Wood

10" Heavy-Duty Cabinet Heavy-Duty 17" Extreme
Table Saws w/Riving Knife Bandsaw w/ Cast Iron Wheels

Perfect for cutting panels and wide stock! Only Grizzly offers these features for this price!
• Motor: 3 HP, 220V, single-phose or Riving Knffe
* 3-phose can be used with • Motor: 2 HP, 11 OVl220V,
5 HP, 220V440V,
/ qUick release guardl
single-phose, TEFC
• Precision ground cost iron table ~
• Table size w/extension: 27' x 75%" - • Larger precision ground
• Max. depth of cut: cost iron table size: 24' x 17'
33116" @ 90°, 2W @ 45° • Table tilt: 5° lett, 45 0 right
• Arbor: %" • Max. cutting height: 12'
• 52" rip capacity • 2 blade speeds: 1700 &3500 FPM
• Approx shipping MAPEIN
'440VOPERATIONREQUIRES ISO 9001 • Double boll bearing blade guides
weight 514 Ibs. PURCHASEOFADDmONAl FAcrORY! • Quick change blade releoseJlensioner
COMPONENTS. CAll TECH.
SER~CEFORMOREINFO.
See it on • Approx. shipping weight: 4141bs.
G0651 3 HP, single-phase or
Page 97 the
INTRODUCTORY PRICE $169500 Includes Deluxe Be-slUD Fence,

ZOO8 Catalog.
Mite,. GlWge & !.4" BlIule
G0652 5 HP, 3-phase G0513X2 ~
INTRODUCTORY PRICE $169500 INTRODUCTORY PRICE 00 ~$950
12" Baby Drum Sander 10" Left-Tilting Table Sows 10" Left-Tilting Table Sow
• Sanding motor: 1V2 HP, 11 OV, single-phose w/Cast Iron Router Table w/l'Rails & ExtensiOn Table
• Conveyor motor: Via HP:11 OV, single-phose, • otor: 3 HP, 220V, single-phose Of 5 • Motar: 3 HP, 220V, single-phose
variable speed 0- 15 FPM 220V, single-phose • Precision ground cost iron 10 5-I~~
• Drum surface speed: 2300 FPM • Precision ground cost iron table • Extension table size: 27' x ry.
• Max. stock dimensions: 12' wide x 3W thick • Table size w/wings attached: 27' x • Arbor: %" (accepts dodo bl 10/16')
• Min. stock length: 8" • Cutting capacity: 8' L, 54' R
• Culling capacity: 8" L, 26" R
• Sanding drum size: 4" SIDE HANDlfS • Max. depth of cut: 3' @ 9<f 2'/:' @ 45·
• Sanding belt: 3" hook & loop FOR POI1TABIlJ1Y! • Approx. shipping weight: 500 lbs. • Approx. shipping
• Approx. shipping weight: 532 lbs.
weight: 160 lbs.
2 ADJUSTABlE PflfSSURf ROllERS
& INDUSTRIAL -DUTY BELT •
GI023SLW
3 • sVgle-phase
ONLY
$105000
G0459 mil 5
GI023SLWX
.~hase
ONLY $65Q00 ONLY $119500 G1023SLX ONLY $129500

19" Heavy-Duty 21 n Super Heavy-Duty Bandsaws Professional Spindle Shapers
Extreme Series® Bandsaw w/Tilting Geared Table • Motor: 5 HP, 220V, single-phose
• Motor: 3 HP, 220V, single-phose, TEFC • . 3 HP or 5 HP, 220V, single-phasa TEFC or 7V2 HP, 220Vl440V*,
• Precision ground cost iron table • round cost iron table • Precision ground cost iron table
• Table size: 26%' x 19' x 1'12" . <!: 29'h' x 203f4" x 17/a" 35'h' x 28'
• Cutting capacity/throat: 18'14" .. 50 L 45° R • Sp' die sizes: 3,4", l' &
• Max. cutting height: 12' • Cutting capacity/throat: 1lA' x 7V2"
_
• Blade size: 143" L (Va' - 1'!4' wide) • Max. cutting height: 14' • . Ie speeds: 3600,
• 2 Blade speeds: 1700, 3500 FPM • Blade size: 165" long -100,8000 &
• Approx. shipping weight: 458 lbs. (114" -1%') ,000 RPM
• Blade speed: 4600 FPM . Ie travel: 31,4'
buhules Alumina"; Re-.aw cutter dia.: 51fa'
Fertff Attaehmellt, Dual • Approx. shipping weight:
Ball Bearing Blade Gaides, 6841bs. • ox. shipping
Cturt Iroll Wheels & Feru:e Illcludes 1" Blade, : 602 lbs.
Cut Iroll Wheels & F~
MAPEIN ~ '"" SlNGlf-PHASE
ISO 9001 G05663HP G5912Z0NLY $219500
FACTORY!
ONLY $185000 3-"HASE
G0514X G0531 5 HP imJII G7214Z ONLY $219500

ONLY $115000~' ONLY $1895 00
IWF~ VISIT US AT
2008 BOOTH
~:::o~~~
AUG.23RD
"5435
..
8" Jointer w/Spiral Cutterheadl

Versatile parallelogram
table adjustment system!
• Motor: 3 HP, 220V, t
single-phase, TEFC
• Precision ground
cast iran tables
• Total table size: 8" x 76%"
•
• Infeed table size: 8" x 433fa"
• 4 row spiral cu1terhead •
• Cu1terhead speed: 5350 RPM G049()X
• Max. rabbeting depth: W
• Deluxe cast iron fence size:
35"L x 1W'W x 5"H
Foot Operated Built-in
• Approx. shipping weight: 597 Ibs. INCLUDES
M~k Btue Provides
FREESAFETV . .
Extra Long Infeed Table PUSH BLOCKS
G0453Z Versatik Positioning G0490X & Extra Tall Fence
See it on Page 57 ~ S~eitonPage41
INTRODUCTORY PRICE $129500 _ ofthe 2008 Catalog. INTRODUCTORY PRICE $1 075°0 ~ ofthe 2008 Catalog.
20" Planer 20" Extreme Series® Planer 24" Professional Planers

• Motor: 5 HP, 220V, single-phose w/Spiral Cufferhead • Cu1terhead motor: 5 HP, 220V, single-phase
• Motor: 5 HP, 220V, single-phase or 7 1h HP, 220V/440V*, 3-phase
• Table size: 20' x 25%' Precision Ground
• Precision ground cast iron table size: • Feed motor: 2 HP
(20' X 55%' wI extension) Cast Iron Bed &
. 'dth 20" Infeed/Oatfeed 20" x 25%" (20" x 557Ja" wI extension) • Precision ground cast iron "
• Max. cu1tmg WI : Tables table size: 24 'Ia" x 31 Va" Vanable F",,!, Speeds
• Max. cu1ting height: 8" • Max. depth of cut: Va" ' d th 11" & Lever Ac(jastabk
• Max. cu 1tIng ep : /a Feed Rollers
• Min. stock length: 7W • Max cutting • Max cu1ting height: 8"
• Max. cu1ting depth: 'Ia" height: 8%"
• Feed rate: 17-26 FPM
• Cutterhead /~
l~
• Feed rate: 16 FPM
I
• Cu1terhead speed:
& 20 FPM speed: 4800 RPM 5200 RPM
• Cu1terhead dia,: 3'Ia" ., Feed rate: • Knives: 4 HSS
• Knives: 4 HSS 16 & 20 FPM • Approx. shipping
• Cu1terhead speed:
5000 RPM
• Apprax. shipping
• Approx. shipping
weight: 909 Ibs.
weight: 1130 Ibs.
"«OVOPERA11ON REl1\lRESPURCI\\SE
OF AOOO1ONAI. OONPOHEHTS. CollI.
TEal. SEIMCE FQIlIlORE INFO,
- ~4
_ MAOElN
weight: 920 Ibs. ISO 9001
5 HP. SINGLE-PHASE
fACrORY! G5851Z ONLY $379500

G0454 ONLY $1295°0 _ Gl033X ONLY $239500 _ G72r3'ZONLY $3795 00 fjDI
12" x 83'h" 10" Extreme Seriesl8i Jointers The Ultimate 12"
Parallelogram Jointer • Motor: 3 HP, 220V, single-phase Extreme Seriese Jointers
• Motor: 3 HP, 220V, single-phase • Precision ground cast iron table size: 11' x 84· •Motor: 3 HP, 220V, single-phase, TEFC
• Precision ground cast iron table • Max. depth of cut: Va' • Rabbeting capacity: W' •Precision ground cast iron table size: 121h" x 80"
size: 12%" x 83W • Cufterhead speed: 5000 RPM •Center mounted fence: 4%" x 3914"
• Cu1terhead knives: (4) 12" x 'Ia" 1%.' • Cu1terhead dia.: 3Vis" Built Li"e a •Max. depth of cut: o/1S" • Bevel jointing: 90' - 45'
• Cu1terhead dia.: 3%' INCLUOES • Approx. shipping weight: 977 Ibs. Tank wi •Cufterhead dia.: 4"
HelUlJl-»aty
• Cu1terhead speed: 4950 RPM FREESAmY •Cufterhead
l .... Cast Iron Base
• Max.depth of cut: 'Ia· PUSH 8LOCKS speed: ~""-"":::JIII.
• Max. rabbeting 5900 RPM .!!!l!!iI._•
capacity: %" • Approx. shipping . . ~-~,~\:-."'1I"'_J
• Approx. _----Jc INCLUOES
fREESAfE1V weight: 1253 Ibs.
shipping PUSH8LOCKS G9860 INeLU~ES FREE
wt: 1036 Ibs. H2404 JOINTER PAL·
KNifE SETTING JIG
Handles Fold . . MAOE IN ISO

In For Added 900 I fAcrORY! INCLUDES
Safety
4 BLADE CUTTERHEAD 4 BLADE CUTTERHEAD FRrr ftAF....V
G0455 ONLY $1695°° G9860 ONLY $3150°° PUSH8LOCKS
---
G0609 SPIRAL CUTTERHEAD ~
ONLY $1595°0 G0480"ONLY $2095°° _ G9860ZX ONLY $415000 ~
Circle No. 583

in this issu·e
This seal is your assurance that we build

every project, verify every fact, and test every
reviewed tool in our workshop to guarantee
your success and complete satisfaction.
,~"" .,..--........".,~co------ ~---.,
. ~ ~~.
"""--------- -
PROJECTS
16 Ingenious plug trimmer
20 Quickjig: Portable drum sander
30 Cover: Display or gun cabinet TOOLS & MATERIALS
Build it to suit either your curios or rifles. 26 Wise Buys: Bandsaw fences
49 Shop project: Portable bench 42 Best hardware for making jigs
60 Easy-to-build solid-wood bookcase S4 Tool test: Value-priced 14" bandsaws
68 Child's hardworking crane 6S 11 Awesome dust-collection add-ons
78 Shop-Proven Products
23-gauge pinners; fast-boring drill bits; more
TECHNIQUES
22 Make bracket feet from molding
24 How to build no-warp doors DEPARTMENTS
28 The world's fastest, simplest finish 6 Sounding Board
40 No-math shop geometry! 8 Shop Tips
73 Ask WOOD.
92 What's Ahead
September 2008 Issue 185
on the web
woodmagazine.com
EXTRA BANDSAW INFO ONLINE

This issue's bandsaw review on page 54 is
just the tip of the information iceberg.
Also check out these FREE bandsaw-related
items at WOOD Online:
'. VIDEO: How to Install aRiser Block

woodmag~zine.com/riserblockvid
•VIDEO: Easy Bandsaw Blade Changes

woodmagazine.com/bsbladevid
•VIDEO AND PLANS: Resawing Jig
woodmagazine.com/resawvideo
• PLANS: Circle-cutting Jig
woodmagazine.com/circlejig
•TECHNIQUE: Figuring Bandsaw Blade Length
woodmagazine.com/bsbladelength
START YOUR GIFT "SHOPPING" EARLY

Heading into the shop to begin your
holiday gift-building? Before you go,
pop into the "Gifts, Clocks, and Boxes"
photo gallery at woodmagazine.com/
projectgallery. You'll find hundreds of
inspiring reader-made projects, like this
stunning jewelry box by AI Bibbero of
Littleton, Colo.
MORE FREE STUFF. The WOOD e-Newsletter now delivers

free project plans, Shop Tips, and alerts
MORE OFTEN. you to the newest Web freebies every week.
It's free to sign up at woodmagazine.com/enews, and
NO SPAM. we promise not to clog your inbox with "special offers."
3
woodmagazine.com
September 2008 Vol. 25, No.4 Issue No. 185
We asked our staff:

What are you working on
EDITOR-IN-CHIEF
BILL KRIER··
Managing Editor Deputy Editor
in your shop, right now? ........... MARLEN KEMMET DAVE CAMPBELL
Art Director Senior Design Editor

The baseboard and trim .1 KARL EHLERS KEVIN BOYLE
for a bathroom redo.
Techniques Editor Tool & Techniques Editor I'm mass-prod.ucing
BOB WILSON BOB HUNTER palm crosses
for a youth
Multimedia Editor Multimedia Editor
LUCAS PETERS CRAIG RUEGSEGGER retreat program.
Design Editor Projects Editor

JEFF MERTZ LARRY JOHNSTON ... ............................~ Bent laminated
Associate Art Director Assistant Art Director fenders for my

GREG SELLERS CHERYL A. CIBULA bicycle, and I'm
rebuilding a
Production/Office Manager Administrative Assistant
MARGARET CLOSNER SHERYL MUNYON stairway newel
post. Upcoming:
Photographers radiator covers
Raised garden MARTY BALDWIN, JASON DONNELLY, DEAN SCHOEPPNER, JAY WILDE
beds built from and a bookcase
Contributing Illustrators TIM CAHILL, LORNA JOHNSON, ROXANNE LeMOINE for my remod-
composite deck-
ing materials (from Technical Consultants JEFF HALL, BRIAN SIMMONS eled home office.
the 2007 issue of Contributing Craftsman JIM HEAVEY···
Best-Ever Decks Contributing Proofreaders BABS KLEIN, IRA LACHER, JIM SANDERS I
and Backyard ------"'---S-U-B-S-C-RI-B-ER-S-E-R-V-IC-E--------L.~I'm remodeling
Projects). Go to woodmagazine.com/help or write to my shop space
WOOD magazine, P.O. Box 37439, Boone, IA 50037-0439 and converting
....................... Publisher MARK L. HAGEN the existing knee
ADVERTISING AND MARKETING walls to full-
CHICAGO: 333 N. Michigan Ave., Suite 1500, Chicago, IL 60601 extension drawers
Marketing Manager AMANDA SALHOOT to free up floor
Advertising Manager JACK CHRISTIANSEN space. Next up:
Direct Response Advertising Representative RYAN INTERLAND an Irish pub in
Assistants GAYLE CHEJN, NIA WILLIAMS my basement.
ATLANTA: Navigate Media
DETROIT: RPM Associates
Product Marketing Manager DIANA WILLITS
Business Manager JEFF STILES
Associate Consumer Marketing Director DAN HOLLAND
Associate Director of Marketing-Newsstand TOM DEERING
Production Manager SANDY WILLIAMS
Advertising Operations Manager JIM NELSON
E-Commerce Manager MATT SNYDER
Vice President/Group Publisher TOM DAVIS
MEREDITH PUBLISHING GROUP
President JACK GRIFFIN
Executive Vice President DOUG OLSON
Editorial Director MIKE LAFAVORE
Finance & Administration MIKE RIGGS
Manufacturing BRUCE HESTON
Consumer Marketing DAVID BALL
Corporate Sales MICHAEL BROWNSTEIN
Meredith 360 0 JACK BAMBERGER
Interactive Media LAUREN WIENER
Corporate Marketing NANCY WEBER
Research BRITTA WARE
Chief Technology Officer TINA STEIL
New Media Marketing Services ANDY WILSON
~.~~~
President and Chief Executive Officer STEPHEN M. LACY
Chairman of the Board WILLIAM T. KERR
In Memoriam - E.T. Meredith III (1933-2003)
Our subscribers list is occasionally made available to carefully selected
firms whose products may be of interest to you. If you prefer not to
receive information from these companies by mail or by phone, please
let us know. Send your request along with your mailing label to Magazine
Customer Service, P.O. Box 37452, Des Moines, IA 50037-0452.
© Copyright Meredith Corporation 2008. All rights reserved. Printed in the U.S.A.
Retail Sales
Retailers can order (opies ofWOOD for resale
~ I@
....... I '\
bye-mailingjennifer.bu!!.r@meredith.com
WOOD magazine September 2008

Sounding Board
Our bulletin board for letters, comments, and timely updates
Tool handles: An ideal
project for novice turners
Shoulder prevents spilled toothpicks When I read the
As an intermediate woodturner, I found your article on the 4-in-l
toothpick dispenser on page 72 of issue 182 Turned Handle
(March 2008) the perfect project for utilizing Screwdriver in issue
some attractive scrapwood. I turned mine, shown 180 (November 2007,
below, from glued-up maple and padauk, but I pages 72-74), I knew
added a twist. To keep people from accidentally you wrote it for me.
pulling the cup too far out and spilling the I'm still relatively
toothpicks, I made a shoulder inside the cylinder new to woodwork-
to act as a stop, as shown in the drawing at right. ing, so I don't have
To do this I bored a 1%" hole from the bottom, many tools, and I'm
stopping about 3f4" from the top. Then I bored a still honing my skills. This project
Ilia" hole from the top. After inserting the cup helped me with both. I've made 15 so
into the cylinder, I glued a plug in the bottom. far, keeping one for my shop and giving
- Frank Pickett, Tucson, Ariz. the others as Christmas gifts. I made
the handles from various combinations
of ash, purpleheart, and wenge. Thanks
for the fun project.
11/4' hole
through
bottom
Y
q !
:
1V4" plug
Another great way
-Dave Rector, Denham Springs, La.
to store 6ack issues

To follow up on your "Smart Ways to
Store WOOD Magazine" article in issue
177 Quly 2007), I offer one more
solution: I take the metal splines from
Protect power cords file-cabinet hanging folders and insert
with PVC sleeves them into the center spreads of the
I urge your readers to magazines. Then I hang them in my
make one modification to filing cabinet drawer for convenient,
the electric cord storage dust-free storage.
tip on page 10 of issue 183 -Mark Wile, Marietta, Ohio
(May 2008). As a licensed
electrician, I worry that
wrapping cords around
bare bolt threads could,
over time, damage the
insulation-possibly
resulting in shock. Instead,
slip a short length of 3f4"
PVC pipe over the bolt for
the cord to rest on.
- Charles Tubbs, Murray, Ky.
HOW TO REACH US
• For woodworking advice: • Subsaiption assistance: • To order past issues and articles:
Post your woodworking questions (joinery, finishing, To notify us of an address change, or to get help with Order past issues of WOOD magazine, our special issues,
tools, turning, general woodworking, etc.) on one of your subscription, visit woodmagazine.comlservice. or downloadable articles from issue 100 to present: Visit
16 online forums atwoodmagazlne.comlforums. Or write to WOOD magazine, P.O. Box 37439, Boone, IA our online store at woodmagazlne.comlstore.
5OO37-ll439. Please enclose your address label from a Some issues are sold out.
• To contact our editors: recent magazine issue.
Send your comments via e-mail to • Updates to previously published projects:
woodmail@woodmagazlne.com; or write to • To find past articles: For an up-to-date listing of changes in dimensions
WOOD magazine, 1716 Locust St., LS-221, See our index at woodmagazlne.com/lndex. and buying-guide sources from issue 1through today,
Des Moines, IA 50309. go to woodmagazine,com/edltorlal.
1_
6 WOOD magazine September 2008
._
Free videos help you learn valuable techniques
I want to compliment the staff of available at woodmagazine.com/videos.
WOOD® magazine for the free videos I've been impressed by the quality and
content of these videos,
especially for subjects that
are hard to find on for-sale
videos. As a beginning
woodturner, I've learned an
incredible number of
techniques and tips from
Brian Simmons, shown left.
A video paired with a
magazine article really helps
me see and understand
what you're teaching.
Thanks!
-Pieter DeHaan, Somerset, N.].
Article updates
Issue 182 (March 2008) 0/16" hole 7/3 2" deep, centered
• In the article "A Perfect Puzzler," the ¥B" from back edge
locations of the two magnet holes in
the Caged Dove puzzle box are
transposed. Here are the correct
instructions for Step 4 in the middle
column on page 35, along with an
updated Drawing 2b:
4 FliP the drawer (C) end-for-end

and, using a 5116" Forstner bit,
drill a hole centered 1/2 " from the
back edge and as deep as the rare-
earth magnet is thick. In the filler
(D), bore another magnet hole the
same size and depth centered 3/8 "
from the back edge. (Perry offsets
the holes by lfs" so the magnets
hold the drawer in place.)
Issue 184 Ouly 2008)

• In the WOOD Patterns® insert on page 41, you'll find the zebra and rhino patterns
which were excluded from the insert in issue 184.
Issue 184 Ouly 2008)

• Here are the dimensions for
the District of Columbia and
U.S. Territories coin holders on
page 10.
woodmagazlne.com 7
S pTi~
Helping you work faster, smarter, and safer
Simple story board makes fence setup a snap

A story stick is a great way to set up simple to capture the blade in the story
your tablesaw fence accurately without board and slide the fence into place
measuring every time. But sometimes, against the story board, as shown below.
measurements too near each other can To make the story board even more
be hard to mark and read reliably. My reliable, I record information on it such
solution: Create a story "board" out of a as the date, the blade used, even the
scrap of lis" hardboard. For every fence name of the piece of furniture. I store
setup, after I cut my workpieces, I make all of my story boards on a nail on a Retired civil servant Serge Duclos is a
a short cut on the story board, and rafter for those times when my friends self-proclaimed tool nut. His basement
write in the measurement and the and family ask, "Can you make me one shop holds two tablesaws, three drill
name of the part. That'way, if I forget to just like it?" presses, three mitersaws, and countless
cut a piece or have to make a re-cut, it is -Serge Duclos, De/son, Que. shop-made jigs. He made us promise
not to tell you how many routers he
has in his collection, but the number
falls somewhere between 16 and 18.
That includes the first router he ever
bought more than 30 years ago, which
currently serves in a dedicated
chamfering station.
We're with you,

Serge! A shop can
never have too
many tools. So
here's the 7S-0S0T
benchtop mortiser
from General
International
to add to your
collection.
Top tips earn tools!

