Professional Documents
Culture Documents
66
$3.95
VVM.ILLSHELF........__.
1iI~:HOW TO CUT
DOVETAILS
-_
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__ 0
No. 66
EDITOR'S
December 1989
COLUMN
Sawdust
EdItor Donald B. Peschke
DeSlgO Director Ted Kralicek
MaoagingEdtlo' Douglas l. Hicks
AssiSlanlEdtlots Douglas M. Lidster
Kent A. Buckton
Terry J. Sll'ohman
PrOJeCI Designer Ken Munkel
Ted\nOCaJ IlIuslratOfSDavid Kreyling
Cary Christensen
RodStoakes
Chris Glowacki
Cuslomerservee Linda Morrow, Mgr.
Lisa Thompson
PtoJeCI SUWllos Leslie Ann Gearhart
Controller Paul E. Gray
Compu\erOperat""'S Ken Miner
AdministrativeAssts. Cheryl Scott
SandyBaum
Souroebool< Jean Carey
_ing
ShOws Steve Curtis
BuildingMaintenance Archie Krause
WOODSMITH STORES
GeneralManager Steve Krohmer
Marl<eung Manager Steve Dotier
Slote Managers:
St.louiS. MO Jon Behrle
Be<1<e!eY. CA Michael DeHaven
DOS Moines. IA Kent Welsh
WOODSMITH (ISSN 0164-4114) is publistled bimonthly (Februal)'. April, June,
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December)
by
Woodsmith Publishing Co., 2200 Gland
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'~,Copyright 1989 by Woodsmilh Publish
ing Co. AllRlghls Reserved.
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SAMPLE COPY: We willsend a Iree sampie copy of Woodsmilh 10 anyone. Just
send VS his/her name and address.
ne oflhe most popular projects we've drawers, But it'salso ajoim that manywoodever shown in ~Vooc1s"tit" is the workers tend to shy away from. Too compliEuropean-style workbench featured about cared. Requires 100 much precision.
three years ago (in 1I'0000lilli No. 50). Irs
Okay, let's face it. ii a joint requires using
quite a bench. And probably exactly what hand tools (like a back saw and asetofsharp
most woodworkers have in mind as the cen- chisels). more than likely we'lI find a differter of their shop,
entjoinl, ... Ora different way to make iL
But that bench is quite an undertaking to
Iryou don'l want to U$<1 hand toolsto make
build. Don't get me wrong, Ithink it's well dovetails, your options are limited. There
worth the effort. Rut it's certainly not a are several dovetail jigs on the market that
weekend project.
cut through doveradswith a router. But they
We wanted 10 come up with another lend 10 be expensive,
bench. One U,at was easy to build. sturdy,
Another way is to use a band saw.That's
and would serve you well over the yearsthe basis for the technique shown in Ihis
even ifit isn'taclassic European-stylebench. issue. Aculally. it all started wilh a friend of
Every time we sat down 10 design this mine, Mark Duginske. For many years
simple bench. we ran into the problem of Mark has been a representative of mCA
design overload. It's a problem common La machinery, He works at many of the woodmany projects. Once you gel started. you working shows across the countryand gives
want to add a feature, and add a feature, and seminars 00 worldngwith a band saw.
add a feature. Soon thesimple bench iscomPeriodically Mark stops by our shop to
plicalcd. We finally decided to limit Ibe de- talk about a new technique he's developed
sign by Slitting three basic criterla.
for the band saw. The one I found most inFirst.the base (legs) had 10 be buill cut of triguing was his method for cuuing
easy-to-obtaiu construclion lumber. (We dovetails.
built the base out orlir 2x4s).
The basic technique involves using two
Second. Uwjoinery used for the base had jigs. one 10 cut the tails and one to CUi the
to be basic, not something like wedged mor- pins (lhe two interlocking partsof a dovetail
lise and tenens, 0A'e used very simple ver- joint).!n general. it'seasy 10gel rnyattention
sions oflap joints and butt jQints.)
with .almost any jig, bUL Mark's technique
And third, the lOP had to be easy to con- and jigs are particularly interesting.
struct and nOI too expensive. (We chose a
When cutting dovetails. jigs make it easy
solid-core door. but you CQuiduse IWO layers to make repealed. accurate cutsat the angle
of plywood)
needed (or bOtll paris of the dovetail joint.
What we wound up with is a good solid
However. that's not what got my attention
bench that can be builtin a weekend and will about Mark's technique. The jig he devised
probably lasta lifetime. Butiyou havea little noronlysets the angle. butalso sets thespacing ofe.eh cut. Ily spacing. I mean aligning
time left over. YOIl can add afew features.
Firsf on our lisl was a set of drawers. You the cut to a precise point. And in the case of
can add tile three simple drawers shown in dovetalls, spacing isequaily as criticalas the
this Issue. Or.you canbuild a moreelaborate angle.
storage unit like tile one on the European
TIle spacing is usually determined by
style bench. In fact the base WlIS sized for making a pencil line. BUL pencil lines are not
this storage unit if you want to add it later. very precise. So. how does Mark solve the
(Refer to Woo(bnnjtit No. 50.)
problem of precise alignment? With spacer
As for vises. we've Iisted a group of vises blocks, Nothing new, but in combination
that could be used on this bench, see with the angte jigs. they produce accurate
Sources on page 24. 'These are basic wood- cutsoverand over again. with no guesswork.
working vises that mountto the front of the
IVhalab()ulalllhe othertechniques Mark
bench. You could gel a Iiltle more function told us about? Il'eli. he decided 10 write.
out of the bench by adding a dog row and a book. 1'116 Band Saw Handbook. II just
tail vise at the end of the bench.
came out and Mark is pretty excited about it
OGVF;rAII.s. Just as a good workbench is - a three-month project that took twO years
the cornerstone of a shop.there.are certain 10complete. 0 know how he feels.) lt'sfilled
joints thai are hallmarks of woodworking. wilh bis experience of many years of work
The one that comes to mind first is the jng with band saws.
dovetailjoinL
NE>.'TtS$u.1l1enext.issue of 1ood8millt
This classic joint is great for all sorts of (No. 67) win be mailed during' the week of
cabinetwork, and particularly for making February 12. 1990.
