Nl).

78

NOTES FROMTHE SHOP

------------------------~-

DIS P..&.J..I..
CABINET
I

$3.95

Gun Cabinet
Sewing Box
Box Joint Jig

p-,,~

"'It, at
night) Most ofu:n irsthcchal~It.
uflr)ingtofil!Ureoul3wny 10gelS()m~thinR
done that dca"san easyanswer.
That's the basis of Ihe feature projecl in
this Issue. TIl<' Ili,play/Gun Cabinet is a
traditional dNf!1l with Rlass-paned doors.
The (3~N way 10make these doors;" 10
use a 'Pl'fial ""' or router or shaper bil:,
dc'>igned IIImak~ an mterlocking moldinR
CUIon tIw rail, 'tik ....and divider,
But .....w...... abk tlllifcun, 001 a wa)'lOdu
it with nnlinar)' mutt'1' bib. Tbe process
mean, culting a fe" more p;eces, bUI il
giv"" you the ....",.. re-ults as using an expt'Ilsiw ""101bil'
\\'l' were 01-.0able 10devise a new jig for
cutting box join I, (used lin the Sewing
Box). TI,e jilt a<lju,', 10 Cui nnl' size box
joinlS, and selves some of the problems of
typical boxjoinl jig..
Allin all, the projt'Cls in thls issue offered
opponunilicslol,()III"UP with new solutions
to old problem
SHOPHOftS

nmlWber1aOn
CuntribuhjlgEc:htor Richard S. J)eters
Ted l\raJicelt

A..manl !In 1).,101 Rod S__

SnlIQr IUu_"", 0.,,4 Kn~linlI

Chri.G~
IlIu 0I!0n om. V.... Sloe!!

(.-~

Cl'1I)uIa~

IIMIga [J1l1Or lSdI '111J1kd

....
"'-I~
J... Hak~
~
\I.,_
'ilLve Curtis
CIttUL",un llln-<.or

s..bornpbo,n "_.-

tu B~

Sandy Baum
Cinut.h()n Alu.1rt Jim \\.ood....atI
SrWl tant!Salt. N..-nt\. Buclwm

,\,OOnS\lmISOURCEBOOK
Mark"II"g Dil't'd.r RobenMuay
Prt~;''t'tStI.1I,ti4" u".'i" Ann Gearhart

UodaJ ........

Th<:hlll<a)~ppon Jonatlll1ll Garbison

Sourc:t-book/\dvt'rtiwnl'Jean f\1.)~1li

JU)' JoIUI_
T.tmmIJ"h1

pn.,..,,.,

Looa:

D<>ani"

~"'V.,

Our brandn.
Ill3lCaz'n~ i. ",,110'"
Shup.\otn. and II

M.vdIl..obH
CORJ'()Jt\TEShlt'ICES
(..,.,.,Ikr

\.co

bllll

PouJ Eo GI'1I)

UndaO'Rov~

IIuokk,,'PIIlII JuIWnn"Speats

Ntt"'QrkAdmini~"10r Dougl.-.s M. Ud~ler

Attnlin""trall\l" Asst. Chtt)t A. Scott
Rc-~plJoni,t LoriSciben

Uulldlnl1~f>'nl.","nc~ I((,n Griffith

,\rchieKmu~

SmRE MA.~GJ;RS
1)(" ~U1l\\

1A

Kml

W('i5h

"' rk...", CA \Iicluod DeHa-....,

hnlkl"'ll' nit ill tilt sbop

For the 1'1'4 ),(':&1' we\. been ,,"orldgg on a

spec...11pr01-<1- a new maguine. Now the
fiN iss,wl<aboullo Ill> 10
il,time
lor an ,ntrod""""n.

C"SlbITl<'fSnvl<.. Shipl'lng~1
hoda Mo,,_. ~!jII'. J~ c..-n. s..p..
Laura 1Iath""It",u,
Gloria SI>han
J<nnlt- ...,..

I
___:'_---i

1 U t-.I N

Sawdust

fA.,or OoMkl B.
\1",,1ilC,"~I d"", Oo"ldes 1.. 1Uck..
1\ l,13nlfA1ilu(" Jam ..~ ,to DoWn
G.. rtlon GrupP"
Philip A. 1'ott."

lrt21I\\'ttihodOl'

( o

EI)IT<)R's

December, 1991

'0.78

"YII" IIkl' wllrkllll! III)"U' ,""op. even if

vou tlmfl h.IV. ., fllm.tllll l"uJ<~ 10build.
Ihli'l<-W",.,',II11le IIIIMhllo.I'P<"~10 you.
II :;hllll.\"" .. ~"ulld. Ilk, something
yo,,'d hk''ln ...
-mlill II", cnrd that's
inlh"''''","llI'
I,"ulh (0' if the catdis
mi"lng, call,,! al 1411X441-7(102).\Ve1J
sc"d ) nUIIu 1~."Ul"I....u.ul Sh(Jp.\'Q(u
and > "'1\1JJ' b''''''~II' at h,utl'rSub:.crlber.
,." f \<1. UI, ourse, ~
a~
Olllj1aZlJ1<
reqillm. 10101"ork
.andafe9;
m"'~ p<'QIlk A<a I,,,,, bra,'e ">ui-look on
th~ ta,k of ptooudng Shop\'(/(r" we've
added a fr .. ~" p<'Oj>Ic fllr Wood., ,10
Terry Slruhman and ('M)' Chffill"'","
headed up Ih.' .Ifort ur produting the Iir.sl
issue of Shol'.\".t~. Th.) were quickly
joined by Rkk Pt It,.,. and I\urt XhuJtz. also
from the 1I"",f.,,,,,I/,>laJI
Butil'sbfi-n lungn't'ting IIl!Wpt'IlpjC.\\'c
were able 10hire fourgreal folks.
PhllTorten hasbeena long-timereaderof
11'00(1.,111111and was a It'('IUlK'al writer for a
compoter fiml. He told me about the first
lime he saw W",.I.""I/,. H. picked iLup.
turned 10 his wil.. and said, "Someday 111
work lor Lh" lIl:ij(ll4nc.- Now he'shere.
TIm Rotx,nstJn wa,;aho a subscriber. He
tzugilllinl!li'" in a high ...-hoolin Colorado.
bul dedded 10, ..ilch from the class
room 10 the worlt.Jiop andjoin us.
\\.. re fonunal" 10 have Cinda
SlwnbauJrh', 1ak-1lI' for the mustr.r
tion, (Old. "a, a fl'l't'bnce designer
and ha.duncdraltinSranddesign work
lor a umb<rfranwcompany .
And finally, YIIU <'an imagine the
wurk IhaillOl'll into dc.-igning the fur
nitul\'. jil-!". and shop projects we (ea
turt'.Jan SVe<'isnowhdplng uswilhaJl
01the d''''iRn work. He h... a degree in
archill't'Lureand wasworldngasa cabinNOlak"r (or a local millwork ('Om
pany bdon'joining OW' staff.
INDIX

..,.j"'I..

r-;;;;;;;';;;;~;;;:;;;-l

d..d.:atrd I'1IIJrt ~ lu
your ,hup. 11'. all
aboul ""Kt<I"~rkllll(
lechnique . jigs.
,hop prQJ""". ann
lools - Ill<'hl',ott 01
woodworking
I have a good (toel
ing Ih~ moment I
walk inlo my <hUll
And ...h~n I St,'IO ,,~ ....'on.... ne tl",s shop.
it' j!T('al ('Xj)('rknl'e Th{.,.care usuaJl\'
pan,of proj{....I' lying around.jtg> hen:and
there lhat starllIll ........ung "0),;.......and til,
inevilabk di'I<'U,.Jon,aboullool,
lltar, th. id.... tx,hOld Shop.\'ott.,. \\'c
v.anl.-dlodtvol.'."hok
lnag;tzone 10work
illl( in 1M ,""up.~01 a1..... , building a fumi.
lure projl fl. Soml'llnll'~ just pulZing
around. Ma)tx,,",orkingon aprojecl forthe
.hop il""ll Or. building a Jog for th~ fable
saw, or makilll(an dC(l~"'t')t"ra router.

Endosed

you'lI

find Ihe WMd8>"il}o

Sourr<!Jo<>Ir. Thi' tome wr,, added an
ind~ of aJlth{' ;utJ(:;", and JlI'OJl'<.'1$ .. -e\"
featured.;inc(> Ih('fiN i,'Ut" of lIoo<I.<,,,#h.
you bougtllth;. COp)on the ne'.'<..tand
or the S(/~,.(".,b-Hlk i~
mj&_~ng.call us at
l-l!OO-ltt-7(xr.! \\'t'11 "'nn)'Ou one fnoe.)
liF.XT",,1 . The nc<1 j,"",C of Wood I
'lII,lh ..ill tx, maik'<iby Januat) 21. 1992.

at

__,..

No. 78

LOOK

INSIDE

Contents
ITips & Techniques

Display Cabinet

L...

_"_-! __

I~

Fire grpat tips from fel/ou' wood,

~
icorkers. 1) ill ak i IIg u ,J ig for Sand,
ing Circles, it) Cnttillg Beveled Notches
/01' Stnohorse Leqs. 8) Scrapers /1'0111
Japaneee Saws, 1,) Cutting Odd Allgles,
,j) Ganging the Depth of Dowell/olen,

I f6l Shop-made
IIloldings
palled doors produce

uud yluslS'

..J. ~

a Display

Cabinet with clcseic lines,

1 Gun
.....

11131 Sim
ple
Display

Cabinet

1 Matched

...J.

Moldings

modificatione change the

Cabinet into a hand,~ollie
case to store and display your gUllS.

11141 look
We slunc how to make doors tho:
like they caIne front a cabinet
shop - Ilsing t 11'0 COlnnlonrouter bits.

IShop Notes
L.

j'l1atched,l1oldings

page 11,

Sewing Box

pagel8

Box Joint Jig

page~

11161 2)J) Ins/ailing

Houito Lall Oul Dentil Molding,
Inset Hinges.,j) Posi-

_...!..

..J.

tiolling Shelves ill a Cabirlet, 4) Cllftin{J

HalfLap 011 Thill Stock,

I Sewing Box
L

11181 aThe10l/g
lop "-aus pi /101 open to unco!'el'
case, It's a weekend project

--"'

..J.

with lots o/stOt'age/ol' sewing supplies.

IBoxJointJig
--=__ .::..;=-L.
__

11241 Accurate
bo,l'joinlS are easier than
eeer, Ou,. Bo,( Joint Jig works ali

...J.

!lOll I' table saw

IMaking

Box Joints

11271

";esllowfechniquestolnakeslrollg

unti oitractice bo...joints lIsing onl'

adjustabie

ISbarpening

Contest

I Talking
Shop
--=:.__-=L.. __

1 Sources

'------------'.
No, ill

11281

or router fable.

80.. Joint ,Jig.

The result are

ill/01' Ollr

Sharpen-

ing Tip" Contest. The I/'illllel's: Two

jigs fOI'l'a,~y, marl' acrumte sha1"pl'wing,

113011)Shop.
Tips on R71,~tPrevention in the
Z) Recharqeable Batteries,

...J.

11311 Hardware

project supplies
needed for the project il1 thi issue.
011(/

WvoJsmiln

WOO

~1 FELLOW

FRO

[) \YJ

Tips & Tee

JIG FOR SANDING

R K E R S

ques

CIRCLES

Next.to keep the jig a)i!l11~dwi!h allows you 10 move Llw workand circles on a disc sander can Ill. sanding disc. mount a hard- piece in small Increments.
To rut the diagonal WOOVl. I
be diffll."Ult- you have 10 rounc wood strip on the base thaI filSin
mounted
the base (()1)side d,~\\11
(lie workpiece evenly to avoid yourrniter gauge slot.see Fig, J.
Oal spots as you smooth OUI the
The diameter or 'he ",h('<11or ollaplywc.1d sled Then "'\lillie
Cum'. To ""Ive the problem. I circle you're making is ad- .1"1with a dado blade.st.re I,g.2.
made a jig that holds the worll justable since the pivot pin is
The ann is cut to fit 'fluldy in
the
groove For the pivCIIpin, ,
fIXed
into
Ihe
end
of
a
slidinl!
piece on a piwl pin so il can be
arm. And the ann filSin. groov,' used. If." dowel.
easily rotated . refer 10 Fig. 3.
To use the iiI!. clrunp the base
To make uie jig. sum by rut- cut diagonally acrnssthe baM'.
ling a base from :VI' plyw,d the
lr's litis diagonal KTilOvethai to tbe table so the workpiece is
same size as Ih~sander's table. makes this jig work SOwell II On the side of the sanding disc

Sanding Ih~ ('III!{'$ of whe-el'

.-c:

Ihat >Pin~down. Sl<e Fig. 3.Then

mount the workpicet and slide

Ih, ami m Ih,'groOve.
Wh< IIthe workpiece touches
til< dbc, hold til<"lITIIlin the .101
with one hand. Then rotate the
workpiece with the other hand

as you slide the arm slightly

ch.....-r 10 the '3llding disc unlil
\h,. workpiece is round.
.Iprr}})I(

ft,/itfl'(l"J:f'.