Tell us how you've solved a
workshop stumper. If we print
it, you'll get $100 and a copy
Never miss a bit with combination holder and gauge of 450+ Best-Ever Shop Tips
(woodmagazine.comi
Finding the right bit for bolts, dowels, 450tips). And, if your idea
or other hardware couldn't be easier garners Top Shop Tip honors,
with the combination drill-bit holder we'll also reward you with a
and gauge that I made. I simply drilled tool prize worth at least $300.
holes into the edge of a hardwood scrap Send your best ideas, along with
to hold each bit. Then I drilled gauge photos or drawings and your daytime.
holes of the same size through the face phone number, to: Shop Tips, WOOD
of the holder centered on the bit holes. Magazine, 1716 Locust St., LS-221,
The bits block the gauge holes, but I can Des Moines, IA 50309-3023. Or, by
e-mail: shoptips@woodmagazine.com.
qUickly slide bits out of their holes to fit Include your contact info in the e-mail.
a piece of hardware through the gauge Because we try to publish original
holes. When the hardware fits the hole, Through hoi. . made tips, please send your tips only to
the bit in my hand is the winner. with corresponding bit WOOD® magazine. Sorry, submitted
-Rick Hutcheson, Grimes, Iowa materials can't be returned.
continued on page 10

Take the plunge with this self-centering mortising jig B'ack-saving dustpan
Recently, I constructed a panel door tenons were I/Z" thick and 3" wide, so for pennies
using floating tenons to join the stiles the template hole measured 3,4x31f4". This stand-up dustpan, made from
and rails. This method requires precise (I routed my mortise using a plunge salvaged parts, is easy on both your
positioning of two opposing mortises router equipped with a 3,4" bushing and back and wallet. Cut the body of the
for each tenon. To ensure the alignment, a I/Z" upcut spiral bit.) dustpan from a square-bottom, plastic
I devised the self-centering mortising jig Assemble the jig by attaching the pail used for everything from cat litter
shown here. clamping portion to the template, to bulk food items. (You can often get
To make one for yourself, begin with being careful that the screws holding free ones from doughnut shopsi delis,
the clamping portion, which is held the template to the tie bars are aligned bakeries, and restaurants.)
together with aluminum tie bars, as with the centerline of the template The plywood backer prevents the
shown in the drawing. The slot in the slot. Pencil witness marks to indicate fasteners from pulling through and
MDF template should be 1,4" wider and the center of the mortise inside both protects the plastic from fatigue. The
longer than the desired mortise to allow edges of the slot. handle for my dustpan came from a
for the guide bushing. For instance, my To use the jig, position the rail and broken snow shovel, but any handle or
stile to be joined so their edges to be dowel will work. After cutting the
mortised are next to and parallel to handle to length, use your bandsaw to
each other [Step 1]. Mark the centerline cut a 1,4"-deep x 81f4"-10ng slice from one
of the mortise across both of the ends.
edges. When you clamp the Mark and cut the pail to the profile
jig to the workpiece, align the shown, using either a pair of snips or a
marks inside the jig with the rotary tool with a general purpose
one on the workpiece [Step 2]. cutting bit (such as Dremel 561 Multi-
Finally, rout the mortise. Purpose Cutting Bit). Sand a bevel on
The jig can be used on stock the leading edge of the pan for easy
of various thicknesses and dust sweep-up.
will always self-center. -Raj Chaudhry, New York
-Andy Tischendorf, Sussex, Wis.
0/32" hole,
countersunk
on top
#10-20 x 2" machine screws #10-20 nut

STEP 1: STEP 2: ALIGN WORKPIECE CENTERLINE Lock washers
MARK THE MATING CENTERLINES WITH WITNESS MARK ON JIG
f)

Simple system for marking square on big panels
Marking a square end on a large panel parallel. Next, mark the center of the Using a straightedge, draw a line
can pose a sizable challenge, especially panel across its width. between points A and B. Measure from
if you can't trust your framing square With your square held against one this line or cut <,lIang it for a square end.
to be perfectly square. The simple edge, make a mark at the edge (Point A) Because the sides are parallel and you
system shown here will allow you to and across the center mark to form a marked from the center, even an out-of-
accurately mark panels with your crosshatch. Flip the square to the true square will ensure a square cut.
framing square. opposite edge, aligning it with the -Don Klimesh, Sylvania, Ohio
Before marking, rip your panel to center crosshatch, and mark the edge
width on the tablesaw so both edges are (Paint B). continued on page 12
STEP 1
Mark the edge at point A
and through the
center martt.
woodmagazlne.com 11
One miter mistake you
can make disappear
I built three picture frames for
retirement gifts, but just as I was
about ready to present them, I
noticed that one joint had
apparently slipped in the clamp
and was partially open. Feeling
Blade kerf
a bit desperate, I performed a centered
quick fix that saved me consid- over miter joint.
erable embarrassment.
To repair the joint, I centered
it on the kerf of my mitersaw
blade, clamped a stopblock
square to the fence, and cut
through the faulty joint. Next, I
0
rotated the frame 180 and re-
cut the opposite joint. With a
quick and tidy clamp-up, the
frame went back together
perfectly. Although the frame
was a shade smaller, the glass
and matting still fit, and I made
the deadline with work I was
proud to call my own.
-Jim Culler, Bellville, Ohio

Double-duty from long pipe clamps A right-angle driver at
I often run out of properly sized pipe damps any time I have a a just-right price: Free
project with more than a few doors to glue up. Rather than spread If you've ever priced a right-angle screw gun, you
the gluing stage over several days, I added an extra clamp head and know it's a lot of money for a tool most of us won't
tail-stop to each, as shown. (You may have to have your pipes use very often. Fortunately, all of those hex-drive bits
threaded on the other end at your local plumbing store). Now, fit snugly into a 114" socket, meaning the ratchet you
they do double-duty, letting me glue up two doors at once. probably already own serves as a solid substitute
-Dewayne Ketchell, Roy, Utah when you need to drive a screw in a tight spot.
-Robert Erwin, North Port, Fla.
woodmagazine.com 13
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Circle No. 1846

Wooden fingers 1h" hole 1h" holes
lend a helping hand 3"
When building cases, I often
find that nature did not
provide me with enough
0/4"
hands, so I made my own
"wooden fingers." These
fingers slide down on a long
dowel to steady large wooden
panels for glue-up or joinery.
And they leave the corners 30" +
completely unobstructed for
driving screws or nails.
-Ralph Roberts,
1h" dowels
Thompsonville, Mich.
Complex spindles
from simple cutters
I'm not a master at the lathe, so when
a project required multiple spindles
with adjacent beads, I needed a
solution for turning them out quickly
and accurately. That's when I remem-
bered the three-bead cutter bit
(model no. 23305, craftsman.com)
for my Craftsman tablesaw molding The Wood Tool Sharpener
cutterhead. Bolted to a piece of NEW from the makers of

1l4xlx8" steel bar, it became a bead ~D"III Doctor.
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woodmagazine.com 15
Circle No. 1665
blOCk of wood or scrap of 2x4 stock, a short length of
A hacksaw blade, and four felt dots are all it takes to

make this shop aid. Use the jig to cut off screw-hiding
plugs, to trim protruding dowels from dowel joints, or to cut
decorative plugs for joinery where you want the dowel or plug
to protrude slightly.
Build the trimmer shown, routing round-overs along the top R=2V4"
edges for hand comfort. The depth of the groove in the bottom
of the block determines the length of the dowel or plug 1V2x2V4x4W' ...-:=:;':==:::::r---..V8" round-overs
protrusion that will remain after cutting. Create a shallow
groove in the jig's bottom for trimming dowels nearly flush
with the surface of the surrounding wood, leaving an easy-to-
sand-flush dowel end exposed. Or, deepen the groove and let
the dowel or plug stand proud fo~ a more pronounced effect.
For trimming dowels from edge joints, as shown in the
inset above right, clamp on a pair of scrap supports to create a
larger flat surface for the jig to ride on. •
Project design: Dale Toms, Bedford, Va..
Hacksaw blade
cut to 4 W' long
Find dozens of FREE shop-helper project plans at epoxied into grooves
woodmagazine.com/freeplans
'Adjust this dimension for crosscutting plugs to different lengths.

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quick & EasJJig
Portable
! ,
Drum
Sander
Drum-sand curved edges
quickly and accurately with
this super-simple jig.
sanding drum makes quick work Press the base flat
II
A of smoothing an edge profile
rough-cut with a jigsaw. You
might think you need a drill press or
against the workpiece.
Lock the drill trigger
into the on position,
II spindle sander to keep the sanded edges and gUide the sanding
square to the surface, but a corded drum along the edge.
electric'drill, shop scraps, a few dollars' To reduce chatter, use
worth of hardware, and a set of inex- a large sanding drum
pensive sanding drums will do the on broad curves.
trick. Even if you own a drill press or Switch to a smaller-
I spindle sander, you'll find this jig diameter drum for
II handy for sanding a part too large to
handle on one of those machines. A
tight inside curves. •
few minutes is all it takes to make this

simple edge sander. Here's how. Insert shims to square the drill to the base. Recheck square after
you tighten the hose clamp securely.
Build the jig

Cut the base and upright to the sizes Sandpaper
shown at right. To accommodate large
sanding drums, cut a rabbet along the
bottom edge of the upright. Then
1
clamp the parts together, drill screw
holes, and drive the screws. To help
keep the drill from shifting, adhere
sandpaper to the upright. Strap your 9"
drill to the upright with a large-
diameter hose clamp. Chuck a piece of
%" steel rod into the drill, and check for
square, as shown at center. Make ~6"____ •
adjustments by inserting shims Base '- ~:Y4"
between the drill and the upright.
<1
Using the jig 6":;>-
i• Chuck a sanding drum into the drill so ~
the top edge of the drum is about W' 3/16",rabbet 3/16" deep
l'
I above the bottom surface of the base.
II
I
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W.OOd Woodshop News Woodshop News Woodshop News Woodshop News
!p.~l'5lt"l-l;"'~~
•
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Circle No. 205

Workshop Savvy
Turncrown
molding into
bracket feet
Use a tablesaw and jigsaw to transform
store-bought trim into a customized
foundation for your next cabinet.
wo quick cuts on your tablesaw reset the fence and cut away the short front piece. To make the wood
T can turn common crown

molding into bracket feet for
bookcases, cabinets, and display cases.
opposite inside bevel.
For the two-piece crown-molding
bracket feet we're making here, cut
grain flow around mitered corners like
the one above, first measure the
combined length of the front and side
First, decide what height of molding from each blank a side piece as long as pieces for each foot and add 2". Then
brackets will look best for the overall the depth of the cabinet (or 114" longer cut two blanks that long.
size of your project. For example, 41/s"- to create a reveal, as shown above) and a Next, tilt your tablesaw blade to 45 0
wide moldings work on tall cabinets and test for accuracy using scrap. With
while 3W'-wide molding complements an extension on your miter gauge, cut
the midsize bookcase on page 60. the front piece to length. To cut the
side piece, turn the remainder of the
Foot sizes vary by molding blank end for end, and miter as close as
Moldings follow industry-standard
widths and profiles, but vary in
thickness. The thinner the molding, DREMOVE BEVELS IN TWO PASSES
the narrower the back bevels you'll
II remove and the taller the foot. To see
how much height a crown-molding
First cut
I foot will add to your project, measure

.1 between the bevels on the back.
You also can narrow the bracket feet
and alter their profiles by ripping the
molding at different locations. Taking
just the section between the top and
bottom ridges in the profile (the green
Narrow
and black lines in Photo A) gives you a
crown
2%" blank from the wide crown, a 23116"-
wide blank from the medium, and a Second cut
11,4" blank from the narrow crown.
And nothing says you can't make the
bracket feet with the profile turned
upside down from how it's shown here.
Cut and miter the blanks

After you choose a crown molding
style, set your tablesaw fence to remove
Wide
crown
Cutting at the black and red lines yields the
widest blank after removing the bevels. Cuts
-
~ ,
G-ablesaw
. . ~
the first inside bevel [Drawing 1]. Then at the green lines leave a thicker top edge.
I'I
possible to the previously mitered
end so you leave a triangular piece
of waste [Photo B]. Repeat for the
other side and front pieces. Then
reset the blade to 90 and cut the
0
side pieces to length.
Cut curved patterns

You can create your own bracket
foot cutout design, or use a pattern
such as the one in the WOOD
Patterns® insert on page 48 for the
bookcase. You also can fine-tune
an existing pattern to fit the width
of your molding blank [Drawing 2]. With two parallel edges created after removing the
Because you'll need a mirror bevels, molding blanks can be turned end for end
pattern for the other side of your and mitered to leave just a tiny piece of scrap.
project, use a photocopier "mirror
image" setting to make a reversed
pair of the original patterns.
Otherwise, trim a pattern to the
lines, turn it upside down, and use
spray adhesive to attach it to the
mitered blank.
A scrollsaw with a #7 (12 tpi)
blade will produce clean cuts that
need minimal sanding. If you
don't have a scrollsaw, use a jigsaw
with a 12-tpi blade [Photo C].
To assemble one of the brackets,
glue and press the miters together
by hand [Photo 0]. Keep pressure
on the pieces for 2 minutes; then
carefully release them to avoid
jarring the joint. Allow 3 hours for
the glue to dry. This way, you
avoid problems attaching clamps We used standard wood glue on this hand-pressed A %"-thick mounting block helps reinforce
to the uneven routed profile while joint, but Titebond Wood Molding Glue (800-669- the crown-molding miter joint. Drill
keeping the parts aligned. 4593 or titebond.com) tacks and dries faster. mounting screw holes to suit the case frame.
Add mounting blocks [Photo E]. From %" solid wood or assembly to your cabinet. For the
You could now simply glue and clamp plywood, cut a block smaller than the bookcase, shown on page 60, we left lis"
the assembled bracket feet to your inside bracket dimensions. Then glue of the top edges of the brackets exposed
project. But to add strength and a place and clamp the block flush with the top as decorative touches. •
to sink mounting screws, attach a edges of the foot. After the glue dries,
mounting block to the inside corner drill shank holes, glue, and screw the Illustrations: Roxanne LeMoine; Lorna Johnson
!JSIZE THE TEMPLATE TO THE BLANK
Wide crown Mitered end

Center pattern Mitered end 4
You can modify a single serpentine pattern to work on different crown-molding widths.
23
Avoiding Workshop Goofs
Ward off warped doors
Come on, baby, let's NOT do the twist!
now one thing right up front:
K
GRAIN PATTERN PROVES CRITICAL
You'll never completely prevent
doors from warping. But, you
can greatly reduce the chances of that
happening. Here's how.
Grain is for more

than a great look Flatsawn Riftsawn Quartersawn
No matter what size doors you make,
the grain on a workpiece should be home, you'll be able to flatten it and
your top priority when choosing stock. still get a board that's 3,4" thick.
Insist on quartersawn or riftsawn wood Allow these boards to acclimate to
for stiles and rails, because its grain your shop's temperature and humidity
runs straight along the length, as for at least two days before making the
shown at right, making it more resistant first cut. Then, cut your workpieces at
to warping. By comparison, flatsawn least 114" oversize in length and width,
wood, with its semicircular end grain and plane them to within lis" of the
and cathedral-pattern face grain, warps final thickness. If any board pinches on
more frequently and substantially. your tablesaw blade or splitter, you're
When buying lumber, opt for rough- seeing a telltale red flag of a board
sawn stock or boards that have been releasing tension. Don't use it for your
only partially (skip) planed. That way, door; it will only warp later and cause
if a board warps slightly after you get it you grief. Let the good boards acclimate
for another day, as shown below.
Finally, flatten one face and edge on
your workpiece, plane it to thickness,
rip it to final width, and crosscut it to
final length. Make your door frames
from these pieces. If any show signs of
warping, as shown on page 25, discard
them and make a new piece.
Fill the frame with a

warp-proof panel
Now that you've got your stiles and
rails ready, prepare the panel to best
ward off warping. If possible, choose
veneered medium-density fiberboard
This dresser door, made from quartersawn Arrange your boards on strips of scrapwood
white oak, looks as square and true as the so the faces and edges get maximum
day it came out of our shop 4'12 years ago. e'xposure to your shop's air. .
\

(MDF) for the panel-it exhibits little
seasonal movement and will remain
flat. Veneered plywood panels will
shrink and swell slightly, but still prove
a good option, particularly those with
thinner plies.
For solid-wood panels, choose boards
with similar grain so they'll shrink and
swell equally. It's okay to use flatsawn We glued up this 12 n -wide panel from three
boards here, but rip them no greater f1atsawn boards that proved flat, allowing us
thal14" wide and then glue up your to focus on the best face-grain match.
panel, as shown at right. After the glue
dries, flatten the panel by sanding or hold it straight, this piece will more
planing. Before installing it, though, let likely warp than its counterpart.
it sit in your shop for a day to be sure it • Avoid boards with figured grain or
stays flat. If it warps after glue-up, cut knots when making stiles and rails.
your losses and make a new panel. Although often attractive, these
features increase chances of warping.
Apply these help-ful tips • Machine grooves in the stiles and
to combed warping rails to hold the panel snugly, so you
• When selecting stock for stiles and can just slide it in and out. Loose
rails, put the straightest grain on the grooves increase the tendency for the
longest door parts. The long compo- panel to twist.
nents of a door tend to warp first. • Use two magnetic catches or barrel
• After machining your rails and stiles clasps (one at the top and bottom)
to final size, select the stile with the instead of one to hold a door shut. A
We milled these boards to size after they
acclimated to our shop, but the one on the straightest, tightest grain for the handle door with only one catch could warp in
right bowed and was sent to the scrap bin. side of the door. Without hinges to the free corner. •
woodmagazlne.com 25
Wise Bu~
Our Editors Test
Aftermarket
Handsaw Editor test-drive:
For the price of competitors' aftermarket fences, the Rockier
24504 provides an auxiliary table with perpendicular miter slots,
Fences a 3"-tall fence, and replaceable throat inserts. The 11fa"-thick,

