VOL.16 Ss NOTESFROMTHESHOP (NO. 94 “Woodsmith Build this RAISED PANEL ENTRY DOOR in your own shopNo. 94 August, 1994 EDIT © Rk? OLUMN s% Ear Densla B. Pesce Bxcutive Fallon Ooigsus Les ManagugEaltor Tory’. suoumsn Assistant Ealters ines Dolan ‘onan Garoison Marka, Willams Gieative Director Tat Krlicee “Ar Diredtor Rol Steaks ‘Senior Mhustrators Davia Kreg ‘Sinde Sharnbangh Minstrstors Dit Ver Some ‘More Higdon Photographor Crycis duglind tronic Graphies ChrieGlowacit Design Director Ys Munlel Senior Designers Jan Hale Svee eat Waleh Shop Manager Sere Curts Shop Asst/Fuclidee SiorcToxncon ‘Cireulation Director LisBredeson Subseription Manager Sandy Brum Chetlation Analyst Roi Cain Newsstand Saks Seat A, Buckion ‘PUBLISHING SERVICES Anoe, tor: Goon Gagpo * Graphto Ais heh Cyr CORPORATE. SERVICES fan Clare A, Seo tally Fd Recep Seannelchrion Bu Mein Ret Gite WOODSMITE MAIL ORDER even Dir Ba ery Art Dire Coy ice Yak Matin vPro SppliLintal ones: Tech ‘Sigportetlans © Reo Cia Resa (CUSTOMER SERVICE Superman Cut Sore, Rep: lar r= thy. dry rm, Sea Kono, Ara Get Kit A= ‘Gov, Loans lr Kara Croan ‘SHIPPING DEPARTNAENT Supe Nine leven Rufino’ Ghra Shocan Defi ai Cac Caron Sa Crsy WOODSMITH STORE asap: Dave Ltson Assent homage Pak ‘SKhnctiereSelsn Sug Wendsll Stn Pat Lowery * gee Monger Vie Barris ot eke Ea aaa ies Shey eons oe Moi, iA and aad jane eae Pip soossoanees ee Sawdust re of the things T enjoy abou ‘woodworking is being able 9 by consthing different. A new technique, a new tool, oranew project ‘A good exaliple of this is the featme prsetincs bee ny Doe photo below rit. ANY DOOR Pye been intigned: with the Hea of biting ried pate ity joor for some tim. Bat ine of ustvacy ume ityasthe"Hghtisnd! of project forthe magazine Well, I finally decded to g0 ahead and give itauy.Tmelal | did ‘The Entry Door features basic mootise ad tenon join ery and can be bil with om ‘mon woedworking tool. All you need is 4 table a, router ale, and adillpes. ‘And atique method fr i Stalling Uie raised panels mekes asembly easy Bul as | sad befor, this ‘stl a typied woodwoiking, priject For one thing, 2 éoor has to he mad tft an open ing. Andthe ze ofthe open- i sil vy fiom ow 6 honse, The other thin you're going t0 build your Sm door you shoul et to change the look of x 10 me your house Sowe took aight differ en approach in the waY this ace is pro sented. Beginning onpass 23 ve chow the basic design considerations for building 2 door Alena with step-bysstep istnactions forthe joinery and asertby The idea hete 18,0r You to fake this in fomnation and we itto ceate a dooe that fits your needs, We've even included some different door designs to ve! you sared One more thing. Sic tis is 2 differnt type of project for uy sed like to Tear What you think, Tus jot your thoughts down and send them te, Woods Pub- lishing, At: Teny Stroman, 2200 Grand Ave, Des Moines, JA 50312, LAW SIGN, The idea fr the Lawn Sign came up when Tvistedafiend. He had e- fetly moved to a new house and invied sme to opby. "As I ias diving down the street, no- tical several Houses had _sall_afdress Siats inthe front lawn, Unfortunately, my friend dich't have « sign in hie Town 20it took ne awhile to find his howe. Tsisgested he get a lan sign with his towse number on it In Taf WON be etsy fo make your ov, thought it was a area idea But he ‘suid if/ thonght itwasso easy why didnt/ make one. | had nothing planned. that weekend & decided to give tatty. The sign had to be quick and easy to ‘build only had vo days). But wantedio tne ilook oie nunnbers had been carved by hand. ‘The end results the Lay ‘Sign shown on page 16 The Sion is built wath commen censetion hnberand sim router anda core box bit CORNER CABINET, The ides for the Comer Cabinet, shown on page 6, also came lip while visting my friend's hhouse. You see. his new house vas actly an old hou. The bind that has all sorts of builtin stongs. But what 1 liked best was the built-in comer cabinet in one of the bedroors. t seemed Tike the peifect storage sgh A tion —masirmnm storage ina rninirmam amount of pase ‘Oi version seit built in, but it dose of forplenty of tomge option for an unused cones of bedroom. ‘CHANGES. Onceagain vevermade some changes. Doug Hicks is now Executive itor. Our new Mataging Editor, Terry Schima, isat really new. Hes been the Inanaging. editor of ShopNoles. Nan Jelieine our Stigping Spenser, Mask Mattivssi is oar now Inventory Control Manager. And Pat Lowery ns joined our sows sas staff, “MISTAKE. I doesnt kappen very often, ‘bat we do make mistakes, Tn the las issue there ae some emtors in the plans for the Garden Bench and the Wall Storage Sss- fem Ifyon plan on building one of these projects please call us at 1800-4447527. RA pee tane a 2 WoedsmithA LOOK INSIDE Contents FEATURES Corner Cabinet 6 This projectisa closet, a dresser, and a bookshelfil in one. But host ofall, t provides useful storagefor the leastoused place in @ room — a comer. Lawn Sign 16 ‘This classie-looking Sign makes an attractive and practical fo ony lawn And it ean be built injust a weekend. Routing Signs 1 Greate the look oft hand-carved sien with acere box bitand a router. A few tips and the right technique make it easy Edging Plywood 20 We show threedifforent methodsforusing hardwoodto cover the edges of plyweod. Plus tips on gluing, clamping, and trimming the edges flush. Entry Door 23 No tricky joints, no special tools. This Door is built with basic mortise and tenon joinery. And a unique design for the raised panels makes them easy to build and install, Reader's Jig 30 In this issue wefeature a unique designfor a flush-trim jig. Tt mounts to a routerjor rimming edging on plywood Comer Cabinet paged DEPARTMENTS, ‘Tips & Techniques 4 Shop Notes 14 Talking Shop 22 Sources 31 No. 94 Woodsmith 3FROM FELLOW WOODWORKERS Tips & Techniques ROUND TENONS ON SQUARE STOCK {When