JalL'fA'1:

'~f'Hro11.yil'

,
"j

AnAeH aASl TO
Pl.YWOOD St,fD
AT DISIRD AHOU .

c.........
JIG

TO fABLE

CUTUS!

Tom
$ANOla

,.t.au:

NOTCHING FOR SAWHORSE

LEGS

beveled notches on a table saw, stead, be built a simple jig 10

To do this. start b)' ripping 15' notch the tcp nail on 3 radial ann
bevels along boih edges uf Ilw ,..w.=rtg 3.
lop nail, see Fig. I.
The jig consists of 3 sland 10
Then. to cui the notcbes. holdlh~2x6lopraiJata75 angle
switch 10 a dado blade set at !JO in from of the (enCl' and ,;lOp
and make a <ceil'S of passes ... ee- block 10 hold the rail in the
and chisel. BUI two readers Fig. 2. By kC'eping Ih~ IS' bev- proper posuion 3J'roinSi the
wrote in with neattechnlquesfor eled edges down OII.'Ilinsl\he sa'. stand N' Fig. ~ Both are ofpasses, sec Fig. I
Note: To kC'ep the top rail
cutting qui(k. accurate notches table, you can easily cut the mounted on a ~c" tllywuodbase.
using the table saw and the notches with angled bottoms,
To usc the ji!(. "'llh~ blade 5' square 10 Iht' blade. slip a 11.,"Steve
Brink
of
5\.
Paul.
above
the sa" tabte. Then lean thick spacer under tile oppooile
radial ami saw.
Tom Kolar of 1.a(3Y,u('.Cal- Minnesot.adidn1 "anlll> cut the the rail a!,,,,iIlSI the stand and end oj the rail to compensate lor
ifornia ~ugg('stl:dCUfliJlg IhC' leI! nnlche'S by h,md eilher. In- waste out the notches ina series the thickness ur the jiJ'r'sbase,

Building the 'conventional"

sawhorse shown in Wood.mill,
No. 75 wasn't diflicull.Tho onl)'
tricky part was cutting Ille beveled notches for Ihe lejlS in the
lop rail.Inthat issue We showed
how 10 cui IlI(!lU with. band saw

NOTE:

I--d. CUT NQ1'tHB

WITH aEVtw) ~oGE5

DOWN ON SAWlA8U

STOp

8RACfRA(t.

'UX'I(

ACWNSTMmIt
OAUOl ffNa:

(
'--Rat

IS' 8fVEl

AlONG 80tH tOOtS

CUT
FIIONflDG'
Of SlOts
AI7S"

\X/""dSlIltth

Nu.71)

SAW BLADE SCRAPERS

Many Japanese hand saws it into three pieces. To do this,
come with replac e.abl~ blades, first score a line across lhe blade
Blltinstead olthrowing awal'tht with the com ..r of a mill m", set'
old blad,"!;,I found a new usc for FiR. I 11,. scored line doesn't
thunt- tJlt:y make great cabinet

scrapers.

113V("

to be very deep,

jusl

same way as I sharpen regular

cabinet scrapers. To use my
method, start by damping a

to the scraper. see rog. 1.Once

piece in a vise, Thl'JI bev e1 Ute

lOP edge to 45-. see F'i$.!:. 3.

scraper is ready to use,

J use all the pieces of a blade

you can fee) an even burr along

the length of the edge, the

$I'. photo.

stralght and continuous,

Once the edge is bw('IL"I, you as scrapers. see photo above.
To make a scraper, first nNext clamn UtI'blade in a vise can form burr. To do this. The rounded end. make good
move the blade from the handle with th .. score line at the tOP slowly rubllw bevel,,,1edge with conve-x or concave scrapers,
and grind orr Owteeth. Then file edge o( Ute jaws. Then bend the a burnisher or other piece of Even the small end of the blade
0(( any sharp edzes. and blade until it snaps along the hard smooth steel.see Fog.. t.
thaI fits into the handle makes a
straighten the edge,
line. se... Fig 2. Now file off any
Stan burnishing at the same good scraper ror working in
Since a ful~length Japanese sharp spots.
15' angle as the edge. Theil tight places.
hand :.1W blade is too big tocomTIle next Slcpis to sharpen the gradually changethe angle until
Ji,li TOIII"(onably use asa semper, I break pieces of the blade I do this the the burnisher is perpendicular
San "-"'ff,/ri.scu, ("Iifuntia

KORl atADl
WmtmGi
Of' MfU At[

walDOl
WITH

AU1tN1SttJ..
TOfORM I\JO

CUnlNG

ODD ANGLES

R<'Cell~)"flOUtsome stock tu

DEPTH GAUGE

Next, align the squaredlin c,

lit some unusual angles. But I 011 th...workpiece to (he side o(
had a problem setting the miter the miter gauge slot. see fig. 1.
gauge to make the cuts. So I Then loosen the angle lock on
came Ullwith asimele technique the miter l.'lIug~and slide it up
agaillsl the workpiece. Now,
10 do thi<.
To set the miter gaug~ anl.~e. lock the miter gauRe at that
I first draw the desired cut line angle. Then align th~ cut line
on tilt' stock. Theil I square the with the blade and make tho!cuL
line down the [ront and back
Do IIy C<III way
ed)::l'!ivf

There's noUting WOJ'lW than

starting to glue up a project only
to discover that your dowel
holes aren't deep enough -th~
dowelsare bottoming out berore
the join I i~
closed.
To avoid this problem. you
should always double check the
depth o( the holes by measuring
them after drilling. But bow do
I:; "'lllf'tlCr, ._lfi~xO~1
ri youget n ruler down into. dowel
hole with such a narrow opening? I use a tire, tread depth
SQU~fUN
gauge, see photo.
DOWN fRONT
ANDaACK
A tire tread depth gaul:'~ has a
lDG<S
ul't'dk-like probe thai easily fils
into a dowel hole. Mine is calibrated from 0" to l"in .t!" increments. 'Tlretread depth gaull.'
are available at most auto supply

lh(' pi("Cc', ~lIlg.Ia,

L.; ,

No. 78

stores nnd cost between $2.00

andS3.50.
ReA Scheiderer
RociU'.lt'r, ,Ifill>lC>loia

L.J

WvoJsmllh

SIND IN YO". TIPS

IIYOuW(lUldUketoshttrea
tip or idea. jusl send it

[0

1I',>nd$mitil,TIp" and Techniqucs, 2200 Grand Ave.,

Dt'S l>1oioc'S.Iowa 50312.

\Ve wiD pal' (upoo pubticatioo) .$15 to $100. depending
lin the published length of
the tip. Please include an explanarion and a photo or
skctclJ (welldra)'Janewonc).

H EI RL 0

~1

R 0

J _E_(_'_T

-----i

Display Cabinet

Part of the beauty of this project is in its traditional al>(>carance.

But what you can' t see are the unique router technic/llcs
that go into builtling the glass and raised (>"nel doors

h....
finit Illlng }otlr. 11",,-1\ttl nouce 300m thi~
cabinet ts the upt_ r dO(..... [arll door is neatly
dmdedintot1I.-h'l:b
II; lin. AndC3<"hJ)iUlt'ofglassb
surrounded b) a mold('f) rei"ee llul thaf, not ",ball find
the roost in'.n~
II ~Ill. dC'Iai "I hoI' the doors are
constmcted
How are aJllhmc- p:lI1 on the door J"iMd log~1her?
And how do)ou rul tho Inside corM"""" lb. doormoJd.
ings? There must b< a 101of 'w milt..,.er coped

comers

to cui.

Or "II..",t an .,lIp'",,,,,,..,1 of router or

shaper blts. ();ot at all lIs. n....1 h..-hnique using a
router with common bi1, \\-e'n' 4,lhriflJC a separate artide about thi, 1,'('hniqIlC'>111'111'" II and 15,)
TOPMowr-c;. The dour i, nHI Ih,' IInl) 113ftthat has
inlerestingdewl"111<' ",,,)dhlll "1Ih"II)I,(,1 thecabinet
is made by building up piN"" ..I ,to< k on top 01 each
other. And one of thoSt Ili,,"" is denul molding -and
that's another inlriguinl1
It h., tu bl' cut to fit the
width ollhecabin"1 and Ih.'d'lItil blt,,'k' mus! 11<. spaced

""I).

perfe..'tl)',;o )OUmrl up" IIh" full bI", k 1111 ~.<h

cod.
_.\DESIGN \J.n:R' \ml
I'h. rt" art" t.thtr inler-~
techniqu,."uSl"; on IhisC'lIbmrl. bull ,bould say someIhing h. n- ab.. t;'
(.\oroJ1lc!~11" It'. d.."jgned as a
display cabu !. buill (ould nsll)' be "0')\ ,'tted inre a
gun cabinet
,rlailll'<l on page 13.
\\()()D. I orooth the dL<l'lay,-..bmel and tho' gun cabinet I u-ed r-.d .""'- 11Ir dOt'n, 1ar11lR', moldings. and
,hdh~areaJlrnadt
ufsoUdblu"k, bot all the main pans

.h.

are mad, frum~1 u.lkply,."",II ..1U1tedthemainpan"

to remain flal allll,labl. nil mauer whallhe humidity.
HARt," un. I"IIdd a ttlll,'b of class 10this projl.'<:l.me
hinll'-"",knob" and ,1"'11,uPPllns are all brass. There's
even nillY double-ball cntches behind the doors And.
threadedinsert><aJ'\'11"'() to securethe UlIPCrC>1~
IIIthe
lowercase. (For hanlwa~ sources, see page 31.)
f1;;IS,H.The finalimportant detail 10any heirloom projc('tisU,e finish. For the stain I u>cd 81",,-'poonsolburnt
umber .nhI, oil. mix..! in I quart of Iin.~-edoil. Then
after 411hours I covered il 'nth thn-e C03I<of G<.'nera)
Finishes' Royall-;ni>h (S;,lin'

SUPPLIES
5pailS) Itl5eI bICs:Ihnges..,;th lCIewt
(~)1'.'llYeoooo~
(4) ,'x I Rhrnoct11rOlC!GWS
(4)~'ooo.

(6) 80IICClclleS

(15) V,' StoeIf

suppotls

(2) LQck$ (OP'1()nOl)

Wo"hmnh

No.1S

MATERIALS

EXPLODED VIEW

LOWERCASE
A Side$('2)

-l't.ply-14A' 21~
'I-.ply-14'14x38%

8 SheIf(1)

IWl
CATCH

-@

(~:&)

C Top(l)
D SIde Foongs (2)
E Upper Roll(1)
F LOWEll Roll (I)
G Edg.ng Strlp (I)

.pt{-IM'ex4Q

H KlCkbd Floor (1)

I IOcI<bdSldes(2)
J Side MofOIngs (4)
K Front MoIding$(2)

. x 3 - Ol'.

Bock(I)

'l'Axl-2J'>t

~.xI~A-

371;.

~.x4.-37h

<.ax.-

7f>rgh.

.x3-1()
.vAXI?- 16rgh
'<. I?- 41 rgh.
If.ply- 3~.l( 221111

UPPERCASE
M Top/80tlom (2)

~. ply - 11VA X 37!11,

N Frome Froot&(2)
From$Sides(4)

\?

P SId9s(2)
Q Side FoctIngs (2)

'1'. ply - II II:! x 52

'1'. xl-52

o
IWJ.
CAT(K
\

U Bock01_(1)
V
W
X
Y

BocI< Ponels(2)

Dentll Front (I)

Dentll Sides (2)
FronlTnm(I)
Z Side Trtm(2)

M Ffoot Cop (1)

88 Slc:leCops (2)
DOORS
CC UpperStile$(4)
DO Lowe<StIJes(4)

42lf.'W x 16"D x 777,...H

:VAX1\'.1-52
~-4x lIlt. 30th!
1. 50
If.ply -I T'At x 50

:V."

1'/2 x 1Il(WA

I \'.I x I 12:VA
:VAX1'/4 -41~.
~~.1',.13~
"AX 11-2 42%
'VAX 1\'.1-13'12
~. <'\? - 50'"
'l<A<2\?-ISlit

ilIJ. 2V.- 14\?

