAIL

7' .... __

I'L\'\\'()()D J'.\"~E'_
Todetermine the siz~tU
the panels,
dry clamp Ihe (r,ones 10l:elh('I''';lh the middlp stile <('0('1'\'<1 TII~n
measure the widih and len!!lh of the trame

l,ROO\'I:;$. The 0("1, step is to cut gr()(J\I(~S

tJn tJl",ltl{"I. ('(lgt~ol IllC frame piC('('<I>,
~f"
I:I~_ ~_ I elll lilt" WOUVts on the table ~'l\,.
I() (lptl"fliu$,.'Sand .1(1(1It'.!'' to ea c h dimension for
nlatl...h lltt: Illi(:kJlt'~Sof the plywood. Note: the grC)()\'t~ill tile Jr'dJ11f1.~O". cut four VI"
Since the- actual thickness of I ',"plywood is thickplywood panels (F') to sif'::t'(in my case

Ali FRAMfPIECES' ....ntl('K

'.r----

\\ idtJ't>(thc groove. S~ Fig. 2.

1C'llglhof2:r~.0'1

SIDE FRAMES

stub

tenons on the 1"11 end 01the front (A) and

back (3) stiles. Also cut stub tenons (ll' IHlth
endsofthe rniddlestiles (C);md buuom rails
(I). 5<'~ Fil!.1.Sneak up on Ih,,,", cuts until
lhl'lhic::ktl~:-,1)(tll(, stub tenon matches tlu-

..tih- (t!):t~..) frnrn Ihal tJf n fronl stih (1~1..':t~).

St't_al.'is.!. 1. Then. to allow (or a stub tenon un
the middle sljl('~add I,'s" leIthe difference.
:"10\\' ":\11 t\\'" bouom rails (D) to this
widtll (3" in 111) easel and 16l~' Jonll.Then.
cut two top raits (E) to a fini,hl!d width <)1
21/~'1and

orated by a middlr
,tile and surrounded by a solid oak fraruc,

~'Tl'lITE)1l)SS.Next. ~UI ,(.Iong

FRONT/BACK

FIRST:CVT
",),_--DtEP K~f

-:.

""Y<f(NC'Fl

SECOND:
TO UflARGt GOOVE
TO' ....W1Df"'

' ..- fROM

fENCE

1 .... PlYWOOOJ

snlE

....
-: i

!l

~@
MIDDl
STILE

NOTE:
SIDf~SAn
MIRRORlMAGlS
OF EAC.,. OTHER

1,1,"'_

L
sa AG. 4

f
~

@ BOTTOM RAIL
16','-

)1

..j

cur RUU STRIP

./

10 fn GROOVE
GtUE tN "tACt

TRIM {NO

TO MATCH
OlCOR,A11Vr
PROffll

N... 74

.1BACK AND FRON' rram.,

(In,.,. tl,..~'

arc Ct.mpJt'lt.-~","'ork
can begin on the
back. The back i-,

TOP RAil

also a frame t113t'.;;

jCllltt.'d I() th e sides
with it tongue and
IIACKFR,UIE.Stan
by "ullilll: Ih,' ~."Ihi,'k frame parts, see Fig.
(lit (W"

V)

back 'lill'. (G) 2'"'~"wide alld

wide-and III .' IIIII~ 11ll't'"id~IOPrail (1)

I "~f(/,

4'(I)(l" ttl

CUT TONOut
TO

IN SIOlS

'ACk'~

)-1--

llil (rdlTlt' pan..;,a ...veu did tor

0, ,

Intolltxt ~l'pi~tocut , ..._

lung stub Ie nM' lin b"th ,1Id> 01 each ..ule

,(,I "nd b..uom nul 1111.~" Fig i ~I.,'
/)t" 'f cut l("ftc"Xl' on tho shorter t()Prail (f"
lt 1 TIl".I.~
10 JOin thl" back 10 tht
...Jelt'....l ut tr.... lvng tf.)nul ...alonJ,ttht" clut::.idt
\t!gl of t .tl'h b:ll'k ...Iilt" ff,). Cut Ute tongu...
10i11th. 5:tr",\'\', illlh, ",id(,. see Fig. ~.
11\(' k V"I-'
l'c, dt"tt'mlinl" the size of 1114.:

rn

ClOOvt

lb." 'Itlt, frallll"'!\.

ttTl,.,(,\",

SID< fUME

PANEL
C'.'" .....YWOoDI

:!.o;:~,"lunll Then. nil a bClllom rail (II) ;1"

"1)0" tliJ\'I' 1.'1:1"1, fin tIll' vnd ....<;,() rut 111
.J\tU't'r (11" kln~) ;\l '<1,l"UIJ..'T()c)Vt"~CJnth,

I.

J(f(1.,\t joint,

BACK FRAME

srns

...

b"d. 1""1<'1.dry dam" Ilw fram,' )1,ll1<'r.

Ihvn. nlt'a~\ln' lhl' in~itll' \l.idtll and length
aUfl ndel "'J" 1(. each dlmcnslon r()r tlu
~ltl\I'~ 1\4'\\ (uta ","II,ick pl)'wU()d back

..

i/.. '{''''I:i~,
-;

PlIO(') (J) t(lllli ......

't\( k \,,,..., \IIS"

b;,,'k b\'li"ll!llIill~

lS\'J:lu ~~'Inblin.!o! Ute:

Ihe 1)1)",1Od back panel
III bo,,,,, 1111.' ,iii" Tln n glue and damp
III\.'rail -, to the .;..till'" \:fl1," \1akr ~un: thr
..lluul(l. "I,f II..~lh.",
.lb~ wnh Uk l'nd~uf
II", I"" rail-; and .. ilh Ih~ ,hould"", II! Ihr
~\Ib It nO'I" on 1114'tx,llofit rail "*"t" Fig ~
l
I 1 \......t \Ittl \. -\llt r lIlt'" gJUf: drir--,
lilt' "('"'\1 "'4");0;; If I ,:Iur Ihl' back trame to the
cabuu-t ..Ifl. ... 141 fClrt' gluillg up thl~ l
..l';J'}I...1 ~I"""""bly, 1 dry-clamped it t,) check
tl ... 1;1- ,111111'111111,1111did because the top
rail, ,,' 1111'rablnd did,,'1 aligu, For the rail,

"t"

10'

,r--

80nOM RAIL
I .,'"

,
J

9
5'0<
TO.
IIA"

.-or'

ft1M'
TONGU(ON
IACISTlUS

CROSS
SECTION

littlt' area of thr1(1I'IlU" "" ,'a, h ha,'k 'Iii" (Gllhal ha~ II' bt,
,'ul ufl, '<'" I'lll 'I. Ailer lrilllming this ,.ff.
"dd a bOilum

anet nliclttlt 1';111

It; tht rronl "r lilt: rabinl.'l (llll'
If'l) rttll f' .UIC'I'fllat(r .. (.ut Ult' rails tu llll'
1"nJllh I II' ). but diU"r"nl ",dlh,
ll,,:middl,' n.il (1.)" I ",id",lnd Ih~ 001
tom roil <'I) ..... "jel" 'n1l'0'""\I1 t '~I<'n~
... ,010

tht "' .. ("ltd.........

'(. I-ig_ 11)
:\1 Xl, an."k'h chr rail .. 101M tronl b\ gluing
Ih" bou"m ,.." \\11 fiu,h ",tll tll...bOUOIII"f
the ~.M,t:\'n\ ....""ff 1'11>:.IftL '1"0 position th4.:
middl .. nul. ''1111''0 III! ',~,"g
ml~r$lrip, tu
lil th. j..'TIM)\ t.. in tht ..id,.....and glUt' tht.......
in
pl,,,'~, "'" Ft~.I'la (Se,' lXtg...21 f()rd~lail,
u" fit1<-r,Irilh ) llwn. IIlu~ lh.. Oliddk rail
(I) in ,hi'$!rIH)'o'l "'. it "it ..,," lhl' iillcr~rip~.
"lnnll~ . ""llv'll m(lr~'...tnl> ...l" fiJIlite grOOVf.~S
;,bt1l','lh,' I','il. "'" Fi~,
10.

,lIT
Flu.e.
STRIP

.!)

MIDDLE
RAIL

..tubtl'nOll'U

TO FI1'

Rlut tJltl)!,('k Ie, tht, ...iell,",_ ",',' J'ig, 1('

'1111' 111'\1 '1"11 lv lu

S'IlC

o.

ttl .11iJ...'l1t.'"rrc~ll~',
tlu-re'...a

I'HC"T

,.......

I.'~

,
1

,
......

MIOOI.l

i"

'\

nun
Sf"'P
11 , ...

IOn"'"

I '",..

:I'....

ItJIIl

TOP/BonOM
,

After gluiog up the

cabiner. tbe next

TOP

11

step i, 10 add a ~',".

thick plywood lOP
and bouom panel.

,,...._

",r: " /'

12

PANEL

#,:OWS'OPOf
M.OLDING

~<:
,

l.'

Both panels ar e
glu ...d 10 deals that
are screwed 10 the
sides.see Fig. 11.
determine the lengllt

TOP

flUSH WITH
PA~
~

......

I'~

RAil

<p

'"

@-f
MOLD
ING

t.rth( ~.'-thi('kside cleats. measure the (lisranee from Ille back frame 10the inside edge
(If the boUom rail. refer 10 I'ill. 14. Nowelll
four 1",,'wid,side cleats (R) to Illislcngtlt
(l9Vl',). Then. drill tcur coumersunk shank
holes through each cleat, see Hg 13.
AITACH CU:J\TS. Once lit" holes are
drilled. "'T<~'
two Mth, cleats l() the >ides so
the 1)lywood lOP will be flush with the lOP
edge oj the cabinet back once it's installed.
see Fig. l:l.Then.cul.IV~"-";d e back deal
(S) to fit between the sidt cleats and screw il
10 th~ back panel. see Fig. II.
13
T<)P RAIL. There's one more "cleat" to
mak.... bUI this on,' serves IWOpurposes, II
not only supports the top, but atl"as" fmnt
rail. Culthi.:v,"4hiek top mil (hI loa ";dlll
of 11," and t(l length 10 fit bel ween the side
frames (J.I'). Then $llue it to the t!.\1l<.S(iI
..nd, onhe ~id<,d('als, S('(' Fig. II. (Inb end
llT3in jolnt will be strengthened later when
the LOI)panel is added.)
TOI'!'ANF.I_To determine the len~'1hof the
top panel. measure (rom the insitlr face of
14
the back 10Ihe'II(,.. edg(' ofthe from rail
(K). 111"n, to find the width, measure between the two skle frames. Now, cut the tOP
panel (N) 10size (in my rase. 14" x 20V,").
tOOOtRMJNf
lind glu" a to the cleats and lOP rail (K).
UNG1HOf
SlOt:
etlATS
)IOUlI1<G.Next, I made a moldi"!! strip 10 MEA$URt
fROM
BACIe to
cover the Il'tlnleclgeof the plywood. 5<,'(' fig.
12. CUl lhis molding (0) from :}r,,-thick sonOM ItAIL
stock 10a flnished width of I",,". Then trim
the piece 10length so Iirnatchesth ...width of
the top I",n('] (1'1). Now. rout a profile using
a :v." round-over blt on the top edge. and a
I~""-diameler ogee bit (nULa Roman 0&'41(')
on the bouom, """ fig. 12a. (Far 010 rc on
ogees, ,.., Talking Shop. page 29.) Then,
!!Iue the molding in place. set' ~il!.
13.
15
K<Yrf())I. After cOlt'J)leli11g the top. l inswllt'd the bouom panel. Stan by screwinjr
thetworemainingsidecleats(R)nush tothe
inside bouom edge of the cabinet, see Fig.
"In Then. cut a bottom panel (P) 106Linto
the cabinet and glue it 10the side deal'.
K1CKBO,\RD.To protect the base oflhe file
KICKBOAPO
cabinet I added a kkkboard. Cut the kickboard (Q) from ~'l"-Lhick stock 10a finished
widlh 0(3". Then trim this piece so it's flush
";th the outside edges of the cabinet, see
Fig 15. Next, rout an Ol!"" on ille IOj)rogt'o(
the kickboard In match the ogre on tile tOP
rail.see Fig. 15<t.Finally.glue and damp the
kickboard 10the cabinet.

""

O.

IiNGlII
Tom

1~."
OGEi arT

"."- r-"""'" ~
~r
>."

@"",

~.

...._ J- .. -

"I

ROUND-OVERt

CROSS SECTION

II.

11,..........

wooosarws

fh

"d,'

o.

SIO'
,0Jt.Mf-

10"..,..

PANtl-

-r"

.101

CLfAl

II."

BonOM
PANEl.

,..@

'1.-.1' ..-

SlIlE
ellAT

FhSCUW"

a.
KICK.OAltO

i/

10

<:

1"
TRtM
f(rOCIOAIO
fWSHWIlH

toGI:S-or
CAllNn

,
..DO

C....
,

<,

BonOM

-IWL

\'(/o"d, m IIh

No. 74

DRAWERS
Wilh th e- top and ""110mrompkt e, work

ran begin on Ih~

drawers. I used POP'
1.1' tu make Ih,
drawer

box . nd

screwed on nak
Ironts 10 ,"3I"h the
,.binel. see Pig. 10.
The elm",'r ,id(" ...1 joined 10 the front
and bark with h.UbHnd clav"lails using a
router and clCl\"'lail ji~.(For more on
do\ Ltail~,IUfll,l;tn ... rc.r a ji~.
~
1I', I.,,"11t \0. r>l< J
16

than th, "I'I(oning

...JI

'"

'tm bl
W'lhi,-k

m h' a

I It build 1m' drawers,

l ut (our sides

Alt"r IIIl' drawer pieces have

ruulI'II un Ih(' (mOl molding (0).,","

~idt""

Fig. 12u s..'t ,h,' trunt .. aside (or now ,h('y'rl'lIlli1l")lt-d

1,.1111,' drawers later.

17

14t"}-

;j)

...

st .-

,,

._

It ,-

v'

3'"

80nOM

..(it,

StOE

,,'10 ,"

FAL.5E
FRONT

CfNTU DRAW(J

1}4,"\.'11,-lit t~):-i/4,_. rt,Yllllt,_' dOVi,.laU

jc,i'll' nn uu- l'IICI~of ibv pieces,
""4'"

StD(

13" x ttl"' drawer b1ank~

tel ('3tll dim"nslfln (ur a 1,4" overhang on

each ,id.) Tl...n. cur two IaJ.... (ront. 1'\') 10
this flnal "I.' (min(' nwa,ur\'fl 12" x 141r!").
f'\l'X\, rout th" ,,1111('4)J[{'\' l"dgl' on all tour

,.1
,;,

lil1l,"'<1"iellh of 5\,
...
and !.-n)!th 01 19 . ', sev Fig 16. 5',.
11.. 0. rut (u"r (rontlblK'k:. (U)
1'1 lilt' "\11',: width a.. fht' sides
1
and 101 1I'lIlIlh I" Ie" than the
drnwI'rol"'ninl! 03"),

t'ft~1

\\lwfI Ih"l1h,,' "do'). nwa."'r\ th~"idlh

PAl.'" ~11()\"'. Olll....the drawers are a".

"Ultinj;: Ih, piec:..- from

,",el(k

mak.

t(1

and k-nl!lh "lth.t!rdWl'l'Olll.lImgsand add 100

;\......
"'1_
'Ilil "I, S4al1 a~\_lnlbling each drawer
by in""I1II1~n bottom (V) into the groove"
cut in llor ,id," and (r(lOll/back. Then. glue
and clamp 11wdrawer together

,,'('Ii

,l '

stock

m~.~und 121,0/'x 191,0.1').

