Beruflich Dokumente
Kultur Dokumente
Brad Nailers 4s
MollyBrown'sTable
50
Recreatethe Unsinkable'scollapsibleparlor table.
LockMiters57
Asimpre,
unique,::?:;:il:*ilHl,:
OutdoorRietveld
Chair50
Build this icon of modern furniture design.
'Cover
photo by Mike Habermann
ShopTest:
65
BeltSariders
We help you choosethe sizeand style'
that'll work best in your shop
CherryPieSafe70
The biscuits that hold this cupboard
together are easyaspie.
page 60
Doors78
Flush-Fit
A simple jig for a perfect fit everytime.
ShopTest:
Planers82
Portable
Our favoritemodels,plushow to
steerclearof snipe.
page 82
o Question
o
EDITORKenGollier
ASSOCIATE EDITORSTomGaspar, TimJohnson,
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Thomas 0. Ryder
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Ouestlon&
Anr SMOOTH AND FILL the area
theDetails
Recreating around the missingpart.
U
5. UseMinwax's catalyzedwoodfiller or
2
Bondo auto-body filler and slightly F
O
overfill the mold (Photo 3). Usea small U
E
Q u e s t i o n& A n s w e r
Doessizematter?
You bet it does!You see,
15'Production
Wide Belt Sander
the biggera companygets, . Open-enddesign
the harderit is to keepthe combinedwith 16"x 48"
needsofthe"litttepeopte" in belt enablessandingof
mind. We have never lost up to 30"with no seams
o Pneumatictrackingbelt No* your table saw will support up to 48" oI
sight of the factthat sma[[ osciltationcontrol cut matedal.
cabinetshopsare what got . 1.500unitsin operation
usstartedover21yearsago. Lifts quickly into position and folds out,of.the
We'vesolda lotof machinery way in one simple easy step with no tools...
overthe years,but we have supports 200 lbs.
atwaysstayedtrue to our 25' Produdion Wide Belt Sander
o 25"x 48"Sanding be-!!_,".
originalmission,to provide
the highestquality,most trackingbelt
i n n o v a t i v em a c h i n e r ya t oscitlationcontroI
r Pneumaticbelt
affordableprices.
A,
tensionfor quick &
et
easybelt changing
No matter how much . Emergency diskbrake
r Variable FREE Color Catalog
we grow, we treat every feed,13-52FPM Call: 1.800.624.2027
customerwith the respect o 1OHP singlephaseor HTC PRODUCTS,INC.,
they deserve.Giveus a ca[[ 1sHP3 phasemotor ROYALOAK, MI 48068.0839
o Sotidconstruction:
1,500
tbs.
andseefor yourselfjust how
gooda smaltcompanycan be. -800-929-43
I Cattnowfor moreinform
Visitus ot:www.sunhitlnic.com
Question& Answer
Paint-Filled
Pores
Q' After stripping about lO The small diameter brass wires
layers of paint off an old oak pop the loosenedpaint out of the
washstand I was left with paint- poreswithout harming the wood.
filled pores. Should I sand down
the top until the paint disappears?
CAUTION!
o*""1,'oTl'i,'N
Be sure to use these strip-
pers with good ventilation
A. Putyour sanderaway,there's and wear glovesand eye pro-
an easierway! tection (seeAW #77,p. l2).
Use a methylene chloride- Work outdoors or use a fan
basedstripper (availableat most to take the fumes outside.
home centers-pick the one Remember that methylene
with the highest concentration chloride fumes are heavier
of methylenechloride). These than air and will accumulate
stripperswork from the bottom near the floor.
up and can loosen the paint in
the pores.To freeup the trapped Sources
Brassbrushes:Constantine's,
paint, usea brasswire brush and (800)223-8087;
6 in.,#BRS36$2.60;
scrub the surfacewith thegrain. l2-718in.,#29BRS$7.95.
Buy]ac{on
llircct
-silt-
ilOu$ilDs!
With aWood-Mirer!
o Cutlogsup to 28rrD.x 11rL.
. Extrabed sectionspermitlongerlengths.
' Easilv
transportablt'
- q.1gq$z *
*"***'"t&66
8180\[ 10thStreetDept.Ar0fl53
,..
&iiry Indianapolis,
lN 46214 * wtb furcbaseof
(Shownwith optionalloadingramps.) wwwwoodmizer.com AllMtasvtdco @tIA
rffittRACUmF$'
l-800-567-0553
www.miracletruss.
com
Q u e s t i o n& A n s w e r facedwood. Thesemeterscan
alsobe adaptedto take accurate
readingsat depthsbeyondtheir
normal range.S i mply dr ive
Moisture
Meters uncoatednailsto the depth you
wish to measureand usealliga-
(1. I've been looking at mois- A . If you buy your w ood tor clipsto connectthe pins on
ture meters and wondering alreadysurfaced,then a pinless the meterto the nail heads(see
why I should buy a pin type if a meterwill work fine.If you buy photo). If you dry your own
pinlesscan do the job without your wood rough or if you dry lumber,thesenailscan be left in
poking holes in the woodl your ow n w ood, a pi n-type placeallowing you to monitor
DonaldKutz, meter is the way to go. your wood asit dries.
Ames.lA A pinless meter'sgreatest Still can't make up your
assetis its ability to scanoveran mind?Electrophysics (800-244-
entireboard or evena finished 9908)offersa dual mode pin-
pieceof furniture, without leav- type and pinlessmeterfor $330.
ing a mark. Pinlessmetersare Good quality moisturemeters
alsounaffectedby temperature, are also availablefrom High-
which eliminatesthe conver- land Hardware(800-24I -6748),
sion charts neededwith pin- Woodcraft Supply (800-225-
type meters. I 153) and Woodworkers'Sup-
The biggestdrawbackto pin- ply of New Mexico (800-645-
lessmeters is the flat, smooth 9292); prices range from $50
surfacerequired for the sens- to $250.For further readingon
ing pad.This meansthey can't moi sture meters cal l For est
be used effectivelyon rough- ProductsLaboratories(608-
sawnlumber without first plan- 231-9200) and ask for t he
ing a flat area. report, "Electric Moisture
P i n - t y p e m e t e r s w o r k Metersfor Woodl'by William
equally well on rough or sur- James.
Resaw
WithoutWarp CUT OUT
MIDDLEWITH
Department of
BANDSAW Corrections
(1. I've had a few bad
The cutting list in the
experienceswith wood
Hoosier Cabinet story
warping after I resaw. ls (AW #77, p.63) contains
there any way to tell
double listings. Pieces R-
whether a board is a good
1 through Z-5 are listed
candidatefor resawingl
twice. The second (bot-
TomMartin tom) listing of these parts
Casper,WY
is the correct one to use.
,<X -,
r"
\
t
ThoseBlastedGates {'
Periodically,fine dustand sawdustaccumulates in i,.
my plasticdust col.lectorblastgates,preventing
the gatesfrom fully closing.Becausethe gatesare
MorcBlade \'
permanentlymoldedinto the housing,Icart'ttake for YourMoney e- '/-
them apartto cleanthem.Removinga smalltri- I use my scrollsawblade almost exclusivelyfor cutting stock of
angleat eachof the bottom cornersof the housing ll2-in.thick or less.Consequently,I only useaboutone-sixthof the
allowsthe vacuumin the dust collectorhoseto total cuttinglengthof theblade.To maximizethe life of theblade,
flush out this debris.Eventhough there are now I've built a raisedplatform that fits snuglyon top of the scrollsaw
"holes"in the blast gates,I haven'tnoticed any table.Whenthe bladegetsdull,I installthe platformand now I'm
appreciable lossin performance,
thoughyou could usingsharpteeth.Finishthe platformwith varnishfor a smooth
coverthe openingswith duct tapeandperiodically slidingsurface.
removethe tapeto clearthe sawdust. BETZALEL KIRSHNER
CARL FREELAND AZOR,ISRAEL
DODGEVILLE.WI
e
l(.cJ
.r -i'\ BUTTHINGE
".!'- r
li
n
il
DrillPress
Vertical
. - r_Support
Drilling holes in the end of
a long, narrow piece of
wood, even with a floor-
mounted drill press,can be
Stowing
Table
Now and then I need extra bench space
a challenge. This fixture for assembly or finishing. My garage
helps. Long boards are shop is cramped so I made this easy-to-
clamped to the fixture at stow bench add-on. The tabletop is
the top and supported from built of ll?-in. plywood and 1x4
below on a small adjustable aprons. The legs are hinged and con-
shelf.The drill presstable is nected to the tabletop with a collapsing
swung to the side to put the brace to prevent the legs from being
end ofthe board under the accidentallykicked in. The add-on table
drill bit. With this system, connects to my workbench with a
multiple holes in the ends beveled cleat-a 2x4 ctttat 45 degrees.
are easy-just loosen the Storageis a snap-it slides against the
top clamp, slide the board wall behind mybench.
. over,and reclamp.These PHILPRATT
\ holes will automati- MARCOISLAND,FL
,., cally be in line, the
same distance from
the face of the board. BiscuitJoiner
Jig
DICK FORD Cutting slots for biscuits in small or narrow stock, such aswhen
=
SARNIA,ONTARIO slotting solid-wood edgebanding for shelvesor cabinets,can td
=
w
be downright dangerous. There's no effective way to hold (L
U
both the joiner and the stock with your hands.Also, the rota- z.
