Wood Magazine - October 2010 (US)

W hen you need to cut dadoes, grooves, or rab- So we gave Kevin and Jeff t he sa me assignment, but bets, you want to do it cleanly and quickly, You can make these cuts w ith a tablesaw or on different mach ines. Kevin chose the tablesaw, Jeffrouter, hut whic h proves best? Well, as you'll see, that t he rou ter, a long wit h a self-squa ring straightedgedepends on several fact ors. and a gu ide bu sh in g. The contest: to s~e wh o could finis h first- wit h accurate resu lts, of course.The Dado Challenge The ground rules: Each had to create a pair ofKevin Boyle and jeff Mertz- the guys who des ign and lIx42\" bookcase sides wit h t hree dadoes for Y!\"build most of the WOOl)\" magazine p rojects-were she lves, a rabbet for a ¥i\" top, and a rabbet for a Wd iscu ssing o ptions (or cutt ing bookcase dadoes one back o n eac h p iece. Nothi ng co uld be set up ahead ofd ay, and bega n debat ing wh ich tool would be best: time, a ltho ugh the project par ts a nd any jigs or au x-t he tablesaw or rou ter. Soo n, more of our editors were ilia ry fences cou ld be cut to size. Both chose to ma ked rawn into the d iscuss ion, and we decided that on ly all cuts in one la rger panel, and t hen rip it in h alf (ora showdown could settle t he debate once and (or a ll. perfectly matchin g sides. Now, let's get ready to ru mble...woodm\"9\"zlne.com •• 49

JEFF ROUTS HIS WAY TO CLEAH DADOES WITH AMODEST TOOL INVESTMENT---- r ,\"\") Scrap 'I. scra p ply wood l eft jig arm Right Jig armAfter in st alling a % guide b ushin g and Yl Wit h the rig ht jig arm screwed to th e fences, Jeff makes a test cut in a spare piece of --~down cut spiral bit, Jeff sets t he bit's cutting Jeff d amp s t he left jig arm to it, sp acing it plywood: routi ng one pass aga inst t he rightdept h w it h a reliable com bin at io n square. jig arm and a second agai ns t th e left t o with a pi ece of 0/<\" plywood and a st rip of ~' compl ete th e dad o. scra p (t o match th e bit-and -bu shing offset), Router Dado Jig When the dust cleared, here's what we learnea Arms Kevin and his tabtesaw fi nished about aFences half a m inute ahead ofJeff a nd h is router. We stopped the clock when Kevin rein-1\:::~:::::::::~\"'~G:'~P:'P~IYWood thickness stalled the 10\" general-pur pose blade, plus Ill\" ready for both woodworkers to rip their pa nels in half. As a result oft his showdown, we learned that wit h either a stacked dado set or a spiral (or straight) carbide router bit you ca n cu t dadoes, grooves, and rabbets in about the same time. Each tool has itsKEVIN MAKES SHORT WORK OF HIS CUTS WITH ATABLESAW AND PREMIUM DADO SET - -Kevin staCKS the aaao c lades an a chippers After Installi ng the aad o set ana rna ing a With an au xiliary fence cla mped to t he ri pnext t o a scrap of shelf stock to ge t a close test cut , Kev in checks the fit. Dang, it's tooest imate o n t he righ t com bination . (Place t he wide! He measures t he overcut by inserting fence and set aga inst t he da do blad es, Kevinblades gently on t he t abl esaw to p to avoid shims; he'll re move the o ne (or ones) from his ma kes his first cut , th e ¥4\" top rabbet.damag ing th e ca rbid e teeth.) set up that fits t ightly in th e gap.50 WOOD magazine October 20 10

Jeff begin s his third dado in th e act ual - - J After removing the gu ide bus hing and Jeff rou ts th e fi rst of t he t wo Yo' back rab bets. insta lli ng t he router's edge guide accessory, Job completed at 19:44.work piece . (He cut the ~' t op rabbet earlier Jeff sets t he bit's cutting dept h for t he 'A\"using th e g uide bu sh ing and jig.) back rab bet .advantages. Once you have a tabiesaw set There will be times, however, when Watch the Dado Duelup with a stacked dado blade, you can your workpiece dictates the best method. in real time for FREE atma ke mu ltiple dadoes q uickly by sim ply For exa mple, if you're build ing 6'-ta ll woodmagazine.com/dadoduel.repositioni ng the rip fence. Go with the bookcase sides, go wit h the route r.tablesaw for product ion-type ti me sav- Maneuvering pa nels t hat size across a CO/ltilllled 011 p l/St' 52 ....ings. But the router offers you the advan- tablesaw will prove unwieldy and couldtage of a lightweight tool that you move result in in accurate cuts.around t he workpiece, saving you fro mrepeated lifting and repositionin g heavy O ur advice: Use the method that ma kespanels. And one good downcut spiral bit you the most comfortable and yields the(Y.!\" is a good first choice) works for mu lti- best resu jts.H you can't afford a prem iumple everyday tasks-mortises and in lays, dado set, or a tablesaw to powe r it, youfo r example. can get super-clean cuts with an afford- able router and a single router bit.Afte r resetting ttie rip fence, Kevin cuts tiis Because ttie stacliei:l dai:lo set ana auxili\"••\" ,..' After setting ttie aux ilia ry fence over ttief ir st d ado, seco nd cut overall. fence nullify the fence scale, Kevin uses a blade and making a relief cut-something he measuring t ape t o set t he rip fence to the d id not do for th e fi rst rabbet- Kevin makeswoodm19\"zlne.com correct positi on for t he t hird dad o. his fi nal cuts, the t wo back rabbet s. Job comp leted at 19:16. 51

More help in choosing a tablesaw or routerIn our Dado Duel we grabbed a stac ked dado set a nd downcut suffer. Below are so me cut sa mples to show you the kind o fspira l route r bit-both sharp- from o ur sho p, so we got clean, resu lts yo u could expect to get, depending on the quality andtear-aut-free cuts. Use anythi ng less, and you r projects could shar pness o f you r blad es and bit s.Stacked Dado Set Pointers HIGH - UALITY VS. lOW- UALITY STACKED DADO PERFORMANCEPrice range: $75-$250 \~ By mixing outer blades, chippers, andshims-often a time-consuming When sharp, better-q uality sets (cost ing $150 Dull or lesser-quality sets ten d to tear outprocess-you can cut any width from lJ.\" and up) produce f lat-bottom channels w ith surface f ibers and leave channel bottom s no surface t ear-o ut . wi t h rid ges and sco ring marks.to H/16\", althoug h some sets go up tonearly 1'. (The lengt h of your tablesaw 's <L Nearly all the dust and debris from a tablesaw-workpieces can be damaged or kicked back at you withblade arbor could lim it maximum widths.) these concealed cuts gets whisked away by alarming force and speed. ~ Steer clear of dado sets that comerr Small, bencbtop tablesaws with the d ust collector, or falls below the saw. with paper shims tha t tea r easily and others that do n't include shims at all.universal, direct-drive motors mi g ht <L If you need to cut beveled channels, Freud m -prece metal shim set;partI SS100, S12,strugg le to power a wide dado setup. So it's much easier to tilt a stacked dado setopt for a 6\"-diameter stacked dado set, amazon.com. than to make a jig for a router.which requires less power, for these saws. ~ We do not recommend cutting stopped dadoes, grooves, or rabbets with<L You can make a full-depth cut in onepass on most tablesaws. (Some benchtopsaws str uggle with channels wider t hanlj~ \" and dee per than 1/ 4\".)<L O nce you've set up the des ired width,you can quickly cut multiple channels bysimply repositioning your rip fence, mitergauge, or crosscut sled.Straight or Spiral Straig ht bit l esser-qu alit y bits- som etimes right o utRouter Bit Know-How of th e box-c-prcd uce fuzzing rat her th an Sharp, prem ium bits produce clean, t ear-o ut - cleanly sheari ng surface fi bers.Price r ange: $10-$75 a pie ce, free channels w it h f lat botto ms and square should ers.$40-$150 for sets DOWNCUT OR UPCUT SPIRAL BIT? THEY BOTH HAVE ADVANTAGES<L It's easy to rout stopped dad oe s, Down cu l Upcu lgrooves, and rabbets, by either using A sharp downcut bit- the pr eferred cho ice Upcut spira l b its quic kly rem ove chips f rom astcpblocks o r by eyeballing a mark. for routin g dad oes and groov es- pro d uces channel, pr eventing heat buildup and dulling.~ Odd p lywood sizes usually require you clean, tear-o ut-free channels, bu t d oesn'tto make multiple pa sses with a smaller clear debris as well as upcut bits. But upcut b its t end to lift surface fiber s, sobit to cut a perfect-fittinq channel. Written by Bob Hunter with Jeff M ertz and reser ve t hem fo r ro ut ing morti ses. Kevin Boyle<L Whe n used with a jig or fence p reset Photos by Dean Schoeppner and D\",vid Purdyto a des ired width you can qu ickly routmultiple channels of eq ual size simply byreposi tioning the jig.~ Spiral bits, espe cially those made ofsolid carbide, can cost 2 to 4 times asmuch as straight bits, and prove moredifficult to sharpe n when dull.e- Set your router's speed co ntrol nearthe fastest setting- based on t hediameter of your bit-for best results.~ Whe n routing with a hand held rou ter,dust and debris spew everywhere.Dust-collection shields and attachmentscan be effective, but can be cumbersomewith a vacuum hose attached.<L Whe n routing wit h dust-collectionshields in p lace an d hooked to a shopvacuum, nearly all dust gets sucked up soyou don't have to breathe it. •52 WOOD magazine October 2010

• .\",... Fully-indexed, searchable, printable, and in super-high-resolution .. • Quicklyfind exactly the projectyou're looking for, then build it in a weekend, guaranteed! • The complete collection-all 52 issues-of Weekend Woodworking Projects Magazine. • All projects were built and proven in the WOOD Magazine workshop, though you've never seen them in the pages of WOOD.That's because Weekend Woodworking Projectswas a sister publication to WOOD Magazine that enjoyed a 9-year run catering to thet needsof woodworkers looking for beautiful projects they could build with a minimal\ investment in time, tools, and materials. Backissuesi of Weekend Woodworking Projects are nearly impossible to find anywhere, but this disc makes all of these projects avaiiable to youonce again- at a price of less than $1 per issue! See more of the projects on this disc and order your own copy atwoodmagazine.comjWeekendCD Or order by phone: 888-636-4478 AD # W D l 0 10

