Professional Documents
Culture Documents
75
$3.95
EDITOR'S
june, 1991
No. 75
COLUMN
Sawdust
Editor Donald B. P.,...bke
Oe<lJIIII>inct....Ted KnIIjeek
Managing EdIt.". Dou~
(.. Hicl<s
MsociateEditor TonyJ. SbvIunan
,,"";~IIF.dilJ>'" J"",.> ~1.
Dolan
Richard S. P"'_
(,,,,rdon Goippe
Proj-.'d OelJIp....r KeD Munktl
lliUSlnloN>D.. id KreyIing
CaryChriste~n
Rod Stoakes
Chris GI....... 1ri
Dirk Ver Steeg
Kurt Schull%
CirculalionOirec;lJ>rIJzBred.eson
SubscriptionMBnager Sandy &um
:-r""...tBndSales Kent A. Bu.kton
Grophlcs Director Jon Snyd~r
Projo.'CI SuppUos kslit Ann Gemhart
UndaJones
Wa.rcl1ouse J~ carson, Supv,
GlorinSh_n
RolUlld Long
Dnvid StoUI
C~Qml...SI,_1"Vi.ce-Mgr. UncL'l ~torrow
CustomerSenice Jennie Enos
Janice. K.et$tD\'t!:
C en e1I. BraJl'lOll
Mi. Smith
Robertll RUM!)
Jo)' Johnsen
J ITi.Jyn Pross
Jelln My.....
"L~
conference center
In the process of remodeling, we decided
10 tearup parior the ",,<kinKlol between the
two buildings anti put ln agarden.It's filled
with flowers-annuals
and perenn.ialsand
roses. And there's. brkkwalkwayand patio
area that .igzag. through tll~ garden 10
connect the twu buildings.
So, what does all of this have to do with
woodworkinll?
The patic is a gnoat 1)1a!:~I() relax, But
there was 110 where to ,iL So last year we
built some outdoor furniture - an Adiron
dack chair, a malching seuee, and a patio
table. (The photc on the cover o(
IVoodsmitl, No. 69 shows this hlmilu"... jn
tile patioarea in iront oftltc.;arriagc heuse.)
I had all the best inlenlionsor mOvillJllhi,
furniture inside last winter - bul didn't
quite make it before 111('fil'S1 ""'ow
\VeD. I thought. maybe thl> is a good Op'
ponunlty to see how .....d .. ood turnltunweathers the winter.
\Vood,mith
w.
No.75
LOOK
INSIDE
Contents
ITips & Techniques
I. f4l
Six tip from fellow It'oodworker.~:
L!J 11 Thi/'d Balld/il/' I1/oullting
1)
IPatio Table
I f"6l1Ve
built 0 uniqu.e octaqona!
llsing two tlifferent toood -
.....
...J. ~
/Xlge 6
table
Cal-
IAccent Lamp
t,""-""'-
....!..
11121 Nolhin{J
/'ightells all area like a
lomp. And all
need 10 make this
!JOlt
...J
Aaent
IShop Notes
....
__
...:..
111611)Beating
Shop-Built Kerfillg Jig. 2.1 Pilaf
TI'(Ic/'x.il) Clalllping Solu-
...J
Accent Lamp
page
12
IRedwood Planter
1.
1181 pa,l't
Tne detaite ot theromere ore ontu
of what makes lit;,; Red uiood.
Planter (/ ('lassie for the qnrde or patio,
In keflpillg with the 11'111/;1;'''111.1 lank, it'
IJapanese Saws
1.:.
:,,:::,!~:":":'::"::"'~':"'_':'___
11241 Thel'e'SlIlo/'efoJapClII/iSeIiClII-'stholl
razo II a tp It,
It '110 II
..J.
1'1t
tl'l'(
I{'(, It 0II
I(
IiII'
II)
I Sawhorse.
i; ~_"":"""':"""':""
11281 ('on
The results a,'e infor Ollr
test. ,hid the toin.ner
Reduuod Planter
~(tl/lhOI',~1!
...J.
are:
(I
ITalking Shop
.........:.......:.......:...!:~__:.!:....
..J.
1301H(/ll'
do !lOll refiuisl: outdoorfuruiIIII'e? And hall' fa prevent S/I'pped
tenons toheu culling 01/ 1/11' tabte sal(~
1 Sources
11311 Harduiare
and project su.pplle
neededfor the projects in this issue.
Japanese
No, i5
SCUI),~
page 2.1
FRO
FELLOW
WOODWORKERS
an ordinary
BLADE GUARDS
"lhird hand: see Fig. L Grasp
the cutting end of the router bit
in the clothespin. :-low set the
clothespin on the router table
with the bit in th, COUCL
Then adjust the router height
until the desired amount of the
bit is in the collet. And tighten
down the bit, see Fig.la.
lJo.,."rrl,1f R"I/II","
clothespin as a
Lo"cla>llL Colottu/o
o.
JOhl1 SU"tQ/u'"
B tt~Jla"(I
It. Tl'Ill';S$('r.
tHIRD HAND
I use sawhorsesfora variCty of hangers. see detail. Auach the Ihad a hard tin'" setting the
[or those times when my bench the miter gaUlle on test pieces.
is 100 hi,l!hand the flooris too low.
Here's how. First. (.'tI1 a piece
/{(II';11 ll"""ght
Q[ scrap in two aITlvl'.Then. to
Tr- '11(111" J\'I'U' J')i'~ell check the angle. place the long
,lf~tJdlllOU"',
(1IIt(,
I
~
.,
or
SECO!"D:
,..__
V
/~
~
sUO(
'N
-;'tl-\
.... TItWIGU
t
~
-w
... r-- ,:
\j
I
.-'"
I!lP
"H(r
f1"ST~
PiAClANGl(D
OGI'S lOGmwt
AT 22.)", ANO\.i-
I,
.11
No. 75
ROUTING
MULTIPLE PASSES
10 rout some
"'l'-dcep
a.
spacer (made of Ma
sonite or plywood)
~ig.
1b. By removing the spacer,
b.
fiRST PASS
SECOND PASS
(<<MOW Sl'ActlIl
WORKPIKf
W(MU(Pl1CE
[0 change the
depth of cut on the router before
making the second passs.
To make deeper groov..". use
1;\\'0 or three spacers and remove
one after each pass.