aspinile ioke cn ous suppont blows vx Tig 1. The apinde in the suport biocks, Tous hig tse heitand ofmmy dining momchaits,T had suppot blocks have larwe holes see Fig. 2, With the router bit make several light cuts to form tocomeypwithavaytocita thal suspend the workpiece lowered, cesterthespindle et thetenon. Slowly turntle work round tenon on a square work- over a straight bit, the bit Put two stop blocks in flew coustetelocovse into the piexe To do that, I made this These lols dont have to fit the miterlot to keep the meter bitforkest sills, ee Fig. 2 Simple U-shaped jig tat at the workpiece exatly. The jig gaigefiommoving. Next.toes. Repeal the process until the sill works if they're slightly tablish the Ienath of the fenon, tenon is complete faches to the mitergmage on my routectabie, rferto Fig. 2. oversize. (aboat Yc") postion the fence (or elamp a Rabert© Noelle ‘The fig has a back and ovo ‘To st up the jig, install the stop block) behind the bit Middletown, New Yoré 2 orien 1 Mier Coigy CHECKING MITERS CLEAN YOUR SANDER The normahwayforchecking workpieces topéther edgeto- +o removepitch buildmp from amitered comerforsquareis to eige and placethe square inthe sanding bells, 1 use a. gum bute the miter together and mitered comer, we drawing, mse. But cccasionally, the To clem a Placeatry square onthe outside “This also allows me to place eraser wont remove all of the sanding belt with a Githecomer 1don. Maiilybe- the mulered pieces over the pitch, Soo compleethe job, I cau fle geily rubtlefilebeck Catselfinditdiicnittoholdthe edge of my bench so lcan geta se acardfile see drawing. and forth overthe bek Then to- syuare wih one trend while more acamate reading when The metal bristles on a cand tate fhe bell by hand to expose Feeping the mitered work- checking thinner sock. file aw siffenough to etatthe additional buildup. plese: fight in the other Bob Brye toughest buildap. But it wont John lucas For ie ifs casest to hold the Fairport, Now York damage the belt Gainesboro, Tennessee ie tise!SANDER DUST COLLECTOR + When Ine my bench sander if cartes a lot of sawdust in a hurry. Dus covers everything afierjusta few minutes. A dust Collector would be nice, But I owt lave enough space or moneyTor one Solise my shop vacrumfor aust collector. [turn theutility nozale ypside down and attach it to the base of the sander A EDGE TRIMMER +1 built the mottising tdble fiom, Woodsmith No. 67. Its a ‘2004 {001 for cutting mortises iquiekly andaccuraely. Butwith simple modification, aval also ‘inmedsing lush on plywood, Fist, msertaflushtrimbitin the router. Then, to allowclear- ance for the oversize edging strip, ise the bed of the table “ungee cord” holds everthing inplce, se dawingbelow. “The vaeuam gets meet of the dustasiteomesoffihebeltAnd. the bungee vord males i easy to remove the ngzzke for otier pts. Ph the price was nigt— 1 already had the vacuum and the bungee cond TedWarner Merrett island, Florida vith a pce of Slab ply- ‘Wood, se drawing, ‘Onte the plywood is capet typedte the able, mise orlover the bitso the Dearing is fhash Dae DOG aera ‘Then rout the edging Mash, see easing below. Bruce Prem Apex, North Carona NOTE Feed ‘drectien caretare +10 aot of fishing. And 1 used fo g0 though quite a few foambrushes. But found that en, fue stale fea mish is inexpensive, you rae needjst one—andthey do ad typ. To ext down on the cos of finishing my prjecs, Tve Maite using show kengtis of paint roles instead ‘bay mediun-rap roles in vahiepacks offivefrommy Tocal ardwarestore. Then! eutthem jnto 2" Kengths using the band ‘Each of my olds Sait and fish well, be ‘cause of the thick nap on the roller And there's rinitnal drip- ping. They ast longer and anply 4 more uniform coat of siain than a foambnish. And bes of all, they costabout halfas muck, Greg Forster Waterloo, Jown QUICK TIPS IMPROVED TRACKING = Ifyoutte having trouble with (hetracking onyourbelsuder, toy cleaning the dove dram on the sander, You'd be surprised at how much sawdust and pitch ean acaumnlae on the drum: And you might be equally sur prised how mich beter 4 vill track once ifs cleaned, Ron West Columbus, Ohio PANTY HOSE FILTER + The filter on my shop vacamm_ erm lke ite aways clogged apratsavans Sotohelp| the filter from clogging quickly fad to make Heater'o cea, f Sip vo paic of old panty hose overthe filler, cs To do this, fist cut and dis cari the lowers powtionsfrom ‘ach panty hose Oustbelawthe ‘rotch). Thea tic a knot at each CHEAP BRUSHES A. Cui sections from a patnt roller to ws ike a brushyor ppibtne pain or satis Jeg, opening and sttetch the waistband overthefilter Alarge rubber band suciched over the filler keeps buh puit of panty hose fromslipping off, bert Sandoval Havelock, North Carolina SUBMIT YOURTIPS Ifyou would like to share an original shoptested tin, send it to Woodsnith. Tins and Techniques, 2200 Grand ‘Avenue, Des Moines, Iowa SG. Orifits exterforyon, FAXittousa 515-282-6741, Ir ve pie ve val sendy ouSs0t05150, depend- ing on the pubished rath, Inclnde 4 brief explanction and sketch (or photo). And dont worry, well ewnite the tip and redraw the artif nee- essary. Also, plese inde a deytinephone minber, WoodsmithSiO RA GE FRO LEO Corner Cabinet Shelves, closets and drawers. This project combines all three to add a macimum amount of storage in a minimum amount of space. AX you've lived in a honse long enough, youbogin to experience the ane problem — sionge space, There never seems to-be enough. So to help solve thatproblem, I decifed to build 2 cabinet But notjust any cabinet L wanted one that ‘would take up very litle floor space. And Sill provide a lot of room for steraze This Comer Cabinet is the walt Its a straightforward project tobnild—justtvo plywood exes with shelves, doors, and drnvers, Aid mostly basic joiuery (abbets and dadoes). Both cisesare connected to make a cabi- netthatfitsperfectlyin