W,xxlsmilh
No. 66
F_R_O.:..__M
__
I--
r:
F___:.E_L=---=L_O.:..__W
__ W
D W
R K E R S
ROUTER TABLE/WORKBENCH
edge, or Ih,' board with CUIS IvO'found yet another use for my
about 11.," ekep, see inset draw- 1V000Is,mlh router table: I use il
ing. Then. to flnish resawing ,'S 3 workbench 10 t~mlx>r(lrily
Ihe board all tht' way through, I hold benchtoprools like I,'Tilld,'rs
switch 10 the band saw. S<'(' and scroll saws. (M y shop is
drawing. TIw scored cui lines small. and I don't have
on each t'CiR<'of the board act Ihe space to permanemlv mount these
.'guidl'S
for
the
band
tools Onit bench.)
CUT '.saw blade.
.... ON
Try 10 nil down the
F'ir~l. mount each
1OTl4,(NOS
side of the scored line tool onto its own
'u< closely as possible,
Since the kerfleft by ba",,~ for all LIte tools
base.I size. To
tlu- table saw blade is wood
one uniform
wider Ihan the band make each base, I cut
saw blade, this gives ~."thkk plywood
,
youa-guide-tomake
Ih.. '-3Jl1(' width as the
lOp of the router lable
Ih,' final ClIL
\\,ilh this method, a (On my table. this is
This technique works well with resawing guide on the band saw 30".) Then I drilled
boards of almost any width. bUI is not needed since the scored two \1.4" holes in the
rl'lIlIy irs useful when resawing lines help control blade d,ifl. plywood. t;y~"in from '--''''''_
boards that an' 100 wide 10 CUI Thisresults ill boardsof uniform each edge. (11",,,", holea must
all the way thrnugh on the thickness which means there alilln with the carriage bolts Ihal
table saw.
will be less final planing needed,
hold the router table rente.)
To use Ibis method, I first SCi
EdSiloff'er Each bench lOP 1001 is Ihen
upth .. table saw 10 <core the IWO
RfK'/,p"tlr. J/innnotll
bohed 10 its plywood base
To mounl the 100110 1i1c""'itT
table "workbench." reme",,' the
frl1!'c and Castenthe plywood base
,----===;;;-;=;----,
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r
made~~~.rl?~~~
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l__
SANDING STRAP
GLUE BRUSH
lXCl$S AlTtR
ST'(lONG
SANoP......
fO lAPI
t~
00WI"t..
SI'2-lQHG
movc' ullwanled
pt'ncll nonrks
No. 66
W (){xlsm i[h
.......
..L..u..ll._.J
8diwr'8 Nou
rr yo"r router
('(j
II
unacn
bf'~I(ltlOp
SHOP BRUSH
I keep 3 brush in my shop commocly used by a draftsman, The
bristles on this bn,sh are longer
SIND IN YOURnps
If you'd lil<~10 ~hare a tip
with others, 't'nd in your idea
to \VOOdsll'ith, 'iii'" & TechniquCts,2200 Grand Ave .Des
~oiJl("'. Iowa ,>0:112.
W~ pay Sl5 ror acce","d
tips. !,Iea", >-cndan ~planalion and a ,kelch if nCt'C!ed
(...e11 draw il nt'" on<'),
Sf-lOP
PROJECT
Workbench
Construction lumbe1' and a weekend's work can produce the
most used tool in the shop", a workbench, This one features a base made
of 2x4's and a solid,core door for a cop,
n 1 wanted
t'
Woodsmith
No. 66
EXPLODED
SUPPLIES
VIEW
OVERAll
r:
8ASIC 8ENCH
DIMENSIONS:
(9)2><4S.96'-IOO9
(I) 1'1'.'x30' X 80' soli<;1-core
BENCH TOP
SIDE BRACE
VISE
(OPTIONAL)
FRONT/BACK
CLEAT
DRAWERS
(4) 1.6's, 96'~ong
BOnOM
SHELF
rn '1'.')(S'l.f-96{hordWlOOd
10<drower guide system)
0) piece Yd' plywood, 48 x
48' (tor drower and Iroy
bottoms)
(18) 18x l'llotheod wood-
LEG
RAIL
SCJ9WS
"--
-SIDE
BRACE
UPPER LEG
FILLER
MATERIALS
CUnlNG
8ASICBENCH
A
8
C
o
E
f
G
H
I
Legs(4)
Sidesrcces (4)
Upper leg FIllers(4)
Lowel Leg FilltlJs(4)
SideBroce Fillers(4)
FrnI{BockRo,~(8)
6enchTop(l)
BotlomShe~(I)
SideCleols(2)
Frnt.!Bock Cleots (2)
DRAWERS'
Drower Guide, (6)
'\I, x 2""6 - 22'12
Dlower Stops(3)
% x l - 14~
Dlawer Frt./Bc~,.(6) "'. x 41'. - 14y.,
Drawer $Ides(6)
:V. x 4% - 2011.
o Orower Bottoms(3) It. Ply. - 131,7x 20111
P falSeFronts(3)
'11 4'1'. 16
Q Orower ilIJnners(6)
22'i~
R TraySpfir.es(2)
It, Xy.,- 19'.'.1
S Tr<lySldes(2)
Y.lx 1'1'.-9'1.
