Wood Magazine - October 2010 (US)

ORGANIZE YOUR SHOP THIS WEEKEND! pAO ,I p.56

DAZZLING WHITE MACHINES THAT MATCH G0715P tHESE MACHINES10\" HYBRID TABLE SAW ARE OF tHE SAME WITH RIVING KNIFE HIGH QUALIty ASINTRODUCTORY PRICE OUR REGULAR wtJl $758°0 GRIZZLY VERSIONS!,• (shown w ith optional wing)I G0513P G1035P ,-+ I 1';' HP SHAPER ~.\" J l--r- <-----, G0513P INTRODUCTORY PRICE r, ..~ . ~ $49800 Iil0000p 1?\" HEAVY-DUTYI' \" BANDSAW• • INTRODUCTORY PRICE $69800 m;a G0656P 8\" JOIN~ INTRODUCTORY PRICE \"' \ ~' ~F:=~ wtJl $72800 G0656PX 8\" JOINTER • WITH SPIRAL CUTTERHEAD INTRODUCTORY PRICE ~ $99800 MORE DETAILS FORTHESE MACHINES ON OUR WEBSITE.

G0453P 15\" PLANER .------ ' . \"\"'.:\" .Ii!!! : - INTRODUCTORY PRICE - i:3-~.....~. =- \"'-\". \I WJ,J $898°° - -.<01;. ~ &1 G0453PX 15\" PLANERWITH SPIRAL CUTTERHEAD -----.-~ INTRODUCTORY PRICE WJ,J $1398°°-- -- .•...\". -' -'-'\"- - G0459P BABY DRUM SANDER INTRODUCTORY PRICE \"\"\"~•• .. - \" $528°0 ~ - - ---,,~ ~-/ .- • ~..;;; G0452P .. G0555P 6\" JOINTER WITH ULTIMATE 14\" BAND5AW BUILT-IN MOBILE BASEINTRODUCTORY PRICE INTRODUCTORY PRICE~ $398°0 ~ $39800

WorldMags • Digital Magazines 54 PROJECTS 20 Simple Miter·Gauge Stop for long Parts 24 Shop-Made Tape Dispenser 28 Easy Arts·and·(rafts Bench 34 Turned Bowl Set Beautiful,and a great proje<:t for beginningturners. 54 Sc:rapwood Project:Candle Holders 62 Luminous Display Pedestal 66 Reader Projed: Bread-Dipping Tray SKILL BUILDERS 14 Joinery: Through-Mortise and Tenons 38 How to Make Dead-On Tablesaw Crosscuts 40 Shape Up Your Shop! Organization strategies you(anuse today. 49 Dado Duel: Bits V5. Blades Ahead-to-head battle to learn the best method. TOOLS & MATERIALS 26 Get the Gunk Out ofYour Tablesaw 56 Shop Test: Do-It-AII Routers 71 Wood-Buying Options, from Cheap to Easy 74 Wise Buys: Portable Mitersaw Stands 84 Shop-Proven Products Slop-free jigguides andbenchtoptouter table. DEPARTMENTS 6 Editor'sAngle 8 Sounding Board 10 Shop Tips 22 Shop Monke)': The Importance of Practice 16 Ask WOOD 92 What's Ahead

- on our website- woodmagazine.com GET WOOD . FOR FREE ELECTRONICALLY Ourfully digital, interactiveversion of .. ' ~ WOOD magazine isFREE to print subscribers. Signup at wcodmaqannerom/dicitalmac, and enjoy every issue of WOOD on your computet, iPad, smartphone, or any device with aWeb browser. • •• GET A JUMP ON , HOLIDAY GIFT-MAKING With more than 1,200 project plansat wocdmaqazlne.ccmzptans. there's no reason to wait until the last minute to start making holiday gifts. • (locks: woodmaqazineromzdccks • Kids' Toys: woodmaqazine.ccm/toyplans • Boxes and Baskets: woodmagazine.com/boxes • Kitchen Accessories: woodmaqazlneromzkttrhen • Turned Projects: woodmaeazlne.com/tumedproiects • Lamps, Candles and Vases: woodmagazine.com/lamps • Scrollsawn Projects and Puzzles: wocdmaqazlne.ccm/scoll FREE WOODWORKING VIDEOS See the drama of theDado Duel (page49} unfold in the WOODcuts channel at woodmagazine.comivideos. And checkout theseother free videos: • Fine-Furniture Accuracy from Any Tablesaw • How to Use a Router Dovetail Jig • Four Ways to Drill Accurate Holes for Shelf Pins • Quick and Easy Chisel Sharpening • Basic Finishing, Part 1: Project Preparation l

3HP LOW PROFILE CYCLONE DUST COLLECTOR VARIABLE SPEED PLANER/MOULDER with STAND• Motor: 3 HP, 22QV, single-phase, TEFC Closs ' F' <-.:o:Jl-• Motor: 2 HP, 220V, single-phose PATENTED• Amps : 22 • CyCle/RPM: 60 Hzl3450 RPM L _ I . Precision ground cast iron table & wings - ...I• Air suction capacity: 1489 CFM • Toblesizewithwings:36If.'lxlO\"W •.• Max. static pressure: 10,2' • • Max, cutting width: 7' \"' r~-• Intake hole: 8' • Max, planing height: 71f/ \" ~ a l\", c\" \", ' u\" _ _ .. • Max, planing depth: Ifa'• Impeller size: 141f/ • Max, moulding depth : W <Xlfmi,'/! .,..1«/;'\", \"I\"\",uMi\"K'n i,'n far/h;. ma<:ltj\",!• Sound level: 83 dB• Filter: 99.9% efficiency from 0.2-2 microns • Knife size: 7'h' x 1W Xl// HSS• 55 gal. steel collection drum with casters • Cutlerheod speed : 7000 RPM• Remote controlled magnetic switch • 4' dust port WI81l \ • Approx shipping weight:• Approx, shipping weight: WI816 Pla ner! 330 1bs,403100 . Dust Collector Moulder • 3 HP, 22r:N, single-phose molar • Cast iron lable size: 27' x 40'.4' • Tabla size with extensoo: W1819 - 27' x 53%', , W1820 - 27' x74'h' 1'1'<'1' 10\" Carbide-Tipped Blade • Arbor: W, 4300 RPM , • Max. rip copaci1y:• Rabbeting • ... • W1819 - 29'h\", capacity: %\" Built-ill - W1820 - 50' ,Uohile • Max. depth of cuI: 3W@ 9lr, B (N' 2:Y,~· @45'WI7.H 8\" Jointer W 1742S 15\" Planer \\'1819 10\"Table SawW1741 S with Spiral Cutterhead W 1754S 20\" Planer WUI20 lO\"Table Saw with Long Ext. Table OUTSTANDING SHOP FOX®ACCESSORIES ADJUSTABLE MOBILE BASES RIGHT ANGLE JIG1l2260A STRONGE RFRAME WITH IMProvt:O WHEELS AND GUSst:TED SUPPORTS! c... - . <10<1OO, roil encI& and 8 Solid aluminumMini MobileBase _......-\"\"\"\".\"\".\"'...\",.\".-.\"-..--\"-\".\"'.',--...\".'_.\".\".\".\"-. \"\" 1'9'\" joInI$ ~ &. with comple/<l 8 ExtendBd depth: 13' <ICe \lloey. TI>o S H OP FOX\" llIghI • Closed depth: 7'11\"600 lb. capacity 8 Height: 8' Arqe Jig i< ~onslrucI8d ....ng lopnz057A 8 Max. hofiz, open ing: PI,' x 8' QI>lJIily (lIum....... <xUli\"ll' &. pIoIe<Heavy-Duly wI\"Och at8 machined 10 8 'acfingMobile Base700 lb. ca pacity ~-UZ058A -_---_.....\"\"\"..... ADJUSTABLE ROLLER STANDSuper Heavy-Duty Mobile Base u_-\".,•.•\"•,\"\"''OOU>_ 8 stand length is adjustable from 19'h ' fa 54'1300 lb.capacity 8 Numoor ofrollers 9 • stand height adjusts from 24'h\" to 38\"()2259A Extension Kit (fIaall models) 8 Roller diameter: 2' 8 Two-way locking swivel casters: 4Y.. diameter()22~6A 36\" Extens ion BaI1 (fits all models) 8 300 Ib, COlXlcity WOODSTOCK INTERNATIONAL, INC, IS ALSO HOME TO THESE OTHER FINE BRANDS:STE ELEX8, PRO· STICK8, PLANER PAL8, JOINTER PAL8, BOARD BUDDIES8, PAR ROT VISE8, ROMAN CAR BIDE8 ROUTE R BITS AND SHA PER CUTTERS. VISIT OUR WEBSITE OR CALL TOLL FREE TO FIND AN AUTHORIZED DEALER NEAR YOU,

WorldMal!S . Dil!ital Mal!azinesOc:tober 2010 Be tter Homes and Garden se Issue No. 200 WOOD. woodm.J9oUine.com Vol. 27, No. 5 ~ EOfTOfI~N.Qt IH BlllKRltR ..... ~ Editor Deputy Editor ........ LMARtEN KEMM£T DAVE CAMPBEU - -P.-wtighti .\"._....\".....\".- T~ Editor Tool& Technique1Editor ....- eoe WIlSON BOB HUNnR Art Dir«tot SM;or ~n Editor KARt EHLERS KMN IlO'l'U\"'....\ ~ Editor Mo.J/tirTria Editor ~ LUCAS PETERS CRAIG RUEGSl:GGER~.(omtP¥\"'iirijM: DMign Edilor Auoci;II~ Art Dndor JEFF MERTZ GRfG 5EWRS 8ol:l6nignH ..-I buill: doIfb lor his Productioll/Ofla ~ AdmnwatM Assisbnl dudl'sdloif-. MARGARfTClOSNER SHERYLMU!'tYON Photogr.op/'lPr'l JASON DONNEllY. scan l.JTTU.JAYWIlDE Contributing -...w.tor1 TIM (AHIU.lORN....IOHNSOH, ROltANNE UMOINE T«hniuI C ~ B08 BAKER,. DOUG HICKS Contributing Cr.mnwn JIM H£AYFf Contributing ~adm 'ABS KUlH, IRA lACHER-JIM SANDfRSJoeff(raft\" tI'ft walnUl Pu~ MARK L HAGfIrt ADVERTISING AND MARKETINGth~r,~f~oo~ t CHICAGO: 333 N. Michigan M v Suil.. 1SOO. Chicago, .. 60601 MoIrkHing Ma~ AMANDA SAlHOOTfcu l'oome offb . ~W>g ~ JACK CHRISTIANSEN 0irKt ~ AdYP!tising R~t.l I~ USA GREENWOOD ~ KEVIN lARRY ATLANTA, NMgate Media DETROIT: RPM Al.sodates B~MSS Managt'f JEff STILES COOlOOWf M.lr1<e1.ing [li,rector rOOD SIERLE Retaillh nd MJr-.qer-New»tand JESSUDOlE Production Ma na.gt'f SANDY Wi lLIA MS AdYtonillog Oper~tions M~nqr JIM NElSON (.(om~rce M anager MAn SNYDER Vl(e PresideotlGroup Publ imer TOM DAVIS M EREOITH NATIONAL MEOlA GROUP Preside nt JACK GRIFFIN EXECUTIVE VICE PRESIDENTS Pr~ldent of Consume r M~9azi nes TOM HARTY Ch ief Br~nd Officer ANDY SAREYA N Sped~l lnterest Medi~ DOUG OLSON Preside n t, M eredith Integr~ted Ma r~et; n9 MA RTIN F. REIDY SENIOR III CE PRESIDENTS VICE PRESIDENTS Corpoi'~te M~rketiog Ollieer NANCY WEBER DirKt Response &; Tr~vel PAnl FOLLO Consumer M~rketing DAIII D BAll New M edia &; Market ing Services ANDY WILSON Newsstand DAVID ALGIRE COfPO'ate s,ales MICHAEL BROWNSTEIN I'rodoction BRUCE HESTON R_arch SoIutiom BRlnA WAREEd itorial Dir«tOf, Des Moines GAYlE GOOOSOtl BunER High strength with a shorter Editon.l Dir«tor. N_ York SALLY LEE clamp time along with no dyes for a natural finish makes Gorilla Wood fiNnc:e M IKE RIGGS Glue ideal for your woodworking Mel\"t'dith 360\" JEANNIN E SHAD COLLINS Meredith Womfon's N~ LAUREN WIENER and building projects. meredith C~rman and ClWf EMcUM OfficII'( STIPtfEN M.UCY Voce Chairman M El l MEREDfTH FRAZlEJt In ~ - LT. ~ith Itt 11 9 3]...2011)1\"'*'\"0.. sumcri~Iisl: i:I CKU\ioniIy rNde ......WbIe to c¥dully ~ flmls...no- products IN)' ee 01 irltefet to)'Oll.1I)'Ol1 not to «<_ irlfotmabOn In>rn eese companies by mail or by phone, p1Nse let In know. ~ yourrequestMong with your nwoling Iibelto ~ Cust_ SoII'l'W:e, P.O. Box 374$2 , 1IooJnlo. tA s003744S2 . CI c.\"...1IIftMidI e-,.- 20'\" AI rigIlIls -.M.,..... .tho tu.A.SUBSCRIBE R SEIMCEGo to ~;nuom/Mlp Of write 10W(X)() n-..galirle, P.O. 80. )7439, 1IooJnlo, tA $00374439 5