Krill' P. Broun
De" ,!,lle,
.,fpl"
,/pm(;"
TABLE LBRACKETS
base need slots perpendicular 10
butcher-block style, solid wood table top to move independently about S4.00 for 3 36")ong piece, the bend. see Fig. 23. Slots in the
brackets on the table ends.
top. Bill [ ran into a problem of the table base.
the shortest Icould buy.
But the "L' brackets sold at
What makes il ideal for table however, should be parallel with
when I tried to find brackets to
attach the table top 10the base. my local hardware store don't brackets is that there are holes the bend. see 1;".2b.
To make table brackets, cut
\Vood expands and contracts allow (or any wood movement. opposite some of the slots. see
across the grain "ith changes in So I decided to make my braek- Fig. I. To allow the wood to th~ sI~",1angle with a hacksaw
humidilY. Since my top is made ets out of sloued steel angle. see move across the grain. the into tVl"long segments, sec
of thick solid wood. I needed Fig. L 1be hardware store sells brackets on the sidesofthe table Fig. l. '[ben screw the brackets
10the table base. To attach the
top. use a screw and a washer in
1
,2_J SlOrs.N
each sial
r-
nI)
eAACKUS
AUOWWOOO
TOMOvt
RU88AlfJ'(UIf/pr
Cle~(,/u"d. OMo
SIND IN YOU. ftPS
or
tip
idea, just send it to
lI'ood.miJ)., Tills and Techniques, 22QO Grand Ave.. Des
Moines,Iowa~J2.
a.
NIl.
75
lNO
81lACKn
Wood.mith
FEATURE
PROJECT
Patio Table
It's nor JUSt rhe shape of this Patio Table that's unique. The joinery that
goes into buiWing rhe table is similar co what you'd find in an indoor table.
Yet aUthe joints are made with just a table saw and a router.
No. 75
EXPLODED VIEW
OVERAU DIMENSIONS:
481/4''W x 29"H
c:iY"
j/
, I=~~~
SPUNE
-SLATS
CROSS ~
BRACE
~.
~
1J
5~5~==;::::==;:)..._:~Y
--.
H KEEPER
STRIPS
ARM~
G
r...,...~
NOTE:
rs ARE CUT
OvtISJU. THIN
TRtMMfO to Frr
...(y
$l.A
CROSS SECTION
flAT
-WASHlR
LEG
CROSS
IRACI
FOOT
~
CUnlNG DIAGRAM
MATERIALS
TOP
A F,ome{8)
8 ClOSSBtoce a)
C SiaI.(4)
o SIa!s(4)
E Slats (4)
f SloI5(4)
G Slols(l6)
II l(ee;:>elSlIips(4)
1 Splines(S)
BASE
J Armsa}
K Feel(2)
l tegs(4)
MPods(4)
'2
1',x4.:!O
11?x.4A61:.t
'\1,.2'"
9 Rgh
'II. X 2'~'12ilgh
l;,. 21<& 14Rgh
'\I 2'-t-17 J?gh
11k.4 26+.
'x~.-4
SUPPUES
(4) <t.. Thcd Insem & 1",' Mach BoII$
.( 16) '8. 1'/,' Fh WOQOsctEolNS
.(1lO) -6 x l' fhWOOdsclews (64)Brods
No. 75
Jt
I.
It ,11..,.. )(
.2
S,,,", 60'"
.' :~ ,.".
{Two
Boo"
[.,
ft.,
' ~'
Ia
l
!Z2
c~,
...x 7' ."1.
re ;'
t:-4
I g i ! IS i I
1.'
.
11,.x-71 ....r- 96" (S.3 Ikf~Ft.,
"
k'
lv"zu,t
.....
'2.411
S lid. Fr.loth)
I ,g
ij
G
G
TABLE TOP
The lOPof the table
fRAME
is an eight-sided
frame joined with
o.
-.O'----~~
I"
spliced miters,
SECTION
(ooHTNlmm)
~~~~~=
~
,.
frame,
a pairofimer'
To strengthenthe
oreat" foW'op<'ning
that are later filled with the top slats.
11.'~;i:"i~.
TOPFUME
.~
k on II"!IOPbycullmge",
;,.,.
Startwork
..Ifram I'
sections (A) from a 2x610 [OUIl" lengths of
22" Then rip these 10 finished width (4").
22',,' ""'..._Ii<;""-
-,
....... OH
80111 11(0$
,,:1:::
\
ROVY-POCkm-
'0'
",'.-l ')~,
I '
,~
.....
I
~o'
--1
10
WAXED
PAl'1'
t
s=r
,,'
NOTE:
UPSIOf-OOWN
ONPlTWOOO
WORKSOMAct
~~_u.-
a.
APPtY OlUETO
LAP JOfNlS
CROSS .IlACES
li~~'
~~~:._~~-=l~~[~
__~:::::=~;:=~~~~~~
PlYWOOO
r-:-r---:;;;;;;;-;;;:::-----------::;::::=====;::::===;::::;::::"l
cuno m
is cot on the
top of one brace and the bollom of the other
\SS~IHLV.I assembled the lOP upside
down on 8 half sheet or plywood. see Fig. 3.
Spread some plastic resin glue in eacb saw
kerf. then add the splines. (See page 31 for
more on outdoor glues.)
Clamp the frame pieces10the plywood as
you work your way around the table, Then
glue and screw the cross braces imo the
pockets, see Fig. 3a.
TRIM SPUNES. Once the glue dries. trim.
the" sand the splines!lush with the inside
and outside edges o(th~ frame. see Fig. 4a. '-
0,
ASS(fI(IU FItAM
-1'0'
3'
'=-:i
i 'bn ,- :
NOTE:
. h-
tions
2',,"
.6'~---
' . rEf
(ur~FOa
HAIl W'$ CQ<ItlllD
'...: c' :.
..
__"'2"'12 ___
r==:
'
f
JOlt SPUNIS
'....
.'
.__~
~===========::::J
CROSS BRACE
o~
...... -..;;~;;;..
CUT'''''>Iot ... ,
clNn...,ON Tl4OCkN["
IN FOUR........
5(~CT1~IO~N~$~QH(~"!_
.'"