Cut perfectly square blocks (Al without measuri ng by using the blank as a gauge when setti ng the rip fence and spacer. , Elegant and easy Butt t he end o f the blan k aga inst the scr ap, t hen crossc ut six bloc ks (Al fromCandleholders....,\".,. , I ',.'. th e blan k.ThiS made-in-a-weekend gift will safely cut blocks from t he blank, place a 2Set up a v.\" dado blade in your ta ble- brigh ten the day of the rec ipie nt , 2\"-wide scrap against t he tablesaw's rip saw, Y4\" above the table. Wit h the rip but you get somet hing o ut of it, fence, and place t he block bla nk between fence 1¥16\" from the blade, cut fourto o: a use for t hose small scraps too goo d t he scrap an d the blade [Photo AI. Slide grooves in each block (A) IPhoto C].to t hrow out. In our stash of cu toffs, we the rip fence over until t he blan k justfound maple and wenge. touches the teet h (not t he body) of the 3Ch UCk a W Forstner bit in your drill blade and lock the fence in place. Using press. On t hree bloc ks (A) drawMake the blocks double-faced tape, stic k t he scrap to the d iagona l lines fro m co rner to co rner. saw table in (Wilt o f the blade [Photo BJ. Clamp one of the ma rked blocks in a1For t he blocks (A) [Drawing 11, pre- Att ach an extensio n to your m iter gauge. wood hand screw, ce nter t he block u nder pare a 'Ylo<l%xlS\" maple bla nk. To the bit, and clamp the ha nd screw to the d rill-press table. Dril l a Vl-deep counte r- bore. Repeat t h is for t he other two marked blocks. Sand t he blocks to 220 g rit, slightly rou nd in g the to p edge o f each co u nterbore so t he lip of t he brass ferrule seats against the b lock [Drawing 1]. Test the fit of the ferr u les, t hen remove t he m. Shape the legs 1Cut Y4\"-t h ick stock to size for each leg (B, C, D) [Materials List [. Make a copy of the Short, Medium, and Tall Leg Pat- terns from the WOOD P(/ttt' fIlS'1> inser t. Stack like-size leg blanks together with d ouble-faced tape between each p iece. Spray-adhere a pattern to the top o f eac h stack and ba nd saw or scrollsaw the legs to wit hin %6\" of t he lines. Sand up to the lines wit h a sa nding drum; then remove the pattern s w ith a bit of m ineral spirits. Ca refu lly separate t he legs, a nd sand them to 220 grit. 2scrapwood spacer blocks sim plify assembling the cand leho lders. Fro m a Y2x:2x16\" blank, cu t six spacers: two W long, two 2 \07\" long, a nd two 4 \07\" lon g.54 WOOD m ag azine October 2010

Because of t he ope n area betwee n th e blad e Butt each block (A) agai nst the rip fenceand fence created by t he spacer, t he blocks a nd d a mp it t o t he miter-gau ge ext ensio n.(A) fall away fr om the blad e after bein g cut . Notch each end and edgE' of each b lock. t : : } - -Brass ferrule m '10\" cou nter bor e v.. \"deep. Sp ace rs below th e low er bloc k (Al se t it at t he pro per height. Spacers bet wee n t he le gs (B)centered o n lo p blocko nly pos ition t he upper block. Cla mp with tape .JYo\" ',10 \" grooves \'-t~m7.~ ~?1 1 w Materials List dee p, ce ntered --'. \". Part .'f iNISHEDSIZE MatI. Qty. ' A bloc ks B tall legs TW l Me l Jil\" I ',i,\" w• W• W 'W r w• W 1 ~\" W m\"7\" part® C medium legs5\" part© \"D short legs \"' PartH ul fromlargerblank.See the inslructionS.3\" part@ Materials key: M-maple,W-~nge. Supplies: Spray adhesive. Blade and bit: 5taek dadoset. ~\" Forstnerbit. Source: Brass ferrules (3)no.21766, SO.59. Rockier, 600-279-4441, rockler.ccm . DEXPLODED VIEW Produced by Crai g Ruegsegger with Jeff Mertz Project de$i gn ' Jeff Me rtz Ill ustrat ions, Ronnne LeMoine ; l orn a Johnson From a second blank, cut t welve %><2)(2\" sand pape r.j Press the brass ferrules into Cutting Diagram the to p blocks (no ad hesive needed ). spacers. W ith four 'lit-t hick spacers Now brighten you r next celebration with t hese beauti ful candteholders. • under a n u nd rilled block (A) [Photo OJ put a dot of glue in each notch and press ~E~~~~ the legs in place. Glue the top block in place, then slide two Y:!\"-th ick spacers Yo x 3'h x 24\" Mapl e (.7 bd. ft.I between t he legs an d bloc ks. ' Pla ne o r resew to t he thicknes s listed in t he Materials Lisl._(@j Quick Tip! CI,eup tmd effective 'I. X3'12 x 36\" We nge (.3 bd. ft.)¥ h,pe clumps. Wrap t he assembly wit h painter's tape and let the glue dry.3 Remove the spacers an d apply fin ish to each candfeholder. (We sprayed o n th ree coats of aerosol lacquer, sa nd- ing lightly bet ween coats with 320-g ritw o-odmagazlne .c:om 55



W e'd a1110v(' to have a fleet of routers at our disposal, but few of us can afford 6 requirements of that luxury. So we went on a ques t for the ultimate router: one mach ine a do-it-all router that does it alL After compilin g a list of what's required for a do-everyth ingrou ter, show n at righf, we rounded up every router that meets those criteria- three 1. Ample power to run any bit, even thed ed icated p lunge routers and six mu ltibase kit s- a nd put t hem t h rou gh extensivetesti ng. Here's how each router scored from 0 to 5 in each of t he six requirements. largest panel-raisers.1. Power 2. Speed 2. Avariable-speed motor with soft-startTo compare the routers, we challenged Slow speeds work better for big bits, a nd and electronic feedbackfor maintainingeac h of t hem in these sho p tasks using most route rs' low speeds bott om out at speed under load.new Freud bits in red oa k: 8,000 or 10,000 rp m. Ru t C raftsma n's lowest speed was 12,0 00 rpm . Alt houg h 3. Good balance and features for handheld• W·wide p lunge mortises l Y.!\" deep; it d id not create a problem in ou r tests,• th ree full- depth profiles (two di ffere nt we still prefer slowe r speeds when ro ut- fixed-de pth routing.cove-and-bead bits and a profile-a nd- ing woods prone to bu rn ing or tear-o ut.groove bit from a rail-and-st ile set) and a 4. Smooth, easy-to-use plunge act ion'li6\"XY.!\" rabbet wit h br isk hand-fed rates; Por ter-Cab le and Ridgid ea rn kudos• an d usi n g a 3\1\"-d iameter raised -pan el for showi ng actual rpm markings on and features.bit in a router table. their variable-speed d ials. Almost as h andy, t he Cra ftsman, Freud, a nd Mil- 5. Through-the-base bit-height adjustability All the routers impressed us by plow- waukee routers have a speed cha rt o ning t h rough the ha ndheld tasks without the motor housin g, shown at ris\" t, t h at for router-table use.bogging down, even whe n we fed th em co rrespo nd s to nu mbers on the speedfaster than we norm ally would. Next dia l. We h ad to refer to t he owner's 6. Helpful included accessories: edge guide,sto p: t he route r table, whe re we d ivided manual to decipher t he numbered speedthe 1\1\"·w ide ra ised-pa nel profile into markings o n the rema ining routers. dust-collection attachments, multiple subbasesth ree equal passes. Once aga in, all t he with different-size openings, guide-bushingrou ters hand led the IO-feet-per-m inute Once you dial in the correct speed, it's holder or adapter, subbase centering cone, andfeed rate. v ita l that t he router maintai n t h at speed a carrying case or bag for storage. d u ring t he cut. Using a phototac home- So we u pped t he a nte for the next ter, we eva luated each model's ability to •rou nd, cutting t he profile in two equal do that wh ile routi ng raised pa nels.passes. Th is time, o n ly t he Rosch None dropped more t ha n 1,500 rpm, With the Milwaukee, yo u determine the bestMRC2 3EVS, Freud FT300 0VC E, and wit h a ll but one varying o nly a few hun- spe ed for your bit and th en set the sp eed dialTrito n TRAOOl - a ll wit h test-topping d red rp m once in to t he cut. The Ridgid as indica ted on its chart.I S-amp motors-could do it wit hout wowed us by never varying more thanboggin g down. 35 rpm once it got into the cut. Impres- sive, considering its t r-a mp motor ran ksPower scorecard (0-5) smallest in the test. Speed scorecardBosch MRC23 EVS 5 However, t he Ridgid co nsisten tly Ridgid R29302 5Freud FT3DDDVCE 5 pu lled 12 to 19 am ps dur ing t hose cut s, Triton TRADDI 5Trito n TRADDI 5 cau sing it to warm up an average o f 3° Freud FT3000VCE 4Milwaukee 5616-24 4 wit h eac h pass. Operating at these levels Milwa ukee 5616 -24 4Triton MOFDOIC 4 over ti me could shorten the life o f th is Trito n MOFOOlC 4Bosch 1617EVSPK 3Y2 router. By comparison, t he Bosch Bosch MRC23 EVS 3Crafts ma n 28084 3Y.> MRC23EVS, rated at 15 amps, drew only Crafts ma n 28084 3Porter-Ca ble 895PK 3Y.> 9 to 13 amps to ma ke t hose same cuts Bosch 1617EVSPK 2Y2Rid gid R29302 3 wit h ha lf t he tempe rat u re gain. Porter-Cable 895PK 2Y2 Bosch 1617EVSPK, $220 Craftsman 28084, S220 877-267-2499, boschtools.com 800-383 -4814, craftsman.comwoodm llgllzlne.c:om 57

- De t e n t sYou push Porter-Cable's quick-relea se l ever • •• •to reposit ion its pinio n gea r a nywhe re o n t he Coarse threads o n t he Ridg id adj uster make You'll get more adju st ment ra nge fromrack and st ill get t he full range of adjust m ent . for ra pid movem ent up an d dow n, a nd th e th e bot tom dete nt , shown on t he Bosch qu ick relea se let s you slid e even faster. 1617EVSPK, t han with t he ot her t wo.3. Fixed-depth routing • •Big or small, fixed base or plunge, you 'll Push t he Tritons' ce nte r b utton in t he han dle Conta ct st rips on t he Bosch motor bodyappreciate a router t hat ad justs up an d fo r p lunge action. Release it to e ng age the and ea ch ba se supp ly power t o t he handledown quickly for fixed-depth routi ng. rack-and -pin ion he ight-adjustment syste m. switches for easier onloff con tro l.Among t he fixed bases in the kits, we and more tippy than the ot hers, espe- rou ters; it's easy to engage withoutprefer Por ter-Cable's rack-a nd- pinion cially when routing a long edges and changing your gr ip. co rn ers. The Bosch MRC23EVS, in eitherad juster, show n top left, best because it base, weigh s about 2 lbs more than the Fixed-routing $e;ore(ardhas a q uick release for coa rse adjust- other 8Y.!- 11 Ib kit rou ters, but its lowerments a nd a fine -adjust ment knob that's center of gravity makes it less cumber- Porte r-Cable 895 PK 4 Y.z some than the big plunge route rs. Bosch MRC23EVSeasy to use. Milwaukee a nd Ridgid, Milw aukee 5616 -24 3Y2 And th is Bosch has another adva ntage Ridgid R29302shown top center, also have quick-release on its fixed base: a ha nd le-mounted Craft sm an 2808 4 3Y.zmecha nisms that proved effective. power switch. With ot her kit routers you Tri ton M QFOOlC 3Y.z have to remove or ad just your grip on Triton TRAOOl 3 Fi xed bases o n bot h Bosch models, as one hand le to t urn it on or off. The Bosch 1617EVSPKshown top right, a nd the Craftsma n Bosch MRC23EVS, above rigllt, has a t rig- Freud FT300 0VCE 2112engage one of t h ree detent s on the motor ger just like t he t hree dedicated plu ngebody. You then get a limited amount of 2Y.zup-a nd-down movement before you 2must switch to a nother detent . If you 2select t he wrong detent and ru n out offi ne-adjust ment ra nge, you'll have tomove to t he next detent and t hen th readt he rod all t he way to t he othe r end . The Triton plungers have a rack-and-pinio n coarse ad juster- a d ual-modehandle, shown near rig/It- fo r control-ling fixed-dep t h ad justments as well asplunge action . We found this featureclu msy and difficult to use. Ease of ha ndling proves as im portan tas bei ng able to quickly ad just t he bitdepth . The two beefy 3-hp plunge rout-ers-t- Freud and Trito n's TRAOO I-weigh13 to 14 lbs a nd prove bulky, top-heav y, Freud FBOOOVCE. $350 Milwaukee 5616·24, $240 Perter-Cable 895PK, $260 800 -334-4107, freudtool s.com 80 0-729-3878, mi lwa ukeetool.com 888-848-5175, delta por tercable.com58 WOOD magazIne Octo ber 2010