11,.. 1ll11al -.w,... I

need
W (.j ~:k-Rrnro\, c..n each ,ide . ....a
lilt fini .....
lt.-d !'-.lIt'e)' th..' drawer i-,
1

'St"nlbl, d. bt..nn \\Orkfln tht>tuk false [roOl:;

(\\) ....an b} ghllns: up t'ouns:h ,,-thick

KtnTtl" The' next ",.op ....tnt.,..1a ~-deen

I:nMI\" rur th., \I," ply" sod bouom. sec Fig.
17. Cui thcwidth 01the grUUH'lJ) match the
thickn("""ot tht.~~)I)'\\.}(Jd.(:"iote:Sometime-,
thi"'lhi,,kn('~ i...
le.....tt'an a l~".)
Then. cut a
bouom (\) 10 IiI the drawer (mine

PUll AND (AltO

C\II G.oev._)

HOlDUON

to," PlYWOOD

fA&$( fRONT

I:is.: t,

HARDWARE
St:fort \dtac: hln~tJltltartlv.'OJn.1fiNapplil-d
Ihl" fini h. l"'II)t~ 011 a \41.at o( Gellt't'31 Fin--i,h. ' aL"...,1I(r,~.,.nlln aU the oak pan.
'OIl \\ h.'n 111;.1
".,dF').lapplU!d t\\ocoat<ol
("''' ",1 finl,h,,, Royal rmi:Jt (Sann, o..er
31 Ih. 1'<.11' "'Ih, fill- c.binel
~II.... ~11(}'1'.

'n", n,'xl .Icp is 10 attach

Ih" fal,,' Irulll' Tn do Ihi<-drill (our equally

'I"i' ""'IOI,rbt.I'l'll ,hank hole. in each

$0',,,,

~""\\i..

18
(0.

draw,r. "'.,' Fil('. 1~81\dIlia,

-n'(II. 111[lrka

or b~adju ...tinlo(lilt "f.uridt'"..Ji<!h.)

UR\WtWll \NUl> uu:. T"allachlhedra..-<'I'
.Jid.111<'d ... ",,_.n Ih. cabinet S<'e Fu:. 1:-. harcI\\3r\ . drill hoi," ,'"okred on lb. ..idth
('ok: I( th, (.1....(",nt, .",n11e-.~1.
vou ofth., lrunt" r\ 1 10 hI( II;. Hnally.
can adJ'''1 Ih"m by ~llllt r loosening ',11" Ih,' brn" dra", I' pull,and lard holde ... 10
Nundh(~rl
ilnd rcpo~itionin.R lht:lll th'l. (r.."ll ...,,( tht_ (Irnlht'r..,
",. Fit:! 19 IlIl'II. attach the IAlrackns 10
lhp dra""", Ou,h '''Ih lh~ (abe fronts. and

UA','Ah

WOOOSCR.EW

lin, on the inside (al'c' o(

,'n\'l, Cal~'lronl."..tT up rr(lnlilie

botiOIU, ')(.('

nJl, IR ~( xt. pIa,','" lalse (ranI (ac('downofl

..I.,,"
\
$MANIC

)'our \\'()rk~'llc:l,,Iud lh('n ccnter a drav.'{r

HOU

no , 1"flJ(lh, AliJlI1II... "ullom edg<'o( Ihe

dnl"('r ~i,Jl '}1\' rt'f(rffi\,~~. see Fig. l~

roc",,

To
pilol hole- in the false fronls.
in ....n an "llhrouJ(h ra<'h otlM four shank
hol .._ :.nd rnak" a mark. Then. remo\'~ Iht'
dra""randdriUW
hole-.I.Z -d....'Pin eoch

fal,..fr(,nl '.'1.

"'1'." th" fronts 10 the

dra\\1'1"' with r\oUndh<-aO",,,,ad,..,,,..,s.

The dt3",,,-,; can be mounled in

1M cabinet onn' th,' fronl' are altaCh<.-d,I
",,d 2(1'Ac(Urid",bdt'" (SeeSoum'S. P'III"
:II 1"'13,1 ... 1 in,lrucl;"ns (or installin!! the
,lid," .rtlIldud ..r with Ih" slides.)
I'll in,11I1Itilt", draw~r ~1ides.11".a. le one
l~lIr h" UI' Ittlln Ih~ middle rail (L), and Ihe
111111'1'I';oir ~.' up lrom the lxmom rail (M).

.,'

fUU-I)[T(NSION
DRAW'. SUDfS

COUHTlR.
IORI

.....

OIU>T
,AlS[

fIONT-

I----__./
~UNfI.,

'1JIlf'

19

..

...,.0. IOTTO#I4

.,.....

....._lOCATfllRACKn
-,.

DOWNROM

fOP fOOE Of $101

11

J(.iINERY

Stub Tenon & Groove

F

r-dnlt. and 'f);lrl~'1construe-

'h~ panel i. glued into Ih~

tion i< one "r the hallmark>;

or traditional woedworking. h's

~r('f\Vt',

thl' whule

unit

is

stronger. That's because of the

increased glue surface, Wl..-n a
pa,,<'1 b .\[lul'<1Ollu u frail"'. llw

Ihe technique that'< Irequently

used in "laking dour-, nnd

cabinet frames.
'I ypically a fl':1me and panel is
made..by jvininl{ tilt framv with

glul' exte-nds all t lu- way

around tile Inside of the frame(lht' Jtngtll {)r all four gr(l()\l~)
The glul' i-n 'l cenceutrated ju~l

mcrtlse and 11,'I11)n j()inl'" The

pallcl rests in .I.rrcoves cut aJOIlJ(
the ed~<" 01the {11Ime.

at the corner joints like in a rnortise-and-tenoned irame ""il h a

",mUng panel,.. 'e ~haded areas
in FIgS. I and 2 .

11u1a monl:o.t' and tenon isn't

th"only join I thaI can beused on
frame and panel projecL If the

panel is plywood (or another

man-made material), I ofi.", u-e

Also. modern Ritle'S arc' a If)1

stronger. arid their hf.ldi,lg
power J,.rrealt"r than glut"'> .l\'ililn

a ':)lub tenon and groove jOUll.

ble in the p;hL So when a piece

The Oak Fik Cabinet (page 6)

of plywood (or other man-made

wood substilul,;,) is glued inlu a (rom e , the
entire UUillx~ol1le<V~1)'SlrUltg, 1'rubahly

and the ShOll Cabinet (palW IRJ are both

can)' 311111<',,~ighl. 'ntis means the tenon

vxample- o( tlli:.

can be ""tubby"; il utl1)' h3$10 b,' 8. long .,

tht,J...'TOO\'t~i$ deep. ~ {'1g,~,
sn 'HTE~O~, 11 Lh~~Iued,in panel ties the

',ORTlSE \:>;1) TE~O~. On a tradltlunal

mortise and tenon joint. the lonR tenon and
deepmonise provide ....lfenmh for the frame,
"',. Fig, I, Sn, in a tmllll' and panel unit buih

with morti ...e and tenon joint, the ...In'n~lll

in th unit comes tmm tht' joint it$\'lf.

STUB TENON AND GROOVE
:\ ~tub tt'lU)n '.\nd ){'ruo\'C"
joinl is a little differ~
~ntIroma traditional mOrU""find \enon 'Ille

.,ub I('n<," and groo\'( joint d~n't hay,' a

"true- llIoni~. Insrcad. the Rroove thal
holds thl' pand ai,,, house:; th~ ,hort l<,nun,
see Fil!.2, (Also ~ Pas1,'SJ.I "od 15(ormorl'
lIn Ihe groflvl',od 'lub Icnon.l
BII' tht rno,. imp<)l1anldificrt''''" 11\"1"t't.'!l
lhl tWt) joint~ ha... n()thing to dQ 'ovill1the
tl'R]JI ()r tIlt"IlJorti*. 1t'!i1hat a st\lb tt11unaJld
gro"v~ joinl ha," pand that"!1/It, tI in plac..
CJ_lI!J).IX 1/,\'~El.? \\' ait a rllinUII.:, Itht)tlght
)'IlU w<,r~n'l suppos<,d 10 glue panels into

(raml'< J)tX'sn'1lhe p,"wl have tn "float" so it

('an t'x])an,. and ronlr"'dl.t

\I..it)\

(rnm(' til)(t'lher, why du you even need the

~,ub tenon? T\\',) reasons.The nl()~t important reason j ...the ~lub tenon kt,t'J):"Illl' rail
(the horizontal (I'3m~ pi ec cl and suit (VL'11i

$lr'tIng as.cue solid I)iet.'e of woed, but without

the problems (If w(MICi movemem,
GLUING AND ASSEMBLY
Okay, so il'~
the gIUl'tlill panel that makes

the stub tenon andgroove joint workso ,\,,'11,

cal p.t'Ce) ahgn ...1and flush. Ilwn the rasl II"hot'. the bIg deal about RlulO):. plyw,,,,d
loan', '\\1....t in relation Ie, thestile.~undl)', panel lnto agrnoved framc:? It isn't a bigdt>aJ,
kf"t!p in mintl Ih{~tt~llniflu(_~
Col..! eSl RF'<' E,lsa !i-(ul, tetl('" andl{fO()vt."' v.urks bec.,'au'.)e the gIUlI#IIIII." ttlC'(m.llt' to
joinl ~aUy as strong a~ a nl(.rtis(> and Lenon? the panel ~,a uniL.'nll'~r.1
hI thi.buDd is
N(" llll' jctinl ilse-Ifi~n'l a~ ~.rnng. 1'\\11on('(' an ullbroken (cu"lill\IOU~) glue lint.
till'

stub tenon fills

llll' (lJld of tJ\i.'

MORTISE AND TENON

SOtJOWOOO PANEl MUST
"flOAT-IN

fJlAME

s.,rroove,

as It)nj! as

yC)U

STUB TENON AND GROOVl:

MAN'MAOE PANEl. (~
auto IN F1tAME

SHADlN<>
INOICA1tS

"

SHADlNG

tNotCAllS

GIllE
SURfACE

GlUt

.i

SUVACE

t~hang('sin

hlUnidjt)'?y..,. - \1 til<' pall<.'1;,. ",lid wood.

<\Jui tllal'~ Ulle c.r the II1.idn 1hi'I~'" to un
d~r>land .boUllhb jninl. It', ,,,uall), u::ed

with a plywood panel thai won', ('xpand or

contract - so lhe panel ('(III 1)(glu\.-d into
thr gmovr

STU' 'tENON
O4tOOVl-.
~

,.

......'-'
..

1 ~rr\;l1tDlr.m, \\'tlt'n it'", giut'(l inte, tilt'

groovt.'. OJ pant'} bt~coml"s Pc'_" of the joint,in
raCL a frdJ11t' "ilh stub tt'D()R$and grf)()\'f'S

til" illn{'r ))(lTlt'l.

nllt (rom lI,...,II1<'r trolll<" andjninl>.lt';like
the dilf"I'tnc(' lx'lwl'l'n a lobst('r3ud a 6shone: g(.ls it, supt)Qr( ironl an uut~idt" ~11('1I.
tht: (ltllt'f (ruin an internal skt'lt-ltUl,
Aglu,>din
hdps tir 'h~ framepit'Ce$

gt>lS rnOSl ctfil$:;u'\'Ils:.'Ih fn)Ill

pan'"

IE

..

..
..-

_""-"""
r"
~.

:<

togt'th(~r so lht" com('r jOillls don't n(,M 10

1~

No. 74

I)R\' \.""'\'KI~cu

a, For the frame and

pan...' tn til lngt'lh~r properly as a unit, dry

.-r"

assemble and check the unit for lightj4,int~

and square corners belen-doing an~'gJUiJlg
Then, to S;ue up the asscmblv. sp""ad
Rlul" into the l-rr't)O\.'t: sor U1(> rails. SN" I:ig, 13.

Nt)\" 1)lal't'

rails (.nto tht" t'ncl:.-

')l!'

around the- P311('1. clamp 3l."I't,,' 11't" juints at

both ends. Theil. 10 kct-p the ,Ilk .... (rom

bU:\\'ing

place another clamp across the

middl,' nllh" r.-dln, bdw<'<'n Illl' fir"1 IW<I.
"(,. Fig. 2. lighl"n Ihl' mldrllt damp until
the \Vidtll O( lht pant'!
III\' same
here as it dtk~ alllll' ends,
~hllp :-01,:To k,"'1' Ih,' ,j,,,"slIlllw (ram"
trom IwisUnll. the I'L1mpln~pn-ssureshould
be ft ttt~,',.1 an Ihl' joints. (I helps lel use a
spacerundercach frnlll'"jrl e. ,..e Fill.la. Or
you 1.1u ' plat,'\"a rounded-over bl')l'k between
rhe clamp arul Ilw (nun e. ,.'<' Fill. ~b.

Non,
AUGNENOS
Ofn:NONS
WtTHtDGES

orPAH'"

b.

srlU
W,

11\11.

SP"""

SECOND:

01""",,.,',,

L'~
DISTRIBUTE
GROOViS

CI( lht.

into th(' ~'1'OC)\'C!\of lhtt l\\'(_)!:.itilt.~.$(ll' FiR. 11),

l- ioany. slip these 1\1, U pi4tc.:l'~outu 111(' panel,
(" A'11', \\ ith the rr.-tJnt~...rctions ~luc(1

(onON
SWAe Haps

GlUE RAIlS
ON10PANft

and al't.4,

(.'3("11It'0(ln.

(a.

FIRST:

panel. ,('(" Fig. I

~c:-;'l.spread glut on

~%

GlUf STILESOHlO
PANa AND1tNONS

alADOf
GlUQN
80tH CH(tJ(S
OF EACH TENON

ClAMP A(Ii.OSS SOTH (NOS

Of FRAMf ASSEMBLY

$.PACU STRiP C(NTOS ~

(I,AMptNG PR[SSURf
ON """"

EFFICIENCY
n."jd,,b<11ng 'Irong. <Iub tcnonand groove'
joinerv i:.: also a quick and ,,-'tficlell{ \\"a}' to
build a tr:lnlc'and pam-l unit. \(tt"ryou'vf:CUl
Ih" J.'T(I()V"~and ti'O/U1"'. lhal':, ~II (Ilt"ft" is to

.-

WIDTH Al MJDOU
SHOlJU) EQUAL
WIDtH Al (NOS

aOUNOID.QVIR .lOCk
ItE-OUtK1S PRESSURE

it. "01' don'l ha\'l' to rut (lUI a det'"f) mortise.

Plus. both pans elthe joiru can be rut with
jn-, (In ....to,1 I usu~ill)'use a table saw bUI
\'('U could U:-, OJ
()Jl p8S!('!' I-l

10 (NTIR or JOINT

radial ann saw ur router,

and 15 YO" show hew to cut

stub tenons and grooves u.....ing a table saw

t\J:;.t), .. hown on pa~(~ 17 is a jig (<<II' cUllinJ.r

ClAMP ACROSS MlDDU Of

fltAMf TO KltP STILES
.-.oM lOWING

u-nons \"'iIJ, a router

DIFFERENT TREATMENTS
Th.. Filt- Cabinet and Shl)pCabill~1 ,hown In
OF,COJl.,ll\" EO(:IlS.k: ,;]'OWII inlh<- firsl
lllb; h-.'ue have 1/4"pan"I, in a ""lid wood dro ",In&below, a molllin&'snip Call bead dod
tranu-, 'I he lT3m(~Sfor ,11(>~twere kept around th~ Inside of lilt' frame, The nexu wo
simpte wilh ;;qu;tr(-d-..rr edges, BUI with a drawings show tho ~1TeCtwhl'!!' a decorarive
diJ'l~"'"l treatment to tl1(' fr:mw or Ih~pall('1 ed.lwis n.uled on ~l<,'(rom ...
yc}ucan,gt'!{ a Inor~lini~Jlt.':dl<K,k,
Dlf1oD~" rASELS.TI1C<'l.';;nqreason Ihe

panel has In 1)(>Ihe same thickness as tlugru<w~. " ~.-Ihjck panel with" "entered
10'1I(IJ\'(onthc left In the Ulsld_ing) would
be 0",11orrboth (3('(>$ of Ihe fram.......rabbet
CUI un a vl'thkk panel (al rillht) Qtrs.elSlhr
Pc\llclto\\"'drd unt" fac(.

,
JII'OU)ING
APPU[D TO

DG Of' fRAME

~\lJpl!1n

Ilf

rtl} of

(Z ,\'fnlK)tl,.')'

'1"1'4" r-ll

",f J'w '11#

1'" 701

11(/)1(/

'~u.
tl.l

lHIC.1CNESS
CAN VARY

SlOP Al CORNERS

RolLI" I"'''} ii,

(I

rum,,1

tI,.

tm'I~ilI0fl fi"(ff')t ro (It:iJif'ft (I vlkuall('(rnl;;(";)ffuli (I T",(IJ'rjilli"h,'<i t..ok.

n I,d /,"I't't

p1wur#

'AHa

-ItOUTtO

mGCAN

/"",,11 th~1~"'l!l.fi",htft !,,,th

,1 "."oPPNI" I:://(Lmf,.,./'0
fI;'W Vw j\'(1t1'" (I lid1)(1''''/ll1Ii1n

or jUHt

"ll_,tt:/(Jrlllitl

giJ_'f

llpJlt. '(JIll

,'l'''~

U;,() ,flU"C nJ' t/'I> .fr'trl'l#.' If)

tl?~/1111 $>lull(1 1l0ll!("T lOOk.