J
tion of the joiner blade can fling a small piece of wood away U
P
u \y lE
V
E from you. To avoid this, I devised this jig. Clamp it between
bench dogs or clamp it to the benchtop with C-clamps so the
2
E
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F
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a
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AccurateLocationof \,o,=
SmallHinges
On the jewelry boxesI make,I havea
toughtime gettingsmallhingesproperly
aligned.I've comeup with awayto tem-
porarilyattachthelid to the hingeswhile
the screwholesare drilled or marked.
The hingesare first attachedto the box
with screws.The hingesareopened,
andon eachofthe open
leaves,a largepieceof clear
tfi-
shippingtape(3M,Scotch t",..
pis;$tt
Premium Heavy-DutyPackagingThpe
#3750,$4.69;OfficeMax,800-788-8080,
item#0700-3725)is fixedwith the sticky
sidedown.The hingesareclosed,which
placesthestickysideof thetapeup.When
thelid is carefullyplacedin position,the
tape shouldgrab it. When it doesn't,I
usea thin stripof woodto pushthetape the lid-side hinge leavescan now be reusedin caseyou arenot satisfied
with
ontothelid. Gingerlyopenthelid on the drilled or marked.The shippingtape thefirstplacementof the lid.
hingesandpressonthetape.Theholesto doesn'tleaveany residueand can be HERBNA{N
TurningBowlBottoms
I makea lot of turned"kitchenware"such adjustablejaws,but haven'tbeen satis-
asbowlsandplatters.I've perfectedmost fied. The method I've come up with
of my techniques,but I strugglewith allows me to grab any bowl with a top
turning a smooth foot. I've tried many largerthan its foot (convexshape)sothat
of f - t he- s hel fj i g s , Ii k e c h u c k sw i th the bottom can be easilyturned and
q!*.ri;;{CI
Ro)iil
LrJ
z
o
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a
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tr
F
a
- +'ws, =
**:b.
ffi
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T
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Lrl
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-
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f
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m
t
:tr
o
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T
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a
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z
you get t
L!
o
Lll
rolling s*-
pins take only a couple of hoursto (D
challeng€s,especially
turninga true cylinderand F
o-
M A K E T H E R OL L ER
Mount an I l-in.-longblank between
centerson the lathe.Placethe end you
previouslydrilled on to the live center of
the tailstock.Yourdrivingcenter should be
located on the opposite end of the blank's
center.
Turn the blank into a cylinderusinga
8ouse.
continuedon Page30
-LowPrices
GreatC[amps
Clamps From Garrett \[ade
TheseareGermanmadewith the expectedhigh
quality designand workmanship-and at less
than S4.50each,they area phenomenalvalue.
Light, strongand easyto use(throat depth2Yz')
with vinyl cappedswivelendsand woodenhan-
dles. It'i teriihc to have a bunch around the
shop.The 9l*p size(listed below)is the max-
lmum openlng.
\(/e cannot recommend these enough. Ten of
E=E===E
eachsavesvou considerablv.Real value doesn't
comeany better than this.
Regular sale
37F02.10 4' C.ab.Clamp(10) $62.95 $44.95 --
37802.20 8'Cab. Clamp(lO)$63.95 $48.95 5 A
37F02.30 72" Cab.Clamp(l0) #73.95 ff 52.95
Combo.Setconsistsof 10 of eachof the 3 sizes SOIID3" x 3" SOUARES
of clamps.30 Clampstotal- only 84.65 ach.
Avoiloble in (3) Lengths
37F20.L0 Combo.Set $205.85 $139.50
1 7 ". 2 2 " . 3 0 "
Garrett \$7ade Shipping Charges
161 6th Avenue #6.95 to$'9.95 Surfoced Hit or Miss
New York,NY 10013 dependingon value. lo 215/'rc"
Squore
Kiln Dried lo 6-8"/o
FREE
GARRETT
WADE
CATALOG
O"r high quality Woodvnrking C,aalog hasthousandsof tools to clroosefrom.
FREECATALOGUE
\t"r*if,.@fureibsite ar ww%g?rrrtgqnrde.cofir ot call us at thenumbers below. & "furr*7r6l9rlrrra"' L.r.D.,
Lp.
:J, 974 Fotest Drive. Dept #Aw26
fb
Qualit!.,,Morc Affodable ThanYouThink!
TSC-IOC Table Saw... BW.6R.fointer Ask about easy
withleaturessuchas a largeworkingsurtace,powelulAnerican Acclaineda'bestbuy'among6' Jointers Srldgewoodrodrer
madenotor andsturdyconstructionyou'llseewedidn'tspare bya professional publiation
woodttorking
qua@to nake an ecitnonicaltabb saw .3-knifecutterhead T.EASE PI.IilS
. MitergaugewithT-slotgroove . Castironextensionwings . Jad<sqew knifeadiustment
. Magneticswitch . Quickreleaseplugconnectiononmotbr . fenqe tilb bothways,quick 3 positivestops
andeasyadjustment.
.4" dustcolleclion Nerry
hookuo . Larqe27"x 40'table . Eno|oseg
Enclosed stand
$ano
. Beveledfronttableedgefor smod'th
mitergaugeoperation . 1 HP motor
. 1 1/2HPAmerican mademotor . Batrbetinq
hble andledoe
. ComeswithVEGAoU-26fence(shown) -
. Surfaceg'round
tables
. Pushbuttonswitch
. Castironwheels
BW.l5BS Bandsaw...
don'tletitslowwie foolvou,thisamuino
bandsaw is des:ignedand'fuilttoprovide-
troubletreeooeration cutaftercut.
. Heavilyribbed,castironc{rame
. Cdstaluminum wheels withrubbertires
. Non-rockingsteelfloorstand
. Mitergauge
. Molormounted dhecllyto casthonlrame
for smoothoDeralion
.3/4 HPmotoi
. Twobladespeeds: 2000or 2600SFM
Woodturn ing
CMFT SUPPLIES
1287E. I l20th St.,Provo,UT
84601;(800) 551-8876.
Metalcone-tippedlivecenter,
WOODCMFT SUPPLY
2l0Wood CountyIndustrialParlq
PO.Box1686,
Parkersburg,\W26| 02-| 686;
(800)s3s4482.
l4 mm brad-point bit,llY9l,$6 MAKETHE AXLE CAP
l/2" brad-pointbit, l28f 8, $6 Mount the cap blankin the lathebetweenthe wood cone and the live center.A
pieceof leatheror thick fabric will keepthe metal center from scarringthe end of
the cap.Turnthe cap with rounded endsand a shallow,decorativegroove made by
rollingthe gouge'scutting edgeto makea slicing,semi-verticalcut.
FINAL ASSEMBLY
When you'refinishedturningand sanding, return the roller to the corner blocl<lig
on the drill pressand drill the l/2-in.hole on the other end.Use the hole from
your drive centerto pilot the point of the brad-pointbit.Gluethe dowelsinto the
roller,slidethe handlesover the dowelsand gluethe axle capson the ends.Finish
the whole thingwith mineraloil and wax. /W
RelYon Yellow
thecut.
foT,f 50 standardsizesand a dozenkits to sawthroughvirtuallyany
material.Plus,our pre-assembled
systemfor convenience
Quick Shof arborand saw
anddesign,it's the bestthereis.
Hacksaw r1
and Blades r\w
\-,layton Spindle Sandersare
Ournew,fastercuttingBearcat"
BGIbi-metalbladeswithgroundteethcombinewith built in the USA with precision
balanced spindles, oversized
our Higft-TensionHactsaw framewhichprovides
a 28,000PSIsettingfor optimalperformance.
Twisting andbindingareeliminated. \r-*'
o*
MA
l^m*;wA,
bearings, and a premium
Baldor Induction Motor.
o Benchtopand full-sized,
gr'qrqt">sorl"t" Stswetf
The L. S. StarrettCompany
FREE COLOR CATALOG,
cal l : 1-800.971-5 050
z
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t:
co
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U
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CY
(5
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Photo
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HowTo Make lt (-)
F
U
1, Surface the covers E
-
to about Il4in. and cham- F
C:L
f e r t h e o r - r t s i d ee d g e s .
Album
(Optional: Use a l-ll2-in.
hole saw to cut a circular
frame in the cover.)
2. Sand and finish. We
useda sealercoat of Super
Do you havea pile of photos waiting to walnut was resawn to make front and Blonde Shellacfollowed by
be put in an album? We all do. That's back covers.The maple was resawn and two coats of water-borne
why you can't go wrong making these glued up to createbook-matchedcovers. polyurethane.
distinctive photo albums for yourself T h e 9-l l 4 i n. x 5 i n. aci d-freepaper 3. C ut tw o 4-i n.l eng t hsof
or as gifts. pagescome pre-drilled and are available hinge(two 1l-in. lengths
Figured wood makes an attractive f r o m A n c h o r P a p e r ,( 8 0 0 ) 6 5 9 - 2 1 2 7 , for l 2-l 12 i n. x l 2-1 12 in.
cover.The first album in the photo was # Z R 3 0l -213,$6.50 pl uss& h tor 25 pages. covers)for eachalbum and
made from a 3 in. x 20 in. pieceof tiger The2in.x24 in. continuoushingeand the file a radius on the corners.
mapleand the secondfrom a single6 in. brassbarrel bolt connectorsand screws 4. Use the pre-drilled
x 10 in. pieceof walnut.You can make are availablefrom Van Dyke's Restorers, paper as a templateto drill
l a r gerc ov er s( I 2 -l l 2 i n . x 1 2 -Il 2 i n .), (8 0 0 ) 5 58-1234; barrelbol ts,#A F-S1572, two 1/4-in.holesin one leaf
but they are more likely to warp. The $13.95h ; i n g e s ,# A F - 5 6 1 6 7$, . 7 5 e a . ; of eachhinge.File any
# 4 x I l 4 - i n . s c r e w s , # A F - 5 4 73 9 F , rough edgessmooth.
$3.25packof 100. ffi 5. Drill rwo 5/64-in.pilot
- BARREL h o l e s5 / 8 - i n . i n f r o m t h e
." y' BOLT
back edge of eacl-rcover.
r gl-tn" HoLE
#4X114"'
+! :
PRE-DRILLED
ACID-FREE
Mount the hi nges t o t he
PAPER cover with #4 screws.(Nip
off the ends of the screwsif
your coversare 1/4-in.thick
or l ess.)