FF HOfil.0Mdef3(6)
GG IJ Vel Ovdr>- (2)
HH Up.Ver Ovdrs. (2)
II HOfil.Co~(Q)
JJ VeJt Copo (10)
KK Ro~Cops(8)
II Lower Astrogol(1)

~xl'.!-141'o!

NN Poneis(4)
00 GIossStop
pp St>e1ves(3)

LOWER
CASE

I.37V.

EE ROils(8)

MM UppeJ Astrogol(1)

OVERAll DIMENSIONS:

40'1.

."X1~121?

'I'.x

R Fooe Ro,ls(2)
5 Boci< Sr,les(2)
T Bock Roljs (2)

.@

x 1'.?

~xIn 15iII
"x!~ -50'7
~x 1-14%
~ x I - 11\8

~x2"'-14V.
~x. -14~

"x~.-

490/.

"'x6~-11'11l
lr.x 14 70 un Fl_

~.xIOV.-37~

CUnlNG DIAGRAM
~4"'.

7l1t" . '06- (5 lid. A. ICKb)

";

1
~." PlYWOOD 0"

96-

Kif

KK

EE:.

EE

--.--~
~.. '"
No. 78

Woodsmlth

..

v
L

LOWER CASE

TONGUE & DADO

rabbets on the ;1!SWR face of the sides (the

is constructed b)' same (ace as the shelf dado) and boIl'.m' of
stacking a Lall case the top panel, see Figs, 1and la, Note: Don't
on lOP of a short
CUt. rabbet Onthe back edge of the shellcase. Plywood was the back extends 10 the Boor,
IIOLESINmp. There are two sets of holes
used for tile sides
and backs, and to be drillc'll in the top (C) before the case
then I covered the can be assembled. First,drill. seriesof:Vu,"
exposed plywood
shank boles Dear each side for w'OO(!=e",'S
that bold the top to the sides. see Figs. 2 and
edges on the front with solid wood strips,
The lower case is trimmed oulnlth,' bot- 2a. TIleD drill four liflG" holes fo, bolts that
torn with a kickboard and molding strips to will be used 10hold the lOP case to the botgive the appearance of bavillg a base. It's an tom case. see Fig. 2.
A:!SEMOI.V. Now the lower case can be aseasywdy W gtlthe lcok of abase without the
sembled. I did Ibis in 1'w 0 steps. FiI'!'I.~ll1e
extra steps needed to build one.
I began work on the cabinet by building and clamp the shelf in the side dadoes 10
the lower case. II starts out .. ilh 1:1\'0 sides ferm an "H" shape. see Fig. 2. Thencheck 10
that AIX' mirror images of each other. The make <rurc the! case is square.
Next, position the lOP (C) on the sides (A)
sides are joinc'<lby a shelf 10 form an "H"
shape. and then a top is added to help hold so there's an even overhang 00 each side
and they're flush in ihe back. TIleD glue and
the a..ss embly together, see Fig. I.
SIDes AND SHElP. Start by CUlling two screw the LOpdown ihrough the pre-drillcd
sides (A) for the lower case from :v,"thick holes. see Fig. 2a.
plywood. see Fill. I. Then cut another piece
on-,"thick plywood forth es bclf (8). (Note
1
the grain direction. I think il looks best if il
runs vertically on the sides and along the
length of the shelf.)
DADO FOR!mEI.F. Aiterthe sidesand shelf
have been cut to finished size, cut a 14"wide
dado across the i....
i<i.' face of each side
piece. Thescdadoeswill receive 10000uesL'Ut
on th~ shrlf. see trill. I (Why not just elinunate
tongues and cut the width of the
dado the thickness of the plywood shell?
There are a couple of reasons. see Ihe box ill
thc upper right-hand corner.)
SHElf
To cut the dadoes, vou "an use either a
table saw with a dado blsde or a V4"straight

bit on the router table. To allow the shelf to

SIDE
pull up ti~hlIyto the sides during assembly.
@
cut the dadoes slightly more than V." deep
as shown in photo (b) in the box al upper
right-hand comer.
The display cabinet

""~rcart-

"'-ay. to joill

many different

s.aelve$lo cabinctsides.A fullwiGthdado

(photo a.) works fine, but if the Shelf
d~n't
fil ~"acllythere "ill be a ll'ap
above the s!u)lf.
The to~
and dado joinl (pholo b.)
looks better b<>e8USCit hides any gap
above the longu~ o( the shelf. It also
covers up spljn~
thaI may occur at
the edge oCthe dado.
1...

DllP

BACK
RABBET DETAIL
.0UTta
RNCI

'."

U,.

TONGUE
DETAil

"

CUTlONGlI<

",-

TONGlia

'."

a.

CROSS SECTION
3S ..

~.,

1',.....

,..fh. WOOOSCRlW

J:" SHANK
HOllS

Non,

notethegraindirection.)

FOR11A(CK.
Now rabbets can be
cut along the Oork edge of the sides (A) and
top (Cl 10 accept a back panel Cut Ute V4"

MAI(SUa'
SUtts ANO

HAlIBm

,n

OAOO

Nowyou can cut thetongues on

the shelf (B) to 61the dadoe~. The tongues

are formed by CUlling IwO rabbets on each
end Of the workpiece. St.'C Fig. lb.
To do this 1mounted a ~. straight bit in
the router table. Then Icut the tongues in a
couple of passes, sneaking up on the final
depth untilthetongue justfitsthedado in the
side panels.
Alterthe tongues have been routed on the
endsofthe shelf. rout a tongue the same size
on the/"lIIt edge of each side (A). see Fig.
I. These tongues will hold "'dnlt pieces
added later. refer to rig. 3.
C\.<; ml'. Once the tongues have been
rouredon the sides,thenextstepistocut the
top (C) to finished size, see rill. I. (Again.

JO

C(NTtRfD

0VlIt
SlotS

~l.
HOU
'0
MACHINt
IOLT

5H[U AU SQUARl

WooJ~mir.h

No. 78

FACING AND RAILS

The next step on the
lower case is to add
the facing pieces 10

TOP
VIEW

also add the rails between each facing.

....

SLOE FACING. First

r _1 ....

,
21 \,-

SIDE
FACING
MO\DING

width (I"). se....Fig. :13. Theil cut the pieces

10fhe same length a$lhe sides, see rig. 3.

ADDEO

Next.cut a gruove on the back sideof each

racing 10 fit the tongues on the plywood. see
Fig. 38. (To mak, sure IIw), fit the tongues, I
USt'(ll11Cserne dado blade iused forthe shelf
dado.} 111.11 glue the facing,; in place.
tl'rER "'''II U)lYER RAil.. Cut an upper
mil (E) and a lower ruil (F) to fit between
the facing$, see Fig. :l. Glue and screw the
upper rail under the top (C). 1110nglue the
lower rail 10 the shelf. and screw it 10 the
facing. see ~~1g.
3b.

,_;'TlR

.all I',"

(I.

oaOOV'tTO
FrTTONGUE

J_

the side panels. and

rip IWO side facin"

(D) pieces 10 final

an

_l_.

b.

.... W()OO..

scalW

,12" .. "

I'

J 16"

5MAHK

./

HOt.!

, ','

,J_

LOWER

SIDE
FACING

RAil

,'

__...LJ..

....

MOLDING AND KICK BOARD

Next I added edging

strips, " kick board.

and molding 10 give

the lower case a
finished look. All

three are mitered.

and cut flush with
ih~back.

length to fil across Ihe front edge of the ply.

wood lOp. S<'C ~ig.4. Then glue it in place.
Now miter the front ends of the side strips.
and tUI the back ends flush with the back.
Then glue these strips in place.
KIC!iHOAJUI. To make the kickboard. rip
three piec es of:Y~'-thiclc.
stock W width and
rough length. see Fig. ~. Next. miter the

The safest way to make molding is 10 sian

will. wider pieces. Sl'C Fig. 5. (I uS<.'<II V."wide blanks.) Ripenough stock 10 make four
side molding strips (J) and tWO front

molding strips (K).

Next. rout a Roman ug,;e on the outside

L-dg{~f.)( eaeh 'Strip.

then rip the JlluldiJlg tu OJ

finished width of \12". see ~lg.5. Cut the

molding strips 10 length. then glue and
IiOGING S11U1'. To kickboard fronl(H}and kiekboard sides
hide the ('dge. oi th~ plywood top, I glued (1). To complete the kickboard. cut the back clamp them in place, set' Fig. 4!lACK.The 6nal step on the lower C:I:;.,is
:~"thick ed~gstrips (G) to 1I1~iront and edges flush with the back. Then glue and
to add the back panel (L). Measure besides, see Fig. 4. Start by ripping a blank 10 clamp the pieces 10 the lower case.
width the sallie thickness as Ole top, sec Fig.
RO:lL\!\OGEE_"OWING.J added strips of 1W('('nIhe rabbets on the sides, and between
,I Then rough cut the strip into three pieces. Roman age" molding to the lOPedge of the the rabbet (In the lOpand Ihe floor. Cut the
Ne).t. miter both ends oftbe front strip to kickboard and undcrthe lOp (e). see Fig. 1. back to size.then screw it in place,

,"

/ '6 .. ~.fh.
,

WOOOS<:RtW

CROSS SECTION

~=:::;;;:_~~@-~.~:;;:w-

::.>

./
/"

BACK

/-<i)

OGfI
MOWING

'_.- PLYWOOD

BACK

ROMAN
OGE DETAIL

(i)..

WASn

ROMAN
OGEE
MOLDING

ROMAN
OG
MOLDING

e-

11. .... __

-<D
NOTE:

CUTAND OW! ON
FItOHT MOl.DlNG FIRST,
ntm GtUf ON sto( I\\O\DtNG

No. 78

-~0

3"

KICK80ARO

UPPER CASE
After th~lower case
was com pi ele. I
began work on Ute
upper case. The
upper case is buill
much like the lower

L,:-"'" "1
';'L:? "----1

the sldes.

b.

The top and bottom (~[)

I.o.~

art' idemical Each is a plywood panel

framed on three side'S. To build them. cut
two :v." plywood panels to size. see Fig. 6.
Next, to accept tile frame pieces, cut a
groove centered on the front and side edges
of the plywood. see Fig, 63. Then cut a ~',I'.
wide rabbet on the back edge of each panel

10acceptthe back.see rig. 6b.

TOI'/KOTIOMF'RA."~:. Now the frame
pieces can be added. The frame fronts (N)
and side (0) pieces arc a little differem than
uSllal-they'reonlr ",,".Ihick. Since the plywood 1> :}f,.!hick, a rabbet will be formed
when these frame pit'<.'<!S are glued to the
panels. see FiR.6, lhis rabbet will accepuhc

I,," ROUNO.OV(R

Ca!<E'. but the shelves

aren't dadoed into
TOP/pan'()M.

clITTONGUE
TomOROOVf

Q.

-@

a.
:

-,-...

CUTRAun ......
ON lACK (OG

FRAME SIO~

"1

CIIJ .....

an

ON THEINSto(

SIDE

TOP ASStMal.Y

",(I(

RfMUae"
fACING

EDGt

DOWNW..o

sides and front faces of the dille.

AileI'

culling the frame pieces to width,

roiu a ~., reond-over on one edge of each

piece, see Fig. 63.Then CUI a rabbet on the
OJlp08il.'edge.to create a longue thatfits the
groove in the 101>/bottom (M).
Ailer the tongues arc formed, miter the
frame pit'Ct. to fil the panels. St'C Fig. 6,
Then cut the ends of the frame sides (0)
Oush with the back edge of each panel
TlIREADED ISSER'r.>. After Rluing the
frame ill place, threaded inserts can be installed in the bouom panel 10connect the
two cases. see 1'iJ!. Sa. To locale the inserts.
center the bouom panel en lOpof the lower
case while making sure the back edges are
flush. Then mark through the holes you've
drilled in !be top (C) of the lowercase.
SlIll:S. Nowyou canstart on the IWOsides
(I'), First CUllWO pieces of :}f," plywood 10
final dimensions, see Fill, 7. Cut tongues for
fadng (Q) on the front edge of each panel.
and. rabbet forthe back framc on the i1I id,
back edge of each panel.see I'j~,7aand 7b.
.-IS."~IBIX. To assemble the case. firsl
drill shank holes 1I1roU)(hthe tou/bouom
assemblies. see Fig. 8,1'hon glue and screw
them 10the sides (I'), $C(' Fig. Sa,
SIDEFACIII'G.
To rude theedgcsofthe side
panels, glu(' a I"wid(' face frame to the
upper ease, To do this, firsl cut two side
facings (Q) 10 ICIlRth In fit between the
lop/bottom (M) panels. see rig. 8.
Next. cut a groove on the back face of each
side facinll (Q) 10fit the longue Onthe front
edge of the sides (p}.11lenglue the racing 10
the sides. S' Fig. 8,
FACt: RAILS. Nowcuttwofaee rails (R) to
fil between ine side facing, sec Fig. 8, Then

.,.