GROOVES -

STEPBY STEP

\\'11<'t1 buikling. ir,ltlle and p",wl proje<.t using

stub tenon and groove joints. thc' thicknessot
ihe panel is til!' k,'y, So the first step b to

determine lit, actual thickness uf till' panel

(\i,",thick plywOt1d, particularty hardwood
plywood. mayactually beles>< than V'''thicit),

The thickness olthc panel determinesthe

width ufth. J!TIXl",-.,,-and the thlckness et
th!' tenon. that will fit in the groove'S, So, if
I'm building a .. ries of frames u,ing the
same panelmat c ri-nI.111 cut thejoints inpro-

CfNTER CROOVE
ONTH1CKNlSS Of

F'tAMEMas

duclion fashion, First I'll cut the grooves to

fit the panels, then I'll cui th e tenons to
match the grooVt"'S.

all [ram piece" their

1
li'!~.lIcddiml'".inn. (All",,,torth
',"oli,.
tllU",!! Ihe Mil .. 10

TAIlI.SAW,111~rearea nurnberof ways 10

l'Ul the grooves. but I u.ually use the table

UPJAAS'"Y pifff~-IhchO",Oltt<l1 ro'1$11lid

J-'"..I CIII
".h("

saw and a carbide-tipped combination blade.

TIle table saw provid es a quick way to make
a straight cut, And. by moving the fence
slightly. you can ('asil)' sneak upon the final
width of the J!1'oove
Start by checking' thai the blade b set 90'
to the table. Then adjust tile height of the
bladeto l1Jt thl'groov('slightly (\It~')dt'eJl"r
than the desired length o( the tenon" This
helps ensure that the tenons won't bottom
out in II", woove s. and thatlhc trarnes will
pull tOll"lherlil(hlly during final glue-till.
resr rl~X'll. One problem with cutting
grooves is getlillR Ihe- groove exal'll)f Ulc'
right size alld centered On thr thickness o(
tile workpiece. A (ril'k J use is to CUt the
groove on a tC'lit piece fil"SL
OOt IIIJ' ""->;S. Anoihertrick logt!tting the
groove centered is to make a double pass
without moving the ripfence. Make one pass
over the blade Ul cut half the grOOvl', see
Step 2. Thl'n flip the piece end-tor-end and
make a second cut with the opposite face
against UtI' renee.

I,)

i,.II!IIh,)

the ~t('rlir(11~/11''$-I~lu~t
I~tlu:S(lf)f" /1 )Igl/l
orth ('(1I't~

1"))'

JY!I}ftl(i ltf'fU/.Iof,1H

1111'~1J111')~
Fur

OC('141Tllt

!,rn It.'ill, n tl'HIIJlff'

11(11''': (J

r"tltl~rl;?I"nn thr ""d o.l'tllilS It!xi pil'C't'

fENC,[

FlitS' CVT
fOAMS HALf

OF GItOOVE

s"", set

blade hNl/hl to

2
(/"';1'1'(/ I/mm'p depth. rll,,,
the
piece il'ssligltll!1 off-<elltl'l'~rlilp
(I"

(Ill

ft$: ltglll

(l!1Qi)I.~r tltf' workpier.

(lift

It

ficliitcr/J;XJ,.,/I() hnld II/~ lI'o"kfl,<rr IQ 1/.,le~1

So
Ji'Iltf ..\1J11"'laA..ra/; r~t
JK'~ Oller I),,., 'J/(tdfl.
"'/f'I"mce Ii II., Lock. tI,e ripji lice ill plar~",1 Itu/,i IlIgtltfl ,,-'.-:t pic'rt d'J1PII till"l t~'/1..' t(lblt!.
/),,.il'(1"

"NeE
SECOND CUT
COMPlETtS
GROO'I

Sc'C St~p3,

TEST"t" tTr, Now. check this test groove

again~' thi: mat~rial tIl be used (or the panel.

Iflltt g1'O<w,' is not "ide enough to produce
a "friction fit.- you 11have to move the fence
After mallillg the first I/(Iss.flil' Ihe jllttt the jrPTrl> "uti umke It("fJ "IQ",,' JJ(l:$ses
piece ('lId-jfJr-elld UI/(I mnke a 1)t'CO)t( O/lf'rtJIt' btude. ()}It'j'I/lt J)(IIIt'lJ'iI~ :S111(yI1' ill
slightly and repeat the process. This "''''Y.
you sneak up on the perfect fil- when the I" .... SUII' check if Ih. [l0lltl1ils ill tbi thr I/roo,,- lif th,' 1.. 1 piec e, (,II 1/" frum
p"nt1slid,.,; inthegroovc but doesn't iall out. {{TfIO"",I!lhr1)11,,,1 tf_,,'llit properl!!,"11- piece C(I u be !1,Yj(JI'('(/.

TIPS AND TROUBLESHOOTING

O.

lOC>W1Pf:

jGOOVl
".l.
---PAt4l ......../
SllCltS ott
'"RAMtptct
SPlITS

,/
NOT

AGO<
GWfJOtHT

Kt:ep 11'J_~/onTt
p,~."p~u.reOR the IfYJJ*p(eCt

o\a"",,,blq 11l IlijJirull (l)w/ralltePI(J Y (fI'ftI

1I"'flltgilO.,t the Un/gtl' oftll<'Cld.I''S(tir.,,1~/'"

<'pUt) ifl}"{{TfIO~'(t1.l'Ifooli().>T(I\I'. T(1O ,oiIUJ

gloll,~k]J"pOlrclMIII smllll{/ 1>l't)}l('rly)

14

ffY'Xl'" rMIII1~i>I" """~flTljoi1l~

PANll. ms
aESTIllOGtS
AAl SUGKT1.Y
t>WoIfllttO

ThrPI' IIJd wl'l ~lidt<_ifllll1l~ (fl~grlJol>

if!/(lll. .ltorr>ff!l' iJ8etlgt;< ('i1<'O~11t1i"lJblotk
or hand p/(I61O "witt.tt.!iq11tchll "'/&'

l"o, 74

STUB TENONS - STEPBY STEP

Aft",.the groov('S are CUi inallthe piece s, the
stub tenons have 10 be cut tofit the grooves.
Typically. the stub tenons an" centered on
ibe thickness of the workpiece and cui
slightly (\Its") shorter than the depth of the
groove.
SET lIP SAW.I cui the stub tenons making
aseries of passes using a lIIilergaug<' on Ihe

~llHON

AWGROOVl

table saw. Once ;ij.'1IinI used a combmation

ON (NO
OFSTlUi
blade and made sure it wasser at exaclly\l\).
(II it's nOlat!)(r. the shoulders of the tenon
won't 611ighlagainslthe mating pieee.)
Bejo''I!!JOt(m"k"""llcII" .jirlll mark tenons lofil pn)perl Illhcy "''''" bt>thf.am~
'he franu: section tleedil1g tenons. th,ck",'ss n~,It .. PII"'" (ax thirk' ,.. th
To ac,'Uralciy set the IWlght of the blade.
j\rote:
rhen!(lrtffi;u r (('YII)JtJol. but UteJJ'rt"cttt grcK/l'P i~
Ifiell' J. To tiltS" "I.' (I pro'[if!r fil.fir.~f
use one of the grooved pieces, see Slep 2.
This determines the thickness cnhe tenon. U/~ tltl Mld.fl. IJI jl{-.'" ",." I)il!('f)i(f. For (h_e mt (l '.'sf t(''fIOU nIl (1 P'I!C'C O/""tTUp.
And. to determine the leftgllt of the tenon.
I position the rip fence as a stop. see Step 3.
DtSTANCl
fO ours.D!
(Nole: Since you're DOlcUlting
the
SET 'LADE.
OPalAD(
H(KnTO
piece. it's ukal' 10uSCthe rip fence and the
/
BOTTOM EDGE.
DmRMINU

,_.

"'''''''flll

i.
miter gauge togcther.)
'me last step in setting up is 10 check the
miter gaugewilh a try square.It must bc9!r
10 the rip fence. If it's not, (he tenon's
shoulders won't be perpendicular 10 the
edge of the workpiece. and the assembled

';'>/ p,~./
~.

OIOItQOvt

_.

..-

"-

lNGTH OF

frames won't be square,

TF$rem. As in cuItinS!the groove. the

;\011' lJlOll't! Illf Ir-'I('( Jf~t',l tlu IJi/(
best procedure forgelting Iheril!hlfil when
Use the grooC"'/ piece 10 set "P tne
tu"'" bt'lllV'<'l' tile JI' lIe' a11(/
uu/
cuuing IlW$lub tenon is 10 work with a IC51
''''''Jor II",.
l,(fl/"" pifCf 0"
piece firsl.l'""~$t piece has 10be Ille same th taMI' (lila .-(Ii t/,.I>/,fltlp '0 the lips er- .ide .dll" 'if III, bled cquoi rite de.i,,,/
/('Ilgti, oJ tit" tenon:
thickness as the finished workpieccs.
It'lul to ttie /olt'ltr!'(igeoflj.c grt)(l1)('.
Push the test piece up again" the fence '- __ ~I'="2I"-~""" --::==::-~;P-_-::?e'T-;:::::;==;;;::;=:;;;:;::;;;;==;::::-l

flll(lllo;,p

the miter gaugf"

10 guide

it thrnuzh

"'JII~.

;-

CUlltNON IN

the blade. making multiple passes until one

side (check) is cut. see FigA.
To Cui the ether cheek, flip the lest piece
over and 1'l1ltal the same steps, This win
ensure that the tenon is centered on the
thickness of the workpiece.
MITtR GA.UGE
TEST'~Tr.Now check 10see how well the
KIIP~PlKflesl tenon filSinto the grooved piece, Like
SOU_tO
ItAD'
with the panel, there should be a friction fil
And the shoulders of the tenon should fit
I\'i/It (I I t piec bltlt,d 10 IltejM'ce,
tighl agsinsl the mating frame piece.
uX.II.../,/i/(J('IIye (/I,tI m(lk~ II pa
When you've got a testtenon Ibat fils the
'It','r
tile
bl(l(/6. Tlu'l( /)(trk I/le piece (lUf(J.U
groove ;.nugly,cut the tenons on both end.
Jrot11 ,11.(' /e)lC'C (I ltd "lilJ..'e .l"fll(,CeMiLt6 cut-s.
of thll remaining frame pieces,

NOT(:

""

Tllrll tlu! fiiec'QI'~r(l'''' "'peal th I'rt.,.t~.

in tl)1)11,/.fpI lit" 11~"O't.Teet .(it Ill(' tenon

t/,r groo,'Cd "" ...kpirre. 1j'IlPctled. 1'01."

Illatll1

III

u.~

lit.

ASJIMBlY'S

fA"""

~ tOO"_

,tNDS~1
CHAMHIl'l>
SUGNTl.Y

wiU 16w(>rid.'lf',~Olilhe faCil,.<if If t/,~U'lllJ1I ;8 too /IJIIf! or tQt> tJli,.,. th" A $liflltt

a {JfJOII./il. frnm .. pierefl ...,,, ljilin well. AvOid tJtI~by

CWtftlUY $J'4''iltl",m ojfttoit},lJ.WI.I7J r:hiJJel. rt1tti;l'fl (Ite Wlon on II tell! piece fir>lt.
th"tt!fl()n ..(f

No. 74

n J,d J'("(",llJ tht t('IWI' Jar II /riclfQII

llHONtS

DON" SHAW: TlNON.s

100 n.'H - THEY~L1
"LOOSE IN
GROOvtS

Th b/~

SVtRAl PASSU

TIPS AND TROUBLESHOOTING

1/".

Ik. ridgt. ,."..",.n1

Wcxhl$milh

A,

{/p at flu' I>otro'ii oj tlla (eIIO/'

kl~
Ih".ltlJulJm'.,'>tUrtptightlyw tlrnnal
ingpie_. Cha."'jlJl"'(/ etvJ.s easetheftl,

15

TIP

SOlv1E

FROlv1

S H

OUR

Shop Notes

DRAWER PULLS
You coukl usc' store bought

to rout 3 V~IIround-over on

l:l<.'I, strip. I US4._"'>(1a router table

drawer pulls lor lIl" Shop Cabi- and .l '-'I" C,'(I\'(:' bit "-(,' Ior a I,.._!'".
n4"1~-hown on fl.,1$!.' l~.hut it'~
a nl!1'Il cut ... t(> Fij.!. 2 (C)r you
IOll11tlrt fun (;Inrlltts<.;.c1lslly. leI l:'(,ulcl use a 1.-2" con- b4,~ bil.)
make them from h(tovtr -a'rap. -":t'XI. tunl
strips over

we l!j{. I

rnund

'h,'

nVt'r- t.ht.- [ronll>fIg\JoS

,inn

ends 01 the 1)\,11

s, Bill 111('1'''is "
problem when Ih. eml-, ar e
routed. They have a ivndcucy I()

slightly 1311:<'rthan the bit

Then. '0 hold the pulls "'tUB'"
t,. tilt' routerfencewhil .. rollli,,I:',
I u",,-n a backerb ..ard made (fOl"

'Slip int" the

n l1iet't .. of scrap. St- Fiu. :~,N()I("

th('

('ll'-'llill~in 111,
t.abll~fence aJllI l'aU~'111('

with a

router
bit I\) goul!~the workpiece
started Y,;I)llIJI1K strips and .11PiI
To prevent this. you can (to.
Ct7 Pll.J.'. Now thv pulls c'"an
cut each onto to Iilli~h4U I('ngtll. be cuuo I,ngth. The llUlls Imad" duce th(~"i1'(> of tlu..()pcning by
Io do thb....rip several ,)iL'C(:~of art' ,I" I('lni!. bUI lllt.'~ can b(' flalnping an auxiliary fenr(' 1(,
lnngl'ror -:-.Ilont:r a~needed,
the regularfenc e, see rig. 3. r ,'ut
1"lhi(k scrap I" a "'idrll I"
ROlTSTRII~. Then, rout a IinROI '<I) OVER1'1)$, Ntcr cut- the auxiliru) fence frOID 1'1" )lIn!l'er grill (In th., back t'dg". II( tins: the pulls to length.! wanted sonlte and (.."\11 a notch in jt jus,

rll

",(ely mak th, pulls. I

t 4"round-owr l)it. ~'t>Fll{. 2.

or

~~," Pllor MOUS

Faa SQlWS

STEP 1

1Tl~ (1(1/t'" Oil the drawer pull

whil~I"";,,ill!/Ihr backer board
tl' Illlid" Ihe pun J).1>t the bit.
OHIIJ.. 11('I.Jo~.1'0 mount the

l)tdl~with Nt" Hscrews. tfrllll'''Cl

:~~:ll l)i101holcv in each pull. C C11~
rer th~ "1"clcp holes on the
width ofthe pull. refer to ~ig.
I

STP2

I ..
" ROVND--

OVE.
t ...

RNC[

COV["

1.." (oV( Irf

r---j

WJTK.A(XUt 8.0AAD
PIlfSS DOWN ON PUU AND
PUSH.WOftKPllCFPA$T

Irr

\
GLUING UP CABINETS SQUARE
and 1Ia1. I( the sides nt" square. C3D cause the cabinet lO twist or cabinets that arc the same' size.)
Stan b) <'Ulting 3 pair of ply
issue. Ihe fil. Cabinet. and the then- art' a (ew Irick, 10 hold Ih. ruck. see Fig. 2.lf}ou\'~ applied
Shop Cabinets. arc-assembled in cabinet square while damping,
the clamps correctly and the \\'(x>d squares lei fit in the cabia similar manner. Gluing the asPOsmO!(H<t: Cl.\\U.".,\ trick cabio(,l.<li/l isn't squa ..... try rt'- nt'l Then.lo keeplhem frl.m tilt
!;<'mbli('$ 10g"IIlC'r i$ a (airly thaI I 1IS('ohcn 10bring. t-abinel posili'>ningthcclamJl~ 10bringit ing ur falling. scr('w a p;Jir ur

TWf) ul tht- )Jrf)jt!CI~ In litis

sinll>lt" Ia.."'"- but tlanlpulJ! Lht"

C'~I)inets~q""y"
(1U1 be tricky
CHEl'KSIOllS. Clamping a cabinet sl.Ur'b \\IU..'11you asscmble
th<' side (ramI'S - )'(lU have 10
mnkt'" "tlrt'

I usea plywood insen, <C<' Fig, 3.