6. Bolt the loose leavesof
the hingesthrough the
paperwith the barrelbolts;
add photosand enj oy.
38
I I fhat wasthe first
Y Y tool you ever
bought?l'll bet it was
a hammer.After all,
hammeringis some-
thing we begin to
master as infants.No
other tool feelsas nat-
uralto hold or conveys
its purposequite like a
hammer does. But
guesswhat?As a tool
for drivingnailsto fas-
ten things, there's
somethingbetter.
Wheneveryou pull the trigger on a brad naileryou save time. lt
drives and countersinksbrads instantly,without pre-drilling.
Air-powered nailers havebeen fixtures on job sitesand in
professionalshopsfor yearsand there'san air-powered
nailer for practically every nailing situation. But they're
still uncommon in home woodworking shops.Yes,they
do require a compressorand consequentlyseemexpen-
sive-especially compared to the cost of a hammer. But
there are compelling reasonsfor a woodworker to own
one: Theyre useful tools, much faster than hammering,
more convenient to use and they give a cleaner result.
Wouldn t you be willing to pay for all that?
=
z
=
-o
z.
-
lrJ FIG.A AX AIN.PCWERED HATI]IER
= A BRAD NAILER is a simpletool, containinga cylinder(A) with
lrJ
l a head valve (B) and piston (C), and rubber O-rings to form airtight
N
J
J
sealsbetween the parts. A second valve at the trigger (D) controls
the supply of air and operates the head valve.When connected to an
t
I air source,pressurizedair fills the body of the gun and surrounds the
E top of the cylinder.Pullingthe trigger opens the head valve.Air rushes
(J
F
into the cylinder ( l) and drives the piston downward with great force
T (2).This is the drive stroke. A metal drive rod (E),attachedto the
(L
a bottom of the piston and housed in a guide shaft of its own (F),drives
E
tr the brad. After driving the piston;the alr immediatelycycles into a
I
Y
return chamber(3,G) that surroundsthe lower half of the cylinder.
E,
From there the air rushesback into.the cylinderunder the piston/driver
ko- assembly(4), and drives the piston back to the top (5) before exiting
2 through the exhaust port (6).This is the return stroke. CLIP OF BRADS
tr
c)
lrl
F
E
2" LENGTH
HowtoAvoid
lmpactMarks
Brad nailers sometimes leave dents
on the surface.These dents arent
made on the drive stroke. They're
FIG.B ABE''ERBRAD caused by the gun's recoil on the
AN l8-GAUGE BRAD for a nailer return stroke.Themanufacturers'sim-
(above right) looks different than a
traditionalfinishnail (aboveleft) and
ple solution is to supplya plastictip
its designhas severaladvantages. lt's that fits over the drive point and pro-
smallerthan its traditional tects the wood surface.lt works, but
counterpart,so it leavesa smaller,less obscuresthe drive point from view. A
noticeablehole.ltstip isnt sharply
pointed.lnstead,it's slightlyblunted, sure-fire way to avoid dents is to buy
which makesit lesslikelyto split the a nailer that has a trigger-controlled
wood, and it's wedged-shaped, so it return.This mechanism,designedfor
can be smoothlydriven and set by a safety,allowsyou to controlthe return
singleblow from the nailer.A finish
nail hasto withstandnumerous
stroke-it won't occur until )rou
hammer blows,so it must be madeof releasethe trigger.Toavoid marringthe
harder steel,is noticeablylarger in wood, simply remove the nailer from
diameterand hasa biggerhead. the surface before you release the
trigger.
100
BRADS
OUCHI Dealingwith
a pile of 100 bradsis a
pain.Either you'll get poked,
or they'll get dropped all over the
place.Brads designedfor a nailer are
much easierto handle becausethey're
packagedtogether in clips.
BETTERRESULTS
SPEED
The Baneof
Brad Nailing
Because they'remadefrom soft steel,brads
BLOWOUT is unpredictable, haveatendency to deflectwhentheyencounter
instantaneousand dangerous. something hard.A hiddenknot,a bitof metalor
Keep your free hand away
from the path ofthe brad. eventhecellular structure of a hardwoodcan
causethebradto comeshooting outthesideof
yourwork.Theresultcanbecatastrophic
(photo,middleleft).
Y o u can mi ni mi zethe chances of
blowoutby the wayyou orientthe brad
(photo,at righQ.Thebradisguidedby its
vee-shaped tip, so anydeflection almost
alwaysfollowsit. Orientingthe bradso
thistip is perpendicular to theouteredge
of theworkpiece will keepanydeflection
parallel to the edgeandunlikely to blow
through.
Eventhoughyou do everythingright,
blow-outcanstilloccur-it's thatunpre-
CLIP OFF A PROTRUDING dictable.
Repair thedamage byclippingthebrad
AVOID BLOWOUT by holding the
BRAD as close to the surfaceas (photo,bottomleQ.Don'ttrytopullitthrough nailer perpendicularto the outer edge of
possible.(Got your safetyglasses
or backit out-you'll makethingsworse the workpiece.This orients the vee-
on? Good.) Countersinkthe
because the bradwillbendandbreak. shapedtip of the brad so any side-to-side
remainingmetal and carefullyglue
deflection is containedwithin the wood.
the damagedsplinters back in
Hold the nailer level with the surface,so
place over it, usinga block of
you shoot straight. Always wear
wood (with waxed paper benneen
protection for your eyes and ears.
it dnd the damagedsurface)to
Presseverythingflat; then clamp.
WORK SURFACE
A REAR. USUALLYLOCATED
HERE
DIRECTED
EXHAUST PORT
is an innovativedesign
that meansyou'll never
get a blast of air in the
face.Theret even a
spongemuffler insidethe
vent to reduce the noise
and the force of the
exhaust.Other nailers have
an adjustableport mounted
on top of the cylinder.
A PACKAGE DEAL, includingnailerand compressor
can be a good buy if you dont alreadyown a compressor.
On sale,thiscombo was only $300.
THEWHOLE PACKAGE
A compressorprovidespressurizedair
for the nailerthrough a supplyhose
equippedwith quick-connectfittings.
Contractors often use"pancake-style"
models ("A PackagedDeal," bottom
left) becauseof their compact size and
portability,but shop around-a bigger
unit, with more power and a larger
reserve tank (at right) may cost less.
byTim fohnson
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Fig.A1ilfrf,#f$:.*
Hinges,dowels and friction hold this table together.There are only eight
parts and you can make four of them at once.With simple changes,this
table could be square,round or half round.
I HoLDTHE LEGBLANKs
I. r TOGETHERwithdouble-stick
tape (see Sources,p. 56).Using the paper
pattern at right, outline the leg on each
blank.Thiskeepsthe blanksproperly
I
oriented and shows you where to put the
tape. Pressthe blankstogether,one pair at
1-112"
#12
a time. Keep the back edgesof the blanks PANHEAD
alignedby standingthem on a flat surface. SCREW
Align the end-grainedgeswith your fingers
and then pressthe blankstogether.Glue
the paper pattern on the completed stack
aligningit with the edges(Photo 2).
CUTTING
LIST
Overaf
f Dimensions;28-114"
H x 22"W x l6- l/2" D
, TRANSFERTHE
ur.re for the !4" x8" x27-112"
A I dowelsonto allfour blanksat
!4" x l6-ln" x22"
once,usingthe referenceline on the paper
pattern. Before making these marks,true
!4" x 7-aD"dia.round
up the ends of the stack on the tablesaw 38" x 6-58" dia.round
usingthe miter gauge,if necessary. !4"x 5"x5"
2" L x l- l/2"W dullbrass
Making the Legs
Look for boards without sapwood that are -' | ^ Patternand Plan
8-1/2-in.wide, otherwiseyou'll haveto gluepieces IIg. It I ilr cuttingtheIrg
together.You can sawthe legsindividually, but it's
better to sawall of them at once.Stackthe four leg Enlargethis pattern to
blanks together,using piecesof double-sticktape 200 percent.Takethe
(Photo 1). Keep the edgesaligned. Then affix a enlargedcopy and
fuIl-size paper pattern on one side (Photo 2) and enlargeagainat 170
sawout the legs (Fig. B and Photo 3). percent.Cut out and
Sawingthe ganged-togetherleg blank on the glue the pattern to the
leg blanks.Thesequence....r8-
bandsawis a simple combination of curved cuts,
of all the cuts you'll need v
accesscuts and relief cuts. To be successful,it's to make is shown right
important that your sawis in tune (seeAW #25,p. on the pattern. Stars
18for how-to) and the blade is sharp.A 3/I6-in. mark points where you
4-tpi skip-toothblade (seeSources,p.56)will do need to make access
a good job. To make accuratecuts with smooth cuts.Justfollow the
curves,it's also important for you to be in tune numbers to cut out the
leg.Cut #l is best done
with the saw.Usealighttouch so you can findthe
on the tablesaw.Do the
blade'soptimal feed rate and seehow it tracks. rest of the cutting on
Then advancethe workpiece steadily-don't try the bandsaw.lf you have
to cut too fast-and let the saw do the work. a l4-in.sawyou.cancut
Make accesscuts first. They allow the blade to out the entire leg
escapefrom dead-end curved cuts easily. without flipping it over.