SPUN<
SHoULD lX1'I.NO
N"I'OHO IOTH.too-u
OF ftAM( stCJ10HS
0'
/ SAND
OR....,.._
ft.U$K 10 1NSIDt ANO
OUTSrMllAMf IQGU
--1
\Xlo<xhnllth
No. 75
TABLE TOP
C'-",r
EO
v.r
ROUT ,,"
ROUND-OVUt
em 1NSIDt IDOlS
NOTE:
Of OUt-SIDE tOOlS
ROUT ~.
I,,"
l.[OO[
fOUR OPiNJNO$
10
SLATS
.,
RABBil
i- OfEP AROUND_
CROSS SECTION
.ono,,",
fAC'l' UP
"'00
.'~
NOTE:
cur
tcl(PtJl STili'S
to Fff ACftOSS
(NOS Of SLATS
>'WI........
TABLE BASE
When the tabletopis
complete. work can
11
ARM/FOOT
BLANK"
Q.
..,..-
NOTE:
OWE UP nlRtl-
~
'\
_::::::==========~
,",
..0--31.,..,-....,
L
_:~
r---r-------------------==-=-====---,
12 NOTE:
c- _,~ 2'"
O':.":~
~ .=.s
ctNn. fOOTe..
.....;J
i" ;....__..".
__- _
UPON OOlTOM fOOT
FOItH~W'ON-~"
lACHfOOT
.- .__.-
_ .... ~,
......-"
).
IFEn
Q.
13
14
Q.
v,
fOOT
fOOT
CurTO
..__
-fOOT
Q.
...
_L
NOTE:
[0
?'
45'
No. 75
TABLE BASE
COI'.rINtI"O
ARMS
To make the arms. start by ripping the remaining glued-up blank into IWO lW'thick
pieces, Do this by fin;! ripping one w finished
size. then ripping the other to match lite firs!.
Note: Unless your saw can CUI 3' deep.
you'll have to make LwO P3."'" 10 rip each
arm. see Fig$. 15.1 and ISb.
IlAl.F.1AJ'S.To cut the notches that form
the half-lap joint, first lay our the position of
the notch cente re>d on the lc.lIR\h of one of
lite arms. SI'e Fig. IS. Then cut the notches
using the same procedure as on the feet.
CHA.\lFER.When thi- arms are cut 10
finished si7'<:. CUIa 45' chamfer across the
ends of eacl m. J\gain. orient the chamfers
in relation to the center hnlflaps. see rig'. IS.
ASSEMBI.E & ROUND O\IF.R. Now glue and
clamp the arms together at the lap joint
Then complete the arms by routing a V,'
round-over on the lower edges, see fig 17.
LlGS
To make lite ~
15
RtplACHAIM
a'r=,..!!:IN~fWTOT:!A!!:S$!.:"~I...._
I....
..COND'ASS
b PROOUCiS
ONE AI.M
a
NOTE:
1OT10MINOS
Of AIlMS AJt(
awnRNOTCH
CHAM......
-'OR KALFlAP
ON f.A.CHAR.M
16
r~,,
LJ,r-t
..
17
.....
I'..'_'
c'
<D
LEG
ONLOWfR
26'."
fOGES Of AIM
AHDUPPlR
tDGESOJfW
'0
-'--
AnACH
THE TOP
3'
_t_
1~ ~- _.,.J
31.,-
ROUT ~~..
ROUNO-QVEIl ON
AU (oots OF lEGS
b--
1.'~:::lJ--I'-P:'>:::;:7--I"",,,;::-----::=========:::::l
TOP fACE UP
a.
.I.
r<:;,e;~
r"""""'~~;;:"
No. i5
I!AS( ARM
arossluCU
\V",>dsmnh
11
WEEKEND
PROJECT
Accent Lamp
There are three challenges to building this lamp - getting
the cord through the post rapeling a short piece and adding decorative
strips - and all have surprisingly simple solutions.
I
12
\XIoodsmuh
No. 75
POST
I began work on the lamp by making the
tapered post, Insieadof using solid stockand
drilling a hole the length of the post for the
electrical cord. it's easier 10 glue up four
pieces. S(>(' rig. 1.This way you can build in
a channel Cor the electrical cord.
r-""'T---------------------------,
,., .. 1tMPOAARY
a.
POST SIDE
s-.
..---
__..
SPACER
'."
....
10"
DOwn
2"
2"-~~
a.
ft.'11CC. you"1Ineed toclampor screw an auxiliary fen", 10 II",rip fence first so the post is
No. 75
.'P
f'(Nef:
.,
,:
..
'."
t.
..""
I
TA...
JJG
i! :
J '
.......
,,"
1,1.....
0(" CUT
NOTE,
ANGU MrrtR GAUGE.
so 10TH rOGES
Of POST 'OUCH
,_ .. 0'.A00 &lADE
FEN ATeO'M'OM
SUPPLIES
MATERIALS
OVERAll DIMENSIONS (WITH SHAl>E)
ll'W x 19"Hx 12"0
A Post Sides (2)
x2 . 9'.-2
& PostSpocel$ro
1,'x~.9""
,
2'", <W6
o f'OO'IeI'!eces (4)
'h xl"
E F&&I(4)
,.
1-1
.7
r
L
(1) LQmp$hQde
WooJ,mirh
:. I
(4) No 8x ~ AolneodWOQdsctews
(2)No.8x 11;,'FlOtheodWoodscre-.",
(l)Conof~I'SoII"CIeo<Wood
rll'liSh
11
LAMP BASE
Once the lamp POStls complete. work can
On
begin
theplatform
base. The
up (rom
a !!tl"thick
thatbase
sitsi<built
on a Vz"thick
_.-I
14
_.- ---
1-~---':,,:,!,",~2~'~'-;-~-;~~~
~ t
2',,-
"'"'"
WIGTlt
"11'00fOR
-'-
""AL"'"01 CIIt
--t;T
@--
PIECES
MtTUONE
..---::::
j..
11'l'r-
I'"
:/
-,
fRAME
PIECfS
.,...
..-I
-j
r-
<L.+_=:-=~
____
-r-
k:
,-""PLATFORM
SlIP!
... 30"
~ 11"1"'
"'"
r-
....
,'1..*
STP 2
_Of
SlOP
fIlOCl(
I
IUT1' ~K
AGA,lNST
STop atOQ( Af40 ADJUst
FENCETO WI JIIKf: to l.INOT'H
NOTE:
aoTTOM
HAll- OF 'ENCI
and make unother cut, 'Iheo repeat this-procedure (qrthf' remaining pieces,
CL1' ~'R.o\.\1PIECES. To cut the frame
.,'
WASTl ......