IHSlOf:FACl

b,

SlOE

SIDE

<p

IABIET fOItM,ED
AROUNI) lACK [DOES TO
HOLD BACK fRAMllN PlACE

IUAlIItAlIUT

fACING UPWARD

UPPER

SIDE fACING

FACE RAIL

@
,

<?..

ORltL ~'." SHANX

HOIISfoa
WOOOSClfWS

LOWER

v:

.,..

FACE RAIL

UPPlll CASt

ASSlMIlY

'It"

e.

aonoM

aoTTOM A$SfMal Y

.<;
\

Mlx.1."Fh..

I.

WOOOSCREW

....lOWIR

fHREAMD

CASE

1N.SEAT

TOP

glue and screw 1I1eminplace.

10

Wo<xlsmith

No. 78

BACK FRAME
Once the top. botS1\1lIn:NOSS. Nowcutstub tenonson the the back panels (V). see Fig, 9. CUI Ute
end. ofthe rails
and divider (U) 10 fit the back panels M from \14" plywood 10 final
tom. and sidesolthe
dimensions. and glue the frame and panels
upper case arc as- grooves, SO!(! F'Jg. 9a.
P,I)'/Et$. Next, dry damp the frame in the together. see Fig. 9.Then glue and screw the
sembled. the next
part to build is the cabinet 10 determine the final dimensions of back frame in place. sec Fig.9b.
back. TIle back tonslsts of IWO 1('" ply
9
wood panels in a
frame. joined with

en

_=

L..t::::~_

stub tenons and grooves.

~1IA.\'E.To build !lw J'rdOlC. first rip we
stiles (Sj.rails (I). and divider(U) to tinal
widths. see Fig. 9. <Noticethey're aU different widths.)
To determine the rough length of these
pieces, measure the opening in the back of

ihecabinet

NOTE:
GROOVlCUT
ON INSlDE mGES

rabbet to rabbet) .a nd add

10 this rough length.
(('hey11 be cut 10 finished length later.)
(Crolll

I". Now cui the pieces

BACK

I
51"

Next. cut agroove centered on the inside

Sl1U

STtU

BACK

edge of each piece to accept 010 I,lywood

back panels. "e~ l'lg. 9a. On the center
divider (U) cut the groove on both edges.
Nowthe pieces can be cut to length. First,
cut the stiles 10 fillhe heigh; of the opening
(52"). and dry clamp them in place, To determine the length ofthe rails (0. measure the
distance between the stiles (5) plus the
depth 01both grooves, see Fill.9.
Aflerthe rails are cut 10length. dry damp
them in place. Then determine the length of
the vertical divider (U). by using the same
procedure asthe mils. see F'Jg.9.

OMDER

-(!)

--...

BACK

PANEL

b.

-.~~~%

MOLDING
The final step on the upper case is to add the
molding to the lOPofthc cabinet. The moldillg is built up 01thr ee dilie",nt.trips: a dentil molding. a Roman ogce melding, and a
square edge cap. see rJg.ll. The trickiest of
the three is me dentil molding.
DE~"L ~tolJ)DOG.
1 wanted the blocks in
the dcntil molding to be equal in widih and
cvenlyspaccd apart. Ialso wanted full blocks
on both ends. see Fig. 10.
tmadetheblanksforthcdennl
front (\\')
and side (Xl pieces from two pieces of '1'4"
thlck stcckgluedtogether.see rlg.lla. (Or

10

'\1'- DfP
DADOES

-~--

you could usc

single piece of I \o'z"thiek

stock.) Lay out the dentil blocks all each
piece and then cot the grooves. For more
information. see Shop NOles. page 16.
Afleryou're finished cutting the grooves.
miter the dentil pieces to fit around the front
and sides of the cabinet. sec fig. 10. Then
glue and screw them down. see Fig. l la,
TOP MOIJ)tNG. I found it easiest to make
the Roman ogee molding pieces, and glu.
them to uie square edge caps bero", cutting
them 10final length. To make the the froot
(Y) and ..'ide (Z) ogee trim pieces. first rout
3

11

a Roman ogee profile into the edge of lV,"

wide stock, see Fig. Ila.
Now you can cut the pieces for the front
(AA) and "ide (fiB) caps I \ft' wide. Then
glue and clamp the caps 10 the agee trim
pieces with Ille bock edges Rush. ""'" Fig.
Iia Aftcr the glued-up pieccsare dry. miter
them to firon topolthe dentil molding.
CABINET
ASS.\IBtl'. Merlhe top molding
is glul'(! and screwed in place. set the upper
case ontopofthe lowercase.Thenfastenthe
two cases together using V." machine
screws to fit the threaded inserts,

CAP

- ':::::i.
~C' . ~

;..i'

-- .,~~..:::.. ._

,8x 1-"'.

. wooo~~

<!)...Y
ROMAN
OGEE

MOLDING

No. 78

Wood,;mi[h

II

DOORS

...-....I!!."'"---,

'IDe doors offered

the biggest

RAll.SA."O DIVIDRS. Then, to determine

chal-

lenge on the display

cabinet, (For an explanation on joining
the door parts. see
pair<'14.)

sn LES.

DOOR

I';"co though

the
upper doors and lower doors are cli(fc"'01
sizes, the apprc>achto building them is the
same. To determine the length of the stiles
(CC. DO). firsl measure the height of the
door O)X"1liDg. Then add "'." since the doors

are liptX.'dwith a II," OVIr!aP. sec r.g.12.

Next, cula groove and round over the it,
"tipedge of each stile, see Fig: 12a.
OOORwnnn. To determine the knglh of
the rest of the door pieces. start by rneasuring the width ofthe opening and divide Ihis
measurement in half for the two door> (in

mycase.ISW').

Now suhtr.lCI half the gap you want be.

tween the IWO doors (VI6").111enadd the
overhang for the in,.,1 hinlll'" 0',0") Thls
made the width (,f"a,'h door 18-'11.".

12
'.'

-,~
-

111., ..

111})"~

thr length ofihe raits (EE) and horizontal

dividers (FF). layout two stiles with the
routed edges facinginasin thcfinishcddoor
(ItWA" apart). see Fig, 12. Now measure between the wooves.
Nler rutting the rails and horizontal
dividers to this length. CIIIthe Iongues and
dadoes on each as shown on page 15.
VElmt'AL l)l\11)llS. To determine the
ltngth of the vertical dividers (GG. HH).

dry assemble the stiles and rails. Then cut

the dividers 10 length and cui the tongues
and half-lapjoints, so.'CP'gl' IS.:-lowglueand
clamp Ihe pieces together,
CAl'S. All the rails and dlviders have a
molded cap (IJ. JJ. KK) glued on lop. The
caps arc rounded over on the lOPand coved
on the ends to match the molded edges of
the stiles and rails, sec Figs. 13and 133.To
determine the length o( all the caps.
measure your assembled door. (Again thi.
is all explained on pages 11 and 15.)
O'1-:R1lA.'1GAND ROONl).()\'ER. Once the
door is assembled. rout a 'lot" rabbet around
tile back edges of each door. see Fill. 14.

This will (ann a II." overhang and leave W'

clearance between the door and the cabinet
op;tning. Next. rout a II." round-over on tile
ji'<J"f edges, see l'ig.14a.
.~"J'llAGAl..The next step is to add an
ast:rag;ll (IJ... MM). Whal'san astragal? It's
the strip lhat hides the gap waen the doors
are closed. Glue it into the rabbet in the left
door. see Figs. 14and lla.
ItANG nOOH!i. Before installing the glass
and panels in the doors. I positioned the
hinges and drilled the hinge screw holes.
(For a tip on doing this. see page 16.) Then.
remove the hinge, In mount the ~
and
raised panels.
P"'~as. STOPS. U,\RUWARl: To dress up
the bottom doors. I made :Vl"thick raised
panels (N'N). They're "raised" on both
(aces with a ""'. core box bit. see Fig. 15a. I
held the panels and glass in placewith quar-

ter-round glass SLOP (00). see rig. ISb.

After the doorsare rchuog. install the knobs
and door catcbes,
SHU'1-;s. Finally.glue upandcut stock for
three shelves (PP). For information on 10'
eating the shelves. see Shop Notes, page 17.

13

-"I

-@

VERTICAL
CAP

RAIL CAP

ctD

HORIZONTAl.
DIVIDER CAPS

a.

...1-_
I....
ROUNOoOVfR

,.,

ir..

<W

CtJTtOM

GRoove

......

ur

I" .. OVUlAP _

.-

a.

21)}- __

14-",-

' ,"

ASTRAGAl.

ROUNDOVER

b.

@@BJ

GLUE A.S1'RAGAL
- lEn HAND

12

...

RAISED
PANEL

oev..tt

a.

CAPS

-~

...

+~=F::"
J';'
' .._:
__
---' T

LOWER STILI:

14

_2'4-

--@ GLASS STOP

I.",_ I,,"

to

DOOft

\VooJsmlth

No. 78

.)

 Gun Cabinet
W

llh a few changes, the

thick stock to width. see Fig. 1.

I>isplay Cabinet shown Then, lo determine the length.

Oil pag.6can beused In show off measure the distance between
a collection of riOes.
the sides in the upper case,
l PPElt DOORS. One major
Aftercuttingthe rail to length.
change I made to turn Ihe cabi- cuuhree notches along the back
net into a gun cabinet is the edge o( the barrel rail io (il
upper doors, To offer a beuer around the stiles and divider in
Vtew. t used a single sheet of
glass wiLI\out dividers in each
door instead or eight panes. TI,.
stiles and rails remain the same

as on the Oi.piayCabinel.
U)CKS.Another change on
ihedcorsis toadd locks. To belp
keep the guns and ammunition
secure, Iinstalled locks on rhe
upper and lower righlhand
doors. see Fig. 3. Each lock is
mortised into ihe back of the

the back frame, see Fig. 1.

The barrels rest innotchesent
in the front of the rail. To make
tile notches. fi""t drill I" holes as
shown in Fig. 1. Now CUl up lO

the holes

to complete

the

notches. Then round over the

top and bottom edges of each
notch and the fronl edges of the
rail with a VI" round-over biL
I screwed the barrel rail in

place through the back frame

doorrail.and hooksoverastrike
plate on the back 01 the cabinet
face rail, S<'C Fig. 3a. \Vilb the

aOOultwo-thirdso(lhewa)'upon
the upper case, see Fig. 2. (You
may need to reposition yours.)
right-hand doors locked, the leftRUU: BAS!>.The rifle base is
hand doors are locked securely CUi from a piece of'll."thick
in place by the astragals,
edge-glued stock. CUi i19" wide
Two.PARTMel\. The major and 10 Ipl1j!th to fit inside the
change on III.. inside of the cabi- UP1>& case, see iJR. 1.
nel Is Ihe addition of a lWO-p"J1
Aller the riOe base Is CUt10
rack lO support guns, see ~ig.I. size,lay QULfln(1cui the slots for
Ibased the dimensions ror the the rifle butts, see Fig. 1. I
rack on standard rifle barr ..ls rounded over the lOp edges of
and buns, see rig.!. If yOu have each slot and the front edge o(
a gun that's unusual. then you the base piece with a It," roundmal' have lo modify the rack.
over bit Finally. screw (don'(

build the bar- glue) the base in place rrom the

rei rail. firsl cut. piece of'll,". bouom of tile upper ease,
HARMEL WAlI_To

1
~,------

BARRfL RAll
3"""

w,' Ttl". SlOG'l

,I

BARRfl
....-RAll

.ACt(

$_

' ...

11..,-fh.

lACK

BACK

DIVID,..

5TIU

WOOOSCUW

No. 78

-3",'."---------~

Wuodsmith

J~

JOINERY

Matched Moldings
I

always admire thelightfittingjointson a

wellbuilt cabinet door. If irs a glass or
wood panel door with dividers. as On the
Display Cabinet on page 6. I'll spend as
much time looking at the coped and mitered
joints as Ido at what's on display.
To build a door like this. you could either
hand-cut the eepod miters. or use an ~~nsive serer router bits. Instead. I use another
technique for making matched molding
joints. At first. it may look ~omplicated
(there are a lot ofpieces) but iI'Soot difficulL
The keylo this technique isin the ralls and
dividers. Each rail and divider consists of
two separate pieces of wood (a%"thick bot
tom dividcrorrall and a cap) glued together
to look like one. see photo.
Why go to the trouble of making raJIs and
dividers out 01 two pieces? The biggesl
advantage is lbat you can break the operations on these pieces down into three sepa
rate steps. First tongues are cut on the bot
10m pieces. Then round-overs arc routed
along the inside edges of all the pieces.And,
finally. the endsof the caps are "copedwith
a core box bit to match the round-overs,
\Vhen all these pieces are glued up, the
parts should mate together perfectly. The
Longue on the dividerorrail fitsintoa groove
cut in the stile. And the decorative roundover 011 the stile fitsinto thccoped end of the
cap like a nut in a shell, see detail at right.
Using this matched molding technique to
build a divided door requires a few more
pieces (and steps) than a typical doorfraroe.
To keep them all organized. I juSI take it a
step at a time. starting with the stiles. When
they're finished. cut the dividers and join
them into a grid. refer LOthe Dividers/Grid
section. FInally, make the caps and glue
them to the grid. refer 10the Caps section.

