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From Our Firs 100 Issues! PLUS

(0) Quick

Gifts (Q) Under $20!


Display until Jan. 26. 1998


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Circle #135 on Resource Directory Coupon


r-- " '/2' --j

T 3'''"



. : , ..


Those who've h a d a sneak preview have nice things to say about it Priced in the m iddle of the pack-we're betting it'll end up at the head of its class.

This D el ta excl u sive gives you a lock on snip e control. Patent-pending cutterhead snipe control lock stabilizes the cutterhead dUring operation, for complete rigidity.

Quick-change 2 -knife system in clu des two high-spe ed stee l, double -edged, reversible knives, a wrench and installatio n tool for q u ic k and accu rate knife changes. Pl ane your own s tock up to 12 1/ 2" w id e a n d 6" thick . A ll the way down to '/a" thick.

Easy-to-re ad E nglish /Metric Sca le makes fast work of d epth-of-cut s e ttings.

Beware of snipers.

Grab it and go. Weighing in at only 6 5 pounds, it' ll go to work ~ wh e re ve r

you want it to. Stash it o ut of the way when it 's not in use .


Properly adjusted in feed/o u tfeed tables c an go a long w ay toward snipe reduction. A low-fri ction stainl ess ste el b ase , in combination w ith these a dju s tab le infe ed/outfe ed tables, g ives y ou a large smooth surfa c e for moving stock th ro u g h your pl aner.




CELTA Practical as th ey ar e, most portable planers are notorious snip ers. If you're looking to minimize sniping without sacrificing portability, check out Delta's new 12 1/2" Portable Planer (Model 22-560), with its exclusive snipe contro l lock. Call toll free for the nam e of your nearest Delta dealer. Delta International Machinery Corp ., 800-438-2486 . In Canada , 519-836-2840.

Circle #113 on Resource Directory Coupon


A Pentair Company

Proud sponsor o f The New Yankee Workshop on PBS.

Features Wood Preparation


by Steve Shanesy Finishing, part two. The steps to take and not take - to ready your projects for finishi ng.

Chimney Cupboard


by Ste ve Shanesy Tall and graceful, this maple cabinet can be built with minimal tools, using a few unu sual (yet simple) tricks.

Sam Maloof Table


by David Thiel One of our first how-to projects revealed the wood master's methods for his table's elegant base.

Exploding Bank


by Frank Longmore and David Thiel Have a mischievous mind ? If so, you' ll love these "banks." Deposit a co in and the bank explodes. Caution: Don' t try this on friends with weak hearts !

Mighty Mite Excavator


by Howard French and Jim Stuard Put your youngsters at the controls of our mechanical steam shovel - they'll dig it!

Prairie Chair


by David Thiel Eve n beginning woodwo rkers can mak e this classic Arts & Crafts-style cub e chair by masterin g the basic morti seand-tenon joint.

Musical Toys


by R.J. DeCristoforo Our three unique toys use inexpen sive musical movement s and some shop scraps. The result s will deli ght the young and yo ung at heart.

The Sawyers Whirligig


by Ande rs Lund e and Christopher Schwarz Catc h a good breeze and these sawyers go to work. Build this classic whirligig from scraps.

Shaker Wall Clock


by John A. Nelson and Jim Stuard We revisit a class ic pine project by one of the best Sh aker cloc krnakers, Isaac Benj amin Youn gs. 2 Popul ar Woodwork ing

Project File This special section, exclusive to Popular Woodworking, f eatures building basics for six projects.


Pine Puzzles

Band Sawn Basket

Need a last-minute gift idea? Tum to this page for two fast , inexpensive band sawn presents.

Folding Candleholder


Thi s stylish candelabra can change shape every time you use it, and it folds flat for easy storage.

Notepad Holder The perfect project for the youngster who wants to make gifts for family mem bers or a teacher.


It might seem impossible to cut a single board to make this basket, but it's not. In fact it's easy, really.

Victorian Mailbox


Readers clamored for this mailbox post becau se it's good looking and the gingerbread is easier to make than it look s.


Safety Note


Safety is your responsibility.


Manufacturers place safety devices on their equipment for a reason. In many photos you see in Popular Woodworking, these have been removed to provide clarity. In some cases we 'll use an awkward body position so you can better see what's being demonstrated. Don't copy us. Think about each procedure you're going to perform beforehand. Think ahead . Safety First!

Out On a Limb "An Explanation is in Order..."


InfeedjOutfeed Letters from readers Cris Cuts

8 18

Tricks of the Trade


Caption the Cartoon Tales From the Wood

30 31

Projects From the Past 36 Easy-to-Build Bobsled New Products 76 From the Chicago Hardware Show Wood Types 79 White Oak Classifieds Out of the Woodwork 'The Rest of 100 Issues"

86 88

Cover photo: Pam Monfort/Bronze Photograph y

Steve Shanesy Editor & Publisher

Christopher Schwarz Managing Editor

Specialties : Projects, techniques, article and project selection (513) 531·2690 ext. 238

Specialties: Article submissions, letters, reader contests (51 3 ) 531·2690 ext. 407

David Thiel Associate Editor Spec ialties: Projects, new products and tools, tr icks of the trade (513) 531·2690 "'-ext. 255


Jan uary 1998 3

For All Your Woodcarving &Sign Carving Needs Terreo provides a full line of machine carving and sign carving equipment. Beginning models are the T-11 0 single spindle bench carver and our CM61 4 singlespindle sign carver. Intennediatemodels include the K-Star, a two·spindleheavy duty bench model, and the Northstar, a heavy duty floor model available inone toeight spindles.



Terrco, Inc. 222 15t Ave. NW Watertown, SO 57201 USA (60 5) 882-3888 Fax (605) 882-0778

January 1998, Vol. 17, No.6

Model T-11 0 Dupli-Carver

Our advanced model is our Master Carver series, which is an extremely heavy duty floor model with from eight to forty spindles. Writeorcall for more information. Model CM614 SignCarver Multi-Spindle Carving Machine Circle #121 on Resource Directory Coupon

Editor & Publisher Steve Shanesy Managing Editor Christopher Schwarz Associate Editors Jim Stuard, David Thiel Editorial Intern Jamie Doan A rt Director Amy Schne ide r Editorial Ad visory Board: Bill Austin, Makita USA. Inc. • Jon Behrle , Woodcraft Supply Corp. • Mike Birch , Black & Decker . Scott Box, Delta International . Jim Brewer, Freud, Inc. • Chris Cable, Fein Power Tool . Chris Carlson, SoBPower Tool . R.J. Decristofaro. Jeff Dils, Ryobi • Steve Erbach, Grizzly Imports, Inc. • Art Finkel , AE Furniture M fg. Co., Inc. • Edward Janda, Panasonic • Todd Langsto n, Porter-Cable Corp. • Rory Leyden, DeWalt Industrial Tool Co. • Cliff Rickmers , Jet Equipment & Tools, Inc. • Dale Zimmennan, Franklin International

General Mana ger Jeffry M . Lapin Magazine Art Director Nancy St et ler CIRCULATION David Lee , Director Mark Fleetwood, Single Copy Sales Mgr. Terry Webster-Isgro, Direct Sales Mgr. PRODUCTION Barbara Schmitz, Director of Manuf acturing Martha Wallace, Magazine Production Dir: Vicki Wh itford. Coordinator Ruth Preston. Art Production Manager ADVERTISING

National Sales Representative Bill Warren, Fi ve Mile River Assoc. LLC RRI Box 1400 Stockton Springs, ME 04981 Tel. (207) 469-1981; Fax (207) 469-3050

Ad vert ising Sales Joe Wood - Tel. (513) 336-9760 Fax (513) 336-9761

Classified Advertising Sales Kathy Georg - Tel. (513) 531-2690, ext. 324

Adve rtising Production Coordinator Debbie Thomas - Tel. (513)531-2690, ext. 219 SUBSCRIPTION SERVICES Send all SUbscripti on Inqu iries , order s and addres s changes t o: Poputar Woodwork ing, P.O. Box 53 69, Harlan , IA 51593 or call (515) 280-1721. Please all ow 6 to 8 weeks for delivery . Popular Woodwo rking (l SSN 0 884-8823, USPS 752-250) is

published six times a year in January, March. May, July, Septembe r and Nove mbe r by F& W Publi cations, Inc. Editorial

and advertising offices are located at 1507 Dana Ave.• Cincinnat i, OH 4 520 7: tel. : (5 13) 53 1-2222. Unsolicited manuscript s, photograph s and artwork should include ample postage on a self-addressed. stamped envelope (SASE) ; otherwise they will not be returned . Subscription rates: A year's subscription (6 issues) is $ 19 .97; outside of U.S.A. add $7/year. Copyri gh t © 1998 by Pop ula r Wood working . Periodicals postage paid at Cincinnati, Oh io. and additio nal mailing offices . Postmaster: Send all address changes to Popu la r Wood working. P.O . Box 5369, Harl an, IA 5 1593 Can ada GST Reg. # R I2 2594 7 16

Produced and printed In the U.S.A. ATTENTION RETAILERS: To carry Pop ular Wood working in your store, call (513) 53 1-2690. ext. 327. or write: Dealer Program, F& W

Publications. Inc., 1507 Dana Ave.• Cincinnati. OH 45207. Woodworker 's Book Club: 1507 Dan a Ave., Cincinnati , O H 45207: (5 13) 53 1-8250

Circle #109 on Resource Directory Coupon

4 Popular Woodworkin g


71zakita. Motor for hig h performance Externally Accessible Brushes for easy replacement

Model 6233DWAE

e 872-9872.

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Packed With Value P ric e d Fea tu res • Wagn er' s Pro ven Pin-Free Electromagnetic Wave Technology • Easy To Read Led Display • Pocket Size • Narrow Sen sor Ideal For Testing Moulding !!I~~ and Trim

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Circle #120 on Resource Directory Coup on

6 Popular Woodworking


~~[p)~~~u~@~ is in Order: .•

N THE LETTERS SECTION of the September 1997 issue I responded to a note from Richey Wallis, a reader who wanted to see the return of the "Master Craftsman" projects. My reply resulted in a heap of mail. I appreciated hearing from everyone. A sampling of these letters appears in the letters section. First, I'd like to apologi ze to Mr. Wallis and those who thought I took him to task . That wasn't my intention. Second, the issues raised by these letters caused me to think again about the objectives of Popular Woodworking , especially as we prepared this 100th issue. Here's what I tell people when I'm asked about the magazine: Each issue has about 15 projects to serve readers ' varied skills . The se range from novices, to intermediates and include a fair number with advanced skill s. We choose many projects because they aren't very time-consuming, although some are not easy to build. We also run a couple time-consuming projects for tho se who have the time. Most importantly, we show you practical bu ilding tech niques that result in quality work . One letter from Mr. Doug Green suggests I underestimate the skill of ad vanced readers . If so, I stand corrected. I welcome photos of our readers' finished projects. More photos from readers will help me evaluate skill levels better so I can set the bar appropriately. And I invite all readers to suggest projects they'd like to see . Mr. Green also argues that master craftsmanship always requires the use of fussy , time-consuming joinery (my words). He says, and I understand his point when viewed narrowly, that rabbet joints are no substitute for dovetail s. I take issue with this notion. The current belief that there 's no substitute for old-time joinery is founded on some incorrect assumptions. It overlooks the performance of modern glue s and lowcost fasteners.


Cabinet makers have always embraced new methods without sac rificing quality. For example, in the 18th century the dovetail became wid espread only when tall case pieces ne ed ed a stronger joint using lighter materials. For tho se who wi sh to use ha ndcut joints in their projects, fine. Just don 't look down on those who don 't. Su re, some might lack the skills , but othe rs have the skills but don 't use these jo ints for legitimate reason s. The snobbery associated with dovetail joints, et ai, is presumptuous, unwarranted and a disservice to woodworkers, woodworking and the public at large. I'll defend the practice of good woodworking (the use of well-cut, common joints) as equally legitimate as the practice oifine woodworking, which can be wonderful , although it is sometimes pretentious. Looking through the fir st 99 issues of Popular Woodworking, we were surprised at how it ha s changed but in some fundamental ways stayed the same. The first issue stated it would serve the interests ofthe small cabinet shop owner and carver. A few years later we looked like woodworking magazines do today. Later, we introduced the PUIlOut™ Plans, a first among wood maga zine s. Last year, we changed again to our strong emphasis on project building.The changes reflect an evolution to bett er serve an evolving readership. But the underl ying fundamental s have rem ained con sistent, practical and down to earth. We intend to sit squarely in the front row of the good woodworking school of thought and provide you ample projects built using practical techniques . We want you to enjoy your woodworking, both the process of building and the fruit s of your craft. PW



G1852 Brad Nailer

An excellent lightweight unit that is very we ll bal anced. Capacity is Y," to '1." and takes 100 ISgauge stap les. Measures 2"w x 7"h x 9W'L. Weighs o nly 2.5 Ibs.

A favor ite for casing and finish ca rpent ry work , this gun acce pts 100 18gauge %" to 1V,6" brad nails. Measures 2"w x 7Y8"h x 9 Y," L. Weighs o nly 2.62 Ibs.


$5 9 9 5

WAS 98 9 9S ONLY

$5 9 9 5

G3811 Super Stapler

G1861 Super Brad Nailer

This stapler offers outsta nd ing power and dependability. Takes 100 'l'H " to IV'6" IS-gau ge stap les. Weighs only 3.S lbs. Includes wrench and oil.

Our bes t all aro und finishin g gun shoots 150 ISgauge brad nails from %" to 191\6" long. Measures 2%"w x S;;"" h x 12V,6"L. Weighs o nly 3.3 lbs .


$799 5

WAS 91 2 9 95 ONLY

G3690 Angle Finish Nailer

This is a dependable, • h ea vy -duty uni t / de signed for o ptimum performance with minimum maint enan ce. Drives 75 to 105 2" to 3\1," clip pe d head nails. Fast loading. Weighs only S.3 lbs. WAS S3 5 5 95 ONLY

STAPLES F O R GI847 8c. G 3 811 (B ox of 5000 x 18 gauge) ,/, ' S's 413 K G18 48 ' 9's 'Is" 416K G18 49 ' i i'S 419K '14' G1850 "1 2'S 'I, 422K G185 1 1" "1215 425K G38 12 "13'S 1'Is" 428K G38 13 "14'S 430K G38 14 1'1" BRAD N AI LS FOR G 18S2 8c. GI861 (Box of 5000 x 18 gauge) s7u %" F10 G1857 'Is" ' 795 G1853 F15 og's 'I. F20 G1854 "i i'S 1" F25 G1855 "12's 1'1,. G1856 F30 "1 3'S 1'Ie" G1858 F35 "1 3'S 1'h" G1859 F38 1';'. "1415 F40 G1860

G2414 G24 15 G2416 G2417 G2418 G2419

Marvel at the po we r and light weight of this nailer. \X'eighs only 5.9 lbs. Accepts 100 15-gauge or 90 14-gauge 1W to 2\1," clipped head nails in its sp ring activated magazine. Includes o il, wrenches and goggles .

$2 7 9 9 5

BRAD NAILS F O R G2 4 1 3 (Box of 2500 x 16 gauge) 1'1." 1'12 1W 2" 2';." 2'12


"7's 18 9 5 ' 995

G242 1

"i i'S "1 2's "1 3'S

G2422 G2423 G2425

FINISH NAILS FOR G3690 (Box of 4000 x 15 gauge) "1 9'S 1'12


G3693 G3694 G3695 G3696 G3697 (3000)

$7 9 9 5

PI. 2" 2'14 2'h"

BRIGHT m ox of 4000) 2" x .113" BRIGHT (Box of 2000) 2'12 X .113" 3" X .120" 3 '12 X .13 1" GALVANI ZED mox of 4000) 2" x .113"

G242 7 G2428 G2429 G2430

"2 2'S "23'S ' 24 85 "2 5'S

2'h" x .113" 3" X .120" 3 ';." x .131 " 3'h" x .1.3 1"


Cust. Svc: (717) 326-3806 • FAX: (800) 438-5901 "VIsit us at



Circle # 136 on Resource Directory Coupon

"2 3 50 "2 9'S "3 9 15 "4 9'S

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Call , FAX or Write Anytime - 24 hours A Day, For A Free Wood or Metal Catalog ! 13709 7658

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From the PW Mailbag Editors' note: Man y readers responded to Septembe r 199 7 ',I'leffer from Richey A. Wallis who complained abo ut the lack of "Master Craftsman .. projects ill Popu lar Woodworking. Other reade rs responded to Edito r Steve Shane sy '.I' respon se to that letter: Here are some ofthe mo re interestillg letters. To read Steve '.I' thou ghts Oil the issue, see his " Out all A Limb " column Oil page 6.

We welcome your comments about PWor anything related to woodworking. We'd also like to see color pictures of what you're building. Send your input to: InfeedjOutfeed, Popular Woodworking, 1507 Dana Ave., Cincinnati, OH 45207. Our e-mail addressis: popwood@eart hllnk .net. Letters may be edited for pub\icat\on. - Steve Shanesy, editor, PW

Magazine is Good For Weekend Hobbiests

I'm afraid I have to agree with the opinion of Richey A. Wallis (September 1997 "Infeed/Outfeed") . Popular Woodworkillg definitely emphasizes projects for the weekend hobbiest. Don't get me wrong, there's nothing wrong with that. Your magazine fills a niche and does so quite well. But please, let us speak realistically. My subscription renewal carne yesterday, and I've just spent the last hour reviewing the value to me of this magazine. When you say you present projects that "challenge the skills of [your] more advanced readers . . . [and] keep the best hands busy and challenged" you are either overestimating the difficulty of

8 Popular Woodworking

your best projects or underestimating the skills of your advanced readers. I agree with you that master craftsmanship entails expert skills producing works of enduring quality. However, based on what I've just reviewed, I disagree with your definition of what constitutes "enduring quality." By the very definition of the term, if you truly want to produce "enduring quality" you simply must use the techniques that time alone has proven to be truly enduring. There is no shortcut. Rabbets are not a substitute for dovetails. Dowel joints are not in the same league with mortiseand-tenon construction. Anything less than the best technique, regardless of how the joinery is accomplished, is something less than the best. And anything less than the best is certainly not "master craftsmanship." What your "best" projects lack is an attention to detail in both design and particularly in joinery - that's right, those "fussy" details that distinguish true craftsmanship from the woodbutchering weekend wanna-be . Doug Green Boulder, Colorado

Circle #105 on Resource Directory Coup on

Continu ed 011 page /2

To understand you have to know how to

something completely,

read between the lines.

Trigger finger drives 5,000 nailsa day.

Subtle touch ensures accurate fastenerplacement.

Palm lifts 4,000 Ibs. of lumber a day. ------..!~-~

Wrist bends 23,600 times a day.

Your hand s say a lot about you. And when you're a professional craftsman, they have an especially lon g story to tell. That's why at Senco" we talk to thousand s of professionals. We study their hands in detail. T hen we design our too ls to fit those hand s. So when you pick up a Senco tool, it feels right. It's lightweight , perfectly balan ced, and moves like it's pan of you. In fact, every produ ct we make at Senco, from the smallest finishin g nail to the most powerful too l, is developed in the same way. Because und erstand ing how something wo rks is the first step in making it wor k bett er. For the Senco locat ion nearest you, call 1-800-543-4 596 . Visit Senco on the Worl d Wide Web: http: // SLP20 C 1996 Senco Produ cts, Inc.. 8485 Broadwell ROOld. C ino;inn' Ohio 45244 ¡161)< )

Sa(rty First. .;.') T he only way 10 work .~

Made in the U.S.A.

Circle #122 on Resource Directory Coupon








DRILL PRESS HIGH SPEED STEEL ROUTER BITS Have the right bit on hand when you need it. Available in 1/4 " shonk sizes Ihese high speed steel bits have a greater resislanceto heat. Longlasting bits work well on wood , plastics, soft metals and composite materials-Iaminotes, plywoodand more.Cornerround TYPE

eases edges and softens sharp corners. 45 ° chamfer makes bevels for joints in moldings, panels and frames. Cove bit makes finger pulls easy,while on ogee odds a decorotive touch to nearly any projecl. ITEM


1/2" Co rner Round


1/4" Rabbeting


45° Chamfer


1/2" Straight



51121 ·1SHA

3/8" Straight


1/2" V·groove


3/8" Corner Round


3/8" Cove


3/8" Core


1/4"Core BoxNeining


5/32" Roman Ogee


3/8" Hang Slot(keyhole)


1/8" Straight


1/4" Beading


1/4" Straight

51277· 1SHA

1/2" Core Box


$3 9 9 $3 9 9 $3 9 9 $24 9 $24 9 $24 9 $3 9 9 $3 9 9 $3 9 9 $1 4 9 $3 9 9 $3 9 9 $3 9 9 $24 9 $3 9 9 $24 9 $3 9 9 $3 9 9


1/4" Corner Rou nd



HARDWOOD CLAMPS Hardwood jaws distribute pressure evenly, and easily adjusts far nonparallel surfaces and odd shapes . Wood construction help s eliminate workpiece damage . JAW OPEN JAW LENGTH CAPACITY ITEM PRICE 04852 99 4-3/4.. ·3S 8" HA 04853 9 9 10" 6" ·4SHA 04854 99 12" 8-112 ·5SHA

$3 $4 $5

• 8-114" maxi mum o o o

distance spindle to table 113HP motor 0 2" stroke. 8-1/4 " swi ng 620 10 3100 RPM 0 112" chuck 22-112"high. 47 Ibs.

ITEM 34231 ·6SHA



$34 9

ITEM 37056·2SHA


1-112" thraat depth


Weight : 1-4/5 lbs.

$ ..09 ~-




14.4 VOLT, 3/8" CORDLESS


14$mSpowec Tools!






o o o

o o

High powered 10.000 RPM 5/ 8" spindle with 7/ 8" arb or adapter @) Motar: 3/ 4" HP, 1l5V, 5.18 amps = High pow er to WI. ratio 11-718" long Spindle lock


ITEM 31135-65HA

High voltage, heavy duty battery gives long run times between charges. T-handle design makes this drill easy to use.