9
Sf(
&LAD(
17,..... K1GK.
THlHllU
TO 11"
a,
%lao
CI..UdtA.NCI:
1NSlRT
I,'
11
."
a.
ROUHO-OWa
..".
.-
DIULLHOUS
" fROM
INSlDE lOGE
Woodsmllh
N.). 75
DECORATIVE STRIPS
After the base is assembled.the next step is
to cut and miter 14"wide decorative strips.
The strips fil in the dadoes in the post. and
around the shoulders of the base, see Fig. 12.
I chose brass {or the strips, but you could
use thin suips o{ contrasting wood. see
photo on Conteots page. (For sources o{
brass. see page 31.) Whether you usc wood
or brass. youll need five VI6"lhick strips.
each 12".Joog.lo make one lamp.
MrTERnG.Toaccuralely cut and miter the
strips, I made a simple jig. The jig has a V.
wide greovealonz the edge 10hold Ihe strip,
see Fig. 13.Then One end is mitered 3145'.
and a shallow kerlis CUi near the other end.
(j: :~-
13
12
STIIll'$
I-~
t.....
J
\
;:_:::. - ~
. l~
r
15
a.
l-
AT SUGKf
, ~
ANGt,,(
(NO
"
t-
'"
ANO alFft"l
fa <.RUn
COMPOUND ANGU
.e.
.t:
"l
a.
'.IWU'
f1
./
<,
~P"
CHECK
RtNG_
Ern
CLAMP STRlP
_..
c--:
..
ru
~(>
00'"
s:
1,/
G'~
ASSEMBLY
I(
6~~~
.-;t
aASlSTRlPS
14
STlUP ~
rt /C.. -
.__
IoIIT"JIG
IltMn(.ON
IN.'''
PUSH
otJTtR
SUMlNTO
aASE.m.
WIRING 1$
~I
..... :;>
PI"
n,.HeTOOI
STRAIN A'UEI
co"""",,,
....
SCREW BASE
OHtO FIXTUA,(
'
J
POST
UNlCOlD
~
@-@
b.
PLATfORM
\.
lCCl(
.JI
it
FRAME
~J~:~ ~
:.S;:
~..j
I~
"--"~
<,
Woodsmirh
<r .
...
-
t:
1Ii -
.8xll/,"Fl.ATl4tAO
WOODSCRtw
NtIJ
15
SOME
TIP
FRO
51-lOP
OUR
Shop Notes
KERFING JIG
With thai much blade ex- mitered frame sections, The Ii"" raise the saw blade to the
building the frame (0" the tOPof posed I wanted my hands in a other two parts of th" jig are desired depth, Thenposhlon the
th~ Patio Table (page 6). The safe position. bUI <till in rcntrol .;implyplyv,ood strips that hold jig against the rip fence anti rut
frame sections 01 the table top of the workpiece, The:jig Icame the jig together and create a jll.1 the fence so the blade is
roughly centered on the thickare nlitE'r('n then joined with up with securely supports thC" -"""kct for the workpiece.
To make the kerfing fig. glul' ness ofthe jig. see Fig. 2.
splines that fit in kerfs. But workpiece as it runs vertically
To ensure the kerfs arc
they're 110t just any ~plincs.al(lDg the rip renee It als<) pre- the two plywood sides 10 the
thesesplinesare l"cl" thickand 4" vems chipoui at the back end of mitered cutoffs with a third cut- centered on the thickness, cut
offtemporarily held in place as a each kerfin two passes.just turn
long. \\'hkh means cuuing
the cui,
~tejigaroulld backwards for the
some pr~uy serious kerfs. (I
~L\IO"C;1lIE JIG. Two of the spat'('r. S('(' Fig. I.
I SL'IGTIIEJIG.Tocut a kerf on second pass (without removing
used a lItwid.- d.d" blade seue pieces needed to make this jig
the workpiece), see FiR. 3.
arc cutoffs from the already- the end 01a mitered workpiece,
CUIZ"d",,,.)
I11IJl into a problem as Iwas
-<UTOffS fl()l4\
fRAMl SKnOHS
Glut PlYWOOD
SlOES TO fA.AM[
CVtOm
l
ROUTER BEARING TRACKS
Alter rounding over the Patio
Table frame (J);lge9).1noticed a
shallewtrnck" leil by 11ll'muter
bit bearing. see Fig. I. \ line of
I'R~'YE'TINGA TKACK. 0 ne
y,<ay to prevent a track WiUl a
_ClOTH'SIRON
WORJ(PIfC(_
HOTlRONOH
DANoPCLOJH
RAlS(S
COMPltl$$(I)
,(eras
16
DAMP ClOT'H
PRlSSUIt(~E
rvtNlY
'rtlAN PilOt lu.RrNO
No. ;5
,,
CLAMPING SOLUTIONS
.1 came across some Interesting solutious 10 a couple Qf
damping problems that WP experienced while making the Accent Lamp shown on page 12_
CLAMPING THE BASE
The firsl problem was how to
keep the small mitered piece, of
the [ra11lc and platform square
FQAMr
ts CLAMP(D
-.
I
nJM SCAAPS TO TRANSllll
PUSSURr TO lOWUt SHIPS
REMOVING
A ROUTER BEARING
cuner from making contact with the comer of the workpiece can
No. 75
SURING
AtMOvto
17
OUTDOOR
PROJECT
Redwood Planter
This versatile redwood planter fits into almost any garden or
patio arrangement. There are four design options to build, and each has
an adjustable shelf to accommodate plants of differen.t sizes.
18
\V()(x!>mitb
No. 75
EXPLODED VIEW
OVlRALL DIMENSIONS:
....ry4
SHELFlAT
SHELF SLAT
...
0 I
1','
{~.
d:, ~~
~~.
r,
--'-
~~
CR.OSS SECTION
(TOPYllWJ
I %: ~
:/"
i~~
:'
~~
,
z
./
~~
-~
~~
-',,-:4
CROSS SECTION
IS10rVllW1
SLAT
OPTIONS:
;..1-----32h'
""'---0--:."
~I
......
t---
I"
-, I
J
'-~;;;;;fJ
"'t:;;:;:;;:::;:;:;:f1
''I ',I
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....
.1
18-',-
311.,-
25' ,.