EXPLODED VIEW
HORIZONTAL
DIVIDER

snLE

RAil

THE STILES
lNSIOCFA-el-

TOWARD FtNCI

f- -\ ~

smt

RIP

"_;Na

~~THIOC
$t1U

fAei
DOWN

INSiDl

-~,"i'! .
~

..
."" II

--.;1,.-

[.~
.

1I

\. I

RNCI

Ir-

INSiD[ fACli UP

~
.

'4. ROUNDOvalO'

First, loek
the rip fence -v.'
Nert.trim 1/,'of/tilt back ;lIsi.Uedg.
._l10U1tt '1,bit
1/romolltsideo[sawb/(Ide.
2
TJIIl'!,lqith
3 tabte, mw at.(j1<st height to
0/ eaclt stile. To do lilis .et "eight 0/
Ur i'll1!iJJJ!/act o/th."i/eu(J<Iillst tlw/eIICP.
dOlO'll

eu; a +'x'-det!p kerj

14

011

in.ide odg~o/$Iile.

J"Ol'IIut-ol't"r

ill

router

le<lt't Ifa'

blo.de to jll.1 CI<I hllo ""rJ. PO.itioll/ellu ~"O/llbr TIl"" rollt ",Mb edge Of each
anaW till! (rim"'''AIpietefallw u'l1!tellide. stilt. (Save set"p/ar rollliug ClIppieces.)

Woodsmllh

No. 78

THE DIVIDERS/GRID
The bouom dlviders and rails separate Ole
glass panes or panel. of Ole door and bold
the frame IOg\!lher. The first step (Step 4) is
to CUi tongues on the ends of each piece.
Then, half-lapjoints are Cui (Steps 5 and 6).

Wfom

Of: OADO
EQUAlS WIDtH

HORJ:ZONT Al
OSVlDflt/ltAJl

NOTE:
TONQUI MIJST_~--...

INSn&.!

FnGROOVt

OJOMDatS

and the pieces art' assembled in a grid. ""

nally,lhe grid is glued 10 the stiles (Step 8).
To determine me length of me horizontal
rails and dividers, begin with me final outside measurement of your door, Then subtract the width of the Iwo stiles, and add :V.".
(This lakes inlo consideration the :j1;"-deep
To tIlt tn t<m!!,(f-$on Ute dividers,
Celliera 1!lI1flap(}>,tlleumgtltofea<:/t
kerf that was made on the two stiles, a.
cia "'P all a".:ciltary feuoe 10 tilt
boreonta; divider/rail. To Cllt theJJe,
shown in Step 1.) 111(: vertical divider is the fonce, Tht11 St t/t.uce1{.,"au'(lV/ro", tJtl:ortt .. ..t "digl.t of ,' iUJdJ> (or width of vo"r
samelength asthe sules.
tride rdoe oftlte bltuh. and make tlu: cut.
divid"rk) toll(llftlt~ thick)!fs"ofyolt r81Q<:k.

"P 5

STIll

V[ITICAL

OM"..

Cut IlUtl.<:hill9ho.if 10./'8on l",rli<o.l

To "elt positiQII IIorizollll1l divide,.,.
First, gl". up lite dWlders and miu
6
7
di<'itkr witl<""II", d(ld" xet-up. End
for assembly, ".e Ihet't11ir(l./ dil'idl'l'
8
Tlu!tl 9lue ~Iile.~
"alfla~
Ihpa71d boUo", are IOll9(Jrlofit as (/.
slick." slark lcx:atio1l of each grid. T() keep the comers from lifting.
l

ill/o II grid.

a/.
",ider top (Hid boUQm roils.

"SIO)'1I
Oil blu-k j IIside edge

half I(lp

of the stile.

(0 UI~

cw.mpaj!o.t piece of wood aC""'8 U,e .tries.

THE CAPS
Once the frame is ""''''<lolbkd,lhe 18S1steps
areto add thecapsand insen Ihel[lasspanes
or wood panel s,The purpose of the caps is 10
stiffen the frame and match the molding 10
the decorative round-over onuie stiles.
To determine the thickness of the caps,
measure from thefront face ofthc stile down
10the grid tW' in my case).
In a divided door, r.behorizontal and vertical caps can', both run Ihrough uncut. for
RAILCAP
the most rigid door, I always span me shanest distancewith the uncul cap. (00 the DisRip ra~ to .!'idlll al/o.mng V,' 01'CT'
Witl, heiglot of rot(Jr bit set tlte
play Cabinet. that's the horizontal divider.)
11("'90>1 IWell tdg<l an.si(/(> edg' o1lly
.'ioml' (J1r l(lht'"ll 1"OlltiJ,g th stiles.
Then piece in the caps running in Ihe other for rail raps). TIt<!OI:t:l'hIl11I1f(fm,~arabh<'t IVUt tlu: pl'Ojileollboll. ,>dyes of rite divid8r
(vertical) direction.
thu; }IO"'" rheg/a",' or wood panel ill pto.ce, capsa71d"'~ldeedg.ofeaclt rail cap.

10

CROSS SECTION

s""'f'"

c"......
..

ClASS

?
"

.,

(1'C" OUA,ftTtR.
ROUND

5l

!Will enels of all cap pietu with

Positio cap pieces un botlom
Apply a feu spots of rilico>!. if!
II"!" ('ore bar bit to Jnatc/l ro-t"ld
grjd~1tJril1yQ 11-, "spacerasQg<J.uge.
grooves. Tilt: rured silicon "'ill
Oller.! 0" malin!! pieces: AfllklJ tria! cuie t Ali!!,' edge of spaceT1(tilh edge of cap. Then.
keep 9/4& from moving SIdeway s. Insert

11

iklm'm;'lt }wight of bit and deptll of "<41.

No. 78

13

12

glucatuic/4mp

ill p/flre.

Woodsmlrh

glass alldsec",,, lUith 1/,'quarter-rOlwd.

IS

SOME

P S

FRO

OUR

.~I

SI-lOP

Shop Notes
CUnlNG

DENrlL MOLDING

.11 you use an il1dcKinllsystem So. use a tape measure lhal'~ as you can usc 10gel all the demit cabinet. It's nOI practical to
like a bu.joint jig ItJ cut the den- least as long AS lh(> workpiece, blocks 10 up""ar very close 10 divide the- extra ~" among all
til molding 011 the Display C3b~ and don 'I move the tape a, U1e' same size.
th~ blocks 10 g~lthem the exact
net, you Call run into a problem y(,u'r~ marking Otherwise,
After you've measured and same sil~.Jl
worksjust as well to
If the jilt i,n'l "'I up ".',{ccl/y. you're Roing tt) be back with the marked, you'll know whether make 'Jp the- ditrc!rcncc on just
there can be a slight gain (or .gain" problem again.
the last <'1.1isgoinglo produce a Sumu of the blocks.
IOS$) between each cut that can
COlll'EJ>SAlL"1G. Whal if you dentil block the same size as the
For example, to comoensate
(or
a molding strip thai's '-II" roo
add up. It doesn't lake muell cut 3 molding strip Ihnl fits your first. II it doesn't work out
error (a$lilll~a. 11128") in Ihedi ... cabinet, bill it's nOI Uw same ('XacUy,YOIIcan "chear" slij!htly lnng ... art chealing \t.t" on the
lance betw~n CULS tobe notice- length as called for in the plans? on the layout to compensate for laSt eight marks, ,..,fer 10 Fig. 2.
able by Ihe time you get It) the Won't each of the blocks be the difference
This way, each of the last eight
end of a long workpiece
dirferent than ~ificd
in the
Say your dentil molding strip blocks will be \t.t' 100 large,bUI
Ifthere' ~a l"lin or 10"". \hv last pian'? Yes. bUI there's a Irick has to be out '-II" longer-to fit the thls shouldn't be-noticeable.
derail block won't be the same
....
ize as IJlt' rest, and Y{lU11 be able
1 ....T DENm e.tOQ(
LAY OUT STau> nur~
2 TO "CHAT, LA,T0Ul DADO
ISSAMl stU
THEN CUT DADOES
to"," the' difference, $4.'<' Fig. 1.
, AS OTHlR:S
TO MARKS
..... MAAJ($ $l.lGtnLY OIITSIOl
MEASI"REM'O'1AR1t The best
r
D(SlRlD lOCAnDN
wa) I've found to get demil
blocks that all look ~I~ sante 011
a lollS!workpiece ii' lola)' our the

position of the dadoes with a

pencil instead of usingajig. (For

the Display Cabinet. the 1'4"
dadoes arc :v.." apart.)
\Vbe" you CUI 10 a mark. it's

I
..,.,...._,il

..__,...t.ASTDlNnl.locLK:-.....J
IS NAUOwtl

important that the marks (or the

dadoes arc laid OUI accumld)'

THANOMU

-!'1..

r 1......-1

posmo,." Of ,DADOES
CUTwmt fNO!lCQ'tCJIG

C4N GAIN AfT(R MANY curs

INSrALUNG INSEr HINGES

.lnsel hinges. like the ones
used On th. I);splay Cabinet on

page 6. can be more frustrating

to install than ordinary butt
hinges. Since both leaves of the
hinge arc inside the cabinet
when che door is closed. the
screw holes in the hinges are

tough 10reach.
POSmoN lOP AN.DBonOM
HlNGf.$: 2',," FROM RAIlS

IIII>GE TO CABINET, Ta g~t down and a1sole[IICl right.

around the problem. J used
CUUIPTO 1)()(lR.Then.tohold
clamps as temporary screws to the doors in this position, I
hold the hinges 10 the doors clamped the free leaf of each
l><Im" the glass was installed
hinge IQ the door slile Iltrough
To do this, firsl screw all the the windowopenin~.see Fix. 2.
hinges (0 (he cabinet frame. see This way, lh.. damps hold the
FlJ{.1. Nnw pUI the doors in the door ill place,
door opening centered up and
ll1NGETflDlJ(IR,Wilh aclamp

POSfT1ON OOOIU IN. c;AltNlT1

~-.'r-

,/J. - .

-/

for the screws, seeFig. 3. (I used

a Vix bit, see page 31,) Then,

screw in the screws (In(1 remove
the clamps 10 check each door.
Now the screws can be removed
and then reinstalled afler the
gla5.~i$illplatt)

snlf

'"(i:; -l

1~

.t

SCR[W AU HlNOf5

to (A81NnfUM'

16

the doorsanddrillthe pilot holes

THtN Cl.AMPfltH llA1

TO D<>Oa

~ 2',

on each hinge, youean nowopen

-,

OPfNDOOCt,

LAY

DAiU PIlOT HOUS

CAllNflQN
ITS BACl<,
TOPOStrtON
DOORS

IfOI; SCREWS

Woodsnllth

No, is

POSITIONING

CABINET SHELVES

\Vben Ulcr. arc windows ou a and lOp edge of each window

<'1lbinCIwith shelves inside (likt' divider. see rill. 1.
Ih<-Display Cabinet) I Ihink it
MAlIK SUEI.!' .:oc..;". Now. relooks best if the shelves are hid- move the slick (rom the cabinet
den behind thewindowdividers, and lay nut the position of the
I( th<' shelves are much higher shelves on the stick, see Fig. 2.
or lower Ihan the window
MARK rrx LOCATIONS.The
dividers, Iht' dfecl of 100 many flnalthing 10 lay nul on the Story
hori7.onlallinc<can look "busy," stick is the location of the holes
STORYl,TI(I(. To gel the lor the shelf Support pins. On the
shelves positioned properly I Display Cabinet, I used spoonborrowed a I.",hoiquc used by shaped pins. see Fill. 2a. (For
cabinet installers. The I.. ch- diIferenIpins. adjust the posilion
nique involves marking the posi otthe holes accordingly.)
lion of the shelf support pins un
By centering the hole on the
aseparate marking gauge called width of the story stick. the hole
a story Slick. Then. when holes will be the same distance from
are drilled inthe Slick. the gauge theedgewhen marking the front
will acl as a guide when dolling and back of the cabinet,
the holt' for the shelf supports.
USlXG TIlE snoc AlIE'rholes
To make astory stick, fil'Sl rip are drilled through the 'story
piece of scrap wood 10 a width stick Cor all three shelves, the
of 2". Then cut this Slick 10 stick can be used as a !(\lide (or
lellglh su 11 fib Ilghlly up and t1rimllg 111<,.ltd[support hoi.".
The only secret to using the
downinsidctbccablnet,
Tokeep
everything <truiRhl. J labeled SIOryslick is to keep the front
nne end 1'01>."
edRe 01 the stick Ilush 10 the inTo gel the holes on the slory side edge of the cabinet when
stick in juslthc right place. firsl drilling the holes for the frunt
lemporarily clamp the Slick 10 pins. Then bun the oppnsile
the door. 5C<' Fig. I. Make sure edge of the slick 10 the back of
the stick is strnigl,t lip and down, the cabinet when you drill the
and turn it so a narrow eds,::e holes ior the rear pins. see Fig. 3.
raCt'Sthe Cront.
Note: To keep the ~helves On
the Display Cabinet from sag.
MARK 01\10ER EOCES.Then.
use a Iry square to make IWO ging. 1 also pUI a pin (or each
pencil marks on the story stirk shelfin thevertlcal dividerin the
that correspoud 10 the bouom back of the cabinet,

SEQUENCEFOR CUnlNG

""'K$fOQ
WINDOW

OlVlOfR .. "-

f
rna<
YO

"AUGH_
...