Editor's Ang=-=Ie _ Be a part of WOOD'! WOOD This issue marks the start of several new ways MAGAZINE to see your best projects and ideas published.WOOD Magazine Coniesl T he WOOD Magazine team of photos or illustratio ns as you see fit), Build any Crealive ed ito rs, p roject designers, via e-matt to bttt. krteresmeredtt h.com, artists, and craftsme n is a or through t he USPS to: Project with Extended talented lot for sure, but we WOOD Magazine, Reader ProjectTenons & Raised or Flat don't pretend to have a corner N Technique Ideas, 1716 LocustPanels to Enter to Win! on the ma rket for woodwork- ing creativity. Just go to our sr., LS-221, I>es Moines, IA 50309. \"P rlzes to Win: Web site, woodmagazme.com, and yo u'll see what I mean : [ ca n't wait to hear fro m you. Grand Prize: 4 day/3 night Trip fo r 2 Thousands o f woodwo rkers fro m Somet hi ng tells me I'mto Italy and $1,000 of Freud Prod ucts around the wo rld regu larly con tribute going to be impressed! fantastic p roject ideas and advice in t he Second Prize: $1,000 of Freud form o f gallery images, shop-shot Woodworking writer wanted Innovative Products Videos, and fo ru m posts. I guara ntee And here's you r chance to be a par t you , so me o f what 's on t he site we of WOOD in a full-time capacity. Third Prize: $200 of Freud cou ld not have d reamed up in a We have an opening at our locat ion Innovative Products hund red yea rs. in Des Moines, Iowa for a journalist who's passionate about woodwork- Contest Runs: Of course, lon g before the Internet was ing to join o ur team in producingAug 1,2010 - Dec 31,2010 even a remote conce pt, we tap ped in to inspirational prin t, digit al, and ou r readers' creati vity (and rewarded it video con tent. For more details on For More Oetails Go To: wit h tool prizes and cash) by publish- th is o pportun ity, and to apply, go ing your best shop tip s, iigs, and to www.meredith.com. click o nwww.WOOOMagaline.com/Fre udContest orga nizers, and we sti ll do. But now we careers, and sea rch for wood. also wa nt to publish in the magazine Subject to Official rules al 'II'VIW.woodfTlilgazme coml1reudcoll1esl you r best projects- everyt hing fro m No pu rchase necessary 10 erser or wio. To enter visit WNW indoor and outdoo r furnit ure to toys,WOOOfTlilgazirlewmllreudcontest ilO(l clickthebuhon 10 erser Then gifts, a nd whatever else you ca n complete the r~iSllatiC)fl all(llo llow the instructions 10 upload ore imagi ne. And, we'd like to kn ow abo ut (I) album 01 prolcs lup 10 six (6) photos) 01 a project utilizing flol any better met hods you've d eveloped for mastering com mon woodwor kingor raised panels and exteodoo tenons. 0110) album i5 one entry One tas ks such as preparing stock, cuttingentry per person Opento legal residents01 the50 Unrted States. and joints, assembling cabinets, applyin g fin ish, a nd so o n.theDistrict 01Columbia.21 YIlilIS orolder. TheUllilTlilte Rail '\" Stile Kicking off t hi s new series of read erPhoto t ortes eotry period belJ i~s OIl AUQust 1 2010, a~d ends on pro jects is the b read -dipping tray a/Jovepecenter31. 2010 Entries must be eceeo by 11.59 p m CI,on Decemer 31 , 2010 Void Whereplohibited, Sponsor Meredilh and o n page 66, a design we purchased Corporal ionand Freud from Ralph Bag nall o f Mu rfreesboro, Ten ne ssee. (See more of Ralph's work at ww w.consu lt ingwoodworker.com.) We fou nd his p roject concept att ract ive, fu nc tio nal, novel, and easy to make- just what we're looking fo r. Thanks, Ralph ! In t he co ming mont hs, we pla n to ru n more reade r-sup plied pro jects and woodworking techn iq ues. So send you r pro ject and techn iqu e idea s (include a brief su mma ry a nd as ma ny 6 WOOD mllguln<;> October 2010

FUSIONHOW CAN THE BEST GENERAL PURPOSE SAW BLADE GET EVEN BETTER?

Sounding-=B--o=-.a=.=r-d=- _Our bulletin board for letters, comments, and timely updatesReaders create pieces to match WOOD\" magazine projectsBench adds seating for bedroom set \" Wove n\" table complements oak rockerI loved t he cherry-and-ma ple bedroom set in issues 135-138 After building the rocki ng ch air in issue 183 (May 2008), I(September to December, 2001), a nd built the sleigh bed,d resser w it h m irror, and n ightstanct for my home. (Un fort u- wa nted a side ta ble to go wit h it . So I designed one taki ngnate ly, I d id n't have room for the armoire.) eleme nt s fro m the roc ker's design , with rou nd tenons o n the I wanted a benc h to match the set, so I built one based onthe design a nd joinery of the nightstand. My benc h measures rails and stretch ers and tabletop slats that mi mic t he chair's18x36xI8\". I had an upholsterer in stall the cush ioned seat. seat slats. It's 17'/2\" square and 16\" tall. To get til e wove n look in - Keith Alberico, Round Lake Beach, III. th e tabletop, I joined each piece wit h altern ating half-laps . - john Graham, r• _0 Leesburg, Flo. ••(Buy downloada ble plans for the bedroom suite at (Buy downloadablewoodmagazine .comfsleighbedset.) plans for the rocking chair at woodmaqazlne. com/ctasstcrocke r.)Article updates Issue 197 (May 20 10)Issue 194 (November 2009) In \"Add Sto rage to Tool Stands \" on page 24, there is an error in Section 2 of The full-size patte rn for the Trad itio na l customizing yo ur ow n stand . For Ste p B, the diffe rence in our exam ple sho uld be 1';'\", As a result, the new length in Step 0 would be 113;'\",Ame rican Blanket Ches t base on page4 8, should be 4\" tall rat her than 3%\". To ~DO the math (but just a little)use this pattern, align the bottom edgew ith the bottom of part s C and 0, and Ste p A Step 8cut to size as specified in the article onpage 30. ====Ifyour stand measures 13\"for dimension If your stand mea sures 8\" for dimension © Please work safely cID, calculate the difference from our stand calculate the difference (9V4- - 8\"= lW' ). In order to show you precise details in (13\" - l l'.4- = lW') . photos, we frequently remove safety guards. In your work, be sure to use all Step C + f W 0 - f v.\" safety devices, as well as wearing vision, Cross out the original breathing, and hearing protection. dimen sion. Step 0 Add or subtract the difference between part - WOOD magazine editors sizes and write in the new part dimensions.HOW TO REACH US • Subscription assistance: • To order past issues and arndes: Tonotify us of an add resschange or to get help with Filr past sues of WOOD magazine in print or on• For woodwortdng advice: your «rbscrlpncn, visit woodmagazine.com/serYice. DVD·ROM, our newsstand-only issues, Ofdown loadable Post your woodworking questions (joinery, finishing, Or write to WOOD magazine, P,O, Box 37439, Boone, IA artides, visit woodmagazine,comJstore, tools, turning, dust ccfecnon, etc) on one of our 50037-0439. Please enclose youraddresslabel from a online forums at woodmagazine,comlforums, recent magazine issue. • Updates to previously published projects: Filr an up-to-date listingof changes in dimensions• To contact our editors: • To find past articles: and buying-gUide seunesfrom issue 1through today, Send your comments via e-mail to See our index atwoodmagazine,comlindex. go to woodmagazine.com/editorial. [email protected]; orwriteto WOOD magazine, 1716loc ust St., lS-221, Des Moines, IA50309.8 W OOD m a g .....in.. October 201 0

Lee-Blocks> make woodwork ing easy again by gripping both your work surface as well as your project without the use of any clamps. Perfect for sand ing, drilling, routing, fi nishing and a whole lot more. Loc-Block stv also function as a project suppo rt by elevat ing your work , which provides easy access to every edge. What makes them work? Anti-vibration , non-slip rubber pads on both the top and bottomof the bloc ks. Our uniq ue design allows the blocks to be placed at each of the comers of your material or they can be connected together by their interlocking do vetails.Customize the layout of the bloc ks for your project - co nnect them together to createa stra ight. sturdy base for working narrow stock, or you can config ure them to form a full M:i\" x 6W ' block for smaller project s. A must have fo r any size workshop . Peachtree Woodworking Supply Inc: \" Your On e Stop Supply Sho p'\" Available at ptreeusa.com or call toll freel -888-512-9069