191'"
10',,'
'
~,-",,,.III.
...L...J_
_LJ...
WOOD
A legs(~)
2J/AX21/~191~
8 !l00l$(8)
1~.2h-16'"
"'_x3\o:>11
-1'4 x 3~~
l'4x 2Y1 IS;-.
D ~lfSlols Cd)
E Cleo's (2)
II
I.
DOUBLE UNIT
1.1
- lL
'-
,w.
..
MIDDLEHEIGHT
(RlCTANGU)
MATERIALS
....
TAll HEIGHT
CUnlNG DIAGRAM
U" (31..'1-"31..,"). 96- (10.614. ft.,
b: Z2JZ'2< z lZZJZlll; ztZZZ%ltZ;"""'tZ1 'm::z&,-r~;;~Zt;;;)I7W{?Z01
2.4
b,...,.z;~n' .I,,;, ,t
I
II"
'Jit6 (~!c
51')"".'2" (3 1Sd.
n.,
SUPPUES
ITlOI1O lnIO<matton
SourCEISpago 31 )
()(l
Inshas, see
F ~ i ~.
I ~+-~-:.-+I-~:---II-"":~---lI--7~-+I--=-~__,~
19
LEGS
When I bought the
4x4 redwood POSIS lish two Oat sides that meet at a 90' comer.
to make the legs. I
SQUi\IlE. FlAT SIDF.S.To do this. begin by
..~
learned something
placing the Oauest sideof each piece against
the rip fence. Now trim a narrow strip off the
about redwood 4x4 POSISare rarely opposite side (A). see lOPdrawing in F'1g. I.
kiln dried. So they're (Because the post. are too thick tocut all the
likely to be wei on way through in one pass, you 11have 10 turn
the workpiece end.fer-end and finish trimthe inside.
WET RF.O\\'OOO. \\'orking with very we! ming the first sllip wilh a second pass.)
Nexi. 10 cui side (8). position side (A)
wood can be a real problem. So 10 avoid
having the llOsts twist or bend as Ihey dried down on the table and rip off another narrow
strip, again in two passes, see second draw
ou~ I dealt wilh the llO.LS in three stages,
l'ir$l. 10 speed up the drying lime. I jug in fig. I. Side (A) and (13.) should now be
trimmed an <'qualamouru (V." 10 W') of dry flat and 90' to each other.
Ct'l'TO I'1NISIlED SIZE.Nowyou're ready
wood offall (our faces, Then I rough (''UI each
leg 2" longer than the finished length 10 10 cut the leg to finished thickness. To do
this. set the rip renee 2V. (rom the blade.
allow (or some checking on lite ends.
NC.Xl.I put the wood aside for a lew days. Then. with side (A) against the fence. rip a
(Don'l PUI il out in the sun. or burry the sllip (rom side (e). see third drawing. rig. I.
Then roll the leg one last time. making a
process -Ihal'n create more problems.)
",nally. J lrimmed all lite posts aeain.this pass with side (B) against the fence. see
timeto finaldimensions. To make the pieces fourth drawing in Fig. 1.
Once the
legs are cut 10final size.layoul the locations
01 four mortises on each leg. see Fig. 2. (II
helps 10 mark the top of each leg and make
allyour measurements from that end.)
Then, using the drill press. J bored the
mortises VII;" deeper than the desired
length of the tenon. see rlg.3a. 'Thisway.the
tenon won't bottom out in the mortise. and
the assembledjoim willpull tOIlNhertiJ!htly.
TOdo 11Iil>.first drill a VI hole at each end
of Ihe mortise. see ~ig.
3. (I used a special
mortising bit. see page 31.) Then drill a series 01overlapping holes in between the end
holes. Now "mill out" the mortise by $liding
the workpiece from side 10 side, see Fig. 4.
\Vhen uie morusesarcdrilled out, square
up the ends and clean up the sides of the
morrises with a chisel. see Fig. 5. You can
leave the ends round. buuheuyou will have
to round off the edzes of the mating tenens .
IA\'OUT A.'iDCl T1lIEMOlmSES.
........
r-
2' ~
2',,-
t?}
;'
NOTE:
ORIU.
\1')....DltP
~
8
~~
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r
21~'-I
..
I
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t
20
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~
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~~4'r.
\C'-
Woodsmlth
LEGS ...'-'"II
'. JE!;.
OF.CORAl1\'
CVI'S. After cleaning up the ~
~
mortises 1 made a series of decorative cuts
Onlhe legs. Begin by rutting a sial around
the top end of the legs. This isaclually a%"
.....t.:
dado thar's cut around alIfOUrsides.(p
/ ~..."
To make this continuous dado. first ser ,..,.....:;;> ./''
your dado blade 10CUI II." deep, TIleD posl- ~
lion the rip fence 1~" (rom the blade. see
Fig. 6a. Sbop NOIC:Using an auxiliary fence
>,'
on your miter gauge will give you better control 01 the leg. and also prevent chipout as
'0.
you cuI Ill. dadoes, S<.'<1 Fig. 6.
Wilh the end of the leg butted to the fence.
CUI the dadoes on an four sides 01each leg.
~WI)I)I)CflA"ftER.
table.
stopped
chamfer
Utere.
the topI cut
andthis
bottom
of the
legs on
Ute 100.
router
Stan by setting the height o! the chamfer
bilsoi"sr;,~GabovelherOUlerlablc.seeFil!.
&I. Then a1i~'I1the face of the fence so it's
Hush with the bearing on the bit
To indicate the extremes of the slopped
chamfer. I mad" lWO marks on each leg.One
mark (S" from the lOp end) indicates where
10 plung~ the rOUI~rII)stan the chamfer.
The second mark (ISVi' from the top) indicates the Slopping point Then I made a reference mark: 011 the router fence 10indicate
the centerpoint of the router bit,
Now tum on the router, and with a pivoting motion. plunge the leg against the fence
so the first mark on the leg lines up with the
mark on the fence. see fig. 8. Then slide the
Iej!10the lefLWhen the second mark Onthe
leg lines up \Ooilhthe reference mark on the
fence. SLOP and pivot th~ leg away from the
fCJ1c~.SCt FiIl.9.
TOP CH,\\ltERS. Once the corner
chamfe rs are completed, )'OU can CUI the
chamfers on the lop end of each Iej!.This is
aJ$Oa :"lb"widfcllamfc:rsoy()u don', have to
th,mlle'lhe
router bit.