•• • a nd on ly t he Milwau kee's stop-rod slipped in its lock: \.16\" ove r 25 ho les. WeThe best plunge lo cks can be easily reached With some routers, such as the Freud , you liked the de pth scale best o n t he Freud must loo sen much of you r grip from the because it's easy to read a nd has coa rsefrom th e handle and depressed to unlock. as a nd fine ad justers. Trito n's routers have handle to secur e the plunge lock. no de pt h scale, so you have to measureo n the Milwaukee. plunge dept hs by ot her mea ns. A m icro- wau kee, show n abuVI' tctt. Freud (aboVi' adjuste r on t he Bosch MRC23EVS lets4. Plunge action rig/It), Porter-Cable, and both Triton s you twea k a de pth setting even after stay in plunge mode, locking o nly when cinching the loc k, a helpful feature.We prefer models t hat plunge smoo t hly you push t he lever. The Ridgid's lever iswithout stde-to-stde play and wit h not spring-loaded, SO you have to change Plunge-ac:t1on SC:Qrec:ardplunge locks easy to reach wit hout a lso your grip slightly to engage it.cha nging you r grip on the handles. We Bosch MRC23EVS 5like locks t hat you depress to plunge and We tested each router's ability to Freud Fn OOOVCE 4return to locked when released, such as plunge mu ltiple holes of equal de pth, Bosch 161 7EVSPK 3V2all t he Boscbes. Craftsma n, a nd Mil- Craftsma n 28084 3Vl Porter-Cable 895PK 3V2 Ridgid R29302 3V2 Milwaukee 5616-24 2 Y:z Triton MOF001C 1 Trito n TRA001 1S. Router-table use Although all the routers have •• t. through-t he-table elevatio n capabilitySwitching any of the th ree dedicated -c-effectlvely, a built-in route r lift- Triton's plun ge routers ha ve the best height-plunge routers in our test from ha nd- three perfo rm this function bette r t han adjustment tool, a swive ling cran k that letsheld use to t he router table and back ot hers. Only the Freud and both Trito ns you make changes q uickly.typica lly req uires more work t han with let you easily change bits above thethe mult fbase kits. For kits, you can table, than ks to integrated spindleattach the fi xed base perma nently to the loc ks. These engage an d lock the spin -table and simply swap t he motor into d le, letti ng you loosen the collet nutthe plunge base for ha nd held work. wit h o ne wrench above t he table. When installing any of the routers in To cha nge bits wit h t he kit routers,a table o r to an insert plate, you want t he you have to eit her lift the router andaccess hole for the height-ad just ment insert out of the table or remove thetool closer to the front of t he table wherethe fence won't cover it. But sometimes motor from the base. To change bita n upfront height-ad justment access height in the fi xed bases, you have tohole dictates t hat other router cont rols, unlock the base before making changes;such as the var iable-speed dial, power th is requires reachi ng below the table.switch, or base lock, be located towa rd With the dedicated plun ge route rs andthe back of t he table where it can be di f- Cra ftsman's plu nge base, you simplyfi cult to see or operate. The Bosch insert t he adjust ment tool t hrough the161 7EVSPK, Milwaukee, and Ridgid have table a nd turn. Triton's adjust ment tool,the best table-mounti ng geomet ry for at righr, worked quickest at ra ising andaccess to a ll features. lowering bits because its hand le swivels Ridgid R29302, $200 '1-< - - Triton TRA001 , $270 866-539-1710, ridgid.com Triton MOFOOlC, $200 800-624-2027, triton tools.comwood mllgllzl ne.c:om 800-624 -2027, t ritontools.com 59

on an easy-to-use cra nk. Freud's palm- .•Height-adjustm ent'grip knob, at rigllt, an d fine-th readadjust ment rod requires wrist-fatiguin g a rbor lock t oolpartial-tu rns . For an easy way to getbetter use from a com mon T- or t -shaped ' -- -hex wrench used by most routers, seet he Sh u l' Til' on page 11 .Table-routing scorecard )Bosch MRC23EVS 4 Y2 \"'Hei9ht-adjustme~Freud FT3000VCE access holeTriton TRA001 4 Y.1Milwaukee 56 16-24 4 Y.1 ABOVE·THE·TABLE BIT CHANGES AND AD USTMENTS ARE BESTPorter-Cabl e 895 PK 4Bosch 1617EVSPK 4 With Freud's rou t er t ab le-m ounte d, you raise t he co llet nu t fu lly a nd t hen lock t he spindleRidgid R29302 wit h the sam e heig ht-adj ustme nt t ool fo r easy one -wrench bit cha nges.Triton MOFOOlC 3YlCrafts ma n 28084 3 3 2 MOTOR FIXED BASE (3) § 'i' w~Where to put your money -a, ez~ v~z ~If you ca n buy only one router, make it a mulnbase ~kit. The power ful Bosch MRC23E.VS proved to be a ~versatile, feature-packed route r kit wit h lots of \"'-xcaccessories, topping our six-category showdown Z , s a~ 0 -c w~and ea rn ing Top Tool honors. v0 ~ ~< If Bosch's $325 price tag keeps you at bay, consider Z ~ w w~ ~ Zthe Ridgid R29302, a W()()V@magazine Top Value, w~ zv~ Z V cz ifor $200. Despite its motor being rated at on ly 11 -- w ~ z~ 0 ~amps, this router kit stu nned us with its steadypower, even during tough, conti nuous tasks. • Z ~ wJ -~c '\" e c ~• \"\"z ~ z ~ww ~ ~ Z ~ ~ aw~ w ~ Zw ~ w~ w z~-c ~ 0 ~ ~ ~ 0 ~< zec -c w ~ w 00 80 w~ ~ ww ~ -z~c \"ww ~ 0 x~ z~ \"~ Z <X a~ w MANUFACTURER MOOEl ~ 0W 0 <z~ V~ ~ 1617EVSPK z 12 8-25 W TR 21. BOSCH \" '\"MRC23EVS z 15 10-25 W TR 21. BOSCH ... \"'8084 ,~ CRA FTSMAN 3 12.5 12-25 L TR 3'11• z Final scores: FREU D FT3000VCE P 15 8-21 L NA MI LWA UKEE .-z 13 10-24 W TRBosch MRC23EVS 25 112 PO RTER-CABLE 5616-24 aPorte r-Cable 895PK 22 V2 RIOGIO 89SP K '\" \"\"\", ,.a 12 10-23 L RPRidgid R29302 22 V2 R29302 '\" ,.a 11 10-23 L TR awMilwa ukee 5616-24 21112Freud FT3000VCE 21 TRITON MOFOOlC P 13 8-20 L NATriton TRC001 21Craft sma n 28084 19 TRITON TRAOO ' P 15 8-20 L NATriton MO FOOlCBosc h 1617EV$PK 17Y2 NOTES Kit with fixl'd and plunge bases Kit with fixed. plunge. and D-harKlle baSel 17 ,,,t. 121 Plunge ''I Spindle hxkand one wrend' 2w,enchel z III IW' 3. (NAI Does not come with a fixed base Written by Bo b Hunt er with J\",n s ve e 4. (TRI Threaded rod IRPI Rack and pinion with quid relea se60 (NAI No height ·adjustment mechanism WOOD m\"'gnlne O ctober 2010

6. Accessories • Accessories scorecard The Bosch MRC23EVS a nd Crafts ma n Bosch g uide bushing s f it only Bosch rout ers, Bo sch MRC23EVS 4 Y2 come with t he most sta ndard accesso- locki ng int o a special ho lder (p hoto at r ight ). Po rter-Cable 895 PK ries, addi ng value because you do n't P-e-sty le bushings tighten with a t hreaded ring Ridgid R29302 4~ have to buy t hese later. With t he Bosch in to prem old ed subbase openings. Craftsm an 28 084 4~ you get a centering con e (to center t he Milwaukee 5616-24 subbases to the spindle), t hree dust-col- adapt ers or duct tape.) Craftsma n, Mil- Triton MOF001 C 4 lectio n hoods, t hree of its proprietary waukee, and Ridgid gobbled dust best . Triton TRAOOl gu ide bushin gs (shown r('{lIt) , a nd an Bo sch l 6l 7EVSPK 3~ ada pter for Porter-Cable-st yle gutde The Craftsma n an d Ridgid kits co me Freud FT3000VCE bushings. The Cra ftsman co mes with in canvas bags t hat are easy to repack 3 th ree du st hoods, an edge guide, and a and store accessories, but don't offer t he D-ha ndle fixed base- a nice option if protect ion of a hard-plastic case. Both 3 you ded icate your regu lar fixed base to a Bosch routers, t he Milwaukee, an d the 2 rou ter table. Porter-Cable come in plast ic cases. We 1If,. like Porter-Cable's best because t he All the routers except the Bosch motor stores easily in either base a nd 161 7EVSPK come with at least o ne dust there's roo m for optiona l accessories. hood that connec ts to your shop vac- The rest do n't include a ca rrying case. uum. (But few of the ports on tested models were t he same size, requ iringDO-IT-All ROUTERS: THE ONLY ONE YOU'll EVER NEEDBASE PERf ORMANCERATINGS(6) ACCESSORIES(8) WEIGHT, LBS-OZ PLUNGE BASE PRIMARY SECONDARY FIXED·DEPTH USE PLUNGE USE~ \"> vw~xz \"a ~ a~~ ~ \" sEw ~x < Z v~az 9 a-vwxc -~c -azc ix~ zvw~x ~ zvw~x -0 x- zw~ ~ 5 5~ xx w~x w~ ~ -v~c ~ ~ --affcei v-~c ~ w az ~ --w > zV ~a \" \" \" \"aw atw aaw~ .z; ~~ -~e ~ -avvc zw~ ss w ~-c w -v~c ~- a~ U ~ ~ ~~z ~ x \" ew\"\" aw~ ~ \" \" ~s~ z ~z z~ -ffci w X w~ w o ~ w w~ w w \"\"~ ~ a \"~ w aw w G G -0e\" \" § 9\"\" a \" \"\" \" \" a \" \"v~aZ a~w azZx <~ ww \" 8 •\"s \"z~ -Zvxc -Zvxc -vc ~ w v-c aw Z ~ ~~ ~ ~ w~ a~ zw ;;; a w ~a aw aw w\"~z ~ ~x W or \"a<~ ~ sw ~ w az~ a w 2v Vw -wc -~c \"wa w -c 0 w ww~ a ~ ~az a w~ a 3zwx w ~ w\" \"\"\"0 x az~ < -w~c ~ J ~ aw ~~ ~ -vc\" \" \"~ azv~ aw aw~ azv~ aw \" \"x xw ~ ~aw z~ ~x ~ ~ w ~ $220\" 3w -c a -~c >aw ~ ~ w ~ w 0 \"-e ~ -Zc ~x ~ w~ Z w> \"~ azs~ w X w 0 a~ <w~ a~ <w~ \"-e sZ ~ -~c w~ w aaZv 220 ~ ~ 0 0 0 0z \"a 0 0x ~ • \" \" \" \"\"w w M 350>az a-Xc ww V-c a~a w w ~ D,E,f,G,1 § § \" \"\"av 0z ~ ~ M a~ -~c >aw E,f,G,1 C 240 a-e~ ~ <w~ -w~e \" \" ,. \"b a a d b+ a a ~ e,G,IS ,8-14 ' M ~, 97 5 ~ ~ ~ ,H ' H 10 '00 C '60 A,C,W E,G ,8-13 to-e ' ~6 99 M8 >l\" NA 21. 31« F 8 8 8+ a d b b- E,G,H C '00 ,TR , I« 31« F O,E,G T '007 '* 8+ ba a ba a a a a a a A,C,D,G,W E,G,P T ,., ,m 3v. F 8 2705 \"\"., 8+ 8+ b+ a a a b a r b b b a O,E,H,W G ,.ra 3* F 8 NA b+ a a b b a b+ a a b a NA A,D,W G4 ,.,m 31« R 8+ NA ' H ~ 7 107 56 '\" ,.NA F 8 a a a b+ b a b- a d b+ b b- C,D,W 8·13 'H 8 10' 5 8- a a a d b a a b a a a a co-w 8·10 11-12 10 97 36 '\" ,., \" ,NA R 8 8 a a a a b+ a b a b+ b a C,D,W 8-' 10-15 12-3 ss 3'32 ,'\". \" ,RP 3\" 3\" R 8+ 8-3 ,NA 10·8 ~8 96 ,RP 3\" 3\" R ,NA 14·2 ~5 98 NA b NA NA b a b NA NA b a NA O,E,W3 3\" NA NA NA b a a a NA NA b a NA D,E,W IF'5. Round with a flat edge 8 ''I Subbase adapter for guide bushings , lifetime ~ervi(e agreement available Ce ntering COne '\" upon regi,trat ion, 1\" Rou nd '\"10' Dust-collectjcn hood (' =Plunge base only) '\"IF' Edge guide to (0 China 8 Exce llent fin e adjustment control exremon Mexico (''\"I' Guidebu,hings 'M' Spain 8 Good O-ha ndle base Ta iwa n !'P\"' Inlay kit 0' Fair Plunge depth acIjustment extens ion Poo r (51 Opt ional subbases IT! Route r·tab le depth-adjustment wrench NA Not Applicable 'W, u Price s current at ti me of article production and r Mea~ured with a pho tot achometer while routing a do not indude~hipping, whe re applicable. rai, ed-panel rxofile on a router table. woodmllgllzlne .com 61