ShOR TiR-=--s Top Shop Tip _Helping you work faster, smarter, and safer Wall bracket bolted to studPoor man's panel saw \" 8' st raightedgeDespite my sma ll sho p, I like to make 2x41egs 8' long saw gu ide forlarge project s (such as the ceda r-st rip Wo rkpiece lon g rip cutscanoe shown with me). So to maxim izemy sho p space, I bu ilt this inexpensive, • Str aightedge saw guide \"ma keshift panel saw for breaking dow nsheet goods to rough size. Support b lock s Vl \" dowe l holes Fi rst, I bolted 2' fo ldaway sta nd-o ffs S\" apartto the bo ttom s of a-tong 2x4 legs, asshown in t he d rawing. The bottom of 24\" st and -offthe legs have 'fl\" ho les drilled every 8\"to hold the removable, doweled supportblocks, as shown. At the to ps of t helegs, and in three wall brackets lag-bolted to t he wall studs, I d rilled 1'14\"holes to accommodate a 1\" d iametera-long iron pipe. After drilling the end sof t he pipe for cotter pins, I slid thepipe through the brackets a nd legs andsecured it with t he cotter pins. To use it, I spread t he legs to supportt he outside edges of t he workpiece. Forcrosscuts in full sheets, I stand t ilesheet o n t he floor and clamp it to t helegs above the cut line to preven tbinding. For pa rtial sheets or for ripcuts, I rest til e sheet o n the suppor tblocks, wh ich I position at a com fort-able heig ht before clamping the sheetto the legs. To position the saw guid e, I fasten aclamp about 9\" below t he outline onone side and rest t he end of my sho p-made straightedge saw gu ide on theclamp while I position and clamp theother end for t he cut. The n I go backand position the first end of the guide. - Bill Anders, GettY5bufg, Pa.Editors' \" ol e: For (l FREE video show ingYOIl how to //l ake (I st miglltedgt' saw g /lideO (or your circular sow go to wo{)(lIllago7. ill('.wl lll\trrligJItt'(lge Tell us how you've solved a worksho p stumper. If we print it, you'll get $100 and a copy of 450+ Best-Ever Shop Tips (w ood magazine.com/ 450tips) . And, if your idea garners Top Shop Tip honors, we'll also reward you with a tool prize wo rt h at least $300. Send your best ideas, along with photos or drawing s and your daytime pho ne nu mber, to Shop 'nps, WOOD Magazine, 171 6 Locust St., LS·221 , Des Moines, IA 50J09 -J023. Or, bye-mail: [email protected] . Include your contact info in the e-mail. Because we try to publish origi nal tips, please send yo ur tips only to WO O~ magazine. Sorry, submitted materials can't be returned.10 WOOD m ag azine October 2010

Cranky routers raise without a fussIn t he course of testing t he do-it-a ll routers on pase 56, Ifound myse lf ma king hund reds of turns of the Includedrouter-ra ising wrenches. Ha nds crampi ng, I decided to speedthe process by converti ng the hex-head wrenches to cranks. To ma ke on e for your router, start wit h two square Ill\"MOf blan ks with sides equal to the ha ndle's length (o r, inthe case of an t-sbaped wrench, do uble the shor t leg'slength). Cut a centered slot in each of the blan ks to snuglyfit the wrench ha ndle, and d rill a centered hole in thebottom blank for the wrench. Then d rill an d counters inkthe botto m blank and secure the two blan ks toget her withscrews, as shown. Handsaw t he joined blanks rou nd . Finally,disassemble, d rill a %\" hole t hrough the top bla nk to fit a2\"-lon g do wel, and reassemble with t he wrench in place,gluing the dowel in to its hole. - Jan SVt'(, Des Moines, Iowa'Is' doweI2'long~:=,--_-;:;;- _ •Ro uter lift '1;, ' MDF diameter to match handle speed wrench •• •• v ',.• F.H. wood screwCut slot to fit wre nch.o oo • NO RESIDUE No Residue Duct Tape. To find out where to buy, go to ScotchToughTape.com continued 011 pllse 12 Cl200'1 3M.SC(}{'h, .... ScOld, Toog!l O\"'t T_ • • , 3l1li 11 o...~ ' M <h. PbOd 0 \" ;1\" . ... '''Oeomrl<' or 3Mwoodmagazlne.com

Shop Tips Magnetic attraction opens your eyes to the blind hole If you've ever bu ilt a bed using t raditional bed bolts, as shown below, you know how di fficu lt it is to b lind ly ma tch the bolt-access hole to t he holt hole in the rail . M isa l ign the two holes even slightly, and the nu t won't slip over t he bolt threads. Here's my method to perfectly ma rk t he center- po int of t he bolt access hole. After d rill ing t he holt hole in t he end of the rail (but before boring t he access ho le), slide the bed bolt into it . Now roll a cylind rica l rare-eart h magnet, or a stack of flat, round o nes, over the ins ide face of the rail. The magnets will be drawn to the i n ternal bolt and \" fi nd\" it by co m i ng to a rest directly over t he bolt . Mark that locat ion and repeat, movi ng the magnets farther from the end unti l t hey no longer att ract. You have located the end of the bolt. Mark a center point there and drill t he access hole. - Mike Schupp, Prairie Village, Kan. Bed bolt hidden Bed rail inside rail Trace hole • location on Bed bol t cover screw hole inside of rail. leg Bed rail Order online at leg oneida-air.com 12 WOOD m agazine October 2010Call for your FREE catalog!

lO-minute microadJusterThis simple route r table microadju ster ta kes o nly m inutes tomake, and pays huge dividends in accuracy. It consists of arabbeted backstop that hooks over t he rear of the rout ertable and locks into the sa me Titrac k that the fence rides in .The backstop houses 6 ':~2 pro nged 'r-n ut s in through holesto hold 6-32 threaded rod. I added a jam nut and couplersto act as a ha ndle and a referenceto indicate the adju stment ROD MOUNTING DETAILa mount. Each full turn of t hecou pler nu dges t he fence '/J2\". T·nut- Richard Lacey, Rome. Po.- Backsto pConcealed cord catcherThose plastic cases that tools com e in never seem to fi t thetool's cord once it's unfu rled for the first time. However,there seems to be ample \"filler\" space in the molded top. Ita ke advantage of that space by d rilli ng and cutt ing out alarge slot in the top of t he case, as shown. The cord storeseasily inside a nd stays contained while I d ose the case. - Dave Jenkins, Cuba, N.M. 8 Slot cut in case top Transparent Due t Tape. To find out where to buy, go to ScotchToughTape.com \",,'em.rt,~2009 I N. SCot<h. tn\" S<ot<h T\"'-'P Du<' T.pe D ID 3M ~ \"\"\" .... Ploid ~ign ..\" 01 3Mwood m llg llzlne.com 13

Call it a nod to woodworkin g To join parts of equa l th ickness, cut For parts of uneq ua l t hickness, ma ke history. Call it a skill stretcher. both the mortises a nd tenons o ne-th ird the mortise and tenon u p to a th ird t he Hey, call it showing o ff if you t he pa rt t hickness. On a joint using th ickness of the larger pa rt. To join awant to . Cutt ing t hrough-mortise-a nd- :j4\"· th ick parts, for example, t he mor tise :j4\"·t h ick table apron a H~t-t h ic k leg, fortenon join ts and pegging t hem wit h exa mple, cut tenons %\"-W t hick on t hedo wels gives you r project a d istinction widt h a nd tenon t hic kness both apron en ds.you do n't get with ti me-saving screws measure lAo,and biscu its. As its n ame implies, thi s Make the teno n Ij,z\" longer t han t hejoi nt features a tenon that goes t hrough W(@) Quick Tip! Allow seme wiggle widt h of the mat ing pa rt if you' ll sandt he mor tised workpiece, wit h t he end of room, If your smallest ch isel the teno n end flush with t he mortisedthe tenon protruding slightly. measures lAo wide, layout mor tises part afte r assembly. For beveled-end a ha ir wide r tha n t hat to simplify tenons, like the one shown above, make If you're up for t he cha llenge of chiseling out waste later.ma kin g this joint, try it as an alte rna- continued 011 P\"S(' 16ti ve to t he biscu its in t he Ha ll Benc h SIZE MORTISES AND TENONSTO SUIT YOURWORKPIECETHICKNESSESp roject o n pose 28. Here's how. Joining parts of equal thic kness (..... ) Joining parts of unequal thic knessJoint-sizing pointers Vo \" '1,\Maximum;\'; thickness of the mating piece ('1;,\")Through- mo rtise-a nd- tenon jo ints Minimum;\"'- )ty pically go together one of t he t wo 1ways shown at right. Either bot h pa rts ,... ..are t he same t hickness-a W rail Face cheekmating a Va\" stile, for example- of t he '. . YiI,' chamfertenon fi ts into a mortised part of 'I.Length oftenon equalsgreate r th ickness, such as a :j4\"-thick Face cheek Shouldertable apron aga inst a l W sq uare leg. width of stile + t w 1'1:1\" Length of tenon equals width of stile + 'I.'14 WOOD m ag azine Oc tober 2010

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Challenge Skill • 'A.\"-dia meter drill bit •r3 ~~.. •Overlapping holes drilled with a brad-point ,bit should leave evenly spaced scallops and (]rounded corners. The guide holds the chisel90\"to the workpiece and prevents cutting outside the layout lines. CHISEL GU IDE Miter-gauge extension '110\" stock--. '\"'\" Fence '\" '\" /, ,Face : ' cheekthe ten on s lfl \" longer tha n t he mating J-'-~~\"\"-\"'cEhdegeekpart width. ..............Begin with the mortises ~n~y~o~\"~,:te~\"~o:\"~P~,~,,:.~,·o~ver the dado blade I!]Tenons ca n be fine-tuned easier than To fine-tune a tenon with a rabbet blockmortise widths, so cu t your mortisesfirs t a nd match t he te nons to them . to avoid leaving a score tinewhere you'll later plane, shave away equal amounts on bothFirst layout a mortise on two o ppositefaces of t he workpiece a nd check that bevel the end of the tenon. faces. Checkthe fit after everytwo passes.t hey're equal d istan ces from o ne end.On your d rill press, mount a bit about that mortise wa ll, t hen flip t he wor k- gauge. Cut tenon passes with minimall1i6\" smaller tha n t he mortise width and piece and do the same from the overlap to reduce scoring on the faceattach a fen ce to t he drill-press table. opposite side . cheeks [Photo C]. Th en turn the wo rk-Clam p the workpiece to the fence and piece o n edge to cut the edge cheeks.drill th rough the workpiece along t he Cut tenons to fitlengt h of the mort ise IPhoto A]. To fine-tune the tenon , remove In stall a dado blade as wide as you r To clean up the mortise, first use a tablesaw accepts a nd set the h eight to material fro m each face cheek equallynarrow ch isel to sq uare the ends. Then leave tenons slightly t h icker than your using a scrap bloc k with IOO-gritassemble a ch isel guide as shown above. mortise widths. Test the settings on abrasive on one face (not the edges) or aSlide the flat face of a chisel t h at 's 1\" or scrap t he t hic kness of your tenon pa rts.wider dow n the edge of t he guide and rab bet block plane IPhoto 01. Stop whenjust dee pe r tha n ha lfway t h rough t he Set the rip fence a d istance from themortise to smooth t he scallops left blade equal to t he ten on length and the teno n slides th roug h the mortisefrom drilli ng [Photo B]. Switch the mount an extension on the miter wit h o nly ha nd pressure.guide to the opposite side and clean up Insert the tenon t hrough the mort ise16 and lightly scribe a line around t he cont il/ ll ed 011 page 18 WOOD m\"911Zlne October 2010