T TrayFrnl ./ Bocks(2) 'I)X 10/.,- 12~
U TrayBottam(t)
'I4Ply.-9%x 12%
'Material tor three drowers and one Iray
K
l
M
N
v..
No. 66
.-v.,
LOWER
LEG
FILLER
screws
(3) drewa<pulls wI screws
OPTIONAL
(I) ,"oodworking liGe(see
seorees on page 24 for
~... x 4'"aoLT
ANDWA.$HER
DIAGRAM
BASIC BENCH
2 x 4 96" (ON! GOARD)
I
2
e
x4
I
2
x q 96"
(FOUR BOARDS)
DRAWERS
1 x 6 96" {ONE80ARO,
I.
II
"
:
'.1:';./1"
44
~
)114
:J;~'ACTUAL'
x5'/~. 96" (3.1 80.
P
fOR GUIDESAND RUNNfRS
x 48:"
Woodsmitb
END FRAMES
The first
step in
building the bench
is 10 build the two
end frames.
To
make each frame.
begin by culling IWo
1e,!S (A) to a length
of 321,2". (NoI.:This
gives you an overall
bench helllht of abouI34\!,t" when the top is
on.) TIle l~nJlth of the legs can be varied to
fit your helllht.
UUIIJ)tNC:11lE FIIi\MF.~. Wilh the legseul
to length, CUI the tW(I side braces (8) 23"
long,l>('t' ~iR.
L l.aylWo legs (A) side-by-side
and pol>ilion one side brace (8) 4~ upfrom
the bottom ends. Then place the other brace
flush to UI('IOPof the 1"1(", see Fig. 1.
Once the pi(.'<.'e' are in place, lay oul the
S('I'l'W locations. see ,,'!g. 2. Then. drill and
countersink IS" shank holes in the side
brae.... (R). set' Fill. 2a. Now glue and screw
the side braces to tJw legs using No. 8x 21,2"
wood >'Crt'WS. see Pig. 2a.
ill'rACU
rus
To
I'II,I.F.R PIEr-ES.
LEG
SlotNAt.
~.'
lRACE
O.
GWflMlN
SCHW TOGmtD.
"..
fO.SOU".,
TO OUTSiDe OF UOS
A')
/~.
..
CHICt(
(NO '1lA/I\l
ItDllltActS 'lUSH
/'
2'"
DRI111IHA.
COUNTIRaou., \_ .. 0("
(NOFRAMf
OUTS1D1_
FACI
SlOE
UPPER
LEG FtWR
lRACE
@-
FIWR
LOWER
LEG FIIiER
RAILS
~
",il~
....
NOTt:
TOTAl Of fOUR
1tAAS"(DlD
BlOW TH RAIL.''-
holes before scl'ewing the pieces together. length (If 4s:l<.".sec Fig. 5. (Note; 1lle only
see Fig. 5.
reason (or thls particular length is so the
TNIM'ro U-:NG'TII.After gluing together all Tool Cabinet shown in W(}o<ismitil No. 50
four rails. I trimmed them to a finished would fil between the end (rames.)
FRONT IIIACK
RAIL
.8
2''11''
WOOOSCRfWS
Woodsmith
...._
No. 66
RAIL CONNECTORS
The rails are connected to the end frames
with a draw-bolt system. This system not
only allows the joint to be tightened if it becomes loose. it's also easy to make and jlues
together quickly.
POCKET HOJ.-ES.The first step is \0 mark
the location of the pocket holes On the rails.
The hole. are centered On the face of the
rails and located 1:V4" in from each end. see
Fig.6a. Now. drill a 1"-ilia. hole, 2" deep at Ole
marked location. Then. to provide a flat surface for Olewasher and nut to draw against.
square up the edge of the hole nearest the
end of the rail, see Pig. 6.
END HOLES. Once the pocket holes have
been squared up, 1 drilled 1/16"-dia.holes
centered 00 the ends of the rails. see Fig. 6a.
These holes are positioned in Ole center oC
SHOP TIP
with a
-:-=DOUIU.$II)(O
CARPfT1APf
OAA.
ItA'L
9
RAIL
NOTE,
FACt POCKET
HOW10WARD
fiRST:
CINUIt OF arnCH
DRILL.1I)IA.
POCKET HOLE 1" DEEP
a.
'ir--l-------l
,'1'.' t-
AND WASHER
>,' .4'
SOlfAND
WASHER
SECOND:
SQUARf UP
[OGOF POCKET
KOlI WITH CHlsn
.___
.._____
lNDFRAME
CTHIRD:
DRILL'II.
HOLE, CNTfR(D
ON (NDS OF RIJ~5
J%".U,ick solid-core
door as a top. BUI
you could 'laminate
two pieces oC +'4" plywood together instead.
AttACH OlliE TOP. To attach the top (G).
turn the top and the base upside down and
center the base on the top. Then mark and
drill the mounting holes on the bottom side
of the toprails, see Fig. 8. Now attach thetop
with %" x 4" lag screws and washers.
WSTIIIJ.SHEt..F. Finally. cut a :v.l" plywood
shelf (H) to width to fit between the rails. (1
used a 4$"long piece 10 fit between the end
Crameswhich are 4~" apan.) I,lse someleft
over plywood to make 1t11"wideshelf cleats
(1)). Then altach the shelf cleats :\'4" down
rrom the tQPinside edge of the bottom rails
and side braces, see Fig. 9a. Note: Don't
cover the pocket holes when attaching the
cleats so YOIIcan gel to the draw bolts.