J9 9 9 $8 99

o o o

4-1 /2" x 1/4" GRINDING WHEELS (PACK OF 10)

Jacob'" keyless chuck 0 6 torque settings Variable speed. reversible; 0 to 600 RPM Includes 6 pc. drill bit set. 6 pc. screwdriver bit set, magnetic extension bit. char ger. batt ery, keyless chuck, and carrying case

ITEM 06674-05HA

fS4H $~Q"



ITEM 34793·3SHA

9 99



$ ~999


ITEM 34794·0SHA ~

~~~[JELTA @ Delta 22-540


IBlI 12"



Carbide steel tips lost up to 50 times longer and can be resharp ened . High spee d steel blades are denser and stronger far greate r impact resistance. Does nat have 10 be removed fram saw to odiu st cutting w idth. 4500 max. RPM; 1" arbo r w ith 5/ 8" adapter

Four pre cisian ground columns effortlessly raise and lower curterheod. Precise thickness sca le conveniently located for easy reference. M otor; 15 amp . 120V; Cap : 12" w idth. 6"t hick. 3/ 16" depth 01cut; 26.2 FPM feed rate; Table size w ith extensions: 12-1/ 8" x 26" ; 8000 RPM. 16,000 CPM; 27-1/ 4" x 20 -112" x 15" overall di m; 68 Ibs. tool WI; Factory recondition ed . fa ctory perfect; removable table extensions. and fold awa y depth adjus tment far easy transport




ITEM 06177·1SHA




Weight: 2-7116 Ibs.

ITEM 05901 -0SHA


* Within the 48 States1 S2.95 handling an all orders

1-112" throat depth



$489 9

]lO V , j PJS69 9 9

CallTo Orderor Askfor Free Catalog: Q./~" Order24 Hoursa Dayn Daysa Week Most Phone OrdersShipped in 48 Hours' - ~

Hand le screw operating range: 2-118"




Make a squ are hole in the fraction of the time iltakes by hand' Easier layou t for professional mortise and tenon [olnts in furniture. ca binets. a nd restarat ian. Fence w ilh hold da w n clamp keep war kpieces from lifting off the tabl e. l ar ge capacity - up to 5" ma ximum heighl. Includes fence, w orkpiece clam p. and 1/4". 3/8 ", and 112" mortising chisel s and bits. o 10-718" X 7-3/4" base o 13-3/8" x 6" table 0 60 lbs. ship ping wt. o 3580 spindle speed 0 5" throat • 5" ma ximum workpiece height o Accepts .745" chisel shanks


ITEM 31255·8SHA






DRILL 1/4 ", 3/S " , & 1/2 " SqUARE HOLES

PIPE CLAMP SET Constructed from heoHrealed costiron, these durable clamps keep your work rock steady. Just screw the handle side onto a 314"threaded pipe and slide the spring loaded end on. You're ready 10 gol Pipe not included.


lliiiii!il 1- 800 - 423 - 2567 Circle #127 on Resource Directory Coupon

$~999 ~

CHARGE ~c:::~d.• •~~ IT' ~~~ Or 5en~ C,heck or MoneyOrderto: Harbo~ Freight Tools, 3491 MISSion Ooks Blvd. Box6010, Camanlto, CA 93011 0


Pittsburgh .

~ .' IE4tJ COMBINATION 4 " BELT & 6" The 36" long bell operates at Z168 feet per minute and will handle both large and small surfaces plus inside and outside curves. Includes a tilting lable that locksat any position from 0° to 45° tor bevel sanding. Table Idie cost aluminum); 7-1/2" x 5"; Sanding belt: 4" x 36"; Sanding disc: 6" dia. Idie cost aluminurnl, Discspeed:1720 RPM; Bellspeed: Z168 FPM;Motor: 1/3 HP, 115V, 60 Hz, single phose.


8-lIZ" x I-liZ" x l - lIZ "


ITEM 30766-1SHA











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Anoth er step forw a rd in dr ill desig n th e so m e power in onl y 3-1/8I bs. Only 8" ov erall length handles easy an d get s into tight spots. Featur es 0 to 700 RPM reversible vari a b le sp eed s an d 6 stag e tor qu e settings for a va riety of applicatio ns . Electric bro ke stop s chu ck fa st ! Includ es 1hour chorg er, TWO batter ies, battery cove r & cor rying case.

M o de of he avy duty triple te m pe red too l steel. lips a re 4-1/2" io ng and p recision g round. 10" hordwoo d ha nd les mi nimize operator fatigue. o Contains: 1/ 4", liZ" and 3/4" gouge; l IZ " and 1" skew; 1/ 2" spearpoint; l IZ" porting tool; and 112" round

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Die cost aluminum table Z5-3/4" x 16", has adjustable 17-7/ 8" x Z" rip fence and inchl metric scale for precise cuning. o Max. depth of cut at 90°: 3-1/ 8" ; 0145 ° : Z-II2" 0 Blade sold separately, below o Motor: Z HP, 115V, 60 Hz, 10amp, 4500 RPM 0 Shipping weight: 36 Ibs. • Miter gouge cdiusts O· - 60° left and right o Blade capacity: 10" with 5/8 " orbar


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Cont inued fro m page 8

Mr. Wallis Responds Boy, did I touch a nerve. I simply made an observation. Nothing personal was intended. "Master craftsman" is not my term. It was featured in my first issue of Popular Woodworking (May 1994). If you will read the editor's comments in "Turnings" in that issue you will see my point of reference. I am not a master craftsman. I said so in my first letter. I do not own quality hand woodworking tools. I do not know how to use them. My "handmade" dovetails are router-assisted. My basic point is that there has been a continued emphasis on quantity in your magazine since the July 1996 issue. Every cover has featured from eight to 24 projects. Woodworking is a source of pleasure for me. Therefore, there is no rush to complete a project, large or small. There is pleasure in the doing just as there is pleasure in the finished article . I'm aware that there are other woodworking magazines on the market. I subscribe to some. I may take your invitation to leave Popular Woodworkin g. However, I would prefer to have some article s and projects that interest me. Richey Wallis Mount Juliet, Tennessee

Don't Lose Your Cool Boy, Richey A. Wallis sure pushed your button! So much so, in fact, that you lost your cool. From my point of view you are doing a satisfactory job. Your magazine fits within a niche of woodworking periodicals, and as a reader should I choose to undertake the "Master Craftsman" projects I would tum not to you, but to Fine Woodworking. I would advise Mr. Wallis to do the same. The reason for this letter is to say to you that I believe you stepped out of bounds in your response to Mr. Wallis. Deriding a reader in print is no way to win friends and influence your readership. You would demonstrate equanimity and demonstrate good character traits, therefore, if you would apologize to Mr. Wallis in print. Thi s may not pacify Mr. Wallis, but it would reveal to other readers that we are not dealing with a hot-headed editor. Dr. Gerald R. Ogden EI Do rado Hills, California

Editor Did the Right Thing I want to shake your hand for defending your magazine against the writer from Mount Juliet, Tenn.! Here is a bored reader who complains of not seeing plans suitable for a master craftsman, yet states clearly that he is not a master craftsman. I'd like to be a plastic surgeon, but I can 't seem to locate enough quality "how-to" videos. Keep up the good work! Steve Veal Dallas, Georgia

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With respect to yo ur magazine, one word describ es it: excelle nt! But I think it's time that you reinstated "Scrap Solutio ns" from the early 1990s. I recall the reason th at it was ca nce lle d but I don ' t fee l it' s fair to punish everyone because of one cheat. Whi le I do enjoy woodworking I am not very creative in the design aspect and did enjoy and looked forward to "Scrap Solutions" rathe r than bagging up my scraps and donating them to another fireplace . Mack Cam eron Brooklin, Ontario Editor 's note: A s some ofyou might remem ber, we sta rted a "Scrap Solutions " contest in Novemb er 1991 that let readers send in des igns/or p roj ects made fro m scraps. Unfort unately, some readers' entries were plan s fro m other publications and the contest was cancelled. However, we still think the contest is a good idea and are thinking about ways to resurrect it.

Continu ed on page 14

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Now That 's Small Because I would rather be making sawdust, writing to a magazine has never been by cup of tea . But I would be remiss if I didn't share with you the many hours of satisfaction I've derived over the years from the "Scroll Sawn Animals" article from November 1990 (#57). I've made some of the reindeer 36" tall, others I've made as sma ll as possible, like the ones in the photo . Thanks for all the fun . It was great.

Lore n Lang Sidney, Mo ntana

600 new items The smallest reindeer is made from black ebony. The largest is made from cocobolo.

Woodworking Tools Patterns, Books & Accessories Advice on the Circle-Cutting Jig For the past several years I have been making wood and metal wind chimes for gifts and to sell. The __ most difficult part of making them was cutting the two or three circ les of wood for each set. Finally, I "cobbled-up" a simple band saw circle jig, wh ich was only marginally accurate, not really what I wanted. Then I picked up the September 1997 issue and saw the band saw circle jig article on page 52. After reading the art icle and studying the drawings it became apparent that a couple of important things had been overlooked in the construction and use of the jig. Nowhere is it mentioned that the pivot-pin slide bar must be positioned precisely perpe ndic ular to the side of the saw blade. If this is not done, the work piece could pinch and possibly break the blade. Also, in using the jig, the pivot-pin must be aligned with the blade tooth gullets in order to cut smooth accurate circles . Aligning the pin with the front of the teeth causes the work piece to pull the blade toward the center pin , cutting a spiral and possibly breaking the blade. I know, it happened to me. Since reading the article, I have built my own version of the jig that give s me the accuracy I need, and I can cut circles anywhere from 1 1/2" to 53" in diameter by j ust reversing the slide bar in the jig and providing extra off-table support for the larger work pieces. Thanks much for the help. I enjoy your magazine. It's one of the best. Keep up the good work.


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Harold H. White Madison, Wisconsin Circle #100 on Resource Directory Coupon

14 Popular Woodworking




More Ways to End "Glue-Up Voodoo" Youreditorial "An End toGlue-UpVoodoo" summarized the sorts of problems caused by the inconsistencies of articles about woodworking .Yoursummary of the operations was excellent but incomplete.When r attend special project classes at the local community college, r observeseveralproblems with the work of entry-level woodworkers. They would get cleaner work by: 1. When gluing wide boards , glue only one joint at a time . Maintaining good alignment of boards when more than one joi nt is glued seems to be difficult for most people. 2. Align the projected axis of the screws of the clamps with the center plane of the boards being glued. Boards tend to push up or down if the projected axis differs greatly from the centers of the boards. 3. Use much less glue. Excess glue is difficult to remove completely. Your series the "Little S hop That Could" provides a very useful service to entry-level woodworkers . The series shows non-trivial projects that can be done successfully by entry-level woodworkers. r don't recall seeing such articles in other magazines, but beginning woodworkers certainly need them. Harold A. Hubbard Berkeley, California

Important Notice to Readers In our las t issue (Oc t./No v. '97, No. 99) we ran a project prov iding dimensions and construc tion methods for building an earring rack on page 45. After the issue was dis tributed , we learned that the project design may be protected under one or more U.S. patents. Beware that building this project for yourself or others could be a violation of the patent. We regret any inconvenience this may have caused. PW

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Woodwo king

For new, expanded listing of E.C. E. tools andprices write to: David Warren Direct, P. O. Box 542, Crystal Lake, IL 600390542.. Call (800)724-7758. Forty different woodworking planes, European work· benches, frame saws, squares, marking gauges, chisels, mallets, andmore. Circle #104 on Resource Directory Coupon


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Secrets- from Ni ck Engler. A quick reference guide that helps you ident ify, correct and even avoid th e most common fini shin g prob lems. Put Nick's 30 years of woodworking savvy to work in your shop , and you'll put beautiful fini shes on every piece you make! A $3.95 value, it's yours FREE just for joini ng now!

All books arehardcover unless marked Pb. Prices are publisher's listprices


Membe Every 4 we receive th ews describing th e Main Selectio nd up to 100 more woodworking books. ou want th e Main Selection , do nothin nd it wil l be sent automa tically. If you ant a di fferent book , or want nothing t a month, you'll always have at least 10 s to decid e and return your selection card. If late mail deli very should ever cause you to receive a book you don't want, you may return it at club expense. You are und er NO OBLIGATION to buy any more books- you're just tryin g out the club for 6 months. After that, you may cancel at any tim e. Every tim e you buy a book from th e News, your membership will be renewed for 6 month s from the purchase date .

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Offer good in U.S. andCa nada fo r new members only. Remitin U.S. funds. One membersftip per fto useftold. Tfte clubreserves tfte rigft t toapprove all applications and ma y cancel membersftip at anytime. Please allow 3·4 weeks for processingand delivery.



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A Plane [RV1] 0~~

Plane rough lumber and make miles ofmoulding with one machine. NE OF THE MOST INTRIGUING experiences in woodworking is watching a rough board emerge from a thickness planer. Magically, the true character of the wood's surface is revealed (photo 1) . The same can be said for seeing a piece of rectangular stock emerge as an intricate moulding profile. There was a time when home-shop woodworkers who needed to smooth a number of boards would truck them to a local lumber yard where an employee ran them through a monster machine for a fee - negating the bargain of buying lumber in the rough. We yearned for the day we would be able to transform rough lumber into finished stock in our own shop. And the concept of making our own moulding simply was unthinkable. Now those dreams are a reality because of the fairly recent introduction of "small" units that can be purchased for less than $700.And other planer/moulders, such as the Jet, can be used to make moulding by the yard or the mile. While the machine doesn 't look like the rna-


Moulding curved components is a practical application, but it calls for precise fabrication of the jig required. The feed rollers take the stock through the cutters - whether It 's curved or straight. Take light cuts. A few passes get the job done.

chines in the mills, it is structurally similar and is ample for the home and small commercial shop. Th e Jet can accommodate I3"-wide boards up to 6 VS" thickness. The I V2 hp motor rotates the threeknife cutterhead at 4,500 rpms, which provides 13,500 cuts per min ute. There are two automatic feed rates: 20 feet per minute for planing and 10feet per minute for moulding cuts. While operating this machine does-

n't req uire expertise, there are essential rules to follow to ensure quality results.

Planing Planing refers to smoothing a board or reducing its thickness while producing a plane that is parallel to the opposite surface. The board is moved smoothly into the infeed end of the machine until it is gripped by a feed roller that auto-

Diagram 1: Extension Table

' t 's " hands off" as soon as the work makes contact with the infeed roller. The machine takes over, moving the work from start to finish. It 's important that the tool be equipped with extension tables both fore and aft to avoid planer troubles such as " snipe."


18 Popular Woodworking

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Continuedfrom page 18

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Developed horsepower

matic all y moves it past the c utterhead whe re a second ro ller helps move the wo rk a nd to kee p it fla t o n th e planer bed. Always feed stock so the knive s are shaving with the grain of the wood. Grain

direct ion mi ght not be o bv io us when worki ng with rou gh woo d, but yo u ca n us ua lly determine it by makin g a slight rip cu t along the edge of the board . A ll thickn ess planers have lim its to

the depth they can cut. On the Jet , a 1;8" cut is allowable on stock that is narrower than 5 1/ 2", but 1/ 16" is the maximum cut on wid er stoc k. In all cas es, you get the Continued on pa ge 22

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Continu ed from page 20


The extension tables pivot down to minimize storage space. I made my tables with medium density fiberboard. It's a good idea to seal all edges and surfaces before installing the pieces. Keep them bright and smooth with an occasional application of paste wax .


best results by making a few light cuts rather than a single heavy one . Your board must not be shorter than 14" or less than 1/ 2" thick . We 'll talk a litt le later abo ut ways to get around these restrictions. Keeping th e Diagram 2: Bedboard board flat through..1.-3/ 8 " Holes C/L out the pass is very 2" important. "Sn ipe" o - a thickness planer buga boo that is 9" actually a slight depression on eit her o end of a planed board - is usua lly 1/ 4" Countersun k holes caused by failing to support the work on Tall fences true p lane a keep the work throughout the pass. vertical when Snipe can occur, for planing edges and example, whe n the when using mould weight of a board ing knives to form glue joints or entering or leaving tongue-and-groove the planer tilts the joints. The jig board up into the adjusts to accomcutterhead so more modate various wood is removed at stock thicknesses. the end of the pass. That's one reaTop view Diagram 3: Fence C/L son that extending the length of you r planer bed is a must. l "r-Accessoryexte nsion tables are avail1--- - -14 " -- --1 able. as are freestanding ro ller stands. I made my own extension table shown in diagram 1 . If you dup licate the idea, have the steel bars bolted in position and secure can fold down for storage (photo 2) . a long board on the planer bed by raisYou need a "bedboard" that' s secured to the planer bed for moulding ing the table so the feed rollers grip the operations. If you des ign it like the one board. Then clamp the extension to the shown in diagram 2 , it also will serve board before insta lling the self-tapping screws. Lock each exten sion with four as a base for attac hing jigs that add conbolts . If you remove one bolt from each venience and acc uracy to particular opContinu ed Oil page 24 side and loosen the others, the extensions

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22 Popular Woodworking


Bandit'?' Sawblades: An Industry Original. the exceptio nally smooth cuts SystiM atic has been known fo r since

The Origin al SystiMa tic w as the fir st in the industry to design bl ades w ith TFE Red coa ting, o rig inally developed to redu ce frictio n o n mil itary fighter p lanes and commercial aircraft.

1956. Coo l running blades, tougher perm anent coating, lon ger tool life, and opti mum designs are exceptional features that make SystiMatic Bandits truly an industry origi nal.

TFE Red is a thicker, permanent coat ing that lasts lo nger and dissipates heat bette r than other coatings . It acts as a lubricant for cool , smooth running blades.

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A gaUge iS furni shed so mo ulding knives, wh ic h co me in sets of th ree, ca n be correctly aligned. Allow the mac hine to run down for a few minutes when you 're done, t hen check all t he locking sc rews.



St riPs to be moulded must be guided to move straight and in line with the knives. The ji g I made is adjustable so it can be used wit h various stock widths. Be sure the guides are parallel.

SAND alo ng edges and into corners witho ut vibration

eration s. One ji g shown in photo 3 , ensures the boards will be held vertically when doin g edge- planing or jointing. This also is the set-up to use when using moulding knives to form glue joint s or ton gue-and-gro ove joints. The reason for not gluing the upr ight - or fen ce - to the ji g 's base (see diagram 3) is so you can supply a fen ce of a different height if yo u need one.


Why buy ju st a "deta il" sa n de r wh en th e FEIN "Tria n gle" Sander offers so mu ch m ore ve rsa tility? Sure th ere are a lo t of other sanders that cost less, but none o f th em have th e patented o scill ating motion . Our Newest Sander features variabl e speed control, 20% m ore power, ye t weighs 1/2 Ib less than th e o riginal FEIN Sander.

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24 Popular Woodworking



Mouldin g knives are available in shapes ranging from quarter-round to crown moulding. Large ones are installed in place of the planer knives, but ones that are 2" or less in width can be used witho ut rem ovin g the planer kni ves in the Jet. Th e moulding knives, in sets of three, must be aligned in the cutterhead . To ensure this, a gauge, which is shown in photo 4 , is furnished. With one knife in place, the others are installed so they barel y touch the gauge when the cutterhead is turned by hand. Incidentall y, this is one area of woodworking where you should wear tight-fitting gloves. Planer and moulding knives are sharp. Wood to be mould ed must be aligned with the knives and guided in a straight line throu ghout the pass. One way to ensure thi s is to for m a tunn el by cla mping par allel strips of wood to the bedbo ard . A bette r way is to make an adj ustable ji g that will accommoda te di ffer ent width s (se e photo 5 and diagra m 4 ) . In so me cases, dependin g on the size and style of the kni ves, the feed rollers have to be lowered. Becau se this is cove red in the manual s, there' s little point in repeatin g it here. It's always a good idea, es pecia lly when working with a new knife set-up, to make a trial cut on scrap material. And, as always, you get better results by makin g several light cuts.

Diagram 4 : Fence

Top view

Diagram 5: Curved Jig

3/8" t hick o utside gu ide

'/Z" x 51;4" x 32"


Top view

l"r - -


• 13/8" x 31;z" slot s


Feed -p ath of work Attach strip with glue and nails fr om unders ide

Curved Moulding It might seem strange to think you can produce curved moulding with a planer, yet it' s a practical application. The possible radius of the curve depends somewhat on the size of the machine, but you 'll find that smaller radii are more limited than large. The procedure is fairly simple but call s for a precise jig setup like the one shown in diagram 5 . "Inside" and "outside" guide s that suit the exact curve of the work are secured

to a base that in turn is clamped to the bedboard so the intersecting centerlines of the jig and moulding knives are exactly aligned. Thi s can be established visually by making the set-up with the dust hood temporarily removed. Once you are organized, feed the work through the jig just as you would a piece of straight stock. One thing is certain : If you can't move the work smoothly through the guides by hand, don 't expect the machine to do it.

Other Techniques (diagram 6) Boards that are too short to be fed through the planer can be butted end-to-end with other boards so they can be processed like they were a single piece. A fellow woodworker connects the boards by gluing them - not a joint I would recommend, but it serves the purpose. After he planes them , he snaps the boards apart or cuts them on the glue line. Feed rollers flatten warped stock Continued all page 26

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January 1998 25

Continuedfrom page 25

Diagram 6: Other Techniques

Support strip Carpet tape

Squaring Stock on a Jointer


Smoot h side 1 on a j ointer

Smooth s ide 2. co nfirm 90' angle

Finish s ides 3& 4by plan ing

as it goes through the planer, but because of wood's inherent springback, the warp will return when the pass is complete. Narrow thick pieces might resist the temporary flattening, but not wide ones. One way to get around this

is to flatten the convex surface on a jointer so you 'll have a flat face to put down on the planer bed . Another system involves placing the warped board on a larger flat board, with shims under the warp. This will remove warp, but

with considerable loss to the thickness of your wood . So face it, extreme warp cannot be cured. It's better to rip the board into several pieces, each of which can be planed and then reassembled with glue. To square stock precisely, it's best to smooth two adjacent sides on ajointer and then finish on the planer. Planing stock thinner than the machine normally allows can be accomplished by securing the work to a thicker board and passing them together through the planer. Carpet tape hasenough bond to keep the pieces together. If you have a lot of these thin boards to plane, it might be worth your while to "veneer" your larger support board with ISO-grit (or coarser) sandpaper. PW R.}. DeCristoforo is the author of more than 30 how-to books including Jigs, Fixtures and Shop Accessories (M cGrawHill) and is a member of Popular Woodworking 's editorial advisory board.

The l]@ [I)~~u Tricks rom our first





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Each issue of Popular Woodworking offers tips and tricks for the home woodworker that we 've accumulated from readers, contributors and from our own workshop and woodworking experiences. We want to encourage the free exchange of these time-saving and safety ideas for all woodworkers. If you have a good trick, we'd love to hear about it. Send your trick, whether it's one your father taught you or one you came up with on your own, to Popular Woodworking, Tricks of the Trade, 1507 Dana Ave., Cincinnati, OH 45207. NOVEMBER 1992

Sandpaper Alignment Aid

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How many times do you stick and peel the hook- and-loop sandpaper to align the ho les? If they're not properly aligned, you defeat the dust extraction system. After a bit of frustration, I devised this tool. Layout the hole pattern using a sanding disk for your model , and size the dowels to fit into the holes in the pad your sander. A nthony A nello Buffalo, Ne w York


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Filling Small Gaps I've heard many times it's a good idea to keep a little sawdust from each project you make. If the project is damaged in the future and needs wood filler, there is nothing better than making your own from the original sawdust. Mixing sawdust with glue works well for filling small imperfections and gaps. Recently I mixed sawdust with varnish, and the results were even better. Bill Bu ck welder Horseheads, New York

MAY 1995

From hightech euro stylekitchen ~ilir'Ji ~ hardware to finely cralled humidor components , hardwoods , plans , tools and much more!

Handy Drill Storage I don't know about other woodworkers, but I really appreciate having my drill s, both corded and cord less, near at hand and ready to use. I solved this by mounting a ready-made scabbard on the wall right over my bench where most of the use takes place. A lbert Beale Littleriver, California Continued all page 28

Circle #118 on Resource Directory Coupon

January 1998 27

TRICKS OF THE TRADE " , Continued from page 27 JULY1989

The "Ghost" in Your Lathe