':\"\"1 Micra Pacl'l- Drill Guide Tackle ~S material w ith ease! Drills 25% sma ller Pocket-Holes . Includes Drill Guide and Drill Bit. ' 49\" ponable Base Give your Kreg Jig- the power of z-tcois- o-t ! Connects to most Kreg Face Clamps, for portable use . 119w r - - - -\"'-:'\" QulclChangUIl Quickly switch from drilling Pocket- Holes to driving Pocket-Screws, in just seconds. Includes chuck, Drill Bit, and Driver Bit. DuSi Call'CUan Anachm'nt Faster Drill Strokes, longer bil life, and best of an.; no clea n up! ..\" Ma.erlal suppan Stap Repeat preci se Pocket-Holes over and over, and support large panels with ease. ..\" Clamps Face Clamps, Corner Clamps. Bench «tamps: every type of clamp yo u need for Kreg Joinery tv ! Prioe$ vary- -n_----.--no-

Challenge Skillexposed end of t he tenon [Photo El,Separate the joint pa rts, a nd sand orplane a 45° bevel o n each ten on facea nd edge until it reaches the scribedline [Photo Fl. To assemble t he joint withoutsmearing glue on the ex posedtenon, ligh tly glue t he center of t heface chee k, insert t he te non, andclamp u ntil dry. To mecha n icallyrein force t he joint, drill 1,4\" holes 1\"in from the mortise ends and deepenough to pass th roug h the tenon .You ca n a lso drill through bot hfaces of the mortised pa rt jf you ta keca re to avoid blow-out whe n drivingdowels t hrough. Bevel th e ends of t wo LA\" dowelsa nd drive them into the h oles, asshown at the top of pllge 14. Cut t hedowels flush a nd sand the surfacesmooth up to 180 grit using a fir msan ding bloc k. •Il ::----;,.,JA m arking k nife with a sing le bevel helpsyou sco re around th e tenon fl ush wit h thesurface of the mortise.Plane fro m t he edge to the center to avoidt ear-ou t when beveling te no ns. Thensa nd th e bevels and end to 180 g rit.18 W OOD magazln<;> October 2010

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( -A S10PblOCk o n your mi ter-gauge wo rkpiece end agai ns t the sto pbloc k To cut pa rts with mitered end s, extension provides a simple, (wit hout ben d ing t he ex tension) and replace the stopblock with one that's foo lproof way to crosscut crosscut t he pa rt. mi tered the same angle as your pa rt .mu ltiple par ts to equal length without Co mpletely capturing t he m iteredmeasu ring each one. Ru t what if you' re If the sto pblock slips or wobbles, add workp iece end adds dead-on repeatabil-cutt ing ext ra-long parts, suc h as table a second clam p or adhere 100-grit ity to t hose cuts. Always chec k to ma kelegs? In th at case, clamp on a tong-part sa ndpaper to the hack side of t he sure there's no sawdust between you rstopblock like this one. m iter-gauge extens ion whe re it overlaps workpiece and the stopblock. • t he long-part stopbloc k. Start by attaching a n MDF orplywood miter-gauge extension to your LONG-PART STOPBLOCKmiter gauge. Make it at least 1\" widert han the th ickn ess of your workpteces ~11 /Cut 10 the desired length. --....... wand long enough to reach fro m just .• ...... I I\"-J-past the blade on o ne end to 6\" or sopast the end of the mi ter gauge o n the Miter-gauge extensionother end. Mou nt it to your saw's stockmiter gauge, and cu t a kerf t hat ma rks Kerfthe blade pos ition . Long -part stop block Subtract the len gth of t he extension ANGLED STOPBLOCKfrom t he final leng th of the workpiece,and cut a st rip of %\"-th ick MDF orplywood about 10\" longer than th atd ista nce . Next crosscut a }lh\"-long pieceoff t he strip and screw it to one end oft he st rip, where shown at riS/lt. To use the stopblock, measure thelengt h o f the pa rts you'll cut and clampit t hat d istance fro m the kerf. Butt the20 WOOD m a g azine Oc tober 2010

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The ShoR Monkey ..Don't be afraid.., he'strained.Practice MakesProficientW a nna become a star th ird baseman for a Majo r League Baseba ll tea m? It's easy. Go buy a baseba ll glove a nd show up at t he stad iu m. How about a talent ed heart su rgeon? Piece o fcake. Buy the board game Operation and sign o n at the Mayo Clin ic. Is th is how you ma ke it in t he real world? Of cou rse not. Inthe real world, success comes o nly a fter developing your skillsthrough hard work, practice, and study. W hy, then, do so fewwoodworkers see t he va lue of practice? Or do you \"practice bybui ld i ng\" pro ject s? Th in k about it . Say you have a project that begs for dovetails.The last ti me you cut a set-by ha nd or mach ine- was a litt lemore t han a year ago. Even if you're su re the chisels are honed o rthe jig is pro perly set up, wou ld you have t he co nfide nce to put theblade or bit to a stack of gorgeously figured ma ple, quartersawnwh ite oak, or flawless mahoga ny boards? Some woodworkers do; others don't. So me succeed; ot hers rea lizethat someth ing was not qu ite righ t o nly a fter gaps, ch ip-out, orcomplete mtscuts turn t ho se precious ti mbe rs into scrapwoo d. It's notcarelessness o r a lack of skill. More o ften t han not, woodwor kers whofait simply need to be more co mfortable wit h t he task. That's why I advocate practicin g your woodwor king skills, even iffor o nly a few m inutes a d ay. Wit h just a few pla in, low-cost boa rds o fpo plar, pine, or whatever is cheap and plenti fu l, you can vastlyimprove t he q ua lity of your work. In my shop, I'll freq ue ntly clam p a poplar board in the vise and cut arow of stra ight lines with a doveta il saw. I'm not building anyt hin g,just t rying to get the feel for the saw cutt ing, focusing on my a rmmovement to ensu re the saw follows the layout line. The first five orten minutes o f shop ti me go toward wa rm up, and then I spendanother ten o r fifteen m in utes at the end of a shop session readyingboards for the next pract ice round. It may seem bor ing and repetit ive at first (and my wife sometimeslooks aska nce at th is \"u nproduct ive exercise\") but once I get t he feel ofth ings, the practice helps sharpe n my conce ntration, d evelo ps musclememory, and puts me in t he right fra me of mi nd to work in the shop. No matter how ta lented t hey a re, good performers always ta ke t hetime to practice. Ath letes put in tra ining ti me, even in mid-season . tohone their skills. Musicians tu ne t heir inst ru men ts and pract ice ch ordsand progressio ns every day between co ncerts. Even professio nalairli ne pilots spend ti me in a simu lator to stay sharp and keep the ircertificat io ns curren t. Once you u nderstand t his essentia l need for practice, taking t hetime to hone your woodworking skills doesn't sound odd at all. Infact, t he on ly t hings t hat should be sharper t ha n you r chisels areyour woodwork ing skills. • The Shop Monkey (oka Tom Iovino of Tampa, Flo.) blog5 prolifically at woodmagazine.com/5hopmonkey.22

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Great Ideas for Your Shog I•S enser- Clean lines and crisp cuts make this shop helper attractive and - functional. -M ake quick work of d ispensing d ispe nser to shape. Rout a 'h\" rou nd - d isc to fit sn ugly ins ide a roll of tape. painter's tape for masking o r cla mping tasks by converting a ove r alo ng all but t h e botto m edges. Cut a piece o f W dowel I W long a ndfew o f your shop scraps into th is ha ndyaccessory. Ad he re the fu ll-size patt ern Ma rk a zvtong sec t ion on a hacksa w glue a nd cente r it inside t he d isc.on page 48 to th in hardboard or blad e. Use a ha m mer a n d cold chisel Appl y a finis h, avo iding the sectionplywood. Cut the template to shape, to inde nt t he b lade wh ere ma rked . d irectl y behind t h e blade. Tape willincluding the ta pered groove. Drill a ,/,.. Bend a n d b reak t he blade at th e stick bett er if left u n fin ished . •hole th rough each marked centerpo int. indentation s. (WeCut t he two side bl an ks and t he front h eld o n e end in a 1lI\"·d~p grooveand rea r spacers to t he sizes noted on vise and held t het he d rawings. Use the template tot ransfe r outl ine, hole cen terpoints, and other wit h plter s.) ,/,\" hole ~-:;?:;~;- 'A\" hole, centeredthe ta pe red groove location to the inside Cu t a kerf in t h eface of eac h side blan k. Drill t he t wo dispenser for th e l4\" deep @~~!VfT '/' dowell V' longholes on the inside face of eac h side blade section. Thebla n k where mar ked . Drilling the %z\" blad e shou ldhole first provides a perfectly round en dto t he bottom of t he tapered groOVE'. exte nd 'A.\" beyo nd Ad here the rectangular side blan ks toyou r workbenc h wit h double-faced tape. t he fro nt end of ..No finishFit you r router with a IA.\" stra ight bit, t he d ispenser. Sa ndand freeha nd rout a '/K\"-deep groove o nthe inside face of each bla n k. t he d ispen ser Glue and clamp the space rs betweenthe side blan ks, wh ere shown on the smoot h and us efu ll-size patt ern , keeping the groovesd irectly across from each ot he r. Later, epoxy or instant V,\" round -overremove the clamps and trace arou nd thetempl ate to transfer the d ispen ser glue to glue t heou tli ne to t he outside face of t helamination. Band saw and sa nd t he blade in t he kerf. Ma rk a No round-over 3\"-dia mete r d isc on bottom edges on a p iece of Materials List It-thick stock. At th e center- FINISHED SIZE po int used to Part T W l Qty. ma rk t he ci rcle, drill a Iii\" hol e. side blanks V,\" 4'1,\" 10 '/.0\" 2 Ba nd saw a nd front spacer 1'/,. 1'1\" 3 Y> ,1 Projett delign: d isc-sand t h e rear spacer I 'h. tw 4\" , Mlltt Selle r tape dlsc '\" 3\" diam.24 WOOD m llgazlne October 2010

f WOOD.;r•••• MAGAZ IN EII1, / ),i••I!• Issues 1·19S Septtmbef 1984 _~J\"n lOO\"9 / \"• - - -••• ..-~•- -.-\"'- -;;;:.... -~-.J---~ ;:.- -Why this massive archive deserves a place in your shop:oThe user·hiendly searchable index of all back issues makes it ~ Clear 300·DPI resolution. View every photo, drawing, and detail ineasy to find any project plan, shop tip, or skill-builder from this huge digitally reproduced, crystal clarity. Zoom in for a closer look, or printcollection. (lick on the indexed article and go to it instantly! Or art icles for use in the shop with the handy \"Print this art icle\" button. browse through the issues using the prominent bookmarks, linked Save hundreds of dollars versus buying back Issues. In fact, covers, and table of contents. There, too, one click takes you to the many of the most sought-after issues on this disc have been out of print lor years and are no longer available in any other format. information you need. ::) Compatible with PC and Mac. If you don't already have it,o Free up shelf space in your home and shop. The disc and- protective case fits 195 issues into the space of a slim paperback, Adobe Reader is included on the disc for viewing. Where else will you find more than•••295 525Furniture Projects Tool Reviews and Features230 1,515Shop Projects Shop Tips900 765Weekend Projects Skill-building TechniquesOrder online at woodmagazine.comjDVDlibrary or by phone at 888-636-4478