After sawing,clamp the legsin a vise and sand There is only one critical
dimension.Thetongues
the edges(Photo 4).Attach the hinges(Photo 5),
at the top of the legs
then pry the legs apart. Use a putty knife with (cut #2) must be 314-in.
blunted edgesand smooth faces-any burrs on wide for the lock block
the knife will scratchthe wood.After the legsare (Fig.C) to work properly ('
loose, remove the paper pattern and any dou- (Photo l0).
:
ble-stick tape that remains.Then sand the faces.
FlexibleRubberSanding
Pads (seeSources, p.56) .or" in
TEARDR9p a varietyofshapes
and contours,
CONTOUR a ^ ^ , t cost
^ ^ ^ + much
*,.-L ^^) -^t.^rl.^ r^L
dont and make the job
of hand sandingmuch easier.
A Ganned Finish
This project begs for a spray finish.
Brushing the legswould be a drippy .r EASE
rT THE
nightmare and oil would make the
// . EDGEs
end grain too dark. I used shellac,
of the lock block
sprayedfrom an aerosolcan asa seal tonguesso they'll
coat. First I folded the legs together engagethe legs
and sprayedall the endgrain edgesat smoothly.
once. Then I opened them up and
sprayedthe faces.Ittook only 10min-
utes.The next day,after a light sand-
ing,I sprayedon a topcoat of aerosol
polyurethane.
1.1/8'TONGUE
\
Fig. C lfi'.IockBlock
The locking block swivelsto
lock the legsto the top. Center
the block on the round lock
blank and glue therh together.
Then drill the slip hole and cut
the curved profiles.
? $*
qt
usETHEToPASATEMPLATE
ror X g LocATETHE NorcHES intheshetf
by
fr. t the notched shelf that stiffensthe legs. -& -& * centeringthe shelfin the circle drawn on
First,draw a secondcircle on the top that'sthe same the top and transferringthe leg lines.Thendraw another
diameteras the shelf.Then,with the table assembled, 6-1|2-in.-dia.
circleto mark the bortom of each notch.
mark where the legsintersectthis circle.
Sources
3M Scotch 666 double-stick (coated) Brassbutt hinges,satinfinish,l-112"x2" 3M 2l5U ProductionRN Fre-Cut sandpaper,
tape, 3/4 in. about $4 per pairithree pairs needed $ .50 per sheet
#9 t0455,$8.54 Dowel centers,about $4 per set, two sets Tools on Sale,(800) 328-0457;www.Tcorner-
Office Depot needed.Get these at your local hardware shdwe.com;also availablefrom auto body
(888) 463-3768 store or home center supplystores
www.officedepot.com
FlexibleSandingPads Chalk MarkingPencils
3116",4tpi bandsawblade Tadpolecontour sanders(completeset of l8 Availableat art supply stores
# 1 2 6 1 7 l ( f o r 1 4 "b a n d s a w ) , $ l l profiles),#K150000,$ l8
Woodcraft Supply Teardrophand sander,#KL05245, $6 Learn MoreAbout Molly Brown
(800)
22s-r
rs3 Flat rubber sandingblock,#KL052 | 5, $8 Molly Brown House Museum
www.woodcrafc.com Klinspor'sSandingCatalog 1340PennsylvaniaSt.
(800) 228-0000 Denver,CO 80203
wwwwoodworkingshop.com (303) 832-40e2
www.mollybrown.org
A lock miter
router bit.
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ock miters are strong,
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assemblyeasy.So why the
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I think it's becausethey can be a pain
J
dependson the thicknesses of yourwood. Eventhe small-
I
:)
Ld to set up. Wellr rro more excuses.Herets estlock miter bit makes a cut, so I preferbits
substantial
N
a cut a lock miter on endgrain,asshownin our photos,or to haveon handthe materialrequiredfor your projectplus
F
o- on the long grain.Almost anyplaceyou'dusea miter,you six testpieces.It'scriticalthat the testpiecesbe the same
2 thicknessastheprojectpiecesbecause thebit setup is spe-
F
can successfullvusea lock miter.
LrJ cific to the thicknessof your material.As you get more
E.
o
Tooling Up familiar with the setup procedureyou 11needfewertest
Lockmiter bits comein a rangeof sizes.The sizeyou use pieces.
Fence Position
The correct fence position has cutter,
fence and top of workpiece all
intersectingat Point A.
TESTTHE
HEIGHT of
the router bit
by cutting two
test pieces.
Hold each
piece flat on
the router
ASSEMBLETHETEST PIECES.When the cutter is perfectly
table.
centered,the facesof the two pieceswill be aligned.Adjustthe bit
as needed.You must have the bit centered on the mater-
ial before you start working on the fence position.
58 Woodworker
Now,setthe
fenceposition.
N='--\ STEP
q EXAMTNETHETEST l\ \ lNDlcArES
\ \ CUTTOO
J CUTS ro determineif rhe sHALLow
r \\\
N\A
fenceis correctly positioned.lf
the cut looks likeA, the cut is
too shallowand the fencemust t
be moved back.lf the cut looks \\\
like B,the cut is too deepand
the fence must be moved for- \\ \Nia
v-l
ward. Adjust the fenceuntil the
cut looks like C;producinga
perfect knife edgeon the cut.
Ar lock
you'llbeableto cutperfect
lf youfollowthesteps
\l miters.Herearesometipsto makeit eveneasier:
cutyourparts.
Finally, Use wide pieces. Your pro-
ject parts must be cut to the
right length before cutting the
lock miters, but they can be
any width. Leavethem I in.too
wide. and cut them to final
width after you've done the
r o u t i n g .T h e y ' l l b e e a s i e r t o
handle,and the "blowout" you
get on the back of the cut will
be cut off when you machineto
final width. lf your project calls
for narrow pieces, 2 in. to 3
in.wide,machinepieces6 in.to
7 in. wide and rip them to the
MACHINEYOUR PARTS.One part is heldflat on the sizeyou need.
cable.Thematingpart is held verticallyagainstthe fence. Use a tall fence. Holding a
p i e c e v e r t i c a l l y a g a i n s tt h e
fence is a lot easier if the fence is high. Use one that's about
q
c AS S E M B LE
TH E
PIECES.
7-in.tall.
Use a "zero clearance" fence. Having the opening sur-
rounding the bit as small as possiblehelps prevent your work-
Yourcareful piece from slippinginto the opening.
mac hining will Precut your parts. A 2- or 3-hp router will hog all the
re s ultin material off in one pass,but it's going to be a lot easier to
per-fect-fitting machine the lock miter if you precut your parts on the
corners. tablesawwith a 45-degree bevel.Trimoff only about 3/8 in. on
314-in.stock.
Use push blocks. Neoprene-paddedpush blocks will make cut-
Sources ting lock miters easier and safer (see Sources,at left).
Router Bits: Make a perrnanent set up piece.When you haveallthe set-
cMT, (888) CMTBTTS
up done, machine a piece and keep it for your next project. lf
EagleAmerica, (800) 872-251|
(800) 53 l-5559 you want to set up the whole operation for the same thickness
Jesada,
MLCS,(800) s33-92e8 of material again,use the set up piece to set the thickness of
Whiteside,(800) 225-3982 your work, the height of the bit and to position the fence.You'll
Woodline Arizona,(800) 472-6950
still need to do some test cuts and some final weaking, but you'll
PushBlocks:
be darn close. IW
EagleAmerica, (800) 877-251|
American Woodworker APRlL2ooo 59
Rletve
lNfif.:'Lli"';m.';
reduced the idea of a chair to a 3D
grid of painted sticks and boards.
His revolutionary design became
one of the most famous pieces of
2Oth-century furniture-the Red-
hal r
Youll need a tablesaw,planer and router to mill the wood, anda#2
T
o
-
Blue chair. square-drive bit for your drill to put it together.That's it.A drill press
-
Iet's take a new look at it. Although and a router table are helpful, but not necessary. E
z
his chair appearseasyto put together, Honduras mahogany is a good choice for this chair. It's easyto eut, ;
o
'ts
getting all those sticks precisely sandsquickly and is weatherproof, even without a finish.Alternative E
F
locatedis tough, especiallyif you have woods include teak and white oak. Softrnroodsthat are often used for o
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only two hands. And all the pieces outdoor furniture like cedar,redwood and c)?ress are probably too a
u
x
look alike! To make this jigsaw Etnle weak for this chair and do not hold screwswell. If mahogany ip too J
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simpler to put together,I've figured pricey for you,I've scaledthe chair so you could usetough construc- =
, N
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out a building system based on two tion lumber such asDouglas fir or Southern yellowpine instead.Both d
plywood boards and a few spacing are available at most lumberyards and should hold up outdoors if -
blocks. I[ like most people,you want painted. o
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o
to build a bunch of chairs instead of One chair requires about 12 board feet of 614 wood and about
just one, this system is the ticket. 10board feetof 4l4wood. That'sabout $150per chair for mahogany, q
J
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Once you've built the first chair, the $50 for fir. Y
E
restwill be easyasABC. If your chair will be outdoors, use stainlesssteelscrewsand water- L
Wo o dworker
\|
ry
'
-.-t
$.