the comer afarcom, PRACTICAL. Athough the Cabinet isprety basig there area couple things that make it ‘unigue. Fist, ifs designed to be disassem- bled So alter its teen completed in the shop, itcanbe taken apar:andessily moved. to a room where ifs needed, Then Tater, when the Cabinet is needed somewhere eke (like adormroomorapart ent) itean be taken apart avain. And this time set back up differently — with the ookstelf and clos cases reversed. VERSATILE, Another thing Ike aboat this projectis the versaility, Depending on your somge needs, you can "axstomize" theinsides ofthe cabi- net any way you FINISH. list t0 € perimentwe bit wo Comer Cabinet and finished each. differ- enily. Ove version re- ceived a. traditional treatment of, wiping vvamnish, ace the mai photo, Batfora com. pletely different look, the second Cabinet see Finished with pao- ‘el shins, For more on this, se page 13,EXPLODED VIEW MATERIALS =O ® @ ‘A Close Case Sides (2) 4 py 30%4x7012 B Closet Case Toni. (2) % py 302% x 1814 © Shot Csse Ses 2) Y py 1147002 D SholfCace Tops. (2) spy 1i)4% 18\2 E ChoetDivder(i) py 2914x184 Dior Edging (1) ane 2 © Vere Edging) axl 4 70% HH Honaonal €9gng (90/4 1 Case Becks @) wpy- 1812x692 4 BeveledEding 2) Yin 's~70%4 K Platform Cleats (4) 32x 192 -12¢eah) 1 Paatiorms 2) 4 py-8x 18 60H) 1M Phair Edging (@) xa A) NN inside Tim Sip (1) 3182-68 © Kiektoardacirg ) 34 By 472 eh) P Kiekboerd Chats 4) 94 ply 220 rg), QFLGueBbdtsi2) 412-31 Bk GueBown) — 34x4-3le Shakes @) py: 1VAx17 6 1 Sho Eeging (4), aK) ATG U Backing Glas(9) ip: 224 gh) V TopAoWing(3)——34x1-24 (ah) W Closet Done (t) Mp 17444756 X Cont 9204(1) 4 By- 1274 6850 Y Door Sieos Eigng ()3I6x3/4- 7 eh) 2 Door Topo. Edging @) vax 4-66 Fh) AA oer So99 2) raxiia-2 BB Drawer FonSacks() YanB¥8—17 ‘GG Draner sides 6) XB%A-24 DD Drawer Botoms (3) 416/24 23% | EE fate rons @ A py -ATAxONAs | SUPPLIES |= @) 18x20" EnWootesrere + fe x2" En Woodscrews = ()¥0x 12° PhWoatserews Ron (is x 1/2" Fn Woodscrews OT PURI |S aa) a x 1 Fr Necorserews | @)¥e<1" Fhvloodsorews + Gm. Wepaand Kes * (6 24" FulLextenson Crane Sides CUTTING DIAGRAM | # @) Magnatis Caichas + (agurtadie tag leveer 00 boas @ 3.8 Sy. Foe | (rect Gosatroe sockets + (1) 14d, Sed Oak Dowel (13°) + (0) ar-dia Rad Oak Dowel (18°) {i} 2a Red Ook Dowel (36°) 5x $6" Fed OX (0.764 z x eet Te tes Masonite (or Baawor Baton i 45" 3 66" Bid Oak Pywood 2 host) is 48" 1.5" Red Oat Pywoedd No. 94 Woodsmith iCASES At hie heat of this project ae two large piy- ‘wood eas One cise farms acosefcompart- ‘ment fieotherbecomes ashelfoompactinent To make the case, I started by cutting the sides (A) and toto B) for be lost compattinent “Thealutthe sides (C) andtopybotom Dis theshelf compattirent, ABBEIS: The pray onary on bath boxes consists ofa rabbe!alora three edges ofeach piece This is forjoiningthe top and Bottom t the sides and alo for accepting tho plywood bacls (addediaton. First lused adado bladein the ablesaw to aut rabbeton the back, (op, anf bovtom edges ofeach compattmentside, se Detail aatright And aso a mbbet along the back ‘edge ofthe compartment top and bottom, ‘Note: Cut the rabheis deep, amt wide ‘enoiigh to fitthe %4" plywood pieces. DADO, After eating the rabbets for the compartmenthecks, I setasidethepars for the shelfcompartinent Then setup and cat ava'deep dadoacrossthe inside fice ofthe closet compartment sides, see Detail, ‘These are fora plywood divider DIVIDER. Now the selfeomparment can ‘be glned and sewed together: Btbefore azembling te closet compartment, the ‘losetdivider(E)mustfirstbecuttofitbe- tiveen te daoes. ‘Note: The divider is cut to width so ifs ‘lush With the inside edge of the mbbets along the back edue ofthe closet sides, se ‘Detail b. And inset\4" from thefront edge ofthe ses, we Detail ¢. ‘With the divider in place in the dadoes, the cleset compartment can be siued and screwed together, sce drawing above, EDGING When building projects from plywood, 1 usually try to hidethe edgesoftheplywood. To do this, Tused several hanfwood edsing stips_Al these ships @ G, and H) are cat from SaMthick stock But their widths and lengths vary, refer to Materials List, page 7. Design Note: The vertical edging sips (G) are wider than the thickness oftheply- Wood, see Figs. 1b and Ie. Thats beciise they acts fillerstips between the Cabinet and the wals when the entire asembly is phicediina comer eee cereal length, I cat the divider edging stk tfliniontl cig spr) W Eieb, ‘These ae ripped fo atch the thickness of the plywood top andbottom pieces. Now, all heedaing stipscan beatiached with glue and clamps, Assembly Note: T started with the stip for the divider, then ‘moved oa fo the vertical stips, and finally the horizontals, see Figs la 1b, and te, Non forsorrom, eerie) 8BACK ‘The act thing todo isto cut so plywoed ease backs @) ofits therabbetscatear= lie, se Fig, 2 Afterthe backs ae ot, they ‘ean be installed inthe cabinets, see Fig. 23. [Before serewing the two assemblies to- ether, frst decide on which side of the ose yon prefer to attach the shelf cam. partment, sie Options bes at Nec el wae enn installed from inside the closet compar ten, see Options bax an drawing a lef. “Afterthat, when the wo boxes (he seit ‘compartment ard he closet compartinent) aye screwed together. the whole thing be- gins to lonklikea cabinet CENTER COMPARTMENT Herds the most interesting (@nd anique) ant of the whole project I's building the enter compartment thet “bridges” the fronts of the coset and shelf cases, ‘Thiscentercompartment isadded fortwo reacens Pit, it Visually ties together the fo plywood oaset. And second, it creates another somg> compartment BEVELED EDGING STRIPS. [started the center unkity ripping pair ofbeveled ele ngstrips (J),see Hig 4. Theseatachtothe Veticaledeingstips on either side ofthets- angular opening, referto Figs. 3and5.Their ‘Dunpeee isto flame in the opening and pro- Nide a surface for hanging a dor ‘Tho edging atips ate ont in a two-step presse to form a notch, xe Fig. 4. This hioteh "hooks" ouo the veuical edging ships seeFs. 