While spraying th e cleaned pa rts with a lubricant, tu rn th e han dwh eels thro ug h a full range of mot ion to d istri but e the coat ing.It's iron ic Tablesaws create dust with After you've blown off all t he d ust them with more grease will on ly att ract every cut, but that same debris ca n you can th roug h the blade th roat, o pen gu n k-bu ilding dust again. Instead, coat rest rict t he saw's abi lity to ti lt, or remove all t he access doors an d them (ahoY(' photo) wit h a pe netrating,elevate, and make more cuts . Even with panels. Now blowout as much dus t as self-drying lubricant such as ProGold'seffective du st collection in place, gunk possible by shooting co mpressed air I'G2000. (See So urce below.) Th istends to build up on t he gears, tru n- th roug h a ll t he openi ngs. You'll likely prod uct soa ks into t he pores of the steelnions, bea rings, a nd moto r. Here's how have to do th is severa l times from and cast iron to provide the much-you can beat the dus t gre m lins . above and below to completely evacu- needed lubrication without att racti ng ate the dust. du st. Squirt some o nto t he clea nedMake a clean sweep parts, and then turn the handwbeels to Next, use a steel or brass wire brush spread the lube even ly. Have a ragBegin you r cleanup by sucking out as (top ,isllt ) to d islodge g rime from your handy to wipe up a ny excess lubricant.much debris as possible from ins ide t he saw's gears, threaded rods, tr unn ions, Wa it for the PG2000 to d ry beforesaw cabinet with a shop vacu um, and bevel stops. For tough grease-a nd- cutt ing wood again. Make sawdustpreferably with a narrow nozzle. Be sure gun k deposits, dip t he brush in mineral while it's wet and you'll just create t heto wear eye a nd breat hing protect ion. spirits and scrub. Just keep any such problem aga in. You might need two orNext, close the access door an d remove solvents well away from bea rings to th ree applica tions fo r best results. •t he blade from t he arbor. With your avoid damaging t hem.dust collecto r ru n ning, blow com- Sourcepressed air into the t hroat opening to Apply lube-but do It rightclear as much dus t as possible, d irecting ProGoldPG2000: product#147403,16oz., $10,it toward the dust port . Once you've blown and brushed clea n Woodcraft Supply. 800·225'1153 or wcodcrettccm. all the intern a l components, lubricati ng26 WOOD m ag azine October 2010



WorldMags . Digital Magazines • M41 teria ls: W ., W ., and l 1,?\"·thick quartersawn white oak, a quarter-sheet of 'h\" plywood. PROJECT HIGHLIGHTS • Overall dimensions: 43\" long \" 20· deep \" 27 ~· high. • Learn to cut biscuit slotsqui<kly and accurately. • Create a wrinkle-free upholstered seat. .. -::--.~ >J.;;;. -28 WOOD mA9Bz1ne • OCtober 2Ol0

Authen tic Arts & C rafts fu rnit u re once required advanced joine ry skills. But yo u can assemble th is bench using easy-to-make biscu it joi nts and t he sou rce o n page 32 for q uarte r- sawn wh ite oak. If you're ready for a bigger challenge, b uild it wit h rea l th rough -moruse-and- tenon joi nt s. I.earn how to master t hat joint on page' 66. Two sides to the story 1Cut the legs (Al to size from IW- Set a square to check the outside slat (El thick stoc k [Materials List, page 32J. offsets from the rail (8. C) ends. Align inner- slat (D) cente r markswith the rail centers. i_(Wj Quick. TIp' Gille lip YOllr OWl. l 'lz\" stock. Rip W -t h ick stock at least 4\" wide down the center. Glue and damp o ne ha lf back-to -back to the other wit h o ne edge flush. Later, rip t he glue-up to width for llh \"-square leg blanks. 2Cut t he bottom end rai ls (B) about DBENCH SIDEASSEMBLY W oversize in width, the n t he top end rails (C). inside slats (D), and outside slats (E) to size. Sand them to 150 grit. 3 Using masking • tape, mark the centers of t he in sid e slat (D) and t wo II'\ II #0 biscuit slots, o utside slats (E). Th en transfer t ho se centered marks to t he bottom 'i l AI (B) and top (C) en d I I, •, #10 biscuit ra ils [Drawing 1, slots I, .I' .,.• Photo AJ. O n a flat I , ••..2Yl\" , surface, al ign the rail 14V,\" E and slat marks, and II27lA\" I I .,,,, ' ,1 check the slat in sets from the rail end s. \' , 4 Set your biscuit I joiner to cut #0 slots cen tered in :j4\"-th ick stoc k. (See • the Shop Tip be/ow for • help.) Cut slots whe re marked o n t he edges o f t he bottom (B) and top (C) en d rails. Then Bull's-eye your biscuits To accuratel y cen ter b iscuits o n th e thickness of your wor kpreces. use a rule instead of th e jo iner'S b uilt-in scale. First unplug the tool. Place your ruler on the biscuit-joine r fen ce and center the blade mark at ha lf t he t hickness of the part. For exam ple, center the blade W from th e fen ce for ~\"- t h ic k parts.wQOdm19\"z1ne .com 29

Trace an accurate arc CutoffTo mark an even curve on [J~the bottom end rails (B) andfront and bac k rails (F), cut a The bottom end rail (8) cutoff creates av.. xl \" strip of plywood ab out straight surface for clamping. Set a square for6\" longer tha n your pa rt . 2V,\" to check the outside slat (E) offsets.Attach sp ri ng clamps to yourworkpiece to position th e st ripflus h wit h t he arc start andsto p marks at t he workpieceend s. Then pull the st ri p upand aga inst the clamps un til itmeets the arc ce nt er m ark onthe workpiece. Trace t he arcand re move th e spring clam ps.cut one #20 biscu it slot on each end of EJ LEG BISCUIT LAYOUTt he top ra ils, and cut two #10 biscu it (Front right andslots on each end of the botto m end ra ils back left legs)[Drawing 1[. Now reset the biscuit joi nerfor In\"-th ick stock a nd cut #0 slots on the 20\" beveIs \" 1\"ends of t he in side slats (D) and out sideslats (E). ,J. ISRefer to t he Shop Tip above to lay out Lk the a rc o n t he bo tt o m end rails (B). \"• obiscuitslotJigsaw on t he waste side (save t he cut-offs) an d sa nd to the lin e. 27JA\" A6 GIUe the biscu it slots and cla m p a I I bottom end ra il (B) and to p end ra il(C) to a n inside slat (D) an d t wo out side 2W •slats (E) [Photo B], ma kin g sure t he endsof t he rails align. Repeat for the otherside assembly. Get the sides on their legs 1\12\1:,\" biscuit slots ~ -:-' ,1-; 1Tilt your tabtesaw blade to 20°. Then V• Adjust the miter-gauge stopblock exte nsio n attach a m iter-gauge extension that until bevels on all four sides of each leg (A) reaches past yo u r blad e and cut an 2W meet in the cente r. angled kerf in the extension. Place a leg T 1 (A) agai ns t the extension with one end ( biscu it-slot location s IDrawings 3 an d 4 J just tou ch in g t he kerf, a nd clamp a lo ng- and cut the slo ts in t he ra ils. Th en lay pa rt sto pb lock to t he extensio n. (See \"3'1j':1\" out t he curves. cut o n the waste side, \"Long-Part Stopblock\" o n paSt' 20.) Ma ke and sand to t he line. two cuts o n opposite faces of the leg and -I L- check where they meet (wi thout CTOSS- STem porarily clam p the fron t and in g) on the end . Graduall y slide t he leg lYl\" back rails (F) to the side assemblies and stopblock clo ser to the blade unti l (A-E) and measure be tween t he inside t he cuts meet in the middle. Then cut all 3G lue an d clamp two legs (A) to a side faces for the length of the seat su pports assembly (B-E) [Photo 0 [. Re peat for (G). Cut the supports to size and d rill fou r faces [Photo C1. Repeat for eac h leg. t he other side assembly.2Lay o ut biscu it locat ions on two right and t wo left legs (A) [Drawing 2J. 4 C ut t he fro nt and bac k rails (F) abo ut \n\" ove rsize in widt h . Layout th e11(@j Qulck Tip! Flllsl, \"rose [leeks, Quar- tersawn white oak d isplays distinctive DFRONT/BACK RAIL \"'- - - - - - -l flecks you'll want to show off. When orga nizing t he legs into left, right, fro nt . L :==1\"1-1.'\" ,=---'-- ¥o\" 20\" -;1 and back, m ark the biscu it slots on the faces o pposite the m os t attractive faces. .2Yl\" : ® Then cut ce ntered bisc u it slots and sand - the legs to 150 grit. r .;-- I#10 biscuitslots #0 biscuit slot l v.,\"-- iJ30 WOOD m ag azIne October 2010

rn D ~·_Dry-fit th e bottom end rail (B) and to p end Tape clamps to prevent squeeze-o ut f rom d iscol oring t he wood . Then cant clamps torail Ie) to t he legs t o check biscuit-slot alig n the screws wit h the seat support s (G).alig nme nt s before adding g lue to the slots.and cou ntersi nk lh\" mounti ng ho les. apply Lockwood no. 144 Ea rly America n D _~_ ~_~ _~ Maple Golden Amber dye. (Keep a wet,Glue a nd clamp the supports to the fro nt feathered edge as you work an d avoid lap Elevating th e bottom side assembly p rov idesand back rails [Photo E]. After the glue marks.) After t he d ye dries, sta in wit h clam p clearance. After clamping, rest all fourd ries, sand to 150 g rit. Va rathane Traditio nal Pecan no. 218 to legs on a level surface and check for sq uare. even o ut the dye color. Apply two clea r6 £levate one of t he side assemblies coats of water-based satin fin ish. (We (A- E) off the floo r [Photo Fl. Glue the used Old Masters acryuc.jfro nt an d back rails (F), add the secondside assem bly, and d amp. Finish-sandthe completed bench fra me to 150 grit.7TD stai n t he qua rtersawn white oa k flecks and su rrou nd ing wood even ly,ID EXPLOOED VIEW #\0 biscu it #0 biscuit slot slot A #10 b iscuit slots - 2'1>\" 31 4{)\"Written by Bob Wil son with k evin 60)l l eProject design , Jeff MertzIllustrations: Ro xa n ne LeMoine; l o r n a Jo h n sonwood m1l9\" zl n e .c:om