No. 66
k;;;::
'\ Jl, I~
8ENCH
.<;
a.
,"CIA.
COUNTtIlBORf,
~ DEEP
TOP
--
J B _~
StDE
LAG S(~rw
0--
FRONT/BACK
CLEAT
~.'
CLEAT
a,
1r--~-nJ.-_--..j
.ax
UG
SHtLF')
WOOD
\. . -:.._;.
l'I.'
DRILLAND-
PI.lOTHOUl
COUNTtRSINK
~ SHANK
8EN(HTOP
"
PLYWOOD
111)"
SCRtw
tAIL
ANDWASHU
Woodsmirn
SHELF
...
-.
~f,'(
Of
:1." X 4"
BOttOM
~.~
aonOM
4'
CUT SKELFTO
_r'ITBETWUN
RAILS
HOl,EINTO
CWT
RAIL
~
..--'
-- -..::
. ____
~
;~:
1"
~,
--,
I,
..=-I."j.:~
.1.
FRONT/BACK
CLtAT
DRAWER GUIDES
Afterthc basic bench was built. Iadded n set
of drawers.The (""I.lep here is 10 buikl and
10
install the drawer jlUides (K). For durabilily. I used hard maple 10 make the llUid('$,
bUIyou could make them out of pine (same
as the drawers).
Ctrr GLJIOJ;.~
1'0 SIZE. There arc a total of
six drawer ,!(tlides made from :V4"thick
stock. However. the two center guides are
laminated together. see Fig. 10. To make
things easier. 1 glut-d up the two center
llUides to a rough width of tv,". Then I
trimmed the center guides along wilh the
two side guides 10a finished v.idth of2Wu;"
and cut them 22Itl"long. see Fig. 10.
C~'TTHE GR()OVK~. Once the guides are
CUI 10 size. grOOV('S are cut to accept the
drawer runners. see ~ig.10.I CUI these W
DRAWER
GUIDE
11
LliGS
I _
lOP IUUl
MOUNT OUIO(S
FlUSH TO JiIIIONT
OFTOf' RAIL
12
TOP IAII.
.h.:
ou,W(IS
((Nfl.
OU'OI
IlL
DRAWER
STOP
~'
~.
SHOULD
DAAWU
MOvtFREEL
13
aN Glfl()(S
11 ....
WOOOSCIUWS
,.ONT/ ....C
AUXIUAaY ftNCE
...
ON TAII.1 SAw
IIHI'"
NAlLS
--y
...._
-
RAISE 8lADE
UNTfL TONGUE
,rrsOAOO
~""J
oaoow
,,-
14-Ca
.LADE
Woodsm'th
11
L-
~
~
1,-
No. 66
DRAWERS
- .-
14
DRAWER
FRONT/BACK
CENTEA:DRAwtR
HANDLE ON
FAUf;FRONT
FALSE
FRONT
J
...
141,..,-
PI>
_,
20V."-
DRAWER 510 @
4~
.
.
(SIX RlQUUlIOI
($'X OECW'IIO)
16
lS
FALSE fRONT
CtNTtRIO ON
wroTH OF DRAWIR
18xl-
WOOOSCctEWS
(
ORAWlA
I_."X 4~"
HARDWOOD
RUNNER
fALSE
fRONT flUSH
WJTHaOnOM
O'DRAWlR
FRONT/lA.CK
TRAY
lt's always aggravating when small tools get
lost in the bottom of a large drawer. 1i> keep
OIlS from happening. I builta shallow sliding
tray for OnC of uie drawers.
111 SJDS. 11.e first step in buDding the
tray is to cut the "'i'thick. l:v.."v.ide tray
sides (S) to length. see Fig. 17.11lcn cut the
front and back
pieces \-Il" smaller than
the inside ofthe drawer. On our lray this was
12lfs".see fig. 17.
Once the tray pieces are cut to length.
the ends can be dovetailed together. (If
you use the alternate jOiOl shown on the
opposite page. t.he length ofthe pieces will
be different.) Also cut grooves for the ply
wood bottom (see Fig. 17a.) and assemble
the tray.
17
o.
-~,,,.
r-
No. 66
,
I
.'
~<~....
12'...
T~Y
FRONT/BACK
Woodsmith
--"
TRAY SIDE
PlWOOO TRAY
aonOM
SOME
TIP
FRO
SHOP
OUR
Shop Notes
JIG FOR DOVETAILS
When it came time 10 make
the dovetails for the Wall Shelf
(shown on page 111).1buill 3 jig
to hold the stock so I could accuralely align my chisel tochop out
the waste sections.
UUlLf) "fH JIG. The jig COD'
sists of a base with.a guide fence
bolted on top. see Fig.2.1 started
bycUlting the base and theguide
fence the same size. see Fig. 1.
(lip: I used double-sided carpel
GUIDE
FENCE
PLA5nC KNOB
ORwtNGNUT
s;.'6" X 3"
CARRlAGE SOlT
_l ,
3-'4
.,,"
NUT
ANOWASHER
1/."OEtP
2'/4" _,
,
l_pIA.
cou_
.....
/"
~'''DlA.
HOU'
,
FRONT
STOP
.8
x ',,,,"FH
WOOOSCRtw-
-....