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Mark outline of turn ing us ing a template


Here's a great way to make duplicate parts on the lathe. Layout the pattern on two perpe ndicular sides of each piece. Carefully band saw to the pattern lines on one side and then tape the sawn pieces back onto the stock with masking tape, so you can cut out the pattern on the other side. Discard the waste and mount the stock on the lathe. When the wood is spinning, the outline of the pattern will show up as a "g host" line agai nst the squareness of the stock. Carefully tum the pattern. This works best on thicker spindles, but it can be used on any diameter. Don Kinnaman Phoenix , A rizona NOVEMBER 1996

Drafted For Accuracy Circle # 119 on Resourc e Direct ory Coup on

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28 Popular Woodworking

To set up the miter gauge on your table saw to exac tly 15, 30, 45 and 60 degrees, first purchase two drafting triangles,one 12" ,45190 degrees, and o ne 14", 30/60 degrees. They're available at most large office supply stores. With one edge of the triangle agai nst the miter gauge, and the other lined up along the mi ter ga uge groove (pa rallel to the saw blade, of course), you can use these to double check and fine tune the desire d angle. To get the 15 degrees setting, you need to use bo th triang les side by side. Th ese triangles are also handy for checki ng blade tilt ang les, includin g 90 degrees. Joseph G. Z weck Madison , Wisconsin MARCH 1995

Dado Gauge A stack-type dado blade can be time consuming to set up each time a particular width dado is needed . To solve this, I keep a strip of hardwood hangi ng near my saw. Eac h time I set up my dado blades for a different w id th, I make a shallow dado cut on this strip. I then record the number of chippers and any sh ims used for each dado cut. The strip provides a handy future reference. Daniel Cassidy Medway, Maine


Make Beautiful Inlaid Boxes!

MAY 1996

Wascally Rabbets! Rabbet s and moulded edges like those used for picture fram es are difficult to cut safely and accurately on small frames for pictures or photo g ra p hs w he n usin g a route r. I make moulded fra me sides without trouble if I do the router work on the edge of a wi de board , then cut that piece off o n the tabl e saw. Then I repeat my router cut on the new edge and so o n until I have enough pieces for my frames. Thi s wide board gives me a goo d bea ring surface forthe base of the router so I ca n c ut th e ra bbe t fr om one side and my m oulding fro m th e othe r wi tho u t fea r of th e router wobbling and spoil ing the wood.

Creating Beautiful Boxes With In lay Tech niques Now building elegant boxes is easy using this handy reference packed with step-bystep projects! You'll be making gorgeous inlaid creations with features ranging from handcut dovetails to hidden compartments as you study... • 13+ lavishly illustrated projects • fantastically precise drawings, cutt ing lists and step-by-step photos • full-color photographs of finished projects that show off the unique beauty of each box • plus, imaginative advice on how to tap creativity and design adaptations of these and other projects

John Clarke Venice, Florida JANUARY 1992

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Laying Out Large Curves and Arcs

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Thi s sim ple j ig results in a sharp, clean layout line when drawing large curves and arcs. Bow It consi sts of two part s that I '/4" thick disk ) w/pencil hole in call the "bow" and the adjustthe center ment "arrow." The bow is made Offset pencil line from stock 3/16" to '14" thick and 3/ 4" wide. The length can vary depending on the size of the curve needed . The one I use the most is 32" long. Cut a thin slot in each end , run nylon string betw een the notches, and secure it with a knot at eac h end . Make the 12" to 14" long adj ustment arrow from 3/8" x 3/ 4" stoc k. Narrow one end of the arrow, and cut slots every '12" to perm it different curvatures of the bow. To use the device, place the arrow in the bow with the string in a notch that bends the bow into the curve you want. Note that by changing the positi on of the arrow in relation to the center of the bow, different shapes can be created . Here 's another simple device you can make if you want to draw a curve exactly parallel to a curve drawn with the "bow and arrow" jig. Simply tum a '14" thick disk with a radiu s equal to the distance you want between the two parallel curves. Drill a hole in the center j ust big enough to accomm odate a pencil tip. With the pencil inserted, hold the disk against the bow and allow it to tum as you move it. The line will be parallel to the curve of the bow.


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Robert Colpetzer Clinton, Tennessee Continued on page 30






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Janu ar y 1998 29

Continu ed from page 29 JANUARY 1990

Scrap Wood Framing Clamp All shops accumulate large amo unts of plywoo d, often in hardw oods such as birch , as h, oak, etc . We ofte n d on 't wa nt to throw out even 10" to 12" sq uare chunks beca use we might have a need for them later. Here is yo ur need for them right now. Thi s is a co rne r c lampi ng aid to be used with C-c1amps, han d sc rews or bar clamps. These aids are designed to "sq ueeze in the corn ers" of boo kcases. picture frames, or other hard-to-clam p proj ects. The hole on the inside corner perm its the per fect fit of a 90- degree mitered joint. and prevent s any ooz ing glue from sticking to the aid. The notch es on the top and side are for positionin g C-c1amps for a tight fit, or they can be used with bar clamps to pull the co rners on eac h end toward ea ch other. Mak e these aid s from two o r thr ee thickn esses of Y4" plywood for extra strength. TIle measurements shown here me not critical; make them to suit yo ur ow n needs.


Routing Oak Whil e making a display cab inet of oak and glass, I need ed to cut 1;2" rabbets in the oa k. Despite my sharp router bit. I found myse lf splinter ing the oak. To avoid thi s, I first knocked off the sharp co rners of the oak down to a depth equal to th e rabbet ( 1/ 2") with a 45-deg ree cha mfe r c utter. Th en I went back over it to cut the rabbet, and got no tear out.PW

Kingsley Hamm et Santa Fe, N ew Mexico

Don Kinna ma n Phoenix, Arizona

RYOal illustrat ed by Bob Rech Submit your caption(s) for this issue's

~r~~~~~n cartoon on a postcard to Popular


• 0.:

., .; .=-6)


.. ', '

Woodworking, Cartoon Caption #28, 1507 Dana Ave. , Cincinnati, OH 45207 by Dec. 19,1997. Winning entries will be chosen by the editorial staff. The winner will receive a Ryobi 14.4-volt %" cordless drill/driver. The drill features a Jacobs industrial keyless clutch, a 24-position adjustable clutch and an electric brake. A fan-cooled motor produces high to rque - 275 inch pounds. It also comes with two screwdriver bits , a carrying case, two battery packs and a onehour diagnostic charger. The two runners-up w ill each win a one-year subscripti on t o Popu lar Woodworking.

The winner of our " Capt i o n the Cartoon Contest #26" from the September issue and recipient of the Ryobi drilling system is: Bob Chastain, from Bedford, Texas . The runners-up receive a one-year subscription to Popular Woodworking: Gary W. Martin, from Hanson, Kentucky, for: " I know how ya feel, I thought it would drill more holes than that, myself. " Jim Gorman, from Thousand Oaks, California, for : "No, it's OK••• It says right here it's reversible. "

30 Popul ar Woodworking

" It still doesn 't have as many holes as th e current tax bill. "

Where Do You Hide A Roll-Top Desk?

Readers ' most amazing stories from their workshops.

WINNER! It's Perfect -

Except For One Small Detail

On e day my wonderful wife rema rked, " W ha t we need is a side tabl e with a divider." For 3S years we had spent late eve ning hours sitting side- by-side in our loun gers, surrounde d by books: ove rsized books, an atlas and photo albums that needed orzanization. So I built a 20" x 22" x 24" side table with two levels for books. The bottom shelf was flush to the bottom of the legs and had a "pass-thru" to house huge tom es, while the upper shelf was divided for personal effects. B ecau s~ we vacuum and clean the carpets frequently, I made the bottom of the table as slick as the polyurethaned top. This gave the table stability and made it easier to slide. (No wheels for me !) I patterne d the top to match the arms of the chairs. . , . After a week's wo rk, I place d the finished product on end for my WIfe s In spec tio n. Her re acti on : " It's perfect! " Th en she tipp ed the tabl e up sid e-down , slid it into place and filled it with our largess. Oh we ll ! It looks fine. "Bottoms up," as they say in English pub s. Louis J. Finkle

Surfside Beach, Sout h Carolina

Share Your Story & Win! Turn your favorite tale from the woodshop into a $150 gift certificate from Lee Valley Tools in Popular Woodworkings "Tales From the Wood" contest. We're looking for your funniest, most embarrassing or incredible story. And if we can learn something from your yarn - even better. Each issue, our editors choose the best tale and print it here. Runners-upreceive a Veritas Sliding Square (shown at right) from Lee Valley Tools, the catalog company that features an impressive array of quality woodworking tools, supplies and accessories. One final rule: Please, no stories about people getting hurt. That's not funny. To make things easier, you don't even have to write your story down. Just call our hotline anytime at (513) 531-2690 ext. 587 and leave your tale and daytime phone number. Or you can e-mail your story to us at or mail it to: Tales From the Wood • Popular Woodworking • 1507 Dana Ave.· Cincinnati, Ohio 45207

A few years ago I decided to surprise my wife by building her something she had always wanted:A roll-top desk.After working on it for two mont hs she still didn't know about it, despite the piles of sawdust. On e Saturday I was cleaning up the sho p when my wife ca me wa ltzi ng into the sho p w ith some cookies st raig ht fro m the ove n for me. I stood di rectly in front of her because if she looked over my sho ulde r, she wo uld see the incomplete desk and the surp rise wo uld be ruined . As I ate the first cookie, I shuffle d in a circle , gent ly guiding her to follow. As we talked , I star ted movin g her toward the doorway. Eventually she sensed thi s and asked if I wanted her to leave . I said yes, and she went back to the house with sma ll pu ffs of smoke comi ng out o f her ea rs . Lu ck il y s he soo n fo rgot about the inciden t. Eve ry Chris tmas Eve we open one gift eac h. I asked my wife if she wa nted her big gift or her little one. She said the bi g one. Sh e was so surprised she could not believe her eyes . The n we had a big laugh abo ut the cookie inc ident.

Tom Verity Pensacola, Florida

When Your Joints are Too Flush Sometimes you ju st can' t anticipa te how a project is going to tum out. A few years back I made a cherry toy box for my two children. Th e top was ma de from fo ur pieces of solid cherry and was pe rfectly flush with the box's sides. Too flus h, in fact. To my d ism ay I quickly discovered that my children were unable to open the box. Th ey had noth ing to hold on to. A knob or handle would have been easy to add, but it would have detracted from the appearance of the box. So I took the top off. Then I ripped it back into four pieces and reglued the top, adding several strips of l/ S" walnut and mapl e between the che rry board s. This gave the toy box a :YS"overlap on the front: perfect for the children, and it gave a striking appearance to the finished projec t.

Paul E. Hu rwitz Ro ckville, Maryland

Janu ary 1998 31

@@[Q) re a



Thou shalt make it . easler on thyself The second in our series on finishing shows you the best way to handle an unpleasant (but essential) job. HEN DOES THE fini shin g process begin ? After the project is fully assembled ? Wrong. When yo u presand the part s before assembly ? Wron g again . Actually, the time to start the fini shing pro cess is before yo u even begin . Your finishes will improve and you' ll ge t imm ediate result s when yo u co nsider two imp ortant factor s: â&#x20AC;˘ Wood Selection - When yo u plan to color your project with stain or dye , ch oose wood species that don't blotch . (I' ll cover this topic in the next installrnent .) Once yo u selec t a woo d type, match as closely as possible the co lor of those boards that line up side by side. â&#x20AC;˘ Finish Selection - Will yo ur project get an '111paint finish; a natural, stained or co lored finish ; and will the final finish be oil or so me type of clear top coa t such as polyureth ane, shellac, varn ish or lacqu er? These factors, along with preparing the surface before applying any finish , are the importa nt first steps in the finishin g process.


Finish No Wood Before It's Time Becau se our first co mmandment for finishing involves wood preparation, it' s time to have an attitude check. Much of wood preparation is sand ing, and we ca n agree that sanding is near universa lly hated. It's borin g, it's tediou s and if there's more then 20 minutes worth , it' s hard work . The good news is you 're probably working too hard at sanding, and there's a good ch ance yo ur next sanding job might get eas ier if you just read on. First, let's look at what we want to accomplish during wood preparation. Thi s includes rem oving dent s, go uges and errant dried glue, rem ovin g washboard mark s left from planin g or jointing the wood, fixing rout er bit burn marks, and sanding to prepare the surface to acce pt the finish. It' s imp ortant to eliminate these imper fections. Th e eye is drawn to dip s, dents, din gs and go uges - those flaws that otherwise break an unint errupted Ilat surface. A good fini sh requires as Ilat and smooth a surface as possible .

How to Eliminate Flaws Let me say straight ou t that there is more than one way to

32 Pop ular Woodworki ng

Getting your wood ready to finish is perhaps the most import ant step to a beautiful finish. Here I'm exam ining a board for dings, scratches and gouges by looking at it from a low angle. The light fixture in the bottom left corner of the photo really makes these defects jump out.

go about all this, and there are sure to be some who don 't entirely ag ree with my meth od s. It's a case of what works for yo u; but believe me, what I recommend will work for yo u, and it is entirely practical and efficie nt. Here 's how I do it: It's best to rid your materi als of mill mark s, those tiny bumps or lines cau sed by machin ery, before you assemb le your proj ect s. Do this with the materiaill at on yo ur benc h, working on it at a conveni ent height. Eliminate them by sand ing or using a scraper. If you are amon g the initiat ed who know how to sharpen or put an edge on these tools , use them . But if you are amon g the 19 out of 20 woodworkers wh o don 't , you'll be sanding those miniature peak s and valleys flat. We ' ll get into sanding a little later ; but the point is, ge t rid of the machining mark s whil e it' s easy on you, before asse mbly. Like so much in woodw orkin g, always think ahead! Dents and go uges ca n happen durin g the buildin g process. A dent - a depr ession where no wood fiber is broken or lost - can be ea sily fixed if not too seve re using a hot iron and damp rag . A go uge , on the other hand , consists of torn or missing fiber s and is a larger problem. If superfic ial, say less than 1;64", yo u ca n sa nd (or scra pe) it out. If deeper. yo u' ll need to use so me so rt of f lIer. Using filler is a compromise because yo u rarely match the co lor of the wood. Th e othe r probl em , of cour se, is that stain never takes to putty in the same way it is absorbed by the woo d. When applying filler, always use a putty knife


Why Dustles Some of the products you can use to fill small holes.

How to Fill Small Holes For small filling jobs, like a set nail, it's often best to wait until the finish job is complete and then use a wax crayon (even your child's crayons can do the job in a pinch). At this stage you know what the final wood color is so the guesswork is taken out of matching the filler color to the wood. Filler used before finishing not only fills the gouge or hole, it also fills the grain surrounding the gouge. So if you must use a filler, handle it carefully and apply it only in the opening needing repair.

Aside from the convenience and health benefits of keeping dust out of the air you're breathing, these sanders with dust-collection work more efficiently and increase the life of the sandpaper you use. By extracting the sanding dust from the surface, the sandpaper doesn 't load up with dust (when this happens you are sanding the dust, not the wood surface). These machines also vacuum up pieces of broken-off abrasive, which if left behind when you switch to t he next finer grit of sandpape r, will impart coa rser scratches to the wood surface when the loose grit gets under the t he sandi ng pad. That 's one reason to sweep or blow off all the dust from your project when you switch to the next finer grit sandpaper.

and force the material into the opening. And alway s leave it a little proud of the surface so it can be sanded flush later.

Get the Glue Out Even after what you think is a thorough sanding, you might find glue near joints or smeared on a surface after you've started staining or top-coating. First use an ounce of prevention and be careful not to allow glue to get smeared on your work. When it does, clean it up right away with a clean wet rag . And make sure you wash the area completely, not just wipe it off, which could compound the problem by smearing the glue even more. I've had more than one honest disagreement with other woodworkers about the water and rag clean-up method. I still recommend it, and here's why: If you wait until the glue is dry you risk either tearing out wood fibers when scraping, or just making the sanding harder. If you scrape the glue when it's soft, you fail to remove the partially dry glue that has soaked into the wood. I think those who have not successfully used the water and rag method have simply not been thorough or aggre ssive enough. If you put yourself in the sloppy category, or if you ju st want to make darn sure you haven't left any glue behind , wipe down your entire project with a wet (but not dripping wet) rag before sanding . The water will reconstitute the glue to its pre-dried milky white color, making it easier to find. To locate these problem areas, however, you must carefully inspect the piece a few minutes after the water has

Steaming Out Dents If there are minor miracles in the world, steaming a dent out of wood is surely one. Here's how to do it. Simply take a clothes iron set to its highest setting, wet a clean rag, place it over the dent and apply the hot iron. Hold it in place for at least 10 seconds to allow the iron to force the steam Into the wood fibers below. Chances are you can swell the crushed fibers that made the dent and restore the surface to Its original , undented state. If your first attempt doesn't work, try it a second or third time. Fortunately, wood fibers have a memory, and as long as the fibers are intact, they can return to their original state.

been wiped on. After you 've identified a spot, dampen more until the glue is soft enough to remove. I like to use a single-edge safety razor blade to scrape off the softened glue. Then clean the area with the wet rag.

Choosing Hand-Held Sanders Power sanding machines have made the unwelcome chore of sanding much easier. When used properly, you ' ll get good results . Of the three common types of sanders, belt, orbital and random orbit, you should choose the latter. Why? Because random orbit sanders are more agg ressive and efficient than an orbital sander and they don't leave obvious swirl marks. Also, the random orbit sander is not as aggressive as the belt sander, which is almost always too aggressive and can ruin a project in the blink of an eye. Belt sanders are great for removing stock quickly doing rough work, but don 't use one on a surface that will be finished! That said , there are some woodworkers who know how to keep this powerful tool abso lutely flat while applying uniform speed and pressure. If you don' t like playing fast and loose with your projects, keep your belt sande r on the shelf and use it for other work. It's too easy to oversand, leaving what I call a dished, or hollowed-out look. Orbital sanders tend to leave swirl marks, sometimes called pigtails , in a geometric pattern that call attention to themselves because the pattern of the wood grain is so random . Pigtail s create real havoc when applying stain because the stain highlights the scratch pattern in the wood

January 1998 33

RANDOM ORBIT SANDER â&#x20AC;˘ The best choice. Spend the extra buck and buy one that holds the sandpaper using hook-and-Ioop.

ORBITAL SANDER â&#x20AC;˘ These sanders tend to leave swirl marks, also called " pigtail s."

Pigtail sc ratches

Random orbits leave t he leastnoticeable scratches

BELT SANDER â&#x20AC;˘ While it has its place in many shops, don 't use it t o prepare your projects for finishing.

Deep scratches left by a belt sander



-- - - - -


and, being darker, sticks out like a sore thumb. If you own an orbital sander and don't feel like trading it for a random orbit machine, check the owner's manual for tips on using it. The speed of the orbit, which can vary greatly from one machine to the next, has a direct relationship with the recommended speed you move the sander over the work. As a general observation, most people move them much too fast. You should always sand with the grain when using an orbital sanding machine. The movement of the pad on a random orbit sander breaks up the swirl pattern created by the orbital action . The pad rotates free in relation to the orbiting action. And unlike its orbiting cousin, the random orbit can sand in any direction of the grain. When using the random orbit sander, start the machine with it resting on the work to prevent the fast-spinning pad from striking the wood surface. By the way, the opposite is true for the regular orbital sander. Start it first, then place it on the work surface. Should any of this advice prompt you to shop for a new sander, look at the so-called dustless sanders. They work best when a shop vac and hose can be attached to the sander; bags work less well but are still a big improvement.

Sandpaper and Sanding Now that you've removed the mill marks, dents and gouges from your project, and you've wiped it down with a damp rag and inspected it for errant glue smudges, it's finally time to begin sanding. For sanding raw wood, choose garnet (the orange colored abrasive if you can find it) or aluminum oxide, which is usually brown. If you sand by hand, use a sanding block that has a 1/ 4" thick piece of cork or felt glued to the bottom. A right-sized block will use a quarter sheet of sandpaper with just enough paper returning up the

34 Popular Woodworking

sides to give you some paper to grip. Whether you sand by hand or machine, start sanding with 100 grit, and increase to 120 and 150. If you are using a finish that forms a film on top, like polyurethane, lacquer, varnish or shellac , stop at 150. If you're using a penetrating oil finish, sand to 180; and if you just love sanding or think the project is really special, go one grit higher and stop. You're done . What about raising the grain with water? It's a good idea if your finish plans call for any water-based stains or dyes, or if you are planning a water-based film finish like water-based polyurethane, lacquer or varn ish. But just raise the grain slightly with a damp, not we t, rag. If you wet the surface too much, you'll ruin all the good sanding you've already done. If you raise too much grain you must sand too much to knock it down . In effect, you sand through the nice surface you spent so much time preparing. Think of it this way: When you sand off raised grain, it's like shaving off a 5 o'clock shadow, not a two-day growth. Further, when you resand your project after raising the grain, be sure the wood is dry and use the same grit you finished with , or one grit finer.

other Ways to Remove Glue You can also use solvents such as acetone, xylene and toluene to dissolve glue. These chemicals won't swell or raise the grain of the wood. I've never found raising the wood grain to be that much of a problem, so I stick with the water method. Yet another approach is to simply sand or scrape the area thoroughly. This Is a bit of a guessing game because you never know how much sanding or scraping is necessary.

FINISHING Types of Damage to Woods



You have to pay attention to how you are sanding, especially if you will be staining or coloring the wood. Always sand every area, every piece , the same way. Use the same pressure, the same amount of time, the same pattern with the machine, the same number of passes and lap each pass the same way. Sand every area the same amount. This will provide a consistent surface that the stain or dye will react to in the same way. I'd go so far as to say that I'd rather see a piece sanded consistently but inadequately than one that is sanded thoroughly but inconsistently. Change sandpaper regularly. Once the sharpness of the abrasive is gone, you're not only wasting your time and energy, but you're sanding inconsistently. I wish I could give you the benchmarks for when to change to fresh sand paper, but I can't. You'll just have to pay attention and occasionally feel the paper, inspect for bald spots on the sheet where the abrasive material is altogether gone , and get a feel for the action of the machine on the wood.

How Much Sanding is Enough? The first sanding with coarse grit should be complete enough to give all the surfaces of the project a uniform abrasion, removing slight imperfections not dealt with in other preparations. Once this first sanding is complete, the sole purpose of all other sandings with progressively finer grits is to remove the coarser scratches left from the previ-

Sanding Larl!e SurTaces To help you sand a large surface consistently, like a table top, create a kind of grid pattern in your mind for the piece . Sand one square grid section, then move to the ad lacent square , then the next , etc . Then move to the next row of squares until the large piece is complete .

Machining Marks