Add a soft seatThere's not hing tr icky about this simple ® ®upholstery job if you: Allow 3\" elCtra• Work o n a dea n surface. batting on• Avoid wrin kles in t he batt ing t hat eac h side,will show t h rough t he fabric. Cut batting to fit a ro un d t he foam an d seat (H). Pull t he batt ing sn ug a nd fa st en it to t he• Pull the fabric t ight a rou nd t he seat seat ab o ut eve ry 2\" using ¥$\" st a ples.an d between staples as yOll work. CottonII Fabric ~~~ba\"tt\"in\"g\"\"\"\"\"\"~SEAT UPHOLSTERYSECTION VIEW 2\" foam-%\" staple Use t he seat (H) as a patt ern to cut iii piece of 2\"-t hick upholstery foa m using a utilit y knife or an elect ric carv ing knife.Beg inning on iii long side, pu ll th e fabri c up, Pull the fa b ric t ig ht and st a ple the o pposite Pull and fo ld the fa b ric to red uce t he numbe r side a nd bot h e nds, The n beg in ga t hering of wrinkle s alo ng t he sides. Cut off exce ssfold th e edge und erneat h, and st aple it to t he the fabri c at the corners. fa bric a nd st a ple each co rner,seat every 2 \".Add the seat and sit a spell Cutting Diagram Materials List1Cut the seat (H) to size and follow p¥ !®I 0 Part FINISHEQ SIZE the instr uctions ooove to make * x 7'/.0 x 48\" Oak (2.7 bd. ft. ) (2 needed) A ''9' ,.' ,T W l Mati. Qty.an upholste red seat IDrawing 51. W IIX') © , W 27*\" 02Lay the bench cen tered on the z upholstered seat (H) and screw it 'l4 x 7'/.0 x 48- Oak (2.7 bd. ft .) (2 needed) B' bottom end rails zto the seat supports (G). Now plant ·Plane o r resew to the thickness listed in the Materials List. \" 5\"\" ,C topend rails17' 0your newly completed be nc h a ny- 0where yOli need a h and y seat. . \" \"0 insideslats 17\" 0 0 MORE RESOURCES , \"' ,outside slats W ' W 14W 4' 14 v.,\" FREE VIDEOS • Bask Finishing (in three parts) sw 40' 0 z woodmagazine.comlbaskfinish ' W 17*\" 0 FR EE ARTICLES • For more finishing advice on using dyes, 18l'l \" 39 ~\" Be 1 * x S'!:I x 48\" Oak (2 bd. ft.) J F' front/backralls woodmagazine.comlfinishes * x 7'1. x 48\" Oak (2 7 bd ft ) (2 needed) RELATED ARTICLES 1:1 \" ,G seat supports • \"ShowOff Figure with Dye\" is~e 157 \"\"'H seer ' Pam in ilial~ wtO'Ierlize. See the in\UuOk!n\. (September2004) S woodmagazine.com/Wooddye Materials key: o -cee (quartersawnwtliteoakis • \"Howto Get Started in Biscuit Joinery\" preferred), BP-birch plywood. issue 128 (November 2000) S Supplies: #8xl',I0\" flathead wood screws (6~ #0, #10, end woodmagazine.comlbiscuil #20 biscuits, ~\" staples. Upholstery foam, baning, and fabric ava ilable at fabric shops. S=Download lhisankle for a Im~11 f..... ® Source - Quartersawn white oak: We obtained the wood to build this bench from the FrankMiller Lumber (0. - (all 800-345-2643 orvisit frankmiller.com to arrange a mail-order delivery. Lumber may be ordered machined •Vi x 24 x 48, Birch plywood to thickness. see thecutting diagram for quantities. For a guide to otherha rdwood soede, visit the American Hardwood Information Centerat hardwoodinfo.com.32 WOOD mag azIne October 2010

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The broad, sweeping curves of t hese Note : The W -decp IlOk required for till' Materials List bowls a llow plenty of room to see what you're do ing as you turn, screw-celltt\" insert o( our (ouf-;mv chuck Part FINISHED SIZEma kin g this an ideal project for evenbeg inners. Using a four-jaw chuc k [More wouut naveout tile 11011' close to the {iI/iS/led T Diam. Mati .Resources, //(/ge 37) leaves no trace ofhow the work was held on th e lath e. depth of tile 51111/// bowl. So ins tead, we la rge bowl l ro\" I I\" APrepare the bowl dri lled a '>fI\".deep Iw/(' ill tnc small- bow! large ba se l ro\" 3ro\" Aand base blanks blank {/l1d slipped a W ptvweod spac{'f ova medium bowl II'.!\" S\" AFor each bow l and base, band saw blanks tile .screw centerbefore mountingtnat blank.1Jl\" la rger t ha n t he fin ished d imens io ns medium base 1\'1\" 31'1\" A(Materia ls List]. Drill a pilot hole cen tered Photocopy the bowl patterns from theon one face o f each bla n k to accept your WOOD Pattl'rl/S$ in sert, spray·mou nt sm all bowl 1\4\" 6\" Alathe's screw center. them to card stoc k, a nd cut them to sm all base 1\4\" 3W A shape. The procedure for tu rn ing each bowl and base is t he sa me; on ly the Note: Parts inrtiallycut oversize. Seetheinstructions. d imensions cha nge. The patterns con- tain the di mensions referenced by lett ers Materials key: A-ash. in t he drawi ngs and text.34 WOOD magazine October 2010

1 Shape the outside of the baseTools : ¥s\" bowl gouge, parting tool perpendicula r to t he lathe bed and t rue wor k. Stop the lathe an d test the flat ness of t he spigot shoulder [Skill Builder,Speed: 600-1,000 rpm the face of the blank. M ark the :t\6\" bt'/owl. With th e lat he ru n ni ng, ma rk heig ht of t he sp igot, t he B d imen sio n t he shoulder wid t h (Yl\"). Wo rking fromMount a screw center in your fou r-jaw (base height), and the C radius (spigot t he base bottom towa rd the spigot, shapech uck and t hread a ba se blan k onto t he dia meter).screw center. W ith t he lathe runn ing, t he side of t he base, tctt, Check you rmark on th e face o f the blank the A Re posit ion t he tool fest parallel to t heradius listed on the Base EKterior Pattern. bed . Cutting in from t he edge wit h your progress with the Base Exterior Pattern . par ti ng tool, form the spigot. To create a After reac hing the final shape, sa nd t heUsing you r bowl gouge, reduce the bla nk flat shoulde r, keep the side of t he tool cu rved por tio n fro m ISO g rit throughd iameter to t he ma rk. Move the tool fest against the fresh ly cut portion as you 320 grit . Don't sand the spigot . Spigo t e Markthe spigot height and the base height (B dimension). ., ~ . -~-~-r...0 Turn the blank to the , base dia meter (A rad ius). (A rad ius) ! f ) True the bottom face. o Mark the spigot diam eter (C radius). A rule for checking Note: For the small base only, mount a 'I\"-t hick flatness and depth space r between the screw chuc k and blank. Use a 6\" metal rule to chec k your 35 progress when trueing faces or hollowing. Place t he rule across a face to check its flatness, right. If you cut in at an angl e, the ruler will either rock o n the hig h spo t near the spigot o r show a ga p at the low spot nea r t he spigot. As you hollow a base or bowl, the full-size pattern helps you chec k the shape and depth as you near completion. To chec k your progress along the way, bridg e the opening with a straight scrap, far right. Measure fro m the bottom of the scrap to determine the d epth and compare it with the fi nal d epth (0 o r H dimension) shown on the pattern.woodm llgllzlne.c:om

2 Hollow the baseTool: %\" bowl gouge base bottom, brin ging the base to fina l the excess with paper towels. We t henSpeed: 800-1 ,20 0 rpm height . Mark th e \4\" th ickne ss of th e sto pped t he lat he a nd b uffed with a base rim and beg in hollowing the base, cloth, repeati ng t his process to buildRemove the base from the screw center four coats.) Remove t he base fro m t heand remove the screw cent er. Gr ip the worki ng from t he outside to t he center, lat he a nd set it aside .spigot in you r four-jaw ch uc k. True the left . Stop the lathe occasionally and gauge your prog- f ) Mark the base ress, measuring th e wall thickness. o d imensio n and checkin g the shape r0 O True the bottom face. against t he Base \ \.'~::'; Int erio r Pattern . \\i;J10 HolioWthe bottom. After reaching the fina l shape, ••, sa nd the interior to 320 grit. Stop the r------::::;;1w lat he and apply a fini sh in sid e a nd 1 out. (We liberally bru sh ed on bo iled lin seed o il; the n, with the lat he fun - n ing at its slowest speed, wiped off3 Shape the bottom of the bowlTools : ~\" bowl go uge, parti ng tool, the fit of t he base spigot in the recess. arc. Ma rk the G dimension to ind icateskew chiselSpeed: 600-1,000 rpm Increase the diameter of t he recess to the end of the are, and mark the th ick-Reins ta ll t he screw center and mou nt a achieve a p ress fit o f the spigot in the ness of the rim YJ6\" above the G dimen-bowl blan k to it. Mark the centerpoint oft he bla n k's face and use t he Bowl Exterior recess. Quick Tip' EstuMI.d' puper- (@) . sia n. Shape the bottom of t he bowl,Pattern to layout the E radius (out sidediameter). Tu rn the blan k to t his mark, Oil .. tolerm,ces, Cove r t he top of ¥ below eel/ter, work ing between the firstt hen true the face. Lay out the recess (Fradi us). With you r parti ng tool, begin the spigot wit h two layers o f painter's two mar ks, checking you r work aga ins tfor ming t he recess, working inside thelayout lin e so the recess is slightly u nde r- tape, and use the spigot as a d ept h gauge. the pattern. Sand the boltom to 320 g ritd iameter. Switch to a skew chi sel andt rue the recess bo ttom, below; t he n test The recess is the proper dept h whe n the and apply a fin ish, as you did o n the spigot shoulder just rests on the bowl base. Do not apply finis h in t he recess. botto m. Remove the tape after complet- ing the recess. --_··--- ·,+-:0 Turn the blank to finished Layout t he shape of t he bot tom by diameter (E radius). ! marking \4\" from the outside of the Eradius e True the bott om face. recess to ind icate the begin n ing of the -§ ~ Top ofrim ' 1,,~ O Ma rk the recess diameter (F radius).Skew Shape bowl 1i 9 r rue the recess bottom.chi sel bet ween lines. :itv\". -OsFoligrmhtltyheunredceersssizedi.ameter :T • O lncreasethe recess to fit ..~J, the spigot on the base. Fmm the bowl bottom. 'JD8 J~ Mark the bowl height (G dimension) and rim thickness.36 WOOD magazine October2010