3. New, the edging staps ean be serewed in A With his Corner Cabinet the sheVease can be comecied 10 ether side of the closet ase, It takes three pair of#8.« 11;'Fhwood- screws installed from inside the cioset. place (sven sews in each), se Fig 3. ‘Nate Ididit hie on the strips in cae L decided later fo reverse he doseiand shell ‘aes refer Options, above, "TOP & HOTTOM CLEATS, The second pat ofthe cenierunitane to par ofeleats (0, sec Fig. 5 And, like the bovoled edsing iro, tases sks as catto fit the trae lar opening (atwith asineler eu). To? SBO:TOM PLATFORMS Arte Cating four cleats to it inside the triangular open ing, the nest thing to do is eat two, plat forms (1) to reson the eeats see Fi. 6, HDGING THIS Aer he li ae served in plaos, cut and atach a paie of platben elging sips sos Tig 7 INSDETRMSIND, The last hingsto dois to cut and install along beveled trim stip (S) over the inside comer of the cotter compartment, 3 Fig & 4 Teew Blade to 45° ‘STEP ONE TEP TwoBASE ‘Aflercompletinathecenferunit,I moved on to the base of te eabinet The base serves tbvo purposes: Fit it clvates the cabinet oifitefloorso you don't sub yourioe every thme youwalkupto the cabinet, (that'swiy acabinetbsseisoften called a"kickboard.") ‘The kickboand base also gives the cabinet a neater appearance. When its lifted offthe floor, the cabinet assembly will clear the beseboant that nansinto the comer. The base consis of two assemblies that ate ached separately to the bettomn of the cabinet, see Fig. 9 and drawing atright. Both ate "L-shaped assemblies, with a plywood facing stip atached 0 a cat se Fis. 9a, PLYWCOD FACINGS I started the base by first ripping alength ofpiyywood to sore as blank forthe kiekboard facings (0). Rip thisto width so when is attached, the cab net will ckarthe height of the baseboard, se Fig. 9a. (For my sha™nigh baseboard, the ficingis4” wide) Tien, eat agroove along the inside ede tocwept a kickboard cl, sex Fig. 9a Now the blank ean be cut into five oversize strips, ‘To soeare ihe facings tothe cabi- net, next cut four Kiekboard cleats (P) to rough Kength of 20", (Three will be used around the fro ofthe cabinet, and one Will be use forthe back comer, se Fig. 2) Ther, eutarabbet along one edge to foun a forge that fits into the groove inthe fac- ing stips se Fig. 9 Now the cleats em be luedtothe facings to form the “L*ahaped lackboard brackeis sec GLUE BLOCKS Befere mitering and x taching te bracketsto the cabinet, fist cnt pair of glue blocks (Q) ortheftont ofthe kickboart assembly, see Fig. 10 These add stength fo the miterjoinis and also help to align the picoss when they're installed Tow’ abo ata sae blade (B) aed to reinforce the kickFoard asembly that goes on te back che cabinet, se Fig. 1 INSTALLATION. Now the Kivkbourd go tions can be mitered to length to fit under the caine, sce Fig. 9. Then they cat be sScreived in place. Note: I installed one seo- tion atatime, Then addeda glue block be ‘fore installing the next secton, see Fig. 10. TUB LevBUER, If a Jeg leveler is needed, nowisthe kest time tn insall ne. sa piece ‘ofhardware that aitachestothe insidef the front sedtion of kickboard. Our levsler has athtcaded "ks" that screwsup and downin the bracketto raise or lower the front ofthe cabinet, se box below. 9 vex1web Wooscen NOTE: 80 Bits Be lad data asoray of Keokiosd unis ‘The Comer Cabinet ean be placed in any rightargle comet. But if the floor is cat= peed. therecnheaproblem Actually fhe problem iswt the carpet but the tacking stpealongthe wall undertle carpet, Thess ‘vill oud to tip the Cabinet ornard, away from the wal “The best way to tipthe Cabinet back into the comers to mise the front A lez ivelet ‘is what Lused, (See paze 31 forsoutces.) ‘The bracket for the leveleris installed on the back side ofthe front kickb oard facing strip, seo drawing, Then, cholethroush the pletformallowstheleveriobe adjusted. T 10 Woodsmith No.94] | SHELVES & MOLDING After the cabinet bate wis installed, T sfaited on the shelf system But instead of JOLES. The fist hing to de is dill series ofholes forthe ¥4"-ia, stelf support ins, see Fig. 12 and the dravi a ‘Shop Note: To make aligningthese hoks ee eG “ ‘52 aude while marking an Gillin the toes Fot the mvs ajuabiliy, tex ae 23 pits oP ioles spaced 2" qpat on either: ofthe shel{conrpartment, see Fig. 12. SHELVES, Alter the holes fave been dulled, Tirade ‘our adiutable sheives (9) (You canmrake any mmber) When eating the shelvesto length, cnt them Vis" shorter thanthe width ofthe opening, see Fig. 13 ‘Asfarasthie width Gepth) ofthe siclves, a theanso that wien they're installed they Fit flash (oie frontedge ofthe cabinet after thick edging stip has been attached tothe front, se Fig. 13 and drawing att. After cutting the shelves fo sia, I cat a groan along the sides of each shelfto as Sommodate the shelf pins, ae Fig, Ba SEELREOGING, Next, [ eat an edgin Hae ee Fa aioe he oak des ot a Shell, we Fig. 1 Note: The edi si are "thick and 1” wide. eee ‘Then, rout a decorative profile on the front of each edging stnp, see Fig, 14. (See ‘page! forsoarcesofacomerbeadine bit) ‘Now the edging strips can be aluedto the front of each shel 1en, before installing the shelves, out four ¥4"Jong dowel pins to suppou each shelf, TOP MOLOING To finish offte cabinet T added molding around the top, Like the font kickboard asecby, the molding on {op consis f thee sections. Each has. a ‘backing cleat (U)and atop molding sip (V), see Fis. 15 and I5aThe backing cleats au Bide plywood picecs aut 24" long. ‘The molding sttips are made just like the shelfedging (F) eu eater. The ony difer- ence istheit lengths, euteach ofthe mld- ang pees to ¢rouzl Fensth 