ous grit. Just as soon as those coarser scratches are removed, move on to the next finer grit. Sure, it's hard to see the tiny scratch marks , but a careful inspection, especially when aided with a strong light source from a low angle across the surface of the work, will help a lot. In fact, using the light will aid the discovery of all kinds of little problems on the surfaces throughout the whole surface preparation process. If you're past age 50, the raking lowangle light source is an indispensible aid. It might seem logical to continue sanding beyond the 150 grit to eliminate these scratches, then the 180 grit scratches, the 220 and so on. For all film finishes, the benefit of sanding past the 150 grit stage is almost imperceptible. Further, if your finish plan calls for stain, sanding beyond ISO grit starts to interfere with the stain's ability to be absorbed by the wood surface. Of course you need to "break" or "ease" the sharp edges of the project as a final step before moving on to applying color or the final clear finish. Do this quickly with 120 grit paper, removing most of the material, then follow up with a fast once-over on the edges only with 150 grit. Again, do this uniformly, taking equal amounts from all edges. Lastly, begin the coloring and finishing process within a day of your final sanding. If you wait longer, resand with the last grit you ended with . This is because humidity in the air will raise the grain slightly. Freshly sanded fibers take stain more consistently. Thorough preparation will make the application of color and clear finish easier and result in a greatly enhanced finish appearance. The best way to make the chore easier is to make a real effort to do "clean" work throughout the cutting and assembly process. Treat your parts gently, be neat with glue clean-up, fit adjoining pieces so they don't require a lot of work sanding them flush . These are work habits that make less work for you in the end. And remember, don't oversand, and don't skip sanding steps. The right amount is just enough, which may very well be less than you've been sanding in the past. PW - Steve Shanesy, PW staff

January 1998 35

[? from the This issue's project




a rlie r thi s century, Delta

HE ENTIRE SLED is built from hardwood such as maple or oak. The body of the sled is braced with edge frames and cross frames, which al so ac t as foot rails and hand rail supports. Cut the runners from 11;8" stock. Band saw to shape and then cut the " V" in the und er sid e of eac h to receive the ~" steel round stock. Runners are drilled near the ends and held in th e " V" grooves w ith ro un d head wo od screws . Th e rear runner s are


EMach inery published a magazine filled with woodworking projects.

screwe d to the und erside of the rea r ends of the sides. Th e fro nt runners are pivoted on the 6" carriage bolt as shown in the drawin g. The front ends of the runners are kept rigid by a hardwood dowel glued throu gh the front end of the runn er s and locked with screws from the top . The sle d is g uide d by the foot peda ls and a rope passed through the ho les in the fro nt runner s. Seal all lumb er with shellac or polyurethane and paint sled to suit. PW

These magazines are more t han nostalgia - the plans are stili darn goo d! In the interest of history, we 're hap py to offer this issue 's project from yesteryear. - PW

Bill 4 1 1 2 1 2

Detail front view of runner

1/2" Pipe \


1'/ 8" x 5" x 24" 1'/8 " x 23/ 4" x 32" Back foot rail 1'/ 8" x 23/4 " x 20 " Dowels 3/ 4" x 20'/ 2" Top 3/ 4" x 10'/4 " x 76 " Frnt. foot rail

Side rails 4 Mddl. foot rails 1 Wood disc 2 Pipes 4 Steel runners

Diagrams Top

of Materials

7/ 8" 7/ 8"

x 2 3/ 4" x 65 3/ 4" x 2 3/ 4" x 24 "

2" x 7 " '/ 2" x 46 " '/2 " x 30"

, .J.-- Sid e n.

Middle f oot rail Deta il pro file of body construction

Front runner assembly is bolted t o the body th rough the disc wI a 6 " carriage bolt

Middle foot rails



124" : Side ra ils : 12"


1/ 2" pipe


65 3 / 4"

' /2" hot roiled steel runner

36 Pooular Woodworkin z

1" squares

Rear runner screwed to side rails

$50 REBATE D eluxe E d ition 14 " B and Saw with e n closed st and, inclu des m obile base , 18 " R ip Fenc e and Cool B locks':" Model #28-280 Z

$50 REBATE Delta Sanding Center" B e lV Disc Sander, Model #3 1-280

$50 R EBATE 15 " R aner w ith free stand and extension wi ngs. Model #22-675Y

$50 REBATE Deluxe E d ition Con tracto r's Saw " wi th 30" Un ifence~ includes table board and legs, cast iron wi ng and 50-tooth com bi natio n blade , Mode l # 34-445Z

$50 REBATE D elta 0 -3 18" Variable Spe ed Scro ll S aw . Mode l # 4 0-650

$50 REBATE D elta Con tractor's" S aw with Jet-Lock " F enc e Model #34-4 44 ( 10" Contractor's Saw" /I is n ot p art of rebate o ffer.)


Proud sponsors of The New Yankee Workshop on PBS.

Every tool you see here come s with a $50 check in the mail from Delta. Opp ortunities like this don't come along every day. So if you've been wishing you had Delta Quality in your shop-you migh t want to get shopping, now. (August 1 through Decemb er 31, 1997.) You'll also find that we've snuck in a few extras on our 15" Planer and the Deluxe Editions of the Contrac tor's Saw and 14" Band Saw. Machin es that will still be proving the ir worth for yea rs to come. Call for the name of your nearest participating Delta dealer. Delta Internati onal Machin ery Corp ., 800-438-2486 . Circle #114 on Resource Directory Coupon





A Perrtair Company

Ii, Doll Dinette '\ 1

PUZZLE his might be the onl y dinette set in the world you really can make in a weekend . Not only is thi s an intere sting puzzle , it's also servicable doll furniture.


STEP ONE: Start with a 11/2" x 13/4" x 4" block of scrap

wood and cut out the inside piece of the large table on your band saw. Be sure to leav e a small lip on the bottom legs o f the table to hold the other pieces of the puzzle in place. Put the table aside.

STEP TWO: Cut the interior block into two chair-shaped

pieces as shown in the diagram below.

STEP lHREE: The two smaller sets of chairs are cut from the la rg er chairs. On each chair, cut a small block below the seat tha t runs from the front to the back of each chair. Cut that block into two chairs. Th en set the chairs aside. STEP FOUR: On each large chair cut out a larger block from below the seat that runs from side-to-side. These make the smaller table s. STEP FIVE: Sand as needed and break the edges to remove sp linters. Finis h as desired .

- Edward Coombs

Full-Size Diagram Flr5tcut \





cut ~


Full block, side view


ro,r;t ;


Large chair, front view

38 Popular Woodworking

Small chairs


Fifth cut

Large chair, side view


WONDER PUZZLE Full-Size Diagram


eople love to receive puzzle s as gifts . I've made this box for years, and it never fails to delight the recipients. This puzzle is made on the band saw; and once you get the hang of it, you can knock out more than a dozen in an hour.

STEP ONE: Start with a 1%" x 13/4" x 3" block of scrap wood and mark the two patterns shown in the diagram on adjoining sides. STEPTWO: Make both cuts on one face of the block, then hold the block together as you cut the pattern on the other face. STEPTHREE: A little sanding will clean up the saw marks, and you can finish the puzzle however you like. You can even leave it unfinished. -Edward Coombs


An APPLE for Teacher (or Mom) T

his project is perfect for the young woodworker who wants to make something nice for teachers at school or family members at home. As a bonus, you need only a couple power tools for this project, including a router mounted in a table and a drill press .

STEP ONE: Begin with a piece of 3/ 4" x 4 1;4" x 9 1/ 4" scrap wood for the base. Rout a profile on all four edges . Make it as fancy as you like (or as your collection of bits will allow).

STEP TWO: Youcan buy the apples at a local crafts store or through catalogs (seeour story on catalog shopping in this issue). Drill two or three 3/ 8" holes in the top of the apple to hold pencils. Cut the 11;4" deep slot for notes with a coping or back saw. A piece ofleather from a shoestring works nicely as the apple's stem. STEPTHREE: Sand the base and apple. Paint the apple red and put two coats of clear finish on the base. Then screw the apple to the base. Attach a note pad to the base with two-sided tape. - Edward Coombs

January 1998 39


o m birthday s to power failure s, we have all come across a time when candles were a necessity.This candleholder can be used as a centerpiece for a candlelight dinner or as a simple decoration in any room. Its pivoting legs allow it to be set up in different ways, and it folds flat for storage. For this candleholder, I used 4;4 purpleheart. Nearly any wood will work, but quartersawn is great because it's less likely to warp. Buy candie s before picking the wood - this could sa ve you a headache later. Depending on the s ize of candles you have, you might want to go with a thicker piece of wood.

on the scroll saw or band saw. When you 're cutting it, leave some extra material at the feet. This will come in handy later when you 're assembling the pieces to make the stand level. STEP TWO: After you've cut out the pieces, sand and check the fit of the legs. I had to do some extra sanding on the insides of all the pieces before they could be rotated without rubbing or sticking . STEP THREE: Drill the holes for the hardware that holds the three pieces together. Line up the holes as best you can so that the pieces are flush and can swing apart. To do this, clamp the middle piece on top of the bottom one, drill through the middle piece and then

STEP ONE: Begin by gluing up your material to 12" long x 9" wide. Attach candleholder diagram from the PullOut" Plans to the wood with spray adhesive and cut it out

See the PullOut Plans for a full-size diagram of the folding candleholder. 40 Popular Woodworking

drill just enough into the bottom piece so that you can see where the hole will go. To line up the top piece with the middle one, I used a dowelingjig. Then drill the top piece from the bottom, about halfway up. You need to counterbore the bottom piece about I" in from the bottom. See the PullOut Plans for the drilling locations and measurements. STEP FOUR: Next, attach the pieces together. There are a number of ways to do this, but I opted for a 1/ 4" threaded rod that was glued into the top piece. The rod runs through the middle and bottom pieces and screws into a threaded t-nut inserted into the bottom piece. Peen the end of the threaded rod to keep the rod from unscrewing. STEP FIVE: This is where that extra material on the feet comes in handy. Cut the base piece of the candleholder to size and insert the t-nut and rod. If the t-nut is not flush with the wood, you will need to leave the feet just a bit longer than the base to give the candleholder stability. STEP SIX: Drill l/Z"-deep holes for your candles according to their diameter. Sand the candleholder while it's lying flat and check that the pieces are flush wit h each other. You can either break the edges or you can give them a roundover. For the finish I used a couple coats of clear topcoat. You might consider using drip cups around your candles to better protect the wood. PW

- Designed by Warren Asa; constructed and written by Jamie Doan. This story first appeared in January /990.


PuliOutâ&#x201E;˘ Plans â&#x20AC;˘ January 1998


Carefully open staples 10 remove plans, then bend them closed again

INSIDE NOll': lI'e had so manv proj ects this issu e \I '/' had lu pili some of the Pull Out Plans 0 11 pa ge .I f.)





Candleholder Basket Mailbox Maloof Table

40 50

Mighty Mite Prairie Chair Musical Toys Whirligig

62 6.6

51 57

70 73

Musical Toys


, ,, ,,,

, ~~ " ',r"" " ,, ,, ,, '" ,,, '"'"'"'" ,,, Full-size diagram of the Leg top

Full-size diagram of the Leg bottom


Handle Basket

Band Sawn Basket Full- s ize plan of basket and handle cut out.

Sawyers Whirligig Full-size "Jerry" parts




, I IL


r - - - - -,


1 _





Folding Candleholder Full-elze diagram of candleholder part6 and drilling layoute




- ---











I .... ....





.... ....

....I ....

<, ........


.... ....

r ..






.... ....

.... ....

.... ....


-- -


._ - - ._- - ._ - - ._ - - ._ - - ._ - - ._ - - .-

Musical Toys

Poster Board

Full-size diagram of side stretcher (Tenons not included)

Full-size diagram of front and back stretchers (Tenons not included)

Full-size dia(;1ram canopy section

awyers Whirligig Full-size diagram of tail fin

Sawyers Whirligig Full-size "Luke" parts




Luke Body


Prairie Spindle Chair Full-size diagram

of corbel

Maloof Table Base

__. .__i

. . . . . . . . ._

Prairie Spindle Chair c


Supplement to PuliOut™ Plans Victorian Mailbox clearance 3/4" holes


~ et

@ 3/4"13/4" 1 7/8"

r I


1" d iameter hole

3/8" hole

1 '/2" 1 518" 3/4"




r r

9 '/4"

(~ --t- - -t- - --~- - --- - ----t--t--t)~ '!J18" '\ F------ ~, - ---- --®- ----- --Fliole~J~


9 1/4"




4 3/4"


2 1f4" -P.-----L--,;:-'----...::-'




Prairie Spindle Chair

F-- -- --~ -----~- -t----~------=t1 ~ l


3 /4"


Important: By making these dimensions the earne.the saw setup is the same for each dimension and t heref ore square! Always use these edges to fence .


: I

5" I I I

2 '/2" I rad ius : I I I I I

Musical Toys Hex Plat e


Musical Toys


Wiring diagram fo r carousel Solde r wires t o bulb and switch leads. Attach wires to "D" size batteries. Secure batteries wI electrical condu it brac kets.

318" holes



0 The hexagon al plate has 4 '/2" s ides

1/4" Plywood


'/4" bushing and two washers



3/8" holes



Sm all broom clip

Pictu re disc

'/4" X 7 ' Block 3 / 4"

x 1 1/ 2" x 1' /2"

(tight fi t on shaft)

Drive drum 1'/8" x 1 314" d ia. Coat wllDD grit sandpaper (tight fit on shaft)



Bulb from flash light

Bushings t ight fi t (3 places)

314" X 2" x 6 "

~. .-t-""TI

' /e" sh aft

Rubber band drive belt Music movement wI pulley assembly

3 / 8 " hole throug h


\ side fo r winding stem •. ,...... '. of mus ic movement ~ ~

Rotary switch

1/ 2"



' /4" Plywood

3 / 4" X 2" x 5"

'/2" x 6 " x 6 "

January 1998 49


Band Sa\Nn



askets come in all shapes and sizes, and they are made of man y di fferent materi als. Thi s basket is unique because it folds up for storage and can be made out of almost any wood .


STEP ONE: First choose a straight-grained, knotfree 3/ 4" hardwood that measures about 7" x 13". Sand the top and bottom surfaces. STEP TWO: Layout the pattern from the PullOut H 1 Plans on yo ur wood. You can trace the pattern using carbon paper, or yo u can photocop y the plan and use spray adhes ive or rubber ce me nt to attach the pattern to the wood. STEP THREE: Use a band saw or scro ll saw to mak e yo ur cuts . I used a band saw becau se the sc ro ll saw was a lot slowe r when cutting 3;4" material. With the table of yo ur sa w flat , cut the out-

side edge of the basket's handle. makin g s u re to stay ju st outside the line. Then sand the edg es down to the line. STEP FOUR: Cut the inside surface of the handle and sand the exterior of the basket. Set the handle aside.

Diagram /'





FOld down

/ /

bra ss ta ck th is s ide (3/4" brass t ack o n t he ot her Side)

1/ 2"




Schedule of Materials: Band Sawn Basket No. I Item I Dimensions T W L I Material

Detail of hand le bottom

50 Popular Woodworking



3/ 4" x 7 " x 13"



Large Base

x 1" x 7"



Small Bases

:lt4" :lt4"

x 3/ 4" x 3/ 4"


STEP FIVE: Set your band saw's table to 6 degrees and begin cutting the outer arc. Cut right on the line as much as possible. When you get to the end of the cut, turn off your band saw and back your blade out. STEP SIX: Cut out the large base piece and the two small base pieces from some scrap wood. Glue these pieces to the bottom of the basket in the locations shown in the PullOut Plans. Clamp and allow to dry. STEP SEVEN: The part of this project that takes the longest is the sanding. I used a small rotary tool with a sanding head to remove the bum marks made by the saw blade. I then sanded the whole basket, inside and out , with I50- grit sandpaper. STEP EIGHT: Attach the handle to the basket using brass brads. Use a 3;4" brad on the side where you started your cut and a 1/ 2" brad on the other. Sand one comer of each end of the handle to make it ea sier to open the basket. Then complete your basket with two coats of clear finish . PW - l o/m A. Ne/son is the author ofdozens

of books. many of them dealin g with scroll saw projects. This article fir st appeared in AI/gl/st /988.

Victorian Mailbox Post orma lly we d on 't run outdoo r proj ects in the wi nter issues, b ut this o ne require s yo u to be o uts ide just lon g eno ugh to dig a hole. We recommend usi ng a weath erresistant woo d such as red wood, cedar, cypress or pres suretreated lumber.


STEP ONE: Th e basic sizes for all the pieces are listed in the Sc hedu le o f M at eri a ls. Th e base trim pi eces for the post have a bevel cut on one edge that is easier to cut while the board is still long. Make 45-degree angle bevel, leaving an 'Is " flat at the top. Cut all the pieces to size as spec ified. STEP TWO: Th e pattern in the Pullfrut" Plans shows the hole ce nte r locat ion s fo r the brack et pairs. La yout the locations and dri ll the holes with a drill press. Sp ade bits wo rk fo r the sma lle r holes, while the 2" - and 3"-dia me ter hole s w ill require a j igsa w, hol e saw o r a fl y- cutter. With th e hole s cut, split the bra ckets diag onally. STEP THREE: Cut 45-degree bevels on the ends of the crosspiece and the corners of the mountin g board . Then use a '14" roundove r router bit to ease the edges of the mountin g board and brackets. STEPFOUR: Cut the 'I2" -deep teeth in the dentil bands with a 3/ S"-wide dado stac k in the table saw. Lay out the teeth locations to determine the best spacing. STEP FIVE: Still using the dado stack, cut a I" x I 'Is" rabbet in the front edge of the cross-piece.Then cut a 3'12" x 13/ 4" deep dado for the cros s-lap jo int in the cross-piece and post to form the half-lap joint. Diagram

The Mailbox is mounted with screws to a nominalsized piece of cedar.

Cross-piece Mounting board Brackets Base trim pieces Front dentil band Side dentil bands

STEP SIX: You can purchase the 4 x 4 post with a top finial detail pre-cut, or you can cut an alternative top as show n using a 45-dehlfee angle on your table saw. STEP SEVEN: Assembl e the post by first attaching the front and one of the side dentil bands to the bottom of the mounti ng board. Place the cross-piece against these parts to locate the position for the remainin g dentil and attach. Next , join the cro sspiec e to the mounting board and j oin the cro ss-piece to the post. Fina lly, attach the brack ets. STEP EIGHT: The base trim is attached once the appropriate height of the mailbox is determined (check with your post office). When digging the hole for your post, remember that the post should be at least 18" below grade. PW 3 3t2" x3 3t2" x 36" -Phil Keller 's ori ginal article 011 the 1 3t2" x 9 3t4" x 22" victorian Mailbox Post was pu bl ished ill the July 1990 Popul ar Wood working. It is offered here ill all abb reviated fo rm. 1 " x 2 " x 73t2" Phil continues to be a woodwo rker and 1 " X 2 " x 18" writer in Pomp ton Plain s, New Jersey.

January 1998 51

UILDING this chimney cupboard using the limited tools in the "Little Shop Tha t Could" is a bit of a challenge. The hardest part is routing the boards to get an edge good enoug h to glue up slabs for the sides . The only other challenge is setting up the table saw to make the door parts. Even that isn't as hard as learning the patience to make sure it's right by using scraps before cutting your good parts. I used solid maple for the visible exterior parts. The shelves, top, bottom and back are plywood . I purchased the maple hardwood already surfaced to 3/4", and I picked four flat boards.


Editor's Note In Issue #91, I built this workshop on wheels, which folds in half for storage. Then I outfitted it with $498 in tools and equipment. Reckoning many of you work in small shops with limited tools, I wanted you to know that we can work that way, too. "Uttle Shop" projects are designed to be built simply. For a copy of issue #91, send $4.50 to Popular Woodworking • Back Issues • 1507 Dana Ave. • Cincinnati, OH 45207 • Ask for #58066.

52 Popular Woodworking

"" STRAIGHT TRICK • To put a ..Lst raight edge on the rough-edged lumber, I tacked a piece of :lt4" plywood to the work piece. It's a simple matter then to run the straight plywood edge against the table saw fence, thereby cutting a straight edge on the lumber. After this cut , remove the plywood and flip the board so that its straight edge is against the fence and simply rip a parallel cut.






IL =

17' /4" 18"



Profile of raised panel layout



Detail of glass door assembly

S ee crown mouldi ng) det a il at right -> , ( (








See glass door deta il abov e






38 1/4" 40 '/4"

Detail of crown moulding


Se e


ra ised


1 3/4" 4" 1 3/4"



back <;

panel de t ai l

112" X3/4"

27" , I




-, I.

I. L

12 112"

I 2"



. ~


2" 3 1/ 4 "

-, 3 1/ 4"

____ -



3 1/4"



3 '/4"


chedule of Materials: Chimney Cupboard No . Item Dimensions T W L Material


Plan of door chamfer on closing side



1/8"~~ Front of door

17 1/ 4" 18"

1 1-- 2'




1- - - - - -




30 1/4"



Ogee mo Idi ng



23 1/ 2"

ab ove""

I I I -- -------I I

No. Item

Dimensions T W L



3/ 4" x 17:lt4" x 7S:lt4"




3/ 4" x 17" x 18:lt2"







3/ 4" x 1 7:lt4"X 19:1t2"






Top Stretchers 3/ 4" x 3 " x 19:1t2"



Fixed Shelf









3/ 4" x 17" x 18:lt2"



:1t4" x 19:1t2"



3/ 4" x

x 713/4"

163/ 4" x 18 7/ 16"

Upper Door (Glass)

Lower Door (Panel) Maple


3/ 4" x 1 3/4" x 27" 3/ 4" x 1 3/4" x 13:lt4"


3/4" x 13:lt4" x 24:lt4"




Face Frame 2


3/ 4" x 2 " x 7S:lt4 "



3/4 "


Top Rail

3/ 4 "

x 4" x 16" x 2 " x 16"


Base - 1" x 3/4" x six lineal feet maple


Top - 3/ 4" x 3 " x six lineal feet maple


Top - 3/ 4" x 1" x six lineal feet maple Mullions - :1t4" x 3/ 8" x six lineal feet maple

January 1998 53

ANOTHER TRICK • To make a j oint good enough for edge-toedge glu ing , use a router wi th a straight bit and bear ing mounted on the bottom. Secure t he lumber to a straight edge - a really straight edge - so the lumber ove rha ngs t he straight edge no more than ;-3 2". Rout the edge with the bearing fol lowing the straight edge and remove the overhang. If your edge is true, you should achieve a smooth, straight edge on the lumber t hat ' s su itable for glue up.


Q.1RiP Your Stock • Start by ~ selecting en ou gh so lid mapl e to glue up the sides and door panel, then rip the stock for the door fra me, stiles and rails. The edges for the sides and panel were rou gh , so I had to straighten them. Without a j ointer, th is ca n be trick y, but the meth od shown in the photo does the job.

In 2

Smoot h Your Edges • Before gluing the sides and do or panel , you need to put a bett er edge on the board s than yo u ca n ge t on the sma ll bench top table saw. Th e photo shows a way around that problem usin g a router. If there is too mu ch ga p where the boards meet after truin g the edge, check the straight edge board, whic h must be perfe ctl y straight for thi s technique to wo rk. Wh en satisfie d, glue and cla mp the piece s togeth er.




Make the Face Frame • While the sides are drying, cut out the bottom, top and fixed shelf. The panel squari ng jig as described in the first "Little Shop" series (iss ue # 9 1) is helpful for this step. Next rip out the stiles and rails for the cabin et face frame and door part s. Cut the face frame parts to length, then join the stiles to the rails using biscuit s as


54 Popular Woodworking

BISCUITS WITHOUT A BISCUIT JOINER • The fa ce frame stiles and rails are joined using biscuits, but sinc e the " Lit t le Shop' s" budget doesn't allow a biscu it joiner, a router equipped with a slot cutter does the trick, and does it well. Make slots on the ends of t he rail s and their adjoining locati ons on the stiles.


shown. Carefully lay out the posi tion for the intermedi ate rail. When do ne, glue and clamp the face frame together.



Rabbets fo r the Carcass • Nex t, rout the rabbe ts on the top and back edges of the sides . The side top rabbet is 3/ 4" x 1/2" wide, while the back rabbets of the sides and the back edge of the top are '14" x '/4" . I made these sma ller ones using the table saw, makin g two passes with the blad e set 1/ 4 " above the tab le. The sides were too unwield y to stand on end to make the seco nd rabbet cut on the tabl e saw, so I used the router instead. Next, nail the ca rcass toget her. Because the top edges of the bottom and fixed shelf must align with the top edge of the lower and intermediate face frame rails, carefully lay out their location. I drilled pilot holes through the sides for the nail locations (don't worry about nailing, we' re going to make the cabinet look old later by filling the nail holes a special way). Nail the bottom and fixed shelf through the sides, then attach the top by nailing down through the top and into the sides.




Add the Face Frame • To nail the face frame on, lay the cabinet on its back and posi tion the face frame on the carcass. Check for the alignment of the bottom and fixed shelf, then rem ove the frame and driII pilot holes for 2" finish nails thro ugh


HOW TO M ILL THE RABBETS • M illing the rabbets on the top edges of t he si des req uired a few steps. The fi rst cut was made on the table saw cr osscutting the top edge with the fence set to establish the 3/ 4" depth. Next the router and slot cutter established t he ;-2" rabbet width (ab ove). As you can see, however, the sl ot cutter didn't cut deep enough t o complete the job. To complete the rabbet, I used a chisel to snap of f t he rem ain ing waste stock (below) and cl ean up the corner of the rabbet. Although it sounds time consuming, it wasn't.


the face frame . Put the face frame back on and nail it in place following the nailin g pattern shown in the photo .



Doors at the Table Saw • Now make the doors. All the joinery for the upper and lower doors is do ne on the table saw . All the stiles and rai ls receive '14" wide by '/ 2" deep grooves ce ntered exactly, as they will also serve as mortises. It takes three passes on my saw using a narrow -kerf blade. T hese grooves run all the way thro ugh all the pieces.


St opped Rabbets • The upper door requires a rabbet to hold the glass . Whil e the rabbe ts in the rails can be run all the way through, the ones in the stiles are stopped . To make the stopped cuts, first raise the saw Q.






pencil lines




GROOVES AND RABBETS • The door stiles and rails require a groove for the lower raised panel and a rabbet for the upper glass. The groove also serves at the mortise at the top and bottom of the stiles. Set the fence to :lt4" , cut the outside cuts first, then move the fence to clean up the center portion.




Start here


NAILING PATTERN • When attaching the fac e frame to the case , it ' s important to make sure the face frame open ings remain square or else hanging doors later will be a big headache. To make sure the openings rema in squa re , use the nailing pattern shown above and check the opening frequently. Use clamps t o pull the case to square if need be.

blade to 1;2". the depth of cut you want. As shown in the photo, mark lines on the table saw fence where the fron t and back of the blade first project above the saw table insert. Now mark lines where you must start or stop your cuts, that's 13/ 4 " or the width of the rails. With the stile edge again st the fence (which is set 3/8" fro m the blade) rest the end awa y from the blade on the saw table and slowly lower the stile until the pencil line on the fence becomes visible but before the blade begi ns to cut. Align the fence and stile penci l marks, then proceed to slowly lower the stile onto the blade and beg in the cut. Push the stile until the the pencil mark on the other end of the stile alig ns with the pencil mark at the front of the blade. While holding the piece fir mly in place, turn the saw off and hold the piec e until the blade stops moving. The waste piece is left on the stile until the door has been glued up. Once supported by the teno n after asse mbly, rem ove the waste stock and square up the corner with a chisel.