(i'lotc:lllis mrlhod ise$p('dally
tha.I the)"I'~ squat'"t'" corrn:ti)' CilJring a!o,.c;,t"llbl}.lll~ (,se(ul if you're nlakjng iIe\'ernl

CAlINIT 1$

SOUAAt

Figs. Iand 2,
If clamp' 3r~n't p(lSilion~d

ClAMPS PA,AAu..n
WITH WORKPI[CE

16

inlt, square, is y.113lrltltS("...man)'

~)t.'ats.l()('a('11squarE'. ~cfig. 3.
inlf)SCIU3rtt.~Fig.l.
llL"\,V()()l) l.!'liSE-RioU rep(.lsi~
I:abjnet~to bec:tuneOul of $CJuare
To use llle" irL""n$, plac(' one
-lhe
pcl!:>itit)n (Irtll{o(..'lamflS.~
tinning the damp!- doesn'l help. at L.Jlt>lOp arid (lOt: 8l11le bol'On\

CORRECT

POSfTION Of ClA"MPSWlU MJlCT

5Qu,U:lNl$1.Of <.AilNfl'

t'\

l!

olthccabiocl. A<thc daJ1lps ar~

tighl('ned. Ih. rabinN will
!'ooCJuareitM!lf ar"uJld lll~insert=",-

(AI5JNET SQUAR;.S

1--' ITstll

AROUND'NS!RT

TRIM CORNVlS
fOR GlUt
SQUEf%,OuT

INCORRECT

..

ellArs

Nil. 74


ROUTER TENON CUnlNG
.Ilt'rc!'o an alternative

1()

cui-

a lal)I,> AA\\l
(a!o> shown on l)aJ.:~lfi). For this

lillg stub

1('1lQ11~CJn

JIG

(("nee>.Then screw it down to

the (pnr~,see ~ilt.l.

\)1\"

FENet

To hold the workpiece in

place, drill a hol(' through the
ann and the base for a carriaze

nu-thod, y(it111 11("(.,,1 a router. a

"':l' or :v.."-diaillcter ~trniJlh\ bit.
and 1111'shop-built jig shown boll. sec Fig. 1,,- Ihe boll exI",n', Sl'('I'i~,I. And once thejil( lends up through the base and
"
i< buili. il ran be used 10 cut arm. and a wing nut on top lij!hlens the ann down to pinch tile!
I011g('r tenon ;111dlJalI laps, too.
11.e jill holds II", workpiece yvorkpiece in the jig.
STOPIlUlCK. Fora SLOPblock,
'<'tlrd), and w,ide, the router
for a ",rrl,'1 911'cut. The stop use a piece or scrap thai's Ihe
block assures that Ute tenon's same thicknessor alilll~thinner
o.
than the fence.
sh,)ulder~
properly aligned.
Rf:FI-:tlV~c.:..: I)\I)().'10 provide
~\U\.\N'r\{;f..S.One advanlag("
CUT(HAMFE. IN FENCt .....
fOR $AWOuSf RWI-r;
tv usin~ this jig is your router a point for aligning the workwill cut a much smoother tenon piece in the jig. rout a ~ lI"-dCep
reference dado across the (~nt_'"(.
than your <II'" or dad" blade
'Illb will rnakl:'finingandassem,
~>f"'Mg. 2. L'$t" the same router
CAIlalAGElOll
bling the joints easier, Another and bit that you11 use to Cui (he
advantage isthat th~ straight bit tl'tJ10JIS. (NOtt: 111" collet (Ill a
_BASf
will cui square shoulders, ",. router can be Oul ()f cenu-r in reo.
COUNTt:R80Rl HEAD
you're assured of a ligl11liL
lauon to (he base plate, To avoid
--Of
lOll INBASf
~L\.KINGTIlE nc. I buillll' c~jig prnblerns whl.. shoulder aligll1(,t('"ullt!-I10IlSOU ~ 1"4Wit:k stock.
rnent, 110Id the router tile same
(:'\ot~:This i~
nne of the limita- way each time yourout a tcnon.)
l'StNGTIlEJtG.To CUI a tenon, router base aj!ajn~ltile riRlll the depth of cut,)
tions of the jig.To ~'Uttenons on
U)SGTE;':ONSANn IL\LF lAPS.
thicker or thinner <lock, you'd start by marking the location ot 'ide of Ille arm. Roul across the
end of the workpiece and all the Longer lenon~ and end half 131)<
have I(J make a new jit{. or re- the should('r on a tCSIpiece.
Then sliti('thepi('C('underthe wuy through the fence, sec Fig, jOitlts aloe routed much like Ihv
place 11", fence and SLOpblock.)
'J'11e jig is made up of four
ann and align the mark wjLhthe ~.(Thls firsl cut mavremove the stub tenons, But these join," will
lake a number ofpasses,
pieces: a base Qf:V.,' ph~">Od. a 1(,(1edJ!t' ofthe dado in the fence. comer ofthe SLOp block.)
xcxt.loosen the winl! nut. flip
Align tho workpiece in the jig
fence, a hold-down am t. and a :;c<I~g.:1.Now lighten the wing
and
set the stop. Then, back the
the
piece
over.
and
cut
the
other
$lOp block. all made Iron. :v~". nUL to hold Ih.I~SI piece in place.
thick stock. see Fig. 1.
And then move the ~IOp up side of the tenon. Then check workpiece ;J\Y3y from Lltt! SlOI)
To build the jig. siartby screw' again$t the test piece 311et(:Iaillp the fit in the mortise.lfit doesn't and make till' first pass on the
fll. in\~r('ase the deplh or cUL. end oflhe Iliecc.Aftcreach pass.
inlt t h~(t'n~"('
10 Chl' ba~.
~eFig. it. set: fig. 3.
sneaking
UI) on the final deillh. move Ihe piece dos('( to Ihe
1. Then. cui Ih, 3",wide hold,
Nt'Xl . ..;;(t VOlir routl'f bit to
<~ghtlyk'SSthan th~u.pth o(the (Note: To keep the lellOIl slop.ll.e last pass i"mad~ whpn
do\\'n al111 to length
~exl. damp lhe ann II"from .houldcr. and mak".I<'Stcul. 1'" clilliered. always roull)(uJ. fal'es the end o( the workpiece
thl'end ofthe jii!so iL"squa ....lo d .. Ihi . hold til<' "dgo of the of Ih~ workpiece after changing touches Ihe SlOp.

at'"

...,.

/----

AUGN TtNOH SHOULOOl

oAOO

1----1...."....~.....:MARKWITH REfE"'NCf

ROUTJlUutENCE
~ooIN fEN-

Nc). 74

Woodsmnh

17

S HOP

PROJECT

Shop Cabinets
Customize these cabinets wich any combination of drawers

and doors to fit the needs of your shop. You can even build
several cabinets and join chenl together with a bench LOp.

e'v~ been "making do with a couple of old

)L'TII.lALS. To keep the cost down. I used ~<"
pine to
storage cabinets in the lVood.<nulh shop for make the frames and V,,".rnick Masonite for U1C panels
several years. Finally. I decided it was time to do and the drawer bottoms. The door frames and drawers
something about iL
The new cabinets hnd to meet three requirements:

are also made frornpine.And the drawers slide onwood

runners (you call use metal drawer slides ifyou prefer).

first,they had to be simple to build and easy to assemble.

Second. they should be relatively inexpensive. And
third. it should be easy to ,,"stomize the cabinets to fit
different needs. (You
build as many as you need. and
use different drawers and doorconfigurations.)
JOINERY.The basic cabinet i$ buill using a frame and
panel technique. A wood fmme is joined together and
holds a plywood or Masonite panel. The frames are
ioined with a stub tenon and groove - a simple joint to
make. and ODe that's ea.-y to set up for making multiple
joints. (For more information. see pages 12to 15.)

Even the pullsare made from pieces olscrap wood.

FTU.R STRIPS. The trickiest part about de~iJlTling
these cabinets was coming up with a simple way to vary
the placement of the drawers and doors. f ~"3J1le
up with
atechnique that uses grooves along the front stiles. The
drawer rails are set in these j!rooves. Then the grooves
are filled above and below the rails with filler strips.
TOP. After completing the cabinets. I built a plywood
and Masonite top. (For other options. see page 24.)
~'N'sn.Finally. Iapplied a couple coats of lung oil
fil\ish to the completed cabinets and top.

can

18

Woodsmith

No. 74

OVERAll DIMENSIONS:
x 16''W x 2.11)'2"D

351_""H

OAAWOI
RUNNlR

1M.
DRAwta

SM.

fRONT

8A.C~

&

<.D
-

c:::v.
""'"

,1.....

-::("'" --~
~LL

..., -~

--.

i'UtL

x,
14.1>00II
~ANSl

"

ft

r=-~

CROSSWl
nONTTOP

..,

--

~"

~
~

IWl

!j

: :

I::;
[;

:,i~I

-~
".,

'

-'

CIol'at-

~.,.:;.d

,~&-

~._

---l'~

'v:,

crf~

cw.T

'

FRONT
BOTTOM
CROSS RAn.

t-:

ift

;;:::;,

li:~

"

t-~

,-

='='_--

=
=

STRIP

f=;,

....
Il

flLLlll

c.:::)

G_:l

In...

LG~OOOR

RAIl

J_
SlOt
,

! -.,

If

!}

!>

1"-

-a

_INt.

P~U ~-@RAlL

' ...:~:,.
f ~ -=

-- .
.,'
INlff

fJ..

~'

DRAWIR

...c:-

"11

SM.

8OnOM

.....wt.

"-

VARIATIONS

EXPLODED VIEW

LG,OQOR

ST''''

MATERIALS
HARDWARE

WOOD PARTS
IlASICCASE

.~""

A SJI!es(4)

'hx3' ,

RQ.ls(6)

,}-,x3\'2' 15

C
D
E
F
G
H

Fl Sin) Cros:;flo~(I) ."x31S

Ff TopCrossRoII(I) .....XI~4 IS

Ponels(3)'
Cleots(2)
8oMomPOI'Iel(l),
""erSlr1)$

'/4 1:;'<19
~.x~.'2O
1'e-""~ x2O'~
I.~
xV, 10fII

SMAll DRAWER
I f<onH1)

'Ilo X411 15

2O>io
~.x3\f;>12'"

Sld<>s(2}

K Iloc:it ( l)
l BotlOl'l'l (I)'

LAaGEDRAWER
M Froni (1)
N Sic!e$(2)
o Sock(I)
P 8otlorn(i)"
Q fluMe ....
R DtowerRoij

'1-." 3h

' c"-THICK

.x80.15
.,. x & ' 2Ol'o
~." 1)"12,,

I., 1~"'x19%

-.x2118~
.x~. 15

E-

p.."

K,

lARGE DRAWfR: ,.10 '~."

'I'.x2t-:!IO'~
l". )O"X nV.

WOOCfSCrews-

FinIShno~for ossembIing dro,.e<S

1,,8 C~1I".,1 ..).72- (3.7 ed. Ft.,

8
8

" 7'...) .

t ,

it

"

, fl.,

"

LARGEDOOR: 1Jt6 p-..-

11.,

x 51 '''J 48'" (1.8 ad. ft.)

--+ H;:~~
Vi(;:"f 1:_,:JIa
v
v

7//V,u;;;,! 7

x 9' ., - 96'" (6.2 ad.

$J...,"} - 96" (3.7 Bd. n.)

~.

-i=~~F

7'" (3.7 ad.

!' ';~'~J f

SMAU OAAWR: xb

"

~.x~'\'14W.

lab (' .. 51,..) - 36 (lA ad. ft.,

I '

v.. 16{-2eXISh

BASteCAaiNff: lx' ("".- J(

MASONm

00Qa!

~~2~10!o<.!

L ....;.-.. I

a(oufUl):

A&.5O

(2) Bros:;plolOO, ",'Inwl I1Inges for

eecn doo< In lhe coblnet
(l)lloiIercolcnperdOof
(\) Pull for eocn Q<eweronddOof
(d) lSrockeJ' requited fo, Oltochong
'he top 10eocl'l oobonel

4x2~I~~.

a.ASK ~H(T:

CUnlNG
DIAGRAM

\f" _ 12', x 10)",

PIecesOOHrorn 'A'th1kl>/IosOOfIe
"lwo runnersperdrOWet
... One d!ower rai per<1<ower

N". i4

SMALLDOOR
5 SI,195aJ
T RodsCl)
U Pon<lIor
lARGEDOOR
V lQ Door Stiles (2)
W Lg DooI Ro'is(2)
X Lg Door Ponel (I)'

;7 "

~:,ka;~

; :..

19

BASIC CABINET
I started buildilll: til{'
cabinet bv making'

(,!) CROSS

..L.f" -

l:)id~ frames.
Tnen I connected
[\\'0

RAil

IS-

GROOvtSro
....II\ATCW TKJ<KftESS

3~.[_~....oJ

them wilb <'fO>S rails

\.,

Fig. 1 Eae h <id~

&ame is made from

--,

stiles (vertical
pieces). two rails (hOo7.,I"lal piee es). and a
panel. Th.. key 10 holding th~"" fral1l~ 10gctheri~t)\( groove onthe insideedgeof the
stilt'S and rails. This ,..roove holds the pand
in place and forms a "mortise' far the tenons

Non:

~
.!,.

PANfl

CUT1HIS

,,"

11

PANEL

.1

.t.;.;.-J -

tA"'jIt'

LJ

'."

BACK
BOTTOM
CROSS RAil

J.

sizo. (Xote: Two of uicsc rails nrc used as

..-

GR:OOVE
ON
I.CK
'ocnOM

o. T b.

and length.s<'~ ~;g.l.

Thencutsix rails (8).

back. see Hg.

I,"

351,"

stock. cui four stiles (A) 10 finished width

cross rails forthe

}- 'L"+-.,..+

I..). ...

lWO

10

OfMASQHm

-,

and a back panel, see

en the ends of the rails, n((r to rig. 2.

Since the groove Is the-same sizt:' on all of
the pieces (11.",,;ooond ~1I;"de~p).1cut the
stiles and rails to their finished dimensinns
- then l cut 111~
!-'Tooves.
snus j\XO R'\IL~.First. u~ing
:Yl"thick

CUTCENIUED

O~~

-'

I.)

GI)(l\"~ FUKt',\,"'.;I.$. The ,lext $11'1' is 10

cut the groove for lb,' panels 011the ;".,,10,

{/Ig~of all Ult stiles (AJ and rail. (B), This
groove is centered on the thickness of these
pieces. sec Fig. la,

GROO\'E FACE OFSOI ....

;.

oUL...ide edge of the stiles, see 1-Jg.la.

norros:

CR()!;S RAIL xowone

oflh"

rnil~ (S) '11$0needs a groove on the inside

face, St'C 1"1.'.3. This rail ",,11 be used as the
back bottom eros. rail and the groove will
hold the back edge of the bouom panel in
place. 5<'1: Fig. lb.
F'R()~TCROSStWLS, To hold the front of
the bottom panel. I made the fronl bottom

cross rail (C).

j;('('

~lg.~.This rail is the

1.")(1.-

C.

RAil
STILE@--

Mer grooves arc

cuI on the edge. of Ih'$til..sand rails for the

panel.anothergroove iscut nn the faceofrhe
stiles. These zreoves are used to join the
side frames together wit), cross rails. see
Pig, I. Each grOl)"" is Ic)('atcd .," from the
l"'l'K

FIlONT BOTTOM
CROSS RAil

1'NON CtNTlAfI>
ON STOCK

ASSM!.lE BOTH
Slot fRAlo\[$ RRSl

same length as Ul~ other rails (15"). but it's

tl111>! 3"wi/Jf'

and il tIt\....;:lltrI~f~
(ot'll1{' bottom
panel to <it on. To form Ih, lcdgr-, cut a rabbet on the lop Mll'e "fuli, piece. SI't' ~ig. tc,
There's one more mil 10 cut for the bask
shopcablnet, and thar'sllt(' front top cross
rail (0). ThisraiJ is narrower than the other
rail, (I:Y~\\id~),
bUI it'< Ih(' same lcngih

(15"). see fill'. 1d.