<,
DON'T
UN.DlRCur
IIYQNO I.A5T _
TAJl. OR UNDt!RC~
WIllSHOW
10
Woodsmith
-,.... -~
'fi'
No. 66
UNDERCUnlNG
Sometimes irs diffiCultto gel the ends of lite rails. see Fog. 2.
lighl joint line when you but! Then I chopped straighl down
one piece into another. (Like at- on this border line WiUIa chisel
taching the rails to lite leg$ on to score lite line lils".cJeep.
the Workbench shown on page
CHOP our WAS'l'1:. Once tile
4.) TIle problem is both surfaces border line is defined. the waste
need 10 be perfi,etly Ilat [or the can be chiseled away.To do this.
joiotto pull completely together,
tJNOl>RCUTI'TNG. To avoid
r:
use a technique
called l<'I1ilerclttWrg. This is
simply cutting 0111 a recess on
the end of the rails until a small
shoulder remains around the
perimeter.
Since only lite
shoulder touches the adjoining
piece. ifs much easier to pull the
joint tight, see Fig. J.
UNDERClrrIlNGTIIE ENOS.To
undercut the rails on the Work
bench. I laid OUI a l4"wide
border around the perimeter of
problems.
liO
a.
WASlII'It
START
......
FROMTRl
~
HIlC.IOLY
Our5ID! IDGl
)'j
WORI<ING
~,..-li:-
TOW"'D'_~"",
CtHTlR
--..,PlACE
BEVIl.
OF CHlsn
AGAINST
WORKPIct
TOI)RMNl
GOUGING
SAWDUST RELIEF
.Jigs and fences are great tor
aligning and guiding work-
somewhere
to go
Rcurtl
fENcE
awEF
WORKI'rEa
- (HAMffR
WOOD
'-CHiPS
No. 66
Woodsmith
II
WOO
W 0 R KIN
TECHNIQUE
Bandsawn Dovetails
A
such
gether perfectly.
12
LAYOUT
L.1yingout a dove!ail joint - tbe site and
placement of the tails and pins - is worth
some time and thought. If the layout isn't on
the plan. it's best to draw the tallsand pinson
paper. Th('II. once you get a layout you like.
it can be trnnsf erred to the workpieces,
wurm OF PIN \'S. TAIL It's a matter o( in
dividual preference, but l prefer th.. pins to
r:
AUXIUARY BAND
SAW TABLE
_...-m,p BLOCK
_,
1'1")"
1/._ MASONITE
V/
.UNN
,l,
lONG FrTS IN
~I
SLADE SLot
"
'\ [,
...
r-
1
21n"
' !.I
"
STOP BLOCK
'1',.
s",.'" X 2\1,,CARRIAGE
BOLT
8ANDSAW
TAII.
r:
T1CtCKNES5
Sl.IGim.Y LI$$
THANBANO
SAWTAIlf
,..--~-:.._---.
KNOB Oil
"","
WING NUT
TUAN4UCKLE
POsmON RUNNER
SECURE JIG
No. 66
TO EOGEOF
8ANO SAW TAW
W1TH TURt'<I&UCKl..S
13
WOODWORKING
TECHNIQUE
AOJUSJ..... U
TAtl JIG
STOPftN(~~." x , .. x: 15- )
.-
PLYWOOO
'RONTflNet
,It" 241.
~-4.lIC
10
sn_
GAUOI FOR 10
(1tIADS 10' ON
50MfMITfA
OAUOfSI
~". PlYWOOD
U.
AOJUSTABU
STOP FENCE
f-
,-
11,,- ..
lAS'
""-DIA.
_ .....
HOUFOI--_
C-ClAMP HEAD
IUNNtl
14
SGUMI ..
CUT TO m SlOT
~XIUAlY
'JAiU
f.! ~
3"
>,"
r
_J_
.; '" ~
No. 66
BY
S T E P
STEP
CUnlNG SEQUENCE
BEVEL
SQUARf
FIRST:
CUTIS-MADE
W_SPACllI
alOCKS
Jlla l'k
SECOND:
cur lS MAJ)E WrrH
the
"'I t""endol
(OUALS
WID'"
OfON
SPACEIt
"I.(LcI,
wit comerofon
/-
the ,,,i,ttl!
To dete,min.
left conw"ol
t/U1""",UQil.Then Clttblock to Oi2e.
tailloupper
SlOP
mlCO
NOTE:
STOP CUT
At BASI:
WAST.
aA$l
UN.! <,
, .r\-
T..,'
8AND$AW
aLAn!
Utll
OON'TMOVE
STOP flfilet:
--.....
TAl'
X
_
'-
REPEAT PROC!DUR
",OVE,. SIARl1NO
-'CUTTO
wmiOUr A SPAcR
WASTE.S,OE
OF LAYOUT UNE
N"".
PA!t-OUT
RlMAtNlNO
WASTE
r:
out wo,stehetweenfhetaU., I
fi'inaUy. 1'O/(g" ctu area Olll.itie tltt
7 1'0eno
8
u8etlwhase
sl1own01l
laslta il.JI/a' over;rize. Th"" scere tile
shoulder with a wille chisel (left) and pate
lirt,ejig
pa{/B10.
No. 66
Woodsmith
l5
WOODWORKING
TECHNIQUE
PIN JIG
To cut the pins. there's one last
jig 10 make -thr pin jig. Itholds the workpiece at an angle Ihal matches the tail angle.
CIJT1WO !<Ql ~Rt;S. The jig is madt from
two square. of "," plywood wJlh anllled
wedges between them. see Fig. L I started
by CUlling the two squares 12" x 12".