By day, it's a display table withclean, simple lines. It reallyshines after dark, though.W oodworkers ta lk about fin ish- ing wood to make the gra in glow. But whe n you tu rn onthe light inside th is d isplay table, t hegrai n litera lly shines as the q uilted mapleveneer pa nels co me to life.Clearly It's time to start1Mount a general-purpose blade and zero-clearance insert on your table-saw and raise the blade to II!\", Cut four12x32 Y.!\" panels from .oat-th tck clearpolycarbonate. (We used texan polyca r-bonate instead of less-expensive plasticsfor its added impact resista nce an d rigid-ity.) Peel the protective plastic off oneside of each pa nel a nd sand t he surfacewit h ISO-grit sandpaper until it looksfrosted. Later, t hat w ill provide a \"tooth \"to improve t he epoxy's bond.2Trim four veneer sheets to the sa me size as the potyca rbonate panels. SHOP TIP Flatten veneer for perfect panels Until you're ready to use t he venee r sheets, sto re them pressed between two sheets of lj,,\" MDF weighted with two concrete blocks. To avoid bub bles or gaps between the venee r and the polycarbo nate shee ts, start by flattening your veneer. To fl atten the veneer, spray it with a com- mercial venee r softener (see Sources o n page 65), place paper towels on bot h sides, and press the venee r and towels betwee n MDF sheets until dry. -.... WOOD m ag azIne October 20 10

Pourthe epoxy down the center ofthe panel immediately after mixi ng. ••The hardener we used causes the mixture to gel in 15 minutes. Working outward from the center, distribute epoxy across the polycarbonate panel until you have an even, thin layer.Begin at one end of the polycarbcnat e panel and carefully lowe r the •veneer in place. Press out air bubbles using a roller. Allow yourself plenty of clamps to generate th e pressure necessary to bond veneer to the polyca rbc nate panel. ~~ >1 7~ --- < - 17:'-(We used quilted m a ple veneer.) If you r D EXPLODED VIEW ~\" ! 'r lveneer h as a wa vy text ure, see the Shop r Figure ·S fast ener iV.:\"..: #Sx ~\" F.H. wood screwTip, left fo r a way to flatten it. Th en cuttwo sheets of %xI2x32Y.z\" MDF to create .OS x 11 x 31'1:>\"lexana press for bondi ng the ve neer to the YO\" groove v..\" deep,polycarbonate. Lay a sheet of wa xed centeredpaper on one MDF sheet, t he n a polycar- '>.--'bo nate panel w ith the sa nded face up. 4<)\"3 Mix one o un ce of epoxy resin (see Sources, Pi/gi' 65) to o ne-h alf ounce 31'1:>\" I Io f h ard en er in a d ispo sable containerand sti r. Pou r t he mix tu re on the poly- Icarbo nate pa nel IPhoto AI. Safety note: 1'.4\" \::. #S X '1:>\" panhead screwYOII 'II likely mix more epoxy tlWII YOII 'lIl/si' ,for Cdc!' panel. Leftover epoxy am reacn 'I. x 1'1:>\" mortise 'h\" : '.4 x 'I.\" notchtemperatures too lIot to touch, so ImV(' tile(UP of.mrpills 011 a noncombustibte surface' \" 6\" deep ('until it cures and cools. #S x 1'.4\" F.H. )4 USing a wood scrap, spread the epox y wood screw to the edges a nd corners of t he poly-carbo nate [Photo 81. Then im m ed iatelylay th e veneer over t he polyca rbona te[Photo Cl an d cover it wi th a sheet o fwaxed paper.5 Lay on t he second sheet o f MD F and clam p t he stack [Photo 01. Re pea tsteps 3, 4, a nd 5 to veneer the remai ningth ree pa nels. Let the epoxy cu re over-n ight, rem ove the MO F and wa xedpape r, a nd carefu lly sand t he ve neerfrom 180 to 220 grit.woodmllgllzlne.c:om In·line switch 63

Cut legs to hold the panels Begin the groove bydropping the mortise !·m·'·'~k~;\"·9·'·O·\"~'~h;~'·<·ir\"c'·. ~,·,m\"p·,~,~,,·, -_· over the straight bit.Stop when the bit1Cut th e legs (A) to size [Drawing 1, reaches the opposite mortise. availableat art and office supply stores, help Materials List[. Ce nter the morti se youquicklydrawaccurate quarter-circles.locations [Drawing 21 o n t he t wo inside EJ lEG DETAil EJRAll AND STi lE DETAilfaces of eac h leg. Note: The mortises mea- r-w___-- p'I. ):1\" A.\ 11f1' tile same distance f rom each ('II/I. i~*' ~\"\" \"..\",~ , • !'$: 2¥!\"21n 5tall a lA o Forstn er bit in yo ur drill press a nd drill overlapping hol es Ylo\" Yo\" ,dee p to for m mortises in the legs. Thenchisel square the mortise comers and walls. '1. ,, 11h\" 1'h\" mort ise3 Measure the t hic kness of the ~ ven ee red pol ycarbonate panels. (OUf ~.. deep <,panels measure a ha ir less tha n 1,1;\" thick.) W groove W ___ '/.0\" d eep,In sta ll a Vi;\" st ra ig ht bit in yo u r ta ble- cente redmounted router, set the de pt h to lfl\", androut a centered groove between t he mor- Let there be light 2 Run the wire th rough the centeredtises o n each leg [Photo E]. If you need hole in the bottom (E) and attachgrooves slightly wider than lh\", see the 1Cut t he bottom (E) to fit between the ends to a light socket [Photo II. Screw the four bottom ra ils (B), and cut a the light socket to t he bottom usingShop Tip below rigllt. l,4\" I,4\" notch at each corne r. Drill a cen- #8 xlh\" panhead screws an d install a co mpact fluore scent lamp. Note: We4 u se a 2\"-d iameter object or round- teredb\" hole for t he elect rical cord. We opted {or tile compact {1uOf('S({'I/t equivalent hole template to mark a 1\" rad ius on O{II .\"WO-watt incandescent {amp bemuse itt he inside faces of both ends of each leg bought an 8' la mp cord with a plug on[Drawing 2, Photo FJ. Ba ndsaw and san d one end and an in-line switch at a localto the lines. Finish-sand t he legs to 220grit and set them aside. hardware store.You're ready for the ralls Rout grooves In two passes Test scrap1Cut t he ra ils (B) an d cleats (C) to size, If your veneered potycarbonate panels and cham fer bo th ends of each cleat measure slightly thicker than W , rout one pass between the leg mo rtises just[Orawing 3J. Then cut lAn_th ick tenons a hair off-cente r. Then fli p the leg end for end and make a second pass tocentered on bot h ends of each rail. Using create a centered groove that's slig htlya W straight bit, rout a centered groove wider than the straight bit. The panelson t he inside edge of each rail. Sand the shou ld fit snugly, but not tig ht enoughrails and cleats to 220 g rit. to damage t he venee r edges and ends.2Dry-assemble two legs (A) and t wo rails (B), t he n double-check the mea-surements between the grooves in thelegs for the size of t he veneered panels. Ifnecessary, recut the panels to Vlb\" sma llerthan your measurements. Remove thesecond protect ive sheet from t he poly-carbonate a nd insert t he sheet into a leggroove with t he veneer facing out . Gluean d clamp the fra me/pa nel assemb ly[Photo G], restricting t he glue to the ten-ons. Re peat for the second assembly.3 Apply glue to tenons on the remain- ing four ra ils ( B) and ins ert theminto t he mo rtises on a framed pa nel(AlB/F). Add t he other two polycarbon-ate a nd veneer panels and the secon dframed panel, and clamp [Photo HI.4 Glue a nd clamp cleats (C) to the bot- tom rails (B) with t he top edges fl ush.SEdge-glue stock to make a blan k for the top (DJ; then cut it to size. Ont he underside, drill fou r co unterbo resfor t he ttgure-s fasteners IDrawing 4J.Then fi nish-sand t he top a nd pedesta lto 220 grit and ap ply three coats of clearfin ish. (We used General Finishes Arm-R-Sea l sati n, sanding with a 320-gritsponge between coats.)64 WOOD mll911Zlne Oc tober 2010