CI TTE!\O~S.Now, tenons

nerd to be cut

on 111<'end> of all til. rail pieces. )\11 the

tenonsare the same sizcandarccut to fit the

groove In the stiles. :-;010: Center all tenons

on thl: thickness "f each pi ece. see I"ig.~.

PAHfIo

NOTE:

I' \Nt-

rs, The next step is to determine the

size ofth e panels (E). see I;g. I To do thi-;

d'l assemble one "f the "id,' frames frr,l\1

two stiles (A) and two rail. (Ill. Ih"n

,!.

measure the opening,

To aDO\, fur th,'

groove'. add
10 the \\;dth and beigh!.
Then t"U1111rt'C panels to these dimensions,
:>I.'(' Fig, I. (One-panel is for the baek.)
ASSE)IBLY. :-;ow,",""mblycan begin. ~;rst

assemble UU! two slde frames, ~(" f-iR;. I

:\1'). the basiccabincrca be-assembled by
adding the cross rail, and the back panel.
(For 11101'('infomtation 011.IlluIIIg up cabi-

neb. see Shop :-;"1,,,)" pal.',. Iii.)

cl

C.UTGROOVE-

FOII.lonOM
PAN(L

STIU@

-r:

./

tNom

ClIT '."x '.AAunON

TO_ DOl

itAilONlY

RAIL

Non:
(UTGROOVt:

ON fHSlOE
FA.crOF
All snus

20

r~~

FRONtlonqM

PA,.l

Ct'OS$ RAIl

SIDE "'tAME

OAC.OCTTOM-

aoss

1tAIl.

SlOt FRAME:

BonOMPANEL
Af"'r the- j1ll1eis dry and the clamps

art' re-

moved from the cabinet, you can begin work

on the bottom panel.
J cui IJ)is pane'! trorn v4"thh:k MaSOJlilc.

BOTTOM'G'
PANEL

'l<'

.~

To k<>(!11
it from sasrJlinj1under the weight of
heavy tools, I added support ck-ars 10 the
sid,,,, or f hI' cabind, ",,' Fi!!, 5,
tI'&\1';,

Cuuwocleats (F) from ~," stock

10fit between the lrunland back cross rails,

Then screw the cleats to 1111'
side frames so
thvy'rv flush wilh Ihc bnlh)lll oflh" rabbet
in tl~l'
front cruss rail, 311(111us11with Ilu.:
bouom o(th., j1roovc in the back cross rail.
I"g. Sa.
l':\.\'"EI- Once the

MOl'

e,.lcat:- are screwed

ill

place, tlll' bottom panel (G) IS cui wide

enough to fit between tlw sid,' frames. And

long enough 10fitinto the groove in the back

cross rnil and (he.' rabbet in \]1(' [ron' cross
rail of IIII'cabinet, $<'1,' Fig, Sa.
Now, with the lJaIWkuILO,i7.eand thcck>ats
j"",,,IWrl. the p.m(1can Ix>j(lued in place,

If;

.
6
F1tOf<T
BOTTOM
I CROSS .....

ll:,r

CUT CtuTS

eslabll.h

Ilw ord"'j'r opc'ning,

T~111diUy,10(' tcnoos,oll !,he cads of tbe

drawer J'lliisaJ:(!-SC'\
into mornS('s, U the tabj
'1('11.3$ scve~~l
drawerS it means cultiJl~a lor
ofmortil!S,
To make things simpler. 1 used a
COlllp)CI(')Y diff,'r,ol technique - I set the
d'.. wer rails in a 91&",. Then to create a
"mortise." I mlod the grooves above and
below Ih~ rail with filler strips. Tbj,.way the
height of Ihe opel)ing L< delermincO by the
I~ngthof 0,. strips.see I'ig, 6,
lll(,\\\ lik MIlS, t;acll drawer rail (R) for
thv $hop cabinet is made from 'lf4" square
stock, The kngd, of th~ rails is the same as
the tap and b~Ltol.1lrail>. (1S for Ihf mop
",,1>111,'1), An(llne I<:I'OIlS
oOlb~<lnds~n' the
same-as tile oth<!n"ti,\$ (Vt" x 1'1"),
fll.J,.R "TRIPS. An-er i;ompl ling the
drawer rnih>,the fill~ $lrip~(H) arc cut to Iii
Ihe grOlwosin thcsicle MUle cabmct.see Fig,
7.1 found il easiesllo ''HI these pieces in 1""1:
strips (h'II m"ICItIhe width and depth ()f th..
groove in Inc stiles. Then Icut them (I) k'nll1JI
III malch th~ d('slr('<iopt'niog bei)lltl, Note, I
used two differem drawer <ius, and two
dilll'l'''ntlioor ";7.<'$. see Fig, 6,
ASsEMllf,\'. Altor the fiU~rstrip-. 'll''' rut 10
length, the drawer rail. and slripS are glued
in place, Staning at the bollnm. I(lu(>a filler
strip lntolhe ..,'l'llQveon bolh <ides (If the cal).
ioe\, Then inse n a rail and 81u~and damp it
ill ptare Continue workiD)( your way up the
cabinet llJllil;illQftbet',ulsand tille, stripsare
in place. ~ Fig, 8,

No,7~

TO fIT BlTWftN

FRONT AND aACK RAn.S

DRAWER RAILS AND FILLER STRIPS

Wben bllilding 3 cabine~ rails are instillied
acresstbefronuoholdtb ...~!(>!!~Ih~l'and

"

'-

"'f'CUAt

\V

DRAWER
RAIL

rNSRT
nUfR STRIP
ON[ACK

SlDE. THEN
SEAT A AALL
ON TOP

Of STRIPS

I
FILLER STRIPS
FOR DRAWERSI
DOORS

B t

A SMAll DRAWl.
31..lONO

8 . lAaG

nll.(R STRIP
,. ' ... THICK
' ... WI.DE.

at ...lONG

C SMAll DOOR
~

171 ... LONG

o . lARGE DOOR
26'."lONG

..

t
'
{

DRAWla

ANGL! DRAwtR tWL AND

SUM ONTO Flw-ft STRIP

.1!

\'(1""Jsmilh

21

DRAWERS AND RUNNERS

The drawers shown
here have lipped
fronts and the sides
arc'simplyglucd and
nailed in plac e.

'c'_

SMAil.
DRAWER(l)SIDE

(Note: For other

~

dmwerjoint optious,

"Cc Jl3S(C 25.)

ORA\\ ER FRO~-rs.

To make the drawe rs, start by measuringthe

drawer openings. Then, to allow for ihe Up

cut the drawer fronts (lor M) 1.<z" longer

andwiderthan rhesedancusions,see rig. 9.

:>IOl~:The dimensions for both large and
slllal1 drawers are shown in J:j~.
y,
With the frontscut to size. the next step is
10 CIII a 'b".(Jt'<'p rabbet around the inside
tacetocreatea lip.I lowever,the ",i,UI,otthe
rabbet varies. On the lOP and bouom of the
drawer Ironrs, cut a%"wide rabbet, refer 10
~ig.10. BUl on the ends. the rabbets arc
widl'r (Iv!,') IQ allow forthe thieknessoffhe
:-.i(ll) pieces 3J\d tllt' wood drawer runners,
OJ1<':l~
tIle' drawerfronts are rabbeted, rout
a s01all decorative chamfer around the out-

side (ace orthe drawer fronts, see fig. Yb.

DRAWERSIDES. After making th~ fronts.
Ihedr awer sid,,,, (J or i\')l'an bccuno size.
The leOllLhof the sides is 2().1-1;". BUI the
width of the sides i~
the same 8::\ the
shouklcr-to-shouldcr dimension on the inside (a('~01the drawer front, see I~l!l.9.
111On.10 provide a channel 10 accept the
wood runners, cut 3 ...L"~\\i(l~
groove in the
outsid face 01each drawer side, sec ~ig.10.
ORA\\ERIHCK./\ftercutting

Ih, grcoves,

tf'-deep dadoes on the inside facc of all

the drawer ~idl'< ror the 'I-,"4hick back, see
f'ij!. \)a. The width or the small drawer
back (k') and the large drawer back (0) is
CUt

the same width as the sides. see Fig. 9. To

determine the length o( the drawer backs,
O1('O>lIr" the width o( Ihe inside of the
drawer (act' (rom rabbeted shoulder tu rabbeted shoulder Then. 10 allow (or the
dadoes, add ,,':!" to this dimension anti cut
Ill(' drawer backs 10Icnwb.

agroove in the
drawerpieces (or a It," bouom.see ~-Il!.
9.
HOTTOM GROOVE. N('),1. cut

11".
<, ADJUSTA.aU ORAWlR STOP

( xl"

ON FIONT lool'

NOle: On UICdrawer front the groove is

located

It," from U,e s IWllld,rofth e rabbet,

see Fig. 10.

CIll'TIlf: R(lTJ'(IM. Todrtcrmint

the sizeef
the bottom (L or Pl. dry assemble the
drawers and measur e the distance between
the grooves. Now CUIIIt"'lhkk ~ lasonite to
these dimensions, Then glut and clamp Ih e
drawer pieces together. Nail the '5idts to the

front (or extra strength, sec Fig. 9b.

RI ~'NERS.A(ler completing the drawers.
work can begin lin the runners. Each Lshaped drawer runner (Q) is cui from"
pieceof~,"lllick stock 108finished width of
21.1;"and I('nglh of2(l". sec Figs, II and 12

11 DRAWER
I-J
RUNNER@)
SlOt

1," CHAMFJt

flh WOODS(ttW]

..\1T/\CHTItE Rllr\"XERS.llIC next step i~

to
mount Ute runners to 11,~inside of the cabinet, To do this. drill IWO countersunk shank

hotes in e3,'h runner, S<'(' Fig. II Then pesilion the runner so it rests on the top of th...
drawerrail (....lCrom the Iroruofthe rail) and
b parallel 10 the top edge of the cablnet.
\Vilh Ill' runner ill position, mark Lh,hoi"
loeatienson thestilesand drill pilothQk~ (or
No. S" I" flathead woodscrcws, Then screw
the milner in place. see Fig. 12.

Finally. I screwed a couple o( :-l(). R x I"

roundhead woodscrews into rlre ends ()f
each drawer side 10 acta~a<iius13bll"' stops,
S('(' Fig. 9a

,-.P"'-====l 12

.
.,'

o....wnt
SlOE

_'-

CHAM""

"'h '

.
OAAWU
fRONT

~ _

J,.-

DRAWU

22

Wo()<ismlrh

RUNHOt.

No. 74

DOORS
If you don', fill the

length ofthe rails. lake the finished width of

cabinet with drnwers. the door (15") lind subtract the width ofboth
8llY ;,Iorng~,;pacemn
stiles (5"). Then. 10 allow for tenons on Ilte
be covered with a ends otthe rails, add ~". sec fIg. 13.
door.The cabinets I
CLTTIIEGROOVF..Once Ihe rails are CUI10
built use two door lel\),'Ih,CUIa groove on the inside edge o( the

.:::,:;-.-~

stile, and rails, This I.'1'tlOVi ls centered on

the thickness enhe pieces and cut to match
the thicknessolthe panel. see Fig.14a. N~1.
ICOOnsare CUIon [he ends of the rails 10 fit
the grooves io Ihe stiles, we Fig. H.
Here again Iused V.'~lllCk10makethe stiles
PANF.I, ASSF.~lIII.Y. Having completed the
nnd nails. and V." Masonite for the panels.
tenons, the door panel (X or U) can be cut to
sruzs, r~.dvterminv 1he filli!'11t"d Ill.ighl
size, "0 do 1I1i:.-.(try as:,c:nlblc tIlt: doorfrwlltof th.. doors, add I,ol' ((or the liJ)l') I" the and measure tllC opening.Then add ~to the
height olthcdoor opcning. see Fig. 13.Now. length and width. see Fig. 13. Now CUIthe
cut two 21tl"widestiles (V or S) 10 match panel [Q these dimensions and glue up the
Illis measurement,
pieces 10make the door.
RAil". Aflcrculting the stiles 10length.the
To form the door lip.rout a ~'!o"x 3ro" rabbet
next step tsro make Ihe rails (\\' or T). First, around the iol,'litlr fact. sec Fig. 15.11,('11
rout a
rut two rails 2V,:" wide, To determine the- chamfer around Ih~()Ufs.uIt> face.see Fig.l5a.
The finished
",idOL of each door is
the same as Ihe
drawer troms (15"). But the h('ighl of Ole
doors will depend on the slze oflh, op,:ning.
.. i7A':;.

LARGE DOOR

13

r.:~--"'--"]
-.

-- I

ALL RAII.S ANO smss

2.'7"WlOE~1-.~lHfCk

DOOR

PANEl

SMALL
DOOR RAIL

_. -"e

tached

111(.'111 l(, t11f." drawers 811d

door'S. (For

more Information, see pago 16.) The door

pullsarecentered on the widlltand length of
tlle stile. see I;;g. 17. And the drawer pull is
simply centered on ihe face ol the drnwer.

Finally. 10 hold lite door dosed. mount a

roller catch inside the cabin.'. direclly lx'
hind the pull, see Fig. 17.
000. RAIl.

14

ij_ .

i_

22""

stMlL

, '

-----J

26"

:;crt"WinglIt!' hing,' [0 Ule.'door. _I;;g. 16.

Kow. center the door in the opening and
mark the hinge hole locations on the inside
face of ihe cabinet, see Fig. 16. Then drill
pilol bolcsauhe markedloeaticnsand screw
the hinges 10the cabinet.
PI us, Next. [ made wood pulls and (,I

SMALL
DOOR snu

T r+

on the lOPand beuom edges of the door

Then. mark and drill pilol holes before

eooe srus

LARGE
DOOR STILE

iCl.lI;

1AIIGE

NOTE:

RAIL

MOLNT TIlE I)OOR. Once Ihe doors are

finished. l auached them 10the cabinet with
semi...ollcealed~" inset hinges. To do this,
position each hinge IY$" from [he shoulders

PANIl

2...

""u.s

_-

DOOII

1a....

HOW
fO~

1-.

101,.

;::zz

'--'

r-

10'., . :-:

.__

"1

-----

10"

.--10'.,-

..

16 :::_~ d.::_--.;.:;:...:::;
~~
- r--::::::"

15

I.....

. ~--':::...~
Q.

OtlfSIt>t
FAct

I.~,

.~----...

-_-..

J
Nn.74

!I

-i.,

t:;
:~I"""

#~I'"'
~l.
d'

",,10

0......