24") ‘Next, rout the front face of each stip to thatch the profile ofthe shelf edging, sce Figs. Maand Isa, Nowthe edging stipe canbe aluedto the tacking cleats Then each oversize piece an be mitered to fit around the top ofthe cabinet and sew wed in pce, se Tig 16. Desig Note: Whe attaching the mold- ing, je sioald overhang he front ofthe ca et by 14, see Fig. Also, the outside ends ofthe molding should ajgn with the outside edge ofeach vertical edging stip. ELE GROOVE DETAL, 14) ‘@. CROSS SECTON TopMOLDING —24S}ent LEAT.DOORS & DRAWERS After installing the shelves moved onto the doors, There's one for de eleser compart ‘ment and one for the center unit, see draw- ‘ght Both doors can be cut from one shee! of 8" plywood. Hardwood edying is ack 10 cover the exposed plies DOORS To make the doors, thefirststep iso deter- ‘mine the size ofthe plywood pioses, To do this, measure the length and wath of the ‘openings, Then subwact the thickness of the edging sips cutnex). And, tallow for a Ye gap around the doors, Subract ¥4" from the length and the width In my case. Icut the closet door (W) TW wie and 4794" long, The center door (X) is cut 1274" wide and 68¥6" long. EDGING STRIPS Afler both door panels Ihave been cutio size, the door edging strips can be cut. The edging strips (¥) on the sides ofthe doors are the same width as the edging strips (Z) forthe top and bottom of the doars, see Fig, 17. Butnote tha! the top and bottom stips ae thinner, see Fig. 7a Afterall four edging strips have been cut and glued onto the door, they can be aimed flush, see Edging Plywoodtonp. 20, “Then, [routed a decorative profile on the front of the (thicker) sie strips only, see Fig. 18. Its the same bit used for the shelf edvin and molding strips. referto Fig. Ma INSTALL DOORS. After the doors are com: plete the next sep is to install them, To do this, [ used brass-plated offset hinges, soe Fig. 19. Note: Bach door bas three hinges, and the middle hinge is centered on the length of the door DOOR STOPS. After installing the doors, | madea par of door stops (AA) forthe deor ‘on the centerunit see Fig. 20. These are ust short blocks of wood with a mitercut across ‘ne end fo ft behind the bevel strips The stops also provide 4 mounting sor- face for a pait of magnotie catches. 1 at- tached these next, se Fig. 20a, “Then installed apair ofimagneticcaiches forthe close: doar, see Fiz 21. Since these ‘can mount directly to the eloset side, 0 ops are needed. To complete the inside of the closet, 1 added a pair of closet pole sockets, ee Fig. 21. Anda 114i, dowel forthe closetpole DOORPULIS. The last thing to do to the ‘doors is ddl doorpulls. For these, Ldecided tomakemyown, seeboxonthe facingpage. Thea the pulls can be attached 10 the door, centered on the length, see Fig, 22 Shop Note Dnil the pilot holes the full length ofthe serows to prevent splitting out the dowel handle, soo Fig, 2s, Ys Dowel wath rodover bom exes Porn fat tongs sce Woodsmich. No.94DRAWERS: Afterthe doors are complete, work can be- in onthe drawers. Lbuit three ofthe all the same size, from Y2"thick oak, DRAWER PARTS. When messing forthe raver pars, take into account the length ofthe drawor slides (the ones Tused ae 24" ous), Ako, my deaver stides call for }e" clearance on te sidks of the drawers. ‘Then cut the drawer front’backs (BB) andsides (CO) to finished size, see Fg 23. Forthe drawer bottoms (DD) I used V4!" thiek tempered Masonite, sxe Fig. 2 DEAWBR SLIDES. After the drawers are aad up, the drawerslides can be attached. et sea Bott Sie sentee can ‘Todo tis, [irs indatled the eabinet half SHOP-MADE PULL the sides inthe cabinet, spaced at equal in tervals. Thea 1 attached the drawer half of the hardware in the same position on exch ofthe drawers, FALSE FRONTS, Afterthe drwers were in- dalled, I aut plywoodfalse fronts (EE), see Fig, 24. Theto pisoss ate sized co that alter the cilging is applied thee’s a Yio! zap all around, see Fig. 24a. Cn iy case, the Ese fronts ae all 17is'wide and 61M" long) DRAWERFULLS, After attaching: the false fronts, the next thing to do is to add the drawerpills, see Figs. 25and box atright Finally, the eabinet can be finished, For ‘one option see the box below. a 4 shopmadedoos or drawer pul can be rade in less time than i takes to 29 fo the hardware sore. And they're less ex- pensive, too. The pulls for the Comer Cabinet ae male like the bar for hang~ ing a towel, A length of dowel fis into holes in a pair ofbrickets, The brackets ‘ae cut from an oversize blank with rounded-over ends, sxe belo ‘ROTE: Be Sahel Soe blow i Oa ne BRACKET oy eect Me c (none of ark aes COLOR STAIN ‘Thereareavariety ofwaystofinishaproject as versitile as the Comer Cabinet. For one version of the Cabinet I simply applied a ‘lear ping vans, see main to on pase 6, But forthe other devided 9 adi Some color Paint was out because T didit ~ want to maik the grain inthe oak plywood. So T used a "new type of stain — pastel ‘Wood ctain, ace photo. The brand of stain Tused (Miwa, see page 21) comes in several col Alter some experimenting on pieoes of sap ply- ‘Wood, {decided on lac Sue pase ut thought using aif blue might be too muck. Sol used a lighter color ofthe same stain forvariety. (The color I chose is called Wit ter White.) | applied this tothe molding at the fop of the Cabinet, and aso (0 the ‘oor/ drawer pulls and drawer sides, see photo on the back cover. USNGFASTH STAINS Pastel_st like ordinary svoed sine, excot with difer- ‘ent color pigments. They're applied like stain too simply wipeon wihabrust then ape oftany exces ith 2 ean “Foundthattwo coats ofeach eoboriooks ‘best Then, to protect the surface, T applied ‘woenaisafGeneralFinshes witigvamsh No. 94 ‘Woodsmith BSIOME TIPS FROM OUR SHOP Shop Notes ROUTING THIN STRIPS The Entry Door on page 23 Ins mised panels held in place with narrow strips of