~ Measure diago nilily betwe en t he out side St rip abo ut 'h\" from t he e nds ofthe co rd, corners of t he legs. Eq ual measure ments t wist t he m a ro und t he li g ht socke t screws,Position clamps t o ap ply pressure d irectly a nd tig hte n them in place. mean you've squared you r glue-up.o pposit e t he m ort ise-and-ten on j oi nt s. Thenchec k for sq ua re and flat ness.D TOP MOUNTING OETAIL MORE RESOURCES Materials List l lri1\" co unterbore FREE VIDEOS f iNISHED SIZE YaH deep • Go to woodmagazine.m m/woodvisionand look \"',Part T W L MatI. Qty -:::-:;:; B ~ under \"veneering: A ,,\" \"\" •1%\" 40\" B rails l \" 11 \" RELATED ARTICLES C deats C • \"Very Easy Veneeri ng\" tssua 193 ()(;Iober 2009) ,0 \" rop Ca woodrreqenre.comzveveneennq . $ bottom ,,\" •lOY.'\" C • \"Easy no-russVenre ring\"issue 179 octoeer lOOn F' veneer .\" ,,\" K woodmagazir.e.<:omlnofussvenreri ng. $ ..\"\"\"11\" 11\" \" •11 \" 31y,o M' .....-($=Download this artklelO1\"aIffiiIII fee.) ' Pa rtsinitiallycut oversize. See the instructions,'''\"'_1\"'_i,I1I-1__,_ \",,, I Mat<;>rials key: (-cherry, E( -edge-glued cherry. BP-b4 rchplywood, MV-mapleveneer.generates less ll caf IIl/ d siwi/hi fast 6,000 coun terbores [Dra wing 4J. Drill a nd Supplies: Figure·8 tabletopfasteners (4), #8xlllo\"(4) screw the ftgure-x fastene rs to the to p. and #8x'll\"(8)flathead wood screws. and#8xY.,\" penteedhours. Avoid incandescent O ( lla/oxen temps Now find a ho me for your completed screws (2). d isplay pedesta l and, after the sun goes Electrical: Plastic light socket, 8' lam pcord with in -l inethat call (ft'ate t'llOlIg\" heat to damage the down, fill your room wit h t he soft light switch, and 65-watt compact fluorescent lamp (equalto a of glowing wood. • 3OO·wall oceooesceon al lavailable at homecentersandpotycattonate. hardwarestores. Written by Bob Wilson wilh Kevin Bo)'i<;> Bits: }\\"straig ht routerbit, 110\"and H. \"Forstnerbits.3 Drill and screw the bott om (E) to t he Project design: KevIn Boyi<;> cleats (C). Then place t he to p (Dl o n lllustratlcns: Ronnne LeMoln<;>; Lorna Johnson Sourcesyour bench with the counterbores u p. Quilted maple veneer:Orderfourslicesat least 12\"Screw figure-S fasteners to t he tops of wide at their narrowest and 321h\"IOIlg to avoid joiningthe legs (Al and place t he legs in the strips,CallsuppliersfOf availabilityand price infonna- tion plus photos ofspecific veneers.M BRare Woods. 303-986-2S85, wood-veneers.com.(ertainly Wood, 716·655·0206, certainlywccdromJoe Woodworker, veneerscppies.com Veneer Softener: Pro-Glue veneersoftener no. 828924. $15 for aquart Woodcraft, 800·225·1153 or wcodcreft.ccm. EpOllY: System Three epoxyresin J'lO. 124520. $27 fOf a quart and.1 hardener no. 12452 2, $22.50for a pint, Woodcraft. Polycarbonate sheet stock: OearLexa n, .08\"x3x4', $65-$68at mosthomecenters and hardwarestores.Cutting Diagram JI:I x 12 x 12\" Birch plywoodm .fuN \" ) ~J1JI:I x 3'1, x 96\" Cherry (5.3 bel. ft.)· Plane or resaw to the th ickness listed in theMat erials List.~_@(g@;~~I~co ::~!®-::~!-®::E~'to x 7'1. x 96\" Cherry (5.3 bd. ft.)woodma9azlne.com 65

Satisfy your craving for a quick projectThese serving t rays, designed by reader Ralph Bagna ll of Mu rfreesboro, Ten nessee, were inspi red by a po pular ap petizer: fresh ly baked bread served with a dish ofseasoned olive oil. Using Ralph's techn iques, we made two-dish and single-dish versions, each usi ng Ly ptus and ba mbo o. (Ot he r goodwoods would be t ight-grai ned spec ies such as ma ple, beec h,che rry, a nd wal nu t.) Ra lph shares h is methods for cra ftingthem below. -Craig Ruegsegger, Projects EditorBuy dishes, make a tray waxed paper or painter's tape. Using 2screw the two endpteces and one water-resistant glue, la minate t he th ree middle ha rdboa rd piece to a cleatBefore sta rting, I have my oil d ishes on tray layers IPhoto A] . [Drawing 2]. Place this assem bly ove r thehand to ensure accu rate layout o f the 3After the glue dries, cut t he t ray (A) tray (A) blan k. Wit h the remain ing cleatrecesses for them. Also, the trays require blan k to size [Drawing 1]. Lay out theY.!\"-th ick stock; I create mi ne by resawing sha pe, but don't cut it yet . against t he blank, pos ition t he last ha rd - boa rd piece, a nd screw it to t he cleat.thicker stock [Skill Builder, 0PI1Osite IJIIs4 Build the routing jig 3Mount a 1\" guide bushing in the1Cut bla nks for t he top, middle, and 1Cut t he jig pa rts to size fro m Yi\" base of your router and install a Y1;\" bottom layers of the tray (A) W lon- hardboard and }4\" MDF or ha rdwoodger and wider than listed [Materials List, [Drawing 2]. To determine the rad ius of st raight bit. Quick Tip' For d eull cuts, {@j , the rou nd hote, add \4\" to one-half theDrawings 1, 3a]. d iameter o f the dip ping dish's base. Lay irout wltll U twist. I use a sptral upcut out the hole, and cut and sand it smooth.2e ut two platens of :W-th ick MDF or bit to eli m inat e grain fuzz ing a nd tea r- plywood just larger t ha n t he t ray out . From \4\" hardboa rd or plywood,blanks, and cover the face o f one platenwith a glue-resistant material such as make a 6xl6\" auxil iary subbase for your rou ter. In the center of t he au xiliary sub-66 WOOD m ag azIn e October 2010

Platen witl\,; _ Simple resawingpainter 's ta~ - for thin stockf J - , . ,- - . . ; To make the \4\"-thick top and bottom layers of the tray (A) lamination, resewThorou ghly cover th e face of eac h tray (A) a piece of Y4\"-thick stock at least 7\"layer with glu e. Fi rmly clam p the layers wide . I prefer to do my resawing onbetwe en t he p lat en s for at least t wo ho urs. the tablesaw- at least partially. Raise the blade l Y2\" above the table. Then position t he rip fence to center t he blade on the thickness of the board. Standing the board on one edge, run it over the blade, th en flip the piece end for end and, keeping the same face against the fence, ri p the o pposite edge. Raise the blade as high as it will go and repeat this proced ure. Slide spacers into the kerfs to hold them open, and cut throug h the th in connecting piece with a handsaw, right. Saw half the length, then flip the board around to complete the cut. Plane t he boa rds to \4\" t hick and you're ready to beg in building your tray. Y. spacer Oil di sh ~ DTRAY OPTIONS DOUBLE-DISH TRAYSpiral bit set \"r ·diam. recess 1-- ---,. ,.-- - - --r- - - 7\" - - -'1..\" bel ow t opof dish base ~\" deepAuxiliary routers u b b a se R= Y. \"Stac k your o il dish an d a !A\" spacer on the -- - - - ~ - ~ ~ ~ ~ ,subbase. Adjust t he route r bit to match the ~\"-d eep 3'1.2 \"MI' .he ight ofthe dish's ba se, then retract it recess \"3\"·d iam. recessw' deepbase, drill a hole to fit t he bush ing.Adhere t he subbase to your router wit h 1----------22~\" ----------_1dou ble-faced tape. \" Diameter and depth based on ava ila bleTime for recess serving piece; see the instructions.1To set the router-bit height, use the -+\"r SINGLE-DISHTRAY oil dish as a gauge !Photo 8[.l'osition C-- - - - - - 17\" --,-----the jig over t he tray (A) with their ends ,.-- - - -1Oflush and clamp t he assembly to your - - , - - --bench [Photo 'I. Starting in the center fland working out to the edge, rou t t he 'A. -deep recess %\" \"3\"-diam. recessround recess. (I have a helper hold a ¥16\" deepvacuum hose nea r t he recess to clear t hech ips.) Lower the bit 11.12\" for a clean uppass. Fo r the dou ble-d ish t ray, flip t heblank end fo r end, raise the bit 1/12\", an drout t he ot her recess in t he same way.2 Without cha nging t he bit height, rout the center recess. Lower the bitth\" or less for each successive pass untilyo u reach the ~6\" depth of the centerrecess [Photo CI. Aga in, remove Yu\" orless on the fi nal pass. 67

•• • Hole diam. is • \I:I\" targerthan base of bowl.3Leave t he jig in place, and cut t wo 2set up a III\" dado blade in your table- blade; then attach to your miter gauge an spacers to assist wit h chi seling the saw and, making test cut s on scrap extensio n that reaches past the blade.corners sq uare [Photo OJ. the same thickness as t he insert, raise the 3 With t he insert (B) facedown, cutMake a groovy grid blade until its height is exactly one-half two grooves by running each longBrea king bread causes crumbs. Ide signed the thickness of the insert . Quick Tip! Wj.edge against the fence . Flip t he insertthe inser t (B) so cru mbs fall t h rough , VFllllilralfwitlwllt measuring: I do faceup and, guiding t he piece with yourt rapping them in the recess. Simplyremove the inser t for easy cleanup. this test by mak ing a cut on one face, miter gauge, cut dadoes wit h each end1From lh \" stock, cut the insert (B) to fit then flipping th e piece a nd ma ki ng a cut against t he fence. Move t he fence tou\" the recess in t he tray (A) [Drawing 3J. on the opposi te face . Whe n t he second fro m the blade (I recom me nd measuring DEXPLOOED VIEW cu t just removes the remaining th ickness, wit h a steel rule for accuracy) and repeat• Diameter and depth based onavailable serving piece; see the instructions. I'm ready. Set your rip fence lA\" from the th is process [Photo EI. Keep movin g the fence in Y.!\" increments u nti l you have a ~\"-w ide a rea rema in ing in t he ce nter o f the grooved face. Center the blade in th is area a nd make a fina l pass on th is face o nly. 'I. dadoes'14\" deep 4 1f necessary, reset t he fen ce to the n ext Yz\" increment and con ti n ue cut- ti ng dadoes on t he opposite face. W hen W rema ins in the center o f the face, cen te r t he fin al dado as before. (@) Quick Tip! Clem .h ,g lip Made I\"\"\" V marks. I wrap a n arrow scrap in sa nd- paper and sand the sides a nd bottoms of the dadoes a nd grooves. E!lTR AYSECTIO N VIEW \4\" round-over\1:1\" Lyptus ,-_ 'no\" cove along straight 'no\" cove along 'cW-ba-m-boo- - - - - - - -68 bottom-side edge only strai ght bottom-side 'I,\" round-overs edge only WOO D m ag azine October 2010

SHOP TIP Reverse routing tames tear-out When routing the edges of a round piece, the grain direction changes as you rot ate the workpiece. This ca n result in chip-o ut at certain points. To prevent Jig this, Ifeed the workpiece in t he op posite directio n, known as a \"cl imb-cut,\" in ® th ese problem areas.I1J To know where toCut YoxW spa cers to fit bet wee n the jig and climb-cut, imagine a clockth e edges of th e recess. Pare st raight downalong t he spacers to sq uare up t he corner s. face on the round piece %\" round'over bitShape the tray with the 12 and 6 lined up1Using a 14\" blade, ba ndsaw t he tray with the g rain direction. (A) to rough sha pe, stay in g VJb\" o ut-side the marked cu tli ne. Sand up to t he Rout as shown in theline wit h a spind le sander, o r a d ru msan der mou nted in your drill press. drawing, rotating the Climb-cut - f ',,;;;'; piece counterclockwise2At t he router table, machine t he LA\" this quadrant. rou nd-overs around both faces of the from 9 o'clock to just pasttray (A) [Drawing 3; Shop Tip, obove rigllt l.Switch to a %\" cove bit and make three th e 12 o'cloc k positionsuccessively deeper passes to rout the covealong t he bottom straight edges only and from 3 o'clock toward Climb· cut[Drawings 3, 3a]. 6 o'clock. Rotate th e th is qu~dr~ nt. workpiece cloc kwise to3 sand t he t ray (A) an d insert (B) to 220 gr it, easing the edges and ends rout t he remaining areas.of the recesses a nd t ile insert. The clockwise rotation4 TO reach all t he nooks and crann ies in the insert (B), I brush o n three creates a climb-cut, andcoat s of a wate r- based polyuret hane fin-ish. Between coats, bu ff lightly wit h th e bit will want to g rab Router table320-grit sa ndpaper, wrapping it aroundthe edge of a scrap of W hardboard to the workpiece. I hold th e tray firm ly and take very light cut s. reach into t he gr id of t ile insert. After Produced by Cra ig Rueg.eg g er with Jeff Mertz the fi nish d ries fo r 72 ho urs, it is safe for and Ralph Ba gnall Project de~ign, Ralph Bagnall serving food. Drizzle olive oil and sea- I llu~tralions: Roxann e LeMo ine ; Lorna John son son ing in a dish, wa rm some bread, and boll appeut.• Materials List Materials List (Double-dish tray) (Single-dish tray) Part FINISHED SIZE Part FINISHED SIZE T W L Matt Qty. T W L Mall. Qly. \"A double-i.1ishtray 1\" 6~\" 22Y.\" Bil l I\" 6~\" 16\'/ 6/L B insert 1'J\" 4~\" 8 ~\" L B insert \"laminated part initi~ l ly cutceersne,See theinltructionl. 'laminated part initi~ Ilycutoversee.See the irstnc tons. Materials key : a-bamboo, l - l yptus.Su p p lies: Double-faced tepe, I\" guide bushing. Blades and bits: Stackdado blade; \'/ spiral upcut \4\" round-over. M,\"cove router bits. • Cutting Diagram Cutting Diagram (Double-dish tray) (Single-dish tray)® k§S : ::] ;\"J§8f~t.~, ;;~~'® :;io x 7'1, x 24\" Bamboo (1.3 bd. ft.) :;io x 7% x 36\" Bamboo (2 bd. \"Plane or resaw. See the instruct ions. . ..\" \" , '\"~_ r~••)i,·'0 :;io x 7'1, x 36\" Lyptus (2 bd. ft.) \"Pla ne or resaw. See t he instructions.Wit h a Yo\" dad o blade set to o ne -ha lf t he 69t hickne ss of t he insert (B). pe rp end icular cutso n opp os ite faces create a g rid.woodmagazlne .c:om