17
.a .. t' .."
I-.J .""""
WOODSCAlW

'-.e-;

-c

HlNGr

SCRlW
CATCH TO

C:LOStD POsmoN

C(NTU

0' HlNGI

CATCH9IN

'=

Woodsrmrh

fNsaotQf
CABINET

8HtND

PUU

000It
I'UU

(
CAIINlT

SID<

21

BENCH lOPS
After completinl( the shop cabinet I added
a lop to tum the cabinet tor a rew cabinets)
il1to a workbench. There arc a variety uf
ways to arrange the cabinets, Three options
are shown at ibe righl. bUI the size of the
bench tOil can be chanzed to fil your needs.
~jpr('RTf'R,\.\lf:. If you plan to mount a
top over two cabinets with an OJX'D space
between them (as shown in the photo on
page 18). you'll wam to add a support frame
between thecabinets.see FiR.18.To do this,
I used two :jI."~hick stretchers that fit between the cabinets, and IwO I ~t-tltick end

~ig.l8a.Finally.glucand nail
the frame together.
iU1'ACH THe "1L-\..\IJ:!.T(, at-

tach ,tIC tranu- between the

cabinets. align the frame

flush to the back of ihe cabinetsand temporarilyclamp il

in place. TIIClIdrill holes for

hexhead machine bolts. and

boll the cabinets and frame
togetlwr.l\('~Fig. 183.
TIIET()P. After the f,.aOle is

TOP DIMENSIONS
A. SINGLE UNIT -------

24 x 20
auuched, work C'JD begin on
8. QUAD UNIT ------48x48
members to ('()l1nCCI the stretchers,
th. top, I made th. top from
C.lWIN UNIf
24x78
SJlIE1U1ERS.T" make the frame. deter- rwopiecesol :~."plywood(or
mine how much Sf>3C('You want between the particleboard) (lnd a piece of 1,1," ~lasonit._ and screw them On the bottom piece. Then
cabinet s, 0 have a 3()"' opening.) Then cut see ~-tg.19.Then I covered the edges with use a router 311d a flush trim bil 10 cut the
two stretchers to this length, _ J'i!(. 20.
:l-."-Lhickpine trim. see ~jg. 20.
edges of all piec...", flush, see Fig 1!la.
-111\!stretchers are joined to the end memo
If you're building a "",all top.these pieces
(Shop :-;OL<:: \\'hcn cutting: the bouorn
bers with a rabbet and dado joint. see FiR- can be glued and screwed togeiher, then pieccof plywood to size. don't forll,'1t"allow
IBa.\\11<'nrutting thisjoint.Ipositionedthe
trim the (.'"(Ig-esto final size on a table saw. fur the "'t"-thick trim.)
dado so tll(' end member would be set in However, if)'Clla're mttking alargr ..tOll. it ma~' TRI~l..\SI) HkAc.;KJo:J'S. "0 complete lilt! top.
'tt,,'. from the ends of the stretchers, This be too heavy and awkward to handlt' casil)' glue and nail the trim pieces to the edges,
allows the frame 10puUtighl against the cab- as you try 10 trim it on the table saw.
Then rout a chamfer on the corners and the'
inet. refer LO fig. 18a.
The simplest solution to get the edges of tnp and bouom edl:e' .... e Fig. 2Oa.
E"~O~1E.\'aRS.Aflert'uuU1J,( dadeesin the all three pieces aligned flush is to cui the
Finally. I screwed Lshaped brackets It>
stretche -rs, CUi me cad members IS~long.
bouom piece of plywood to final size first. the insidecomersof each cabinet to hold the
Then rabbet Ihi' ends lOGLthe dadoes. see Next. '-11l the ()tJ\".'rpirc~()J,,..)'i~i. and giU( lOPin place. 5C(> Filt. 20.

18

-~

1." NUT

ANOftAT
WASHR

30"

--

SUPPORT FRAME

o.

CABINET

STRrtCHllt

'." ~ 3

, ,."

MACH'HE
BOU

(NO

MMa1Jt

1.- fLA1
WASHER

19

o.

TOP ASstM8l '(

.. ~, .

flUSH
-TIUM 8fT

!
PlYWOOD OR:
PAstftQ.UOAIU)

3. ...

l-l

CABINET
118

It

1 ".-

WOOOSCRI'WS

CUTTOP lwO LA,([RS

OVlRSIZ .. JR.IM FWSH

\V oodsnurh

SIDE

L$HAPlD
BRAC.K.fl

'I,.7-1

JOINERY

Drawer Joints
quire 1...J_.. rh__
aranre oneach side.
,hal has several drawers. (like I used the lipP"tl drawer from tc
the- ShUll\."ubintb), WI' spend u cover t his clearance space
grc'<ll deal of tinll' cli-.:cu,-=:illg
This ,"ould also be accomhow III build thorn \-Itl>l of lhp plished by u<ing a falS('front (as
decisions involve two main on the File Cabinet, see page t;)
points, - the style 01 drawer l~ut thi...:. require':'. more material
Whenever .....
'e build a project

from, and the joinery

1J.&"'(110

rJ':;'

sembk-the drawer.

ur','!;!)

fRO~"n'.In II", case of

Ih<'Shu" Cabin,I". I d, ...id,~1'"

use a lilll)('(1 Irnnt on lht'
drawers. The nl(l..;,l imponant

because you're actuallymaking

two drawer rronts.
JOIXER\. '1'11(' "(,XI step is 10
determine what kind of jOillery
to

use to assemble the drawer. I

(lk.lor heft'

consider three f"CIOT< for Ihe

joinery. Slrength. the rime and

",rIal slides), Ih,' drawers re-

to..I~required 10 build it.and ihe

appearance of the joint,
STRESfiTII .. lt's not justa "I,U,

is Cf,,'enn,K LIlt! gap

needed (or the drawer runners,
To nll()\\ (ur the runners (or

NAILED BUn JOINT

..

,,,"

"

""'
-

iabte saw, But the sliding

gerhcr, Thr key factor is that ~w dovetail requires n dovetail bit
joim has 10 be strong enough I.) and router lable. And. course.
with'land tilt' weighl that's ill 111('half-blind dovetails require a
the drawer. especially if ,I's special jig. (Vor more Informajerked open or <lammed shut,
tion. " ... 11'0(.1811,,1" No. 56.)
.\PPE,\R.\;<cE.I;nally. how im
This is the most critical racior
for the drawerson theShop Cab- ponant is the appearance of the
inet becauseof the weiglu ofthe joint? On the :;hop Cabinets, aplools that win be in them,
pearance i$ not critical, unl e-ss
~'P.c.:MI.
T()()'$. All of the you want to show off lillie.
j<linl$ shown be-low are sarOnR
So. what's the final decision?
enough. bUI Ihey requi re vary- II' 1)\<" main aruck- we showed
ing amounts of lime and special till' nailedbuujoint because it's
ttl!' C'a~C'SI, IJlll Illlr~
art' three
'oc)l~10 build.
The nailed butt and locked mon- options.

ur

1'-,"-

NOTE: "EISSUE'6'

TOP VIEW

fOR INfORMATION

ON IMlNO

tHIS JOINT

~..&...

1,"

.,"

','

COUNTtRS1NIt
fHE NAtl HlADS

'---r--:---

:).111'"

<

rabbet joints loan be cut easily on

8

LOCKED RABBET JOINT

TOP VIEW

ter of making the joint strong

"n()URI! 10 hold the drawer 10'

4d FfNISH
NAIL

_ ~ '.'

THICKNESS
OF SAW
&lAO.

OAA-wtR SIDE

I II;x p(lgc. 11111111 il "Ii 1lIIlljr,i III

(I "/)/1,,/,' I!(III iIIg II ik, IIIHIIII II';,.in; III. Fi 1'.,1.

iIpI"(/I'irle.<
(I
rr 1'/(I ill amount I)j' i",(rl(lrk; "11,I...1I{111t.
Seci.~tl'f NiIIIJ"I'~' /(1 'i"'~" tnu! "('~II';I'("-;"(I'~J)pr;tlli:,~(llrl(il,..;,
'I'll i.<jil; III !/, I.' "ili/1"II!J fI 1/ it., ""('''Ul'' .(1'1111 I II" "({ i/" "/ld. il <inp,,1""'llIil"(' (III II "I)('rill I /",ds. "thl,,'/Im II " lablf
1/1"11'1'11I/IIYJI'!I" 1/11: ,;d.x (I m/ ;,110 1/11' rllY'II'~'Jj'olll. 1"0 P",- SI(. Tlte d'YIIC"iJ(lCk/I) lit i.j')illl is /II., glllr Nil t;/(/{.( - you're
"I*ll ( I Jill Jlil il.~
1)'U/)t If't"'A' i1111 (Jill, t'("IIII(I',~i "A- tl,l' 111'(lII,~. II/lfinll most/lIlo'
mil/mill.

[] (If "II IIII' ;,,; ,11xx I""f

/I ""

SLIDING DOVETAIL JOINT

NOTE: Wlt)l SMOUlD[R
N(lD(D FOIt
StRENGTH

."
f

HALF-BLIND DOVETAIL JOINT

TOP VIEW

1'."

NOTE:

Sff JSSU .SI

fOR MAKlNC
THIS JOfNT

TOP VIEW

""

,"

DJlAWfR 5lDfi

[3 Therr orr

DRAWER $10(

0.III (//(1('. '11f',iI'd I" "'flk,' /lit., .1"; "I ;.< (( "',11//(('1,,011 II"II IilIrilc: 11CI1_r./iII1I1(dOt'elailjf)illl
CIdOl"dail bil. Tit, /Ii,o,, i,(lt-l'iuck (I "tlll/lI'e Y{1(J(1
Y/II~ sll/',
_lilrtK 1l!J"""'''. il ,'(111 b< 1/\[(i(',,11I" !If'l lite I,iere~ I" fil
'''11'/lu r
Alld if lin dfll'I'lailec/ dad" (}II /Ill ,/rall"'"
I rtJull.' laf>ri""1 II' flit '({f/t. /lw cdyr mal/",., (11
.."Jf.

"-,,II.

,t
,"otl.

_,
I;

slUllcls (Jill (IS (J'I( (Jllhc'

,'rollue,t all(/ llto.1cll'ca>'olire 0.(011(I I'll f{"(',jo;III.;;. Tlte plll.
(Hid lails 11,,1"'''lIlrock IO!ld/wI".litl!!I
l)f)t'id, (III "xc'clitlt!
gille S 1II1;lrc.rhe nil I!I proMe 11/ is I hul 11011 IICC'ti (I SIH'cialjig
(1/(1 (t fl,"ln. (II" YOIIIU/I-"Irlcui IIlelfl bl/ItCHld.

2;

WEEKEND

PROJECT

Kitchen Canister
A lthough the three......
in-one
1"\...d~gnor lili~canister i:-.

Nlta~urtlht. distance lrorn thc'

bounm or 111(>'('nnlainf'r1Ipllllhlrim and add li,". (I ('Ul II"",.

pj(~'l""ti'! \\ ide, 84,',., fiu. I.)

unique, \h(' plastic containers

in<idc ar ...the beSi pan. lbe lids

fittight 10keep <>01

moisture, and
the..pla~'il: containcr-, d(ln'. gi\'('
the contents an <obj(',110nablr
odor as wooclt"none>" might
I used [{ubbcnru,d', "Servin'

'\..,,, cur a case top (I') the

"'"'". width as Ill(' lid 11Ii) (61 ,wJ

~('\\ lout each (1f th(' six pit'Cto<i\ tu
a finislwd 1"fl$(Ih o( Ill". (Awlin,

Ihi> b for Ih,,', Hubbr-rmaid

Saver" ~ix cup (:\f'. 5) contain-

bl"'dJld

e<s,,;to( pa!!,' :11, but any plastic

containers ,,;11 \\'ork with some
dirnen ...ictn ,~hang(
....Once.. r had

\~.s.;'IUt.F C \!'\E .\~l)t.m.

;\It~r .11 the pi,,,,, an' cut io

length, glll~'llpl hv I"" L
S113J)t1(j assemblies: "WI.' Iig. 2.

chosen till' t.'(Jntaillc~, tht' challengl' was buikling an oak box 10

(ShUll '111':T" h"ld the

huld Ihree ..I them fur Ooltr

"'''Rar.andloff,,,
The box I bullt (.'on~i'$;(::-,l)ftw(J

the assembly. ",... I'ig. 2.)

R(H T. Once thr ghl<' dries,
create a finger lift b) routing a
'~'" ' ('Q\'(' on tilt!' top t'dgt' 01 the
1'35C front and also un IIw bOI
10m of Ih~ lid (mill, see Fig. Ia,

parts: :I

shon Udand a tall case, ",,~'I'i!!.

I. The lid and lb,' ca.",' an' Iwld

'ogt'thc:r with 3 pian hil1g(' and

fit bet ....cell (WI)end pieces, All 01
the l)icc~ :ir,,' 4."tll (ron, 1"~thi4,.'_k
stock

taiuers.

UP

r,\llT". &:wn by cutling

3 lid

Iront

IA) loa width of 1~~","'~' Fig I.To allow for

npiano IlhlgC.cullhe lid back (U) narro ....
C!
(1"',.") '111('11 cut the lid lOP (C) I .,. wider
than II... "idlh ufll"'lirl,on
th .. plastic con-

(I cut

nnru-, fll

--

C\51;

nil' wid",

(beil!hll ,,( the

casefmnl (D) and b"rk (F.) i,drlrrntinrd
by the h~ighl "f Ih,' pla<lk ,'onlainrr;:

UDTOP

---

@
UD
fRONT

".\t<r.;.

and Ih,' bottom of the lid back, Set' Fig,.. Ib

and 63, Finally, round over the top tc'(I~~:o'
of
Ihc lid anti ihe 1"'l1um edg,,:; 01 the case
Ilin") round C)V('r the (ond.;). S('(I ,..igo 1,,",

.P

','

.otINDOvtR

CASE TOP

NOTE:

111~n.to accommodate the piano Iling<-. rout

a '>1'" ,'hamfer on the- lOP o( Ih,- case- back

UDBACK

~ -=-~,;::---.!!I
ta-

wnhed to

ca".' parts. (T1l1'Y'R' aUlh" same I. ngth.)

I.'

~. widr-.) J

ClIIthe lid I,il"'(':; I" fimd 1,n).1huntil I"" II",

1
11,,-

I)K:"''''

square while dampinf{. plare

ternpornry ~p3(,t>rblocks ins.icllto

upsidt: <10\\'11 l"$tlaPt.od

comainers.)

3,," C.OVE
su DTAU. ..

CASE'i'
BACK "-'

OOWl'ItOUNO
Ovut rHOS

NOTE:
AllPlECt$
J." nttc1(

c,

CHAMftJt lIT

1," ROUND.

ovnln -

~n.14

CO~TAlNERnOtES. The next $kp is 10 .'UI

hull", in th~''a.,,I<>p(Fl (ur the pla<lk CfIIltainers. TCJ duermim- tht correct slze, I
found It ~.a,i~>1
10 cut a paper pattern fiJ'Sl.
see Fil:. 3. (A f,,11";'0 pattern [thc case lop
with Ihrt't hol\~
i~
aV;lilal)ll\ SCt.IWj.!t' 31.)
To make Y(M.lf own pattern. liNt trace a
half pattern of lhe /JollolIl of the container
onto a folded sheet of paper. "",. Fig. 3. Then
CIII"ulllll" hok-aud ,I,," I)'....Il!arg< ituntilth e
pauern fits: around the container about 1"
(10\\'" from the rim. This will create a friction
fil when til\' rim uf Ill\' container i, pushed
down lighl agnin;;t Ih~ lOP ,)1111<'case,
Xowunfold ihepnuern andrracethe holes
onto thccase top (Fl. Cent e rene hole on the
knllth. and position the outside ('ti,!!<' of the
other two h()I~~"
Irom ihe ends, ,,-,t Fig.
I. Then (."tn cut the 11C)Ic?sfor lhl;!' centalners.
.:"1)5. The rase ....nds (G) art> rut ~~.
wider Ihan th....lid and '2" long.r Ihillhcr)
than thccembined height ollh~C1l"" and lid.
see Fijl. 1. This allows ~." ow'rhang on all
side......Afl.:r c-ultinJ,.'! lilt" ('nct~to e, soften
each corner with ~ radius TIlCn drill
('OUIlI erbored shank 11(,1e0.0; til multit \.1U.~tt(' n,1

CROSS SECTION

a-~.."

. ....
'

"

illO

tbe \"'8$(',

st't'

:1-1 '."

6' ...

~_'

4,

L
RUI'EItMAlO

,.,

r-

CONtAINER

e"

CASE END

l~

.!.
r:
a.

,
I,J

J...THlCIC

I'

~~

[.

--{

f- ~.

f!> -

CASffNO

..~

.~.
'"''

:..L '-" J

,.3

SPACElt BLOCk

U$(D TO SUPPOIitT

~-

CASE

),* RADIUS

a.

OR'U-1."
COUNlUlIORI

CAStENO

.-1 x 11,,"Fh

WOODsc..tw

1.-DElP

\~

w.

pi("C\ ;\ to screw

:1.1

T 1.....

SHANK HOl[

I:ig. 4a.

ASSEMBLY
:-10". dry assemble t1w case with clamps,
(Shop lip: To position 1I1"IXIl'ISso only tbe

NOTt:

a.

f1U &N.DS OF HINGE FOR

(UARANCi

UO AND CASE BACK

euds will touch IIIe kitchen ceumertop after'

assembly, place " 1.- .... 1\:"lpOrar~ spacer
black under the case, see Fig, 5.) Then drill
pnot holes and screw the ends to the case.
Finally. plug the hol~", ,.'. fig.5a.
PI;-\.;'JOfIISGE. To make it mon' ron\'('ni('nl
to access just one canister, I cut the lid into
three sections, And. 10 keep the three secuons aliWl,'(I. I used ;1 sing) ..' piano hingl'
il1$.1(.'3(1 t,flhn1c.""fparah. hins:(~.(()"4 flap of
the piano JlinR"e has 10 be cui so each 1i(1
-ection wilJ open N'parattly.)
~an I' c.'utlinJ,t'i tllh"y vicltl)i;1Jlt, tlillgC
I<> 61between the lwo ends (IS"lonj(). and
fIj,. the ends <lightly (or clearance with the

NOTE:
I' l.W1D PIANO
HINGE ISflUSH Wltl1

WITH CASE ENDS

filM ' 1." fROM

80TH (ND!