molding. Ripping the narrow sri wasnt, ‘a problem, Bue to get the dece- Ialive look I wanted, the sips al ad to be routed. ‘Koating thin stips of wood és vvays tricky on the router ta ble. And the molding sts on the door have tivo edges thet teed to berouted A narrow mb bret along one edge and a round- ‘over along an adjacent ede, soe Deiail in drawing. ‘There ae actually two chal Fenges to routing these. stups. First, because they've thin and Jong, the strips can pull avay fromthe rouiertable fence onlift ‘ffthe table. (Thin stps tend t9 behave like noodles.) ‘The second clllengeis more important routing the stigs ely. ‘The problem is, thin sips of wood aen't mach ofa barrier between your fingers and tho router bit ‘The bet way to rout thin sipsaccurtely and safely is 0 ave complete control overthe workpiece as ws fed across the totter bit. So Tereate a "hinne? that tape the thin stip and holdsit whore f wantit ‘Todothis, Tus ateatherboard conn top fora liold-down. And aa eadge suide to lee the pi from rolling and tight again the fence. Then feedthe pieces: fnga puchstick, see dring, se: For the best control, touted thereundoverafter rout ing te rabbet, Se Detal Fostheiboerd campit inde 97 outed °F pasar Be 4x4 “COLLAR” Im TheLaven Sign oo page 16has aptirof dscontive grooves cut atoand the top of the pests. teed atable sa (0 do tis. But re also cane up with a Way to cal the giboves using @ roe, Te involves. a twopart "cola that dames around 4-484, see ri 434 rheapais 3 Roque, so tho jis has to be built to fi tisity atoand it By making it will (Wo. parte pars (jaws, the Jig can be Toosened forstpring onto 4x ‘Then tightened. wih a pur of ‘wing mus, ee dering NAKING maIIG Thultthejie fiom sone sorbet 6 alone 3, oe drawing, But 0 ft round ax andallbe adjust ak, a fourpns aes ae Tged toe different wid THefore the jaws. are aser ted, a anotch in the tivo wide ed Bees Noe. The nctehes Imuct mitch the diameter ofthe hhauger bots aided next Then, to seca the haes of thejig-aoand a workpiece, Li sfalled apairofhangec bot tha align with the notes cit care lier se drawing Thay, thetwo pars ofeachiav can be glued and screwed to- Sefer to forthe coll USING mali There are only couple thins to legs in mind when usin the ig, Fst, maks il mati othe post we place the jig on the pose and Higily titen the wingnuts. ‘Next, positon the jig_and rouser 0 the router bi aligns ‘withthe pencil mai Now tle swing. auts ean be tightened and the groove can be uted, se fin photo. ‘ANOTHER USE. Iturnsouthe jig ca also be used Forcting. a ‘44 tolenath, Jost clam thejiz position and use it asa pide foryour drcahe saw, soe Hake photo above. Different too} Sune procedure A Ths shop: made collar guides 1 router and helps produce per- fectgpooves around $4 pox A The sanejig ca be wodfor ‘cutting apoit io length. There ‘ut ascot, flat ene. se deen etch for hanger bor 4 Woodsmith, No.94

fered molding stips But get- ting. stall miter joints to fit per- fecily tales cometime, Here are a few tips that make the job ‘uickerand more aovurate EASURE DIRECT, Wh mitergauge 1s drawing below. But the citical ‘atisthe second miter that pre- ‘ces the finished length ofthe molding sp. ‘To mark the finished length [ don't measure the opening. as youtniaht pect Intel ad accurate to place the Stipmntheopeatagant mark die reeily on the sti, see draiving, FRESSHIL insaling the mold- ‘ing stups inthe opening can also bea didlenge. Actually, its the Jast stip thattends bea prob- ‘km — i often has to be jammed into the opening between the bg aljicen! is raging the mi- nds, I insert the last two sips with a "press fi” motion, se secom drawing, This en ies atihtfitwith no damaze. UNDERCUT. The hsstripre- fuses fo fit into the opening, | dort automatically cut ad, [undercut the botiom inside end ofthe stipuse ing a sham chide third drawing, Ths ustally helps the Stipfitin the opening, pa Tenth, stad ip Praet ie550 Measure Direc When fitingncll sivios Prees Fit. he ast stip ofmolding is cut Isalwayw more accurateto take to ft p opioid 4G drectmeasurenstithan ibis a use tape. Undercut. Asivip haifts oo tightmay not a Fe too long, Rether thencut itshortor, frst Instead, inscrtthe lasttwoatthesametine. weachisel o "rdieve” the end offic miter No. 94 Woodsmith 15WOE KEN Dy PROJECT Lawn Sign Address numbers on your house can be dificult to see. Here's a sign that puts them out in the open. Y dont think much aboutthe numbers on your house until people say they’ pot lest trying to find you. The problem i, rbers are usually too small or hidden by an overgrown bush. So f designed a Lawn Sign thatsitsoutin the open, This way, ‘your house number ean be "planted" whers is easier to see, ‘Note: Check that oeal ordinances allow yard signs before be this project The Lawn Sign has arouted sien panel that "floats" between (wo ‘posts and tivo rails, Itistt glued or railed so itean expand or con ‘race with seasonal changes in humidity Butthe best part ofthe Sign are the "raised" numbers. To give them a handcarved look, I used my favorite carving tool —a router. Set up with a core box bit, the router is 2 great tool for ‘quickly carvingawaythebackground ofthe numbers, Anditleaves rough’ background just ike a gouge would. ‘To make the sign arable, {used cedar forall the wood pants, ‘Cedar has relatively staight grain which make it easy fo rout the mbers. Plus, it’s really available and the cost is reasonable POSTS. The first step in building the sign is to make the posts ). To dothis, I cutan 8footlong4y4 in half, producing postsiust under48" jong. The postean be cut to length later. Just make them Jong enough for the spot where the sign will be located. (The bot= tom of our sign inthe photo isabout 8" offthe ground.) EXPLODED VIEW GROOVES. Next, devorative grooves are adde, each pest. The key to making the grooves look alizned all around the Todo