24"-square MDF table easily clamped onto my bandsaw's.. table
and offers nearly twice as much surface area as typical factory
tables. Removing blade drift proved easy and intuitive; I only had
to adjust the two bolts that thread into the T-square end bracket
(that mounts to the rails).
After that adjustment, I could resaw 1/a"-thick pieces of red oak
Why buy? with almost no deviation in thickness. A T-slot milled into the
If you use your bandsaw only for making curved cuts, you'll M DF fence face accepts feather boards, hold-downs, or stopblocks,
likely never need a rip fence. For accurate ripping and resawing, but overtightening can crush the thin walls. (I'd prefer aluminum
though, a good fence helps greatly. That said, many bandsaws T-track in the fence.) With only one working face, this fence must
don't come with afence-including three of the eight we tested be used left of the blade-a drawback when tilting the table
on pages 54-59. Those saws that do have fences, particularly on because I like my workpiece to ride against the fence in that
lower-cost models, often don't work that well. The three fences situation. Rockier includes a jig for cutting circles up to 26" in
we recommend here fit virtually any 14" bandsaw and some 12"
diameter.
models. (Before buying, check with the fence manufacturer to
-Tested by Craig Ruegsegger, Multimedia Editor
see if its product works with your bandsaw.)
To learn more: rockler.com; 800-279-4441
1· ..····.. ··..········.. ·································· _ _ .
KREG, #KMS7200, $120 WOODHAVEN, #7280, $140
Editor test-drive: Editor test-drive:

My bandsaw's factory fence is always on the saw. Not because I want my bandsaw fence to be intuitive to use, easy to take
I love it, but because I have to remove the blade before I can slide off and put back on, and have T-slots for mounting jigs and ac-
the fence off the right end of the rail! And that's one of the main cessories. Woodhaven's fence does all that and more. It starts
reasons I replaced it with the Kreg KM57200, which lifts on and off with two 24"-long aluminum rails that mount to the holes in my
anywhere along its rail. The lock holds the 23/s"-tall fence securely saw's table, with no drilling needed. These rails slide left and right
when resawing, even with long workpieces that apply greater when not locked, giving me plenty of options for fence position.
force against the fence. Fine-adjustment screws on the fence make And, although the fence can't simply be lifted off the rails, it's
it easy to counter blade drift. The fence sports T-slots on both only a five-second job to slide the rails to the right and then the
faces as well as the top and bottom of the fence. 50 I can lay it fence to the left. No blade removal required.
sideways to reach under the blade guides for short, thin rips. The fence itself is 24" long and 3" tall with eight T-slots, and
The micro-adjuster accessory (#KM57215, $15) proved dead-on holds solidly without deflecting. It's easy to adjust square to the
and well worth the price. It mounts to the left side of the fence and table and to correct blade drift. I like the included handy stop that
helps precisely dial in a rip cut. I used the micro-adjuster to find the mounts in the T-slots and prevents cutting into tenon shoulders.
exact center of a W'-~hick piece of red oak and resawed it at that Finally, Woodhaven sells this fence with an optional circle-cutting
point. The resulting cut showed almost no difference in thickness attachment (#7285K, $183) that mounts onto the ends of the
from end to end when checked with a caliper. fence rails, enabling you to cut circles up to 26" in diameter.
-Tested by Bob Wilson, Techniques Editor -Tested by Kevin Boyle, Senior Design Editor
To learn more: kregtool.com; 800-447-8638 To learn more: woodliaven.com; 800-344-6657

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By penetrating deeper into porous areas of
curly maple, an oil/varnish finish. brings out
the beauty of the grain figure•
• '7/
Both the oil and varnish in this finish add
amber color you can see on this pale maple.
Also, both ingredients will darken with age.
as maple, a warm amber color, as

shown above.
Many oil-and-varnish recipes call for
equal amounts of boiled linseed oil,
varnish, and mineral spirits. But as the
sample below left shows, you can get
hether you're new to finish- the cabinet shown on page 30 and the same results and build a film finish
W ing or just want a fuss-free

way to protect a project, a
wipe-on mix of oil and varnish brings
above, we mixed three parts gloss
polyurethane varnish to two parts each
of boiled linseed oil and naphtha,
quicker by increasing the percentage of
varnish until you notice wiping marks.
out wood's natural glow while building which evaporates faster than mineral Apply a flawless finish
a shield against humidity and wear. spirits. The oil penetrates the wood, To prepare the wood, sand up to 180
And you can repair most minor damage deepening the grain of such species as grit. Then vacuum off or blow dust
in minutes with a light sanding and walnut and adding grain contrast in from the pores with compressed air
touch-up coat of this finish. curly maple, as shown top. The varnish before you wipe down the surface with
Although commercial oil-varnish leaves a thin film finish, while the a soft cloth.
:1 mixes are available, you can save naphtha makes the mixture easy to Wipe on the finish with a clean cloth
I money by mixing ingredients in your spread with a soft cloth. Together, the until you saturate the wood surface.
shop. To create the finish we applied to oil and varnish give light woods, such Then remove all excess finish with a
clean cloth, especially in recesses and
corners where it may pool. Excess finish
will turn soft, gummy, and tricky to
remove. After an hour, check for signs
of oil bleeding out of the pores, and
wipe it away before it cures. Allow one
full day for the finish to cure.
Then lightly sand the finish with a
320-grit sanding sponge. Clean the
I
surface and apply a second coat, again
wiping away the surplus. Wipe on as
I
,I Increasing the percentage of varnish builds protection faster without sacrificing grain- many coats as you want-with 24 hours
Ii enhancing benefits from the boiled linseed oil (BLO). The mix on the left produced the same imd a light scuff-sanding between
i color and depth as the one on the right, but added 50 percent more varnish with each coat. each-but four is sufficient. •
'i

Custom Woodworker
has Competitive Edge
Thanks to Woodmaster
Now, turn a $5.00 rough board into "Woodmaster really changed
$75.00 worth of high-dollar molding in the way I do woodworking.
It set my career in the right direction. Making curved
just minutes. Make over 500 standard molding with the Woodmaster really separates me
patterns, curved molding, tongue & from my competition - it's like a PhD in woodworking:'
groove, picture frame stock, any custom - Gary Striegler, President, Striegler &
Associates Custom Homebuilders
design. QUICKLY CONVERTS from
MolderjPlaner to Drum Sander or power-
feed Multi-Blade Ripsaw. Made in U.S.A. SHAPE 3 SIDES
5-Year Warranty. Choose from 12", 18"
or 25" models.
IN I PASS'
NEW 3-Side Molding
. Variable Feed Makes System turns your
'lte DiHerence! Woodmaster into
Just a twist of the dial adjusts the Woodmaster a POWERFUL
from 70 to over 1,000 cuts per inch. Produces 3-SIDE MOLDER
a glass-smooth finish on tricky grain patterns no that efficiently &
other planer can handle. Plenty of American- AFFORDABLY cuts
made "muscle" to handle money-saving, T&G flooring, paneling,
"straight-from-the-sawmill" lumber. Ideal for much more!
high-value curved molding.
Circle No. 1820

It's your call which venion of this handsome cabinet to build: One showcases collectibles such as
glassware, the other displays your hunting rifles and shotguns.
Trlgger and cable locks have

removed for photography. Always store your
firearms in a way that's safe for your circumstanals.

• Overall dimensions: 33W wide x 16W' deep • For the self-closing hinges, knob, cam lock,
x 74" high. full-extension drawer slides, and low-voltage
• Display up to six rifles or shotguns, or build the lighting kit see Source on page 38.
version with glass shelves and a mirror back to
display collections. Skill Builders
• Two pull-out trays under the display • Learn about stub-tenon-and-groove joinery that
compartment provide hidden storage. speeds construction and produces sturdy furniture. See a Slide Show of this
• Outfit your cabinet with low-voltage lights and • Discover how a simple plywood guide makes project coming together at:
a three-position dimmer. positioning biscuit slots a snap. woodmagazine.com/slides
S
tanding a little more than 6 feet extra strength. For efficiency, the top, shelf, end, and make another pass. Then, mov-
tall, this grand walnut cabinet and bottom are constructed in the same ing the fence closer to the blade in small
lends distinction to any room. As manner. To ensure accuracy and eliminate increments, cut, rotate, cut, move the
a gun cabinet, it's perfeCt for a den or repeat setups, machine all the parts that fence, and repeat until the 1;4" plywood
recreation room. The display cabinet, utilize stub-tenon-and-groove joinery at the fits snugly in the groove. Now, cut the
with its glass shelves and mirrored back, same time. grooves in all the parts. Raise the blade
will add sparkle to the living room or
dining room. Either way, it's a beautiful
piece of furniture you'll be proud to say
1 Cut the side stiles (A), rails (B), and
middle rails (C); bottom, shelf, and
top stiles (F) and rails (G); and door stiles
to 2", and make two additional passes
over the blade with the door top rail (T).
For uniform-width grooves, especially
you built. (Q), bottom rail (R), middle rail (5), and in the long parts, use a feather board to
top rail (T) to size [Materials List, page keep the parts tightly against the fence.
Form grooves and tenons 38]. Mark the part letter on each part
Note: Most stub-tenon-and-groove joints with chalk. Also, for cutting the grooves,
have #i"-long tenons and #i"-deep grooves. mark the inside edges of parts A, B, F, G,
Because the side frames and door in this Q, R, and T, and both edges of parts C I!IBISCUIT GUIDE
project hold large glass panels, we increased
the tenon length and groove depth to W' for
and 5 [Drawings 1, 1b, 2, 2a, 6, and 6a].
Reserve some scrap pieces of the same
thickness to test your machine setups.
-----j
2W
i-
I.
r
I
7 W'-;j-221;1/"
I
I
' ~4
l
2
J
Cut centered grooves to match the
aSIDE FOR GUN CABINET thickness of 1;4" plywood in the
(Left inside face shown) Biscuit 11 W'
marked part edges. To do this, adjust
centerlines
your tablesaw blade to cut W' deep. Posi- )
#20 biscuit slot tion the fence to center the thickness of '¥4" plywood
1 111/4'--1 a scrap piece on the blade. (You can just i I I
2"~ center the part by eye.) Make one pass
I. 14V2" .1
3" .~ over the blade, rotate the piece end for
3/a" rabbet
1/4' deep
17"
IISIDEFOR
Va X 11 Va X 52%" glass DISPLAY
#20 biscuit CABINET
slots (Left inside
A face shown)
A W'rabbet
V2" deep
routed after
(/
17" V4" holes
assembly #17 x 1" ¥a" deep
brad IDISIDE TENON DETAILS
(Viewed from back)
74"
*V4" grooves j,it:{4"
V2' deep, V2 11
centered rabbet
53"
V2"
deep
E
E routed
after
assembly
#20 biscuit
slot
3" V
:,J 21/4' *Thickness of 1/4' plywoOd
woodmagazlne.com 31
•
With a partially housed Sfs" dado blade, the
•
Using 2"-wide spacers to position the rails (B)
• • ••
After making one pass over the inner lip with
fence as a stop, and a miter-gauge extension at the top and bottom (bottom shown), glue a 114" rabbet bit, switch to a W' rabbet bit and
as a backer, cut the rail (B, C, G, R, 5, T) tenons. and clamp the sides (AlBIC/D). climb-cut to remove the remaining portion.
1/4" grooves 1/2' deep, centered

E!JTOP, SHELF, AND BOTTOM TENON
DETAIL
wr-
1/4" groove '12' deep, centered
,I
I'
EJTOP, SHELF, AND II FACE FRAME

BOTTOM ¥a" (Inside face shown)
TI
3"
L
2"
3 TO form the rail (B, C, G, R, 5, T)

tenons [Drawings 1, 1b, 2, 2a, 6, 6a],
install a 0/8" dado blade in your tablesaw,
to produce a lh"-long tenon and form
tenons on the rail ends [Photo A].
17"
#20 biscuit slots
housing W' of it in an auxiliary fence Assemble the case parts

attached to the rip fence. Using a scrap
piece guided by the miter gauge, adjust
the cut depth so passing each face of the
1 Cut the panels (D) to size and finish-
sand them. Dry-assemble one lower
rail (B) and middle rail (C) between two
scrap over the blade yields a centered stiles (A) to check the fit. Then, cut two
tenon that fits snugly into the stile 2"-wide spacers from %"-thick scrap that
grooves. Then, adjust the fence as a stop match the tenon-shoulder-to-tenon- 17"
shoulder length of the rails. Now, glue 74"
and clamp the sides [Drawing 1], insert-
ing the spacers at the bottom and top to
position the rails (B) [Photo B]. Check
the sides for square.
2 ChUCk a W' rabbet bit into a hand-

held router, and rout a rabbet for the
lower back (K) and upper back (L) along
the inside face at the rear edge of each
side assembly [Drawing 1].
------26"'-----~
3 Remove the inner lip of the groove

in each side assembly to accept glass
and glass stop (E). To do this without
risking tear-ont, start with the rabbet-bit ¥a" cove on
setup used in the previous step. Place a outside face
• •
Clamp the guide to the side assembly,
side assembly on your workbench with
its inside face up. Make sure the bit pilot
position the biscuit joiner against the guide, bearing runs on the edge of the outer lip
align the centerlines, and plunge the slots. and the bearing screw clears the bench
32
Using the guide as a spacer and a squaring Transfer the guide to the top end of the side With the guide clamped between the bottom
brace, glue, biscuit, and clamp the bottom assembly, and glue, biscuit, and clamp the and shelf to keep everything square, glue,
and shelf assemblies to one side assembly. top assembly in place. biscuit, and clamp the second side assembly.
surface, and the cutter will remove the II!JCROWN SIDE SECTION DETAIL
entire thickness of the inner lip. If nec- t--15/a'~
essary for bearing-screw clearance, place 'l
scrap blocks under the side assembly.
Clamp the assembly to the workbench, 1"
firmly grip the router, and climb-cut, Designer Jeff Mertz shows Va" grooves V,S" deep
removing 1;4" of the W'-deep lip. Switch the features of the cabinet
to a YZ" rabbet bit (or switch pilot bear- in a FREE video at:
ings of a rabbet set with interchangeable woodmagazine.com/videos
bearings), and complete the job [Photo 2"
C]. Square the corners with a chisel.
I!IBASE SECTION VIEW
4 If you are building the display
cabinet, layout shelf-support hole
centers [Drawing 1c]. Chuck a W' brad-
o/a" round-
over with a
V's" shoulder
point bit into your drill press, position
the fence to align the bit with the hole
centers, and drill the holes. (Support the
#8 X 0/4" F.H. wood screw
side with a work stand where it hangs ____ r-- 291J, " )
4~
over the table edge.) ___ -------------.--------------------------- __--
140/4"
ElEXPLODED VIEW GUN CABINET
~-30~;-----------------~-::
o/a" inset
~ self-closing
hinge -- ------,)
#8 X 0/4" F.H.
/"
#20 biscuit A
wood screw
74"
woodmagazlne.com 33
• •• •
Clamp one stile (I) in place, position the over- Glue and biscuit the rails (J) to the second
• ••
Starting and ending with the 3fs" cove bit
length rail (J) against it, hold the second stile stile (I). Then glue and biscuit these parts to pilot bearing against a stopblock, rout
(I) in place, and mark the length of the rail. the first stile (I) and the side stile (A). stopped coves along the edge of each stile (I).
5 Cut the glass stop blanks (E) to size.

Crosscut four blanks to length for
the side stops [Drawing 1], and cut the
sand the side assemblies. To ensure a
tight fit between the front stiles (A) and
face frame stiles (I), do not sand the
2 Cut the face frame stiles (I) to size,
and the rails (J) I" longer than listed.
Dry-assemble and mark the finished
top and bottom stops from another one. front stile edges. length of the rails [Photo H], and cut •
Clip the head off a #17xl" brad, and use
it to drill brad holes through the stops.
Finish-sand the stops.
8 Transfer the biscuit centerlines on
the guide to the bottom, shelf, and
top assemblies. Adjust the biscuit-joiner
them to length.
3 Plunge biscuit slots into the front

edges of the Side-assembly front
6 Cut the top, shelf, and bottom pan-

els (H) to size, and finish-sand them.
Dry-fit, and then glue and clamp the
fence to center a slot on the %" thickness
of the stiles (F) and rails (G), and plunge
the slots [Drawing 2]. Finish-sand the
stiles (A) [Drawing 1], and mating slots
into the rear faces of the face-frame stiles
(I) [Drawing 3]. Then, plunge biscuit
assemblies (F/G/H) [Drawing 2]. Check stile and rail faces. To ensure tight joints slots into the inside edges of the face-
each for square. where these parts mate with others, do frame stiles and mating slots into the
7 Make a %" plywood guide [Drawing

1a] to position the biscuit joiner
when plunging the biscuit slots into the
not sand the edges.
Construct the case

ends of the face-frame rails (J).
4 GIUe, biscuit, and clamp one face-

frame stile (I) to the front stile (A) of
side assemblies and to transfer the bis-
cuit centerlines to the bottom, shelf, and
top assemblies. Plunge slots for the bot-
1 Glue, biscuit, and clamp the bottom
and shelf assemblies to one side
assembly [Photo E], and let the glue dry.
one side assembly. Then, add the rails (J)
and the second face-frame stile [Photo I],
and clamp them in place.
tom and shelf assemblies [Drawing 1,
Photo D]. Now, reposition the guide 2%"
from the top ends of the stiles (A), and
Then, glue, biscuit, and clamp the top
assembly in place [Photo F], and let the
glue dry. Now, add the second side
5 TO rout stopped coves along the
outer edges of the face frame stiles (I)
[Drawing 4], first cut four 4W'-long stop-
plunge slots for the top assembly. Finish- assembly [Photo G]. blocks. Clamp a block to the top and
bottom end of each stile (A), and rout
the coves [Photo J]. To avoid burning
111 EXPLODED VIEW and· chip-out, rout each cove in two
DISPLAY CABINET
passes. Finish-sand the face frame.
6 Cut the lower back (K) and upper

back (L) to size [Drawing 4], and
finish-sand them.
Make the base and crown

1 Cut the base blank (M) to size. Rout
a shouldered %" round-over along
the outer top edge [Drawing 4a].
Cushioned IDCROWN SIDE SECTION DETAIL

shelf
support r----- 15/8"--------j
t
i' 2"
J
34
with the base parts, miter, mark, and cut
the parts to length. Glue and clamp the
crown to the case [Drawing 4].
Assemble the door

1 Retrieve the door parts Q, R, S, and
T. Using a fairing stick, draw the top-
rail (T) arch. (For a free fairing stick
plan, go to woodmagazine.com/fairing.)
Bandsaw and sand the arch.
Align the heel of the mitered end of the base
front with the face-frame stile (I) corner. Mark
the miter heel at the other end.
Clamp the base front in place, position a base
side, and tape the miter together. Mark the
side length flush with the rear stile (A).
2 Cut the panel (U) to size, and finish-
sand it. Dry-assemble the door to
check the fit of the parts [Drawing 6].
Then, glue and clamp the door, check-
ing for square.
3 To support the long groove lips at

the base of the top-rail (T) arch and
reinforce the joints between the top rail
and the stiles (Q), cut the splines (V)
from W' plywood [Drawing 6]. Glue the
splines in place [Photo 0].
4 ChUCk a W' round-over bit into a

handheld router, and rout a shoul-
dered round-over along the outer front
door edges [Drawings 6 and 6b]. Switch
to a %" rabbet bit, and rout the outer rear
door edges [Drawings 6 and 6c].
Working on a flat surface, glue and clamp the With the crown base blank (N) and crown cap
crown base blank (N) to the crown cap blank blank (0) glue-up dry, glue and clamp the
(0), keeping the ends and rear edges flush. crown bevel blank (P) in place. v." round-over with a
V16" shoulder
on outside face
routed after assembly
2 TO make the base wood grain wrap

continuously around the case, cut
the piece for the base front from the
BOOOR
(Inside face shown)
center of the blank. Make it as long as 2" corner of

the case width plus 2". Miter one end of glass removed
Leave the
the base front and the end of each of the V8 x 220/4 X SOVe" glass 0/8" radius
......···········0/8" rabbet at top.
short pieces (the base sides) that mate
0/8" deep
with the base-front. Next, mark the heel routed after 32%"
of the second base front miter [Photo K], 5/8" radius ~ assembly 1%" brass
and cut the miter. Now, mark the length ( knob
of the base sides [Photo L], and cut them #17 x 1" brad V4" grooves
to length.
Layout the base-front cutout [Draw- .. J 1/2" deep,
centered .
::'-r~i:~:"
~.
3 ing 4] and bandsaw and sand it to

shape. Finish-sand the base front and
3116" hole '\
Cam lock
sides. Glue and clamp them to the case. Q

E 1/2" rabbet
4 Gut the crown-base blank (N),
crown-cap blank (0), and crown-
bevel blank (P) to size. Rout a 14" cove on
E
V2" deep --......-
routed after
IIIII"''-----l-~ assembly Q
64V2"
the base blank and a %" cove on the cap

blank [Drawing 4b]. Cut a lAl"-deep
groove in the front face of the bevel
blank, and bevel-rip the bottom edge.
Cut Y16"-deep glue-relief grooves in
blanks Nand P. Now, finish-sand each
blank, and glue and clamp them together
\ 1/2"
[Drawing 5, Photos M and N].
5 From the center of the blank, cut a

piece for the crown front to a length
equal to the case width plus 4". Then, as
~%' C
Self-adhesive
bumper
woodmagazine.com 35
m DOOR TENON DETAILS
(Viewed from back)
•• ••
Using a thin splint or small brush, spread
• 1Il'!Ali1iI~1:;
Sand a radius on the top end of each door
glue in the spline area in the stile (Q) and top- side stop (E) to match the radius at the top
rail (T) grooves. Then, insert the spline (V). ends of the door rabbet.
3/8 " rabbet 3/8 " deep