OIUU t ,"~D[lP
Pllor HOLE

ca...ends (C). see Fig. I;. Then position th.,

hinge nn III(' lid back (Ill and en...hack IE)
iUI(1drill pilc)l htllC's (elr tl1(, ser('\\'!',
6a. ~ow~rewthe llingc ttllhc' \"3S('
CtTlllE

IJI). TIlfrt>

$("('

Fig.

flllll,.

are a few n)c;rc ~It>ps

Ix'(ore scr<"'inll th, hilill" 10 Ih" lid. Hrsl.

divide the lid into lhi,us. Sf'<! I'ig. 6. N".t. to
provide deamnce l>elw('('nthe case ends.
trim ~lIi'l)crbolh Clldsofthc lid. "'''' Fig 6.
Inen <"I th, lid allart will, Ih...Saw blad,'
cenlered on the dividinjllin~. !'('(' Fig. 7
Cl TTliE LUNG.:. Now .. '!'('w Ihe Ihree lid
pi,"'" 10 Ih" I,iao<) hintl'' and cui the 1"1'
IIn(/'ofthe hinge \\ilh a h~ck,"w al t'och saw
k"n. !'('t' Fig. 8. (1'0 prOlecl 11,,, case top
when cllllinl:.1 PUIa Ili<'<.'t'o( S(rap plywooo
unill'1' Ihe lid.) Th,'o angle thp hark!18w and
"ullhruugh the pivot pin. <t'C ~lg. !lao
~lnally.I fini.hed lhecani$lerwilh

."L'".

tW(, l'f)3_UO nf ~lil1

f)t'Jlyurelfwle.

Nil. 74

e
I)
CVflKROUGH

toP0' HINGE

o.

cur TH*OUGH
PlVor_1N
Of HINGE

COMtvlENTS

AND

QUESTIClNS

Talking Shop
ROUTING DIRECTION
./II'(','II~I ('/(1 ('trr{,'x 1I',fl, III!! difference. see ~ill.I.
FEt:DDlIlt'11(IS. Feed direrrt)lllrr"),~/,, try,")))11'1,)('~}'t.but
m\~1~IEt.r'()(~,...when rout- tion is important. however,
IIItll'en '1"I'HIlflit, l\th~frlld !t(,U ing with a trammel point, tht
when ~'OU're reducing thc' size elf
IlllII tl, 1"fJ111rirri,'x rl()r~If'i.~(>
itt router can only move around in cirCleor molding the ('dg~ of a
"~ooli~mith\0", .!I tlutl :..!. hIlI a circle, <;(1 you clt)n't have t/) circlewhh n trammel point

rOil,,11f'('11~k,rt.~r'}I ,\'(1.4.;-?

worry about il skippinll or run-

H,1l fi,p. ning with 111~Rrain.

01gIll/Jilt. \ \'a.~lti
)'(1'''11
I':vI'n chilII'llI i< rarely a probYou' n- ri!!ht. HiU.we did say to lem when cutting solid stock
(10illxltll ways. So which way is usinz atrammelpoint. 111i5ist>.
corr<'Ct?If yt)ure u,jnl! a tram- causethe wood Iilx-rs are tll" ays
md point to rout cirrk .. in solld backed up b~ other wood fibtrs.
stock, it doesn't make much see Fig. la and lb.

Xonnally I'd advise you to

rout the outside

edge of II",

circle counterclockwise 10 have

better router control, But that
can cause chipout, S('(' rlg,2.
BACKROInsc. To avoic1chipout. YOll can "ba"k,mlll-the ffigt'
of tl,e ""rkpiere by moving the

EDGE
ROUTING

-,

--:7fl5.)~~
::;tJJ!

tV UNCU'f

C C1.OCkWISf

'OIII(T KEEPS
SIT fROM SkIPPING

WOOD
_;

REACTION WOOD
I "I ('( IItl!1 ripI'fd 0 1,,1 (~r
J (" Your v.,t)(xi (and mine)
I

''u.

Q/

TJli'I't""
r i t'/I,
A:<
;';{11)f'I' th('/~~,
.f!,(J,'t,' I,ie("'j; iJt.ltl

1;"1"',/,

"lIYl !I.r'1J1I1 11,1' IJI(ldl', 1111(/xn,ul'

,,'
'
y
tli,IIJ"H "(fIJtH"',
"",l ,~ Ih,tr,' n "'all ~(IIJ'" ,,1it!
,/;,11,'1.

II,

Jail"!I'

ri,l,,,,,

(;(Ii/t)ud. r('.J.'f'~

I've h~d. <imilarproblrl11in the

\\r'}')(/.O:i"ilh shelp. As I ripp(.'d
Ihe wood. the kerf closed up and
~Iancrl to bind on Ih~ blad~. (lr it
olwllt'd up lik, a wishbunl.
FJ'oio tll~ \va)' thl' \\ ()()(1belli, 1
knt'\\' I'd run into \vhat'$ kJJ{)Wll

as "reaction ~,..,(.,d,"
ABl\'O!t\lAl GRO" TIl. '1l1e re,.

!ion sonle piece:; dt!veloJ)

tl

-,'rook- or "rdgr bend- and

othe!" don't has to til) willl the
lhe tref' Ihf>;' ''''('r('' cut (rulll.

28

,.'

and can't ..bounce ".

Ba(_~kr')UlinJ.! IIrC,'V('11lschipuut ...inc.., the wood being rl....

movedis supportedby the ,t",'k

in from of the bit. see 1lg.:1.

- fj
n.

ROUtiNG

QO(ttWlSf

BACK,
ROUTING
AN EDGE

,_..

MAKl
SHAllOW
PASS'S

.~

NOTE;
Ttnf 114A'YU SOMf

WOOD rN' F=RONT0'

CHiPOIJT WHEN ROUTlNG

COUNIDCtOCKWlSt

WHEN 8ACt(ROUTING

W3~ cut

come across a hard .pot when

from a le-0111in,t!
tree.like one that nailing or curting' I)in(' or fir.)
J(rt.'\\' Out over a river, or .!!ot
Rea,'oon wood in harrlwoods

i!'i

gl)ug~the workpiece. But when

u!-oinR a trammel poi'll. the
router i~
ht\)(iliRlltl)1 in Il.):--ilifln

l~\, -

STRAIGHTIII

the router

'I'

harder
contrnl. II It'nd~ II,
bounce :llung lite edgl' <l1\(1

f"\

TRAMMll

l'(lgc,' Irer-haud.

o.

router clockwise, "'ft' Fig, 3,

Nelle: \\'hCil back-routing an

NOn:

an IS suPPOJtTlO

'\""H-<:1. And

it shrinks unevenly.

II you juint the f>dg(~

!:!>trai}!llt.0\ er tinll' the- t~dgl' i...
'\0 ('\'('U

knocked partly over bythe wind. is called tension wood. 11,i:;.is lik...)' t(o bend again,
\_,the IIW el"<'\\. il had 10ad because hardwoods' abnormal
'~I~(. R~-\(,TtOSwoou.
[usr or react tf, gravity trying to cells form on the lop 'ide uf th(' Slutuid you 3\'()idu.sillg tllt'I'lh,'r
pull it down. So it developed trunk. rhC'~'arc- "$tr'lcllcdboards that came fn)ln the sarmsJkcialc,'ell~ in .Ilt.~lnlnk I()
kt"'p itself S13ndinl{. l1w wllod

11QI(liog.11(,11'(,(,up a~ajl1~l t.l14.:' (f,1o:? ~ulllt"Cc~~ly.

'111\'
~~v('r'
pull of gravity.
ity uf ntilcLiul' ""ood \'ilrit~ frtlnl
lhal ('ontaio$ Ih~StSIX"';alc~lIs
Tension v.0()() i~usuall)' b<.ard to b<>ard. So if tllt' ,,,t .,1
is called reaclion wood.
slron"_rer than nomlal. 50 it'~
dif thC' wood ${"('m::>lu)nllal, U~(' it,
:;qnlf'

HI~'(Tlt)l\ \, (lOll. ~"'OrSOIIIl"

unknoWJl rC"d~,n, n-aaction w()()(1

is f"mled ,lifll'renll), in hardwood.<Ihan in ."flW(lC)<Is.

When

ficull to 111a(:hint.".And y,.llen ClIl.

lan you a\'oid bll~'ing il? I)ro~
it often It'lIVl'$a -woolly- <llrL1Ce ubJ~' n4J1. l)nct" tc'.I!S art' c.",1inti'
Ihat rreall'S a blotch), finish.
Iward. it's hard 10 tell if Ihl'Y
A'\~OK~IJ\J

SIIRINKAGE,

<l1t-aning 5()ft\Yooo Ir('(' rCf.1C:I~

t(1 The-re's, ancJlllf.rpt"Culiarit~t'l
gravil), tl1t,' (.':11:- on lJ11:)v""4.'r r~u:liQn \V()4Id. \ nlik.~nr}rmal
sid,_.of Ih0 trunk art' ('OlllJ)r{'sS('(i.
wood which shrinks mnSlly
This ('(,nlprt'ssi(,n ''''()oc! is ctr/"().k:RIh(' ~dill, rCOi;U,,'liol1
\\00<1
u:;uaIJ)'harder - b," more brittle al~o ~hrink~ 11 ;11, 111(>gr.lirl- 1('
- ll1'111OOrtrull. (You may bave lo 20 liln('s nlor,, tilan l10rnlnl
1

\'VOI>.i>nll

rh

conlain rt'tlction

'\'Hm.

E\'en a

rc'ptJlablC" lulllbcr (h:illt'r ,,,c>n1

ifl1t'~S(~llingyellJ rc':lclitln
Wf>O(1.So iCY(lUclornn into ':oo(lmc,'.
kll(l\\"

it'~
bt:st. n~.lttl ust it. "r .~,~,(~Ul
it into \'c:I)' ~llon I"il.~c~'S
(or small
projc:<'l,,- (1ryour Iir4'\\'(HXII)ii{'

Nn. i4


RADIAL ARM MITER JIGS
'l'/i111!lll'lfrl'l

"!/(J. 1'114('/'

(f1(/i/,1 (I J )11IIII/""j'll'

(f

""t ~ I'>IIU~

'/",. t,l flf. "",' 'I'Jlt (/f~rl',IH'/'"

Wood-euhh .\'" ";,1 /Jltl',f!f.llfl
,.",'I'II ....
(:l'I (~ft' "",I/,f,
frilltlflll/',"
Ilf't,l. ~r"'It'c,J fll/((~(I IIIYIIYJ(J(/
hf,:x. l\'''ttl'~u ('(/t'(Ju1tl!l1. ,,,'

II"

,"'f,' !I",c/f' . .:. rl',""""'{'

.Ii Ilrl-.I.,'.I"'tll,I('J.,'i"JI

ir

U'llItl nU(6/

/t "'/~'!(fk,

6tr~!Ulrlk't. \'~,'IIII",t

Your question bring~ up what

fell abuuI our earlier radial

31111

'~I
sists of a pair of narrow fences

miter jise shown in "Otxjif.'f)/;;tll

o. '" . Sl>(, L-'jll"
rig. _. lalllll conscrewed lu the base.sec fig. 2.
The unly di(f('r~oct' berwecn

your jig and lJ1Jr earlier jig is in

the placement of Ih~ workpiece

wh"11l'Ulling the miter, On your

jill. you pul] Ih~ workpiece
again~t tJI\' ",dHld, ~

Of

the

llianj..~,l". guid,. On tht- earlier

Ina} bl' (IIJt' uf 111,n\(I~tba.~ir 1\,HJtl.<ofI",II, jl~.lllc\\'urlqJj"'C'l~i:-

(acts 31)I.ut Wflodworking

LI,("r~"!,seldom (111)' ",,. righl

\\'U)' to de) anything. Your miu-r
jig will "orl. IItrf" ..lh ...."'1 (ur

I)ft-c"d Igain<.tltlll.;f(xidf_
orl hv (t'flfe

(_-d~l'

SITlfl' tll'~} IJ4llh work. why

build I'Iltlclrl.' ~llu'J:)1il'all"t' jig lik,~
ll1l' Oill.' lrorn \\',,,Jdlt'flliit \l).

\'ullin,l{miters \"itl. 8 n..(I;aJ ann

saw, ~"C Fi~.1 If il (h~.sw h.Il 72'! (R\,!t'r ("I)hol() abo\I.',) Two
you need ill
du'''1 d'at I)"". n:.L-,nlb - \'\1"SI1illL)r:md l"t)11W1.
For a lung time, lhfll'~ I,e)\\ I
".""',nun. I think l',mrjig

,,,It,-

and the earlier Irfl(,d~lIIil" jig

I Iikc' the ,'Xlrn control thai you

have a similar drawback -II,..

width orrhe workpiece i~ limited
(by the sa" fence on yours: b)'
the jig's second fence

)tt'l

011 ours).

BUI on the lalCSI [1'0".1.",;1/,

mit er jig the fencf's an- removable so il doesn't have this lhnita-

with an inside ~'lljdc:(like yt)1J~)

you have 10hold lI,c workpiece

tilIn. ""-"'l' pht)IO above,

very lightly to prevent 111\.'spinning-bladefrcmpulling thcpiecc

The second
n-ason fur builtling the lallosl
milerjig iscl)nlrOl.lf you've ever
I;"-nu l't);\iRUL.

had a \\(,rkpiec('

-crcev"

U\\'3y

{rom Uteguidt!.

The higher. narrower fence

011 the

when

CU11illg;t miter, you 'II know

with th new ji~,

lIaving a fenc,' on Ih,' back

side of a radial arm miu-r jig
coume r 's the pull on 3 workpiece
from the spinning blatt,. Oil PI('

lalt'!'Otjig makes th....work-

pi,..:, easier 10 1.'111>11.

And Ihal

why

means tess force is needed 10

counter the pull o( the blade.
WID".

This makes cutting

Jl1itt'n-o

IJll" radial

"lOrt' acCII-

r.lle-and

ISUMmo

IYS((OND -

arm S(j\\'
safer.

"ill.

'ThC'r(>'s 011(' last bel1efil, Yuu

can add a long (core 1<> Ih~

....c.

,Ie"

jig. With thaI and a slop bl",k.

YOll can cut It)n..:-er idpnli(..'ul
n\itt'r~ l)lan "'ilh 11ji~
that ha't' a
Jixe(l~upport,

OGEE YS. ROMAN OGEE

I ''OIIl<'() an :",ll3pedprtJfilc"n

inlerchangeable

thl' drd\\'<:r frullt':., top 111Uldillg,

and kickboard of Ihe rile Cabi

use the nlOft: cvn1111011

Roman

net Sll0\\llonpagc.j;oflhisisStlc.
', ...Il't:ling tll<' bil 10 roul Ihal

to do this.

I)rofilp ('an beo c()nfu:;ing sin('e

lhcr. aN' IWU S.~haped roult.'r
bib Ihal look
lIIuch aUk....
lilt' Clgt'(' and lIw R'lman OI:C"'.
HOW TO 1,,1.1. fle .....s how 10
leU them apan..The Roman ogc'C
hit llasa 1"'J)1,t,:rCUl'Vl' neX1l0 l ht

."'1)'

)'UU

CQuld

ROMAN
OGEE BIT

y()U

FENCl

NOTE: .our
ROMANOGlE ON

ollee 10fonn nn ogee profile.llut

(DQ( 10 PRODUCE

OGttSHAPt

"luSt 11(lld lile

\\'c)rkpicc(' t'-Cl'ti(,rlily on lhe

router labl,'. se,' fig.3. And Ihi~

can result in chipc)llt on Lh~face
Wlltn (.'Ulljl1gacro$~ the s:rnin,
I "SE TIU: RIGIIT urI'. The r(,(,

ommendcd (and safesl) way 10

rou' an

Og{.-'e is tll~

traditional

way - with all ogc,<:bil. _Fig.