lh Iii


STOPPED RABBET CUT • The stiles of the upper doo r require a stop cut to form the rabbet and leave the chee k of mo rt ise at the top and bottom. The st opped c ut is made by lowering t he piece onto t he running blade , using penc il marks on the and stile to indicate start and stop points.


Tenons for the Doors • Next cut the tenons on the upper and lower rails, carefully fitting them to the grooves yo u've cut. It's best to use so me fall-off from the rails and make test cuts. First define the leng th of the tenon by cros s cutti ng the rail ends on both sides . Use your slot miter ga uge with the end of the rail up aga inst the fence to index the cut. Th e fence should be set to 1/ 2" to the outside, not inside, of the blade.

lh g Iii

Raise the Panel • If you haven 't already, cut the glued up panel for the lower door 's raised panel to finished size . Now "raise" the panel by cutting all edges on both sides using the table saw with the blade tilted to an 8-degree angle (see diagram ). Aga in, use a piece of scra p to test your set-up befo re cutting the actual piece. Rememb er, the set-up not only raises the panel , but also defines how deep it fits in the stile and rail grooves. It also forms the shoulde r at the point where the bevel meet s the flat of the panel face s. After raising the panel on both the front and back, test fit the panel in the stiles and rails. When satisfied, glue up the lower door and upper door frame. When the upper door frame assembly has dried, square up the corners where the stiles and rails meet and remove the waste strip of wood on the stiles that will fully form the rabbets.


TENONS ON THE RAILS • Finish cutting the t enons by running the rails on their ends ove r the saw, assisted by a bac k-up block. The tenons are centered on the rail ends so set your blade to the appropriate height and fenc e t o leave t he :lt4" thick tenon. With the fen ce set appropriately, one pass on eac h side of the rail will center the tenon.

lh Iii


Door Details • Ch eck the doors for fit and make any trim cuts that may be necessary. A properly fit, flush inset door should have a 1;16" gap aro und the doo r edges. To make the door close without hitting the stile opposite the hinge side, use the table saw to make a 3-degre e bevel cut on the handle side stile so that the bevel is to the inside of the cabinet and you leave abou t 1;8" flat on the stile edg e (see diagram detai l). Before mounting the hinges, first mark their locations; then use your router and mortise the hinge leaf on the door about 1/ 16" deep . Set the hinge in place and mark the hole loca tions, then start the hole with an awl, and drill a pilot hole for the screws .

January 1998 55


Add the Moulding • T he top mo uldi ng is made from two separate mou ldings nai led togeth-

er. T he top mold ing is made using a cove bit, and the lower piece uses an ogee profi le. Run the top moulding first using the dimensions give n in the Sched ule of Mater ials. Cut the mitered front co rne rs and glue up. Nex t cut the lower mould . Miter the fro nt corners, then nail it in place on the upper piece. When do ne, the upper piece sho uld rest on top of the cab inet with the

lower surro undi ng the top edge of the ca binet. Fasten the moulding using screws throu gh the top mouldi ng into the ca bine t top. Rout a ogee detail on enough stock to make the base moulding, then miter the co rners and nail it in place with finish nails. It's a good idea to drill a pilot hole in the moulding to prevent splitting, es pecially near the ends. Before sand ing and preparin g to finish, drill holes for shelf pins. While the lower cabinet shelf location is not criti cal , yo u' ll want the upper she lves to rest directl y behind the glass door mulli on s. Speaking of the mull ions, these pieces are simply glued to the outside of the single piece of glass, which is inst all ed after finishi ng . Mak e the mull ion strips at this time, but leave them long for cutting to len gth afte r fini shin g.


YOU DON'T NEED A SHAPER • The table saw also raises the panel for the lower door. Tilt the saw blade to 8 degrees . Set the fence so that your cut will give you the dimension given in the detail drawing in the diagram. Make the cuts running the panel on edge and remember the panel is raised on both the front and back. Concentrate on keeping the panel perpendicular to the saw table using hand pressure against the fence.




Age Your Project • One way to make the cupboa rd look old is to foll ow the directions in the photo. Now give the entir e piece a good sanding. I used a rando m orbit sander and started with 100-grit, followed by 120 an d 150-grit. Hand sand the mouldings and ease or break all edges. You really need to sand the interior to only I20-grit, but be sure the upper section will look goo d through the glass. Brush on two or three coats of clear finish. To make a reall y smooth surface, sand lightl y betw een each coat using 360-grit paper. Th e finishing touches includ e installing the glass and mullions. Use V8" or dou ble-strength plate glass, or if you can find a piece of old glass with all its imperfections, use it to further impart the look of an old cupboard. I held the glass in place using glazing points and glazing co mpound. Then add the mullions, setting the long vertical one first, centered in the opening, then set the shorter horizont al ones, taking care to place them so they match the shelf locations. Glue the mullions in place using a few dabs of two-part epoxy. Lastly, rehang the doors then install the pulls and your cabinet is co mplete. PW - Steve Shanesy, PW staff

Put the screws in by hand . If you use a drill or screw gun you' ll likely snap the screw head off. After marking and routing the hinge location on the cabinet, follow the same procedure to fasten the hinge to the cabinet.




A LOOK AT THE TOP • Make up the two-piece crown moulding and attach to the case later. Shown here upside down, the top moulding has a coved profile and the lower piece an ogee, Glue the top miter pieces together, then nail the lower piece in place . The completed assembly rests on the top of the case and is secured by screws.

56 Popular Woodworking

lNSTALL THE HINGES • Use a router to mortise the doors' edges for the hinges. The relief should be about :lt16 " but can vary depending on the thickness of your hinges' leaves. After mounting the hinges on the doors, lay each door in its opening exactly in position and carefully mark the hinge locations on the cabinet face frame. Remove the door and rout these locations for the hinge as well .

A NAIL TRICK • First set the nails as you normally would. Now take the head of a square concrete cut nail and make a second square or rectangular "countersink" mark over the round depression left from the nail set. Putty the old-fashioned square mark , leaving the impression that the cupboard was constructed with cut nails.




Sam Maloof's


U&[]3[1 One ofthe first "how-to" projects ever to appear in Popular Woodworking. NE OF T HE EARLIEST "how-to" projects in Popular Woodwo rking (w hic h at the time was ca lle d Pacifi c Woodworker) had the distinction of being a tab le by renow ned woo dworker Sam Maloof. While the article was not an actua l step-by-s tep ex planatio n (indee d, there were n't even dimensions offered), th e process for co nstr ucti ng th e d istinctive table base was described. Using that article, I built this Maloof-style table. And while thi s isn't a weeke nd project, it's not a particularly difficult piece. More importantly, this table will rem ind yo u of why yo u love to work with woo d. If yo u're co ncerned about co pyi ng anothe r person's desig n, keep in mind w hat M al o o f sai d in hi s boo k "Sam Maloof, Woodworker" when asked about those who copy his furni ture: " T his re m ind s me of an anecdote about Hamada, the Japanese potter.When someone aske d Hamada if imitations of his work bothered him, he replied, 'When I'm dead, people wi ll think that all of my bad things were made by the other potter, and they will think that all of his good th ings were mad e by me.' "


1 t;;


Starting at the Post • The first ste p is ro ughing out and sha ping th e base's center post. Th e post measures 3" x 3" x 23" , and unless yo u're very lucky you' ll have to glue up a co uple board s to ac hieve thi s dim e nsio n. Using 13/ 4 " thick material, I was able to glue up two 3"-wide pieces with roo m to spare. If yo u've ever tried to glue two nat pieces together you know that glue works like butter, and the wood wants to slip apart. Dri ll two dowel holes on the match ing faces and use dowels as guide pins durin g gluing so you won't fight with your pieces. Next ru n th e pos t down to 3" x 3" .

r. A cra;ft1W1VlI'v /'YIUW meecr 10 WIVlrert A l...f--{uw /'YIUCh. h'lqre mttf~~ itf ecrrmts If rrtte Wetfrs tf ~it- rtf ~t1J t1wrr dluws /tifr\. rrr tfchwwle1Je t1wrr itu rrnb Grrl'l wh.rr u r h.e MmU r Cra;ft1W1VlI'v. f--{e Vlses VlS. OW MMSnrc f--{u iN~J1:tJ ." - (tffr\. M tflrrr;f


CENTER THE GROOVES • The 3/4" x 3/4" grooves must be centered in the width of the post to make the fit (and the sanding) acceptable. A careful setup with a dado set makes this quick work.

You sho uld leave the post longer tha n the fini shed 23" for now to allow for titting. The first milling procedure is to use a dado stack to cut grooves the length of the post on all four face s.



Forming the Inside Curve • With the post grooved to accept th e leg tenon s, make co ve c uts on the four corners so that the shape tlows into the legs. I accomplished this with a 3/ 4"



MAKE CAREFUL COVES • Getting the cove cuts to align with the edges of the leg centers makes sanding and the final finish easier. If any thing, allow the cove cuts to be a hair wider than necessary so that the sanding to fit occurs on the leg cen ters, not in the cove cut.

cove bit. This bit is a $50 necessity. There is no other tooling that provides the contro l given by a router and bit set up in a rout er table. As shown in the photo, the location of the cove cut is critical to how easy it will be to assemb le the base and how goo d it will look. Use two passes of increa sin g depth to put less stress on your router.

Janu ary 1998 57



Quite a Joint! • With the post esse ntia lly co mplete, it's time to make the legs. You will be making four duplicate leg sections, eac h made of three pieces. The tem plates for the three pieces are in the PulfOutt Plans. Cut the pieces to rough size, bei ng careful to mark the 45degree angle locati on exactly. On eac h leg' s top and ce nter pieces you still have a flat edge to use as a guide to cut the angles on your table saw, or powe r miter box. On each leg' s bottom you' ll need to make the cut with the band saw or a hand saw and sand the face flat. T hese are cr itica l joints that determin e how flat yo ur tabl e wi ll sit, so pay special attention to makin g them meet correctly. With the pieces ro ug hed to shape , mak e the two rabbet cuts on the leg ce nters to leave a 11/ 16" x 3/ 4"-wide ten on. Ch eck th e fit wi th the grooves in the post. It sho uld be a hand -tight fit. Nex t sand the leg pieces to matc h the templat es. A spindle sa nde r is grea t fo r thi s step, but a drum sa nder chucked in your drill press will work, too. When yo u sand the shapes , lea ve a couple of inc hes to e ithe r side of each joint wide of the line. Th e j o int s sho uld be sha ped to match after th e leg piece s have been g lue d to geth e r to e ns ure a s mooth transi tion . Layout th e loc ati on s for th e 1/ 2" dowel s as sho wn o n the PullOut Plans and in the photo.


Diag rams


DOWEL THE LEGS • Use dowels to join the leg tops and bottoms to the leg center. I used 3,'2" dowels, which were lat er pinned th rough the side of the legs with 3,'8" dowe ls. A self-centering doweling jig like the one show n in t he photo takes some of the measuring out of this step.

fii 4

Cl amPing Ballet • The g lue- up o f the leg co rnponents is tri cky, but the photo shows a method that worked well for me. Next, again look to the PullOut patterns for the locations of the V8" dowels used to pin the larger dowels. Drill com pletely through the leg and dowel, but use a backing board to avo id tear out on the ex it side. Th en add some glue to the


Schedule of Materials: Maloof Table No. Letter lit em Dimensions T W L





7/ S" x 42" x 42"





3" x 3" x 23"




Leg tops

1 3/4" x 2:1,'2"x13:1,'2" Walnut



Leg centers 1 3/4" x 2 3/4"X 23 "



Leg bottoms 1 3/4" x 3 :1,'2"x 14:1,'2" Walnut




Cross bands 3/ 4" x 3/4"x 5"





:1,'2 " x 2"





:1,'s " x 2"


3/ 4" 3/ 8 "


3/ 4 " 3 "



,L-..,Y 11116"

Deta il plan of leg j oi nery

3 /8,, }<--'-7 L-------i; i------".;;'-"--,!'

Pedestal Base Exploded Diagram Detail of Crossbands

58 Popul ar Wood working


3 / 4 ".,,----1'--1

3/ 4"


5 CLAMP CAREFULLY • Properly gluing and clamping the leg sections is awkward. The clamp arrangement shown here glued two leg sections at the same time with only four clamps. The block between the leg bottoms kept the clamps from sliding on the sculpted leg.


A Maloof Finish

2" dowel lengths and tap them into place so Mix one-third semi-gloss the dowel protrudes polyurethane varnish, one-third on both sides. When pure tung oil and one-third boiled with the center post. the glue dries, sand linseed oil. You can substitute Chisel the 3/ 4" wide the dowels flush . linseed oil with another third x 5" long grooves for With the pinning tung oil if it is polymerized (pure the pieces to a depth done , use a 1/2 " tung oil dries too slowly). Apply of 1/ 2" at the center ro undover bit with a this mixture three times at oneof the "X" and allow bearing guide to ease day intervals. the bottom of the all the edges of each For a final coat, heat a SO/50 groove to level out leg - except the mix of pure tung oil and boiled into the legs. This tenon edge and the linseed oil (or 100 percent polyleaves the trench top edge. Be careful merized tung oil) In a double boiler. about 5/S" deep at the while routing because Grate solid beeswax and add it to of the grooves. ends the grain is likely to the heated mix until it is the conNext cut the halfchange direction, essistency of heavy cream (about joint in the two lap pecially at the joint, two double-handfuls of wax per maple pieces and fit and tear out. gallon of mix). Let cool. The wax in them into the two After routing, glue the cooled mixture will stay in grooves . Then drill the legs to the center suspension and has a good shelffour I/ S" pilot holes, post. Definitely dry-fit life. This is applied a minimum of V2" in from the ends the base assembly, three times, vigorously rubblng in of the pieces. Then clamping the legs in the mixture each time. dri1l 3/ S" x 3/ S" deep place. Make sure the holes to allow the screw heads to recess base sits flat without rocking, and mark the into the maple. After inserting the four center post to cut it to length to match the #8 x 2" flathead screws, plug the holes legs. After that, glue and clamp the base. with 3/ S" diameter walnut plugs. After that, the rest is rasping and Q. Strength and a Decorative ~ Touch • Before sanding, there is sanding. Maloof's pieces are known for their contours and smoothness of tranone detai l Maloof adds to his sculptedsitions. I honestly spent about six hours base tables that add s strength, as well as shaping and sanding the base through a nice touch. to 220 grit. It was worth the effort. The half-lapped maple cross pieces It seems silly, but the most visible are added to provide strength across the part of the table took the least amount base, tying the opposing legs together


DETAILS • The half-lapped pieces of maple are shown in place (top), shaped , screwed and plugged. The process was more time consuming , but the finished appearance is dramatic. The photo at left shows a recessed screw slot to attach the top to the base. Maloof's pieces would have been screwed then plugged.

of effort. The 42" square/round top was made of four 7/ S" x I I" walnut boards . I didn't want to use more than four boards for the top , so I had to buy 8/4 lumber to get the width I needed - the resul t was that after resawing the boards o n the band saw I had some nice 3/ 4" wa ln ut for another project. While Maloof makes no bo nes about using sapwood on his tops as long as it's stable , I prefer a more consistent ap pearance - though I did leave a little sap as a nod to Maloof the master. The top was edge-glued usi ng six #20 biscuits per joint. To shape the top, mark a point 2" in from each corner, and locate the center of each edge. Bend a strip of V4" maple across the center point of each edge in toward the 2" marks and mark the c urve for the top edges. Complete the top (except for sa nding) with a V4" roundover on the top and bottom edges. To finish the table, I used Sam Maloof's line of finish ing products offered through The Woodworker's S tore (800-279-4441) . These reproduce the Poly/Oil and Oil/Wax formulas mentioned in "A Maloof Finish" at left. PW

- David Thiel. PW staff This project originally appeared in the July 1982 issue of Pacific Woodworker.

January 1998 59

Exploding "Bank" Your friends will get a big kick out ofmaking a deposit! POPULAR WOODWORKING


ERE' S A PROJ ECT for plent y of fun. If yo u mak e it o ut of pine or scrap wood, the cos t is close to noth ing; and yo u can make at lea st 15 of them in a day. Believe me, you' ll need that many once your friends see them ! T hey make great gifts and craft show item s. The top and bottom of the bank shown here are '12" mapl e; the sides and ends ar e 1/ 4" bir ch plywood. T he o nly essential tool is a router with a '14" straight bit, but a table saw also comes in handy. Begin by cutting the top and bottom pieces to 3" x 5". T he n cut the 1/4" plywood into a 2 1/2" -wide by about 16"long strip . Eac h 16" strip will yie ld the two sides and two ends necessary to make one bank. Next, angle the saw blade to 45 degrees and bevel both long edges of the strip. Then , agai n using a 45-degree


60 Popular Woodworking

angle, cut the side and end pieces to 4 '12" and 2 '12" length s respecti vely. Using a '14" stra ight bit, set up yo ur rou ter a nd tabl e fo r a '/ 4" de ep c ut, '14" in from the edge of the piece. You' ll wa nt to make guide marks on the router tab le '/ 4" from eac h edge to set the start and stop points for each cut. Another option (espec ially if you're making a lot of ba nks) is to mak e ajig as show n in the photo on the next page. T he guide stri ps are locat ed accord ing to the d ia me te r of yo ur router base . A plunge router works exce ptionally we ll for this and the next ste p. After ro uting the '14" x 1/4" tre nc h o n the unde rside of the top piece, and the top side of the bottom, cha nge to a '/ 8" straig ht bit. Reset the fence or j ig guides to cut the 1'/ 8" co in slot in the

Shown in action , the exploding bank can make a very dramatic impression on the unwary. Any coin should work, just make sure the breakables aren't sitting right next to your "t rap."

__ ~E-" P LODI N G

Diagram (exploded view)


Schedule of Materials: Exploding Bank No. Item IDimensions T W L IMaterial

Top and bottom with a 1/4" x 1/4" channel routing.

Cent erline 1/8"

wide sl ot


Top & bottom :lt2" x 3" x 5"



:lt4" x 2:1t2" x 4:1t2" Birch plywood



:lt4" x 2:1t2" x 2 :1t2" Bi rc h plywood



Ma ple



The routing jig was made from a scrap pie ce of :1t2" plywood and a few strips of poplar. The jig itself is two " L" shaped pieces to allow adjustment for a t ight fit against

With the mousetrap and screws in place, the top is carefully lowered into posi t ion. You may want to tinker with the sensitivity of the mousetrap or it will end up going off

the piece to be routed .

premature ly.

center of the top , starting 3/4" from one edge. For a finishing touch, cut a 45-degree ch amfer on the top edge of both the top and bott om pieces. Now yo u ' re read y to asse mble the sides , top and bot tom. For the bank to explode with sufficie nt gusto, the parts must be fitted somewhat loosely. With the top remo ved, eac h side piece sho uld lean outward about 30 degree s. You might need to sand the top and bottom beveled edges , especially the edge s on the end pieces. No w parti all y insert a #6 x 3/ 4" sc rew into the center of one end piece and into both side pieces centered from top to

bottom and I " in from the end. These screws se nd the parts flying when the trap spring is released. Fina lly nail, screw or glue the mousetrap to the bottom. I recommend Victor mousetraps because they have enough spring tension to cause a good explosion. After appl ying a finish to the bank, set the mou setrap, assemble the pieces and ask a friend to make a small dep osit. Then stand back ! PW - Frallk Longmore works wood ill Olath e. Kansas. This ar ticle first appeared in the Mar ch 1992 issu e of Po puiar Wood working.

January 1998 61

F YOU CAN'T AFFO RD to bu y a full-sized stea ms hove l for your childr en to pl ay with, the n re ad o n . Th e Mi ght y Mit e Ex cavator is th e perfect machine for scooping, moving and dumping back yard sand - witho ut the mess and fuss that come with real steamshovels. Best of all, the Mighty Mite is much less expensive. I built thi s vers io n from pin e and popl ar, but yo u ca n use any thing that will endure many "jo bs" and incl ement weathe r. I rec ommend bu yin g all the hardware before you start because some piec es might be trick y to find . Th en cut out and label all the wood parts acco rding to the Schedule of Materials.



er, then fasten the seat to the top of the body wi th fla t head wood screw s. The sub-assembly is now comp lete and can be set aside .



Base Sub-Assembly· The base sub-assembly includes three legs, three foot pad s (wi th a 1/ 4" radius on both sides) and the two base reinforcement discs. Drill a 1/2" diameter hole through the ce nter of one of the base reinforcement s, then glue the legs to the two base reinforcement discs. Place the disc with the ce nter hole on the bottom , with the grai n of the two discs at right



Central Sub-Assembly· After cutting all the parts to size, start with the central sub-assembly. It is made usin g the bod y, the boom suppo rt and the body support piece s. First, drill a 1/ 2" diameter hole in the bod y as shown in the PullOut" Plans, counter boring the upp er end for a flat washer and a 1/ 2" nut. Then drill a 1/2" diameter hole through the center of the body support. Attach the boom support to the body, as show n in the diagram, using 1/4" x 5" la g sc re ws a nd wa te rproo f g lue .


Counterbore the lag screw holes enough to recess their heads and a flat was her. Drill the 3/ 8"-diameter bearing hole in the boom support as shown. Depending on the actual outside diameter of the 1;8" x 1 1/ 2" pipe nip ples (which wi ll fu nction as bearin gs), you might have to experiment to produce a press fit. Drill out the inside diameter of these pipe nipples to a full 1/ 4". Align the body support with the 1;2" hole through the body, (keeping the grains at ri ght angles for stre ng th) , and se cure the two with glue and screws . Install the vertical axle and its wash-

62 Popu lar Woodworking


GET YOUR PARTS IN A ROW • Layout all drilling locations on th e cu t parts before you drill the first hole. Tape parts H together so they ca n be drilled at the same time.



Diagram of the Boom Actuator




1/4" d iameter



radius '-- -(+


13/ 16 "


7 15116"

Profile K






~,:¡I) --:

Hardware Schedule: NO.1 Hardware

Schedule of Materials: Mighty Mite Excavator Item No. Letter I Dimensions T W L



:1,'2" x 10" vertical axle


:1,'2" fender washers


:1,'4" fender washers


:l,'s" x 3/4" Iron pipe :l,'s" x 1:1,'2" iron pipe






1:1,'2" x 5:1,'2" x 16:1,'2"



:1,'4 " x 4" lag screws



Boom Support

1 :1,'2" x 1:1,'2" x 10"



:1,'4" x 4" carriage bolts



Body Support

3/4" x 5 " diameter



:1,'4" x 3:1,'2" hex head bolts




3/4" x 10" x 11:1,'4 "



:1,'4" x 5" hex head bolt




1 :1,'2" x 3 :1,'2" x 12"



:1,'4" x 3" hex head bolt



Foot Pads

3/4" x 3:1,'2" diameter



:1,'4" x 2 " hex head bolt

2 2


Base Reinforcement

3/4" x 8 " diameter



:1,'4" x 3:1,'2" carriage bolts


Boom Members

3/ 4" x 1 :1,'2" x 17"





Boom Stop

1 :1,'2" x 3" x 7"





Boom Stop

1 :1,'2" x 3 " x 6:1,'2"





Bucket Beam

1:1,'2" x 1 :1,'2" x 21 3/4"



.062" x 4" x 10:1,'2" sheet metal



Bucket Bottom

3/4" x 4 " x 4 "



.062" x :1,'2" x 12" sheet metal



Boom Actuator (Long)

3/4" x 1:1,'2" x 18:1,'4"



:1,'4" x 11:1,'2" iron rod

Boom Actuator (Short)

3/4" x 1 :1,'2" x 12" 1:1,'2" x 1 9/16" x 3 7/16"



:1,'4" id screw eyes



:1,'4" x 2" eye bolt (s/S" id eye)



:l,'s" cable clip



Compression spring



:l,'s" x 4 ' nylon rope



:1,'4" id flat washers :1,'4" id x 1 " od flat washers :1,'4" hex nuts





Boom Control Lever



Boom Control Leve r

3/4" x 1:1,'2" x 17 3/4" 3/ 4" x 1:1,'2" x 17 3/4"



Bucket Lever

3/ 4" x 1:1,'2" x 10"




1 :l,'s" x 1:1,'4" diameter



3/ 16" rivet




3/4" x 1 :1,'2" x 7"



#10 x 3/4" RH wood screws


January 1998 63

BASE CONSTRUCTION • Hand fit the legs where they co me together in the center to a point. They should be 120 degrees apart. You can see in this photo where I used positioning marks on the legs.


TEST FIT • To connect the central sub-assembly and the base sub-assembly with the :1t2" threaded rod, I used a nut with a lock washer and applied Threadlocker" to the end of it. Tap the rod at both ends.



LEVERS TOGETHER • Tape the actuating assembly parts together to drill them at the same time. The position of the parts shown here is not correct, but it made it easier to drill them together.

angles to each other. Drill for the three 1/ 4" diameter x 4 1/2" hex bolts, washers and nuts, then attach the legs to the discs. Tum the base sub-assembly over and use the center hole in the lower disc to drill the 1/ 2,,_ diameter hole for the vertical axle through the legs and the upper disc. Finally, glue and screw the foot pads in place . To continue assembly, lay ou t the hole loca tio ns fro m the Pull Ou t Plans on one of the boom members, then stack them and drill through both pieces. Clamp the boom stops betwee n the boom members using two 1/ 4" bolts thro ugh the end holes as alignment pins. Once these parts are correctly alig ned, dr ill th rou gh the boom members and both boo m sto ps . Temporarily assemble these co mponents using four 1;4" x 3 1/2 " carriage bolts, flat washers and hex nuts. It may be necessary to use fe nde r washers as spacers du ring the final asse mbly. To attach the hardware to the bucket beam, locate and drill the holes for the two bearin gs and the thr ee screw eye s as locat ed in th e di ag ram o n th e nex t page. Cut out and perman ently install the bucket bottom onto the lower, fro nt surface of the beam . T he radi us of the bottom sho uld be flu sh with the beam. Locate and dr ill pilot holes for the two wood screws that serve as retaining hinge pins for the sheet metal bucket.

64 Popul ar Woodworking

fu In