Take your pick: On one extreme, lumber is locked awayin log form, waiting for you to slab it free with a milland some muscle. On the other, you drop it into a shop-ping cart, surfaced, edge-glued, and shrink-wrapped.The long journey wood ta kes from /lCxr pas,e for a rundown o f sides (525) and st raight-line ripped o n log to project-ready lumber affords your d rying options. o ne edge (Sll E). Of cou rse, you pay you plenty of pu rchase po ints. mor e for those addi tional operations, Commercial Sawmill b ut you also come home with wood thatAlon g t he way, you'll fin d a d irect rela- Even if the nea rest com mercia l sawmill is just short of fully d ressed, wit h on lytio nship between convenience and cost is hal f a state away, t he wood a nd the final squa ring and th tckn essr ng needed.per board foot ; as o ne goes up, so does savings make the drive wort hwhile.the ot her. So where does your budget Expect to find warehouses full of Big-box Storeand a mbition place you in t he cost/con- expertly kiln-d ried , graded lu mber at If you r pro ject need s to be finishedven ience con tinuum? Read on to learn nea r-wholesa le costs. Sawmills generally before kickoff this weekend , look noall about you r lumber-buyi ng optio ns. a ren't set up to hand le retail shopping; farther than t he wide a isles of your local you wo n't get to pick t h rough the piles home cent er. There, you'll find woodPersonal/Portable SawmIll for the perfect board . So, be sure to call t hat has been squa red and surfaced onJ( you have access to wood in tree form, ahead wit h yo u r orde r-species, grade, a ll four sides (545). If you' re selective,and the muscle/ mac hinery to move it, a nd quantity- to ensu re it is available you ca n pick o nly the clearest, straight-co nside r buy ing a backyard ha ndsaw and will be waiting. Expect a min imum est boards, saving t he t rouble of furtherm ill to satis fy your lumber add iction. order requirement or a sliding price scale dressi ng wit h a jo inter a nd plane r. that encourages larger orders. Remember, you pay a boa rd-foot Don't let t he en try pr ice tag of $3,00 0 prem iu m for that machi n ing (andto $6,0 00 scare you away from investing Hardwood Retailer shrink-wrappi n g, and inventory man-in o ne of t hese burl y ha nd saws. For agement). But whe n conve n ience mat-most woodworkers, t he wood savi ngs Not lim ited to local logs, your wood ters, the home center delivers.will quickly cove r the mill cost. And you retailer brings to the table a smorgasbo rdca n speed the savings by selling some o f o f species both dom est ic a nd exotic. If Now let's lo ok at t he p ros and cons ofthe lu mber you produce. But even if a you're t he t ype of con noisseur who likes each wood -shopping met hod.m ill isn't in your future, you ca n sta rt to see, feel, even smell the wood beforesaving money now by h iring a portable- you take it home to you r shop, head form ill operator to b reak down your logs. the hardwood store. Buy or hire, be sure to take d rying In ma ny cases, you'll find wood in ao ptio ns into consideratio n when you more finished state: surfaced on bot hstep into the green-wood world. See thew oodm llgllzlne .c:om 71

Chainsaw milts, like t he Alaskan MKllI f ro m Granberg Intern atio nal (800- 233· 6499, gra nberg .co m), cut much slowe r t han bandsaw mills, b ut co st far less, mak ing t hem a portabl e, if tabor -intensive, altern ative. saving hyd raulic mod els and t railer packages for additiona l portabilit y push the price even higher. :iIt .. _. .. \" Price for Red Oak: FREE! (after investing in the eq u ipment) or $ OAO~ O.60/bdftIf you're not ready to buy yo ur own sawmill, Wood -Mizer (800·553-0182, wood-mizer.com) or (hiring a portable sawmill owner at aTimberKing (800·942·4406, ti mberking.com) will provid e you wi t h a list of local sawyers for hire. rate of $SO-75/h r).Pros: o You'll have a forest-to-finish story to insider Secret: If you h ire a sawyer, vol-o Mill wood to any t hickness. tell of each project you build. unteer as a laborer. Ma nhandle logs,o Walnut a nd cherry cost t he same as pull boa rds off t he mill, sticker, stack-pine and poplar. Cons: do everyt hi ng you ca n to make sure t heo You won't pay a pre mium for riftsawn o Hefting heavy logs is labor-intensive. saw keeps cutting, logs keep gettingand qua rtersawn stock. o Selection is lim ited to local woods. loaded, and your cost per boa rd footo Wider availabi lity of species (pin k- o Great-loo king logs could yield plain keeps d ropping.tinged box elder, sycamore, a nd many or even unusable lumber.others depending on your locatio n) o More ti me milllng means less ti me for More Resources:offers options not typically sold at reta il. act ual woodworking.o Wit h a top rate of 125 board feet per o Drying takes months-do it wrong FREE VIDEOS:hour, a solid I6-hour weekend of work and you'll wind up wit h firewood.could net you as much as 2,000 board o The initial invest ment is la rge: $3,000 Wood-Mizer bandsaw mill demo to $6,000 for ent ry-level models. Labo r- woodmagazine.com/woodm izerfeet of lumber. Granberg cha insaw m ill de mo wood magazine.com/gra nbe rgLumber Drying Options wa it. As a rule of t hu mb, it ta kes I year and cu pping. And boards of equal per 1\"of th ickness to air-dry green wood length ensure that a stack dries evenly.If you choose to mill your own lumber, to a usable moisture content. A moisture Depending o n the type of kiln andyou're not quite done. Newly slabbed meter ta kes some of the guesswork out wood species, t he mill may requ est t he(green) wood needs to be dried down to of the process, tho ugh. wood be ai r-d ried for a short time first. Solor kiln. You can sho rten drying t imea usable moisture content (typica lly from yea rs to weeks by building a solar More Resources:between six a nd twelve percent). First, kiln-a cross between a greenhouse andcoat t he ends with latex paint to slow Build Your Ow n Solar Kilnuneven release of moisture that causes a garden shed. Fans an d baffles keep the woodmagazine.com/solarkilnchecking. After that, you have op tions: air moving t hrough t he stack of stick-Alr·drylng. Pick a shady spot ex posed to ered lumber. And t he temperaturethe preva iling wind . On a bed of level, diffe rential speeds the drying.ctnder-block-supported, sticker-toppe d Custom drying. Many sawm ills offer the4x4 run ners spaced 2' on center, stack use of their kilns for a fee. You gain theyou r first layer of lumber. Keep t he lum- peace of mind that comes from profes-ber layers of equal th ickness, wit h the sional kiln-d rying a nd low moisturet hickest boards on the bottom. Add a content. Expect to pay $0.25-0.50 perrow of I\"-squa re stickers o n 2' centers; board foot. Also, a custom d rier needst hen stack the next layer. To p the stack enough of a load (at least 300 board feet)with a sheet of plywood to keep t he rain to keep itself weighted against curlingoff a nd cinder blocks for weight. Now72 WOOD m ag azine Octobe r 20 10

These fres h-from -th e -Iog boards aregraded and st acked to be ki ln-dried a ndwa reho use d for wholesale customers.Pros: Careful stock se lect io n at t he ha rdwood Talk about convenience: At a hom e cent er, store nets you just t he right grai n you can sho p for lumbe r at t he same placee Prices come close to wholesale costs. patte rns with minima l waste. you bu y t he tools to work with it.o Professio nally m illed and kiln -d ried Pros: Pros:wood is likely to be free from checks andd rying stresses. e You'll find a wide va riet y of wood spe- e Co nvenience: There's a big-box hom ee Additio na l services, such as skip- cies, bot h domestic and exotic. center in every city of any size. o A reliable, on -ha nd supply means no o Time-savings: No need to plan aheadplan ing (see be/ow), surfacing, and pausing your project to wait (or wood. for your t rip, and careful sho pping canstraight-line ripping a re often avail- net you project-ready wood.able- for a n upcharge. e Experts are on location for hel p. Cons:Cons: o You choose t he size, grade, a nd grain that suits your project. e The premium price does n't always netc Availability of species could be Cons: you prem ium wood.affected by region , ma rket trends, log- o Surfacing and straight-line ripping o Species selection is often lim ited totruck-ha lting weat her. often come as part of the package and pine, maple, and red oa k.o The mi n imum order size m ight raise the price.exceed your projects req uirements. e No extra ma rgin of t hickness for cor-o Yo u're rarely allowed to choose your c Qua nti ties (as well as grain-pattern,own wood. recti ng cu pped o r bowed wood. widths, a nd lengths) are often lim ited to o Edge-glued panels may not gra in-Price for Red Oak: $1 .80 -2.IO/ bd ft what you see. match as well as yOli could do it yourself.Insider Secret: Purchase No. I Com mo n Price for Red Oak : $3.I 5-4.1S/ bd ft Price for Red Oak: $6.20-6.80/bdftgraded stoc k if you r project allows. Youcan work around any defects, and you' ll Insider Secret: 4/4? 6/4? 8/4? Those mea- Insider Secret: Ma ny ho me centers t hatsave up to 30 percent compared to pre- sureme nts aren't new math . Hardwood dea l in lumber offer free break-downm ium-p riced Firsts and Seco nd s (FAS) is sold by its pre-surfaced thickness, services, so t hey also produce offc uts.and Select (SELo r SAH), priced above. measured in q uarter-inches. In ot her Make your fi rst sto p t he bargain bin to words, a so-called l t-t h ick board is snag unexpected dea ls.More Resources: referred to and sold as 4/4 (pronounced \"(ou r-quar ter\"), but could range in More Resources:A Sawyer's Secrets to Buying Hardwood : thick ness from 1-Y16\" to %\", afte r bot hwoodmagazt ne.com/sawyersccrets $3.S0 faces a re surfaced. Planed More Resources: area FREE Download; Wood-buyi ng BasicsRough -saw n woodmagazine.com/woodbuying areaAsk your sawye r fo r skip· plan ing to get a FREE Article: Hardwood Buying Tipsglimpse of t he g ra in t hat is obscured behind wood magazine.com/hardwoodti psa rough-sawn board 's mill ma rks. FREE Download; Mail-order Wood woodmagazine.com/mai lorderw ood m19\" zl n e .c:om 7l