this, [clamped a block to the table saw fence. This actsas 2 sop block for aligning the post to the blade befare each cut, see Fig. I. Then clamp the post to the miter gauge to make sure it CROSS SECTION (near the top of isto wet them mn NOTE: ram posts 0 tesredhnginoetre ‘ining Se ma ‘ — as — yt Waster seu = ae , 2 “ tS poe vor MATERIALS WOOD PARTS A Poi) Saale B Rae @) 1Max3-18 © Ggiten 447-18 SuPPLes Ye n6? ag Bats 1G eave 16 Woodsmith No. 94dost move during the ext. (Se Shop Noles onpage 14 for maliemateteebnique and ito cutie sio0ves using arouter) BEVELTHEPOSL After the gfooves have ‘een cut, four bevels are cut across the top of the post, see Fig. 2 These make the top lok like a flat pyramid. Tadd the bevels for two reazons. They sive the posis a ‘shod leok on top, and Felp itched water. Before outing fheberels, measure Yup ftom the fop stoove and mark the location om all four sides The tick to making the pyramid shape 15 to cut all the sides the ‘zum sino. Youll know thatthe bevels have all been cat equal if the pyramid ends up ‘with & sharp point on top. To gat the sharp pitt, you need to pre ‘en thepost fiom moving during exch ent After the post is aligned with the blade, clamp ittothe mitergaigetohold tin plas, see Fig, 2. Then ent the bevel NORTISES, After the posts are beveled, the next siep isto ent a shallow mortise in ‘each post to hold sign panel and rails, 1 use a Forster bitin the dil press f0 f= move most ofthe wate, xe Fig 3, Then ‘square up the sides and ends ofthe mosise ‘wil a chisel. MOUNTINGHCLES. Now, fipiiepostover and. drill two counterbored shank oles through the pos Dril the holes so they are centered on the mortise. These holeswill be ‘used Inter to attach the rails that hold the gn, sce pos deta SORATIVE COVE, Finally, T rented a cove on all four dacs ofthe poss, xe Fiss, Sand Sa. Fist deat ine” aroundthe [post nearthe top. Then use ai%' cove bit 10 Toutthe coves, stopping atthe lie. est WU ee aa =a ‘The scaite agood-lookingLawn Sign: theplacement ofthe numbers. Thewood partsofthe projectean be cut and assem led perfectly. But if the numbers aren't. placed wel, the sign may lok like graft. ‘To enedle the pattern, start by cating couttho nambersyon needfromthelisibe- Jon, (U'you prefer s different lodk, many artSupply Sores and pattern books have sets of mumbers mn othertypetaoes, BASSLINE. When eutting out he mm- ters, be ae to mclude the busling the number ests on, These baselines wal be used to keep the nombers in a straight Tine, What may lookumasual hee, is for henarakersto"appear’ tobe stmightthe bortomsoftheroundednumbersactually sithelowihebuseline, SPACING, Now adjust the spae te= ‘aveeathenuimbersuntlthepattern Looks 1234567890) proportional. Thespacebetcenthemim- fess wont be the same, Thats becanse rounded numbers (the 2, 3, 5, 6,8, 9,and 1) needles spice Fetween them than straight nambers (the 1, 4,and 7). “When the numbers are hid out, ape thamtothe papertskeopthemtromshi= ing. Then ents the pate on aphoto- copier sojhenutibers ares tall Seepase Hloorderafull-sizepatter ofmambers. No. 94 Woodsmith. WSIGN PANEL & RAILS When the pattern is complete, work can be- ‘gin.on the sign panel and supporting ral. SGWIANE, 1 stuted with an oversize blankto make the sgn panel (B) Ifsthree 2et's edgelued together then cut to fin- ‘shed size, exe Fig. 5. ‘The sign panel will move with humidity auges To allow movetnent, Tut grooves ‘on the top and bottom edges to accept the tongues on the rails, Se Fig. 6a, ‘Then I cut tenons on the ends to fit the riortises in the posts, see Fig. 6b, ‘Nest, ct two herfe-across the font ofthe panel, se Fiz. 7a, They'll help to centerthe pattem on the blank. ‘Finally, attach the pattem with spray ad- hesive oF mhber cement, see Fig. 7. Then the sign can be routed. Gee the next page ‘on routing sim.) RAILS. With the pane] compicte, the nex! step isto make the rails (C). The tails sup- ‘port the panel between the posts. Tenons on the ends fitthe mortises and tongues on the ‘edgestitthe grooves. euithe milsto finished size, ce Fig. 8 Then cit the tenons and tongues. Sneak uw on the thickness so the fit sm. Fe nnlly.dpadonblebeve dtiooks ikea stall roo) onthe remainins wide ede ofthe rll TDRCCRATIVEREVELS To nak the son ie stand tt from the rl clan 4 [ixal that "coer" the edges and loops them ftom splintering, soe Fi. 9. TDRY ASSEMBLY Pauly. [vsteulytoas ut its, dy clamp it together to ma the plot hole keaton, ee Fg. 10. Then, bolle sign together and find good spt conyonr lan toplan i a 6 See eta. Atashgator a ion poral wit spiayadnatee secowb: ven though the sign ie made with ‘oatborresistantwood,it ill needstobo proicded fromthe elements ‘To pied the panel and posts, I wed a extetio: Wond stain. In Ty case She ‘win Williams’ Extettor Semi-transparett ‘Slain, Its formated io prevent the nat tal checkingthat ocanrs when woostisex= posed to the sun, and to hejpresistrot and ete eee eae ‘stain with a Tight aray int an applied wo evastotliewood.Thesecond ‘vat i optional — only if there's Tap ‘marks that need t0 be covered, Af the sain has dig I desided to int the sian panel to add a litle accent Enimakeitmorevisible Soluedawhite ‘ctctiorpaitt (you can use latex or of). ‘Bur 1 didnt want to painr the whole ate ve lnsiesa, painted only the, fies of the numbers and borders (see photo at tigh). [left the background ‘arcundthe numbers ry. ‘The easiest way to do that is to use a foam brush Tes stiffer than # bristic bush, 50 it doesn't sag over the sides of the numbers, Use ight touct, and load the brash spanngly to prevent paint runs, 18 ‘Woodsmith No.94WOODWORKING TECHNIQUE A sign with hand-carved mmbers is what I Watied. But I didut want alltbe work Sor tused.a router with a cor box bit. The seoret to making the sin "look" handcarved isthe ronter bit Itinritates the Took of a hand eonge. The bumps and grootes it leaves