Fig. lOa.
To make cuning
the sec
chamfers
more accurate.lusedaS" X 8"""uarepiecc of'l""'lhkk
ply'\\'cw.rl as
10,..
~( . 7S
tHStoE
n cK
y~~
_........ -::
-,---i
li'{/L
clofAMfla
ovm..
CORNta.
o~
. J.
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UG
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e. CROSS SECTION
.'
." lfG
,_
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10
.......... ".7
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In
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SIDES
Once the legs are
cemplete. you can
start work on the
sides. Each side eonsists of two rails and
four slats held in
place with longue
and groove joints.
--I RAIL"-I started by
resawing (from 2x4 stock) enough pieces
for the railJ! (B) to I V4"thick.Thcnt"Uteighl
rails to final width and Iength, see Fig. 11.
"'_"O~~.The rails havea I"long tenon on
each end tofitthemortises in the legs. Toset
up the saw, posltien 1111'rip fence as astopso
the outside edge of a dado blade is I" from
the fence, see Fig. 12a.
Now, to create 3 centered tenon, make a
pass on each face of a piece of scrap rail
stock. Slowly sneak up on the final thickness
of the tenon until itju$1 fusthemortise.Then
the tenons can be cut on the rails by making
a series ofpasses over the dado blade.
To create shoulderson the top and bouom
edges. re-set the height ofthe dado blade to
\14". Then stand the workpiece on edge and
make a series of passe" over each edge.
TO!o;Gt.ES. Once the tenons are cut on the
rails. the saw can be set up to cut a tongue
along one edge. This tongue hold. lite slats
in place, sec Fig. 13a.The V,"-thkk tongue
iso(fnteronthethickncsso(th"rnil-it's
set back ~." from the face.
To make thetougue.the dado blade has to
be "buried' in a wooden auxiliary fence so
only V4" of the blade is exposed, see Fig.H.
"1"11 raise the blade lV." above the table.
Now. with the Iace side onne rail down, cut
one side of the tougue. see Step t.
Then. lower lite blade and cut the other
side. leaving a Vi'thick tOI\l,.'Ile.sec Step 2.
t'IIA~n"R TIlE RAlLS. The last step in
making the rails is tochamlerlltrw ofthe four
edges (,11)/ the edge closes! to the tongue).
Chamfer lite orher edge 011the tongue side
with the fence set back 114" from the bi~ sec
Slep I.Fig. IS.For the remaining edges. align
the bearing Hushwith the fence, sec Slep 2.
SI;\'JS, Arter Ih. tongued
rails are
complete. Ih~ groc>v<.fisiR'" (C) can be
made 10 6t between the rails. refer 10Fig. 13.
(There arc (our slats on each side.)
To determine the width o( each slat,
measure the shculder-to-shouder length o(
a rall (l4W') and subtract \oi" to allow for
expansion. Then divide by four. (This made
each of my slalS 3Vt wide. see Fig. 16.)
Now cut tile slats to length to equal the
distance between the mortises on th~ legs.
GROOVE TIlE SI,.\TS. \Vitll tile slats CUI to
size.cura V."...idcgTOOVein the ends lO fit tile
tongues on the rail. see F'lI!. 16. (l:ote:Offset
the groove %" from the fronl face, see I~g Ilia.
CHAMFER. To complete the side slats.
chamfer all (our edges on the (ace side.
11
"
L--_-=-__
22
RAILS
SURG. t3
(CUTOORl)
NOTE:
12
13
curttNONS
tomMOImSU
.-<::'.
c:
.d-
t ~."
,1
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UG
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114
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'ENet TOCHAMID
l'KJ$1I>O'
F(NCr
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16
:~~~
,...ct
WmtRHC[
TO CHAMlIH
TONGUf
' ,,"\'1
I
'I 2
DON'T CHAoMf'EA
'''SlOI lOG, \
THlSElOG ...
",(.
'\ \ \,
II
15
r-Qf'S(T
SIOl
OFF-ClNTER tONGur
'AC!!
4"
r.:
I
J
,,'
[,.:
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~!;h
V
11....
~
I
II,
ClHTtR TtHONS
....--OH IlAJIS
IlAJl
'"
firP
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C~'R
a.
,"
--r:
l
,'to_
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a.
2tlo" __..I
t.t
,,"
SlAT
','
NOTE:
cur A TOtAl
s"."_'"
Of 16 SLAtS
Wooosnuth
r--
ASSEMBLY
After aUthe pieces are cut.the plantcrcan be
assembled, But first. I laid out and drilled
LAYOUTHOW
'OR PLN SU9POftt'S
17
18
o.
NOTE:
ASstMali 0PP0Sm
StDU Ran
... t,
ADJUSTABLE
,-------,
SHELF
---
19
131.."
-_
.'\S!;t.\WLY.1 romplcoc-oth(.'shelf~s..",,",bl)'
20
SHElf SLATS
o.
c~
SKEtf C1AT
.UTSON
PiN
CUAT
Nil. is
\'if oodsmuh
23
TOO
TECH~IQlJI:S
L S
Japanese Saws
W
thin.
'nlland ....,.-u;Kh.,'CllIOmake
the 6rsl,-UI.)apan'_ '3w"hav~
long. thin handle-, usually
"'"TlIl'I'<"I y,'Ih rallan You bold
tht-m mt.r,-,Iik a hammerthan a
""'''
....
u-m-aw
(l 'J', ()'
i~
under ten-um. it can be considerablythin-
WEsnRNSTYlf
lHKK Il.A.Dl
..I':
IUCKllNQ..I';
../
'.""NT. /' .
!loll 1""',
s{."("
F~
fa
111"".". On.
of the b<'SIap-
OO%UKIIIACI(SAW
BACKS?A,=,W,--""
NlCU$AOY TO
"_/
cro~,,'Ultt,th h l\
LOOSlN s(1tlW to
MOVlIlADI
CUTS ON IllUlLSll1tOKI
,J
/..
p.'N .....
""
NOn:
c:aoss SlOT
AUOWS aI.AD{ 10 at
MOUNTlO At ANGlE
a.
WESTERN CROSSCUT
......
.........