Check for Fit· Temp oraril y insta ll th e ce ntra l sub-asse mb ly onto the base sub-assembly on the vertical ax le rod. Use two large flat washer s between th e two sub-asse mblies . Install the main boom sub-assembly onto its support bearin g in the boom support with a 1/ 4 " x 5" hex head bolt. Th en install the bucket beam onto the front of the main boom sub-asse mbly with a 1;4" x 3 1/ 2" carriage bolt through the upper beam bearin g.

fu 4 In

Act uat ing Lever Assembly' This assembly consists of the two boom ac tua tors and the sto pper. G lue them togeth er then drill the three 1/ 4,,_ diameter holes as indicated on the dia gram on the previous page. Fit the right hand lever with two bearings as shown in the PullOut Plans. The space r is next g lued to the bucket lever. Nex t, temp orarily install the lever s onto the main bearing bolt and the actuat ing asse mbly in place on the right hand lever. Drill one 3;16" hole throu gh the buck et lever for the actuation cord, then attac h the fro nt end of the actu ating assemb ly onto the lower bearin g of the bucket bea m. Tight en all hard ware to a sn ug co nditio n and chec k for freedom of movem ent and ex tent of tra vel for all wood parts and th eir bearin gs. Thi s is where yo u will determin e how

man y fender wa sh er s will be need ed, and where , for cl earance betwee n the moving part s. Set the two outer levers parall el to each other, with the buck et beam resting agains t the stop of the main boom assembly. Then bolt the brace piece between the left hand boom control lever and the boom stop. Then run a deck screw throu gh the brac e and into the left-hand boom member, and check again for correct operation. In stall the buck et lever and spacer onto the left hand lever using a 1/ 4" x 3" hex head bolt, fender washers, a 1;4 " lock washer and a 1/ 4" hex nut. Once the proper travel and freedom o f operation ha s been found, di sa sse mble all the sub-assemblies and note the number and locati on of all the fender wash er s. Sand all the exposed surfa ces and apply an appropriate outdoor paint. Then re-assemble the fini shed component s, again ch ecking for freedo m of movement as yo u ass em ble. Add a nut and washer to the lower end of the 1/2" vertical axle.

fu In


Make and Install the Bucket Form the sheet metal bucket by tightly wrapping it around a 3 1/2 " di ameter can. Its inherent spring back will bring it to about 4" diamete r. File smooth all sharp edges and attach it to the buck-

Diagram of the Bucket Release Mechanism

2 1/ 2 " 4 7/8"

5 7/8 "

0 7 1/4"



et bottom wi th two # 10 x 3/ 4" sc re ws and flat was hers. To fo rm the b uc ke t handle , drill a 1/ 4" diameter hol e through center and on the ce nterline. Then, drill 3/16" hole s through both ends, 3/S" in from the ends and on the centerline. Also, drill two 1;s" diame ter holes in the upper "v " of the bucket handle, which will be used during the riggin g of the bucket. Ne xt, fo rm the handl e so that a I" flat surrounds the cent er 1/4 " hole. Then bend eac h end a few degrees I" in from the ends. Att ach the handl e to the bucket with 3/ 16" rivet s and flat washer s to allow for free do m of movement. To form the buck et release mechanism , cut 3/ 4 " lon g, 1/4 -20 threads o n both ends of a 11 1/ 2" len gth of 1/ 4" diameter rod stock. Then make as-degree bend 2" fro m the upp er end of thi s rod and install two 1/4 " hex nuts, as show n in the diagr am. Th ese will be adju sted on final riggin g. Thread the 1;4" rod through the hardware as shown in the diagram above and then tight en the lower hex nuts sec urely in place. Adj ust the upper hex nuts so that they

stop the buck et in its exact closed position (no ga p, no ove rb ite) . Ne xt , pa ss a li S" nyl on cord thr ou gh one of the drilled holes in the handl e and knot it securely on th e und ern e ath side. Then pass the free end of the cord throu gh th e a ppropriate screw eye o n the uppe r e nd of the bucket beam, throu gh a clip (or screw ) located on th e bu ck et le ver , back throu gh th e opposite screw ey e in the bucket beam , and ag ain throu gh th e o ppos ite hol e in th e handl e. Temp oraril y knot the cord. With the bucket fully ope n, and the bucket beam against its stop, secure the bucket lever in parallel position with the right-hand and left-hand levers. Tighten the nylon cord and knot it securely j ust bel o w th e rem ain ing li S" hol e in the


After inserting the eyebolts into the arm, attach the connecting rod to the handle, which has been riveted to the bucket, and attach it to the shovel (top). Then, after reo assembling the arm assembly, go ahead and string the shovel. Use a thin piece of wire to fish the doubled ~8" nylon cord through the 3/1 6" hole (left) , Bring enough cord through the hole to just wrap around a pan-head sheet metal screw . The screw is drilled into the opposite side of the bucket lever (bottom).

drilled washer. Tighten the set screw on the lever. T he Might y Mite Excavator is now assembled and rigged for many hours of service-free operation on the most demand ing of co ntrac ts. PW - Designed by Howard French; constructed by Jim Stua rd. The Mi ghty Mit e Excavatorfirst appea red in the November / 993 issue of Popular Woodworking.

Janu ary 1998 65

ANYAt1S& Crafts enthusiasts consider the cube chair th e sty listic peak of th e A rts & C rafts movem ent. This version borrows heavily from a chair made by the L. & J .G. Stick ley co mpany, but the narrow spindles are characteristic of arc hitec t Frank Lloyd Wright 's design s. Traditio nal quartersawn white oa k and solid co nstruction techniques make it true to Arts & Crafts pti nciples. T hough the chair isn' t complicated, the re are a lot of repetitive steps in milling the many mortises and ten on s. Begin by cutting the lumber to the sizes given in the Schedule of Materials.


14 MORTISES • Except for the through mortises in the arms , I used a bench top mortiser to cut all the mortises. If you don't have one, this project is a great excuse to buy a $250 tool.


66 Po pu lar Woodworking



Getting Readyto Make the Mortises • There are 82


mortise and tenon joints in the chair. A mortiser was my tool of cho ice, thou gh a plun ge ro uter using a 1;z" straight bit is anot her o ptio n. Each leg receives two 1;z" wide x 7/ 8" deep x 4" long mortises for the stretchers betwee n the legs. Th ese mortises star! I0" up from the bottom of each leg, so this is a good time to determine the legs' orientation, making sure the best quartersawn figure faces out where it can be seen. Th e 1;z" wi de x 7/ 8" deep x I I/ Z" lon g apro n mortises are next. Th e rear legs recei ve apro n mortis-


66 MORE· Time spent carefully laying out the mortise locations will pay off during assembly. If one or two of the mortises are off just a little, things go downhill quickly.

es on the same two face s as the stretcher morti ses, whi le the front legs rece ive only one apron morti se per leg, located on the side faci ng the back legs. These morti ses start 1/4" down from the top so the apro ns will be flush to the leg top.


TENONS . A jig attached to the miter gauge keeps the slat tight against the rip fence. The rear board should be :It16" to :Its" away from the rip fence to avoid binding.



Making More Mo rtises • On ce yo u've co mplete d the leg mortises, move to the side stretchers and aprons and mark eac h for the I I 1;2" x I" x 5/8" deep mortises for the spindles. The mortises nearest the legs should be marked starting I 1;4 " in fro m eac h end - a 3/ 4" allowa nce for the stretcher ten on yet to be cut, plus 3/ 4" spac ing between the leg and the first spi nd le. Allow a I " interval bet wee n each spind le, and thi s will provi de eve n spacing. Th e back stretche r and apro n are marked similarly, but the first mark is made 13/ 4" in from either end and then every inch. Cuttin g th e th rou gh mo rt ises in th e arms w ill be amo ng yo ur final tasks, so yo u' re through with mort ises for now.


I started with the spindles and set my rip fence for about 5/8" and the blade height for 7/16 " . By runnin g the spindle through with one face against the fence, then turning it and running the opposite face agai nst the fence, I was certai n my tenon would be centered. When the setup was a goo d fit for the mort ise, I attac hed a gui de bl ock to m y m iter ga uge to keep my fi nge rs away from the blade while making sure the slat didn 't wob ble during the cut. Two passes on eac h end of eac h spin dle, and I was

In 3

M ak ing the Tenons • The next step is to make all the tenons. Whichever piece you start with, the stretchers, aprons or slats, the process will be the same steps with j ust slight dimension adj ustments . I prefer to for m the chee ks first and define the sho ulder last. Thi s meth od prevent s the saw-kerf fro m bei ng see n on the sho ulder, and prevent s a waste piece from being trapp ed b y th e bl a d e w here it ca n be th ro wn back at yo u . In o ur case, the waste on most pieces is all sawdust, so there 's less risk of thro wb ack, but it's still a goo d thin g to be awa re of.


Schedule of Materials: Prairie Spindle Chair No. Item I Dimensions T W L I Material


Front Legs

2" x 2" x 29!¥S"

White Oak


Rear Legs

2" x 2" x 2S!¥S"

White Oak



7/S" x 6" x 29:1t2"

White Oak


Back Top

7/ S" x 6" x 34"

White Oak



3/4" x 5" x 24:1t2"

White Oak


Side Stretchers

3/ 4" x 5" x 23:1t2"

White Oak


Side Aprons

3/ 4" x 2" x 23:1t2"

White Oak


Back Apron

3/4" x 2" x 24:1t2"

White Oak



!¥S" x 1 :lt4" x 13:1ts" White Oak



3/4" x 2:1t2"x 19"

White Oak



:Its" x 2" dowels

White Oak


Seat Cleats

1" x 1" x 22 "


2 2

Seat Frame Pieces

3/ 4" x 2" x 24"


Seat Frame Pieces

3/ 4" x 2" x 23"


Slat s

34 " ;:-'"


22 "

6 "


11// wide with 3// spa cing





Seat Construct ion


>' (j)







>' (j)


x 1/ 211

Detail of Seat Cor ner

~ Beveled edge












27 "

Front Elevation


I J 22 "

2" } 3"

29 '/2"


January 1998 67

SHAPE THE SHOULDERS • A stop block makes the 168 cuts to shape all the shoulders easier, but it's still pretty monotonous. Keep your wits about you , this is the place where accidents can happen!


SIDE ASSEMBLY • It's easy to get a little confused during assembly once you start the gluing process, so make sure you're using the correct pieces to maintain the most attractive grain pattern fac ing out .


ASSEM BLY • Start the first tenon into the first mortise and tap it into place, then start the second and so on, until all are started. Then either tap the tenons home, or use a clamp to pull the assembly tight.


ready to cut the tenons to width. I readjusted my simple miter ga uge jig and completed the c uts.


Crisp Shoulders · T he final cut on the tenons defines the shoulder of the 1;2"-long tenons. The shoulder dep th is c ut using a stop block clamped onto the miter gauge as shown. Again , two passes are made on each end, then the blade depth is reset and the width passes are made. These same steps are used to form the tenons on the stretchers and aprons. The through tenons on the front legs are made last. Again, th e same three steps are used, with the final tenon size being 11;2" x 1'/2" xl". Before you begin sanding, cut the pro file on the corbels, or arm supports, and to cut the arch on the bottom of the side stretchers. Full-size templates are pro-


SHOP TIP The center of a piece can be safely cut away (as with the arm jig template) without cutting through the perimeter of the piece. Mark the cutout location, then (with the blade stopped and lowered below table height) adjust the rip fence to place an edge of the cutout directly over the blade. Turn the saw on and , while holding the piece down firmly (clear of the blade) , slowly raise the blade up into t he piece and complete the cut. When the saw intersects the marked lines of the cutout, lower the blade (while still running) , below table level; then turn the saw off. Repeat the steps to complete the cutout shape. This tip is suggested for MDF or plywood only. Solid wood may cause dangerous kickbacks.

68 Popular Woodworking

~OWELING THETENONS • The dowel holes are drilled 3/8" in • from the edge and at the center of the apron tenon and 1" in from each stretcher tenon 's width (left). After gluing the dowel in place, the +2" of dowel protruding from the hole is then trimmed flush to the leg, and sanded (right).

vided for both in the Pu llfrut" Plans. I used a band saw to make the cuts wide of the pe nci l lines, then I sanded many of the saw marks out wit h a sanding drum chucked into my drill press. Final sanding for the curved edges is do ne with a random orbit sander. Another detai l prior to sandi ng is the 45 -degree bevel on the top front edge of the front stretcher. Thi s attractive detail will keep yo ur legs from going to sleep ! I made the cut on the table saw, leaving a 3/8" face on the top edge.

fl; S PiCket Fence... • With the sandi ng done, you're ready to


assemble. Start with one set of side aprons and stretchers and II slats. Test the tenon fits for any prob lems, and use a chisel to adjust the fit if necessary. To asse mble the side, I clamped the stretcher into my front bench vise and appl ied glue to all the mortises . Make sure you use eno ugh glue, but remember that too much may keep the tenon from seating all the way in. My tenon fit was tight eno ugh to requirejust a little persuasion with a deadblow hammer, but if your tenons require more than a friendly tap, you risk bulging out the thin, 1;8" sides of the mortise. After all the te nons are seated in the stretcher, remove the piece from the vise and place the apron in the same position , and insert the sla t tenons into the apron mortises .


6 ...



And Fence Posts • Next, dry-fit the tenons of the assembled side into the mortises on t he front and back leg s. When the fit is good, glue the mortises, assemble and clamp.



Doweling the Joints • While the sides dry, drill the legs for pinning the tenons and then insert the pegs. Use mask-

SQUARED UP • It takes only a few clamps to complete t he assembly process . But while the glue is still soft, chec k for square, and if necessary, add a clamp diagonally to adjust the frame until it 's true.


WOOD"WORDS (wood "wurds) n. medullary ray: a vertical band or plate of unspecialized tissue t hat radiates between the pith and bark in the stems of trees . Stickley, Leopold: (1869-1957) younger brother of Gustav Stickley; founded L. & J.G. Stickley Co. with brother John George. Precursor to t he current L. & J.G. Stickley Inc . Prairie Style: A sch ool of architecture and furniture design pioneered by Frank Lloyd Wright. Prairie style is considered by many scholars to be one of the styles of the Arts & Crafts movement at the turn of the century.


THE ROUT STUFF • After clamp ing the template back on the arm, use a router with a flush cutting bit with a topmounted bearing to mill the rest of the mortise.

ing tape to mark the I/ S" drill bit at a depth of 11;2" and drill two holes at each stretcher tenon and one hole at each apron tenon. Cut the oak peg s to 2" len gth s and then sa nd a chamfer on one end to allow it to slip into the hole easily. After putting a small amo unt of glue into the peg hole, tap the peg home, making sure the peg's end grain runs opposite the grain of the leg.



A Square Chair • After the sides are dry, use the same procedure to assemble the rear slat assemb ly. Then glue it and the front stretcher between the sides and clamp. You should also check for square at this time, using a clamp to adjust. If your clamps allow it, the corbels can be glued in place at this time. If you' ve got clamps in the way. wait till the glue on the chair frame is dry and then glue the corbels in place. It' s important to center the cor bel on the leg and keep the top flush with the leg top on the back leg and the tenon shoulder on the front leg.


Ih g

ThrOUgh Mortises In the Arms • Next cut the through morti ses using the router template shown in the PullOut Plans. Use a table saw to make the template, and simply tack some 0t4" x 3/ 4 " strips to the underside as indexing guides. These guides provide correct mortise placement, while allowing you to use only one clamp to hold the template in place during routing. (See the Shop TIp for more information on cutting the template .) O nce the tem plate is read y, fit it over one of the arms and mark the locatio n of the mortises. Unless you want to make two templates, you' ll have to work from the underside of one of the arm s, so pay attention to which side displays the best figure. Use a ll/ S" boring bit chucked into the dr ill press to clear away mo st of the wa ste from the hole, then rout, and square out the mortises' corners using a chisel.


THE LAST CLAMPS • With the arms glued in place , check for glue squeeze-out and take your measurements for your seat 's frame.


Th e 45-deg ree miter j oints at the bac k corners of the arms are then glued together using biscu its to align and strengthen the joint. But before gluin g, gently tap the arms into place over the tenons and mark the hei ght of the ar m on the te no n with a pencil. Then carefully rem ove the ar ms, and use a bi scu it j oiner and glue to fasten the mitered arm pieces togeth er. Whil e these dry, bev el the top of the leg ten on by mark ing a square centered 3/ S" in around the top of the tenon , then use a random orbit sander to form a chamfer aro und the top of the tenon . This gives the chair an elega nt finis hing touch.

fh -t


Final Assembly • Onc e the arm asse mbly dri es. apply glue to the entire top edge of the chair apro ns and corbels and place the arm s over the ten on s. To fini sh the piec e in an app ropri at e sty le for an Arts & Crafts piece, appl y a brown anilin e dye to the raw wood , then spray on a coat of lacquer, or she llac. Wh en th at has dried. app ly a warm brown gl aze, wiping off the excess until yo u have achieved a uniform co lor. Afte r allowi ng the glaze to dry overnight, apply finishin g coa ts of lacqu er or orange she llac for a very warm color. We went to an upholsterer for the seat. using a simple foam cushion mounted on a flat poplar frame. Th e sizes for the frame are given in the Schedule of Materials. The seat is then simply dropped onto four cleats mounted to the inside of the chair frame. We also had the upholsterer work up a back cushion at the same time. After that , the chair is ready to put to important work. Ea se down . wigg le into a comfort abl e posit ion an d read Popular Woodworking while yo u plan your next project. PW

t; ~

- by David Thiel. PW staff. This article fi rst appea red in the May / 996 issue of Popul ar Wood workin g.

January 1998 69

, hese toys play tinkling tunes while providing action that adds to a Tyoungster 's play. They're fun to build, and there 's the added pleasure of watching the kids enj oy them as the toys come to life.

CAROUSEL Start the Caro usel by assembling the base. Make the corners by cutting a 1/ 2" x 1/ 2" groove in the ce nter of a length of 3/ 4" square stoc k, then cut the pieces to length. Bore a 3/ 8" cen tered hole thro ugh the top and install the music box movement so its winding stem is cen tered in the hole. Next, make the bottom disc and the top hexagonal plate (see the PuliOutâ&#x201E;˘ Plans) and hold them together while drilling the holes for the posts. Attach a 33/ 4" plastic turntable at the center of the disc using small machine screws.

Use the full-size template in the PullOut Plans to lay out and cut the two halves of the posterboard canopy. Then carefully fold the pieces on the score lines and use adhesive tape on the inside so the canopy will hold its correct shape. Mark the hexagonal shape of the canopy's top on another piece of posterboard using the assembled canopy as a template. Bore a 5/8" hole through the center of this part and attach it with tape. Conceal the joints of the canopy with wide plastic tape and add a "finish." Next, cut the posts to length and

The carousel turns at a fair clip because of the diameter of the bottom disc mounted to the music movement.

~5hape from





1;2" x 1" d ia .

1;8" x 1;4" ra bbet




1;4" x 21;4" x 9"





- - --


70 Popular Woodwo rking

Music movem ent. 'windi ng stem centered

See the PullOut Plans for a parts list

make the knobs that are installed at the top and bottom of the posts. The knobs are made from 1;2" thick slices of I" dowel. Grip the pieces with a hand screw or vise and form the holes on a drill press. Slip the knobs on the posts and assemble with glue. Attach the canopy with hot melt glue and press it down over the hex plate. Then coat the bottom area of the top spindle with glue and pass it through the hole so it contacts the hex plate. A full-size pattern for the horses is given in the Pull Out Plans. After cutting to size, attac h the horses to the post s with glue and 1;2" brads. Th e music movement is wound by rotating the disc or by turning the top spindle.



The band wagon won't win a race, but it moves enough to add to a youngster's pleasure. The driver is a store-bought figure.

The Band Wagon is designed so the music movement drives the wagon by rotating the left rear wheel. The diagram shows the construction details for the wagon, while the PullOut Plans provide full-size patterns for the side of the wagon and the horses. Make the sides first by bonding two pieces of 1;4" plywood or medium density fiberboard with carpet tape so they can be scro ll sawe d as a unit. Next, enlarge the left-rear axle hole to 3/8 " and mount the movement so the winding stem is ce ntered in the hole. See "Attaching the Mu sical Movements" for tips on this step. The dri ve whee l is attached with hot melt glue to a metal disc key that fits the winding stem of the movement. (See supply source at the end of the arti cle). Mount the right-rear axle block to the seco nd side of the wagon and drill it so it will provide a snug fit for the wheel' s 1;8" diameter axle. Now make the end pieces and asse mble the sides and ends. Complete the wagon body by makin g a sub-asse mbly of the top and seat area and installing it with glue. Th e front whee ls, which should Band Wagon

rotate freely on the the axle, are held in place with 1;2" round head plugs, pressfit on the axle. The best way to form the holes in the plugs is to grip them in a small hand screw or in a vise and then drill them on a drill press. Shape the harness and glue it to the wago n and clamp. The horses, made by scro ll sawi ng a pad of two pieces of 1/ 4" plywoo d or medium densi ty fiberboard, are the last step. Attac h them to the harness with glue and 1/ 2" brads . Note that the horses' feet are suspended a little above the grou nd to allow the wago n to move more free ly.

Se e PullOut Plans







. --------- _.

Axle block 3/4" x 1" x 11;2" -




You need special screws that are not easily available to secure the musical movements, but one of the following methods will get the job done with minimum fuss. First enlarge the hole in the base of the unit with a 3/32" drill bit and then drive in a #4 x :lr2" machine screw so it forms its own thread. The material in the unit's base is soft enough to permit this. Or open the holes to :Irs" and use #6 machine screws with nuts.

x 3 " x 61;8 "

1/ 8" x 1;4" rabbet

:~:3;~'-o;':';':'dJ. ~./

Attaching the Musical Movements

1;8" hole " ......


! "'


1/4 " x 2" x 31;2"



x 1" x 3"


3 /2"


Ha rness Music





Front axle: 1;8"

1;2" plug

See PullOut Plans


Left-rear wheel arrange ment

January 1998 71


PICTURE HOUSE In addition to playing music, the Picture House features a rotating disc with small decals that are visible through a view hole in the front of the project. A flashlight bulb, powere d by a pair of D-cell batteries and controlled with a small rotary switch, illuminates the "p ictures." Start the ho use by making the base, front and back parts (see the diagram ). Becau se the fro nt and back are similar, make a pad of 1/ 2" and 1;4" materi al so they ca n be shaped as a uni t. I found it easiest to lay out the shape on the top piece, band saw or scroll saw close to the lines, and then finish by sand ing on a stationary belt or disc sa nder. Separate the tw o pieces and use a hole saw or a fly cutter to form the 2" The back and roof of the house are easy to remove when it's necessary to get at the mechanism or to change the batteries. Uje a heavy r.Q blind as a drive belt.

view ho le in the fro nt part . Mark the loc ations of the three discs and drill 3/ 8" bottom holes. ext, asse mble the base , support block and fro nt with glue and 3/ 4" nail s. Make the mechanism parts and install them before continuing with the house assembly (see the PullOut Plans). Be sure the holes thro ugh the shaft support and the front of the house are on a common, horizo ntal line and that the drive drum and the picture disc are a tight fit on the shaft. Before final installation, paint the front face of the pictur e disc and apply decals of your choice on a radius that permits them to be seen throu gh the view hole. Attach a small broom clip to hold the bulb with hot melt glue. Han d turn the dr ive drum to make sure all is well, then make the sides for the house and install the m with glue and sma ll nails. Attach the music movem ent so its pulley is ap prox imate ly ce ntered with the drum . The wi nder is a 2 1/4" plastic turntabl e. Finally, ma ke the two roof parts and join them with the ridge block. Attach the back to the base with two screws , then

attach the roof assembl y to the back . Using screws - no glue - allows you to easily remove the back and roof so the batter ies can be replaced and should the mech anism ever require adjustment (see photo). PW R.]. DeCristofaro is the author ofmore than 30 books and is a ll the editorial advisory board of Popul ar Woodworking.

Source of supply: Crafter's Mart â&#x20AC;˘ 800-999-3445 All three projects use a disk key music box (prices start at about $4 each) . The Picture House also needs an accessory shaft (about 40 cents) and a pulley assembly (about $1.). Call for exact prices and musical tunes available.

Picture House



I - - - -- - - -J~ - - - 1I T----

11- --- - --------------)

: : #6x 11,t4" ~ FH screw, 1" ~ one per s ide I



Bac k

12" x 11 " x 121,t2" Base

1,t2" x.6" x 6 1,t2"

72 Popul ar Woodworki ng


The Sawyers Whirligig If yo u love cutting wood, you 'll be blown away by this contraption.

N TH E NORTH COUNTRY, amazi ng feats of lumb er ing are a daily occ urre nce. T his whirligig honors woods me n (and woo dswomen) and the pioneers who clea red the land for adve nturo us ho mesteaders. Thi s particul ar whirl igig has qu ite a pedi gree because it was designed and originally built by Anders Lund e of Chapel Hill, N.C., who was commissioned by the Smithsonian Institution to build up to 30 whirligigs for their 'Toys of All Ages" show and who is the autho r of two exce lle nt books on whirli gigs. Whi rligi gs that fea ture a person chop ping or sawi ng woo d are a co mmo n theme in Ca nada and the United States . T his air-powered animation is easy to make fro m wood yo u can find aro und the shop . The base was made from cedar (tho ugh other outdoo r woo ds will work) and the figures were built from 1/ 4" Baltic birch, though COX plywood would also work we ll.