OOOR

"'-

-i'7 .
OF PIN WITH

eonoHOFSIIW

MAlIk.

.oa

lOGo
Of

SHru

a.

O?
$,""
SUPPORT PIN

3
STORY
SflCK

_,
uss SQUAJtI

to

MAU TOP A.NO aOTTOM

Of OIViI:IU ON STORY STiCIt

POSn1ON STORY

mcx

A.I.tSfI. fO tN$IDl

fOGES OF (AaINET

HALF LAPS

followthis same sequence when

cuning tenons.)
The first cut I make is the
shoulder cui. using the fence as
a SLOP block. see Fig. I (Since
\Illen making '11Ch a cut.the this isn't a through -c'UI. there's
end of a thin workpiece can Oex no danger of kickback using the
up and down. This movement fcncc and miter gauge lQgethcr.)
<'WI make the halflap thinner al
The next cut Imake is at the
end uf the workpiece. Then I
the end than at the shoulder.
The solution is tocut the lapin clean out the waste in between
a sequence that prevents the witb successive cuts back
workpiece from Ocxi.ng. (I alsc toward the shoulder, see Fig. 2.

.1 ran inlo 3 common problem

working on Iht! vertical dividers
for the doorsof the Display Cabinel- tUliing lOll!( half laps on
Ih~ ends o( a thin workpiece,

I
l

No, 78

\'(lnodSIl11th

'lMIRD:
JttMOvtWASn

17

WEEKEND

.,

PROJECT

Sewing Box
This Sewing Box is really three separate boxes, all made the same way.
\X/ooden arms connect the trays to the rnain case and, when you pivot open
the trays, there's room inside the case for longer materials.

'"T\c biggest challenge I had in designing

.1. ;i,is Sewing Box didn'l have anything 10

do with making the boxes, The challenge

involved de.igning it SO the tOP trays pivot
open and sit (Ial 00 the lower box without all
the contents spilling out,

The pivot arms used for attaching the trays

aren't unique - ifs the same system you see
on tackle boxes with an inside tray. But to get
them 10work righl invelvesrwo things: CUlling

a traditional s<'wing or knilting box. Bill. for a

box used 10bold other craft supplies, you may
prefer the look of 8 contrasting plywood top,
WOODAXil HARDWARE.Except tor the ply.
wood tid and bottom panels. I built the entire
sewing box (rom clear white pine.
1'0 act as shafts for the pivol arms, Iused
brass rivets instead of screws - SCrews can
work loose after a wbiJe. Then. 10 match the
rive IS, I screwed the carrying handle 10 U1C
main case with roundhead brass wcedserews

the pivol arms so they're identical, and mourningthem all inthe correct locations on the box, and filed the screw heads ftal.
UIl1"REAnlEl''fS. We're showing IWOdiffer
Wood8>1. illl Projrcl Supplies is offering. kit
ent ways 10 complete the lids thai cover the of hardware for the Sewing Box thai includes
Ira)'>. A fabric-covered lid is what you'd fiod on the rivets, brass woodscrews, and birch knobs.

18

Wnc,X,bDlith

No. 78

EXPLODED VIEW
Cl.O'l1t

OVERAL1 DIMfNSIONS:

8"W x 8V."H x 167,'"l

POlY't.STt;R

SIDE DETAIL

umNG--

..

UD
INSERT

- .:

jl>

~,'

Ul>

~-

fAAY

TRAY
DIVIDER
6l.

CAS'

CASE
SIDE

e-

TRAY

/'

"--"",,

'10xlRh
UASS

END

WOOOSCRW

PlVOT@
ARM

CUTTING DIAGRAM

PLYWOOD

MATERIALS
WOQDP ...ats

CASE
A CaseSldes(2)

11
3',,>.16'4

8 Case End$(2)
1'. x 3112x 8
C Case BonomO) ~. x l{)\.a- 'I. Ply

TRAY
D TroySldes(4)
E Troy Ends (4)
F Troy Bottom (2)

11
2.8
11
a x 2.8
7% x 7'1:, - 10'. Ply

UD
G LldSides(d)

lI.x'Y4.S

H LldEnds(d)
11
a x '1' 8
I lid Pone! (2)
7:V 7. - 'f. Ply
J Lldlnse<t(2)
7'12.711>-1/, Ply
OTHER WOOD PARTS
K Hondle(l)
%.6'1 8
L PIVoI Arms(S)
11
a x 112.51'.
M Troy DIvide,. (12) It x 1:V.x 7112

..

(2) %-,[)jo BlrchKnobs &. Screw$

(16) 1I2'Ex!r<XongBross Rfven
(l6)t6f1oIBl~Washer>
(2) '10. 1'!lhBrossWood!c1ew$
Itr. 20' Clolh Fob<ic (optloooO
10'.21)' PoIyesterBoItlng(opHonal)
Genefol Flnishes'Two-Slap SeoIocen

OllJUlI/r()m th4 k<1IUl~.

Toremot'l!lid/rom t/",t.ny,
pulliftro.igirlupoll

No. 78

SU.... UIS

Utekllob.

Wood.mtrh

19

CASE/TRAY /LIDS
Thi:-. Sev.ing Box i~
re allythreebox<s-

TRAY/UD

''''0 square boxes

... ilb lids) on top,

@@-

'.JIHC(

tllM

and a longer box

belew All three

boxes are made

WASl(

from '.-."

JOCI>ITS

pine reo
sawn to 1;.." thick,
HI)\ H'ANK....To 1><'l:ill,first rip a 3-foo,'
1001( I xliII) Ilntd",', IwO blanks - one ;W,
and lint'
rull~h widths. (These pieces
"'ill bo' trimn IIO fini,h,l1 width. 013~~'
and ~tt" .ail,' th, box joims aro cut.l
:\oYo l"UI Ihl' "",i,ll" piece to produce a
16"",,lonl( bl.nk lor the case sides. and an
'" long blank ror th.. <""",' ends, see FI8 1
~')lt.
Sdvtthe wa ..lt.'
-it can be used
latl,- a....t1 t,~ pecv tt)( the b.))" joints,
~lX-l.cullhe n.1ml'Al1" ~t! intu four So ..
lone blanks rur tlwltay (lid boxes, set' FI8, 4
Rt, \1\ ,-'111'{"\'\"" TOR' Iall the blanks 10
a unitonn ,,,. Ihkkn,~s. firsa resaw them.

TRAY/UD
SIDf.

END

Of'

una

CAR""I

I.~~~~~~~

.ox

""""VI
,.,~ uo

eur

:I"".

.._... '.-

,*'("C

I.

CASf

(ND
0

then

l)lotllt'lh('111 all to finnl tluckness.

K()' J()"1". 111(I)i,,\"t~.1rejoined

at the
com,'" with box joinls. T" build a box joint
ji~
lor making Ih"...:'jolnts, see page 2<1.
"l'R"1 C

4
"

I.- ..

CASE

,
aROOVIJOa

CASllOnOM

/'~

tl

SID

to WlMN

GItOO'II TO m
THIOCMlSS0' Pll'WOOO

.'/

I.'.f r !
I
)
,

flISl CUT AUGNS

WITH tDGI

Of PIN oa SLOT

~",,,'nwurm. Afkr you've cut the

box joints, Ih" pieces can be ripped lei

finbh"d widlh. Tomakethecase sides (A)

fU.Y/UD S'Dt
(4 P1tCrSl

.ndend~ (II) ,tan wilh~lt'3'h"-widepleccs

and ril' Ilw w I'''' ull Ihe' tup l-d~t:. leaving
(',urt, ('11 full ,lin" .111(1 ~'k
...
see Fig. 2
:>;exl, In prndun luur Iroy/~d sides (0
and <;) and foor 1tD~/lid ends (E and H).
rip Ih, ",I"~
off the 3 _'-wide pi<-ccs. Thi-,
,,;111.., Iula) ulthin""n full pinsand slots

on each

MOW ftNCl

JlSMWAST'
Of} AU. PI(Ct-s

pit"("

!.IIIM)\ .,.

SC'\'

..

"-

....

O'
CASiIdOl
('""$

"1J,t I

IlOCh ol'h~ thr ee box"," ha-, a

3Cl'C.'J)C' u.'l'lywcKKI. NnlC:1bc.tray /lid pieces

an~~rnH)\+t-rlIIl'3rh/itll t'dg~. set" Fig."

16'."

V,' bouom pam'l

that', glu<-dinto a j(rIIO''t'

n,'arlh, boil"," The'1I""QuatI' boxes h.\e
an additional pam-l r.,rajlToo"" ncar the top.
I us<<l II", tabh- -aw with a rip rc,"~"and
rut alllh"I:roo",', in IWO passes, S<.'C Fig, :1.
Un" up tlu- r...., cut with tile edge of the lao,!
pin (IT,lut), "" Fig, 3. Then move the ftnce
over ,Iillhll)' and rnnkea second pass (on the
tt.\'!\l pil'\:\' fiNI) 1(1 (n1alltt tll(. groove ~ it

0(0'

PI \'\\()()V, To d.'lmnlne the >i7.e 01 the

plywuml bottom, and lid panel>, firs! dryassemble .11 thl1'C boxes, Then, cut the pi),'
w.KKI bottoms (C, F) and lid panels (I) <0
each pil'('(' is \It,,"""lhan ihedlstance from
the bouom- Clr "JII'(I~ile grooves,
A.~~E)lIlt."
T" ."",mbk the boxes, PUI
j(lue on the box joinl' and in the groove.
Th<n clamp th< box ,.quare with u.e piy-

US( aACKING

wood in pIac".. " ~il!5. All"" the boxes

".rr "''''nlbl,'d, I Illm'd w,l1gl"$l,aped

I
I

plu~irue till I"" small ""id, on th~ ends of

tach box, "'t['-III, 6. Then I sanded Ihcplugs

and pin. Ou<h on all <ides of each box

HOI Nil OVtN, To make the boxes look
more (tni<hl-d, round over alkomcn;of each
box,tht 11'/1edll.,,,f .3ch Ira)'lIid "!\embl),
and Iht boUom ..flhe caw, """ Figs. 7 and S.

ao....O '0 J(m

lOX souAltr
ronNa

(c

G.

CUTPlUG Tom

vom..,,(hIOS
01 .oW

SOAP 'lOCI( ONlACHCOlH~

OISTRrtUt'I CLAMPING PR[UU

20

No. 78

SEPARATING LID FROM TRAY

Once Ille three main boxes are built, the two
8"square boxes can be on apan, This will
product' two trays willI plywood bouom
panels. and twolids witIl plywood lOp pands.
I cut the lids from tbe trays on the table
saw and used Ihe rill fence as a guide. see
photo at right. II looks like a slTaighlforward
operation. but there's a trick 10keep the lid
lrompinchingthe blade on thefinal tWOL1ItS.
nTT UD FROM TRAY. To cut aW1lY the lid.
fiThI ",t the blade height 10 !i'ltl' and adjust
the rip renee so the outside o( Ihe blade lines
up with the second SIOI from the top edge 01
the box. see ~ill.8. 111is will produce a lid
tilat has a total of three full pins and slots (in
my case. :y," hillh).
With the fence and blade adjusted prop-

erly, begin cutting the lid from the first tray,

see I'ij:(.8. Butdon'tcut the lidcompletelyoff
-first, cut through twooPP""itesides. then
stop. Here's where the trick CIlUleSin.
To keep the lid from pinchinR the blade. I
slid a picc" of W' Masonite through the box
(rom one kerf to t.he other. see photo. Then
I put tape above and belowit to bold the strip
in position. Now make the last two passes to
separate the lid from the tray. Continue with
the second box in the same manner,
11UMlRAl"ro DEPTH. Now seuhe two lids
aside and trim the trays to fmal depth. see
Fig. 9. For this operation. adjustthe fence ro
produce a tray with a total oteii(ht full slots 7fik"",tlte IidfftJllt pil/clli ItgIJu '010blll<k
and pins, see J'ig. 9a. Trim both trays to this cs it '. rill fN1II1 au' troll . 1ilk a widl' strip
final height (in my case. 2" tall).
of,l{(JJ;QlIil, tit 1'01,(/11
thefi "" tiro sall'kerfs.