"" ..: ii.q&*
,l--.:"*4rlr
;d &Fll'*; r:
T"el
q4
"
faster.Make someextra legsand rails,too. Nowbuild the two gluingand screwing door chair is the bottom of the legs.Mois-
You'll needthem to make spacers(seeCut- fixtures (Fig. E) and follow the photo ture wicking up into the legscan support
ting List, below,right) and stop blocks.The sequence1 through 12. the growth of wood-destroying fungi.
spaceryorlll useover and over again,spacer You can slow down that process by
#1, is simplya scrappieceof rail.I addeda Finishing Touches liberally coating the end of the legswith
tab to it to make it easyto use (Photo 3). You dont have to apply a finish to your epory glue.
Most of this chair'sdimensionsarebasedon chair.Mahogany turns a silvery-gray color
multiplesof this block of wood. if left outdoors and stayssound for many For More Information
Dont sand the sticks before you glue years.However, if you'd like to preserve You can seethe Rietveld chair's original
them together,or you might accidentally its original color, you can apply a clear color scheme on the Web at
round over the flat surfaces.They must exterior oil (seeSources,below) eachyear. http ://www.levalet.com/DESF/IMAGES/
remain flat for a good glue joint. The most vulnerable part of an out- RIETl-a.HTM.
FIG.A
GuideBlockfor ScrewHoles
The overlappingjoints in this chair are screwed and glued together.
Part Name Qtv. Dimensions
This block laysout diagonalpairs of screw holes in five rails (D). Use
one side to mark either end of a rail.Flipthe block over to mark the A FrontLeg 2 l-3€" x l-3€" x l4-T4'
other end.Thenthe two diagonalswill run in opposite directions. B Arm Suppoft 2 l-3z8"x l -ilJ" x20-lt8'
C BackLes 2 l-3€" x l-?lJ" x20-lt8'
D Rail 5 l-341"x l-34J"x27-ffi'
E Arm Rail I l-34|"x l-36" x 30-3€'
F Rail 7 l-3€" x l-328"x24-7t8'
G Arms 2 l-38" x4-|'t8"x 19"
H Cleat | 5€" x2-!4" x | 5- lz8"
Outer Back 2 5€" x 5-l/4'x42"
K InnerBack | 5€" x 5-328"x42"
L Outer Seat 2 58" x 6-5E x l6-5€"
M InnerSeat | 5€" x 5-34]"x l6-58"
FIG.B Fixtures
GoodScrewJoints y4 x 14"x22-1t8"
For this chair to last,the screwed and glued joints must be as strong as
A BetweenLess I
possible.Thatmeansdrilling naroholes of different sizesbefore the joint StopStickA I l-328"x l-38" x}4-lt8'
goes together. First,a large diameter "slip hole" goes all the way through B BetweenArms I y4'x 16"x 19-38
the top piece.Thescrew must be able to slip through it without threading StopStickB I l-34]"x l-3€" x2l-3i'8'
into the wood. A small diameter hole, or "pilot hole," goes into the bottom
Spacers
piece.lt should be about the same size as the shaft of the screw,lessthe
threads. #l Basic 3 l -3€" x l -36" x 3"
countersink both sidesof the top piece.Here's why:When the screw is #2 BottomRail I l-3€" x 4-l/8'x 19"
driven into the pilot hole a small mound of wood is formed.You creare a #3 Top Rail | | -1r8"x l-3/8'x 18"
cavity for this mound by countersinking.Without a cavity,the mound would #4 Railand Les 2 Y4" x6-5€" x 9"
prevent the oro piecesof
wood from closely mating,
#5 Seatand Back | 5€" x 2" x 16"
SHALLOW Hardware
thus creatinga weak glue
COUNTERSINK
joint. 2 Corner Brackets l" x I
4 CornerBrackets l-l/2" x l-l/2"
FULL 38 # l0 X 2-l/2' L StainlessSteelScrews
COUNTERSINK
20 #8 X y4 L FlatheadScrews
13/64" 24 #8 X l-l/2'L Flathead Screws
SLIP HOLE MOUND
FILLS 6 #8 X l-l/4'L Flathead Screws
CAVITY Materials:Mahoganyor DouglasFir
Sources
McFeely's PerformanceCoatings
(800) 443-7e37 (800)736-6346
Square-Drive Stainless
SteelScrews, PenofinMarineOil Finish,
$39.25/gl.
# x 1-l 12"#08I 4-FSS,
$8 / | 00
#10 x 2-l 12"#l 024-FSS,
$ | 5/| 00
M I D D L EL E G
BACK LEG
ASSEMBLY
Detail1
ScrewHolesfor
Arm Rail E
ScrewHolesfor Rail F
American Woodworker A P R 2T oL o o
ep aintedthis demonstration
Welv F I G .D
SideViewof Chair
Steel brackets connect the arms
chairtoshow)/ouhoweaq)it isto to the legs.Thisjoinery is far
better than running screws from
put togethen
Eachcolorreferstoa the top of the arm into the end
of the leg.Screwsdo not hold
well in end grain.
separategroupofparts.
?l
\1-3/8"
-$
American Woodworker A P R 2T oL o o
by GeorgeVondriska
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Whichsizeand
whichmotorstyleis
moreimportant
thanwhichbrand.
ot the woodworker who'sshoppingfor a for scribing cabinetsand countertops.Here
E
l' belt sander,there'sa bewilderingarrayof arethe four sizes:
models.We looked at 26 for this test,and that . 3 in. x l8 in. Easy to handle becauseof its
didn't include all of them. In this crowded lightweight.Greatif you often usethe sanderon
field, finding the right size of sander is the vertical or overhead surfaces.The platen is
m o s t i m p o rta n t almostthe same
choice. size as that on
the3x2l,but
Pick the Size these tools are
that Fits light-duty and
Sanding belts best for occa-
(and sanders) sional use.We
comein four basic do not recom-
s i z e s( s h o w n a t mend them for
ri g h t). T h e fi rs t regular shop
number is the use, because
width of the belt, they'relessuse-
t h e s e c o n dt h e ful for horizon-
l e n g th . Be l t s i z e tal surfaces(the
SIZE lS A MAJORFEATURE.TheTe is a
determinesthe trade-oft Large machines(3x24,4x24) sandfaster and most common
sizeof the platen; are easierto keepflat on the wood;smallersizes(3x18, s h o p u s e ) .W e
the plate on the 3x2l), are lighterand easierto handle,especially on have not
bottom of the non-horizontalsurfaces. included them
sanderthat holds in our chart.
the abrasiveagainstthe wood. So a biggerbelt . 3 in. x 2l in. This sizeis closestto being gen-
meansfastersanding.It'salsoeasierto keepa eral-purpose.The platensizegivesyou a pretty
biggerbelt flat on a surface. stablemachine,without getting too heavyand
On the flip side,bigger belts need bigger bulky.If a do-it-all sanderthat'seasytohandle
motors,which meansaddedweight and size. iswhatyouwant,geta3 in.x2l in.
Smallersandersareeasierto useon non-hor- . 3 in.x 24in.The platengetsbigger,the amper-
izontal surfacesand are often preferred by agegoesup, the sandergetsheavier,all making
cabinetmakersand carpenterswho usethem this tool more suitablefor horizontal surfaces
while still manageableon verticalones.This is
a popular sandersize in commercialshops
and is an excellentchoiceif you are using it only
in the workshop and havestronghands.
. 4 in. x24in.The best of the bunch for big, flat
Comments
HITACHISB75 I t80il47s Excellentvalue. Big motor. Good balance. (800) 546- 1666
BOSCHI275DVS I t50-t550 Love the front handle. Great belt changelever. Motor over-
belt edse. 1877\267-2499
| 6-ft. cord. Squareport on dust bag requires gpecialconnec-
MAKITA9924DB tor. (800) 462-5482
quiet tool. l5-ft. cord. Motor projects past belt.
MAKITA992I 462-s482
MILWAUKEE
5936 Easybelt change. Good balance. (262) 781-3600
I and BruceKieffer
Thisversatile
classic
aoes
togetherfastwith biscuits.
ie safeslike this one were once com- hinges.(If you chooseto mortise-inthe
monplace.The pierced-tin panelskept hinges,check-outour how-to techniquein
insectsout while providing ventilationfor "Flush-FitCabinetDoors"on p. 78.)
coolingbakedgoods.
Our versionis built of solidcherrywith a GETTING OFFTO A GOOD START.
simple,modified-Shakerstyle that blends Youll needa biscuitjoiner,a tablesawset,a
easilyinto mostanydecor.Adjustable shelves routerwith a 3/8-in.rabbetingbit and a jig-
anda pair of drawersmakeit aversatilestor- sawto completethis project.Withthe excep-
agecabinet.Thepierced-tinpanelsthatonce tion of the drawerbottoms and back, the
cooledpiesprovideventilationfor a modern wholecabinetis madeof solidcherry.Oneof
soundsystem.Or,youcanusethispie safeto the tricks to usingcherryis to be fussyabout
storeclothingandtakesomeof the pressure your lumber.The color of cherry can vary
offthat overstuffedclosetor bureau. greatly(that'swhy it's often staineddark by
Biscuitsmakethejoineryon thisprojectas manufacturers). Selectboardswith uniform
easyaspie.If youvenevermadea projectof color or askthat the wood you order come
this scalebefore,or arenewto biscuitjoinery, from a singletree.
this is the perfectplaceto start.Youll needto Wespentabout$S00on this pie safe.You
know how to makestoppedrabbetsfor the canshaveoff someof that cost,(asmuch as
backanddadoesfor the drawers,but hanging $180),bypunchingyour own tin (seesidebar
theflush-fitdoorsis a breezewith no-mortise on p. 77).Now,let'sheadfor the shop.