RUNNER. Next. cut a 20"-lon,ll runner Lo
auach to the bottom of the jig. see Fig. L. This
runner fits in th. groovecuLacros'th, auxiliary table (po;rptondicularto the blade)
To bold the runner, CUI a V,"-dt'<'P dado
centered on the bottom of one of the pi).
wood squares. Now glue the runner into the
dado so ao 8"-10Ilg t ongue stick s out one e nd.
see Fig. 1.
t"f:NCF_ After tilt>runner is glued 011. the
oexlSlep is to glue a fence along one ,'<Ige of
the 'lop plywood square. see F'lg. la. This
(ence keeps til(' workpicceand all the spacer
blocks in position.
WEOOJ;:S_
In. lasl pieces to cut "I'(> the
12"-long wedges, <oe Fig. 1. I cut till''''' off
the ends of a piece of plywood, see Fi~.
2.
Shop Note: To cut a tighl-fitting dovetail
joint the pinangk" must be the sam, the
tail angtes, The ""si<'51"'ay 10 make sure
thcy're the same is to SC'Ithe miter gauge off
the tail jig. refer back to Fig. 2 on 11Illle14.
.>
AS.~~"Ill.\.
Box.
'I'll!.' JIG AROII~II.Nleral! of the cuts iU\.
..
', '".,'(Ne[
I'
"
a,
~/".. Pl YWOOO,
12" a 12"
PIN JIG
_-
10WfDG(
<,
;I ""H.
._ ,.,"
_MUS1
c t--'
I
COMI TO A POINf
T
....10
annvo
lOIH1lCAI."
WIOOU
.
.
ft
)0
..
,..,_.l
-,./..
=.
..
snMIJU
GAUGlA!
16
Woodsmith
10"
No.66
--....
S T E P
B Y ST Er
.......
CUnlNG SEQUENCE
......, ... w
-..0-,....
FIRST:
MAKE r:JlST
curwnUOU'T
"'ACIlt
no
8ACKIL.
IOARD
AUGN
W'rTH
FIRST PIN ANO CLAMP IN H.ACl
PIN
IIOAID
MAKtCUT
AOD $PAC(lt
(A) AND
1 ">I IflU
,(1111,(I
SECOND:
4'('8....
2 .~;d,t
Ill
(JU
IXlutl
HIIUl
41ign jig
110
0/jig.
F-AelMOCHI
ora.cnoN
NO
<""""IftO
110"""
UNI
k
I'OSITIOH
StOP'LOa(
IoOCUfSfOPS
L.._""-'__
AT"'5I! UN.
I'0silioll
I ion 10
lallOl<l line. Ttie blade
.I"mld
area so tne lUI/aut
liuf' ;.'tjlt~IIH,'~IU
"1t((1'~(L"
.... IOUD
TURN JfGSO
ANGU'ACU
0<>P0Sfl't
DIRlCTlON
SfCOND:
ADOSPACOt
8lOCKSANO
fAIL lOUD
5n
c:/e-(r rill
i'lilltl'
1('tIH/('111"('(1.
(~/(l t~tPd()UJ'l)'lg.
('(""IJ/t'till{]
rltlli'lg SCq?tCll(.(t,
rll(III (JI,I umstc ""('(1. the CIlCkuou:
A./1I'"
MAKICUTS
INlHE SAME
$(QUNCE
ASAIO~
YOi' CRII
11';1(l 1'1' it mor ,ifft Il/'1)i "~,l~l!e Step 7.
pi'll . m/ 1il ..[it, (ff//I'!(""'OOli{/1it
GtNnYTAP
- JOIHT
TOOmu.
No. 66
IIiR areas
8 ).fln1I1I'(I",pi .filil1<i, into
tlu joint
/(1
tU'('fU
{'{1{I)1
1'1"('IfNI("('
(t
r(Ltl
I:",,, IHI<ki7l9
t.tJ.PfIW (U[I('(""'"
"d
to prt'tJftllt
Wu<xhmith
beb
board for
SIH itti)lg.
17
r-
F__E_A__T_U__R_E P_R
__O~J~E_C
__T
Wall Shelf
This is the perfect opportunity LO try out bandsawn dovetails.
Even if you don't build the shelf, check out the unique hidden hanging
system that holds the shelf on an)' walL.
18
IIANGINGS\'STE.\t.
Bcsldesdovetails. this shelf offers
another interesting challenge - hanging it on the wall
once it's done. Of cOUJ'S('. i(you U1'(' M"TeWs
or any type
o( anchor devices. you11want to drivethem into wall
'tuds. :-'otaneasytask. Even ifyou can locate the studs.
Ih"re',onlya slim chaneethey'll be in the right location
lor hanging the shelf.
Instead. I mounted the sh~lfb)' hanging it On a long
cleat that is in tum mounted to Ole wall.The nice pari
is thai the screws can IX' Ic)t'n"''' anywhere along the
I""gtlt 01the cleat. Then the whole system is hidden
from view SO you don't see nny serewheadsor even thf'
cleat, (For more on the hanl(ing 'y,wm, see page 21.)
WOOD ANDFlNlSlt.The shell shown here is made
(rom red oak and finished with IWO coals of
\kCloskcy's Heirloom EJlRShdl Varnish, The combination of oak and a matte finish enhances the contemporary look of the shelf desillll.
No. 66
EXPLODED VIEW
OVERAll DIMENSIONS:
16'" H x 36" l x 81/16" D
'--/--,36"====--_--.1
@
SIDE
BACK E
DRAWER
SIDE
,'I--",
DRAWER STOP ..
@ CENTER SHElf
DRAWER
FRONTS
BACKS
/-
DRAWER
BOTTOM
SIDE LAYOUT
I:-:::
....
.:
, ..