Build two slide-out trays lYz" hole centers [Drawing 10], chuck a
routed after assembly
mlROUTING THE DOOR

1 From %" stock, cut the fronts and
backs (W) to size and from Yz" stock,
cut the sides (X) to size. (We used pop-
Forstner bit into your drill press, and
drill the holes. Cut the part to finished
length, trimming both ends. To convert
==----------, lar.) Then, to form the joints [Drawings 7 the row of holes to notches, draw two %"
and 7a], follow the three steps of Draw- radii tangent to each hole and the front
ing 8. Cut grooves for the bottoms (Y). edge of the part, and bandsaw and sand
I
I
2 Cut the bottoms (Y) to size. Dry-
assemble the trays to check the fit of
the parts. Disassemble the trays, and
the notches to shape. Drum-sand the
notches smooth, and then rout a W'
round-over along the top and bottom
finish-sand the bottoms and the inside edges. Finish-sand the barrel support.
faces of the fronts and backs (W) and
.ROUTING THE DOOR sides (X). Glue and clamp the trays, Finish the case, add glass
,....---,r------,
checking them for square. With the glue Inspect all parts and assemblies, and
dry, finish-sand the outside faces. 1 finish-sand where needed. Apply a
clear finish. (We made an oil/varnish
3 Cut the slide supports (Z) to size.
Glue and clamp supports to the side-
assembly stiles (A) and the face-frame
blend, and applied three coats. To learn
about this finish, see page 28.)
stiles (I) at the front of the cabinet [Draw-
ing 9]. Position each slide support at the
back of the cabinet to fall behind the
2 Have glass cut to size for the sides
and door [Drawings 1 and 6]. If you
are building the display cabinet, also
5 TO accept the glass and glass stop (E),

rout away the inner lip of only the
door stiles (Q) and middle rail (S) [Draw-
back mounting hole in the slide. Glue
and clamp the supports to the side-
assembly stiles.
have glass shelves and a mirror cut to
size [Drawing 4c]. (We had the glass
dealer finish our shelves with polished
ing 6], using the same method as for the pencil edges and remove the sharp edges
side assemblies. Start and stop routing Make the gun-rack parts from the mirror.)
where the top rail (T) meets the stiles Note: If you are building the display cabi- Lay the case on one side on a padded
(Q). Square only the bottom corners of
the rabbet with a chisel. Cut the glass
net, skip to the next section, "Finish the
case, add glass."
3 surface, position the glass, and nail
the stops in place [Photo Q]. Turn the
stops to length, and sand the top end of
each side stop to match the ends of the
rabbet [Photo P]. Drill brad holes in the
l Edge-glue W stock for the base (AA) ,
and cut the part to size. Layout 2"
hole centers [Drawing 10]. Chuck a Forst-
case onto the other side, and repeat.
4 Lay the door facedown on the pad.

Position the glass in the rabbeted
stops, and finish-sand them. ner bit into your drill press, and drill the opening, sliding the end with the
6 ChUCk a ¥Ji' brad-point bit into your

drill press, and drill a knob hole
[Drawing 6]. Switch to a %" Forstner bit,
holes. Connect the hole edges with tan-
gent lines, and cut along them with a
jigsaw. Drum-sand the edges of th.e cut-
clipped corners into the top-rail (T)
groove. Fasten the stops (E) with brads.
and drill a hole for the cam lock. (You outs smooth. Chuck a W' round-over bit Assemble the cabinet
can omit the cam lock if you are build-
ing the display case.) With the case lying
faceup, position the hinges on the face-
into a handheld router and rout the top
edge of each cutout. Switch to a %" cove
bit, and rout the front edge of the part.
1 For the gun cabinet, clamp the base
(AA) in place. From the bottom, drill
screw holes through the shelf rails (G)
frame stile (I) [Drawing 4], drill pilot Now, install a dado blade in your table- into the base, and drive the screws
holes, and screw them in place. Position saw, adjust the cut depth to match the [Drawing 4]. (For the #8 screws in this
the door on the case, and clamp it in shelf panel (H) recess, and cut rabbets project, drill %z" shank holes and ~4"
place. Reaching inside the case, drill along the ends and back edge. Finish- pilot holes.)
pilot holes into the door stile (Q).
Remove the door and hinges from the
case. Finish-sand the door.
sand the base.
2 Cut a %x3x31Yz" piece of stock for

the barrel support (BB). Layout the
2 separate the parts of the drawer
slides. Fasten the case members to
the slide supports (Z) [Drawing 9], and

IZITRAY-JOINT DETAIL
14" drawer slide

centered on side
DMACHINING THE TRAY PARTS

the drawer mem- .------------,--~--~
STEP 1 STEP 2 STEP 3
bers to the trays Auxiliary
Auxiliary
Auxiliary wood
[Drawing 7]. Slide wood fence wood
fence
the trays in. fence----...
Outside
3 Clamp the
lower back (K)
and upper back (L)
face
t
to the case. Drill
screw holes and, for
the gun cabinet,
drive the screws.
For the display
cabinet, drill the
holes, then mark
the top edge of the shelf rear stile (F) on
the inside surface of the upper back.
Screw the lower back in place. Remove
each spacer on the base (AA). Apply
double-faced tape to the back edge of 7
TO complete the display cabinet,
install cushioned shelf supports in
the barrel support, position it on the the holes in the sides [Drawing4c]. Then,
the upper back and lay it on a flat surface tops of the spacers, and adhere it to the install the shelves. •
with the inside surface up. Adhere the upper back (L). Drill screw holes continued on page 38
mirror to the upper back with mirror through the back and into the
adhesive. Center the mirror side-to-side support [Drawing 4]. Drive the IiJDRAWER SLIDE INSTALLATION
and align its bottom edge with the screws.
marked line. After the adhesive cures,
screw the upper back to the case. 5 TO add interior lights, drill %"
. holes through the top panel
4 TO install the gun-cabinet barrel

support (BB), first cut a pair of 3514"-
long spacers. Then, place one end of
(H) [Drawing 11], and screw the
lights in place. Connect the
lights and dimmer, following the
included instructions. Remove
the protective paper from the
double-faced tape on the back of
the dimmer, and adhere it to the
back face of the upper back (L)
near the edge. (When placing
the cabinet, leave just enough
room for your fingers between
the cabinet and the wall.)
6 Fasten the hinges to the case

and hang the door. Stick a
self-adhesive bumper (included
with the hinges) to the lip of the
•
Cover the glass with cardboard and drive
door rabbet opposite each hinge
[Drawing 6]. Install the knob and
a brad into the glass stop (E) pilot hole b~ cam lock. (The lock is optional
sliding the hammer on the cardboard. for the display cabinet.)
woodmagazine.com 37
Cutting Diagram Materials List
FINISHED SIZE
Sides T W l MatI. Qty.
A stiles %" 2V4" 74" W 4
B rails %" 3" l1W' W 4
C middle rails 3/4 " 3" 11'14" w 2
D panels V4" 11'/4" 10" WP 2
3/4
F F ~Fiiii:]
x 71/4' x 96" Walnut (5.3 bd. ft.) *Plane or resaw to
E glass stop blanks 3/atr V2" 60" W 8
the thicknesses listed in the Materials List.

Bottom, shelf, and top
S F stiles %" 2W' 28lf2" W 6
Q
G rails %" 2V4" 11" W 6
0/4 X 7V4" x 96" Walnut (5.3 bd. ft.)
H panels W' 11" 25" WP 3
-t!'--" Face frame
088
0/4 X 7V4" x 96" Walnut (5.3 bd. ft.) stiles W 2
,-w J* rails %" 3" 26" W' 2
%
o x 7%" x 96" Walnut (5.3 bd. ft.)
Backs
BB ~~~~~~~~,.,...,.,==-..., K lower back W' 29W' 123fs" WP
M ---- '/4 x 48 x 48" l upper back W' 29W' 563fs" WP
3f4 x 71/4" x 96" Walnut (5.3 bd. ft.) '----- Baltic birch plywood Base and crown
AA
M base blank 3/4" 3'12" 72" W
% x 5W' x 60" Walnut (2.5 bd. ft.)
f--::--- -. --' N crown base blank lf2" 2" 72" W
§VX I @J:
% x 5W' x 96" Poplar (4 bd. ft.)
l{xH~k FE ~._. 0 cap blank 3/4" 1%" 72" W
~-- P* bevel blank V2" 1V4" 72" W

Project design: Jeff Mertz ~
1-. " - "
Door
Illustrations: Roxanne LeMoine; Lorna Johnson
Q stiles %" 2V4" 64V2" W 2
11
R bottom rail 3/4 3" 221fs" W
ImGUN RACK S middle rail %" 3" 221fs" W
T top rail 3/4" 4W' 227/8" W
U panel '/4" 221fa" 7V4" WP
V splines 114" 2" 2" WP 2
Trays
W fronts and backs 3/4" 2" 25" P 4
X sides '/2" 2" 14" P 4
Y bottoms V4" 13V2" 24W' BP 2
Z slide supports %" 1'/4" 11V4" P 4
Gun rack
AA base %" lOW' 28lf2" W
BB* barrel support %" 3" 28lf2" W
'Parts initially cut oversize. See the instructions.
Materials key: W-walnut, WP-walnut plywood,
P-poplar, BP-birch plywood.
Supplies: #20 biscuits, #8x%" and #8xl" flathead
wood screws (l" only needed for gun cabinet), lfa"
glass (plus 3fs" glass and lfa" mirror for display case),
#17x1" brads, double-faced tape, mirror adhesive
2V4" rabbets *V4" deep (display case only).
on ends and back
*Depth to match shelf panel recess Blade and bits: Stack dado set; W', 3fs", and lf2" rab-
bet router bits; W' and lfa" cove router bits; W' and
3fa" round-over router bits; 3/16" and W' brad-point
bit; W', 1lf2", and 2" Forstner bits.
Source
Hardware: '/a" inset self-closing burnished brass
mLiGHTS hinges with self-adhesive bumpers no. A07565
BB, $1.61 pro (2 pr.); lv." weathered brass knob no.
A27030 R2, $3.51; 14" full-extension drawer slide
no. KV8400 B14, $11.45 pro (2 pr.); antique brass
cam lock no. N8055 04G 346, $6.79 (optional for
display cabinet); cushioned shelf supports, bag
of 20, no. G611WPB, $4.60 (display cabinet only);
black three-light kit no. WKSW60lCS, $29.56; touch
di.mmer no. WKA6553CS, $14.61. Woodworker's
~ardware, 800-383-0130, wwhardware.com.

emember sitting in a high school 2 Make an oval top
R geometry class thinking, When
will I ever use this stuff? If you're a
woodworker, the answer is now. Whether
• What you'll need: A %xlV2" scrap 4" Bandsaw about W' from the are, sand to
longer than half the longest dimension the line, and remove the pattern.
of your intended oval, a framing square, Now draw centerlines on the tabletop
you're making an eight-sided tabletop or a hardboard scrap one-quarter the size blank, dividing it into four parts. Lay
rounding off a corner, some basic geom- of the tabletop, and a sheet of paper half the template on the lines to draw a quar-
etry comes in handy. So take a seat, and the length of the tabletop. ter of the oval in each pass, as shown
get out your pencils, a ruler or yardstick, • How to do it: Tape the paper over above. Flip the template upside down as
compass, framing square, and right tri- half the tabletop blank, and draw hori- needed. As with the template, use a
angle. Class is about to begin. zontal and vertical centerlines on the bandsaw or jigsaw to trim about Vs" from
paper. Double-face tape the framing the arc. You can then use a bearing-
square to the paper with the outside guided router bit against the template to
1 Divide any line in half corner of the square at the centerline smooth the curves in quarters. (See
• What you'll need: A compass that intersection and the legs on the lines. this layout technique in action at
can reach more than half the length of Now make the scribing tool-shown in woodmagazine.com/videos.)
the line and a straightedge. Drawing 2. First drill a %2" pencil hole
• How to do it: Set the compass legs into the edge of the %xlV2" scrap 1" from
for just greater than half the length of the end. Divide the oval width and the
the line. With the compass point at the length in half, and drive 1" wire brads
left end of the line, scribe arcs above those two distances from the pencil hole
and below the line, as shown in red on center, leaving about Vs" of the heads
Drawing 1. Repeat for the right end. Lay exposed. Then insert a pencil through
a straightedge at the intersections of the the hole until the point emerges Vs".
arcs, and mark a halfway line, as shown Press both brad heads against the out-
below in green. side edge of the vertical framing square
leg-with one brad at the corner-and
II CONNECT THE INTERSECTING ARCS the pencil on the paper. Press the pencil
against the paper while keeping the
brads against the edges of the f~aming
square as you move the scribing tool, as
shown at right. Stop when the pencil
reaches the horizontal line; then remove
the paper.
Trim the hardboard to create a
90° corner. Cut the paper pattern
9/32' hole BSCRIBING TOOL FOR
~
on the centerlines and on the
Halft=:Ha::,:..
1" wire brads
waste side of the are, then spray-
adhere this template to the hard- --.J - ~- .
1,:7~""':' .-.
board with the pattern corner in
c.
the 90° corner of the hardboard.
dimension (width) dimension I
(length) ----J
40
3 Radius any square corner ElCORNER RADIUS
• What you'll need: A compass large compass to one of the marks (B), and B
enough to span the corner radius. draw an arc, as shown in red. Repeat for
• How to do it: Determine the corner the other mark. Then place the compass
radius you want, and set the legs of a point at this intersection (C), and draw
compass that distance apart. With the a quarter-circle from one edge mark to
compass point at the corner of the work- the other.
piece (A) on Drawing 3, mark arcs (B) on To cut out the corner, bandsaw or jig-
the adjacent edges of the workpiece, as saw to within Va" of the arc. Then sand
shown in blue. Move the point of the down to the line.
4 Draw a 5-point star or pentagon

• What you'll need: A compass large Then divide the circle vertically into Reset the compass again for the dis-
enough to draw a circle for the outer- quarters using a ruler and a right triangle tance between points D and G, and with
most points of the star or pentagon, a to find points D and E. the point of the compass at D, mark two
right triangle, and a ruler or yardstick. Measure and mark the midpoint (F) arcs on the circle for points 2 and 3.
• How to do it: Draw a circle the radius between points B and A [Drawing 4al. With your compass point at point 2,
you want the star or pentagon to be, and Then reset your compass to the distance mark point 4; then use point 4 to mark
divide the circle in half horizontally to between F and D. With the compass point 5 [Drawing 4bl. Now draw lines
find points Band C, using the indenta- point on point F, strike an arc to mark between the points to form a pentgon
tion from the compass as the center (A). point G [Drawing 4bl. (in blue) or star (in red) [Drawing 4cl.
m BEGIN BY DRAWING A CIRCLE m MARK FIVE POINTS mADD LINES TO CREATE A SHAPE
o 0(1) 1
BI-----+A..-------lC
4
E E
5 Draw a hexagon, equilateral 6 Create an octagon from a square

• What you'll need: A straightedge that can reach
triangle, or 6-point star between diagonal corners of the square and a compass that
• What you'll need: A compass and a straightedge. can reach half the length of the diagonals.
• How to do it: Scribe a circle defining the hexagon cor- • How to do it: Draw lines between the diagonal corners
ners. Without changing the compass setting, start at point of a square to find its center, as shown by the blue lines in
(1) on your circle and make arcs defining points 2 and 3, as Drawing 6. Then set your compass point on one corner (A)
shown in blue on and the pencil on
Drawing s. From BMARK HEXAGON POINTS USING the center. With- DARCS MARK OCTAGON CORNERS
THE CIRCLE RADIUS out moving the
point 2, scribe
point" 4. At point compass point, D C
4, scribe point 5. scribe the two
Then from point adjacent edges
5, scribe point 6. (a, a), as shown
Next draw lines by the red arc.
between the Repeat for the
points to form a other three cor-
hexagon (shown ners. Then draw d
in red) or between diagonal lines
every other point between the edge
for an equilateral marks at each
triangle (shown 5 corner to form
in green) or star. an octagon. •
woodmagazlne.com 41
hen you build a jig, you
W expect it to help you do some-

thing more quickly, more
easily, more accurately, more safely, or
exactly the same time after time. These
components and materials will help the
next jig you build meet those challenges.
Unless noted in the caption, you can
buy the parts and materials from all of
the Sources on page 44.
Magnets
The Magswitch, a permanent magnet
you can turn on and off, quickly and
tenaciously fastens a fence, guide, hold-
down, or other jig to a steel or iron tool
table. The device contains two powerful
rare-earth magnets. Twisting a knob
rotates one of them so the poles align to
turn the magnetic' attraction on. Twist
m
The MagJig fits through a hole in a jig base. The
m
Epoxy round rare-earth magnets into
the knob the other way, and the poles knob turns the magnet on or off. Available in blind holes in a jig. Putting them into steel
cancel each other, effectively turning two sizes, about $30 each, Lee Valley, Woodcraft. mounting cups increases magnetic pull.

.. •• •
the magnet off. Several configurations
of the Magswitch are available, includ-
ing the MagJig [Photo A], designed spe-
cifically for attaching shop jigs, as shown
at left.
Small rare-earth magnets [Photo B]
have so much pull that disengaging a jig
attached with them may be difficult.
Putting in fewer or smaller magnets will
alleviate that, but might make the jig
more prone to being pushed sideways.
Use these permanent magnets for light-
duty attachment, such as holding a set-
ting jig or measuring device while you
set up a tool. You can usually buy them Ii
Use 3fs"-deep T-track (right) in thinner material.
in bags for $1 apiece or less.
The track in the center accepts standard hex bolts
and nuts. A4' length of track costs less than $20.
T-track and hold-downs
T-track offers so much versatility, you
should make it your first choice for
adjustable hold-downs and movable jig
parts. Most track accepts T-nuts or
T-bolts, but some track accepts standard
14"-20 hex bolts and nuts [Photo C]. You
can surface-mount the track, set it into a
groove or dado (either Yz" or 0/8" deep x
%" wide), or butt surfaces up against
either side.
An inexpensive (less than $10) hold-
down clamp [Photo 0] anchors a work-
piece to a jig or locks movable jig parts to
a T-slot. Just slip the clamp's bolt into
the track, slide the piece to be held under
Cam-action hold-down clamps thread onto T-bolts Affix a jig to the miter slot in a tool table
it, and tighten down. or hex bolts to make frequent jig attachment or with this miter slot hardware kit. $6 for
Count on a cam-action hold-down movement easy. About $9, Rockier, Woodcraft. two sets, item 26993, Rockier.
clamp [Photo E] to secure a jig or part
that's removed or adjusted frequently.
The clamp's T-bolt engages the track.
Aflip of the cam lever tightens or releases
the pressure for quick adjustment.
An expansion bar [Photo F] secures a
jig, such as a feather board, into a miter
channel. Turning the knob draws the
screw up into the hole, expanding the
bar's width slightly so it grips the sides
of the miter slot.
Toggle clamps
Toggle clamps provide qUick, positive
clamping. Though more complex and
more expensive, they often work in situ-
ations where T-track hold-downs prove
impractical. Install vertical clamps Avertical toggle clamp holds the workpiece firmly The horizontal toggle clamp on this jig
[Photo G] to hold a workpiece against the in place on this sled. The foot adjusts up or down safely and securely holds a small workpiece
surface where the clamp is mounted, to change tension or clamp thinner material. against a notched fence for drilling.
whether vertical, horizontal, or any
angle between. Horizontal clamps
[Photo H] press a workpiece sideways Measuring tapes steel, heavy paper, or plastic, these tapes
against a fence, such as on a drill-press To simplify positioning a workpiece pre- have a PSA (pressure-sensitive adhesive)
jig, or a stop. Some toggle clamps slide cisely on a jig or setting an adjustable backing, and are available in either left-
into T-tracks. The clamps come in sev-4
stop, apply a self-adhesive measuring or right-reading versions with English or
eral sizes and cost $10-$20 each. tape directly to the jig [Photo I]. Made of metric scales. To allow easy centering, as
woodmagazine.com 43
well as accurate measurements in both
directions from a point, such as a drill-
press chuck or mortising bit, apply left-
and right-reading tapes so they meet at
the reference point.
Slippery stuff
Parts slide more freely on a low-friction
surface of ultra-high-molecular-weight
(UHMW) polyethylene. You can buy it
as solid stock or self-adhesive tape, often
called slick strips or slippery tape [Photo
J].When a jig guide slides in a miter-
gauge slot or T-track, make the guide
from UHMW for smooth movement.
For a fence, such as a resawing jig, put a A self-adhesive measuring tape attached to a Slippery UHMW polyethylene comes as solid stock
larger piece or several strips on the face. jig simplifies adjustment and work positioning. in many shapes and sizes or as self-adhesive tape.
Thin UHMW tape is a qUick and less- Tapes read left-to-right or right-to-Ieft. It's ideal for sliding jig bases or fence faces.
expensive way to make a slick-sliding
surface. The tape is ideal for disposable
or limited-use jigs, too. Solid stock gen-
erally costs $5-$25, depending on size;
rolls oftape sell for $8-$20 each.
Sticky stuff
When you need a jig surface that resists
slipping and sliding, high-friction tape
[Photo K] fits the bill. It's similar to the
pads that keep cell phones from sliding
off car dashboards. The tape's adhesive
backing makes it easy to attach to jig
faces. Apply it to the fence of a sliding
cutoff table, for instance, so the work-
piece won't creep. Or, use it to make a
nonskid back on a straightedge guide for
a router or circular saw. High-friction tape adds grip to a surface to Self-adhesive sandpaper on this miter jig
prevent slipping without bonding or clamping. prevents slippage. About $13 for 2W'x30'
.
Another quick way to slip-proof a jig $3.40 for 1x12", item 99K34.01, Lee Valley. roll, various grits, item 68Z72.01, Lee Valley.
surface is to apply strips of self-adhesive
sandpaper [Photo L]. Sold in rolls, the
sandpaper has a PSA (pressure-sensitive
: • • . :
adhesive) backing that sticks to any
smooth, clean surface.
Knobs and handles