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STOPPED
RABBET
INSTILES
STOPPED
RABBET
E A C HS Q . = 1 '
HARDWARE
1 . 3 / 4 "B R A D
P
2. 1'BRAD
3. 1-1l4',BRAD
4. NO.4 x 518"FH SCREW
5 . N O .1 0 x 1 - 1 l 4 "F H S C R E W 1t2"#1t2"
6 . N O .1 0 x 1 - 1 1 4 P" A NH E A D
SCREWAND FLATWASHER
7. 114D ' I A .B R A S SS H E L FP I N
8 . N O . 2 OB I S C U I T
9. NO-MORTISH E INGE
1 0 .P U N C H E D T I NI N S E R T
LEG PATTERNS DRAWERDETAILS
TIPS FOR
TIPS FOR BETTER
BETTER
BISCUITING
. Therearethreecommonsizesof bis-
THE SLOTS
cuits:#20,#10and#0.#20biscuitsoffer in the end of the shelf
the greatestgluingsurfaceandarethere- with the baseof the
fore the strongest.Usethesewhenever platejoiner on the
possibleevenif it resultsin the biscuit cabinetside.Clampthe
"breakingout" of the joint (Photo8). BOTTOM shelfon the sideso
BISCUITFACEOF the top edge of the
Breakoutoccurson the faceframeand LAYOUT SHELF
MARK shelflinesup with the
door framewherenarrowrailsjoin the .?
top edge of the layout
stile.But that'snot a problemif you off- mark on the side.Mark
setthe centermark for thebiscuitssothe for biscuitsin the
breakoutwon't be seen.We did this on middleof the shelfand
the faceframeso the biscuitsbreakout 3-in.in from eachend.
wherethe drawersand top coverthem
1/16'CROWN,
t iExAGGEnnrEo
_ . FOR.CLAB|Iy)
].!"o*EYOUR CAULS from 2x4s cut to the width of the cabinet.Make sure they are well
Idried and all four sidesare square.Planeor sanda | / | 6-in.crown on eachcauland mark the
crown with an arrow.While you're at it, make some extras and keep them for future use.
(Fig.B).Breakouts on thedoorframes the groove and spread it along both 5.Lay out the fixed shelf locations on
arecoveredby thetin panelstops.We sidewalls of the slot with a small glue the cabinetsides,then cut the biscuit
offsetthe top-railbiscuitsto keepthe brush (seeSources,p. 77). slots for the shelvesand the back rail
top edgeof the door clean(Fig.C). (Photos2 and3).
. Assemblywithbiscuitsneedsto go TH E C A R C A S S 6. Drill holes for adjustableshelf pins
smoothlybecause the biscuitsswell l.Lay out and cut the biscuit slotsfor (seeSources, p. 77;Photo4).
quickly onceglue is applied.For a the top (A), sides (B) and shelves 7. Finish-sandall the piecesstarting
m o r e r e l a x e da s s e m b l yu, s e a n ( C ) ( P h o t o1 ) . with 120-grit and working your way
extended-open-time glue like Tite- 2.Dry-fitfirst then glue up and cut to to 320-grit for an oil finish. If you
bond'sTyp. II Extendedor Liquid length. plan to varnish,stop at 220-grit.
HideGlue(seeSources, p.77). 3. Use the leg patterns (Fig.A) to lay 8. Dry-fit and glue the carcassusing
. Thkethetime to dry-fit eachassem- out the shapeson the bottoms of the four clamps and cauls for the shelves
bly usingall the biscuitsand clamps sides.Cut them out with a jigsaw. (Photo 5) and a fifth clamp for the
youll needfor the realthing.You'llbe 4. Use a tablesawto cut the rabbet on back rail. Be surethe carcassis glued
ableto rehearse your glueup andred the back rail (D) for the back (Z). up square.
flaganymisalignedbiscuits. Use a router with a 3/8-in. rabbeting 9. Glue the drawer kicker cleats(J)
. Gettinggluein thebiscuitslotscan bit to cut the stop rabbet on the sides to the bottom of the lower shelf. If
be a bit messy. Justsquirta beadinto for the back. you own a pneumatic brad nailer,
CABINETMAKEF'S
THE DRAWERS
28.Cut the dadoesand rabbetsin the
drawerfronts(W) andsides(X).
29. Finish-sand the insidesof the
tackthe cleatin placefirst so it wont FINAL ASSEMBLY drawerpieces,then glueand nail the
slide around when you apply the 16. Glue the face frame assemblyto drawerstogethermakingsuretheyare
clamps.(Brad nailerscan be like a the carcass.Tack the face frame in square.
third handduringassembly. See"Brad position with brads before applying 30. Finish-sandthe outsideof the
Nailersi'p. 43,formoreinformation.) clamps.Trim the faceframe overhang drawers.
with a flush-trim bit in a router. 31.Attach the drawerrunnersto the
THE FACE FRAME 17. Center the drawer kickers (E) in drawerrunnercleat(Photo9).
10.Layout thefaceframe,asshownin the drawer openings and attach them 32.Drtllholesforthedooranddrawer
Fig.B. to the kicker cleatswith a 6xl-ll2-in. knobs.
11.Cutthebiscuitslots(Photo7) and screw. 33.Attachthebackwithscrews. Screws
dry fit the faceframe. 18. Attach the drawer runner cleats allow you to easilyremovethe back
1 2 . I f y o u a r e m o r t i s i n gi n y o u r (H, Fig. D) with a brad, glue and for finishingand you won't be acci-
hinges,now'sthe time to lay out and clamps. dentallydriving nailsthroughthe side
cut the hingemortiseson the inside 19.Assemblethe drawer runners (F of thecabinet.
edgesof the facestiles. and M) and position them on the
L3.Lay out and cut the leg profiles cleatsso they set 1/16 in. into the THE FINTSH
on thebottomof eachstile(Fig.A). drawer openings(FiS.D).Attach the 34. Finish-sandthe outsidesurfaces
14.Begintheglueup with the drawer runners to the front cleat only (Fig. andeasethe edges.
divider mullion (S) and the lower D). You l1attach the back of the run- 35.Applythreecoatsof Danishoil.
rails (R). Then glue the rest of the ners later. 36.Mountthetin panelsin thedoors,
faceframe together. 20.Attach the top (Fig.A). hangthe doorsandattachthe knobs.
15.Tiim the protrudingbiscuitsand 21. Make the cherry quarter-round 37.Attachthe backand standbackto
finish sand. molding (K and L) from a 3-in.-wide admireyourwork.
piece of cherry. Round over the two Iustthink;food safeslike this usedto
Iong edgeswith a router and a 314-in. holdbiscuits;nowthey'reheldtogether
bv them! IW
76 American Woodworker ApRtL2000
1-1l2"OFFSET
SOURCES
414Cherry,l00 bd. ft.
PIESAFE57-314'H x 42-l/2" W x | 6" D
| 14"x 4' x 8' cherry plywood;
I sheet
e"rt | ru"r" lool Dimensions Paxton Hardwoods, (800)
CARCASS CherryHardwood 522-330s.
A ltop I 3 l 4 x 1 7x 4 2 - l 1 2
B I sides 2 3l4xl5-l14x57
C I shelves 5 3l4x15x39 Titebondll Extended, I gal.,
D I back rail I 314x 4 x39 #t6.50.20, $26
E I drawer kickers 2 3 / 4 x 2 x1 5 TitebondLiquidHideGlue,
F I drawerrunners 4 3 1 4x l - l 1 2 x 1 5 I quart,ff | 6.50.0| , $7.50
I 3l4x l-l12x3
H I drawer runner cleats 2 3l4xl-5/16x39 Smallgluebrush,# | 6.60.25,
2 3 l 4 x l - l / 1 6x 3 9 $2.50for l0; $ l0 for 50
K I molding I 314x314x42 Hold-downclamps, # | 6.60.05,
2 3l4x3l4x l6-314 $ 1 2e a c h
M I drawer runners 4 3l4x3l4x15 HighlandHardware, (800)
I l12x7l8x2-l12
241-6748
FACF FRAME Cherry
P I face stiles 3 1 4x 3 x 5 7 Sixteen l14"-dia.brass shelf
Q I top rail 314x2-314x34-l12 supports,#271| l; $2.50
314x2x34-l12 Three pewter no-mortise
3l4x2x6-l12
10 l 9 l , $ 2 . 7 5
b a l lh i n g e s , # 3
CherryHardwood each
T door stiles 4 3l4xZx 35-3/4 Woodcraft Supply,
U door rails 8 3l4x2x l3-l/4 (800) rs3
22s-r
V tin panel stops 24 3 / 8 x 3 / 8 xl 5 *.-''*-.