1,,-arill1l.sec rog. I. An ogee bil ~. You "un rtlul Ille workpi('Ce
11(.1'5n ('("It''',,,, curvt" CUnmll{ uff flat "n Ihe route,' lable or hold
Ihe pil!)1 bearing. see Fill. 2. ~ Ih... roult'r (n,.,haJld, 'n,is WOl'
,tn (JI-!t't,' bil cuL....lhi! n"Ver'!"{"or tht
you hav, bcuerconlrol and lIel a
~rolil. nil by Ihe Roman agee.
deancrcul. (Forsourcc~ofol(ee
1~'''(.~Jlf~
,tl~ bits, cul rC'Vc!TSe bits, see Ahernale Cal.lug
lin-til. '. th,'\ are lheoretically Sourc.,,; on P"..~"31.)
"11,

,
l--..I1
1

ROMAHOGE[
an KA$ CONV'tX

waVE AT iEARJNG

OGEE 81T

NOTE:

USiNG OGlE BIT,

ROUTfOOl WHH
WOltKPIECf FlAl
ON1AIU

ftHcr

OGLElit
HAS CON'C:Avt:

'UflVE A'f IEARING

OGEE

19

S HOP

TIP

CONTEST

Clamp Organizers
E

\,~rybodYthinkshis shop is
100 small - at least thai

was lilt' opinion expressed by

most cf the entries in the clamp

organizerconrest (anneuncedin
WOOlf.", itb No. 72). The phrase

used

ll\O::,1

often was "in order to

save spac(..... So lhis had :l

major influence On our thinking
when ,\\'1.:' chow the winners,
It

Beside-, Inking up lillie <pacx-,

Ihe clamp urganizvrs
we
s;,lecled are also adaptable 10
any numb." "I damps. They fil
mO~1common typc...~ of clamp&
and lh(,}"r() t.-a'S~'to Cf)n~l'\lft.

SLIDING My" RACK

Sonl(~01 the least used space in
most shops is right underneath

Ihe lOP of the workbench, And

the :.lidiJ,g ....1' rack sent in by
Robin Coggeshall of Fowler,
Illinois lakes advantage of
thai. see Fig. J.
SUJJf.;, LiI>t>ERBENCH. Tlns

pl~'Wvo(11- rack pulls out (nl'l1

undcrthcworkbcnch

on a pairof
t-shapcd runners. and gives
t'a~)' Rt'C,'$S let the clamps, Then
il slides back under Ihe bench
when 110t in use.
The "T" rack i:o. ,litacross the
top and about 5" high. It's the

same length as the bt'nch top is

wide, and it holds an assortment
01C-clamps, s~ring clamps. and
hand screws,

SUDING "T~RACK

WORKI'NCH

CCLAMP RACK
Cdamp> are among the IIIQst
difficulllO orpnizf". They (.>a.,il~
(all off hooks and bar racks. Or
else you have Iu tiKhle" and

loosen them to J(d them on and

off Ih, rack.
Our favorit(> design for C
damps gets around these problems, It carne from MOITi> Lef
kowil~ of Carnarill, California.
see Fig. 2. 11"$dc<illll,"<I to hang
on a wall over a workbench or

$CRlW
RUNN(~S
INlOlOnOM
O'SEN(H.

"ItACK SUOf!
OUT.OR
ACCW10

ctMU>$

set-up table. The clamps are

loadL-d mouth down 311ht>ba,'k
of the lilt~-d table or rump.
-CRA\rrn'" FEED.The ramp is

lilll,<1 10 down at the fmnt (,;;'t

Fig.2a) sotheclampsslide down

the ramp to the lip 011the front

edge, To remove one. ju>t lifl il
UI> about It.!" and lUI it CUJ'Witr(1
Itlcks can be easily varied in
size and length 10accommcdate
your Cclamp collection,
PIPE CLAMP RACK

No collection of damp organiz-

ers

is complete without a rack

for pipe clamps. This one. from

$ 100 CONTEST
WOOD SfOIlAGt
Wha(, Ih~ best way 10 store
weod for future I'r(ljl.'CL". and

scrap from pasl proj<,<:I.5?If you

ha~ a good slorage $~"I"h1for
lumber or plywood (and other
sheet matcdals), tell usabout iL
\\ e'll tJublish the best lumber
non plyw(lQd !\IC)r;ll(" d,,<:ill11s

and ideas in upcominJI issues of

WtlQ(].mi/iI. Winnrs will re-

ceive $:Ion and a \1'(II}.J,smil/l

Ma.tcr Try Square (lupliGatc

er sinular entries will be consilk-red in the order we receive
them, Send YQur lun\lle)" and
pl)'W(I(ld.["raKe id"a~ (poSI.
mark<l'd nil lalcr lhan :\13Y15.
19(11) [0 Shop Tips COlllest.
W(I<I(I.",iti(. 221)0Cr:wd Ave.,
DttsMoines.lowa 00312.

10

Corky Gipson of Pn-scou, \\"i$oconsin holds pipe damp, or -1bar damps. see Fig. 3. \\'hal "C'

really like about this rack is its

simplicity, and tJ,at tJw clamps
can't accidently (.U off.
$1~tPI.F. Ao"\l)S.\J.-r.. The rack is
made from a 2><6back plate and
Ix4 (ront mil separated by 2"
spacers. To hang a pipe clamp

TO

..MOVE,. un CJ.AMP$

ova UP

AND111T'ORWARO

CROSS SECTION

PIPE CLAMP RACK

...

011

the rack. just turn the damp

head sideways and slide it up
Ihrough the gap. see Fig. 3a
Then give it a quarter turn and
set the head down on the fronl
rail.see FlK.3b.The clamp hang>'
securely, And you don't need n
lower rail to sUibiliz~the clamps.
TI,e rack can be made long
enough (or any numb~r o(
damps. We lound Ihal l"IJuing
.hallow dadocs aem<s Ihe 101}()1
Ihe tront rail kepI Iho clamps
ncally spac~>don Ihl.' rack.

DAOO(S K((P
ClAMPS N(ATLY
SPACED

1't

V"T

a.

SUD!
ClAMP HEAD -

UP ntROUGH GAP

PRl"}JECT

SUPPLIES

Sources
Vogi (I"") slideswe're otf~ring
below arc' rated 10hold 75lb$.
77-1210 2O"-Lon~1(\' Draw"r
Slide.", \\1Ih ~hHlnlingScrc-w,;
.
'69"an( II n$lnlt.11('n~
";
) pair

OAK FILE CABINET

\\'OOdsOlith Pn>j~('1SUPI,Ii,'S
is "Ifr'ring a hardware kit lor the

Oak File Cabinet shown on llage

6 Thekil includesthebmsscard

\'ise

holdersand dmw"r pull, in addl

In the I,huiO ""!lag<' ll'. a QukkK(*h,'d~

R~QrdNo. 521) \'isc is

.it}" Ie' (,111 (''<tf-ns-ion i'tt~tlrid...

drawer slides.see photn.
A ;\01" Abolll The Slide" \\"
~lr(,nJ(I)' rvcommt-nd that if
you'n- building the Fil. Cabin,'t

shown mounted '" LItL-bench,

This c:a~tiron vise i:-: avaitabk
from\\'oodsmilh Project Supplies. 111('[aws measure T' ,\idt
by 3" high and open 10a (,,118"',
~1(lUnling instructions arc- ineluded (1'101"' Hardware to

you U",rUIl,'Xllo.ion.silent ball

bearinj, -:-li(lc$ SUCtl a .. ,hIISt'
made by ;\("'110(1(.', These- anfirst-class !'OJidf"io' tharatlow you lel

77 I-ISO Banging r'iIL', Packmount the vise and woo(l(>f1 )a\l,

Ilulllh(: drnwrr all thl;" \\.'a)' l,"1 tCl .","f2:'. 1'I,,"'i, l.abd Tabs 10pads are ""f indudcd.)
geL at thl' la~l fill' tc.tld,r ..... 1" eluded .. '
SIO.!lSp"1(
766102 Qlli<kR..te""" J(;.....
--;;:._---~---j
cord '<0. 52D \b .... _ .__ ~'W.!l5
photo on p,lgc 32. A11(t <incv
101' I"'fl \\'4. u ,'CI (ri'ntrnll''in
th.yre load mwd lcoIIOJbs .. lOU I...
bes St._lltartJI'r,\ IJ"~CI)s,
..~t~ln
Hinges
KItCHEN CANIStER
If) fini ..ll th 1'11t.(;tbillt'l
The 76730 I .11<" S(omiConc.aJ(d,
can nil n drs' ....r wilh hl'd'~
and il "ilblillup"rall '"I1",lhl), ("'I SWp (~'al"n'1I1 is.I tun)! (Iii In... 1 Bing"". Brass Plated,
\Vondsmith I'roject Supplies
Oak Fill! Cabinet
sealer and stain (\\'\ Ciltl!il' Willi Screws
Sa.50 pro is (,fft-rirIR Ij hardware kIt l,'
7741000ak Fik-C abinct
pecan stain 3$ it ulk ...-d a lil(l'L
Door Catch
make lilt! Kitchen Canister
Ilardwan- Kil
S5!l.95 brown color lhal':- typical o( uli:... 77..1-205 Roller Door Catch
shown on page 26. lncluded are
121 Solid Hra" Card (I''''''l' 'Irk oak fik ,.,.bin,!.) The " ..... "'ilh Srn-ws. (one catch
th..... RubbL'nnnidl'olll(linlI'>.a
Piatt") Holders. 2" x 27,~'. ond step (Royal Finh.h) Is en oil n,--(-d~'d
per door) .._.~.$.75t'a('ll rull~il"t' pattern (J( lht: case lUP
f\rtlss ~Iounting&r~\\ s
and urethane top coat,
Mounting L--BrackeL~
(only). a piano hinge. and oak
C~l SoIi,I Brass Drawer Pulls, 761-5()3 S..lardl (P~l'l1nl
;; 1-208 Mounting 1.llrnckscrew hole buttons. IThls kit
-.I ! Cf'nt~n;...IJrn~'"!xn;'\'\'s
Slain and SIoalrr..........$5.95 pint <'I,. (1lICS<' are USI!d 10auach
(loe51ltll include \\'(l()() or fini~h.)
(2 pr.) Accuride Full Extension 761502 koyall'ini$h Oil and Ihe bench top 10 the cabinet s.
Kitchen Canister Hardware
Filc' Drawl'f Slid"", 2U" Long. Urethane Top C".I .....S~,-I:,pinl \\ t' n'('OmD1eJld VQUu'St' (t,ur
774 300 Kilchcn Canister
Inc)I,d.:s ~l()tlllliIIR Serc"' ....
brac~l'I' p"rl'llbinN.), \\llh N(}. Il.,dware Kil
Sl!l.Y5
SHOP
CABINETS
AI1(J InSl~dl:~lion
In:-;!nl\'liun~
IiX '. " 1-1, Se,,ws
S.30each (3) Rubbcml:tid s."o'i" Saver
FI(S. \\'c're alS(l()fftrin~$("P'
Y"u can build th.. Sho"Cabinels
J'\lur Qr In(Jrc
$.25~a('h
Comainer'S. Hold<6CupsEach
arntt'l~f rul' rrnnll~'"to fit Illt.~I-ilc shown (tn P'llo!(' 1g in :l \'aril'ty \)(
Drawer Slides
(I) FullS;;',, Pnt><-.,l'slIcm Of
C,anin," an(1It'ller ~I.l'Ilanwng <'tmfigurnlion" ~I \VoodSD,ith ).'(lI~: On pag" 22. w<, ,howl-d
Co,,, Top. n~
,". 18"
filt $. St'(' jnSt..~II;hoIO.
Proj(,(,1Suppli~si."ff,'';nll tlw Itv\4' ttl mak,< w,')()dt"n drawl'r
(I) Rrass-PlalecJ I~an"lIin~r.
762106 I~," Fr.mw.l'i" U,I'
llardwarc you 0('\'(1 as-llf I~'m'( ,Iide, ("r lit" Shop Cabincl$.
1),1"..." x J8'. "'ith xrt"\\"S
IcrSil Fill!labin~l. (Order
ilttl11S 1I1s(<<;>;tcl01 a kit. <.: h4l(tS(' tll('
could .1""
mClal sidl- (8) Oak Sere" IInle Billion"
onl' P<'rdrnw.'r) ........$..~.!l5<-adl il(,Jn:, tel fit y()ur nt->('(I.s,
m()untf'd ,lidl"~,TIle KnUI)(' &
~1u~hr()o'llt)rpc-,
1-11~.t>"Hole

fil",

'"u

ORDER INFORMATION
BY MAIL
SYPHONE
To order by mail. ~"" lh. fonn I'Qr f;J$l~S1$Co'k, u'" ourTolI
enclQ'SOO wilh a CUITl:nl is'SUc. Fr.", ordofline. Opt'" l\londay
The ordel'I(IfOl illdlldl'S infor Ihrough Fri<lay. 8;00 AM IQ
!Mliuu OILhandliJIg and .hil" 5:00P~I C~ntnd 'lin",.
pU'g4w'ges. <Il1~~aJes lax.
Bcfor~ calling. hav" your
Send your mailerd(,-w:
VIS". Ma~er Card. or J)is-

cov~rCarQ rcady.
\\'oodsmilh Projcrt Supplies
P.O. Bo., 103S()
l)es'l10'11(", IA 50306

L_
No. 74

1-8000-444-7002
.\',)-tt:

/>1"1r'f'A

~II)tY'Ill',C'lltN!/(f

.r~..

f~n('r

I... 1[;91

u..,

ALTERNATE CATALOG SOURCES

$r ",ila,. "tlro/tUI'f' a",1 s" /I/H il'l' III/I!! bfjO'; I,d til t/lf InlIQII~iIlg
II !I /llrll
r(ff(ll'Jfl nr "IJm-r",lhu".

<"llu lug:-" ['I, 11:<1/'t~r'{4/rrl1 c'llu'lin

\Voodcraft

COOSlaI'ltille's

800-2n.tlO87
~(i(I,'X-,HfU{Ji')i, ,.,:'i#:'.<f.

800-22$-1153
8/1/(/)'1.,

C;ri2Z))~Impon:s. tile.

1100-:'>11-5537
(Jy('l

(r"tlt'IIJllyJ

Trendlines
800-767-99'.)<)
SI i(/e~.JJlftt~J"~

B,t. \ ~',"'f'_jl

SI"/t'1t. "iNfs,IJullu"ii,

lbc ~'oodworkers'

Store

612-12~2199
,r;;Jitl,'l(, J-'iJfl.'tjU'X.. J /;I'!Jt';-,

~ 'i"(~"

\\'oodworker's Supply of NM

SOO-S4S-92\Yl
Slid"". ()[I'~Bit.!1

"'[1''1.' ';'PX
31

LAS

LOOK

Final Details

" IYhen 118;119II panel of Jfa.""it. or pl!l"YXHI.

the MIIbtello>! Q,!dgrool, jo;IIt iSIl.1 ''fJlIg .e a"y t..
make allernatit"6 In II mo,1isf Ctlld teno. TIl;
18 sized.to hold the INIOl< wul ilte fJ'llld.

(1-'"

iHla.l,d ,,'or"'lx'IICh lltlO<11'

/rol1'/nu,rO/Olirsi"gtt .~Itt)J'Ct,b,,,J'/lj, l "ldrrlll;
bf'"rl, tell), a vari, til (I}'(I",,(,. nt n JI(I d')(J"" p",t'idt
4

TJli_f01tn/(!T.jtf"ight

atn/)If

~'''r(11('/".

Oak File Cabinet

Kitchen Canister

" FI'OIIttllR.otaitUio'ltrold-jasilioneti Oak FileCabillei lookslike

afineantiqu. But on the inside full-exttm8ioll dral_ .Iilks/wld

.. T/,i3 solid (#,k ra"i.od..-rl(~illln()k grt:(l( 0), ally

kitchrn
To keep 1",1(/ fresh, IIlPrf' nu

lreatyfiles n"d aliolcllccU8 tothe LV!ryIQ8tfiiJ!.

32

I{tOY'fI!/C ~(t"""JII oj

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airlig/,t pl(,.,tlc rnnUJillpr undrreorh rid.

Woodsmilh

No. 74