A knob lets you tighten or loosen a
clamp or other device without tools and
can serve as a handle, too. Sometimes,
though, you can't find a knob with a
threaded stud just the length you need.
Snap-Lock knobs solve that problem by
snapping onto common W', 0/1.6", or %"
hexhead hardware-store bolts so you
can make a knob with a stud just the
length you need [Photo M]. Snap a stan-
dard hex nut into the knob when you ~
need one with an internal thread. A standard machine bolt or hex nut makes one of Screw a handle similar to a plane tote onto
For positive control, attach a dedicated these knobs a custom fit for your jig. $20 for 10 of a jig to keep your hand from slipping into
jig handle [Photo N]. It's ideal for sleds each size, item K15289, Hartville Tool. danger. About $11, item 30876, Rockier.
and other cutting jigs that need to be
pushed firmly and safely. • Sources
Written by Larry Johnston with A.J. Hamler Hartville Tool, 800-345-2396, hartvilletool.com; Lee Valley, 800-~71-8158, leevalley.com;
Illustration by Michael Burns Rockier, 800-279-4441, rockler.com; Woodcraft, 800-225-1153, woodcraft.com.

Better Homes and Gardens®
PATTERNS.
September 2008 Issue 785
Basic-Built
Solid-Oak Bookcase
Page 60
®
BRACKET SIDE
FULL-SIZE
PATTERN
(2 needed) <iii.' !!IiG3 MJ
~-~---
Safari Puzzle
Page 44 Issue 184
Dear Reader: As a service
to you, we've included full-
Join patterns size patterns on this insert
here. for irregular shaped and
intricate project parts. You
can machine all other proj-
ect parts using the Materials
3"
List and the drawings
accompanying the project
you're building.
Centerline
© Copyright Meredith Corporation, 2008. All
rights reserved. Printed in the U.S.A.
Meredith Corp., the publisher of WOOD
Patterns®, allows the purchaser of this pat-
tern insert to photocopy these patterns solely
for personal use. Any other reproduction of
these patterns is strictly prohibited.
45
r==.
.J>.
0\
I ~------------------------- ----------------------
,,
,,
,,
,,, -cc:JV)
,,, Q) 0 0
~O=
i Location of part @ (1)~c..
y, O\Qo
,, O"'Q)
(1)~
,,
,,
,,
,
i L Location of part ©
------------~------------------ ----------------------------------------------------------------1,
,, 5"
,,
---I 1
,,, ''
'
,, ''
~-----------------------------------------------------------------------T-,-------------l---~
I 1 1 1
I 1 1 1
I 1 1 1
1 1 1 1
1 c:_) (t=---+'): : _:
: -J-----t..-:: I
!---------------- ----------- - 0 / , ' ; ) --\ ------- __ J i

I Location of part 0
eLocation of part ® @
BOLSTER
FULL-SIZE TOP
PATTERN
(2 needed)
®
SIDE
FULL-SIZE
PATTERN #1
(2 needed)
Safari Puzzle
Page 44 Issue 184
.. ..
Note: Grain direction
47
~------~------~------------------------------~
t------+----+-----~ - - - - - - - - - - - - <..
-,
L{)
Solid-Oak
Bookcase
Page 60
t--t---.--------------------11VS"---------------;
~~----------------~----------------------------------------------
@
CREST RAIL
FULL-SIZE HALF PATTERN
(2 needed)
48
• Overall dimensions: 26W' wide x 21" deep x 35W' high (on casters).
• Raising the fold-away top creates a 58W' wide x 21" deep worksurface.
• Build it from two sheets of %" Baltic birch plywood
and a quarter-sheet of ~6" perforated hardboard.
• Two-way locking swivel casters hold the cart in
position when used as a tool or assembly stand.
Skill Builders
• Learn how a guide called a story stick
helps you repeat layout marks. See a Slide Show of this
• Make sturdy utility drawers using project coming together at:
drawer sides with built-in slides.
woodmagazine.com/slides
woodmagazlne.com 49
•
Mark drawer-slide centerlines on both case
• • •
Center the slide mounting holes on the line,
•
Joining the sides (A), top, and bottom (8) on
sides (A). The story stick lets you duplicate with the front end of the slide flush with the a flat surface helps prevent racking. Measure
those lines on the other case side. edge of the side (A). between diagonal corners to ensure square.
I
f you've put off making drawer-based
shop storage because you doubt your
case side, and transfer the story stick
lines to the other side part. 6 0n the underside of the top (B), drill
countersunk mounting holes [Draw-
drawer-making skills, then relax. The
combination slides/drawer sides used for
this cart eliminate that obstacle.
4 sort the case-mounted parts of the
drawer side slides into left and right
sides. (Wheels on the case-mounted
ing 2] to later attach the fixed top (E).
(For all #8 screws, drill countersunk %2"
shank holes and 1'64" pilot holes.)
Begin by building the case

slide should be closest to the bottom.)
Center a case-mounted slide on one of 7 Drill countersunk shank holes into
the top and bottom (B) and pilot
1 Cut the sides (A) and the top and bot-

tom (B) to size [Materials List, page 53].
the case side (A) layout lines [Photo B],
and punch screw-starting holes with an
holes in the sides (A) [Drawing 1]. Dry-
assemble the sides to the top and bot-
2 Cut a 0/16" groove Va" deep on the

inside face of each side [Drawing 1].
awl. Repeat for the remaining slides on
both case sides.
tom, and measure between the bottoms
of the grooves on the sides.
3 Tape a %x2x30" story stick to the

front edge of a side (A), keeping one
end of the stick flush with the bottom
5 wrap tape around a 0/32" bit, with the
tape edge ¥g" from the bit tip for a
visual depth stop. At each awl mark on
8 Cut the back (C) to length and the
measured Width. Then disassemble
the case.
end of the side [Photo A]. Use a square to
draw centerlines where shown [Drawing
1] on the side and the story stick. Remove
the sides (A), drill a %2" pilot hole ¥gIl
deep, and mount the slides. Screw the
slides to the sides.
9 GIUe and screw the sides (A) to the
bottom (B). Insert, but don't glue,
the back (C) and glue and screw the top
the story stick, retape it on the other to the sides [Photo C].
Make and mount the tops

DeASE PARTS VIEW 1 Cut the folding top (D), fixed top
(E), stiles (F), rails (G,H), and leg rail
(I) to size.
'Dry-assemble to verify width. ---"
~163/4"~ - I 2 GIUe, clamp, and screw the rails and
stiles flush to the edges of the fixed
and folding tops [Drawing 2, Photo 0].
Sand the stile and rail edges of both
3
3/, 6" groove 3/a" deep
) f
280/a"
tops (D, E). Rout a Va" round-over
along the top and bottom edges of both
tops [Drawing 2].
280/a"
•• •
Glue and screw a stile (F) and rail (G) to the
folding top (D). Then attach the leg rail (I),
followed by the other stile and rail.
50
• ••
Clamp the tops together while attaching the
• •
Allow a 114" gap between the stiles and rails of
•
Mount the locking swivel casters beneath the
hinge to ensure a gap-free surface when the the fixed top and the case top before driving drawer opening end of the case to make the
folding top is raised. the mounting screws. locking lever easy to reach.
4 Clamp the tops upside down and

end to end on a flat surface [Photo E]
with the leg rail (I) away from the butted
5 Center the case (A/B) between the
stiles and rails on the upside-down
fixed top (E). Fasten it in place [Photo F]
bottom (B), then mark and drill pilot
holes %" deep [Drawing 2]. Mount the
caster [Photo G]. Repeat for the other
edges. Center a 12" continuous hinge on using four mounting holes in the top (B). front swivel caster. Now mark, drill, and
the joint, and drill pilot holes to suit the
screws supplied. Then fasten it in place. 6 Place a locking swivel caster flush
with the front and side edges of the
mount the rear fixed casters.
Add a folding leg

1 Using a bandsaw or jigsaw, cut the
leg top m and bottom (K) to shape
[Drawing 3]. Both are
identical except for the
arch on the leg bottom.
Trace the curve on the
leg bottom using a fair-
ing stick. (For a free
fairing stick plan, go to
woodmagazine.com/
fairing.) Layout the leg
shapes on both sides so
you can flip the parts
over on your bandsaw.
~
12" continuous
hinges 2 Mark the locations
of the slots in the
leg top m and counter-
2" eye screw .
bores/holes in the leg
bottom (K) [Drawing 3].
Brace the leg bottom
against a 14"-long fence
0/.' counterbore
0/8" deep with a on your drill press, and
17/64" hole use a %" Forstner bit to
centered inside drill a ¥a"-deep counter-
bore. Rotate the leg and
drill a second counter-
1/4"-20 bore [Photo H]. Without
four-arm
knob moving the drill press
fence or table, replace
the Forstner bit with a
17/64" brad-point bit and
( .
1/4"-20 hexhead bolt
11/2'long
drill a hole centered in
each counterbore.
2" eye screw
4" fixed caster i "

~: ::
1/4" flat washer ~~

#14 X0/4" ~\I,
panhead screw--------"""'l ~!
! 4" locking swivel caster
woodmagazlne.com 51
•
The fence remains in the same position for
• • • •• •
Drill 17/64" holes %" apart, then drill away the First attach one leafto the leg rail (I).-Attach
drilling counterbores and holes in the leg waste between the holes to form slots in the the other leaf to the leg top (J) second to
bottom (K) and slots in the leg top (J). leg top (J). allow clearance for a drill/driver chuck.
3 Without moving the fence, drill

holes at each end of a leg top (J) slot
layout line. Then drill overlapping holes A story board ensures
[Photo I] until you form a slot with happy layout ending
smooth sides. Rotate the leg and repeat Save time, increase accuracy, and
to create the second slot. avoid repetitive measurements by
4 Insert W' washers into the leg bot-

tom (K) counterbores. Epoxy Y4x1Yz"
hexhead bolts with the heads inside the
creating a story board to layout
drawer-front bracket mounting
locations. From %" medium-density
counterbores, keeping epoxy off exposed fiberboard (MDF) or plywood, cut a
threads. Let cure and sand flush. story board to the drawer-back (L)
length and drawer-front (N) width.
5 With the case and folding top upside
down on your bench, clamp the leg
top (J) against the leg rail (I). Center a
Label one edge as the bottom, and
mark the drawer-front bracket
mounting screw locations [Drawing 4].
12" continuous hinge on the leg and Center the story board on the inside of
mark the mounting screw centerpoints the drawer front. Mark top-to-bottom
on the leg top and rail [Photo J]. Drill lines on the drawer front along both
pilot holes to suit the screws provided, ends of the story board, and then
and mount the hinge. transfer story-board screw locations to
the drawer front, as shown at right.
6 Extend the leg-bottom (K) bolts
through the leg-top (J) slots, and
secure with washers and four-arm
knobs.
II DRAWER
B FOLDING LEG * 1 V4" less than the width of opening

Location of 12" continuous ** See instructions.
hinge, centered
r------16' j *314" *Thickness
~~Rfu:/ of plywood
314" counterbore
3/s" deep with a
17/64" hole
centered inside
23"
®i\\!~"1"
Ii ... #8 x V2"
1"
111\ (
J I
1r panhead
screws
~2"k
---16" ·1

Mark center
of slot.
• I I I"' "• • I •• 1IoIAI1:01_a.:

Center bracket mounting screws in the slots The drawer-front bracket can be loosened to Drill and insert the hook eye. Then position
to horizontally adjust the drawer front. fine-tune the drawer-front position. the second eye to hold the leg in place.
Build drawers the fast way Finish up and get rolling bottom (K) [Drawing 2]. One latch holds
1 Measure the distance between the

sides (A). If that dimension equals 1
Remove all hardware and disassem-
ble the drawers. Then remove the
16", cut the drawer backs (L) and drawer fixed top from the case. Sand all parts to
the leg in its folded position [Photo M]
while the folding top is stowed. The
latch on the folding-top stile (F) and leg
bottoms (M) to the sizes in the Materials 180 grit, remove' the dust, and apply bottom keep the leg from accidentally
List. If not, subtract 1W' from that three coats of finish. (We used Minwax swinging sideways when lowered. Now
dimension and substitute that for the Polycrylic satin finish, sanding to 220 you're ready to fill the drawers with your
drawer-back length and bottom width. grit between coats.) tools or supplies, and go to work. •
2 Drill and countersink shank holes in

the drawer bottoms (M) and pilot 2
After the finish dries, remount the
top to the case, and reattach all
holes in the backs (L) [Drawing 4]. Glue hardware. Reassemble and insert the
Written by Bob Wilson with Chuck Hedlund
Project design: Conrad Kuharlc and Kevin Boyle
and screw the backs to the bottoms. drawers, and adjust the spacing between
3 Cut the drawer fronts (N) to size. the drawers using the drawer-front
Drill holes for the handle screws. brackets [Photo L]. Use nickel spacers to
Materials List
FINISHED SIZE
W
4 use the story board Shop Tip on provide a Y16" gap between drawers. Case T L MatI. Qty.
page 52 to layout the drawer-front (There's a Yz" gap between the top drawer A sides %" 22V4" 28%" BP 2
bracket mounting locations. Align a and the case.) Then number the outside B top/bottom %" 23" 17W' BP 2
bracket on the drawer front (N) with the drawer backs 1-5 from top to bottom to C back 3/16" 16%"* 28%" PH 1
slots over the mounting location lines. preserve these spacings after removing Tops
Mark the centers of the mounting slots the drawers. 0 folding top %" 21" 32" BP
[Photo K]. Drill pilot holes, and mount
the brackets. Repeat for the remaining
four drawers.
3
Attach 2" hook-and-eye latches to
the folding top, leg top 0), and leg
E fixed top
F stiles
%"
%"
21"
1'12"
26W'
21"
BP
BP 4
G folding top rails %" 1V2" 29" BP 2
5 Refer to the metal

side slide instruc-
tions to assemble the
Cutting Diagram
f(F F G H
H
I
fixed top rails
leg rail
%"
%"
1V2"
3"
23W'
18"
BP
BP
2
J leg top %" 16" 23" BP

drawers. ~~-
-®-~:_--' -~:. JE)

~ I(@ K leg bottom %" 16" 23" BP
------- ..
_.---::::.>
~ @L)
-0
~-
Drawers
L drawer backs
N drawer fronts
3/4"
M drawer bottoms %" 14%" 17%"

%" SV2" 17W'
4" 14%" BP
BP
BP
5
5
5
--® - ~-~_ .. - f - - c-@-
@ 'May vary due to plywood thickness. See the instructions.
-- ---.- --------.,
~--_.-
-- .. - I-f-,--
------ Materials key: BP-Baltic birch plywood,
"
PH-perforated hardboard.
0/'4 x 48 x 96 " Birch plywood Supplies: W -20x1 W' hexhead bolts (2); #8xW'
and #14x%" panhead screws; '14" flat washers; #6xSJa",
#8x1V4", #8xlW', and #8x2" flathead wood screws; 12"
--...., continuous hinges (2); 2" hook-and-eye latches (2); five-
R~===I----~-_:...-=----------I minute epoxy.
Bits: 3/16" straight bit, W' round-over bit, %" Forstner bit,
171M" brad-point bit.
0/16 x 24 x 48"
Source
Perforated t,Q).r.~',_-
....-..,-..~...J=T:1.11/;;;.~=--=
__:':__=.~-::.. =F~_:::::'_:"'~~~-::==--_".....-/ Hardware: Metal side slides no. 12K38.4s, $8.70 pair
(5); 4" metal handles in oil-rubbed bronze finish, no.
hardboard
02W26.26, $3.95 each (5); W'-20four-arm knobs no.
~~-~ ,..c-:=.. .-_ 00M55.40, $1.90 each (2); 4" caster set no. 00K20.10
includes two locking-swivel and two fixed casters, $45;
= -' 0/'4 X 48 x 96" Birch plywood from Lee Valley, 800-871-8158 or leevalley.com.
woodmagazlne.com 53
f you're looking to bUy
I first bandsaw or-simplyupgra,de

from a benchtop model, con-
sider a low-cost 14" bandsaw for
your shop. Read on to learn which
machines performed best.
It's no monster truck,

but you do need power
After setting up and fine-tuning
the machines, we outfitted each
saw with a brand-new lh"-wide,
3-teeth-per-inch (tpi) Carter Accu-
Right blade, tensioning the blade
by hand. (Rather than relying on
the saw's scale, we adjusted the
tension until, with the blade
guides at full height, we could
push the blade sideways ~".) To
break the saw in, we first ripped
and crosscut 4/4 and 8/4 red oak
Watch FREE bandsaw videos at various feed rates, and all mod-
and get more bandsaw tips els handled the tasks with no
and techniques at: difficulty, although the Ridgid
woodmagazine.com/bandsaw.
Add a riser block to a cast-iron (-frame
This chart compares the average cutting speed of each tested bandsaw while resawing 6" red bandsaw and gain 6" of resaw capacity. You'lf
oak fed by hand as fast as the saws could handle, using identical 3-tpi 112" blades. also need longer blades when you do this.
BS1400 vibrated significantly. Installing resawed JA"-thick panels from 6"-wide Next, we installed riser blocks, shown
a Power Twist link belt reduced that oak-hand-feeding the wood as fast as above, on the Shop Fox and both Grizzly
shaking somewhat, but it still vibrated each saw could cut it. Here we saw saws-performers at three levels in our
more than the others. And vibration important differences. (See the chart resawing-power test-adding 6" to their
makes precision cutting difficult. above.) The Shop Fox W1706 blazed resaw capacities. We found all three
Because bandsaws excel at resawing- through the oak, averaging 60" per min- could power through 12"-wide oak
standing a board on edge and cutting ute, thanks to its muscular 1-hp-rated boards at slower feed rates. You can also
off thin slabs-many of you employ motor and cast-iron wheels that transfer add optional riser blocks to the Jet,
them to get more use from prized fig- torque to the cut. Ridgid, and Steelex saws, but not to the
ured or exotic stock. Most of these saws After that you can pretty much ignore steel-frame Craftsman and Rikon.
can fit boards up to 6" wide between the horsepower ratings as a measure of abso-
upper blade gUides and table (except the lute cutting power. The %-hp-rated All impressed us,
Craftsman 22401, which maxes out at Grizzly G0580, Ridgid, and Steelex The Verdict: but one strike
just over 8"), a real challenge in hard, ST1000 outpowered several saws with against the Ridgid BS1400 for excessive
dense wood. So for our next test we 1-hp-rated motors. vibration.
Don't let blade deflection eat up your workpiece