9USH
_
)
THIRD
IIVlL
JAPANESE CROSSCUT
=- ?PIIU
.J
c:; ::t
WOttKPlKI
No. i'i
DOZUKI
One of the mostpopular Japanese sawsisthe
doeukl (DOlE-oukey) backsaw It's the
most simtlar (0 iLS western COUDter,Mlr1. and
a good one 10 Slart with lt consists of a thin
blade that's supported by a metal "back"
along the top edge of the blade. And il has a
high numberoftecth per inch, u~uaIJyabout
26. TIle u-eth have almost no sri. so Ih,'Y CUI
a verv narrow kerf. This makes lhe dozuki
<'SpeCiallyltood for doing fine work.
Dozuki mean> "shoulder" in Japanese.
and
the original purpose ofthe
TOIMPtovt
a.
CONTROL
""
SHAUOW
KERF ON
AU'ACU
HOtDDOZUXl
WitH ONt.RANO
ROTAn:
WORl<Plta TO
CUTCOHr'HVOU5 )(JtJ
RYOBA
Ii nolhing else.a ryoba (R\'E.uh.bah) $3W will
considerably lighlen your lool box. 11131's
because it can replace two western saws, a
rip saw and a crosscut saw.
Ryob:omeans "double" and refers 10 the
blade-ilhascrosSCtlll""lh
on one side, see
fig 6. And ripping I('('lh on the other. see
Fig. 7. Ryoba saws come in several diCferenl
lenglhs-lhe
longcrthc saw. the longerthe
teeth. The longesl saws (13" or more) arc
designed for limber Imming. The teeth on
the medium length saws (I l" 10 J2") arc de-
WHlNCUlT'ING
ACROSS GUtlN
CUT1NON ( ....roo
WmiSAWlN
VIJITICAl POSmON
N .,
')
'(1,
\VooJ.mith
25
KUGIHIKI
U,ually, wh"n 1counu-rbon- a -;en....to hide
the head.J 61111>,' hole "'ith a dowel or plug.
But a]Il" II1uiJ1Rlh, dowel in the bole, I'm
<.;t_~
kugihiki [,
"''1'0'....'111"~II'with 2IJ.261eelh
Ilow(",,(,.11 )otl nll,h..nlt It tenon, the bindInR ran bt- S(.\t_ n" (smce a tenon is longer
and IlIick,.,. Ihan. dow..l), see Fill. 9.
8
NOTE:
rtmtWlUNOT
KUl(H Sl.al-ACl
GRIJI SA,W
WltHONli_
TlCAOUOH ftNON
AZEBIKI
Thtrt ....aJJtJthcr rvobe ..t\ lc ~'" that has no
din-e I"t .....l. rn t'QUlvaIt"lll_ It'~ called me azebiki ,1'.11-1,hII~.~ k.~,),..,..~i)!.W. It has a
In \~
tlJ.!tlt 'lttlatIOltt.
~) It .. htlptuJ \\ ben
10
Of
STAt' ... ,
WITH $(itlU
0,
11
IJGHT 'ASSU
No. 75
CUnlNG GUIDES
Among the tools you might find in a traditional) apanese toolbox an: block gauges or
cutting guides. These are small wood or
steel blocks that help start a saw cutting at
the proper angle. set' Fog. 12. I like using
them will, )apan<,:' saws. and thl')' can be a
big help witll western saws. 100.
I have two sets of blocks in my toolboxone for culling miters and dovetails in !I:l".
thick stock and another for cUlting both
joints In ~"'Ihick stock. (Note: Each guide
am be used lor only one thickness of stock.)
One block in each set guides cuts for 45
and 91)' see photo.The second block guides
10' cuts for making dovetails. see Fig. 12. I
made tile guide blocks from oak. but any
dense-grained hardwood would work well.
)IAKINGTIlF. GliIDES. To make a set of
guide blocks. start out ...ith a 12"long piece
of stock, t'V."thkk, WId2"wide.lbe length
is longer than you need lor two blocks. but
tile extra lengtb makes it safer to cut the
gT'OOV(>S and angles.
First. cut three groove-sIn fit over the edge
olaworkpiece.Tndothis.scllhedadoblade
for the thickness of the <lock you will be
working on (for example. 'l'l'J.
The next siepis to cuuhe I>ieepinto ),'llidc
blocks with anllk>d sides To do this, I used
Ilw table saw. First. forlhe~5' /90' llUide.IiIL
the blade to 45' and make a cut close to one
cnd. see Fig. 13.Then sei tile blade back 10
90' and make a cut 2" from tlte firsL Next.tt)
cut the dovetail block. reset the blade for 10
and then make two parallel cuts about 2"
apart. (Aguidewith two parallel angll>d sides
will let you cut both angles of tit, tails and
pins byjust turning thcguide block around.)
I)SJN(;TIlE GIIIl)ES.To use a guide block.
CJ
lSTA8U$1oI KERf
13
ClNTfR GIOOvtS
ONSfDES
0,
(\~e~~~r~
.
....~
GUlO[
10'
IDOmAn.
WAn,
oovrrAII.
,.
GU'"
-WASTll
..,.".;...;""
western S3W~.this
has long. sharp.
three-bevel Japanese
t('Clh. see photoatlell.
One manufacturer, S(aIlley. calfstheir lineof
hybrids Short Cut" saws. and make!' them
in Pennsylvania, The lin(' includfs panel
I~
litis claim py timing h"w long it
look IDmake a cut willllhe lSb400g 1"001
Box" saw. and !hen Ilming !he=cul
",it,h
a IljIdilional western crosscin saw, The
saws. backsaws, and a 1'oolllox saw.
<;tanley has mad,' some chang 10 Ihe "Tool Box" sawdid makt'illbto)lgb wiU15(1.
lraditlonal .IaJ)<lMre crosseur too1b desil:n. fewer 5!tokes. but it look me rnesamc
The most obvious change i~
Iilat tile teeth length oflimc as with lhe tr.d1tional sawpofntdown.1lO1back like a lllpane8<' saw, or ~ullingon both.Irak"" k hardwork,
The-S1ltf.Ict!eflby the "Tool Box" saw is
forward like a westem.saw. Thi, meanslbe
Sh(.rl ell/" <'1110'Ittth Ita'. 1/1''''' 61'1" Ik bladecurson both the push and plill woke. vllJ'jI rough. But on Ill. whole. I like it Cor
1I18'kingnl1lgh cuts ia hardwood and for cut1,1;,JOI""" 8#8<I'r3. BlIttlltll TJ(I17l.t$1'YUa'" which5lan.le>.'sayseutsthc'W"od5O\Jaster
ung-COIlSIlUCtiongradcIwnbef.
d(~"'/l/o" ftfll 1)011,IIUS), and pUU(lfJin/(r.jJ. than con~tioJlll] ~ws.