Wise Buxs Why buy?Our Experts Test In the shop, a portable workb ench can serve as a tem porary worksurface, tool stan d, or as a largePortable damp holding yo ur workpiece. It s light weightWorkbenches and com pact size let you bring a w orksurface to fix-it jo bs aroun d t he house. After use, it folds upSKIL XBENCH 311 S, $60 CRAFTSMAN 65796, $80 for easy storage. We tested eight wo rkbenches looking at damping capacity, d urability, stabili ty, and value. These four each offer a twis t on t he trad it ional split-ta ble vise design. BLACK & DECKER WM425, $120 Front jaw tilt s90'. ~ Tilt adjustment '----.. Removabl e benchtop pieceMilK. table size Ij Clw$ ope n): 19'1.><26\" MilK. table size (jaws open): 2 0 'l.x30 '1.~ ...Max. j aw opening : 6'/.Ta ble he igh t: 3 1'/,\" Weight: 271bs MaK. jaw opening: 4'''\" .' L ~ Removable Table height : 30 '/.\" to 4 1'/.0\" Weight : 40 Ibs / ~ benchtop piece MilK. tabl e size (jaws open): 22x 29\" Max.jaw opening: 8'''\" Table height: 24\" or 3 1 ~ Weight : 311bsTest-drive: Test-drive: Test-drive:Although I like the clampin g speed of the Two unique featu res set this workbench The WM 425 offers the w idest jaw open-quick-release rear jaw, this bench too k apart: a ti lting to p (up to 70 Q f rom hori- ing, th e most t able surface area- andsome getting used to. Inst ead of spinning zontal) and adj usta ble height . Wo rking at a front jaw t hat pivot s up 9 0 ° to clam p the raised table was much easier on my items down to t he rear jaw. The front jawthe handles repeatedly to open and close back. The height adjustment also made it release-and -p ivot mechani sm feels a bi tthe tabl e, the rear jaw slides up to the useful as an outfeed support for several of rickety, but it d amps it em s securely. my stationary tools.workpiece. Then you ti gh ten t he jaws wi t h I'm not sold o n t he three-piece A rem ovable benchtop piece f ills t he tabletop, t hough, with removable rearjust a twist of the han dles. space between t he jaw s creating a large, and cent er sections . To use t he vertical gap-free tabletop, but with slight ridg es d amping feature, you remove t he center Th e lo ng edges of th e M DF jaw s are at t he seams. W ith no on-board storage section and position t he rear one in t heclad in durable aluminum with an for t he fi ller piece, I t hrew it on the floor second of t hree sets of key ho le slots. I between t he legs w he n it wa sn't in use. spend a lot of ti me moving table parts.integ ral T-track. The plastic d og s have a The shelf attached to t he leg brace is usef ul for holding a few small hand t ool s. A perfo rated pla st ic belt t ies t hescrew m echani sm tha t locks th em into handles toget her for one-handed The workb ench folds easily, and its operation . A m echanism behind eachthe r-trac k anywh ere alo ng its length- weig ht helps it stay put w hile p lani ng o r handle let s t he belt slip so you can move sandi ng a workp iece. A m olded plastic just one end of t he f ront jaw . But w ith nomuch more versatile than dog ho les. hand hold on t he leg br ace p rovides a exp lanation of t his in t he m anual, wh en ISm aller T-t rack o n th e jaw 's inside faces comfort abl e grip fo r carry ing t he bench. fi rst tightened t he jaw s and t he be lt M y m ain concern is t he lo ng -term slip ped, I t hought some thing broke. Still,accept four plastic pad s wit h notches fo r dura bility of t he M DF top-during use, t he W M 425 does t he basics we ll and it s several p laces along the ed ge s chippe d . wi de sta nce m akes it a st able table.g ripping round stock vertically orhorizontally. Two m etal arms rotate f rom -steuea by Bob Wilson, -steaea by Kf!vin Boylf!,under t he fro nt jaw to suppo rt a Techniques Editor ' '',,\", Sf!nior Df!sign Editorworkpiece in th e opening w hile youposit ion and secure it . The sta nd is lightw eig ht, but sturdy,and easy to carry. It sets up and fo ldseasily w it h just a tug o r push on t hebenchtop. - Tested byJeff Mf!rtl , Df!!ign EditorTo learn more: To learn more: To learn more:877-754-59 99 800-383-48 14 800-544-6986skiltools .com craftsman.com b lackand d ecker.co m74 WOOD magazIne October 2010

Wise Buys ROCKWELL JAWHORSE RK9000, $228 (AS TESTED) -~... . ElECTRIC Foot peda lMax. t able size (jaws op en): 18 'h x 24\" For AFree Catalog Or To Find Your Local Woodcraft Store, Visit woodcraft.com Or CaIiSOO-225-1153.Max.jaw op ening: 4'1.\"Table height: 35v.\" Weight: 58 1b s Easy Wood Tools MinisTest-drive: Easy Wood Tools has done it again! These mini tools feature all of the same benefits and qualities as their full-sized parents. The cutters areCompared to other workbenches, this designed so that you do not have to \"find the bevel\" when turning. Simply advance the tool slowly into the workpiece and begin cutting straight in,is a horse of a different color-and the or sweep the cutter from left to right. or right to left. You will find these tools invaluable for those smaller. more intricate turnings, such as pens,price reflects it. S178 buys the Jaw- ornaments and smaller bowls, and also ideal for roughing, finishing andhorse, a three-legged sawhorse with a detail work. J{g\" x 4\" Blade, OL 16\"foot-pedal-operated, 37\"-capacity vise 845506 (A) Mini Rougher Ci2 A \"'-_---~ ••at one end. It's built to withs tand life on 845746 (S) Mini Finisher Ci3a jobsite. An optional split-table work- 150886 (C) Mini Detailer Ci4 ~_-- Replacement Cutters B .. -surface ($50) attaches to the vise jaws. 845747 Mini Finisher Ci3 149933 Mini Rougher Ci2 ';:;\"( jawhorse offers add itional accessories 150887 Mini netener Ci4aswell.) The l oot pedal provid es d amp- Cing power in spades and lets you hol d a 10WlIORworkpiece with both hands while tight- QUALITY WOOOWORKING TOOLS· SUPPLIES • AOVICE~ening the jaws. Release the foot pedaland the jaws lock in place. Flip a front-mounted lever to unlock t hem. The moderately sized bam boot able should pr ove more durable t hanan MDF surface and includ es a holet o park t he nose of your co rdl ess drill.One gripe : The p last ic dogs fi t toot ight ly in t he bencht op holes; I had topry t hem out wi th a screwd rive r.When the job fi nishes, t he stand foldsinto a com pact foot print w ith the leg slocked below t he upper beam. Andwhile it's heavier t han t rad it ionalportable workbenche s, a roller at oneend g lides over smooth surfaces foreasy t ransport. . -Te5/ed by Doug Hkb, former shop teacher and woodworking magazine editorTo learn more:866-514-7625jawhorse.comwoodm ag azlne.com 75

Ask WOOD HAVE A QUESTION?Answersto your questionsfrom For an answer to your woodworki ng q uestio n. write to ASK WOOD, 1716locust se, lS·221, Des Moines, IA 50309·3023letters, e-malls, and WOOD Online- or e-mail us at askwood @wood mag azine .co m. For immediate feed back from your fe llow woodworkers, post your questions on one of our woodwor king forums at woodmagazine.com /forums.The good and bad sides After routing wit h a template, sli p the t hin, broad, ste el blad e of a putty-knife between th eof two-faced tape workpiece and th e tem plate, and t he n twist to pop t he m apa rt.Q_ I find double-faced tape handy Workpiece e fcr everything from template 8ackstop-------- ,.routing, to stack cutting, to at-taching carrier boards for planing Carrier boardundersized stock. It's after thoseoperations that the tape becomes a The backstop p revent s slipping, while the plane r's ro llers hold th e workpiece against th eproblem. Often, Ican't pry the wood carrier board. All t hat's needed is a small piece of t ape to preven t side -to-side motion.apart without damaging my tem-plate or workpiece. Am I using toomuch tape or what? - Alan Price, Saint LouisA -We go th rough a lot of double- • faced maskin g tap e in t heWOOJ)~ magaz ine shop, Alan. And we,to o, have learned to respect its power.The tr ick: use it st rategically {/IU/spa ringly. For template routi ng, where inline\"shearing\" forces are mi nima l, usesmall, wide ly spaced pieces o f tape.When you've completed the routi ngoperation, p ry t he pieces apa rt wit h aputty kn ife; then sa nd the workpiece toremove a ny marring. For smaller pieces,t ry twisting apart the template andworkpiece li ke a jar lid or wiggling itside to side. That st rategy a lso works well whenstack cutting o n the ha ndsaw. Or, yo ucan strategica lly place t he tape in t hewaste portio ns of t he pattern . Plan yourcu ts to remove the taped portlons last. When you're plan ing t hin pieces on acarrier boa rd, the cutter head exertsmuch greater shea ring forces. Tomi ni mize the risk of slippage, glue abacksto p to t he ca rrier board to keept he wor kpiece (rom moving backward.Use only a small piece of tap e in t hecenter of t he work piece to ho ld it steadyside-to-side on the ca rrier. The do wn-ward pressure o f t he planer rollers doest he rest. Once you've sepa rated t hose pieces,use a shop clot h and mi neral spirits toclean up any adhesive resid ue. continued VII page 7876 WOOD magazine October 2010

A BIG ASS FAN FOR MY SHOP? •ABSOLUTELY!You 've got this great shop with high ceilings. It's too hotin the sum mer and too cold in the winter. The solution isthe all new Shopfcn\" from Big Ass Fens\", eng ineeredw ith our paten ted airfoil technology to improve conditionsin workshops up to 5000 square feet.The monthly operating cost of a ShopFa n is less than adollar per month... ye! it does the work of more than twenty standard ceilingfans. It's an investment thai will pay dividends for a lifetime.QUIRKY NAME. SERIOUS FANS. For over a decade, Big Ass Fans ha s been engineering lorge, high-performance ceiling fons for tens of thousands of satisfied industrial customers worldwide. like a ll of our fans, ShopFon is engineered, precision balanced and hond built wi th aircraft-grade aluminum an d industrial components rig ht here in Lexington, Kentucky. You can have this fan up and running in a couple of hours. And best of all , it's a genuine Big Ass Fan. TRY A SHOPFAN IN YOUR SHOP trBIGASS FANS FOR 30 DAYS 877·BIG FANS I WWW.BIGASSFANS.COM CONTACT US FOR DETAILS An ISO 9001 :2008 cer1 i ~ed company 877-326-0599 Na Equal. WWW.BIGASSFANS.COMMoy be ~ br \"\"\"0< \"\"\"\" ofrI>e fo/hw;og us Po~.. 6.244,821; 6.589.016, 6.817;8J5; 6.939; 108,7,252,478, 7,284.960; DS87,lW; D607,988 g,.J athe< po\"'!> pondiog