Build the Base â&#x20AC;˘ First cut out the base piece, then glue and na il th e pi vot suppo rt piece 4 " in fro m the propeller end of the base . In the middl e of this piece, drill a 3;s" hole 13/ 4 " deep and insert a piece of brass or co pper tubin g as a bu shin g (the co pper pipe used to attac h ice makers is the perfect size). Place a metal "cap" in the bottom of the socket made from a 1/4" sec tio n of a 20d o r 30d nail. Next attach the two angle iro ns to the propeller end of the base. The fro nt one sho uld po ke abo ut liS" ove r the e nd o f the base; The rear one is attac hed with the upright 3 1/2" fro m the front. Make a 2 1;2"-long cut with a coping saw at the end of the


DRIVE SHAFT â&#x20AC;˘ To make my drive shaft, I used a length of 1,'4 " pre-threaded rod. Stick the rod in a metal vise with about 1,'2" sticking up above the jaws. Slowly and somewhat gently tap the rod with a hammer until it bends at a right angle. Toflatten the end of the rod so you can drill a hole for the connecting rod, file down both sides as shown in the photo using a mill bastard file.


ba se fo r the tail , wh ich yo u ca n cut from sheet alumi num or lightweight ga lvanized (old ductwork works nicely). Tack it in place wi th so me short finishing nails. One way to make the drive shaft is from a 61;2" length of 1/ 8" drap ery rod or welding rod. You'll have to thread the end to attac h the propeller and then put two right ang le bends on the other end and then thread that end. Anot her optio n is to

Janu ary 1998 73


End view

Diagram Propeller blades


Connect ing rod




Profi le

Schedule of Materials: Whirligig No. I Item I Dimensions T W L

I Material



3/4" x 1" x 20 "



Pivot support

3/4 " x 1" x 4"




1 :lt2" x 3:1t2 diameter



Saw handles

3/8" dowe ls x 1 :lt2"




:lt4" x 12" x 12"

Baltic Birch Ply.


Cross pieces

3/4" x 3/4" x 8"


Hardware Schedule


SCROLL SAW â&#x20AC;˘ Each figure needs two arms, two legs and two " poc k et s," which make the body fit nicely on the base piece. Photocopy the pattern and attach it to your plywood with a spray adhesive. Sand t he edges of the fi gures after you cut them out.

74 Popular Wood working


Socket liner

3/8" x 2" brass tubing


Angle irons

1:1t2" x 1:1t2" :!f8" or :!f4" wire or bolt x 6:!f2"


Drive shaft


Saw blade

s/1.6" x 6" light aluminum


Hlp joints

1 :lt2" machine screws, nuts, washers


Other joints

1" machine screws, nuts, washers


Prop blades


Screw eye

3:1t2" x 6" light aluminum :lt4" screw eye



5" x 7" light aluminum


Connecting rod 14-gauge wire

buy the copper rod used in toilet s to attach the float. It is threaded on one end, bend s eas ily and won' t rust. If yo u're not fond of thr eading metal , yo u ca n use my method shown in the photo that uses a 6 1/2" length of already threaded rod . Drill a '/ 8" hole in the bent section of rod. The closer to the end the hole is, the more vigorous the sawing motion will be. (It can be a little too vigoro us. My first drive shaft made poor Jerr y slam his head against the log.)

lh Iii


Making the Figures â&#x20AC;˘ Mak e the log fro m a scrap piece of 2x4 cut in a rou gh circle, abo ut 3 '12" in di-

ame te r. Cut a 3/4" -w i de groove in the bott om of the log so it wi ll fit snugly agains t the base. Cut a 1/ 2"-de ep 1/ 4"-w id e groove o n th e top of the log for the saw blad e to run in . Drill a hole in the base tha t's I 0 1/ 2" in fro m the prop ell er e nd and glue a nd screw the log to the base . Make the saw blade from a piece oflightweig ht aluminum (th e fu ll- size d ra wing fo r thi s is in the PultOut">' Pl an s ) and two 3/8" dowels for handles th at ha ve been cut to 11/ 2" lengths. C ut 1/2 "- long slots in the handl es and attac h the hand les wi th br ad s . Drill a 1/8" hole near th e top of eac h handl e to attach th e han d s. Ne xt c ut o ut th e pi eces for th e tw o sawye rs, Jerry and Luk e (see th e PullOut Plans). I used a scroll sa w, th o ugh a co ping saw wi ll do fin e. Some whirligi gs feature a woman in Luke' s place. Thi s ca n be easi ly accompli shed by giving Luk e a flared ski rt, a few mo re curves and so me extra hair.

lh 3

ASSe m b ' Y • Glue th e " pocke ts" o n th e fig ur es and then drill 1/ 8" holes for all the j oints according to the di ag ram . Attach the sawyers' arms with I " machine sc rews and was he rs. Th e mach ine screw throu gh Je rry's legs sho uld be positioned about 5 1/ 4 " in fro m the propell er e nd a nd 3" above th e base piece . Cl a mp Je rry ' s fee t in thi s positi on , attac h a screw eye to his rea r and then connect the drive shaft to the sc re w eye wit h 14-gauge ga lva nize d wire . Tr y diffe re nt le ng th s until Je rry be nds forwa rd but does n' t s la m his noggi n agains t the log. Th en glue and nail his fee t into place. Posit io n Luke ' s hip joint 16 1/ 2" fro m th e propeller e nd a nd 2 112" above t he base . A ttac h the saw to th eir hands wit h I " mach ine screws to see if everything moves smoot hly. Th e on ly scre w that need s to be rea lly tig ht is the one co nnecting Jerry 's han ds to the saw . Th e others can be left loose. Wh en things ar e wo rking right, nail and g lue Luke 's fee t to the base. Di sassemble the figures, paint them (I used a set of $3 ac ry lics I fo und at a hobby sto re) a nd then coat them with a n o utdoo r urethane o r spa r varn ish . Ind oo r urethane will flake off whe n ex pose d to the elements. When you reassembl e the figures, yo u mi ght wa nt to use so me sort of metal-lockin g so lutio n to ma ke s ure th e bolt s stay in pl ace. (I used a brand ca lled Th readlocker w.)




Propeller • T here are ma ny ways to ma ke a pro pe ller. He re' s ho w I ma de the o ne show n in th e ph ot o: C ut th e 3 1/ 2" x 6" pear-s haped b lades from alumi num or lightweight ga lva nize d metal. Cut the two cross pieces to size and then cut 314" x 3/ 8" da does in the center of each piece to for m a half-lap joint. Using a coping saw o r ba nd saw, cut a 2"deep diagonal slot in th e eac h e nd of th e tw o p ieces. Th e diagonal slots need to run in opposite directions on each piece. For example, if your slot runs from the top left to the bott om right o n one end of the piece, it sho uld run fro m the top right to the bottom left on the ot her end. Oth erwise, yo ur propell er wo n't turn we ll (if at all) . Round the e nds of the cross pieces with sa ndpaper, then



GET THE MECHANICS RIGHT • This photo shows where I put the screw eye on Jerry's backside. As you can see from the drive shaft, I tried several different locations for the hole to attach the connecting rod. Don't forget to use washers between the legs and the pockets to reduce friction and wear on your sawyers.

PROPELLER • Metal snips are useful for cutting the propeller parts and tail piece. Protective gloves don 't hurt, either. After you cut out the metal, pound the edges flat with a hammer and then sand or file them smooth.


inse rt the bl ad es into the s lots and attac h th em with brads. Drill a hole in the ce nter of th e two cross pi eces and attach the propeller to the drive shaft. Use nut s an d was he rs to space th e prope ller far e no ug h from th e base to keep th e blades fro m striki ng it. Pound a 30d nail into a pos t, c ut off the head, stic k yo ur whi rlig ig o n it an d e njoy wa tc hing these tw o go to work. PW -Whirligig designed by Anders S. Lun de; construction

by Christopher Schwa rz. This article originally app eared in the March / 987 issue af Popular Wood wo rking .

January 1998 75




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Jacobs" RouterChuck™ Eliminates Wrenches Contact: The Jacobs Chuck Manufacturing Co. 864-654-5926 Availability: As feature on some manufacturer's tools In earty 1998; available as after-market In mld-1998. Feat ures: • Replace a rout er bit by hand by releasing the Sleeve, replacing the bit, and snapping the sleeve back Int o place • Offe rs t ool-free bit changing, simplifying consumer use, and also potentially reducing manufacturers' production expe nses by not requiring spindle lock mechan isms or " on-board" st orage of wrenches • Simplifies use of table-mounted routers by eliminating need to remove router to change bit For more inf ormation, circle #1 70 a ll the Resource Directory C OUp OIl .

"Very smooth table movement, up-front slide release and sof t-start motor all enhance the high-quality cut."- PW

Makita's 10" Dual-Slide Compound Miter Saw It's Loadedl Contact: Maklta USA 714-522-8088 Retail Price: $669 Available th rough Maklta deale rs and catalogs. Features: • Twin-linear ball bearings on both ralls and an angular-mounted motor allow bevel cutting O· - 45 · to the left and right • Pivot ing fence supports tall stock and moves clear of cut quickly without tools • Single machined aluminum turning base remains flat and offers positive stops at O· and on the left and right sides at 15· ,22.5· ,30· and 45 · • Dual-positlon depth-adjustment knob allows for preset depth setting for dado work • The 13-amp motor with replaceable external brushes produces a 87 .5 dBA noise level For more information , circle # 171 a ll the Resou rce Directory CO UpOIl .

First Fein Tools Cordless Drill/Driver

Proudly Madein the USA




12257 Nicollet Ave. So. Dept. AW08 Burnsville, MN 55337

(612) 895-9922 1-800-334-4910 Circle #123 on Resource Directory Coupon

76 Popular Woodworking

Contact: Fein Power Tools 800441-9878 Retail Price: $245 Available through Fein distributors. Features: • 12 -volt drill offers two battery locations, (as Shown, or at the base of the handle) to let the tool adapt to the job • Includes 2 batteries, a one-hour charger and a 12-posltion keyless chuck • Two speed options offer 0-340 and 0-1,200 rpm ranges • Weighing Sibs., It delivers a maximum 230 in.flbs. of torque For more information, circle # 172 all the Resou rce Directory C OUp OIl.

.. -

Makita Offers First Nickel Metal HydridePowered Cordless Tools Touted as the first major advancement In hlgh-draln battery technolo-

gy In the last 20 years Nickel M les provide higher cap~cltles th e:,1 Hydride (NIMH) batterbatteries, which Is the cu an ckel Cadmium (NlCd) high drain applications su~:nt traditional POwer source for NIMH I as cordless drill/drivers a so represents an environ • solution and as NICd b tterl mentally preferable energy capab/litles 'NIMH Is a enes are reaching their maximum , seen as the ne t source for the power tool Industry. x generation power At the 1997 Chicago Hardwar 5 new battery technology po . e how, Maklta unveiled the Hefley, assistant vice reslwerlng a cordless drill. Ken said the new battery t:chn:~nt of ~arketlng for Maklta USA gy will likely be available by spring of 1998,

Storehorse's 20-Minute Plywood Workbench

raise and cut-thars all!!




DOING JOINING? WE'RE JOINING HEADQUARTERSl Best Price . , e e .t Selection, Top qualltyl


NfJI Oon' Ihrllw!hose "shor1S"

NfJI ' Y" FACET& G ..ayt Now anaffora<lable router brt router brtlor upto 1-1j8' ANGER JOINERWL·1429.. 139. material WL-l4a8.. S3O. : f1lr the Shaper WL·1510 2 PC. SET 'Y" FACE T& G ' ..,,$Hl("'... .. S89. ~ nowln 2slzeslorlhe'haper ." 3I8"lOr.'B" WL·1571 ,,\,S119. GWEJOINTS " 2 sues Ioruplll :V4'lO l ' WL-l m .. '139. :V4' (iiso s mO' JOI1I cutler) T & GFLOORING CUTTERS lI 4' shank WL·1430-1 .. S24. forIhe RIllllerWL.1U 8-1 ,,\,S39 112"shank WL·1430-Z.. S24. forIhe Shaper WL-1514 .. ~9. lorupto 1·1/4' material T&GRouter btt F1Jr 1/4' to 112" 112" shank WL·I430 .. $35. matenal WL-14Il8-Z .. S30.


Router btt CORNER LOCK MITRES in3 sizes WL-14ZD-Z (1/4' shank-llp to 5/8' material) .. S25. WL·14Z0·1 (112"shank-112" to 1/4' material) .. S3O. WL·1420 (lormaterial to 1/4'to 1-1/4') .. S38.

NEW Carbide tipped ROSETT E CUTTERS-cuttlng wi dt h: Our PANELRAISER WITH 2-1 /4" $39, 3-1/4 " $49. UNOERCUITER, " allablein 1-;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;-:-.....:..- -:-.....:..__ 5 attractiveprllfiles: Ovee. 12' faceCut wiatt. Rnd., Traditional, Convex, Wave, CUITERS and BEARING SETS (to changedepth Dessed withaheat-resstaet, 01 cut) Two-Flute Cutte.. ,,"nable In 114'or superslick finish, Always 112', hl nk.AUen wrench incl. makes just theright tongue thickness 10 perlec1ly match the groove inyour Rail & Stile-everytlme-what could be easiert!



,,1.14 ",.1,

, 5132" ker1 w/2 bearings, cutsslolto fit all bisou~ sizes. Sample bag01 biscuits incl.

Contact: Storehorse 800-555-9753 Retail Price: $40 Available at home center stores. Features: • Using one 4 'x8' sheet of plywood and six 2'x4's the StoreBench provides an 8'-long workbench with 36"-deep work top and back plate for tool storage • Supplied parts and your materials make a sturdy workbench In less than 20 minutes • Storehorse also offers a number of other helpful shop Items such as the StoreStool shown In the photo For more inform ation. circle # 173 on the Resource Directory Coupon.

"Bosch's jigsaw has been the industry standard for years, so it's quite fitting to celebrate it with a special anniversary edition. If you don't have one, now's the time" - PW

Bosch Celebrates 50 Years of Jigsaws

Withour l ·PlECEPANEL RAIL & SmECUm R. just raisethe bit approx. 3/8" to make thematchil1ll cut Availablein 5 profiles: OOee, Roundover. Cove& Bead. NEW Double-Roundover and NEW Wedve. Oressed wI1h heat-re~stanL super slickfinish. ' Greal fi , NoChal1ll111ll bits. ' No reversingthe pieces. • Just


Contact: SoB Power Tools 773-286-7330 Retail Price: $165, available at home center stores. Features: • Anniversary model 1587AVSK includes a steel carrying case , and --~ - - gold anodizing of the cast components on the saw • Standard features Include variable-speed orbital action, " c llc" tool-free blade installation , and foot plate that adjusts to 45 degrees left or right • Saw offers 1" stroke length , and operates between 500 and 3 ,100 strokes per minute For more info rmat ion, circle # 174 on the Resource Directory Coupon.



314'Bore or 1·114'Bore Shaper Cutter Panel Raiser

HJr@ 59

, RabbetingBtt W1th 3 bearingslor rabbets 01 1/4', 1'8"& 112" deplh , 114'kerfSiol Cutler W1th 3 bearingslor eutlinll slots011/4', 3/8" & 112" depth

Circle #129 on Resource Directory Coupon

If you've been


ii;::::;~(~s~;;;i~thinking about rid of that o ldgetting clunker of a fence, maybe th is will get you going . Choose the premium fence that best tits your needs: A versat ile, prec ision Delta Unifence<!> or a commercial-duty Biesemeye Fenc e. Make your purchase between August 1 and December 31, 1997,and we 'll send you a check for $30,That's one simple win-win situation. Call for the number of your nea rest participating Delta dealer. Delta International Machinery Corp.. 800-438-2486. ltawoodworking .com Circle #112 on Resource Directory Coupon

January 1998 7 7

"JET's reliablewoodworking machinery has now made a strong move into the home woodshop at a more easilyaffordableprice. By offering well-built woodworking machinesfor a procticalprice, JET is movingquality home woodworking to an affordablelevel. " - PW

JET Offers Six Shopline Tools Contact: JET Equipment & Tools 800-274-6842 Retail Price: See each item. Available at home center stores in early 1998.

Rollers aIM} Tables

• Tool Tables • Tool Pedestals • Mitre SawStands • Drill Press Support • Spindle Sanders • Router Accessories • Machine Covers - HTC Products, Inc. Royal Oa k, MJ 48068-0839

Call for a FREE Shop Solutions Catalog.

JSL-14DP Drill Press - $299 • This full-featured f1oormodel drill press offers a 14" swing, while the :1,'2" chuck offers a 3:1,'4" spindle travel • The :lt3hp, 1 phase, 115/22Ov motor offers 12 speed options from 250 to 3,100 rpm

JSL-10TS Table Saw - $399~~~?~t1 • 10" direct.<Jrive tab saw operates with a 15 amp, 115 volt motor • The cast Iron table measures 22:1,'4" x 20%" with two 9" x 22:1,'4" stamped steel wings • Cut capacity Is 3" max. at 90 ° and 2:1,'S" at 45 °, and a 14:1,'2" rip capacity to the left of the blade and a 27" rip to the right • The JSL-10TS also Includes a T-style precision fence, stand and carbide-tipped blade


JSL-6J Jointer - $399 • This open-stand Jointer offers a 6" x :l,'2"cuttlng capacity using 3 knives at an operating speed of 4,850 RPM • The cast Iron table measures 73/S " x 46" with a cast Iron fence that tilts to 45 ° • The JSL-60SJ includes a 3/4hp, 1 phase, 115v/230v motor and a 4" dust port

JSL-12BS Band Saw - $299 • 12" width and 6" depth cutting capac ity using 82 " blades from :l,'s" to :It2" widths • The :l,'2hp, 1 phase, 115 volt motor provides 2,750 SFPM blade speed • The band saw comes with stand and a 2" or 4" dust port

Your Best Work Starts With Us••• With over 4 .00 0 of t he finest woodworking tools in the world. Woodcraft can help you work more eff iciently and skillfully than ever. Call for your Free copy today.


W@DCRAFT" Helping You Make Wood Work"" m 210 Wood County Ind. Park. Dept. 97PvV12S PO Box 1686. Parkersbur WV 26102·1686

Circle # 128 on Resource Directory Coupon

78 Popular Woodworking

PLUS: • Also included in the Shopline set is a 1hp , 610 CFM, single-stage dust collector for $199 and a 6" or 8" two-wheel bench grinder with :l,'4hp or :lt2hp motor for $59 , or $109 respectively For more informa tion, circle #1 75 all the Resource Directory CO UpOIl .

---_. __.-


Oak (Quercus Alba)

Other Common Names: Swa mp Chestn ut, Chestnut Oak, Overcup Oak. Growing Regions: USA, Canada and Mexico. Characteristics of Tree: A moderately sized tree, it can reach a height of 100 feet with a trunk diameter of 3 fee t in good growi ng co nditions. Characteristics of Wood: A straightgrai ned wood that varie s in color from pale yellow-brown to pale brown, sometimes with a pinki sh tint; sapwood is creamy white . When quartersawn, oak shows silvery ray flakes. The wood has a medium-coarse to coarse texture.

Workability: The wood works well with both sharp hand and machine tool s. It takes nails and screws well, but its gluing properties vary. Common Uses: Building construction, interior joinery, furniture and cabinetmaking, flooring, tight coo perage, boat and ship construction, pews and pulpits, ladder rungs, wago n bottom s, co ffins, plywood, veneer, whiskey barrels.

comb. There is medi um movement in serv ice. Finishing Characteristics: The wood accepts stain well and ca n be poli shed to a good finish.

Availability: Readily avai lable.

Special Features: Thi s wood is virtually rot-resistant. Green white oak has exce llen t stea m-be nd ing properties. Many people are allergic to slightly green oak, so long sleeves and a goo d ventilation system may be in order.

Wood Movement: Dries slow ly with a tendency to check, split and honey-

Midwest Pricing: $4 per boa rd foo t, surfaced. PW


Prepa id Freight· Surfaced' Bu ndledGu~~~i~t~Japped • • All lumber is Select and better grade. 4' and wider. averaging 6",7 ' in width, lengths are 6" 8'. All stock meets or exceeds National Hardwood Lumber Assoc. grade rules. • All domestic lumber is Northern Appalachian grown. exhibiting charac-

Superheavy ~:""-_....-:'lIJ..----:~

teristics of fin e grain, text ure and uniform color .

Embroidered Logo.............. '-'/ WOOdworking 95% Cotto n 5% Polyester

NIAGARA LUMBER & WOOD PRODUCTS, INC. 47 Elm Street East Aurora, NY 14052 Call Toll-Free 1-800-274-0397

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Wouldn't you rather they be reading your ad? Call Kathy Georg at 800-283-0963, ext 324 for information on advertising in the



Abrasives custom makes abrasive belts up to 52" wide in any size and grit. Sandpaper is our specialty; we can help you answer any questions you may have on product applications . Ca ll now for your free catalog; it contai ns hundreds of abrasives and woodwor king accessories, including: safety equipment, velcro®-bac ked discs, wood clamps, wood glue, drawer slides, hinges and much, much more ! Circle #111. SUPERGRIT ABRASIVES

offers industrial quality sanding belts, discs, rolls and sheets at wholesale prices directly to the small consumer. An extensive range of hook & loop backed abrasives are available: vacuum and solid discs, triangles for detail sanders, shop rolls for drum sanders, co nvers ion discs and rolls. Try Supergrit Blue Zirconia discs and belts, "The Best in the World ." Free 28-page catalog and incredible close-out sheets. Circle #117.


oldest-established, most comprehensive woodwork er's catalog in the USA. 104 pages, more than 5,000 items, including lumb er, veneers, adhesives, tool s, finishes, hardware, books, plans and more, all cove red by a 60-day money-back guarantee. Free when you call (800) 223-8087 and mention Dept. 386 10 or Circle #102. THE WOODWORKER 'S STORE catalog is the catal og

that helps woodworkers do it right ! Discover over 200 new produ cts, includin g exc iting items for making computer desks, entertainment centers, kaleidoscopes and humid ors. Many exclusives and hardto-find specia lties like unique hardwoods, solid brass hardware, kitchen orga nizers, lighting sys tems and innovative tools - ju st to

80 Popular Woodworkin g




name a few ! Toll-free order- The company, which has ing. Satisfaction guaranteed! nine branch offices, 50 service centers, and over 300 Circle #118. authorized service centers, WOODWORKER 'S features an extensive line of HARDWARE offers a Free tools for both woodwork ing "Sales Flyer" featurin g some and metalw orking applicaof the 4700+ items available tions. They also offer a linefrom an in-depth stock of up of pneum atic nailers, pull s, hinges, slides, locks, including brads and finishing lightin g, entertainment cen- nailers. For additional inforter hardware, etc. Also avail- mation , call (7 14) 522-8088 able for $3.00 is a 190 page or Circle #134 & #171. products and specifications catalog includ ing the entire ARROW FASTENER product line. (800) 383-0 130. COMPANY, Inc. is one of the Circle #126. oldest American hand tool manufacturers. In addition to Clock Supplies its world famous line of all& Tools steel staple gun tackers and S. LAROSE INC. since 1936. staples, Arrow also produc es Products for the clockrnakin g a full line of Brute steel rule professional and hobbyist. measuring tapes, rivet tools, Industry leader in qualit y and hot melt glue guns and supservice. We have it all from plies. Arrow...the standard of quartz to mechanical clock excellence by which all othworks, fit-ups, parts for reers are j udged. Circle #109. pair or new projects. We stock co mplete clocks, SENCO PRODUCTS , INC . watches, tools, watch straps is a worldwide manufacturer and watch parts. Send for a of quality air-powered fasfree catalog WW! Circle tening tools and systems and the fasteners they drive. #155. Many of Senco's products KLOCKIT, a leading supplier are designed specifically to of quartz clock movements meet the needs of woodand other clockrnaking and working craftsmen. For more repair components. A wide information, call (800) 543variety of clock kits, music 4596 or write to Senco box styles, bird houses, boat Products, Inc., 8485 and humid or kits. Kits are Broadwell Road, Cincinn ati, easy as 1-2-3 sand, assembl e OH 45244 or Circle #122. and stain.Circ le #116. FEIN POWER TOOLS. New Hand Tool Triangular Sander eliminates Manufacturers hand sanding. Free brochure DELTA INTERNATIONAL shows how you can sand, MACHINERY CORP. manu- with a power tool, all those factures woodworking maareas where before you had to chinery and accesso ries for fold up a piece of sandpaper home workshops, building and "finger sand." The Fein and construction trades, Sander is ideal for sanding industry and schools. Quality along edges, moldings and line includes table saws, more. Circle #137 & #172. miter saws, band saws, jointers, scro ll saws, wood lathes, R'tOal AMERICA CORP. planers, belt/d isc sanders, offers a wide range of power tools, outdoo r power equipgrinders and more. For the ment, and builder 's hardware name of your nearest Delta distributor, or to order free for the serious do-it-yourDelta machinery catalogs, seifer and professional call toll-free (800) 438-2486. tradesman. Ryobi offers a Circle #112, #113 & wide selection of bench-top, #114. cordless, portable and specialty power tools; a variety MAKITA U.S.A. is the U.S. of gas, electric and batteryDistribut or of Makit a's line powered outdoo r power of high-p erformance corded equipment; and an assortand cordless power tools.

ment of builder 's hardware. Designed and manufactured to exac ting standards of quality, durability and reliabilit y, yet affordable. Free catalog. Circle #129 .

Hand Tools-Retail WOODCRAFT® SUPPLY CORP. offers more than

4,000 of the finest quality woodworking tools, books, supplies, and cabinetry hardware in our free 154 page complete full-color catalog . Circle #128. MORE WOODWORKING PLANES David Warren

Direct added 12 E.C.E. planes to their line of E. C. Emm erich hand tools. Forty planes in all. Unlike metal, wood absorbs vibration. Therefore wooden planes glide smoother and you can feel the cutting action. Our new price list also contains frame saws, workbenches and appli ances, 17 bevel edge chisels from 4 mm to 40 mm wide . 800-724-775 8 or Circle #104.


built the Mobile Dimension Sawmill since 1964. The Mobile Dimension saw produces quality dimensional lumber with ease, accuracy, econ om y and dependability. We take great pride in producing the finest sawmill possible and provide our saw mill owners with fast, courteous and accurat e service. Call us! Circle #101 .


Friendly"® L606 Moisture Meter uses advanced electromagnetic wave technology to accurately measure wood moisture content f~m 6% to 30% to a depth of / 4". No pins to "abuse" wood, leaving ugly holes. Check out boards from top to bottom injust seconds before you buy and avoid the headaches of splitting, warpage, delaminating and failed glue join ts. Call today for your free literature, (800) 944-7078. Circle #120.

RESOURCE DIRECTORY Plans & Kits ANDER SON MANUFACTURING. Put up to 16 drawers under your bed. Wor ld's most advanced, state-of-theart bed. So lid pine and hardwoo d construction. Cedar lined drawer s glide on ball bearin gs. O ptiona l: 6 ft long ce nte r dra wers, headb oa rd, side tabl es, and "dua l co ntrol ," adj usta ble mattress. Saves space ! Ends cl utter and elimi nates underbed cleaning ! Eco no mica l. Shipped UPS . 48 page cata log. Circle #108.

or se rvice have earned rave rev iews from leadin g trade magazines like Wood, Popular Woodw orkin g, Tools ofthe Trade. Air y's new mode l EZ-2 is the first tool that uses both nail s and staples witho ut makin g adj ustment s. Circle #106.

ABRASIVE PLANE , SAND WIDE BOARDS or edgeglued stock perfect ly n at or dim en sion stoc k to a desired thickn ess with a Performax Drum Sande r. You 'll enjoy woodworking even more as yo u prod uce professio nal look ing results. I I mod els WILDWOOD DESIGNS . Sc rollsaw Fret work Pattern s available for dru m and bru sh sandi ng . Se lect models offer and supplies. Fro m simple sanding as wide as 44 ", as projects to 50" tall clo ck s. thin as I164" and as short as O ver 300 patt erns fo r the scro llsawe nthus ias t. C loc k 2W '. Ca ll or wr ite for a com plete brochure. Perfonnax movem ent s, tool s, books, plywood saw blades as low as Produ cts, Inc. 1221 I Nic oll et $2 1.95 per gross. G rea t ideas Ave. S., Burn sville, MN for the hobb yi st or for profit - 55337 or Circle #123 includ ing cloc ks, fram es, HARBOR FREIGHT TOOLS jewelry boxes, furniture & offers the finest professional silho uettes. Circle #119. quality tools & equipment at the lowest possible prices Power Tools guara nteed! Let the catalog be AIRY is the faste st growing line of nail and staple tools in your source for thousand s of the U.S . Inn ovati ve design s, brand name tools. Call 1-800co ns istent qu al ity and superi- 423-2567 today to receive