DRI
w
X
drawer fronts 3 1 4 x 6 - 3 1 8lx6 - l / 8
l 1 2 x 6 - 3 1 8 xl 5 - l 1 2
Four l/4" dia.wood knobs,
AF-S969C,$ 1.20each
Van Dyke's,(800) 558- 1234
iiH$
Y l12x5-718 x 15-5/8 7.""'-"
Six pierced-tin panels"Lace-
CHERRY PLYWOOD work #1" l0-in.x l4-in.,
lrl
Z I back x 48-3/| 6
I 14x 39-314
AAI drawerbottoms l14x l4-314x l5-5/8 $30.95 each,Country Accents,
I (s70)478-4t27.
DOORHANGERJIG
DOOR RAIL OR STILE
T
*
I
I
CNO.4 x 3l4" FH
WOODSCREW
S H OP .MA D ED OOR H A N GERS
(coUNTERSUNK) hold the doors in placeso you can scribefor a
perfect fit.They're constructed from two blocks of
hardwood and a metal tie plate.Tieplatesare
usedto join houseframingand are availablefrom
home centers.
Jl irrrTitiilffirlr
HOW DEEP shouldyou installbutt hingesinto a I S C R IB ETH E LoN G-GR A IN S H oU LD E R
door and caselThe rule of thumb is to measurefrom the with the markinggaugeto finishthe hingemortise layout.
center point of the hingebarrel to the outside edgeof one
leal then subtractabout l/ | 6 in.Thislayoutensuresthat the
door wonlt bind on the face of the cabinetwhen opened.
SETTHE BIT DEPTH by layinga hingeleaf ROUTTHE HINGE MORTISE freehand, stayingabout
on the router's baseplate. Route a test mortise on a l/16 in.insideyour layoutlines.For a reallycleancut,movethe
pieceof scrapand checkfor fit.The hingeleaf should router in the oppositedirectionthat you would normallyrout:a
be flushwith the top of the mortise. A l/4-in. straight- techniquecalledclimbcutting.Routingin this mannerprevents
tip bit is a good choicefor routingthe mortise. tearout,and it's easyto control the router becausethe cut isn't
very deepand the bit diameteris relativelysmall.A scrapblock
clampedto the benchsteadiesthe router's baseplate.
iill
-
SHAVETHE SHOULDERS by choppinglightlywith a DRILL FOR HINGE SCREWS usinga self-centering
sharpchisel.lt's bestto sneakup on your layoutline,makingseveral drill bit. Layeachhingein its mortiseand drill throughthe hinge
thin cutsuntilyou reachthe end-grainshoulderline.Clampa block and into the door. Rub a little wax onto the screw threadsto
behindthe long-grainshoulderto support this delicateareaand take lubricatethem before drivingthe screwshome.Tip:BrasEscrerac
rnultiplecuts untilyou reachthe shoulderline.Finishup by paringinto break easilyt,Use the same size sf,eelscrews lirst and install the
the cornersto cleanup any left-oversliversof wood. brass screws after fitangand finishingare complece.
Sni
bite taken out of
the end of a board.(A
particularlybad caseis shown
here.)The lengthof the snipeis
alwaysabout 2 in.-the distance
from a feed roller to the center
Fig.A The Sourceof Snipefrom a PortablePlaner of the cutterhead.Portable
The cutterheadassemblyrides up and down on four posts in most portable planers. planersmay snipethe front or
The assemblycan tilt forward or backwardbecausethere is a smallamount of play the rear ofa board,but never in
betweenit and the posts.Whenthe assemblytilts, it cuts slightlydeeperthan normal, the middle.
and you get a snipedboard.Thepurposeof a head lock is to minimizethis tilting.
CUTTERHEADASSEMBLY
TILTS FORWARD
CUTTERHEAD
FEED
ROLLER
IS LIFTED
UP BY
BOARD
Snipeat the front of a board is The board is cut evenlywhen Snipeat the end of a board is
produced by the forward tilt of both rollers are engagedand the produced by a backwardtilt of
the cutterhead assembly.Thetilt cutterheadis level. the cutterheadassembly.
shownhere is greatlyexaggerated.
'*l**mdffiitffi;;;;;
tl*ttvour{TT
c LLL..,.
Thkeadvantageof the fact --- won't sni
that the planer
"'
themiddleof aboard(Fig.A).Makea traino, -urlr' ffi
boardsthat are all exactlythe samethicknessand pass
ATRATN oF B.ARDS wiil banishsnioefrom
themthroughtheplaneroneafteranother(photoat yourgoodwood.The trickis.Jilj[:'fil:"r}.,
right).Onlytheleadboardandthelasttrailingboard, thinking
it'scuttingoneveq/longboardbyfeeding
which can both be scrap wood, will be sniped by the many boards through in one operation, each butted
planer. If your boards are fairly short, you ll need a helper up to another.lnfeed and outfeed supports that are
with the main bed of the planer keep
to catch the boards as they come out of the machine.you ll 11",:.',t"ll,':vel
individualboards from drooping'
have your hands full feeding the other end.
E. N 5 LU +O LU
E.
o-
F
a =
-X
v1L I az o_ F
H i t a c hP
i 12R $900 7 5 l b s . 21x2Ox2ON o Yes No SER Fixedhead A,J,K,L (800)
706-7337
Makita2030s2 $1,3 0 079 lbs. 21x21x23 No Yes N o DED Fixed
head A,J,L (800)4-MAKTTA
o-
(( ))nrllz l=A\rratFn5tAG
- - -u-_l?- -v -si/-!- -u-_t:\=-e2
\Y_ \Y_i_Lr_
)roduct
rcviews
Better
than Set the beadLOCKto
your layoutlines,clamp
it to your work and
drill three holes.Tape
Dowels?
on the bit ensures
uniform depth.Thejig's
configurationprevents
usinga stop collar.
1f you'relookingfor a strong,simplejoinery
Isystem, here'sa simpleanswer:beadLOCK.
All you needis a drill.
Thisjig allowsyou to drill a seriesof over-
lapping holesin eachof the mating parts. Slidethe drill guideto
The parts are joined with inexpensivepre- the secondposition
molded tenon material availablefrom the and drill two more
holes.
7
manufacturer, JourneymanTool.
I had great successwith beadLOCKon
:c
faceframesand legand rail assemblies.Ifig-
F ureda brad-pointbit would be a must,but a
E
)<
twist bit worked fine. Unlike a dowelingjig,
- the beadLOCKdoesn'tcenteritself on the
material,it registersfrom oneface.This makes
it easyto keepthe bestfacesof your project
- partslined up.Thewholethitg is prettyfool-
a 3/8-in.system $30
z proof,evenfor a beginner.
a
I l}-in.system $33.
lrJ
Youcanbuy the beadLOCKwith either a Dualset $47
UJ
o_ 3/8-in.or ll}-in. drill guide.It comescom-
pletewith a setof shimssoyou canoffsetthe 3/8-in.x 36-in.pre-moldedtenon $5.50
E matingparts,likethosein a legandrail joint. ll}-in.x 36-in.pre-moldedtenon $0
m
o
You get the best of both worlds,at a price WoodcraftSupply,(800)225-| 153 Assembleyour parts with the
that'shard to beat. www.beadLOCK.com specialbirch tenon material.
NewJointer
lmpressive
GizzIy has a new 6-in. jointer that's
loaded with features,at a very
attractive price.
It has a 47 -in. table, a 4x29-in fence
and a l-HP motor (most iointers this size
.- have 314-HP).The knife-setting systemis unique in
that it has both springs and jack screws,making it
easierto adjust.But best of all is the switching:A
magnetic switch on a conveniently placed post, with
positive off-lock and even a "running" light. No more
stooping or leaving the machine running by mistake.
The machining on the tool we tried out in our
shop was excellent,with good surfacefinish on the
tables,smoothly moving fence and controls, excel-
lent flatnessacrossthe tables and fence and a tough
paint job.
The best featureof all, though, was the price: $a+S.
Erioyfte hnefisofIMPwidraSUPER
System!
Our SUPERmodel offers you the
most powerful 3-stage turbine
motor made by Ametek-Lamb.
"Quolity of otomizotion roted 9.8
outof 10...Ihis systemincludeson
excellent three-stoge turbine.. the
gun otomizes beoutifully ond hos o
full rongeof feotures."
- AmericonWoodworker
Madein
u.s.A.
Cabinet shop owners acrossthe U.S. call Woodmaster's
26" and, 38t' drum sanders "the best kept secret in
woodworking. " These commercial-duty sanders fill the
niche between slow hand methods and expensivewide
belt sanders. And there's no sacrifice in quality. But
don't take our word for it . call today for free
information and the names of Woodmaster owners Visitourwebsiteat:
nearestyou. This way, you can find out first-hand how a www.ameticanwoodworker.com
\iloodmaster sander might be just the machine you've
been looking for.
youcomplete
Offering how-to
\
I
GreenWood
4\r I lll
5ta0il/zet
I like turning bowls from green wood. I go out
to the back 40, cut myself a sizable chunk of
wood and go to it. What I don't like is when
the finished product cracks so badly I can see
through it. Pentacryl, from Preservation Solu-
tions, is the answer for rurners, carvers or any-
one who wants to stabilize green wood.
Pentacryl is a polymer compound that
soaks into wood. It can be brushed or sprayed
on, or you can immerse the wood in a buck-
etful. Immersion gives you the best results.