..... fHlCKSPACtIt
.'01..0$ tctlltf OPt;H
~
1Q't.AST
TWO
(Ul5-----1

uo
~

TItAY

WASTl

....
Y
IDICt

!""'HOIDS
SPACER I}ol pu'CE'

n rl n Ll r

r.:':'
r'L

HANDLE
The S<'wiugbox has
a carrying hand le
that separates the
two trays, To make
the handle (K). first
cui a blank to width

10

)YHANDlE

11

f-....J

uS( Mrru. CAUCf W1T'M

AUXIUARY<[NCr TO

SU1>PORTHANOL(

and length, see Fill.

10. Then loy Out the

arcs on the top and

boltom ofthehandle and the hngeropelling.
Also mark the location of the :y," holes tllat
define the ends of the finger opening.
a

OllU.~."
fIO.. S

CliTN(lTCII!;S. Beforecutting thearcs.cut

notch On each side of the blank to allow

clearance (or the handle to slide into the

case, refer to Fig. 13. I cut these \,,".wide

notches using the miter gaUgl: on the table
saw. see Fig. 11.
SAWT()SH,\Pf_Nowcuuhcarcaonthetop
12 ROUNl>-OVOt
','
and bottom o( the handle. Then bore the f--'
holes at the ends of the finger slot, and
complete Ole slot with a sabre saw. Next, to
make the handle comfortable.I routed a
round-overon the curved edge>. see f"tg.12.
INsr<\U. IIANnLE. To install the handle,
fm;1 drill as hank holecentered on the length
of the case. Then line up a centerline drawn
00 the handle to the centerline on the case,
ROUND OVER AU DGS
see Fig. 13. No.....drill a pilot hole inlo the
0,- HANDli lXcarr
.... fIOTOI(S
handle. and screw the handle to the case,

1(,.

Nll.78

.~
Y

Wood,mirh

13
flU

sc.tW
"tAl)

'LATTO

R(MOVE
SLOT

21

PIVOT ARMS
When you're done
making the sewing
box case, lrayS. and
lids. the trays can be
attached to the case.
BUI the tray~arent
mounted with the
usual metal hinRe5.
Instead. they pivot

.... lt1vtT

14

IMT

/HOU

HOU

'-iLo,-/.,... '-

'" J
CD PIVOT

away from the case on sbon wooden ann"

Am

',"

and brass rivets.

PIVor ARM B!Al~K.Istarted making the

pivot arms by firs!cuttingover-size blanks to

length and width. This way. when the arms
arc sliced from the blanks. they'll all be the

lS

same size
To make blank. (or the pi''Ot arms (L).
first cut !WO lli."'.5 of Vi'thick material 10
finished dimensions o( 2\'.1" wide and 5,'
long. TIl"". Wore CUlling the blanks into
individual sections. rout a V," round-over on
thetwoendscteach blank. see Fig. 15.(NolC

ADJUST

the grain direction as you prepare 10 mund

over the ends.)
SUCE OFF ,\R.\I$. when the ends of the
blanks have been rounded over. you can rip
the blanks 10 (orm tile eight pivot arms. (I
also ripped an extra one to use .,3 test piece
when laying OUI the holes for the rivets.)
Safety NOle: Useapush block on the table
saw to slice the V,"lhick pivotarms (rom the
blank. set Fig. 16.
ftl\'ET'

tlO~

OtIC

of the

~"'fliKiJtPIVOT Ast.M5

0'<=1'1=

keys 10 smooth

operationofthepivoting traysishaving identical size pivot arms. Burthai's not an. \\11(>n
lhe armsare riveted to the case .the distance
between tile rivet holes has 10 be the same
(or each of Ihe arms. So I drilled the rivet
holes using a renee and stop block clamped
10 the drill press, see Fig. 17.
To do this.first layout the position ofeach
hole on tile test piece. see I'ig. 14. Then,
when the fence and "lOP block are locked in
the correct place on the table. driD a hole in
one end of the ICSIpiece. To drill the other
bole.jusl flipthe piece over. Note: Keep the
samcodge againslthe fence as when drilling
the first hole.
IAYOUTGAtiGE. Before you can attach the
arms, holes 1",\'1:to be drilled inibecase and

18

!ENa '0 PltOOUCl

PIVOT ARM

(or rivets. These holes have 10 be located as accurately as the holes in the arms,
So Iused "simple gauge to lay them out.
To make the loyoul gauge. stan with a
piece of scrapwoodeut toawidlho!S\'.I" and
a length of 8". see Fig. 18. No... lay out the
tocadon ofthe four rivet holes on the gauge.
and drill the holes with a VJ6" bit in the drill
PI'l'SS.Then, 10make it easier to line up tile
gauge to the workpiece. I screwed a narrow
cleat on tbeend of the gauge. see Fig. 19.
tray

To U!:OC the gauge. place itagainslthe side

oftho;;ewing box (with the tray in position)
and poke Ih.. drill bil Ihrough the glluge
holes 10 leave a mark that shows the location
ofth~ 'II;t" holes for the rivets, see Fig. 19.
rSSL\LLAItMS \VTn! RIVETS. \\lhcn all tile
holes have been drilled for the rivets, the
armscan be attached to the box. (It's easiest
to do this with the case lying on it> side.)
Then the caps of the rivets can be set with a
sharp hammer blow from inside the case.

CUT lAYOUT GAUGE to Sin. TKfN

MAIM LOCATION OF FOUR \",- HOlES
ATTACH C1EA.t
TO NO

a.

lrvn

... -- ..

"'GAUGl

lAASS

WASHot

."'.
,

,/ ---><::::___/

.J

. Da1U 1fT
TO MAAK LOCAnoN
Of HOLES ON CASE

AND TRAY $)OES

21

aRASS

Woodsmlth

.. HOUS
FOR fUvt1S

NOTE:

rHSTAt1 RlViTS
fHstQUG.H lOWta fNDS
01 mOl AItMSmtST

No. 78

TRAY DIVIDERS
I made compartments In each tru)'
using thin dividers.
The lnterlocking'
dividers also form a
lip around the tray to
hold lbl' lid in place.

dividers). Thencur the !-I!".wiliecndnotches

by standing the pieces on edge and running
them through the saw one 313 lime.
To cutthe center notches. position the rip
f~nce so the CUI is exactly centered on th~
Nm'CIlES. Thetraydividersfiuogetherby
lenzth olthedividers, see Fig. 21. Note: The
means nf interlocking notches. see Figs, 21 center notches are (\11 on the oP/>08itf' edge
err TO SIZ~. To and 22. Each of the notches are tile same as the end notches. see Fig. 22.
make UK! ttay divi- size. so Iused the table saw to cut them with
\\'ilh the center notches cut on all the
de rs (M). cut three pieces of 0/'," pine to just IWo setups. The Iirslsetup is for cutting divider pieces. assemble them to create
rough dimensions of 2" wide by 16" long. the notches on the ends or the dividers. The each divider unit. Then. to allow clearance
Then resaw and plane the pieces to produce fence is moved to cut the center notches.
ror ihe rivet beads inside each tray. plane or
I set the height of the saw blade to cut the sand the lower outside edge of the foor
six ~"'Ihlck blanks.
TIle six blanks can now be cut into tw{"I,,'~ ncrcbcs W' deep (half Ih. width of the divider pieces thOlwill contact the rivets.

21
I""

pieces that fit inside the tntl's. see FI,g 2L

Rip the pieces lO widlh so when they're
placed inside the tray they stand 114"above
the sides. see "'g. 23. (In my case, the
diyid~rs are OboUl1:\'4"wide.)

TRAY

tB....

DiVlDlR OUNlATION

DIVIDER

"

NOTE:
C;ENT[R

HOlCK AND

,..,..

AUtMIll' DMDttS

END NOTCHf.SAU

1ltfN

OH OPPOStTl DGU

INSI.t wro flAY

FABRIC LID

PLYWOOD

ATTACIIFAilRIC. To complete
A shallow rCCL'SSOn the top of
each lid ....'ill accept an in~r1 the lids. Ut'$Icut IWO pieces of
that's covered with fabric. or an fabric 10' square. see Fig. 24.
uncovered plywood insert. see Then cut a piece of backing
box at right Either way. there's material CI used polyester bata wood knob screwed to the lid ting) to fit each plywood insert.
To auach the fabric.()"'1ItL'I" tI,e
SOyou can lilt il from the lray.
ISSI(f & !(Ne)s. 1'0 make the backlog material on the fabric
fabric lid. first cut a tid insert and place the lid insert on lOPof
(J) (rom I>lywood10fil inside tile the backing material. Now Ield
114"recess in the top of each lid. tile rabric OYer the plywood and
staple it in place. see rig. Ua.
Sl'C Fill. 24.
Now turn the insert upside
ATTACH KNOS.Next. put the
down and make a mark in the fabric-covered insert in the lid
center for D screw to attach the recess and push the knob screw
knob. Then drill a W' count er up through the lid panel Then
thread tile knob onto the $('!'CW.
sunk shank hole at the mark.

LID

For someone with different

cvr h''SEtO'TOSm;. When th~

sto~ imerests,a plywood lid shims are cuuo '5i2<l,tltelid inmay be more appropriate than a serts (1) can be CUI to 61 in Ibe
fabrlc-cqvered lid. A plywood lid lid recess, SloeFig. 25. 'Then the
is made tlte same as a fabric shims can be glued inplace. and
covered lid - except the the inserts.glued lOthe shims,

p1ywoo<l haste be Shimmed (because there\slt't any fabric).

mUIS, An uncovered plywood il!<ert has 10 be shimmed
SO it~ Hush with thc10P edge
91 me lill. (1'11(' recess 1$ 11,"
deep, b~.I:V'"hardwood plywood
Is often Ilullllat mick.) So I CUI
rQur sbims ab(tut V!~"thick Jor
each lid,see Fig, 25.

K.'IIOB.
1'oatmch the lid knobs.
first tum !he lid upsldedown and
makea markin the center of the
lid panel (I). Then drill a \'0"
countersunk shank hole
through the lid at this mark,
""ruilly. thread tbe knob onto
a '10 x 1" flathead machine
screw (rom Ihctop.sidl.'ofthQJid.
See Cross Se<itionin FiJ1.25.

1- FlATHEAD
.- RA1l4fA.D

o MACHIN'
....__
sarw
No. 78

lonOM

Of UD INSERT

MACHl:Nf
SCIItw

23

S HOP

PROJECT

.)

Box Joint Jig

I

've seen a lot of different box joint jigs

over Ill" years, So, when I began to build
the Sewing Box for this issue, I decided it
was time to design a box joint jig with Ill.
(eatures I've been looking for,
L'n)[X Pt~. Almost every box joinljig I've
seen uses an index pin to keep an equal
space between the slots in the hoxjuinl But
it's usually a pin that's fixed in place on the
jig. I warned a jig with an adjustable pin SO
you can sneak up all the peITt'Ctjoint.
Another tlting about tile index pill Ithink
is imponant-il should be removable. UYIIU
can replace the index pin with one that's a
different sire, if' a lot more accurate when
cuUinglarger orsmaUcr slots and pins.
C1.EAN cvrs, There "'115 one other feature
Iwanted on a boxjoinljig.lfthejigcut.
box
joinlSllc c"rollly. itshould also cutthejoints
cleanill' So. for this jig. Iwanted a backing
plate behind the C\lL
Mer building several prQtot)'pCs,16n;illy
came up witlt a jig that's adjustable, works
for differentsiz" joints, nnd makes nice,
clean cuts. Pius. il can be built to fit either a
table saw or a router table.
)l;\TER~\L,I made the Jig with hardwood
and Masonite parts. see ~::XplodedVi~w,The
(ront and back fences are maple (to I.';v~the
jig stability),and SOis the index pin (to minimize wear). The table runner can be made
from either hardwood or phenolic plastic
and cut to fit your miter gauge SIOL(For
sourcesofthe hardware needed to make the
ooxjuinljig, sec page 31.)
HOW THEJIG WORKS
To set up for a perfect fit between maling
workpieccs, thereare SIOISinthe back fence.
This ktsyou adjusl the distance between the
index pin and Ihe router bit (or saw blade).
U-'TIiRCIlANGAlltE
PIN.The index pin is
mounted 011" carrier plate that can be taken
0(( and replaced with another plate WI has
a diff~ll'ntsi7.eindex pin. This way, you can
cut ioinl~ of variable Silk.
BACKINGPLATE. Finally, there's the replaceable backing plate hi prevent chipout.
sec Exploded View. This is ju,l a piece of
Masonite that's beveled on IWO edges so it
slides in 3 dovetailed rCC1'SS in the (ront
fence. Ifone plate gelS too chewed up, it can
be replaced with another.
USt;S. This box joint jig can be used on
either a table saw or routcrtable, see photos,
Shop Note: To use lhi.jig on a router table,
th.. loP of the table must have a SIOIfor the
runner, On th~ facing page we show how to
rour a slOI in a shop-built router table.