Nu.7~
li
CO~TEST
SHOP
-----------!
Sawhorses
R
The differences
between
knock-down sawhorse.
What I like most about thi,
folding model is that it goes 10getherquiddy. And when
ir. assembled, it's almost
the
SHARPINING tiPS
Oil:-.tont... warerstones. grinding
wh(~+, and ,.j)arpcnllll1alds- howdo
you {)(I!OU11'. tht.'n1>,,(, they're easily accevvibl .. and can be cleaned up
qukkl) , If \ Oil have aJI)' storage ideas.
or .n) WllClU(.' ,harpcmng lip", we'd
n"~1o."''T10liAL. U you
don't mind giving up
no-
SAWHORSE
....
1
S",
.L
.304'.-0
CROS5BRACE
6\."
END
UN!T5
,l)
"..
-"
....
-]
TOP RAIL
I ","
..
_.s,"
2".-
CROSS
BRACE
..,
15' ~..
.. ". ........
,-~
....-i-: '"
..
...
1..
,'
",'
- .. ,
a.\
"
)"
,....
0_
..,._.,
2.~ Sl..-W
.,'
SltDnMA
TOP RAIL
3':"j
.. .....
pi''''h.'
18
NEXT CONTEST
tional sawhorse,
KNOCKDOWN
I.l.lybt Ihar, why you see beatupold sawhorses Uk" this still in
U\.;t' on construction sites.
"
....,.
''''.''-'':
'
.,
t
__
I~
..
"
_../
No, 75
---=-=-==
FOLDING SAWH0r-RS-,-E
2
SAWHORSE
fOLDED
END VIEW
'6-,
CUT l1.t:t'".w'IOE
DAOO~.on:P
..
'
TOP RAILS
(I."
NUT
-'6----4-1
~O\\'the
BRACfS
CONVENtiONAL
c.
IOlTS
SCUWHNGES
IN PLACi
b.
'-.)
,.toO
I( you
CONS1lIt
SUDlfAllS
One reasonwe
the fold
ing sawhorse sent by Don Paul
of Arthur. North Dakota is the
unique way it folds and unfolds.
pick it up by reaching
under the
rails. the legsclose
up,
the
rails tozerher and the legs
spring open.
.....
... WOOD
SCit(WS
o.
fOR HlNCE
MOUNnNO
AITACH CHAIN
W1TH II x 1'f..t-
--,
tlld)
SAWHORSE
3
SIDE VIEW
'.
END VIEW
__
SfE OffAJl A
TOP RAIL
(b6)
SU
OUAlL.
END
BRACES
LEGS
(1.6)
(2.0<4)
CUT 10 Frf
/
20' CUT ON aOlM (NOS
g(l$
b.
S'''''
SECOND:
fIRST:
GlUt AND NAil
UGS IN PLACE
t-
'-~
ITlll<;
SECOND:
G.WtAND
SCREW END
au.CB TO
LEGS
.a
JC. II"..
WOODSCUW
mll\,t,('ltU'Y.ll'tl'WJ:':lh~a:chi~:Iot':I~._-====================================~
....~';1./')
' --
\VooJsmith
29
COMMENTS
AND
QUESTIONS
'Ialking Shop
WEAIHERED
FURNIIURE
c,~f.:STEIMEl'IIOn.
To
re-
horne centers,
StEPPED
SOUrnONs.we temporarily
SHOULDERS ON IENONS
cuuenonson the table saw. Kct:p
"-..-.,
~t"
3(1
\V"odsmlth
:-Jo. 75
PROJECT
SOlJrCeS
ACCINTLAMP
\'loodsmith Project Supplies
is offering a hardware kit for the
N:ceot Lampshown on page 12.
The kif includes all the electrical
pansand support hardware. The
brass inb}' strips. "'in~antghle.
SUPPLIES
I~"Dia,
(1) Shade Harp. Two Piece.
Bras.. PIated,7"
(1) Ught Socket, Brass-Plated,
It."
ORDER INFORMAIION
"(lrd~(I(lrntl"d$uppl;'~
Illlly
/n.knd Glilt
C(JnsWltioe~tt
ltlO-~
14(' "'J> Pu,.-'., Srn
J,. rlJ~'GI.tW./",
.,." . ~ar "'G r" . ,
PftJ.II ~
S,,,,,,...
~.I"
,j.(..,~
C'rlIf'llotl\lln '~tWld
Sc!nin (, .
~).l.~,1,7
/.AI'HP ,'tIrt.,. n,._/nl
I ,.,." I'!.,
Jl~ ,.
Gilt,
Nn. is
l.elc:htutl$t \Vork.<iliops
1100-32 H1840
Meist'i
lHAlI'rl
Ha:rd\\-"1lJ"e
1IOI.I-HI-!I810
\\'oodatd\
1lOO-22S-1 ts3
J,,_tU til~. Tltfrtk~
J~. ,VU'It.Iu"9 8i1.
R""in GINA'"
,,,.. WoocI.wr1<crs' s.u...
P!(Ulhr
BYMAI'L
Til order by mail. use the f<lnn
enclosed whh a C1.IJTCflt issue,
The order {onn includes iafcrmatlon on bandling ~ shipp;og charges, and sales tax.
tc)l
612....23-2199
301-~
l..a" p Pfjrl . $IIud ....
Wl;>OdsmithPro;ertSupplies
Wood ".""'"",Supply
31$..>97
-3i<3
S,.,,. VdI'W"JI
.')w"
RUI" GI'f'f"
of ~~8'
Mexico
(n",
ready.
1. 00...447002
NI/(t:
i"ri"".ochft1
'Q<J""I(Jf'
~ftf'AIff!"I(> 711M.
~9292
I"
tu'NPP~
Paluon RtIl'd",~.&.uf.
."PHONE
Cl J,.".~
Woodomnh
31
~----------~~~~~~~------A
LAST
LOOK
Final Details
Japanese Saws
Patio Table
The blad
alii/
32
\'(/oodsmuh