4 Hollow the bowl tTool : ~\" bowl gouge O True the face.Speed: 800- 1,200 rpm ,- - ----- ----Reverse the bow l, remove the screw center, and grip the recessin t he four-jaw ch uck. True t he blan k face, bringing it to final ~eROU9h the hollow.th ickness (the rim th ickness marked in t he previou s step).Begin hollowing the bowl, cutting towa rd the center, gradually : 0 Sha pe remainderen larg ing the interior dia meter, until you reach the outside of bowl.d iameter. Keep working from t he outside toward the center e Bring outer third tounti l t he curve matches t he Bowl Interior Pattern. (See the Skill thickness andBuilder tetow for tips all shaping the large bowl.) Sand t he bowl finish-sand .wit h ISO-, 220-, a nd 320-grit sandpaper. Apply a finish as before. After the finish d ries, glue each baseto its bowl, placing weigh t (such as a one-gallon can of paint)in the bowl to apply pr essure. Once t he glu e d ries, brush on afina l coat of oil, wipe away the excess, and allow it to curethoroughly before placing food in the bowls. \" Keeping a large bowl stable Produced by Cr..ig RuegJegger with 'eU Me.\" Proje<! design: Jeff Mert, Hollowing and sanding the largest of the t hree bow ls requi res worki ng in ruoureucns. Rox..nneleMoine; lorna Johnson stages from the outside in. If you turn the full diameter of the bowl to MORE RESOURCES thickness, the bowl may flex as you sand the outside edge. • Read and download a free article about using a lour-jaw chuck at To work around t his, turn only woodmagazine.com/4 jawchuck. one-third of the outer diameter of the bowl to final thickness [photo). Then 37 sand this area to 320 grit, keeping your left hand behind the bowl to provide support. Finish the large bowl by cutting from the just-completed area towa rd the center, bringing the remainder of the bow l to final thickness. Take light cuts to blend the outer area with the inner area, then sand the inner area through 320 grit.woodm ..g ..llne.c:om

W e all strive for clean and accurate table- saw cut s. In chasing perfection, though, we often spend much more tim e settingup a cu t tha n actua lly making it. Here's how tosafe ly get great crosscuts in less time. Extend your miter gauge A bare-bones, standard-issue m iter gauge bene- fits fro m the additio n of an extension, a straight scrap of plywood or M DFscrewed to the gauge so it ex tends past t he blade. Th is provides a couple of adva ntages: A saw kerf cut into the extension, as shown, shows precisely whe re t he blade will cut, and t he wood around t he kerf provides zero- clea ra nce protectio n against tear-out.\"*\"............~: ;:lIIII!Measure from the kerf for fast, precise cuts Clamp on a simple self-squa ring stopbloc k for: cutt ing mu ltiple pa rts to precisely t he same length . Using a steel rule for its hyper-accurate prec ision , position the stopbloc k qu ickly by measuring from the edge of t he kerf. Leave a W gap beneat h the sto pblock to prevent dus t bui ld up from affecti ng your cuts. WOOD magazine October 20 10

• Lock in mitered parts Sel f-adhes ive For pa rts wit h m itered ends, such as I sandpaper pict ure-frame sides, use a stopblock wit h t he complementary angle. Th isIJJ!Add a stopblock to your rip fence provides a more positive \"loc k\" than a rectangula r block. Apply 120-grit,Someti mes the dimensions of a wor kpiece pre- self-ad hesive sandpape r to the m iter-vent you from us ing a stopblock o n a m iter-gauge gauge extension for bett er gr ip o nextension. For example. cutting multiple parts of your workpieces. (See a not her angledeq ual length fro m a 6'-long board mig ht be a stopblock example on past' 20.)problem. Or cutt ing short pieces would placeyour hands too d ose to the blade. III Do the dado two-step To cut dadoes wit hout switching to a The solutio n: Use your rip fe nce as a gauge, as stacked dado set, ma ke a two-stepshown at the top of the opposite page. To prevent gauge bloc k with its two steps offsetworkpiece binding and kickback, always position by the desired dado width. Cla mp it tothe sto pblock several inches in fro nt of the blade. your fence as shown. Then, using yourThat way t he cutoff falls away freely instead of crosscu t or general-purpose blade,becom ing t rapped between t he blade and stop- make a cut using each step . Finall y,bloc k. And to ma ke setups easier, make your nibble away the m idd le with repeatedstopblock's widt h a who le number, such as 2\", passes over the blade. •a nd then use your fence scale to set the cutoff Written by Bob Hunte r with Jeff Mert! andlength-plus t he 2\". Kevin Boyle 39 Cut made using long gauge block

······ .........~· .; .:.:.:.:.:~···· ....: .:....:·········................... THE FRIDAY BEFORE•.. •..THE MONDAY AFTER! To see how this shop was transformed over a wee kend, go to woodmagazine.com/organlzing . ~ Imagine a workshop where you can t hrowaway chunks of wood less than l ' th roug h a newspaper ad, a n on line ma r- fi nd every tool, jig, and board almost long a nd any t hing t hat 's obviously ket such as cratgsust.org (no-fee, local without lo ok in g. Whether you're trash or bro ken beyond repair. buyers pick up the tool), or euaycom mach ining lumber, assemb ling parts, (small seller fee, you 'll likely have to sh ip sanding, or finishing, everyt hing you Toss o r recycle em pty tool cases you'll the tool). need is situated within easy reach. neve r use again. Stri p reusable ha rdware from jigs custom ized for tools you no Now find a new place for home-repair Who owns th is aweso me sho p? You longer own, and toss what's left. items t hat inter fere with your wood- do, if you d rop t he indecision, bad h ab - working. For exa mple, label one of your its, and sloppy housekeeping that lead to Tools: Don't use 'em? plastic tubs \"electrical\" and fill it with clutter and frust ration. We'll show how Then lose 'em switches, outlets, and electrical tools. Do to do t hat and reorga nize your shop to the sam e for your plumbing supplies and Keep t he cleanup momentum going by tools. Fill the t hird tub with painting foc us o n woodworki ng . focusing on tools t hat see little use. supplies, such as rollers, br ushes, and Then divide t hem into three categor ies: paint pa ns. Then put in tubs a ny other Start with a • Tools not worth selling can be donated DIY stuff, such as d rywalling tools. If thorough thinning to cha rity. you work in a garage shop, move lawn • Item s too valuable to give away, but and garde n tools outside the shop a rea. Fi rst round up some 30-gallon heavy- not worth the hass le of a classified ad, Toss into a anot her tub that hodgepodge duty ga rbage bags, several plastic tubs can be sold in the next garage sale. of project pa rts, includi ng T'.track for jigs with lids, a nd a perma nent marker. • Tools wort h $50 or more can be sold Inside your shop, empty waste cans and 40 WOOD magazIne Oc tober 2010

This garage shop's storage systemorganizes lumber over a cutt ing Space beneath this mitersaw bench houses short to medium-lengthcenter with space belowto parkthe jointer when it's off-duty. lumber, keeping it flat and off of the floor.you never built, m iscella neous ha rd - aside a ny sta ins you won 't use again. Ask by t ype and place eve ryth ing on over-ware, a nd pa rts for unbu ilt projects. you r waste-di sposal service about the head racks, as show n a/mve tett, in some n earest hazardo us-waste d ispo sal site. corner away fro m too ls and wcrkspaces, Turning you r focus to fin ishes, cu ll u n der sta irs (in a basement shop), in t hethe water-based fini shes d isco lored by Fin ally, gather up all th ose cutoffs, rafters of a ga rage shop, o r under coun-ca n ru st, and oil-based pol y wit h a t h ick scraps, a nd leftover sheet goods that ters, as shown above right.layer of dried fin ish o n top. Then set survived your ea rlier clea nup. Sort th emOrganize your work areas WORK THE WALL SPACE Put this on your to-do list: Removable shop- made bins keep your most popular fastenersNow use ex isti ng storage and d ivide Screw organized, dust-free, and accessible.the stu ff t hat 's left ove r into work a reas, binS ) Size and square project parts quickly byeven if your tools ride on mo bile bases. ......I • placing the tablesaw, jointer, and planer1. The workbench/assembly area. If within steps of each other.you build mo stly sma ll to medium-size •pro jects or furnit ure smaller th an yourben ch , posit io n t he work bench against a ,wall to ope n u p floor space for stat ion- •ary tools. Use nea rby wa lls to hang t hetools you use most, as shown at right, oWand bins to h old screws or ot he r fasten -ers, far right. (See More Resources o n pllge Apply the 80/20 rule to your shop and keep44 for on line bin plans .) the 20 percent of tools and fasteners you use 80 percent of the time within arm's reach. Sing le out your favorite clamps and that lets you move stock qu ick ly bet weenhang them nea r your workbe nc h. Th en the jointe r, planer, and rabtesaw, In aadd a shelf fo r glue, cla mping cau ls, and garage shop that n eeds to convert bac ksqua ring braces. into parking space, store mach in es on mob ile bases close to the tria ng le. If you build la rge projects, you'll n eedaccess to all fou r sides of the ben ch , somove the bench closer to t he cen ter o fyour shop. lf t hat places it near the table-saw, ma ke the ben ch do dou ble d uty asan outfeed ta ble by ra ising or lowe ringthe bench heigh t.2. Machining area. Set up your n extwork a rea for sizing, join ting, and plan-ing stock. Create a work t riangle, right,woodmllgllzlne .c:om 41

SHOP TIP sandpapercabinet to obta in pfans.) Each uses hanging cteats for quick sho p reo rganization. A cleat with a beveledBuild three versions of one cabinet bottom edge mo unted to the cab inet back g rips a matingBuilding th ree sto rage cabinets doesn't take much lon gert han bu ild ing a sing le on e. So w hile yo u're b uild ing the w all-mounted cleat wi th an ident ical bevel. Gravity hold s the two cleat s together un til you lift off the cabinet.san ding supplies cab inet (lower far left), make duplicatecase and d oo r part s to create cabinets for hand and powertools or finishing supplies. (Go to woodmaqazine.com/~ WiJ ll deat:....!'i.!!!i!!!;;;;;o;,.- ,:1: Perforated hardboard Now fin d places for tool accessories. If t hree key areas, d iv ide up t he remaini n g you're organized, consider glvmg fre-you h ave a cabinet saw eq uipped with space for everyth ing else. Begin with quen tly used portable ben ch top toolsan extension tab le, add shop-made or storage for benchtop and portable power their own mob ile sta nds or carts tostore- bought shelves underneath it to tools. Rank each tool from I to 3 acco rd- reduce setup time.)keep jigs, hold-d owns, m iter gauges , a nd in g to how often you use it. Fo r exam ple,blades . Store accessor ies a nd jigs for a a freq uen tly used cord less d rill may ra n k Store the zs just outside you r th reebe nc hto p or contractor-st yle saw on a I while a pneu matic stapler you'veshe lves or u nused lu mber racks. only used twice merits a 3. Store the Is ma in work areas, and t uck away the 3s3. Sanding and fInishing center. Even near or ben eath your workbench . on shelves or just outside the shop.if you sand parts and apply fin ish at Devote t he corners o f t he shop to stor-you r workbe nc h, storing sandin g and in g tools on mobile bases, such as a W hatever its ra n k, eac h tool ca mefin ishing supplies o utside t he im med i- hand saw, or tools that do n't need la rge wit h a ma nua l th at you' ll need somedayate shop a rea o pe ns up tool-sto rage space to fin e-t une its set up, order replacementwhere you n eed it mo st. For n ow, store tnreedzoutreed areas, for example a parts, o r fin d t he nea rest service center.abrasive sheets in t he ir sleeves and hang Store these ma nua ls in a heavy-dutythe pac kages fro m a hook or na il. For scrollsaw or shar pen ing statio n. (After th ree-ring binder filled with p lastic pageboxed san d ing d iscs, pu nc h a hole in abottom of t he box at o ne corner, secure A COOL IDEA FOR FINISHES protectors, as show n t etow:t he top wit h a rubber ba nd, a nd hang iton a peg hook. Later, add a cabi net to ~ ----E,,_-_l-i\"l..J ~ , r >/,'hold sa nding supplies. (See the Shop Tipallove.) Leave room nea r the cabinet to Cl HAZARDOUSpark a sho p vacuu m. , <:l CHEMICALS\" For finis h ing supplies, cons ider aready-to-assemble cabine t fro m a h ome • COMBUSTIBLEcenter or d iscoun t store. If you're con-cerned about child safety, attach a hasp - -..L.lQUID~and lock to the cabinet doors. We'veeven see n a no n-funct io na l freezer ,tf't urned into fin ish storage, f iSht . ~ Postuon t he finis hes cabinet as faraway as possib le fro m you r water heater, . ' 0.furnace, or ot her o pen-flame applia nces.Date each can o f fin ish (Wit h esti ma tes, -.,....,..,*rif yo u have to) a nd sort t hem by filmfin ishes, sta ins, and solvents. If t he re's A d iscard ed freez er, minus its refrigerat ionroom left, add brus hes and accessor ies. un it, provides lockable, insulated, and air-4 , Peripheral storage. Now th at you've t ight sto rage fo r fin ishes.bloc ked out spaces for woodworking's42 WOOD m agazI ne Oc tober 2010