Blade guides above and below the table
keep the blade from twisting and deflect-
ing side-to-side during cuts. A blade that
deflects does not cut perpendicular to
the table, so your workpiece might wind
up thicker at the top than at the bottom,
or vice versa. As you can see at right, the
Grizzly G0580, Shop Fox, and Steelex
saws showed the most blade deflection.
We tried various feed rates, blade ten-
sions, and guide settings, but the results
proved consistent. These resawn pieces
would still need planing to achieve a
consistent thickness, and removing
nearly W' of material to get there defeats
the purpose of resawing (to save stock).
The Grizzly G0555, Rikon 10-320, and
Ridgid demonstrated the least deflection *Difference in workpiece thickness from top to bottom resawing 6"-wide red oak.
Average of three tests using identical 3 tpi '12" bandsaw blades.
(about Y.lz"), even when we pushed the
wood hard. In 6" oak, the Craftsman
saw performed nearly as well, but at its
8¥J.6" capacity it deflected as much as the sawing through stock less than 2" thick. Excessive blade
Grizzly G0580. Adding riser blocks to the saws that The Verdict: deflection puts
With all the bandsaws, howeve., we . accept them didn't affect blade deflec- the Grizzly G0580, Shop Fox, and Steelex
found no significant deflection when tion: It was similar to the 6" resaw test. on probation.
woodmagazlne.com 55
There's no cutting corners with curve-cutting
To test each saw's ability to cut inside
and outside curves, we installed new
lfl"-wide, 6-tpi Carter blades, and cut out
a block "S" with each saw. TheJetJWBS-
140S and Shop Fox followed the lines so
well, it felt as if they were on autopilot.
Ridgid's vibration made it difficult to
follow the lines, leaving ragged edges.
Next, we cut out 1lfl"-diameter holes,
and each bandsaw performed well. But
when we pushed the machines to cut a
tighter radius, the Grizzly GOSSS, Jet, .
..
..............
Bandsaws excel at cutting curved workpieces, such as circles and the block letter "5" at left in
and Shop Fox excelled; Craftsman and
the photo. Equipped with a 114" blade, most of the machines easily sawed radii smaller than W'.
Ridgid struggled.
We switched to a Yz" blade for larger
circles. All saws handled a S"-diameter Ridgid strikes out model in late 2008, but we could not get
cut, but a 4" one proved too tight for the
The Verdict: because its vibra- one in time for this test.) We also elimi-
Ridgid and Steelex without backing up tion makes it difficult to use accurately. nated Steelex from contention. The
and starting again. (Ridgid will replace this saw with a new Craftsman saw gets a warning.
Frequent adjustments should be easy to make

• Upper and lower blade guides, so the blade rubs against its edge. In our easier to fine-tune among saws with
whether ball bearings or steel blocks, testing, we could find no distinct advan- bearing gUides. By contrast, to move the
keep the blade from twisting during a tage to any of these types of guides other lower gUide blocks forward or backward
cut. The thrust bearings keep the blade than with speed of blade changes. Guide on the Grizzly GOS80 and Jet, you must
from deflecting backward as you feed blocks that tighten with thumbscrews remove the table to access the bolts.
stock. On most saws, the blade rubs prove quicker to set than gUides with • Quick-release blade tensioners
against the face (or side) of the thrust setscrews that require a hex wrench. found on the Grizzly GOSSS and Shop
bearings, as shown below, but Craftsman • Microadjusters on the Craftsman, Fox, shown opposite top, speed blade
and Rikon turn their thrust bearings 90° Grizzly GOSSS, and Shop Fox make it changes and make it a snap· to relieve
Ball-bearing guides, like those on the Grizzly G0555 (left), spin freely while holding the blade in line side-to-side and vertically. Square steel
guide blocks, like the ones on the Jet JWBS-140S (right), sit within a few thousandths of an inch from the blade.

tension on the wheels between work ses- but two saws because table trunnions in
sions. You still have to turn the tension front and in back of the blade better bal-
knob a few times to completely remove ance the table's weight. Craftsman and
the blade, but the process is faster and Rikon-which have the largest, heaviest
easier than tediously turning the knob tables in the test-use a single, wide
dozens of times. trunnion to the rear of the blade. When
When we tensioned the blades by you release the lock, the cantilevered
hand, we found the scales on all but the table drops forward in addition to Tension
scale
Shop Fox and Steelex reliable. You can being loose side-to-side, making it
probably trust the scales alone and get harder to tilt.
along fine for most tasks, but it's a good
idea to learn to set the tension by We vote out the
hand. (Get a free downloadable PDF or The Verdict: Craftsman and
TURN OFF THE TENSION
watch a free video that shows you how Grizzly GOS80 and put Jet on probation Turning the quick-release lever on the Shop
at woodmagazine.com/bandsaw.) for troublesome lower-blade-guide Fox W1706 moves the top wheel up or down
• Tilting the table proved easy on all adjustments. to instantly apply or release blade tension.
/ lbo~.
With front and back trunnions, like those on the Grizzly G0555, the Rikon's single trunnion made it difficult to tilt the table, but its
table can only tilt within the trunnion slots. adjustment screws made it easy to square the table front to back.
-If you still can't decide, consider these factors

Okay, we're down to four saws: Grizzly's upgrade your current one, read about closed base, giving both models handy
GOSSS, Jet, Rikon, and Shop Fox. They three aftermarket fences we recommend storage. Only the Grizzly and Shop Fox
each have strengths and weaknesses, so in Wise Buys on page 26. have leveling feet; you'll have to shim
let's look for more to tip the scales in • Dual speeds. Grizzly, Rikon, and the others to get them level.
favor of the best model. Shop Fox feature dual-speed pulleys and • Squaring the tables to the back of
• Rip fences and miter gauges. The wheels. We cut wood at both speeds, the blade-critical for tasks such as
Grizzly and Shop Fox models include a and found the faster speed not only was bandsawing tenons or dovetails-
rip fence, and we like the GOSSS's fence quicker at cutting but also produced bet- required adding brass shims on all saws
best because it has a cam lock, large ter cut quality. Should you ever want to but the Craftsman and Rikon, which
viewfinder, and scale marked in both cut steel at the slower speed, though, a conveniently have built-in adjustment
inches and metric equivalents. Those steel-cutting blade is a must. screws, as shown above.
same models include a miter gauge; that • Initial assembly. Shop Fox's one-
on the Shop Fox is a notch above the piece cast-iron base needs no assembly, Although the Jet
others because it has the longest bar, and its instructions are the best of the The Verdict: and Rikon saws
tallest face, and three adjustable stops. If group, making it the quickest and easi- don't come with a fence or miter gauge,
you want to buy a fence or simply est to put together. The Rikon also has a we don't vote out any saw.
woodmagazine.com 57
Why spend more when these four test survivors get the job done?
Grizzly G0555, $395 .... Jet JWBS-140S, $4.60
GIJ5SS
High Points High Points
. . Demonstrated the least amount of blade . . Cuts tight curves and follows marked
deflection, about V32". lines well.
• Blade-tension quick-release lever makes • Steel guide blocks with thumbscrews
blade changes quicker and could extend make adjustments quicker than using
the life of your blades and tires. bearings.
• Comes with a miter gauge, and its sturdy • Table tilts 50° right and 17° left, enabling
rip fence with easy-to-use scale was the you to cut high-angled dovetails.
best in this test. Low Points
• Microadjustable ball-bearing blade • You must remove the table to adjust the
guides help it cut tight curves. lower blade guides forward or backward.
• Table tilts 51 ° right and W left, enabling • Moving the top guide assembly up or
you to cut high-angled dovetails. down changes the thrust bearing and
Low Points guide block alignment to the blade.
• Its 6' power cord is shortest in the test. • Its 6' power cord is shortest in the test.
More Points
• Bearing-style blade guides with micro-
adjusters work well but take longer to
adjust.
• Not the most powerful saw in the test,
but cuts accurately and has nice features
for its price.
14" BANDSAWS PRICED $550 AND UNDER

TABLE BLADE CUT CAPACITIES,
BLADE GUIDES INCHES
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CRAFTSMAN 22401 99% Vs,% 1,620/3,340 C 20 7/16 X 15% 50/2 B y R 8 3/16 NA 13 9/164&2Y2 31 9/16 X 23'l's x 70%
G0580 93Y2 Ys,% 3,000 A 1315/16 X
14 1/s 50/16 S N R 6 12 13Y2 4 27 Y4 x 26 13/16 X 67 7/16
GRIZZLY
G0555 93Y2 1/s,% 1,500 / 3,200 A 13'l'sx 14Ys 51/16 B Y Q 6Ys 12Ys 13 112 4 27Y2 x 28% x 67
JET JWBS-140S 93Y2 Ys,% 3,000 A 13 15/16 X 14Ys 50/17 S N R 6 12 13Y2 4 26 5/16 x 22% x 68%
RIDGID BS1400 93'12 1/S,% 2,700 A 14x 14 47/16 5 Y R 6 12 13% 32Y4 x 17% X 67 13/16
2Y2 .
I
RIKON 10-320 93Y2 %,% 1,445/2,950 A 15% 45/3 20 7/16 X B N R 6 NA 13% 4&2Y2 31 3/16 x 20% x 68 112
SHOP FOX W1706 93Y2 Ys,% 1,500/3,200 C 14Ysx 14Y16 50/15 B Y Q 6 5/16 12 5/16 13Y2 4 26'3/16 x 29 X 69Ys
STEElEX snooo 93Y2 Ys,% 3;000 A 1315/16 X 14Ys 52/18 S N R 6% 12% 13% 4 26 15/16 x 25% X 67 9/16
~
1. (A) Aluminum 4. Excellent 7. Using a 1-hp dust collector 9. (C) China
(C) Cast Iron Good with 4" hose (T) Taiwan
2. (B) Ball bearing Fair 8. (B) Blade 10. Prices current at time of
(S) Square steel insert Not Applicable (F) Rip fence article production and do
blocks (L) Task light not include shipping, where
5. Timed cuts while resawing (M) Miter gauge applicable.
3. (Q) Threaded rod with quick 6"-wide red oak (R) Riser block
release (T) Tools for adjustments
(R) Threaded rod 6. Resawing 6"-wide red oak

High Points High Points
• Demonstrated the least amount of blade • Demonstrated the most power, cutting twice
deflection, about %2". as fast as half the saws in our resaw test.
• Showed the least amount of vibration in • Cuts tight curves and follows marked lines well.
the test. • Cast-iron wheels and base contribute to lowest
• Its table is the largest in the test. amount of vibration in the test.
• Hex wrenches needed for adjustments • Rack-and-pinion adjustment for bearing guide
store in a tool holder on the back of post makes for smooth adjustments without
the saw. the post dropping upon release.
• Reference chart inside lower door pro- • Blade-tension quick-release lever speeds blade
vides helpful tips without you having to changes and could extend the life of your
open the owner's manual. blades and tires. '
Low Points • Table tilts 50° right and 15° left, enabling you
. . Table tilts 45° right and 3° left, least in to cut high-angled dovetails.
the test. • Has the beefiest miter gauge in the test.
. . Single table trunnion makes adjustments Low Points
more difficult than models with two . . Showed the second-highest amount of blade
trunnions. deflection in our resaw test.
More Points More Points
• Its steel frame won't accept a riser block. • Its lOW power cord was longest in the test.
• Its table has two miter slots, but no • Bearing-style blade guides with microadjusters
miter gauge is included. work but take longer to adjust.
• Bearing-style blade guides work well but take longer to adjust.
PERFORMANCE RATINGS (4) ACCESSORIES (8) FOR MORE INFORMATION

PRIMARY SECONDARY
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B,F,L 228 7 1 C $550 800-383-4814 craftsman.com
B,F,M R 162 6 1 T $325
800-523-4777 grizzly.com
B,F,M R 168 6 1 T $395
B F,M,R 149 6 5 T $460 800-274-6848 jettools.com
B,T F,M,R 176 10 3 C $350 866-539-1710 ridgid.com
B,T F,M 189 7 2 C $500 877-884-5167 rikontools.com
B,F,M,T R 241 10V 2 T $540 800-840-8420 shopfox.biz
F,M,T R 156 6V2 2 T $325 800-840-8420 woodstockint.com
Band your dollars together and put them into this saw
The Grizzly GOSSS and Shop Fox W1706 separate themselves It wasn't the most powerful saw, but its quality of cut proved
from the field, not for doing one thing well but rather for second to none, and that's ultimately what we expect from a
doing the most things well. The Shop Fox demonstrates the bandsaw. It also excelled at cutting curves because its blade
most power, cuts curved shapes best, vibrates little, and has guides held the blade true without twisting, and it was at or
heavy-duty cast-iron components. But we just can't get past near the top in every performance category with no signifi-.
its blade deflection of %2" in a 6" resaw cut. If this doesn't cant flaws. And it's also the best value in the class. •
bother you then buy this saw. But we'll gladly trade cutting Written by Bob Hunter with Craig Ruegsegger Illustrations: Tim Cahill
speed for accuracy, so we've named1:he GOSSS our Top Tool.
woodmagazine.com 59
Solid-Oak
You don't ne
a dream sho
to build this
handsome p
a few basic p
tools will do.
one-stop sho
at your favori
. I home center
: gets you rolli

right away.
• Overall dimensions: 27¥.!" wide x See a slide show of this
11Ya" deep x 45'l'16" high. project coming together at
GREAT PROJECTS. SIMPLE TOOLS. • Power tools needed: tablesaw, router,
jigsaw, sander, and drill.
woodmagazine.com/slides
Basic-Built projects require only a limited number Skill Builders

of Inexpensive and readily available tools • Learn a simple clamping method that
ensures flat edge-glued panels.
and materials. For more information go to
• Discover an easy way to make ogee
woodmagazine.com/baslcbullt bracket feet from stock crown molding.
Y
Ou'd pay a lot for a solid-wood bookcase in a furniture one cove (F) from the edge of each of these shelf blanks. For
store. Instead, save a bundle by building this handsome the bottom shelf (E) blank) edge-glue three %x3lhx27" boards.
oak piece. You'll get the bonus of enjoying some time in
your shop. Machine the case parts
Edge-glue the blanks 1 Cut the sides (A) and bolsters (B) to size [Materials List, page
64]. Make two photocopies of Side Pattern #1, Side Pattern
1 To make blanks for the sides (A), cut four %x3Yzx43" boards
and two that measure %x2Yzx43". Layout two 3Yz"-wide
boards and one 2Yz"-wide board for each side, arranging them
#2, and the Bolster Pattern on the WOOD Patterns® insert.
Adhere the patterns to the parts with spray adhesive [Drawing
1], and cut them to shape [Photo A]. Sand the cut edges smooth.
for the best grain and color match. Edge-glue the sides. To To drum-sand the edges using an electric drill, see page 20.
obtain the flattest panels, see the Shop Tip below. Edge-glue the bolsters (B) to the sides (A) [Drawing 1].
2 For the top shelf (C) blank, edge-glue two %x3lhx27"

boards, and for each middle shelf (D) blank, edge-glue two
%x3Yzx27" boards and one %x2lhx27" board. You'll later rip
2 Mark the ends of the stopped rabbets along the inside rear
edges of the sides (A) for the back (K) [Drawing 1], making
sure you have mirror-image sides. Chuck a WI rabbet bit into a
With the two side (Al patterns adhered to the side, install a fine-tooth Starting at the marked line on the inside face of the right-hand side
blade into your jigsaw and carefully cut along the line. (Al, rout a rabbet all the way to the bottom.
How to edge-glue
finished-thickness boards
Buying boards already planed to 3,4" thick saves
time and eliminates the need for a planer. But
when edge-gluing narrow boards to make
a wide panel, there's no extra thickness to
plane or sand away, so the surfaces of adjacent
boards must align perfectly. Using the sides (A)
as an example, here's how to ensure the flattest
glue-ups.
Glue and clamp the first two boards,
applying light pressure with pipe or bar clamps.
Then apply clamps along the glue line to align
the board faces, as shown near right. Tighten
the pipe clamps.
After the first glue-up dries, glue and clamp
the third board to the first two, once again
clamping along the glue line, as shown far right.
woodmagazlne.com 61
gROUT COVES AND RIP THE TRIM
STEP 1 STEP 2
GRUT PROJECTS. SIMPlE TOOlS.

@,@blanks
handheld router and adjust it to cut %"

deep. Rout the rabbet into the
right-hand side [Photo B]. Then repeat
on the left-hand side starting at the @,@,® blanks 0/8"
bottom and routing to the line. Finish-
sand the sides.
3 Retrieve the shelf blanks, and cut

the top shelf (C), middle shelves (D), and bottom shelf (E) width. Switch to a l,4" rabbet bit and rout a 3jg"-deep rabbet along
to length. From a %x3Yz" board, cut the crest rail (G) and bot- the bottom rear edge of the top shelf [Drawing 3].
tom rail (H) blanks to length. Rip the bottom rail to width.
4 ChUCk a 3jg" cove bit into a handheld router, and rout the top 5
Make two photocopies of the Crest Rail Pattern. Cut along
the pattern lines, and adhere the patterns to the crest rail
front edge of the top shelf (C), middle shelf (D), and bottom blank, flipping one pattern. Jigsaw and sand the rail to shape.
shelf (E) blanks [Drawing 2, Step 1]. Then rip the cove trim (F)
from the top and middle shelf blanks [Step 2]. Rip the shelves t~ 6
Finish-sand the top shelf (C), middle shelves (D), bottom
shelf (E), cove trim (F), crest rail (G), and bottom rail (H).
IISIDE
Location of side pattern #1
i 'I
Location I ®
of side
pattern #2
rI
\ I:
\ I
I•
393/8"
!I
I
(\
281/2"
\I
Location
of parts(D
I\
• .\ J.
Location of
\
\~ .
bolster \
pattern
42" 42"
3114"

Using the shank hole and center of the slot in the short cleat (J) as With the second side assembly (A/I/J) on the workbench, drill pilot
guides, drill pilot holes into the bottom of the top shelf (C). holes, and glue and screw the shelves (C, 0, E) to the cleats (I, J).
Glue and clamp the cove trim to the top and middle shelves [Drawing 4], and screw them to the sides with flathead screws
[Drawings 3 and 3a] and the crest rail to the top shelf [Drawing and panhead screws and washers [Drawing 3].
3b]. Keep the part ends flush. 2Place one side assembly (A/II]) inside face up on your work-
7 Cut the long cleats (I) and short cleats (J) to size. Drill
countersunk shank holes and form slots by drilling over-
lapping holes [Drawing 4]. (For the #8 wood screws in this
bench. Sparingly apply glue to the back 2" of the top face
. of the short cleat (J). Position the top shelf assembly (C/F/G)
against the short cleat, aligning the back of the assembly with
project, drill %2" shank holes and 164" pilot holes.) Make sure the back edge of the side (A). Drill pilot holes [Photo e], and
you have four left-hand and four right-hand cleats. (The coun- fasten the shelf with a flathead screw and panhead screw and
tersunk hole and slot in the 1" width are offset toward the washer [Drawing 3]. Then glue and screw the middle shelf
front of the bookcase, and the shank hole in the ¥t" thickness assemblies (D/F) and bottom shelf (E) to the long cleats (I).
is countersunk on the inside face.) Finish-sand the cleats. Now glue and screw the shelves to the cleats on the second side
assembly [Photo D].
Construct the case
1 Position the cleats (I, J) on the sides (A) [Drawing 1], and
clamp them in place. Using the hole and center of the slot
3 GIUe and clamp the bottom rail (H) to the underside of
the bottom shelf (E) with the front edge of the rail and the
front edges of the bolsters (B) flush [Drawing 3].
in each cleat as a guide, drill pilot holes into the sides. Spar-
ingly apply plue to the back 2" of the W face of each cleat 4 Cut the back (K) to size and finish-sand it. The oak side
faces up when cutting the plywood on a tablesaw.
E!lCOVE TRIM DETAIL

Make ogee bracket feet
1 Cut the bracket cleats (L) and braces (M) to size. Drill a
1" hole J,4" deep in the top face of each bracket cleat to
accommodate the heads of the panhead screws that fasten the
bottom shelf (E) to the long cleats (I) [Drawings 3 and 3c].
II CLEATS
mCREST RAIL DETAIL mBRACKET FOOT DETAIL (Right-hand cleat shown)
0/'16" slots
3/a" long
/ .~
W4'''i> 1"
woodmagazlne.com 63
GREAT PROJECTS. SIMPLE TOOLS.
2 TO make ogee bracket feet from stock crown molding pur-

chased at a lumberyard or home center, see page 22.
Note: We used ~6x3Wf crown molding for our agee bracket feet. The
article on page 22 shows how to make bracket feet with this as well
as other sizes ofcrown molding.
3 With the bracket feet complete, glue them to the bottom of

the case [Drawing 3c and Photo E].
Apply the finish

1 Inspect all the parts and finish-sand where needed. Apply
stain, if desired, and a clear finish. (We applied Varathane
Golden Oak no. 227 stain and two coats of satin polyurethane,
lightly sanding with 220-grit sandpaper between coats.)
2 Clamp the back (K) to the case, drill countersunk screw

holes, and drive the screws [Drawing 3] . •
Project design: Jeff Mertz
• •• •
Using a 1fs" hardboard spacer to align the bracket feet at the sides,
Cutting Diagram glue and clamp them to the bottom rail (H) and long cleats (I).
Find more Basic-Built project plans for sale at

woodmagazine.com/basicbuilt
Materials List
FINISHED SIZE
Case T W l MatI. Qty.
A* sides 3/4" 9" 42" 0 2
B bolsters 3/4" 1314" 14314" 0 2
1/4 x 48 x 48" Oak plywood

"I \1
C* top shelf 3/411 5%" 26" 0
D* middle shelves 314" 8%" 26" 0 2
A
E* bottom shelf 314" 10%" 26" 0
F* cove trim 3/4" 3/4" 26" 0
G* crest rail 314" 3" 26" 0
3/4 X 2V2 x 96" Oak (2 bd. ft.) H* bottom rail 3/4" 3'/4" 26" 0
I long cleats 314" 1" T' 0 6
J short cleats 314" 1" 4" 0 2
3/4 X 3V2 x 96" Oak (2.7 bd. ft.) K back %" 26314" 39%" OP
Feet
L bracket cleats 314" 'J'oH' 109/16" 0 2
11
M braces 3/4 2V2" 1314" 0 2
N* bracket sides 9/16" 2"/16" 11%" OC 2
0* bracket fronts 9/16" 2"/16" 5%" OC 2
3/4 X2V2 x 96" Oak (2 bd. ft.)
'Parts initially cut oversize. See the instructions.
Materials key: O-oak, OP-oak plywood, OC_9/16X3%"

3/4 X 3V2 x 96" Oak (2.7 bd. ft.) oak crown molding.
Supplies: Spray adhesive; #8x3J4", #8xl%", and #8x1W'
flathead wood screws; #8xl %" and #8xl W' panhead
screws; #8 flat washers.
3/4 X 3V2 x 96" Oak (2.7 bd. ft.)
Bits: %" rabbet and 3fa" cove router bits.