1
Y .
//
DRAWER LAYOUT
/1
7/
,
'/
'"
"
CUnlNG
~ .." IIC8'1."
WOOD PARTS
DRAWERS
SHELF
A Srdas(2)
8 TOp(1)
C BottomO)
D C~,,'arShelf (1)
E Bock(l)
HANGER SYSTEM
F Wall Hongar(\)
G Woll Claol 0)
No. 66
, ..-..J'IA"
21~(I"
'1'4.8\,\. -36
'1'. x 8'1,. 35
'0- "'.,
/.
8\'__
."
'1'. x 8'11. 16
:VA x 2''\1,. - 36
;:;
y
/.
I Or.Sldas(6)
~x2''1',.-7%
J Or. BottOfT\$(3) %pIy.x7'1a-Il:V,.
k Drower Slop (1) *-. 0/1., 34'~
SUPPLIES
-l." x
DIAGRAM
I
at."
:
12. (4.1 ad.Ft.)
0
!:. I ,HI!
Lwu~ff.MffjJ
-K
8.2BoClfdll.-lr.-fhlckook
4 1 Boo,d ft. ~"'hiok ook
12' x 24' place Vo' plywood
McCloskey's EggshellVoml$h
Woodsmirh
,H,
IH,
k/j6#}'~
19
SIDES
I started building the about I" fmm th" trom edge of both side
'" wlIU>hcllbymaking piecesso it doe...n't -,hew,
the IWO sides (A)
To cut Ih~
,toppt-.i dadoes. mourn a V4"
CUI these pieces
straight bil in the router tabte and SCI it tocut
81.t";,, wid<.- (Ioaccour "10"-dl"'p. I'o,ilion the f~nce 3'"," from the
modale the dovetail bil. SC(' !-ill. 2
layout) and to a
Sincctlusis ablind cut (Ihe bitisunderthe
lenglh of 16". sec workpiece and YOII can't -ee where it is). I
fig. I. (The angled put " r('f~I't'nce mark on the router table
fronl "dll~ Ol(lhe.c side pieces will be CUIoff fence allh. t(nwrohhe bit. S~llg. 2.Then
1"I~r.) If y')1! don't have Oal, wide board s. Iplltunullwr mark on the workpiece I" from
build UI) 1111' width by cdllL'lllliingsomc nar- Ow front edge III indicate the stopping point
rower pi('C(s.
forth dado. ".,' Fig. 2.
STOPI>~:1l o.vno. Before cutting the
ROtmNGTil E tl.\I)()P_'\.To rounhe dado in
dovetail joint s, Irouted a stopped dado for the side piece f"r the righl side of the shell.
the center .hell (D). This dado is stopped lay the piec... down on the rourer table and
1 urr
SIDE
RIGHT SIDE
..
,-
MAJtKClNtt.
or 1fTON '(NC!,.----
....
fIIONT
'IIONT
IOGI
lOG
@\
\
$to....,
-'I1
l7".!~
t'r
16'
n.n.n.n.n
~
8'.')."-":
TOP, BOnOM,
.~
,
SHElf
20
( ..... K $TAIIlNQ""NT
INSIDE
'ACI
DOWN
-- ..,
'::>
__- :r---3_::__
CINTER
(Clh."_.
~ :~l:~:f,s~~ize:.s.
___
from the
f"
3'.
-...r&:.-
3\\'3)'
AND SHELF
left.!;('e Fig. 3.
Shop NOll':Allhough you can accomplish
lite same Ihi'l!! by roUlinll from len to right.
I would" 'I recommend doingitlhal way. The
rotation of the bit can pull the workpiece
.t
f. '"
'IIOM'
,F EDGf
,.-
'-
.....K
stOP POINT
TOP
(!'}-
an SKILF 1,,-
lOHOO THAH
ltC'SHOULDfRTOoSHOUUKI
three
,"1I~t(.
areas
ce--"ThR
~HU.J'.All<'r th"
dovetail joints
:.
:'I. ,
No. 66
ASSEMBLY
AI this point all the joinery is complete. All
thatremains is to mark and ("t,t the angles:ofr
the fronl edge of the side pieces (A).
MARK ENDS. To mark the angles. first dry-
(D) meets the side pieces. Now. disassemble the pieces and draw a tine between
the marks.
7
DRY ASSEMBU!
AS.~EAIllLY. Now
the wall
shelf
can be
glued and clamped, see F;ig.9. (Don't overtighten or the lOPpiece might bow.)
ct.IN!JP JOINTS. Aftcr Uleglue dries. remove the clamps and cheek the joints. Ifthe
pins and (ails stick above UIC surface of the
boards. plane or sand them off flush, If
they're slightly recessed, use a plane 10
shave the boards down to !he pins and tails.
un CI.MIP,NG PADS~
UNIT, lHEN
MARKANGlD
-
POtNIX
BOnOMIDGE
OF THE lOP
PI,'c: TO ~E
aNTtA. SHUI'
MAR.
60TH SIDES
NOTE:
POINTY
CHICK
CORNERS
tHE
TO l141 UNit /1
FORSQUAR,
INVISIBLE HANGER
'To mountthe shelf to Ole wall,
I used a hidden hanging system. IIconsists of two beveled
strips that interlock. and permits the mounting screws 10be
1'0 aecomodate the hidden lockinlf strips - a hanger and a ot the back piece (E). Face the
strips. first cut a 2Vz"wide wall cleat, To make tbe hanger bevel toward the back piece,
groove in the back face of the
NOTE: GLUEHANGER
FLUSHWlTH 8ACK
PIECE
WALL MOUNTING.