Ask WOOD Scribing a perfect fit for curves Q_ llm making a wooden tool- _ box for my pickup bed, How do I make a template to fit over the curved wheel well ? - Jeremy Ryan, Anacortes, Wash. A_ Sta rt by cutti ng posterboa rd _ to rough ly t he sha pe you will need, Jeremy. Hold the template in place on t he wheel well where t he project part will sit; t hen set t he legs of a compa ss a litt le wider than the largest gap bet ween t he template a nd t he curve. Kee ping the co mpass points perpendicular to the su rface of t he curve, t race the cur ve with t he compass point wh ile tra nsfer- ring the line of t he curve to the board wit h the pencil, as show n below. Cut a long the ma rked line an d repeat the process, twea king until you have a pattern wit h a tight fit. Use your template to layout and cut t he workpiece to shape. Large Deer \"S' tall WP-OFS·l003 51 3.95 As t he ga p na rrows, close up the co mpassMedlSmall Deer 28\"and 9\" tall Wp·OFS·l018 513 .95 legs to match and scribe t he curve agai n. continued 011 pag{' 80 78 wooo m agazine October 2010

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RELIEFFOR Ask WOOD DST T Straight talk aboutCRACK AND SPLIT. flat tabletopsBuy toda y or find a store near you 1-800-275-2718 Q_ Iam building a tabletop • and wond ering if I shouldWWW.OK88ff8.Campany.cam alternate the boards' growth rings 50 the top remains st a b le. Also,Sweet Spot should I use 6\" boards and narrow- This ruby red cut-g lass er, or is it okay to use 8\" boards? hummingbird feeder has a - Nancy Southall, Baltimore, Md. gracefu l profile and large A.For stability, alternating t he capacity, and is easy to • d irectio n of the growth rings helps but matters less t han choosing hang and clean. Fill with your grain ca refully, Nancy. Straigh t. grained riftsawn o r qua rtersawn sugar-water nectar and wood proves more stable than fl atsawn, cathed ral-g rain patterns. wat ch the fun begin! It Start wit h properly dried woo d and let it acclimate to you r sho p (or a measures 13\" tall ,S Y2\" in couple weeks before mach ining. diameter. Great gift idea. Likewise, the widt h of the planks To order Call ~78-5752 won 't a ffect the stability of a glue-up i f you've chosen your grai n carefully. or visit readershopping.com. (Keep in lnind,t hough, t hat the Please specify item wide r the boa rd, the more likelihood it will conta in a mixture of stable W LH7-WOOD. $37.95 riftsawn and war p-prone f1 atsawn p lus shipping. wood; see photo be/ow). When you a re able to acq uire ideal, wide expanses of stable grain, you ca n size the boards (or aesthetic s and for the capacity of your machines. For instance, if you have a 6\" jointer a nd a 12\" planer, 511..\" boards allow you to glue up sub-panels that won't exceed your mach ines' capacities. If you prefer flatsawn gra in pattern or are unable to wor k a rou nd it, 4\" or less serves as a good rule-of-thumb board width for a stable glue-up. IRift sa wn Flat sa.....n I Rifts a.....n Riftsawn grai n offer s more stab ility, but wide board s, such as t his one, often also conta in warp-pro ne f1at sawn wood. continued oll/Jase 82 80 WOOD mllgazln<;> October 2010

We Can Only Find OneA rare chance to claim a unique piece of watclnnaklng history for under $IOO!Eigh ty-six yea rs ago, a watchmaker This limited ed ition Ste uer Meisumcit Try it for 30 days and if you are not in Paris famo us for build ing the allows you to wear a watch far mor e thrilled with th e beauty and co nstructionmag n ifice nt d ocks at Versailles created a exclusive than most new \"upscale\" models. of the Md.\tcrzeit, simply return it for alegendary tim ep iece. He invent ed the fi rst Here is your cha nce to claim a prcce of refund o f the purchase price.watch with an au to matic mechanical watch making h isto ry in a rare design that Extremely limited availability.d rive. These in novativ e moveme nts is priced to wear everyday. Since it takes about 6 mo nt hs to bu ildrequired no batt eries an d never needed Elegant and accurate. This refined each Meistt'rzeit, the release is a limitedto be manu ally wound. Only seven of beaut y has a fastid ious side. Each move- ed it ion, so ple ase he sure to orderthese ultra- rare watches were ever made ment and engine-turn ed rotor is tested for yours soon,an d we've studied t he one surviv ing 15 days and then certified before it leaves WATC H SPECS;mas terpiece in a watch history museum . - 14K Cold-dad case and bezelInspired by h istory, classic de sign and the factory. • Pre<:i~ion 27-jewe led movement • Interior dlats di~play day and monthtech nology, our Stauc r Mcistazcit has The best pa rt is - Croc-embossed leather strapbeen pai nstakin gly handcrafted to mee tthe dema nding standards of vintage that wit h our _ Fits 6 l/4'-F, 1/4' wrist 76% special price, youwatch collectors. OFF can wea r aWhy the new \"a n tiq ue\" is hetterthan the original. The origi nal time- su pe rb classicpiece was truly in novative, but, as we stud-ied it closely, we realized that we cou ld h istorica l repro- Exclusively Through Stauerengineer ours with a much higher level of duction watc hprecision. The zz-ruby-jewel movemen t Steuer Meisterzeit Watch- u.s-utilizes an automatic self-wind ing mecha - and laugh all thenism inspired by a patent from 1923, but way to t he hank. Now only $95 +S&;P Save $3ootbuilt on s:n million in state-of-the-art Steuer specia lizes Vi\"w Ill\" p \"-'t:h i\" n Call now to taKe advflmage ofthis limited offir. in classic time- less watches and TlIo v\"lll\" n l of t il\" 1 -888-324-4351 jewelry that are M d lt\" I7l'it t hrough lil t' made for t he m il- Promotional Code MZW306-02 rear exhuauon port. Please mention this wde when vou call.Swiss-made machinery. With an exhib i-tion back, you can S('(' into the heart of theStauerengineering and view the rotor spin-it's lio na ires who wan t to keep th eir mi llions. This watch will q uickly move to he irloom status in your ho usehold .powered by the movement of your bod y.- - - - - - - - - - - - - - - - - Smar t Luxur ies-S urprisi ng Prices - - - - - - - - - - - - - - - - -

WOODLINE USA Ask WOODQUALITY CARBIDE ROUTER BITS , The multi-talentedSHAPER CUTTERS & MUCH MORE! low-angle block plane Woodline USA is the official ~l.\"WOODLlNE.::CM Qe 11m a lifelong power-tool ej u nkie w ho wa nt s to trymanufacturer of Maloof router bits! hand tools. I've heard my first tool should be a block plane, but I'm These bits feature a unique tapered rabbet with tapered bearings confused about the differences developed specifically lor Sam Maloof to make the fabulous joints between a standard block plane of the Maloof chair . All have a 1\" diameter and 5/8\" cutting depth. and a low-angle block plane. Can you sort them out for me?PART # SLOPE PRICE 5Q 2 pc Set - John Gutierrez, Coshocton, OhioWl-6220 $75.00Wl -6221 75.00 A•If yo u have to start with justWl -6220 35.00 e one. go with the low-angle block plane, Joh n. The 4SQ a ngle of TnSJ.. tar ™ the standard-angle block- ty pically a blade with a 2SQ cutting-edge Smooth 3 Wing Router Bits bevel and held at 20 ° by the plane that feel like a shaper cutter body- works well o n edge a nd face grain, parting the layered fibers of wood grain . The low-angle block plane holds the blad e at about 12Q for a shallow 37° cu tting angle. The sha llow angle add s t he abi lity to effic iently cut en d grain as well as ma ke cross-grain cuts, making it t he more versatile of the two. • Gift Certificates available The st anda rd-angle b lock p lane's constr uction is id entica l to t he low-enqle block plane e xcept fo r th e cut t ing angl e ofthe b lade. Have a woodworking question? Post it in the forums at woodrnagazine .com/ f o r u m s. It's like having 100,000 experts at your fingertips. EA SY OR DER ING ! 2 4 H OU R S A DAY , 7 DAY S A W EEK 82 WOOD mag azine October 20 10 1-800-472-6950req uest a full catalog or order online at www.woodline.com

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ShoR-Proven Products About our product testsThese woodworking wa respassed our shop trials We test hundreds oftooh and accessories, but only those that earn atleast three stars forperfurmance makethe final rutand appearin this section. Prices are current atthe time ofarticle production and do not incl ude shi pping. where applkable.Build accurate jigs withslop-free guide barsI've made cou ntless tabl esaw jigs and sleds ove r the years,usi ng h ard wood gu id es t h at fit i nto the miter slot . Butalmost without fail they bind in the su m mer and wiggle inthe winter as they swell and shrink with seasonal h umiditycha nges. ZeroPlay Gu ide Ba rs eliminate those problems forsmooth-gliding, perfect-fitt ing jigs. Each gutde bar co nsists of t wo thin, 9 ';'\"-long pieces ofstu rdy glass-filled nylon. Stack t hem toget her in a miter slot,and when you push the to p one for wa rd, opposing wedgeson each piece tighten t he fit perfectly. Then secure t he twohalves with screws and attach your jig or sled . 1rebu iltseveral o f my jigs using ZeroPlay Guide Bars, a nd t hey workbetter t ha n ever. You ca n bu y indi vidual guide bars , or get a kit t hatincludes t wo guide bars and two Zerol'lay Gu ide Stops,1'/2\"-long fixt ures that come wit h a bolt a nd knob, shownbt'/ow, t hat lock in Tit rack. Attac h a com mo n hold-down(not includ ed) a nd one of t hese stops works great forpositio ning a stopblock on a rout er table or securing aworkp iece o n a drill press. - Tested by jan Svec, a former WOO D ~ magazine project designer, builder, andeditorZeroPlay Guide BarsPetformance *****Price Guide Bar System (#l P9-Bl Sl ) Sl7 single Guide Bar (#ZP9 -B1) S12 Guide Stop (#lP9 -S1) SSMicro Jig407-696-6695; microjig.comBenchtop router table loaded with features Benchtop router table, #RAS900 Sl70Skil's well-appointed RAS90 0 router table sur prised me wit h its Performanceperformance-bett er t ha n you usually get wit h tables in its $160 Pricep rice ra nge. (I also tested Skil's $120 RAS800 router table, but it'sno t nea rly as good as its big brother.) seu The RAS900 has a 16'/1 )(26\" table made o f t v-t hick lam inate- 877-754-5999; skiltools.corncovered MDF wit h aluminum T-track and a fence wit h movablefaces, alu minu m T-slot, a nd a 21/2\" d ust por t. The fold ing steel legshave plast ic sto rage pockets for bits, wre nches, a nd accesso ries. Allthis weighs 2S pounds, which helps d ampen vibratio n withoutbe ing too heavy to lift a nd tote. I rea lly like the handy router-mou nting system . Secure you rrouter, mi n us its plastic subbase, to t he RAS900's 7'h \"-squa re steelplate . This plate clamps u nderneath t he table wit h a qu ick-releaselock. To use your router freeha nd , release the lock and simply routwith the plate as your subbase. I also like t hat you plug t he router into an accessory powerswitch for easy onloff control. Howeve r, t he switch'scord measures o nly 14\" long, so you'll likely need a nexte nsion cord. • - Tested by Bob Saunders, owner and teacher, Prairie Rose Woodworking Studio, Indianola, Iowa84

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98% of NOVA lathe owners would recommend their lathe to others*NOVA DVR XP • Packed w ith innovative feat u res • Best value fo r money ~~~~~~:~~~• Incredibl e ve rsat ility - 16\" bow ls t o 29\" p latters, small p en s ~ and long spi n dle work • Power and ca pacity • Port abl e and com pact - swivel heads, exte ndable bedsNOVA 1624 ' Custome , \"\",islaction survey 2009 NOVA designed & manufactured byAvai lable f,om leading outlets, includingWOODCRAFT SUPPLY Te knat oo l I nt e rnatio na !CRAFT SUPPLIES USA vvvvvv.teknatool.comSmart Tools, Powerful Solutions

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