Use the stuff right out of the bottle-no mix-
ing is required. And unlike PEG, it's a liquid The manufacturer says they haven't found a finish yet that
at room temperature; so no heating is won't stick to Pentacryl-another advantage over PEG. The stuff
required. Total time for complete absorption is considered non-toxic, but isn't registered as food grade.
depends on the wood, but plan on about one Plans are in the works for a food-grade version.
day of immersion per inch of material thick-
ness. Once it's into the wood, PentacryI sta- 32 oz. bottl e;$ l 5
bilizes the wood cells to reduce or eliminate gal l on;$45
both warping and cracking. Caff PreservationSolutions (207) 563-5414
Gomputerized world'sfirst
collarcreates
leddog?
radio-colrtrol
Small U,S. company develops technologythat uses radio waves and a microprocessoron your dogb
collar to replace expensivefencing, cruel chains and /eashes,..keepingyour dog safeand tfBe!
W Guy Yeadon
. i,il PetSafeInstant Fencegives you the ability even while traveling. No more ties, cages or the bounda the small training flags
;i I to set up a safe and secure area for your boarding costs-your pet can enjoy vacations as rea. The training takes
' I pet to piay, without the time and expense much as vou. generally learn their
I conventional fences.Most fences can cost The humane solution. PetSafeInstant Fencewill After thirty days,
I thousands of dollars and can affect the provide greater happiness and can begin to rgsgradually.
I appearanceof your property. In many new and your pet. No more cages,dog runs or risk-free...and has it. Why
I neighborhoods, they aren't even allowed. No more waiting for you to go for a walk on to take advantage breakthrough
t Electronic fencesthat use wires and special leash. Your dog will be able to run and play gy? PetSafeInstant comes with a
collars can cost nearly as much to have pro- throughout the yard. warranty lio'Systems,
fessionally installed, usually well over a thousand Easy installation, simple training. PetSafe and bv Comtrad's ive risk-free
dollars. PetSafeInstant Fenceis a.revolutionary Instant Fence emits a radio signal that extends gua it for yourself, if you are not
new concept that is clearly the best value in pet up to 90 feet from the tra ile the sig- satisfied, return it within days for a full
,,NO
containment. keep refund.
Safe, secure and totally portable. This is the
safest,most secure{enceyou can buy for your pet. Exclusiaelim time offer! Order todayand get a
It is far superior to alternative containment meth- ing in the software prevents any acciden factory-direct on PetSafe
ods, because there are no wire.s to bury and tric pulse in the event of a power shortage.
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zone. When the collar picks up the signal from a' signal area. If you Three credit card payments of . . . $sg.ss$19S&H
buried wire, a stubborn or poorly trained dog can pet is poorly hained ar of the contain- Pleasementionpromotionalcode 7#1 -17ilO.
learn to break out. With PetSafeInstant Fence, ment area for over 30 the correction For fastest service, call toll-free 24 hours a day
there is no "other side" to run to, since the only pulses will the receiv-
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Compared to conven-tional fences, which dogs
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ProductReviews
minum andis 3l16in.x 11-3l4in. x
14-314in.Youll haveto setthis plate
into your routertabletop.Ifyou need
to useyour routerhandheld,JessEm
saysit's easyto removeyour router
from the mechanism.This is a very
handy device,with only one draw-
back-th e $220pricetag.
Micro-Adi
ustfor JessEmTool Company
Router
Tables (800)436-6799or www.jessem.com
MAKE YOUROWTIWIITDOWS
YffHOAR
'.PIECE
SASII
CUNER
SErS
Thesesetsallowyouto makesashusing
L a buttjoint,dowels
or tenons.
RouterBit3-pc.set
wL-1364-5
arl7$89.00set
3/4"boreShaper
Cutter
3-pc.set w/bearing
wL-1364-SCS
onty$139.00 set
'SASH MAKING' VHSVideo
WL-V-4onty$12.es
ea.
4-Wlllc CUTTER ronSMALL "R0UND"
BISCUITS.Greatforfaceframes.
picture
frames,etc.
CUTTER plus250SMATL "
BISCUITS*
wL-1942-2 ontf $2O.oo
EXTRA
BfSCUITS
250ct.only
.al
aaa
t a
aa
P r o d u c tR e v i e w s
a a
ta
f a
t a
KeepCordsGoiled
Tired of having a rats'nestof cords laying around?Gettir-rga $ 10
Cordpro in your life can help.
This doughnut-shapedreelacceptsup to 100ft. of t1ll cord,
a
a
ff
94 \ u r c r i c a n \ \ ' o o c l uo r k c r n p R tzLo o o
QuietShopVacuum
Never thought you'd seethose words in the same sentence,
did you? Fein saystheir new Mini-Tlrrbo is one of the qui-
etestvacuums out there.Use it like you would any wet/dry
vacuum, without losing your hearing.
Fein has been making a greatshop vacuum for about
three years;their model 9-55-13.If youve been eyeingthat
one,but holding off becauseof price,havea look at the
Mini-Turbo. This scrappylittle brother offerssimilar fea-
tures,including the samemotor, for only about $tSO.
You can connect the Mini-Tirrbo directly to power tools
for greatpick up right at the source."By-passconstruction"
means the motor won't overheateven when the vacuum is
constrictedby small ports on portable tools.
The Mini Turbo has:
r a 6-gal.barrel
r a 10.5foot hose(longerthan most)
t a floor nozzle,crevicetool and upholstery tool
t a very fine 1-micron filtration
However,it does not have the tool-actuated switch that
the 9-55-13has.
Sandin IUTilBO
YOURBANDSAW! I-desrgnfence odjusts
bond sow drift.
for
Add32'widesanding
capacitytoyourshop
andwe'llthrowina
"-* dustcollector
ata Enhance your
greatprice. creativityin a big way
Proudlymade in ThePenronmu 16-329Pr-us with the firstbandsaw
the U.S.A.
- drumsander will table and fence
I sudace,dimensron, available anpvhere.
-E andfinishsand. Fromthe 24" x24"
LF.J TheJET650cfm
I
worksurfaceto the
* J* -,- dustcollector
*-!# rvitna5micron circle-cuttingjig, you'll
hi.- bagwillpickup get morefrom your Grcle cutting jig cuts
f eventhesmall- bandsaw. uD to 26" diometers
rE i estparticles.
lhD
l,+ 1{
R"OCKLEFL'
Offergoodwhile -'*oNI
ft-#HoRhaX supplieslast.
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Call 800-334-4910 for the dealernearestvou & Ourreeo Tneres,
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Product Reviews
Better
Fire
Extinguisher
If you havea fire in your shop,the
biggestmessis sometimes not from
the fire, but from the extinguishers
usedto put it out.Ordinary dry extin-
guisherscanleavea residuethatbakes
on and becomesvery difficult to
remove.Kidde'snew Fire Out Foam
fire extinguisheris an improvement.
The foam can simply be rinsed off
your toolsaftera fire.
It's an ABC extinguisher, so it's
good for fighting wood, liquid and
electricalfires.Kiddesaysthe foamis
easierto usefor thoseof uswho aren't
fire fightingprofessionals.Itleavesa
film on combustibles that helpspre-
vent re-igniting,somethingother
extinguishers dont do.
Get it at home centersand hard-
warestoresfor about$40.
www.kidde.comIW
Foldlt, Roll lt, Hanglt, Store lt! E d i t eudyD a v e M u n k i t t r i c k
SglsnoP
llPs
Tablesaw
Worktable
Tirrn your tablesawinto extra workbench space
with a pieceof 3/ 4-in.plywood. Attach wood strips
Pegged
Tablesaw
Tools around the plywood edgesfor a snug,no-slide fit on
the metal table.
For a nifty way to keeptablesawaccessoriesin reach, Caution:Alwayscrank the bladebelowthe surface
attachperf-board panelsto the tablesawstand.Drill and unplug the tablesawbeforeusing it as a work-
holesin the legsof an open metal stand and bolt the benchbase.
perf-board in place. I
-
TmlStorage
Bmk h
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Put a ton of tools up on the wall in t
-
this tool "book." Hang I/2- or 3/4- E.
o
F
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S m a l lS h o pT i p s
CONTINUOUS
HINGE
A GrcatSawhorue
These sawhorsesare sturdy and they fold flat for
easystorage.Building them is a snap:joint and
plane2x4 stock to I in.; then rip to 3 in. Crosscut
at 30 in. for the legsand 18 in. for the stretch-
ers. Use a biscuit joiner and double stack
#20 biscuitsat eachjoint. Assemblewith a
I-ll2-in. continuous hinge and locking
table leg braces (availablefrom Wood-
worker's Hardware,800-383-0I 30,
hinge,#LA1 1248 l4A, $5.2S;leg brace,
#5C,446l14 2C,$19.04per pair).
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PowerToolCaddy rt$&sun*'.;
eqatfbro"* ^i
This plywood stand for power tools is compact and mobile. To lock the stand lffi cAsrERg
in place,just flip down the hinged board at the base.
Cut the hinged board wide enoughso it will Iift the castersoffthe floor when
RUBBER
you flip it down. Screwit on the bottom of one of the end panelsusing 3-in.- FEET
wide butt hingesand attachrubber door bumpersfor addedslip resistance.
When youre planing or jointing (in the direction of the flipped-down
board) the stand carit move.
Dust Collection
Eliminate Fine Dust Problems!
ilil6 "$ili$Tl'J,"
Also: PremiumWalnut, figured Maples & a large variety of
exceptionallyfine domestic& imported lumber including free form
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Cartrid$e H
- 15vears
of experience'
National&Internationalshipping
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and Hardware
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llailwano
Seewhy woodworkerscall the l.5hp dust
collectorthe 65Best
Invention Everoo
Call, Fax or Email for a FREE BROCHURE
Visit us at www.oneida-air.com
Email: info@oneida-air.com