24

~ TIl< bor JI1hlt jig

ca)( ". b"Ut jor use
all a labl~ 8aw. lI'ilh

n dad. blade, bu.t

joilJ($
("(t~l be cut
o.1Idncru

qllltkill

rillrly
Alld bll
udJII.ling thr fron!
fi lire, jlt, jig c"n Iw
fi ue-Lu Ilt'd for a

"",.,-,,1 fil ",ill! 11!1

I<',d," dlldQ. TIl<
I(lhle .<1111' olld tlado
blade are best for
InrgerjQillt.<.
....Tlti jIg

r(J)1. be

bit ill/ort:1(tting bo.

)()lllt.J.5

Oft

router

tab/,. By mOllnfillg

tht~
""I.J"I", Y()Ij're alJle

{I

bit

stm/!lllt

in

I" rill ..101. wilh11al

bottom -

e.p''

rmlly""'ndhes/OI3

u,.~.~",allcrthn)l
(,I'(JI.I./ 'I.:", Bu.1.fur

b",T- }(>t}lt~ larger

thu n I,.,, tIlt: table
If(J /I'.

mor

a flU

.'1'.

is a

i!}jid",11ool

EXPLODED VIEW
r------------::------------------,
BACKING PLATE <D-

\".

)I(

21.,-

CARRIAG(
BOlt

tNDEX PLATli

FIXED PLATli

@
RUNNER

Nn.78

FIXED PLATE & BACK FENCE

J started building the jig from the bottom up.
That is. 1started wilh lhe runner. I cut the
runner (A) (rom W' phcnolir plastic (you
could use hardwood) to a length 0(9". sec
Fig.I. HUIme Important thing about the run-

PLATE

IIUNNER

\Ill

(I",,9_l'H1CK ~

.JF)

NOTE:
RiP RUNNlR TO MATCH
W1DnI Of YOUR

ner iathe width-e-it must fitthemitergauge

slot of yallr table saw or router table.
AXEDPI,'''':. Once the runner is cut to
width. the next step is to make the fixed
plate (6) thai the runner attaches to. set>
Fig. 1. Cut this from V." Masonite. then cut a
Vu;".<feepgroove on til," bottom to hold the
runner securely. see Fig. 1 a.
locate tile runner groove tile same distance from th~ edge of the fixed plate (8)
that the miter gauge slor is from the router
bit (or saw blade). see Fig. 1.
Nuw O1e runner c.. n be glued into ~w
groove. I used super glue on the phenolic
plastic. bUI use yellow woodworker's glue if
you've made a hardwood runner.
Next, drillthree countersunk shank holes
near the back edge of the plate (or attachina
the plate to the fence, Locate the IIl/(kll~
hole ill the center onne runner.
IIACKPe."(E. To stiffen tlle jig, I made the
back fence (C) from IV1"-thic.kmapl e, !lCC
Fig. 2. Nter the back fence is cut to stze, a
slot can be bored near each end to allow the
jig to be adjusted. These slots (an be cut by
drilling overlapping holes on the drill press.
or by using a mortising table or router table.
Now screw the fixed plate lD the fence
with the runner 90' 10 the fence. sec l'ig.23.

_--

FIXED Ii'

MITU O"UGl SlOT

a.

IWN_

....".. AS DlSfANct
at1Wt'!N MR't1t
GAUGl SlOT AND

AXEO PlATl

tDGlO"arr
01t .....,.

a.

&ACK

fIH"'C

I,..
T

2"

"

BACK ""FENCE -&

,,'.
.-'

.a.

I" Fh
WOODSCMW

ROUTER TABLE SLOT

To use this Box Joint Jig on the
router table. Ibere has 10 be a
miter ~\lg~ slot in the table lOp
of your router table. So if your
tabl(l-doesn'tbavc a slor.yoll will
have to rout one. (!"his "lot
should al$o be c;ut i(taL"Ct!I)ll'our
mirergnug&)

I'll locate the position of 0111

slot Iusedthemiter 11'lugetrolll
my table saWas agui~e. see fig.
3. Set the miter gauJfo! io-Ironl n
Ih~ bit hole so the gal,lge eka.:s:
the hole and the bar Qftlll.!lwr
g"dug_eis parallel to tile. trolll
edge oithe table.

Then draw a pencil mm on straight bit

Ibe t,ibl~ lOP 10 indicate both
edges of me sIaL

Make ~eral passes. mOving

the straightedge slightly beTo guille the router. 1I'm- tween fJa.'iSCS to,;n""k upon the
porariJy clamp aSlraighledge to final "idLh oClhesloLStopwhco
lh.e.top of your reuter table. see the miter gauge bnrand the runJo'ig. 4. Then. to cut the s101.I ncrofthe BoxJointJigju5t fit O1e
U$<' tile router with a Jh" slot - QOI tOOtiltblortooslop1)y.

AOJUSt StRAIGK1lDGl TO SNEAK

UP ON fINAl WlDnt OF SlOT

U'Sl r-.au SAW Mnn

aAOO TO lOCATlPOS111ON Of St.OT
IN R.0UftR l.uti TOP

o.

ROUTSlOl
tN UVf;UL
PASSU:

ClAMP
$TAAIGtIT.

"

""'.
ro_

PAaAU!l

fRONT OF ROutER tABU

No. 78

mGfOf
TAIl!

, "'
r"'I:'"

25

RONT FENCE
Ihc front fence (I) SUPllOrt<the work
and holds an index pin plate. And. it',

pt,,<,,

,,~ju$lablt. :.otl'" md, x pin coo be fine-tuned

(or th<' Ix>:,tjoiot>; Statt b)l'lllting th" (""'OlO
to'~ from ,othK.-k hardwood, see rIg 5
140."" The fronl it>nl" IS 1,..1d10 the back
f...,.,.. by twO camajI,' 111- and knob, Cu.
v.ingnul5). ref,,! 10I,~. ~ Drilltwo counterbored holes for the bull, tI'UI align with tilt'
,loiS in the back knn'. "'" FIll. !;a_
TIlRFMlf.'DIS"~J(1', llw in<l~x pl"l" atI;o:h(..;10the bottom 01 the irom fence wilh
machine screw. in Ill" .rl. odm",tls, rd"r 10
h~ 10. To ar ......'" I","", mserts, dnD IVoU
hule., in w- bottom .,.jge of th,' renee,,,~
r w. 5 Drill tbe h"I," latx, ''1100gb 10a.n".

(lllc'r It's be..n used

for culling u,llCJ't'nl
.
So 1de..ilt' J()ints,
cided tn make i1 no.
pla<:t'abJt.and slide
In

r;5~:;~;'-;:;:::;::;:;:::-,",,::,"7-;:==--::;::;::;;;::::::l
CH....... - 00... ,1tS
- 're;:-

do\"tail ,,101an

till' "'I1<'e.

10 rout the 5101in

Ih,' trout fence. 1
u,,d a doverail bit

l'~

10

...

--2'

s,-

IV,

...

...

.'

00YfT ....
ROt

lAC.

l=;~ftHCI;:d~~~"UI

..
~

FRONT

on the router table,

...,' Fi~.~.Then, 10

fENCE

,"ok., the backing

','

lHt1AOo10"'Sl ..

.I.... _

pL
.....(F.). fil'Sl 01'1.... L__!__ ~ClHTUU>~~~ON~'~"'~O~'NU5~~_::======:::::
ubt, ....w blade 10

make it ~a.'","'LOremev, th,' backing plate

fTom Ih(' JIlI,I drilled a lillll~rhule in each of
thl' mserts without 'J)~lfingthe ~ iellC"t'
14) n!cnripalol1j(~ripon,\'a<onite":
thcplalc
slides
inlhe
dov(1(u'
!Jo'.>ee
Flit
7
tI", pial." see F'IR.7,
I"UONG ,'(An;, 1111'1.'1 Ihing to add 10
1'(", CUIseveral I<nltlh. olf the strip 10
I\.,"~'ml Y. Fmally .the (rolll fence can be
th,' Ironl(tl1t\ is a ba"killllIJlalt. Thi. back"
b<'lt,~lln
the bark f"n~l' with carriage bolls
UI' till workpivcv bdnK ,,"I and prevents match lh~ height o[ IIII' f'-lIu' (-I"). (Save th"
chlpout, But thl- PWI,' can g.1 chewed up r-xtrabackingplates ["rfulure u-e.) Then.to and kllolb, (or wingnuts), "'~. Fig 8.
trulcll tilt' ~

of lho d<",1all bil

(u.o;ua!I\'

k_

a.

......

"

...

S'
'.ONJ'lNa

,"

........,

,,"

srr SAW

SAJro\I ANGU: AS
00V'fTAlt.11T

,..

..I

",

00"......

en

INDEX PLATE AND PIN

Prubably the mosl unique feature ofthi. box
joint jig is the ntt-n'hanfrl':tblt index pin. 8y

n'1'<lt'(l[or cUlung clifk ...IlI.;lC box joints

I~OEXPI\. The m'x1lhinl!' IIIdecide i> th,'
..v.ib.::hinj!' indt x pm...V"Ur-an ~-urale1)'l'Ut ",dlh of the ind('~pin, Th~ m<ll'ltpm width
dJltt.:n:nt ~(" box-joint'"
'hould match the dado blade or mut.". b,l
PLATES, Each difl('f,", m<lexpin is gl",
) au pianonu>ing locullh~ -lui' far,ourl.
In p'.~ti(1)(,)n toptJr il~o\o\n(lInierplalf'. "<~ JUml,. ~oce mo>! 01 th,' bu. Joint sloLSI cut
I'I! 9. ~CUI anuml. rollh, .....index pia"",
art' ','. 1~, WO,ur ',' "id,'. I slartt'1l by
(I') from t,' M.",nit~.
cunillg an inde" pin IIIt"ell of Ihcsc"idths,
CUI each index pin (G) ~ long from
Nexl drilllwocounk""unk hol('sthwuj.lh
ead! pL't~ In altJtn Voilh Ih,' Ih!'l'aded In,,'nS hardwood._ Fig. 9. I1WII.lomake iteasier
1II1h.. frnnl [enn' 'l1,en, ,-ad, plal~ C'dn h, for Ihl' workpi/'Cj' II) <lid., ,I\I\rthe pin, I
kr'("Y.,_-d10 tht btlllom of t.h\ fence:b ii', -.anol(od3 ,Ughlchamf"r on Ihe upper l-dj('~

INOfX PLATf ,

a,

3'

CHAMJl_
TOP EDOIS

(.R(")\'E,

f,'11<'(', o;c.'t' Fig. 10.

10

fHOtOlM(H~

MUS'

\\1,,," Ih(' index pins have

';1.<', aI!l'OO\t'C30 be CUI
m ..... h plate tu ~pI the pin. ,<,,' tllt.9.CUI
the JII"OOJ\" 1.16" deep, and fIO',UGn il Ille
!iaIII( di-unce (rom the t'1IRcoC th.. pial" as
lhe width of ~ inde~ pin b,:ing alJ.a<'hed,
" fl,<:, 9a. Then glut'lh" pin inlo th~ fronl
",ul (If III.. groov~.
"(RI>I\ ON PL<'TE. Th~ laM SlCp before
0''''11 Ihe jig is 10attad! th(- plmlo b)' Sl.'re"'.
jnll il into thr thr"'ddlod In''''n< in the (ront
,."

ho, n c ut to finlshed

I( ,....SAM[

..

,:'

, ~"

~~----~ ,"

F.ON1

"Net
(~

'1.-'

No. 78