No heavy lifting required PowerW hen o rgan izi ng yo ur sh op eq uipment, _ + - - - -jl--- 'sotoorlageit's easier to push a button or piece of wallpaper t ha n hund reds of pounds of tools.To test and visualize different work- -~ cabinetspaces, use a n online sho p layout tool, ,•such as t he o ne at grizzly.com, shown ,• ,, ~, Suppliesbe/ow. For a low-tech alternative, photo-copy the paper tool symbols shown at , l, wallbottom and cut them out. Then move cabinetthem arou nd on a piece of graph paper ~marked to represent your shop space. ... BenchFIND PLANNING HELP ONLINE 1--- -t- with storage.-6rlzzly fndu!ItrllII 1100'\" LAYOUT below---. --.,... ~ ~ •---- (reate router t _ Wall table in tablesaw 1~!r~:1_ ca bi net to save space. - Cutoffs Vehicle space under mitersaw stand=-This on line shop planner lets you e xperime ntwith positioning tools close in size t o theo nes in your shop. Radial-arm saw ' Parked\" Jointer/planer store under lumber rack . t ools roll into position when needed. 12x20' Garage 4x8 ' This shop provides a place for everything, Including a car!Plywood s heet You can still create wo rkstat ions, even if t hey're not perma nent, Storing lumb er high o n th e wa ll of t his garage shop leaves roo m underneat h fo r a planer and join ter. The t ablesaw extension ro uter tab le allo w s t he r ip fence to serve both t ools, 10\" Table saw wit h 30\" fence 14\" Ban dsaw ~M ~ 6\" Belt, 12\" 16\" 1,100 CFM dust Disc sa nde r Router/sh ape r 12\" Port able p laner16\" Scro llsaw 24x30\" tab le on stand Drum sa nder collector 24 x6 0\" 16Y.M Osc ill ating spindle 20-g all on ve rti cal Workbenc hDrill Pres s sander air comp ressor 14~ Lathe 6\" Joi nter 6x96 ~ B o ardOutline your shop dimensions on '1..'t-sq uare grap h paper whe re each sq uare equals 1'. Then photocopy and cut o ut t he symbo ls that repr esentt ools yo u'll position within your shop. Positi on sy mbo ls to all ow infeed and o ut feed spaces wit hin your layout. 43

CHOOSE STORAGE THAT FITS YOUR NEEDS STORAGE PROS CONS SAMPLE USES Cont aine rs Keep s similar items together. You still need a place to store Fasteners (using small, Perfora ted Sizes range from bins to tubs. the containers. Each con tainer open containers, left);hard bo a rd, wa ll plumbing, electrical, and No assembly required . requ ires its own label. rac k s p ain ting supplies (large, lidded tubs). Cheap , versatil e, and f lexible. Storage dep th is limited to Hand tools, power-tool Tailo r shop-made racks to fit peg -hook capacities. Racks take accessories, clamps. Tool time to plan and make. groups of tools or accessories. storage near a workbench . Sh e lve s Inexpensive and easy to Can look cluttered, even when Portable power tools, organized. lumber, benchtop tools,Ca binets install; fi xed or adjustable shell jigs, and small containers. Cart s support options; allow s rollin g storage underneath. Combines the storage of dust- More expensive and time- Portable power tools, fin - free shallow drawers and deep co nsuming to make than ishes ( left), and hand tools. cabinets. Base-cabinet tops shelves. May only hide clutter. become work surfaces. Perfect for garage shops to More costly than cabinets. Re- Benchtop tools, clamps make room fo r cars. Tops quire time to design and make. doub le as assembly surfaces. Use up floor space. and tablesaw accessories. Some can be turned into router tables, left.Now keep things In order can apply to yo ur own wall-hung proj- Workshop Rules of Order ects. Th is makes it easy to rearrangeAs you upgrade your storage arrange- organi zers as t he shop layout changes. v' If you can't decide where to store something,men ts using containers or o pen bins, ask yourself if ithad a purpose in the first place.invest in an inexpensive label maker to Then develop rules for ma int ainingidentify th eir contents, be/ow. Rem em- your shop, such as th e o nes at right. If v' If you don't want a mess waiting for youber: Hardwa re or tools you ca n't fi nd are you slip up, don't give up. Simply make when you enter you rshop, don't leave onet he same as ones you don't own . time to put th ings back in order before when you go. your next project. Treat clutt er like you'd Next prioritize th e shop organ izers t reat rust : Don't wait for it to cover v' There's no sin in leaving emptyspaces insideyou'd like to build. Start with th e easy everyth ing before you elim inate it. your shop. You're not loading the dishwasher.ones that give you t he most efficiencyfor your time a nd money. For examples Illustrations: Roxanne LeMoine; Lo rna Johnson v' Maintain your shop by wor\( zones. Tidyingof storage cabinets and cart s, go to the sanding area sounds a lot more doable thanwoodmagaztnc.com/shopsto ragc. straightening the shopwhen you 0fI1y have a Many WOOJ)<!l magazine shop-sto rage few minutes to spare.project s rely on mating cleats screwed tocabinet backs and walls, rig/It, that you v' Respec t the wor\( zones you've created and store everything in its place.Ad hesive labels o n t hese open bins make the Ge ets with matinq beve ls let you add orcontents easy to spot and encourage you to move cabinets, perfo rated -hardboard v' Forget multitasking. When two projects occupy you r workbench at the same time, onekeep hardware sorte d by size and type. panels, and racks to reorganize your shop . ofthem im't getting done. v' You can't build a project unless you can find its plan. So file patterns and plans by broad cat- egories, such as \"furniture,\" \"boxes,\" or \"toys.\" v' Store only the lumber you need for an up- coming proiect, orfind lumber storage outside the shop. Let the lumberyard store the rest. v' If clutter begins to spread, reverse it by making a habit of putting away three things for every object you pull out of storage. • MORE RESOURCES • \"RollingWorkshopStorage\"issue 167 • \"BenchTool System\"fssue 179 IDecember/Janua ry2005120(6) (December/Ja nuary 2005/20(6) STORAGE PROJECT PLANS woodmagazinl!.comJwoodplugs.5 woodrnaqaztneccrrvbencbtoolsystem, 5 • \"Take·Anywhere Hardwa re Bins\"issue 165 (October • \"ShopCartlWorkber.ch\"issue 185 (September20(8) (S=Oownloadthis artkle forasmall fee.) 2005)woodmagazine.comlhardwarebin. S woodmaqazme.com'certbench. S WOOD magazine October 201044

WorldMal!s - Dil!ital Mal!azines Better Ho m es and Ga rde n s\" • PATTERNS. October 201 0 Issue 200, ,---------- -: Dear Reader: As a service to you, we've included fu ll-size patterns on this insert for irregu lar-shaped and intricate\ '''-' project parts. You can mac hine all other proj ect part s using t he Materials list and the drawings accompanying the proj- ect you're building. c Copynqht Meredith Corporation, 20 10. All ri g ht s reserved. Printed in the U.S.A. Mered it h Ccrp., the publishe r of WOOD Patterns !'. enows the purchaser of this pattern insert to photocopy these patterns solely for personal use. Any other reproduction of these patterns is strictly prohibited. ' . ... Candleholder Set r- 1%\" \" I Page 54 1 --------- ~,,:r : \" - W' grooves l¥i.,\" r-- ' ,® ' [... - - ... V.tdeep I\ + J1%~ I I \. 14\" 1\ ., 1-, , 7)18\" hole ... _ _ .... 1j.\" TALL lh~ deep, centered 4 LEGFULL-SIZE on topPATTERN(4 needed) block only 7\" MEDIUM BLOCK S LEG FULL-SIZE PATTERN FULL-SIZE (6 need ed) PATTERN (4 needed ) -,,, 5\" ,-- 11,4n -j'--+-i ,. ... © :SH O RT L EG : FULL-SIZE ® L...L _ : PATTERN 3\"! ,,,: (4 needed) ,,,,,,,,,,,, . 1%\"'- + - H--i 45

WorldMags - Digifal Magazines Three-piece Bowl Set ! Page 34 U~Ill)D;;' A radius (17,18\") Centerlin e B (PAt;\") \ - wI-- LARGE-BASE , U I INTERIOR II, C radius (l;-\.,M) ~r - %,,1- Centerli~ FULL-SIZE PATTERN , LARGE-BASE i , EXTERIOR -: /'1ICenterlineFULL-SIZE PATTERN LARGE-BOWL INTERIOR FULL-SIZE PATTERN I,,llH\"\") j I \",\" I T i G, E radius (5W') \",\" , I, -I Yo\" 1-\" -'cr I, LARGE-BOWL EXTERIOR FULL-SIZE PATTERN F rad ius (1 :;-\6\") /\"1Centerline I, I, Cente rline HI o I\"\") -t'-I ~MALL-BOWL INTERIOR (11'\6\") , ! SMALL-BASE Ii iFULL-SIZE PATTERN INTERIOR Cente rline ' FULL-SIZE PATTERN ! : A radi us (19116\") I B I , (13M' ) ! I----- V4\" / ' 1ICente rline j SMALL-BOWL EXTERIOR I, i FULL-SIZE PATTERN C radius (11;\6\") ~6\" I SMALL-BASE /'1 EXTERIOR Cente rline I, FULL-SIZE PATTERN ,I46

WorldMags - Digifal Magazines MEDIUM-BOWL INTERIOR FULL-SIZE PATTERN I 3fI6\"T G(1Y;6~) E rad ius (4\") I ! I;\(,\" ~F radius (1 14\" ) /1MEDIUM-BOWL EXTERIOR FULL-SIZE PATTERN Centerline I, I, I Three-piece Bowl Set Page 34 W'~ MEDIUM-BASE INTERIOR FULL-SIZE PATTERNA rad ius {1 l;.t j (1\"B,'J \ L .1 _. 3;16\" IL- ,C rad ius (l Ys\") z: v.\"MEDIUM-BASE EXTERIOR • / ]CenterlineFULL-SIZE PATTERN 47

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