CUTBACK
TO ftNAl
TO CUT GROOVE
./10,.(8). :
Next,
R.PATPA$SES
(00 OFTO'
see fig.la.
Once lhe glue dries. glue
this unit under the top (B) Of
th!>wall shelf. see Iig. I.
WIDTH
BACK
J_ -
'1',"
\.2"
'
-r
-t
I
No. 66
Woodsmith
WALL
HANGER
WALL
CLEAT
10-.
f4-.'II....
b-r
\SET.lAOE
AT 30'
~/@
"
SlT BLADE
AT 30'
21
DRAWERS
After building the
basic wall shelf, I
=~ built three drawers
i
to fitth. opening between the center
shelf and the bottom. The three
'-Ir':
,<;
drawers arc simply
open boxes with
through dovetail corner joints.
CUT Tut PIECES. Start building the
drawers by cutting lhe ltz"thick drawer
fronts/backs(H) and drawersidesfl) to a
widdl lIu;" less than the height of the opening. In my case. I cut these pieces 2':Y16"
10
t~
\1
.~
BOTTOM
(1t4. PLYWOOD)
on Ul" shelf
11
Nowcuuhe drawer
12
O. CROSS SECTtON
bouoms
(C)
ROUT
CROSS
.OUT
""alIT
11\."
SECTION
1l<AN
TMICKNESS
OF
CHAM"'
INSlor U)GE
Of FINGfJl
HOlE
111....
UlMUS
14
13
O.
,
,(,
CROSS SECTtON .
I
"
NOTE:
cl!AMu'
INSIDE
toG"
CHAMFER
art
$TOP OftA,WlA_
'......
F~M FRONTEOGf
,'
"-
'- .......
t:
,
APPlTGWfTO
UJ.an\lOGE.
22
Woodsmit:h
No. 66
COMMENTS
AND
QUE
S T I 0 N_S
---l
Talking Shop
SOflWOOD PLYWOOD
Of
to act as stops.
In this
issue
arc
made from
BIRCHPLYWOOD
--,.,.,.-,,!
~
... ..(..;..,.r-_"'-d
APPlEPl Y PLYWOOD
~~.~
Pi''''_
'~""~lo.""
M.L*IW_ ~
Ib"")l")l:il
No. 66
WCl<xhmich
23
PROJECT
SUPPLIES
Sources
as two Cambridge vises. (See
box below for catalog sources of
'Vhon \\'0 finished the Work- these and other vises.)
bench (shown on page 4), we
Basically you want a vise that
started looking for a good cast has fairly large jaws (7" wide or
iron woodworking vise to mount larger) 10 hold lumber either
IAl the front afthe bench.
vertically 01' hori1.ontally.
One of the best-known names
Some models come with a
in vises is Record. These vises quick-release feature that adds
are made in England and have a only a small amount to the cost
sound reputation for quality.
butsure makesworkingwitb the
In addition to Record vises, vise a 101 easier.
WORKBENCH VISE
24
COOL BLOCKS
Cool Blocks,
These graphite impregnated.
phenolic laminated blocks are
available to fit a number of differenl band saws. They arc sold in
sets of four: two for till.' upper
and two (or me lower guides.
Cool Blocks are available
from the Garrett Wade catalog.
see the address below.
WING NUTS
'Ving nuta are great for making
any sort oijig that bas a rnoveable section or fence you have to
adjust and re-tighten.
We found some large plastic
BALTIC BIRCH
wing nuts with brass threads.
AND APPLIPLY
These nuts are almost 3" in
In Talking Shop. page 23. we diameter. which makes working
ia Iked about two unique ply- with them ajOy. (They're shown
wood products, Baltic Bin;h and on the base line holding jig on
ApplePly.
r)agc 10.)
1'0 find a local dislriblilor or
WinllNuts
dealer for Baltic Birch. you can You can order large wing nuts
A good basic vise for the call Allied International toll free from Woodsmith Project SupWorkb~nch is the one shown at at (800)343-9074.
plies. TIle brass threaded insert
right in photo above. It has cast
To find a local distributor or in each nut is sized fora !Y\~"dia.
iron jaw~ that are 7" wide by 3" dealer for ApplePly, you can call boh. Packaged in a $<)t of four.
high and open to 314" (between Stales Industries toll free at 766-210 Large Wing Nuts,
Ute two hard maple jaw faces in- (800)537-0419.
Package of Four ..........". $5.95
chided with the vise).
Woodsmith Project Supplies,
Both vises are made by Cambridge Tool of Canada.
Basic Vise
766-103 Basic Vise .... $64.95
ORDER INFORMATION
BY MAIL
BY PHONE
For faster service use our Toll
Free order line. Phone orders
can be placed Monday througb
Friday. 8:00 AM to 5:00 PM
Central Standard TIme.
Before calling. have yow'
VISA-orMasterCard ready.
Woodworker's Supply
5004 Alameda Place N.I>.
Albuquerque. NM 87J 13
\'islJJI
\VoodcraftSupply
P.OBox 2069
Bellingham, WA 98227
Parkersburg, WV 26102
Vwes
18004447002
Allolf)4 IQ6 "",,;k.[ordelit'ltr'l/.
,\'(J/e: Pnr.,'.J$ ~l(bjetJt.(J rhaf~!Jt'
(lfii"t Sir/Jhflfll;qr. JhfH>.
Shopsmith
393) lrnage Drive
Dayton, OH 45414
Vises
Woodsmith
Vise8
Woodworkers' Store
21801lnduslrial Boulevard
Rogers. MN 55374
Vises,AJ,piePlli
No. 66