Ways to Get Dust
(Before it Gets You)
Unless you're having a square dance,
you don't want sawdust on the floor.
And you certainly don't want to breathe
it. We recently tried dozens of products
that promise better dust pickup. Here
are the ones that wor~ best.
._-
"
Gobble up hard-to-tame messes

Catc" a broad blast of debris... ...or pinpoint the suction where you need it
--~- ....
While no single accessory will catch all the dust When you've got to have dust collection
and chips that go airborne when turning wood, in hard-to-reach areas or places where a
the Big Gulp Ultimate Dust Hood, shown above, 4" hose gets in the way, attach a Loc-Line
gobbles up a lot of it. When tethered to a 1-hp or articulated hose to your shop vacuum (or
larger dust collector with 4" hose, the Big Gulp with a reducer to a larger dust-collection
gathers in most of the chips made when hollowing system). Bend Loc-Line to almost any'
out a bowl or vessel. It's especially effective at configuration, and snap on a nozzle to
sucking up sanding dust from turnings-the stuff place the suction right where you need it.
you'd breathe into your lungs otherwise. Use couplers to join multiple h;'ngths of
The Big Gulp mounts between the ways of any hose. We like Loc-Line for use with any
lathe bed on three slotted arms with locking stationary sander, as well as drill presses
knobs, allowing you to position the hood where and router-table operations when you
you need help most. You can also get it on a floor can't use a fence-mounted dust port.
stand (model #DBU30, $120) or the long-armed Loc-Line Modular System
Dust Picker (model #DPICKER2, $60), which has a 21f2"x23" hose, $26
smaller hood, for dust collection behind a miter- Adapters and nozzles, $4-$6 each
saw, radial-arm saw, or other dust-spewing tool. Lockwood Products, 800-423-1625
Big Gulp Ultimate Dust Hood Where to buy: Lee Valley Tools,
Model #DLGULP, $60 800-871-8158,leevalley.com;
Penn State Industries Grizzly Industrial, 800-523-4777,
800-377-7297, pennstateind.com grizzly.com
woodmagazine.com 65
Add punch and simplicity to your DC system
Gain airflow and filtration No-clog blast gates improve airflow
with specially made bags Debris can build up in
If your dust collector's filter bag puffs up the grooves of typical
like a taut balloon, you're probably not blast gates, preventing
getting maximum airflow through your them from closing fully,
collector. Although many manufact- so they leak air and
urers offer high-efficiency filter bags ultimately reduce suction
(1 to 5 microns) as standard or optional where you need it.
equipment, most don't do anything to Lee Valley's self-cleaning
optimize airflow. American Fabric Filter gates extend through the
custom-makes oversize I-micron bags bracket to push debris out
that increase airflow by not restricting of the groove and prevent
it. Top bags cost from $120 to $150, and such buildup.
bottom bags from $70 to $85.
Self-Cleaning
High-Efficiency Filter Bags Blast Gates
Custom-made, $70-$150 2"-6" models, $8-$17 each
American Fabric Filter Lee Valley Tools
800-367-3591, americanfabricfilter.com 800-871-8158,leevalley.com
Better seal eliminates air leaks

Flexible dust-collection
hose has a metal support-
ing wire that spirals
throughout it to prevent
the hose from collapsing
under suction. But with
ordinary hose clamps,
leaks can occur where the
clamp crosses that wire.
Lee Valley's Bridge Hose
Clamps straddle the metal
wire, as shown, which
allows the clamp to fully
seal the hose to the con-
nector or dust port.
Bridge Hose Clamps
2W'-6" models, $4.90-$6.60
Lee Valley Tools
800-871-8158, leevalley.com
Quick changes mean fewer hoses

Here's an accessory for those of us who don't have
the luxury of a central dust-collection system and
have to move the collector from tool to tool.
Fazlok Quick Disconnect male and female fittings
allow you to make changes quickly and without
tools. You simply twist and turn to lock and
unlock the hose from the tool. Install female
Fazlok fittings on your collector's inlet and on the
dust ports on your tools; then clamp male fittings
onto both ends of your flex-hose. To maximize
airflow, you can have several hoses of different
lengths, and use the shortest hose you need to get
from the collector to the tool.
Fazlok Quick Disconnect Hose Fittings
2W' & 4" models, $8-$11 each; kits $26-$30
Woodworker's Supply
800-645-9292, woodworker.com

Make your shop vacuum work more effectively
No-hassle, supple-but-stout hose
proves effective for use with sanders
Okay, you've got a shop vacuum that you attach to your portable
power sander for dust extraction, but the hose proves too bulky, too
stiff, or the ribs catch on edges. Klingspor's Crush-Proof lightweight
hose eliminates those worries. With an adapter on one end to fit any 21;2"
vacuum opening, the soft, flexible I" hose easily attaches to many sanders. We
also recommend Klingspor's universal rubber adapter (#FE921OS, $3) that enables
attachment to virtually any sander, even those with rectangular dust ports.
Crush-Proof Vacuum Hose
Model KA00011, $23
Klingspor's Woodworking Shop
800-228-0000, woodworkingshop.com
You can use this filter for wet messes No holes necessary for dust pickup
We've all been there: To remove the caked-on dust from the Mirka's Abranet sanding discs are made of a porous, meshlike
pleated paper filter of your shop vacuum, you tap it, beat on material, with grit on one side and hook-and-Ioop-style fasten-
it, or blow it out with compressed air, but you still can't get it ers on the other. The result: You get effective dust collection
fully clean. Not so with Cleanstream filters, made of non- through all the pores without taking the time to line it up with
stick Gore-Tex material you can clean with air or water, so it the sander's dust-collection holes. Abranet comes in 13 grits
works on wet and dry pickups. They deliver finer filtration from 80 to 1,000, and costs nearly twice as much as Mirka's
than paper varieties-trapping particles as small as 0.3 Gold sandpaper discs. But the better dust collection means the
micron. Filters fit Shop-Vac, Craftsman, and Ridgid brands. abrasive won't load up with sanding dust, so it lasts longer than
Cleanstream Wet/Dry Vacuum Filters typical sandpaper. And it means you'll put
$23-$35 each less dust into the air. Abranet also
W.L. Gore and Associates comes in sheets and rolls.
800-758-6755, c1eanstream.com
Abranet
Sanding
Discs
Various grits,
$14-$18 for 10
discs (also available
in 50 packs)
Mirka Abrasives
800-843-3904,
mirka.com
Where to buy: Woodcraft,
800-225-1153, woodcraft.com
Master the mess of

machine-cut 'tails
Dust-collection hoods for Leigh and
Rockler dovetail jigs do a remarkably
good job of corraling the spray of chips
and .dust created when router-cutting
dovetails. Each fixture mounts directly
onto the jig's front-including older
models with the help of special mount-
ing kits-and you simply attach your
shop vacuum hose to the 21;2" port. The
Leigh VRS features a flat top that sup-
ports your router flush with the tops of
the jig fingers. A sliding dust port glides
underneath and follows the router. The
RockIer fixture has soft bristles that stick Vacuum & Router Support (VRS) Dovetail Jig Dust Collector
12"-24" lengths, $75-$84 Model #22224, $42
up from a dust hood, allowing the router Leigh Industries Rockier Woodworking and Hardware
bit to pass through without harm. • 800-663-8932,leighjigs.com 800-279-4441, rockler.com
woodmagazine.com 67
~~ntractor-Grade
Mo ·
Junior operating engineers will enjoy
doing the heavy lifting with this fully
operational construction toy.
B
efore your favorite youngster gets bogged down
in video games, give a gift that lets his imagina-
tion do the lifting-this sturdy wooden crane.
Make the chassis

1 For the chassis (A), cab (G), and counterweight (H),
cut a lYzx614xI2" blank. (We used walnut.) Rip a
lYz"-wide piece from one edge, and set it aside for the
cab and counterweight. Cut the remaining piece to size
for the chassis [Materials List, page 72].
2 Lay out the chassis (A) front and rear bevels [Drawing
1], and bandsaw and sand them to shape. Then chuck
an 11hz" brad-point bit into your drill press, position the
fence W' from the bit center, and drill axle holes in both
sides of the chassis [Photo A]. Finish-sand the part.
Build the mast and boom •

1 For the mast sides (B) and mast spacers (C), cut two
%xl~x26" blanks (We used maple). Cut one mast
side and one spacer from each blank. Chuck a 1" Forst-
ner bit into your drill press and drill five holes in the
mast sides [Drawing 2, Photo B].
2 TO assemble the mast, cut two %x214x24" cauls

from scrap. (We used MDF.) Cover one side of each
caul with masking tape to keep glue from sticking.
Apply tape to one side of each mast (B) to mark the
mast spacer (C) locations [Drawing 2]. (The thickness of
the tape provides just enough of a lip to keep the spac-
ers from shifting and makes it easy to remove
excess glue.) Glue and clamp the mast
[PhotosC and 0].
Mark the ¥16" boom pivot
3 hole center on one mast
side (B) [Drawing 2]. Chuck a
brad-point bit into your drill
'press, insert a %"-thick scrap
block between the mast sides to pre-
vent chip-out, and drill the hole.
4 Form the mast (B/C) top bevel

[Drawing 2, Photo E], and sand it
smooth. Sand Va" round-overs
on the top corners of the mast
sides (B) and upper mast spacer
(C). Chuck a chamfer bit into
your table-mounted router, and
rout Y16" chamfers along the edges of

PROJECT HIGHLIGHTS
• Overall dimensions: 25" high x13Ya" reach x 7¥.!" track xll Va" wheelbase.
• Hand-operated hoists raise and lo"'{er the boom and bucket.
• The tower assembly pivots smoothly on a ball-bearing lazy Susan to easily pick up
and place loads.
• A wide-track chassis featuring eight sets of dual wheels provides sure-footed mobility.
• You provide the flat stock and a few wood screws. We provide a one-stop source
for the remaining hardware and special fittings. •
Skill Builder
• Discover how to hold rounded items steady for drilling on your drill press.
the I" holes and the outside edges of the the counterweight to the boom (D/E/F),
mast, except for the bottom. Finish-sand Y2" from the end and centered.
the mast.
Fabricate the hoist Layout the axle hole centers on the chassis
5 From a %xl%x22" piece of stock,
resaw and plane a 14"-thick blank for
the front spacer (D) and rear spacer (E). 1 From Y2"-thick stock, cut the hoist
sides (I) to size. Adhere them face-to-
(A). Clamp the chassis to the drill-press fence
at each location, and drilllW'-deep holes.
(We used walnut.) Cut the parts to face with double-faced tape. Mark hole
length. Bandsaw and sand the chamfer centers [Drawing Sa], and drill the holes width of the mast (B/C) and the hoist
on the front spacer and the taper on the on your drill press with a l,4" brad-point sides (I). Rout a chamfer along the top
rear spacer [Drawing 3]. bit. Layout the angled corner. Bandsaw front edge [Drawing 5]. Drill shank holes
6 From a %xl Vax22Y2" piece of stock,

resaw and plane the two boom sides
(F). (We used maple.) Glue and clamp
and sand it to shape. Sand round-overs
on the corners at both ends of the angle.
Separate and finish-sand the parts.
for fastening the hoist base to the mast
sides (B). (For the #8 screws, drill %2"
shank holes and 164" pilot holes.)
m
the boom spacers (D, E) between the
boom sides [Drawing 4 and Photo F]. 2 Cut the hoist base to size, making
sure the width equals the combined 3 Clamp the hoist sides (I) to the hoist
base m [Drawing 5]. Drill screw
7 With the glue dry, use your drill

press to drill a %2" hole through the
rear spacer (E) for the boom-operating
string, a 0/].6" hole for the boom pivot,
and another 0/].6" hole at the front end of
the boom [Drawing 4]. When drilling
the front hole, insert a W-thick piece of
scrap between the boom sides (F) to pre-
vent chip-out. Then mark the two
tapered cuts, and bandsaw and sand
them to shape. Sand W' radii on the
boom ends. Now rout lIJ.6" chamfers
along the edges. Finish-sand the boom.
Add cab and counterweight

1 Retrieve the walnut cab (G) and
counterweight (H) blank. Mark the
hole center near one end [Drawing la].
Join the two mast sides (6) with double-faced Apply glue and position the mast spacers (C)
tape, mark the 1" hole centers, and drill on one mast side (6). Apply glue and add the
Chuck a I" Forstner bit into your drill through both parts. second mast side.
press, and drill the hole. Then bandsaw
and sand the Va" angled corner. Crosscut
the cab from the blank. Now rout lIJ.6"
chamfers along the edges of the hole
and Va" chamfers along the outside edges
of the cab. Finish-sand the cab.
2 TO position the cab (G) on the mast

(B/C), first insert the boom between
the mast sides (B), and slide a piece of
#10-32 threaded rod through the holes
in both assemblies. Then glue and clamp
the cab to the mast sides (B) [Drawing 1
and Photo G]. Remove the boom from
the mast.
From the remaining walnut blank,
3 cut the counterweight (H) to size.
Rout chamfers on the edges [Drawing 1],
Clamp the parts between the cauls, and then With the glue dry, remove the clamps and
clamp vertically. Keep the mast sides (6) and cauls, mark the bevel at the top of the mast,
and finish-sand it. Now glue and clamp lower mast spacer (C) flush at the bottom. and bandsaw it to shape.
woodmagazine.com 69
As with the mast, cut 3/4 x%x24" cauls, Sparingly apply glue to the cab (G), position Using the holes in the hoist side (I) as guides,
applying masking tape, to align the spacers it against the boom (D/E/F), centered on the drill 3/16" holes for the threaded rod through
(0, E) between the boom sides (F) for gluing. mast (B/C), and clamp the cab in place. the mast (B/C) with a brad-point bit.
, rs-3'~~11f2"
II ~------
DEXPLODED VIEW holes, and drive the screws. (For #6
¥4" screws, drill %4" shank holes and 0/32"
\ j 1/1S" chamfer pilot holes.) Clamp the mast (B/C)
f"i::::::::::=T'l on all edges
, -~ between the hoist sides. Using the screw
1~- \:.1f2" holes in the hoist base as guides, drill
1---
G•• _ #10-32 threaded rod pilot holes into the mast sides (B), and
25/a" long
...-.. _~
"'~"'--- #1 0-32 threaded rod
""iIto 0 11/8" long
0\
'---#10-32 cap nut #10-32 cap nut
Snap hook
./
43/4' •
String 24" long
)
, }
'¥is" hole "--"'--n, -;-r
®
~ 1/1S" chamfers
routed
~
after
assembly
#10-32 cap nut @
22"
""@~
~:: b
i ,
~
#10-32 threaded rod
35/a" long
.....o--!-1O-32 cap nut , \
~
..... #6 x 1/2"
#8 x 2" F.H. wood screw~ i e panhead screw
I!ICABDETAIL 3'" lazy Susan, 1
T~
l 2
11 I J
centered 1
1/8" chamfer r- 11f2"----j
l 2¥4'
41f2"
'-:J.l,,·2\(2' '
-~
11" ~
@
%"
~u ¥S" waSher~~'
2x11f2"
",'em wheel
t 6))
@
~
~
@ ~
~ "&
'1/32 X 2¥S"
tandem wheel axle
~
SHOP TIP
How to safely hold rounded objects for drilling
Enlarging the screw holes in the wood
knobs for the hoist assembly presents
two challenges: holding a part with a
domed surface steady on the drill-press
table, and keeping it from spinning
as the drill bit bites into the surface.
Here's an easy way to overcome both.
Drill a %" hole 114" deep in a piece of
%"-thick scrap. Place a 1Y2x1 W' piece
of double-faced tape over the hole, as
shown at right. Center the knob over
the hole, and press down firmly. Now
support the scrap with the drill-press
fence, centering the bit on the knob
screw hole, and drill, as shown at
far right. This method also works for
drilling into wood balls.
drive the screws. Now, on your drill

press, drill 0/1.6" holes through the mast
[Photo H].
6 Enlarge the screw holes in four 114"-
diameter wood knobs to 14", drilling
them %" deep. To hold the knobs on the
4 With the mast/hoist assembly upside

down, position the lazy Susan on
the hoist base G) equidistant from the
drill press, see the Shop Tip above.
Apply finish and assemble

front and side edges. Drill pilot holes, Remove the lazy Susan, mast (B/C),
and drive the screws [Drawing 1]. Then
position the mast/hoist assembly on the
1 and hoist sides (I) from the hoist
base G). Examine all parts and assem-
chassis (A), and mark the lazy Susan blies, and finish-sand where needed.
• screw-hole locations [Photo I]. Now Slide the wheels and bucket onto a W'
remove the mast/hoist assembly, and dowel, and support it at the ends with
drill the holes. 2x4 scraps. To hold the axles and keep
5 Cut two 4"-long pieces of 14" dowel,

and glue a spool onto each piece,
centered on the length [Drawing 5].
finish off the ends for gluing, drill eight
%" holes into a 2x4 scrap and insert the
axles. Drill six W' holes at least 2" apart Center the lazy Susan on the chassis (Al,
With the glue dry, drill a %2" hole, cen- into another scrap block. Insert short rotate the mast/hoist assembly to uncover
tered, through each spool and dowel. pieces of JA" dowel into four of the holes, the mounting holes, and mark the locations.
~~_---------163/8" • I V(U--43!4"~
3/(.47--
t @ . r~~8"
"~~
_. idB.~.~.,.,. ~';~ .;,:.."'~",... ,~ ;:'" _ ~.. ~
~ 1W' ~
Trim after assembly.
II BOOM ASSEMBLY
II BOOM SPACERS
Parts trimmed
____----7after assembly
woodmagazine.com 71
DHOIST
and press a knob onto the end of each ~~1W' wood knob
one. Wrap masking tape around one end
of each spool dowel, and insert the other #10-32 cap nut
~G ,
I V4" hole 3/a" deep
end into one of the remaining holes. \ '. 1 \ J V." washers
Apply a clear finish to all the parts and "-@ "'0'" @
'ih .\. ..... ¥a x .78" compression spring
assemblies. (We applied four coats of @.~~ '.
aerosol satin lacquer, sanding between
coats with 320-grit sandpaper. To smooth ?~ 1{2 :::::::. 3/32" hole
the wheels between coats, use a soft brass #10-32 threaded rod 1Va X 7/a" spool
wire brush.) 35/a" long
11 1/4" washer
1/4 11
1
2 Slide a wheel and washer onto each
axle. Glue the axles into the chassis chamfer ~
~
W' dowel 4" long
(A) holes, inserting business cards

between the wheels and washers to
ensure free spinning.
¥f\
31/4"
3 Screw one hoist side (I) to the hoist

base 0) [Drawing 5]. Slip a washer,
spring, and another washer onto each Location of tower 1
spool dowel, and insert the dowels into
Shank hole countersunk on bottom faCe)
the hoist side holes. Slip another washer,
spring, and washer over each dowel, and #6 x 1V4" F.H. .~.
0, .
.~
fasten the second hoist side in place, wood screw
mHOISTSIDE
capturing the spool dowels within the ,"
hoist side holes. Add a washer to each
dowel protruding from the hoist sides,
and glue the knobs onto the dowels. 1W' wood knob
#10-32 cap nut
4 Screw the mast (B/C) to the hoist

base. Cut two 3W'-long pieces of
#10-32 threaded rod (%" longer than the
total thickness of the assembly), and
slide them through the hoist sides (I)
and mast [Drawing 5]. Apply medium-
strength thread locker to the rod ends,
and thread on cap nuts. Screw the lazy
Susan to the hoist base 0), and then to excess cord onto the spool by turning Materials List
FINISHED SIZE
the chassis (A). the knobs. Part T W L MatI. Qty.
5 Cut one 2%"-long and one ll;8"-long

piece of threaded rod. Slide the boom
(D/E/F/H) between the mast sides (B).
7 Cut a nil-long piece of string, thread
it through the hole in the front
spool, and tie it off. Then route the cord
A* chassis
B* mast sides
lVz" 4Vz"
3/4" lVz"
11"
22"
w
M 2
C* mast spacers %" 1112" 3" M 2
Slide the long rod through the pivot through the space between the front
holes [Drawing 1]. Apply thread locker spacer (D) and rear spacer (E), over the D* front spacer 11
114 1%" 16%" w
and cap nuts. Slide the short rod through top of the upper mast spacer (C), and E* rear spacer 114" 1%"4%" w
the holes at the front end of the boom, between the front spacer and the front F boom sides %" 1%" 22Vz" M 2
and apply thread locker and cap nuts. threaded rod. Tie the snap hook onto G* cab lVz" 1112" 2%" w
6 Cut a 24"-long piece of string and tie

a knot in one end. Thread it from
the top through the hole in the rear
the end of the string, and wind the
excess onto the spool. Finally, clip the
bucket bail onto the hook, slip on your
H* counterweight
hoist sides
3/411
Vz" 2%"
1112" 3"
4%"
w
W 2
spacer (E), through the hole in the rear hard hat, and start up your engines and hoist base 3/4" 3%" 6V." w
spool, and then tie it off. Wind the your imagination... 'Parts initially cut oversize. See the instructions.
Materials key: W-walnut, M-maple.