your free catalog. Visit our internet site . Circle #127.

HTC PRODUCTS , INC. Easy does it with HT C's power too l accessories . Disco ver many unique item s de signed GREAT TOOLS DIRECT is only with yo u, the dedi cated now offering two grea t item s woodwork er, in mi nd. Make eac h priced und er $ 100 . One your machin er y safer, inis an 18 volt Cord less Drill. crease the wo rking area of Th e oth er is a 14.4 volt your shop, and acco mplish Cord less wo rkshop (drill, nearly imp ossibl e tasks eas isa nde r & wo rklight) ca ll 1ly, quick ly and acc urately. 800-925-200 5 or vis it our Full-line catalog and price list interne t site free. Circle #133. http ://www.greattools.c om or Circle #115. JOINT A-BILLI-T is just as its name implies, a tool for foolScroll Saws & Tools proof glue j oi nts. Use yo ur RB INDUSTRIES, woo drouter to cut these j oints working tools & accessories flawlessly in yo ur sho p: 100% mad e in the USA. Th e dadoes, rabb ets, ang le cuts, new precision hawk ultra squaring large pan els with a scroll saws, "4-i n- I" and "3perfec t glue j oint eve ry time . in- l " universal woo d-sa nde r Circle #165. sys tems, 26" variable spee d drum sande r, 38 " drum Stationary Power Tools sander, the all new panel ma ster II raised panel door maIMPORTS, INC. chine, router tabl es, book s, offers a wide se lection of accessories, patterns and heavy-duty woo dworki ng much more. We stand behind machin er y and accessories at every piece of equipme nt we prove n low prices. G rizzly manu factu re with our excl u- has develop ed a tremendou s sive 30-day money back reputati on du rin g the last I I guarantee and 5-year warran- yea rs as a leading imp ort er of ty. Se nd today for your free fine wood workin g machincatalog. Circle #103. ery, and back s up its sa les


Resource Directory Product Literature Order Form Send to: Popular Woodworking 1507 Dana Avenue , Department CCC Cincinnati, Ohio 45207 Please circle numbers below to order product information in this issue , December/January 1998, or use the card between these pages If ordering free Iiteratue only. 100 101 102 103 104 105 106 107 108 109 1.10 111 112 1 13 114 115 116 117

Eagl e Am eric a M obil e Dim en sion Const an tl ne 's Cat al og RB Indu stries David Warr en Direc t Tlt ebond Air y Sal es Ad am s Wood And ers on M fg. Arrow Fast ener Bon ham ' s Eco n-Abras lves Delta M ac hine ry Delta M achiner y Delta M ach inery Great Tools Kl ock lt Red Hili

136 137 138 'rerrco 139 150 Senco 1 51 Perform ax Wood lin e Arizona 152 153 JET Woodw ork er 's Hardwar e 154 Harb or Freig ht Tools 1 55 1 56 Woodcraft Supply 157 Ryobl Sm ithy 1 58 1 59 Porter-Cabl e 1 60 MLCS HTC Products 161 M ak lt a 162 163 Grizzly

118 Woodwor ker's St ore 119 Wild wood Design 1 2 0 Wagn er Electric

121 122 123 1 24 12S 126 127 128 129 130 131 132 133 134 135

GriZZly Fein Pow er Tools Clayton Machin e Cor p. Systlmatlc Great Lake s Leath er Sherwood Indu stries Co lon ial Time s Cloc k SSHC Sign Design S. Larose, Inc . Vill age Orig inals Pend elton-Dyne Packa rd Wo odwork s Invent ion Submission Ext inct Inc . Bak lund -Hellar Top-Line Products Niag ara Lum ber

16 4 165 166 170 1 71 172 1 73 174 175 300 301 302 303 888

Wood-Ply Lumber Join-A-BIIII-T Sout hern Prid e Craft s Jacobs Chuc k M fg. M ak lt a Fein Pow er Tools Stor ehor se S·B Power Tool s JET Equipm ent Ac c ent s In Pin e $2 Spec ialty Furniture $ 3 Am er ic an Coast er $1 Bri st ol Vall ey $1 U.S. Resid ent Subscription $19.9 7 999 Canad ian Resid ent Subscription $26.9 7

• Circle your choices . • Enclose coupon with chec k or money order for cos t of catalogs/ brochures/items. • We will process your reque sts promptly. You will receive informa tion directly from the adve rtiser. • Coupon expires May 5, 1998. • Please allow 4-6 wee ks for delivery. Order now and get 100 Grea t Projects with a one-y ear subscription (six big issues) of Popular Woodworking, America's Best Project Magazine.

Canadian residents send $26.97- d rcle #999 above.

Address City



Orders fo r inf ormation 01' subscriptions accepted onlyjrom U.S. Canada. All remittances must be in U.S.funds.

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RESOURCE DIRECTORY with unbeatable customer service and techni cal support. Free I64-page catalog. Call (800) 541 -55 37 to orde r. Circle #135 & #136 .

TERRCO provides a full line of machine carving and sign carvi ng equipment. Beginning models are the T110 and F-200 single spindle, 3-D carvers and our CM 6 14 single spindle sign ca rver. Our multiple spindle carvers include our K-Star (two spindles) and our Northstar (two to eight spindles) models. Circle #121. SMITHY CO. New ! Ten tools in one compac t, affordab le machine-the SuperShop by Smith y. Work woo d- and metal or plastic with a 34" lathe, 12" table saw, 12" disc sander, drill press, hori zont al boring machine, biscuit jo iner, router, lathe, mill and dri ll. The perfect frie nd to relax with, the perfect work partn er. Circle #130 .




: .."

JET EQUIPMENT & TOOLS. Unique featur es, one - and two - year limited warranties on both parts and serv ice, local dealers and repair statio ns, and toll-free custo mer serv ice assistance make JET' s woodworking machin ery such as table saws, band saws, j ointers, shapers, planers, dust collectors and sande rs the best value in the market for the serio us woo dwo rker. Circle #125& #175.

Tooling Bits & Blades

Ml1Š~- Professional woodworking products. Large discount s. New expanded catalog featuring a huge selection of carbidetipped router bits, raised panel door sets, shaper cutters, solid carb ide bits, the router speed control, plus our unique line of clamps, tools and supplies. Save 50% to 70%. Value, quality and prompt serv ice guaranteed! Free informati on. Circle #132.

Advertiser Index Adams Wood PJry Sales Corp Anderson Mfg Arrow Fastener Betterway Books

22 15 6

4 29

Bonham's Woodworking Supply 22 Bristol Valley Hardwoods 79 Clayton 12 Constantine 6 David Warren Direct 15 Delta 1,37,77 Eagle America 14 Econ-Abrasives 76 Fein PowerTools 24 Forrest Manufacturing 19 Franklin Intemational 8 Great Tools Direct 20 Grizzly Imports Cover 2,7 Harbor Freight Tools 10-11 HTC 78 Jet 21 Klockit 28

82 Popula r Woodworking

Makita 5 MLCS 13 Mobile Dimension Saw 12 79 Niagara Lumber Performax 76 Porter-Cable Cover 3 RB Industries 27 Red Hill Corporation 12 Ryobi Cover 4 Senco 9 Smithy 25 Systimatic 23 Terrco Inc. 4 Timberl<ing 27 Wagner Electronics 6 Wildwood Designs 28 Woodcraft Supply 78 WoodlineArizona 77 Wood-Mizer Products 15,26 Wood-Ply Lumber 79 Woodworker's Hardware 28 Woodworkers' Store 27 Woodworker's Book Club 16-17

. - -..


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Wood Glues RECOGNIZED ASTHE PRE¡ MIER name in wood glues, Titebond has five speciallyformulated glues for your next woodworking project: Titebond II Premium Wood Glue, Titebond Original Wood Glue , Titebond Dark Wood Glue, Titebond Liquid Hide Glue, Titebond Wood Molding Glue. For more information, call Franklin International's Tech Service Team at (800) EAGLE AMERICA is perhaps 347-GLUE. Circle #105. the most recognized supplier of quality Americ an made Woods woodwo rking tools in the ADAMS WOOD PRODUCTS world . Committed to innova- is a manufacturer of solid tion and qualit y, Eagle wood furniture components. America has developed a They make a variety of table resource catalog that reprebases, Queen Anne table legs, sents one of the most compre- claw & ball table legs, turned hensive collections of wood- legs, plus a variety of readyworking tools and supplies to-assembl e and finish dining available for professional chairs & occasional tables. cabinetmakers and serious Th ese items are carried in hobbyists. Our I 16 page stock in a variety of woods. color catalog is available to There is no minimum order you free by calling 800- 872- size as they can be purchased 25 11 or Circle #100. one at a time. Circle #107 . STATEMENT OF OWNERSHIP, MANAGEMENT AND CIRCULATION (Required by Act of August 12, 1970: Section 3685, Title 39, United States Code). Popular Woodworking (0884-8823) is published bimonthly (six times per year) at 1507 Dana Avenue, Cincinnati, Ohio 45207. The annual subscription price is $ 19.97.The generalbusiness offices of the publishers are locatedat 1507DanaAvenue,Cincinnati,Ohio 45207. The general business offices of the publisher and the editor are: Publisher and Editor Steve Shanesy 1507DanaAvenue, Cincinnati, Ohio 45207.The owner is F&W Publications, Inc.: RichardRosenthal, President Address: 1507 DanaAvenue,Cincinnati, Ohio45207.There are no other known bondholders, mortgagees, or other security holders owning or holding I percent or more of the total amount of bonds, mortgages or other securities.The extent and nature of circulation is: A. Average number of copies each issue during preceding 12 months 231,906. Actual number of copieseach issue published nearest to filing date 263,484. B. Paidcirculation. 1. Sales through dealers and carriers,street vendors and counter sales.Average numberof copieseach issue during the preceding 12 months 22,502. Actual number of copies of single issue published nearest to filing date 23,724.2. Mail subscriptions.Average number of copies each issue during preceding 12 months 160,590. Actual number of copiesof single issue published nearest to filingdate 184,636. C. Total paid circulation.Average numberof copies each issue during preceding 12 months 183,092. Actual number of copies of single issue published nearest to filing date 208,360. D. Freedistribution by mail, carrieror other means. Samples, complimentaries and other free copies. Average number of copieseach issue during preceding 12months 5,824. Actual numberof copies of single issue published nearest to filingdate 9,917. Total distribution (sum of C and D). Average number of copies of each issue during preceding 12 months 188,916. Actual number of copies of single issue published nearest to filing date 218,277. F. I. Office use, leftover, unaccounted, spoiled afterprinting.Average number of copies each issue during preceding 12 months 1,868.Actual numberof copiesof single issue published nearest to filing date 1,148. Returns from news agents. Average numberofcopieseach issue during preceding 12 months 4 1,122. Actual number of copies of single issue published nearest to filing date 44,059. G. Total (Sum of E and F should equal netpress run shown inA). Average numberof copieseach issue duringpreceding 12 months 231,906. Actual number of copies of single issue published nearest to filing date 263,484. I certify that the statements made by me above are correct and complete. Stephen Shanesy, Publisher. Filed October 1, 1997.



A class ic designfrom one of America's mostfamous clockmakers.

NE OF THE BEST Shaker clockmakers was Isaac Benjamin Youngs. Although he built mostly tall case clocks, his most well-known work is this small wall clock. It's particularly interesting in that the backboard was also the backplate for the gear movement. The clock was made of pine and had a light exterior stain and a dark -stained interior. As with any project that has hardware involved with it, you should acquire all of the hardware for the clock first. The company S. LaRose sells a kit for this project that includes the movement (mechanical or electrical), the face, pendu lum, hands, hinges, pulls and door catches.




Build the Case • Cut the case parts to the dimensions given in the Schedule of Materials. Next, cut rabbets on the ends of the sides , top and bottom (see diagram detail) , and cut the I V2" x 73/ 4 " windows at the top of each side piece. Using a rabbeting bit, cut a rabbet on the inside of the window opening, and finally, rout a 1/ 16" deep x 5/ 8" wide x 2" dado on the inside of both sides to capture the divider. Cut and shape the hanger as shown in the diagrams, then cut a 5/ 16" x 5 1/4" notch in the cap to mount the hanger flush to the case back. Cut a 7/ 16" wide x 2" notch on either end of the divider, leaving a 3/ 4" overhang to the front of the case . Then use a 3/ 8" radiu s router bit on the top and bottom edges of the overhang, and on the inside edge of the cap and base. Dry fit the box assembly and make sure everything fits, then glue and nail the parts together. The nails can be recessed with a square set to simulate an actual cut nail as shown in Steve Shanesy's "Little Shop" article in this issue . Check for square on the case and nail the divider into the side dadoes, then glue in the face mounts flush to the front of the upper case opening and sand .




Make the Doors • The doors are the only difficult part of this project, so take your time and measure accurately. For best appearance, layout your stiles so the upper and lower door stiles on each side come from one length of wood to match the grain. Next, mark and crosscut the lower door stiles from the pieces, then rip the fall off to 11/ 4 " and mark and cro sscut the lengths for the upper door stiles . Mortise the stiles first then cut the tenons to fit.Then groove the lower door rails and stiles for a panel, and rabbet the upper door parts for the glass as shown in the diagram. The inside corners of all of the door parts are mitered (see diagram), to allow for a decorative chamfer on the inside edge. Finally, glue up the lower door panel and cut it to the size given in the Schedule of Materials, and bevel cut the inside face of the


FRAME DETAILS • To cut out the holes for the side lights, pilot-drill the four corners, then scroll-saw the waste. Then cut a ~4" x ~4" rabbet using a ~4" offset bearing bit. After routing the rabbet , remove the waste with a chisel (top). Then, to match the chamfer planned for the front doors, I chamfered the edges of the side lights with a mill file (bot t om) .


January 1998 83

WALL CLOCK panel and dry assem ble the door. When everything fits, gl ue the doors together. Be sure to check for sq uare and try not to ge t any glue on the door panel so it can expand and con tract with humidity changes. After the glue sets, fill any loose joints and sand the doors and case where needed. Th en, lay out and inlay the hinges so you get a nice tight joint when they close .

Too ls (800-87 1-8 158). These are very strong and very small magnets , perfect for a project such as this.



Strong Magnets • The kit for sa le by S.La Rose has two mag netic catches. I decided not to use these catches in favor of rare earth magne ts supplied by Lee Valley e,



Schedule of Materials: Shaker Clock No. Letter l it e m Dimensions T W L

Detail of rail and 5tile joint

Detail of case assembly and face mount

51/4"70\1: 0

, --, ,/








:1(2" x 3:1(4" x 303/4"




Cap and Base

5/S" x 4 3/S" x 11:1(4"





5/S" x 3" x 5:1(4"





5/S" x 2 3/4" x 10:1(4"




Dial Supports

* 7/16" x :1(2" x 10"




Case Top and Bottom

:1(2" x 3:1(4" x 9 3/4"





:1(4" x 9 3/4" x 30:1(4"




Gong Hanger



Upper Door Rails

:1t4" x 3" x 3" 9/16" x 1:1(4" x 8:1(4" 9/16" x 1:1(4" x 7:1(4"




Lower Door Rails



Upper Door Stiles



Lower Door Stiles



Door Panel



Works Mounts

Plywood Pine

9/16" x 1:1(2" x 10:l(S" 9/16" x 1:1(2" x 19 5/ s "


x 7:1(4" x 17:1(4" :1(4" x 1:1(4" x 8"





* Rough length. Miter and cut to fit opening. Movements and kits available from S.LaRose Inc. 910-621-1936. Quartz klt# 084556 • price $24.20 plus shipping. Mechanical kit# 084557 • about $110 (prices vary; call for more Information and current pricing).



11/ 4 "


I Material


7 '3/4"X 1112" cutout fo r glass light







The Works • Cut and fit the 1;4" back in the rabbet at the rear of the case , then cut and install the mounting blocks for the works and the chime. Before you install the works, I suggest first mounting them and the chime to a piece of plywood with all of the appro pria te moun ting spacers as shown in the photo. Next, cut the face to fit in the upper opening. You should have equa l spacing on all four sides of the glass opening on ll.

2 '3/a" 10 1/4 "

f-- - --'v - +--'-'----; --' 5/ 8"




5/ 8"




5 1/4"


2 '3/8"





Deta il of hanger 32"






19 7 18"

16 7 18"

Tenon 1112"






'i 112"

7 1/4" 1 11 1/4"


J'112 "


84 Popular Woodworki ng


. ~ 9/ " 1/,~/1 6 4 4 '3/a" 9/16"





/ 4"

1" -


Detail of door mortises and tenons


DOOR ASSEMBLY • I cut the mortises on the stiles with a mortising attachment for my drill press (left). Traditional methods work well here, too . The mortises on t he upper doors measure ~4" x 1 " x 3/4". The mortises on the lower doors ~4" x 1 ~4" x 1 ". After you cut the tenons , mortises and grooves for the door parts , you need to cut back the corner lips on the face frame pieces. See the diagram for the precise locations of the lip. Cutting this back allows the chamfered edges to meet at the corners.


HANG THE MECHANICS • Before you put the mechanics in your clock, it's best to first hang them on a piece of plywoodto find out exactly where the mounting blocks need to be located on the back ofthe clock (left). Make sure that when you're layingout the location of the face that the center spindle Is in the center of the door.Then cut yourface to size. Once you figure out where the mounting blocks should be located, attach them to the back of the clock (right).




the door. Layout and drill the winder holes in the face and install the bra ss grommets and temporarily tape the face into the opening. Lay the clock on its back with the works loose inside. Position them to line up with the hole s in the face and mark their location on the back. The works should be spaced so that the spindle protrudes enough to let the hands work properly(mount them so you can make sure they rotate freely). Once you are sure the movement is working, remove them , the doors and hinges and proceed to finishing.


Finishing • I used a water-ba sed , powdered ani line dye with a lacquer finish. However, my test pieces were too blotchy. To fix this condition the pine with clear Watco oil finish. After wiping on two quick coats of oil, wipe it dry and wipe on the aniline dye . The dye will appear to be separating from the oil finish but keep wiping. After a couple of swipes the dye soaks in and gives nice, predictable results. Apply two co ats of lacqu er and rub the finish out to suit.


QUICK CATCHES • To Install the rare earth magnets, drill a small hole in the frame and the door. Put a few drops of cyanoacrylate In the holes and press the magnet in with the cap of the glue (it won 't stick to the magnet) . Allow the glue to ooze up the sides and onto the top of the magnet. When It dries , sand it for a finished appearance.

CAMOUFLAGED PUTTY • To make the water putty look the same color as the wood , first mix up the stain to the appropriate color. Then add the watter putty. Finally, apply the mixture with a piece of scrap wood.

Clockin' on the Cheap If you can't spend about $100 for a swell German movement, Install an electric movement with a pendulum instead. During construction of the clock, eliminate the mounting blocks and mount the face to a piece of ~4" masonite. Drill the center hole out and mount the movement in the hole and make sure that the pendulum can swing freely when the clock Is running. The part number for this kit Is available In the Schedule of Materials.

Reinsta ll the doors and components. Nail the face in from behind with small brads and screw the back, with the works attached into the case. Now you are ready to hang your clock on the nearest Shaker peg rack. PW -Original article by John A. Nelson . Construction by Jim Stuard. This article originally appeared in the May 1991 issue ojPopular Woodworking.

January 1998 85

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January 1998 87

..__ __ w_ ... _ - -.- _ ... __...--... ---_ _._. __....... ----_ _ .,._........._. _-- .._ -___ -. ._' -..._----_ --'" --_.------_ _--......_.._- ...----__---_ . . _.. _--.._ ......._ __ ..- . _w. . . .






V. f rench , .........-.e.-....... 01



~ ~

1D. . . . ...,ana. TM.aocfI

The largest stemmed chalice we 'v e ever seen .

N THIS ISSUE we presented some of the best projects and best "Tricks of the Trade" that have appeared in Popular Woodworkin g in the la st 16 years. However it would be foll y to sug gest that everything we ' ve published has been great. In fact, as we pored over the old mag azine s to prepare for this issue, we sa w so me stuff th at just boggled our mind s. So after looking at nearl y every one of the 664 projects we 've publi shed, here 's a sample of some of stranger stuff that has appeared between our cov ers:

• Popular Pornography magazine: We don't know how this one got through the editors, but in issue #9 (Nove mber 1982) the then-editors published a pictur e of a nude centerfo ld. Sh e wa s the model that a carver had used to mak e an eb on y tor so that won fir st place at the 1980 California State Fair. Surprisingly, readers didn 't protest. Perhaps it was because two issues later (# 11) the magazine ran a photo of, and we swe ar thi s really happened , a carved scene that depicted three bears filming two other bears in a rathercompromising position. Readers got upset , and we think that was the last display of nudity in PopularWoodworking. • Redemption Perhaps; or the Wooden X-Files: After its risque period, the editors tried to atone perhaps by running an article about a miraculous and mysterious IOO-year-old staircase built for a church in Santa Fe (September 1984 ).





_"" .... "'-



=...:::.---:::::::===.: . :::':" -".

.... .-tI



The " t ac k " shelter with a loophole. Get it ?


88 Popular Woodworking



-~-- -

Our best-seiling cover. Why? It's still a mystery to us .

The circular staircase went from the main floor to the choir loft, had no center support, and was built without nail s. And legend has it the builder showed up unannounced , built the inexplicable stairs and then disappeared before he could be paid. • Don't Try This at Home: The cover of the January 1989 issue is dominated by a photo of Ed Moulthrop turning a 5foot-high stemmed chalice from tulipwood (see photo abo ve). For the sake of saving paper and ink, we were glad there wasn 't a full -si ze dia gram of the chalice in the Pullfrut" Plan s. • He Built a Pun : In March 1991 we published an article called "Tack Shelter With a Loophole." It was plans for building a miniature shelter hou se made for thumbtack s (a tack shelter, or "tax" shelter, get it?); and hanging outside the house was a little noo se (the " loophole"). We all groaned when we saw the article, but some of us wished we had thou ght of it. • A Best-Selling Mystery: The cover of the January 1994 issue will never win a design award (see photo ). It' s a fuzzy photo of a guy planin g a board with an impo ssible amount of sawdust coming out the bottom. The background is an unstylish co lor of brown. It also was our best-sell ing issue for years . Go figure. • For the Tropical Reader: Jud ging from read ers' letters (and our subscription list) a lot of readers live in the warmer climates, es peci ally the ret irees. So it came as so me surprise to us to see the

The Pocket People get our vote for one of the most unusu al projects we 've published.

long article in February 1989 that ex plained how to build snow shoe s. • Oh No, Not Another Bear: In Ma y 1991 we showed you the 16steps to carve a 4-foot bear from a log with a chain saw (At least the bear wa sn 't in front of a video camera this time). • People in Your Pocket: We know we 've built some silly projects (for example, "Stumpy the Reindeer Mailbox ," a Christmas card holder made from firewood, November 1997) but the silliest project we saw was "Pocket People" in September 1991. These little wooden contraptions fit in your shirt pocket.When you press on your pocket, a little wooden head peeks out over the hem of your pocket. We weren't sure if the effectwould either delight or terrify young children . • Shoot Some Wood: Maybe thi s seemed weird because some of us had a rural upbringing, but September 1993's article about building a special BB target with some intermediate joinery made us scratch our heads. We always used old Neil Diamond records. Certainly when thi s magazine ce lebrates its 200th issue in another 16 years or so, the editors of the magazine will look back at these issue s and sometimes wonder what was going on in our heads. Especially when they see "Stumpy the Reindeer Mailbox." We're still laughing about that one. PW - PWs taff

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Reusable , Tig i dust collection ister for maximum pickup and easy emptying. Tool can be hooked up to a vacuum without special adapters.

Hook and loop pad allows for quick and easy paper changes. Dust shrou rotates 360' 0 keep canister 0 of the way.

Get A Great Deal On A Porter-Cable We were first. We're still the best. That's not just our opinion . It's not just the opinion of a leading woodworking magazine. It's the opinion of thousands of professional woodworkers and cabinet makers everywhere. However, the incomparable 333 Quicksand is just one tool in our complete line of innovative, high performance, palm-grip random orbit sanders. Our newest offering the 6" Quicksand with Adapta v-pad gives you even more options and more features from the first family in woodworking. And the 332 and 334 Quicksands are still the standards of the industry. *333 named Best Tool and Best Value by leading woodworking magazine. Write Porter-Cable for details .


Plus there will never be a better time to purchase any Quicksand thanks to great pricing from all Porter-Cable dealers. To get your hands on the unquestioned leader in random orbit sanding , visit your local Porter-Cable retailer. Or call 1-800-487-8665 (519-836-2840 in Canada) for the dealer nearest you.




Professional Power Tools Since 1906 http://www Porte r-Cable is proudto be a co-underwrtter of The New Yankee Workshop on public television .

Circle #131 on Resource Directory Coupon

[ Shown with optional accessories. ]

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The sliding mitre table with precise mitrefence promotes smooth, accurate cuts. Long mitre rip fence aptional. The 10"carbide-tipped blade and ts-amp motar rip even nominal 4x4 stackwith near-jainter quality.

Sturdy steel work stand pravides a stable basefor workshop andjob site operation. Casters aptianal.


First. we gave the B13000 capability no contractor table saw could touch. Then. to raise the B13000 even further above mere, mortal tabl e saws, we creat ed many access ories. From oversized tables to a micro-positioning device. Thus creating something truly unique. Aprecision woodcutting system with unmat ched versatility. At a price that's far more down to earth . Available at participating home centers and hardware stores. For more information call 1·800·525·2579 or visit our websit




Circle # 129 on Resource Directory Coupon

Sliding rails and tables allow extrasupport for tiqht-or left-af-blade operation. When usingthe adapter kit, table accepts inverted jigsawar router, praviding jigsaw and shaper [unctions. Self-aligning rip fence automatically lacks parallel with blade for straight, precise cuts.


t © Ryobi America Corp ., 1997.

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Popular woodworking no 100 january 1998