Cutting Diagram Written by Jan Svec
Project design: Jeff Mertz
Supplies: #8x2" and #6xlV4' flathead wood screws,
G H #6x W' panhead screws, double-faced tape.
Bits: 45' chamfer router bit; 3/16", W', and 11hz" brad-point
drill bits; 1" Forstner bit.
1V2 7V. x 12" Walnut (1.3 bd. ft.)

Source
a
X
Hardware kit: Each kit includes the following parts:
~:: 2: ::~ ::~ ~~ :Jmt:::':::::::::::n *®§ ::::j tandem wheels (8), tandem wheel axles (8), 'Is" flat
washers (8), 3" lazy Susan, #10-32x12" threaded rod,
¥4 X 3 1/2 X 60"
Maple (1.7 bd. ft.) #10-32 cap nuts (8), snap hook, wood bucket, lV.' birch
'Plane or resaw to the thicknesses listed in the Materials List. knobs (4), lV.x '/." spools (2), V4x9y," wood dowel,
¥." flat washers (12), ,/. x .78" compression springs (4),
J black nylon string (14 ft.). Order kit no. 3122, $24.99,
plus shipping. Meisel Hardware Specialties,
D ~00-441-9870, meiselwoodhobby.com.
3f4 X 5V2 x 24" Walnut (1 bd. ft.)
Ask WOOD HAVE A QUESTION?
For an answer to your woodworking question, write to ASK
Answers to your questions from . WOOD, 1716 Locust St., LS-221, Des Moines, IA 50309·3023
letters, e-mails, and WOOD Online o or e-mail usataskwood@woodmagazine.com. For immediate
feedback from your fellow woodworkers, post your questions on
one of our woodworking forums at woodmagazine.com/forums.
Heart-smart woodworking
Q el recently had a pacemaker
e put in and, according to my
doctor, 1can't get within two feet of
my power tools. How do 1save my
hobby and my health?
-AI Lakatos, Brighton, Mich.
A• AI, as a bunch of woodworkers,

• we wouldn't dream of offering
medical advice. And we hope that you
wouldn't dream of straying from the
advice of your doctor, who is, after all,
the person closest to your case and
most knowledgeable about your
medical history and physical condition.
However, we can certainly sympa-
thize with your situation, so we posed
your question to Dr. Henry Halperin,
M.D., M.A., professor of medicine in
Cardiology at Johns Hopkins School of
Medicine. His advice: Ultimately, follow
your doctor's orders, but you should
also be an active partner in your own
health care. Take specific questions to
youl doctor after compiling careful require safety measures to ensure doctor contact the manufacturer for the
research about your power tools and proper functioning of a pacemaker, specific limitations of your device.
your pacemaker. such as keeping the tool a minimum of In the end, Dr. Halperin says that
For example, Medtronic, the world's 6" from the pacemaker. with your doctor's guidance, a balance
largest manufacturer of pacemakers, "For more modern devices," Dr. can be struck. "It's a question of quality
gives specific guidelines about which Halperin says, "[electrical interference of life versus safety."
electrical devices are safe and which is] much less of an issue. They're very And don't forget that woodworkers
you should avoid: "Most household and well-protected. They've got all kinds of got along just fine for many centuries
workplace appliances, tools, and filters against interference." prior to the discovery of electricity and
equipment can be used with minimal If you and your doctor need more the invention of power tools. However,
or no precautions." They warn, how- information, Dr. Halperin suggests do keep in mind that hand tools will
, ever, that heavy equipment, including haVing your doctor contact the cardi- require more exertion on your part, so
arc welders and chainsaws, should be ologist or electrophysiologist who discuss using those, too, with your
avoided, and that some power tools implanted the pacemaker. Have your doctor before acquiring them.
Versatile paraffin bed of your jointer, as shown at right,
Q el've been told that applying

e paraffin wax to the elevation
, screws on my planer will make it
makes it easier to run your workpiece
through at a constant rate. Rub some
onto your wooden drawer slides to ease
easier to raise and lower. What are the action. Some woodworkers even use
some other situations where paraf- paraffin wax as part of a food-safe-
fin might be useful, and where can I finish recipe for wooden cutting
find it? boards, countertops, and utensils. Heat
-Tom Mullen, West Branch, Mich. mineral oil in a double boiler and melt
A•
wax shavings into the oil.
In addition to the elevation You'll find paraffin wax at your
• screws on your planer, Tom, rub grocery store, where it's sometimes
paraffin wax onto the threads of screws labeled as "canning wax," or your craft
to make them easier to drive into wood. store, labeled as "candle wax." Old,
Applying an even coat on the infeed discarded candles work well, too. continued on page 74
woodmagazlne.com 73
Ask WOOD
Curing glue-clogged clamps
Q .llent a friend four damps to
.glue up a large project. They
came back with dried yellow glue
a few minutes before removing it with a
plastic scraper. When you're finished,
use detergent and water to remove the
globs on the bars that he couldn't cleaner. For more stubborn deposits,
get off. What's the best way to re- use a hair dryer or heat gun on the
move glue that's hardened? high setting to 'soften the glue before
-George Noeth, Fort Mill, S.c. scraping it off, as shown at right.
A•
Next time you lend a friend your
You've got a couple of options clamps, throw in a roll of painter's tape.
• for removing dried glue from Tell him to adjust the clamp jaws
clamps, George. For thin deposits, spray during dry assembly, and then mask
on a citrus-based cleaner, such as Citrus the bar between the jaws with the tape
Magic or Polyken 41 Citrus Cleaner. before gluing and clamping. Any drips
Allow it to soften and swell the glue for will come off with the tape.
Stopblocks ensure
a square frame
Q .I want to use my mitersaw to
• miter-cut four pieces of lx4"
stock to the same length for a square
frame. How can I do that precisely?
-Henry Long, Benbrook, Texas
A• First give your mitersaw a tune-

• up, Henry. Following the
manufacturer's instructions, adjust the
saw to produce dead-on 45° cuts at both
settings. Begin making the fIame by
cutting a 45° miter on one end of each
frame piece about 4" longer than the
final size. Now rotate the blade to cut
the opposite 45° angle.
Attach one of the miter cut-offs to a
1x2" piece of scrap roughly as long as
the frame pieces to create a combina-
Holds 2full strips of T50e staples- tion stopblock/hold-down, as shown
shoots up to 1500 staples per charge
At-a-glance below. Clamp the stopblock to the
staple supplY window mitersaw fence at a distance equal to
Staple exit guides the final length of the frame parts. Butt
the mitered end of each part firmly
Introducing the new innovative CT50™ against the mitered stopblock, and cut
the second miter.
Professional Cordless Staple Gun
More than just a sleek, light weight design, this surface with precision positioning of the staple
cordless wonder is a rugged, heavy duty staple location. The adjustable·depth of drive" control lets
gun that will appeal to everyone, from the do-it you perfectly fire each staple to the desired depth.
yourselfer to the professional contractor. ~ Unique to the CTSOTM, this tool holds two full
The CT5()TM has a light weight 1O.SY lithium-ion strips of any of the six Arrow TSoe staple sizes
battery that guarantees more power, while firing up saving time on the project.
to 1500 staples on a single charge. Its unique "on- All this, and more, in a well thought out,
board" battery design maintains perfect balance for ergonomically designed, professional tool that will
increased control and accuracy. make any project faster and easier for both the pro
The Ultra-bright "LED guide light" will light any and the do-it-yourselfer.

Make groovy dowels .
Q .I want to cut a IN' groove

• along the 3' length of a
3N'-diameter dowel. Can I do this
with my table-mounted router?
-Stew Levine, West Orange, N.J.
A• A simple jig should solve your

• problems, Stew. In a piece of
wood about 2" square and at least as
Woodcraft has
been "Helping You
long as your dowel, cut a centered Make Wood Work"
groove that's as wide and deep as the for 80 years!
dowel's diameter. The fit needs to be Woodcraft - your
tight enough that the jig holds the source for quality
dowel in place. Then add a heel at one POWERMATIC PM2000 10" Table Saw
tools, supplies • 3 Hp, 220v Motor '
end, as shown below. The heel becomes
especially important when grooving and advice. • Poly-V Belt Drive
• Quick Release Riving Knife, Reduces Bindingl
dowels shorter than 12". Kickback Risk
For added grip, place strips of double- POWERMA'nc 14" Bandsaw- • Push Button Arbor Lock For Rapid Blade Change
faced tape on the bottom of the groove • 1'1, HP 115/230V Motor • Integrated, Retractable Castor System In
before inserting your dowel with one • Working Surface Area Of 15" x 20" Cast Iron Base
·4" Dust Port • Shrouded Blade Increases Dust Collection Efficiency
end resting against the heel. Then
• Full 6" Resaw Capacity • Unique TIlt Scale With Markers For Measureless
chuck a 114" slot-cutting bit into your ·93'1," Blade Range From '/ 8" To 3/," Return To A Reference
table-mounted router and adjust the 824315 • Massive Cast Iron Trunnion For AStable System
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fence to control the depth of cut. Test QUALITY WOODWORKING TOOLS SUPPLIES • ADVICE®
your settings on 2"-square scrap to
center the cut; then make passes up to
114" deep each until you reach the
desired groove depth.
Heel
woodmagazine.com
Ask WOOD
Doweling 101
Q .Is there a list of tried-and-true
• doweling rules? I want to edge-
join a pair of 3/4 x7x48" ash boards for
rocking horse rockers. How close to
the ends can I place dowels, and how
Measure Master® Pro far apart can I space them?
Feet-Inch-Fraction and Metric Demension Calculator -Charlie Stopcynski, Lawrenceville, Ga.
A•
You'll get professional woodworking results with ease. The Measure
Master makes it simple to work in, and convert between, most common
dimensional formats - as well as Areas and Volumes. Includes built-in We recommend making that first
Board-Feet solutions. Model 4020 • hole about %" from the end; as
Construtfion Master Pro shown below, to avoid breaking out the
Advanced Feet-Inch-Fraction Construction-Math Calculator end grain while muscling loose a dry-
•••••
•••••
~1
••••
Our most complete calculator for the advanced woodworker. It features
more powerful built-in solutions, in addition to those found in the Measure
Master Pro. The perfect tool If your woodworking passion includes
projects such as remodeling or adding a room. It even provides Angles
assembled joint in preparation for a
glue-up.
For edge-gluing, the dowels align the .
.···.1
••••• for compound miters. Model 4065
pieces and keep their surfaces flush
Home ProiedCalc® more than reinforce the joint. So space
•••
Do-It-Yourself Project Calculator
Simplify your home Improvement projects with this easy-to-use calculator. the dowel holes just close enough to
Built-in function keys let you quickly and accurately find material correct any minor warping of the parts.
requirements for paint, concrete, tiies, wallpaper and carpet. Model 8510
For most edge joints, space the dowels
To see how these tools can help you today, go to roughly 10" apart, advises Jim Lindsay
_~==,
, www.calculated.com '
M~_ """"'~
of a.M.S. Tool Co., maker of the

"0 ~~=«O>="''«<o._~~~==~~~~~=,.,~y=~
Dowelmax doweling jig. Because you're
cutting rockers from your glue-up, you'll
also need to position the dowels away
from your cutlines.
As for dowel diameters, use dowels
half the thickness of the stock you're
joining. For example, use %" dowels for
314" stock, and 114" doWels for I/Z" stock.
Drill each dowel hole 1116" longer than
half the dowel's length -usually l1/z" or
2" for precut dowels-to ensure a tight
fit and allow space for trapped glue.
with
FUNGI NAIL
J Maximum Strength without a Prescription
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J

WOOlF Magazine
2005 BaCllISSUeS • CD
All seven issues are completely searchable
and printable for in-shop use. Includes
active links to online resources.
To order, visit
woodmagazine.comI2005
or call 1-888-636-4478
WD0908
Shop-Proven Products About our product tests
We test hundreds oftools and accessories, but only those that earn at leastthree
These woodworking wares passed our shop trials. stars for performance make the fipal cut and appear in this section.
Two new pinners go 2" deep for mounting moldings

Many times, we've attached crown
moldings to cabinets or walls, and in
the past, used glue and brads. But the
job was never finished until the brad
holes were filled, and the colors
matched. New 23-gauge pin nailers
from Cadex and Grex sink headless
pins up to 2" long and leave holes so
small, they require little filler. If you
drive the pins into the grain lines, you
likely won't even need to fill the holes.
But can pin placement be that exact?
It is with these models. Achieving that
precision, though, requires that the
manufacturer remove the safety
mechanism from the nose. So to
maintain safety, these pinners have
two triggers: Both must be depressed to The unfilled pin holes in this red oak crown We attached this thin pine molding with a
fire a pin. Although it's a simple molding are nearly undetectable. pin because it doesn't split the molding.
procedure, be warned that these
pinners will fire anytime you press both
triggers. So get into the habit of placing rear air exhaust, and a durable carrying fires 23-gauge brads (essentially a
the nose on your workpiece before case. But the Grex fires pins as short as headed pin), shoots pins as short as Sis",
pulling the triggers. l/Z", and features directional marks on and has a swiveling air coupler for
In testing these pinners, we found the pins that prove helpful when maneuverability.
both could drive 2"-long pins through reloading. Besides pins, the Cadex also - Tested by Jeff Mertz and Erv Roberts
oak molding and into a wall frame with
no trouble. (You'll need to use adhesive
to help hold the molding long-term.)
They also buried
full-length
fasteners into
solid white
oak and hard
maple, although
a few stood
slightly proud
when our compres-
sor's air pressure
dipped below 100 psi,
or when we relaxed our
downward pressure on
the pinner.
Both pinners feature dry-
firing protection should the pins
run out-preventing drive-pin
damage-but the Grex goes a step
further. It locks out firing with about Model P650L Model CPB23.50
six pins left. (There's also an override if Performance
you need to fire a few more before
Performance ****1:?
Price $340 Price $300
reloading.) They each include a viewing Grex Power Tools Cadex Tools
window in the magazine, a belt hook, 888-447-3926; grexusa.com 6Q4-876-9909; cadextools.com

lrnw-Proven Products
Power Bore bits clear chips
for faster, cooler drilling
This is one of those "Why didn't I
think of it?" products. RockIer's Power
Bore drill bits clear chips much faster
than ordinary twist bits or brad-point
bits, while still cutting crisp, precise
holes. These bits remind me of those
inside hollow mortising chisels. Each
has a centerpoint for accurate place-
ment, a single shear-spur to cut the
hole, and steeply angled flutes that
evacuate chips from inside a hole
without plugging.
I drilled multiple holes into 2"-thick
red oak and hard maple with the Power
Bore bits as well as standard twist bits
and brad-point bits of the same diam-
eter. The Power Bore bits never plugged,
and I didn't once have to back them
out of the holes. By comparison, I could
go only 1" deep with the brad-point bits
and 314" deep with the twist bits before
plugging the flutes. No plugging means
less heat buildup that dulls the bits.
The nine-piece set comes in a plastic
storage case and contains the following
sizes (in inches): l/4, 5116, %, 7,116, liz, 9/16 ,
5/8, 11/16 , and 314.
Invellllil
ust ColleCUol
Svstems Since
1993.
Power Bore Drill Bit Set, model 31345

Performance *** * * Oneida'
Price
Rockier
$68 ~rsyste7
800-279-4441; rockler.com
Order Online! Call Today for FREE Catalog!
woodmagazlne.com 79
www.oneido-oir.com Circle No. 2039 1.800.132.4065
~-ProYen Products
Low-cost, low-speed 6" grinder proves a perfect fit for turner.s
I've long searched for an inexpensive wheel, I can sharpen wide tools without dressing tool to flatten the wheels, and
6" slow-speed (1,725 rpm) grinder for having to slide them side-to-side on the you'll have sharp tools in no time. •
sharpening my turning tools. Problem narrow wheel. Add $15 for a diamond -Tested by Jan Svec
was, all the 6" grinders I found either
had 3,450-rpm motors-way too fast
for sharpening lathe chisels and other
hand tools-or their bases were too
wide for mounting my Wolverine
sharpening jig.
Grizzly Industrial has solved that
problem with its H8126 low-cost, slow-
speed 6" grinder. This pint-size grinder
has all the power youlll need to
sharpen lathe tools, wood chisels, and
plane irons. (Its %-hp motor is a little
on the light side for sharpening lawn-
mower blades.) I like that it comes with
two aluminum-oxide wheels: one %"
wide and 36 grit, and the other 11/2"
wide and 100 grit. With the lOa-grit
6" Bench Grinder, model H8126

Performance
Price
*****
$80
Grizzly Industrial
800-523-4777; grizzly.com
Get your FREE catalog! Proud sponsor of

Online: www.rockler.com
Phone: 1-800-403-9736 (Code 850) Wx>dsmith
SHOP~
Stores Nationwide on PBS
leighjigs.c;om 800-663-8932
Create with Confidence'
Circle No. 661
"When I think about owning my own business ...
When woodworking is your passion, and owning your own
business is your goal, Woodcraft can help you take your skill
and expertise to the retail level.
... I think of Woodcraft"
1177 Rosemar Road

P.O. Box 1686
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Bandsaw Guide kits, tires, stabilizer guides, and
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Log • to WWW.WOOlJWartersCent.com Wood Magazine 5epIember 2008 85
On-line catalog pictures hundreds of full-size
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What's Ahead
A sneak peek inside the October issue (on sale August 26)
Quilt Rack
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92 September 2008
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We asked our staff:

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Associate Art Director Assistant Art Director fenders for my

WOOD magazine September 2008

to store 6ack issues

4 FliP the drawer (C) end-for-end

Issue 184 Ouly 2008)

Issue 184 Ouly 2008)

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12 WOOD magazine September 2008

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