behind look a lt like the Bind a hand geugo would make, "TRACING NIMEEES, The fst stepto rout- ‘nga sianis gluing apatiem ofthe numbers Hye os Cte ee x satis then wed shay knife to ct the cut: fine ofthe mimber in the, w Fig 1 The knife ev does two things. Ht keeps the ‘wood fromsplintering when routing up next to the pattem lines And it adds better defi- nition tthe outline of the muarber. Finally, afer the outlines have been cat, remove the backsrourd paper fromarouné ‘the numbers, se Fig. 1a SETUP. The nxt sep is to st up the router for making signs T stared with the router bace. The fre thing do is replace the base with an over Size avplic one, we plcto. This lets me 366 the patiern lines betterand the larger Sze sapports the router asthe waste (the back- groand) is "carved" away. ‘Next, Il insal the ronterbit, The size of the bit is important It hat io be stall ‘enongh to itthe cues and comers of the mambo when removing the vaso, (n my ‘ase, Tused a Ylia. core bos bit) ROUTINGTIPS. Probably te mos impor- ‘antthing I did when ican time to routthe Sian, Wes fo take the time to practice on a Iiece pfscrap. I warted to get feel forhow slowly tofeed thebit when coating athe fall. Sig! depth ‘When routing the manbers forthe actual sig, found it helpful to rex my foreanns Gite woikleuc, see Fig. 2 Phisgives you mor control of the router. Not to tention ‘making it easier on your back. ‘And when routiig clos: the pattem Tines, feed the bit slowly to nitble away at the Wood, see Figs. 2a&3 When possible, Tronted around the nurrbersin aclockwise dineotion. That way the bit was lo likely to the ed ly, Por hand-carved" look, its ime pottat to vary the way you remove the trace, Dory to mate all ofthe ars cae pletely sraight. Let the router wandera ti ‘th to make wavy looking bumps and ridges. ‘When tie Sans complete sel sande piper to slgly round the edges of the ee ee ee i hoops heels from sc Ce to 2 i sma oloee! No. 94 Woodsmith. 19WOODWORKING T a HEN ROTH Edging Plywood There’sno tri be Plywood is a great material, If stable [sworit expand and contract), resily avail- able, and relatively inexpensive compared to harckwood. The only drawback 3s the edges aren't very atracive So what Il do mest ofthe time to deal with this problem: is wea piese hardwood fo cover the edges. Thats because I can make the « theres more i ting strips from aI ‘Gencrlly Il follow the same base steps whene\er! attach edging to plywood, Fist, Mfigureoutthe way itl be attached to the plywood. Then I plan the best way to hue andlamp itAndifinally, I deside onthe eas. stway to finish the edging so ifs lush with theplywood, ATTACHING EDGING There are three different methods 1 use for attaching edzing to plywood. Ml rectly t) the plywood, cut a toni my shop. But ny edging dan ‘gre0.e in the pieces, or use s spline to keep the pieses aligned, GLUT ON. By far the si cihod oF installing edn isto glue i jytothe plywood, see Fig. LT autihe ‘oversize so thet it stands a litle proud (about 4" on ether side ofthe ply- wood). This way I can trim the edging lush tothe plywood. But there's ene problem, ‘When the plywood pizess are long, it ean be a challenge to keep tho edging in posi tion, Itwants to ldo and squirm around un til you get the clamps (and quik edging dropsbelow the plyiveod face as the ale ies, you cantrmthe plywood ish around this problem isto pace. (Note Drill holes to preven. pling), TONGUES GROOVE. Arotier way (keep things aligned isto attach the edging with a tong coved sez Fig > Atongue caton the phvon eae isi inte a groove cut in the edging “The length ofthe tongue doesnt have to bo very lone (or the groove very deep) to Koop things alzned. But here asain, the cilzing sheuld stand proud othe plyvtood k to attaching hardwood edging to plywood. But there are some asic techniques you can use to get better results and make the job easier. so the edges can be trimmed flush. Ee GOVE. Somcines HL ie 9 mpieloatdiedgninens tp} Groves 2Gitntle pond and ody Thea z nis ts dificult cx tiger lft i Gabe Saw. Eqpcully vier vows Sit ae a per slot cutter in my router to cut the grooves. The Hua at Was bes fr Ss Pecieteet emu cay ese ete oe lend erecta ieee ae eae Leann NOTE: Ege sca Be tinmes kin Begs Glua The quicastend cat etnay Cut groove to ft toigear yo ae Sas Tongue & Groove A tongue on the ply wood mates with a groove in the Ree lng ples ofeing Use our and eet tera, gocreinphweod Spline & Groove. fen TI me a spline Clee eee ites ere cindplpweod egal vil each ote ‘Woodsmith No. 94GLUING & CLAMPING ‘The seeietto doing ez00d jobofedginaply- ‘woodistoapply even clamping pressure (0 the pleas. Keeping even pressure elimi- nates the gaps that crop up while the ghue ‘dies, Here ar afew tipsl'vefound hebbfal GLUING When sluing ging on piy= ‘xood,nseyellow give. Tthasashorter wor Jimie,s0 itsetoup quickly and keeps the ‘edging from aiding around Talso use asinall bush fo spread the ghae oabotitheplywoodandiheetging. helps to getauniform coatfor good adhesion, But {dontuseafoambrush—italways sagson the plywood edzes. Instead, [use an inex pensive hristle brush, It eames a lst of lne ‘and spreads itevonly. And ifs reusable after its insed outwith water ‘Usually [lappy two coats of lt to the plywood else. Tie end grain of the py= fd absorbs ele ikea sponge. lle the ist coat sock in andMiien quickly come back with another light soa ‘CLAMPING After the she capped, dhe ‘edging got clarmpodinplaco. Clamping isa numbers game. The rove clamps you can ‘az, the ese cence for gaps, Ideally, TH put a clinp eveng fourto six inches. Unforu Tata, that would take alot of clamps for some of our lager projests. Batthere are othersvavs to chm edging ‘without having a wall fill of days. One rrothod ses « board with « sight bow across the length, se Pig. 4. By clamping ‘each end, the Loard applies pressure to the ‘edging Located bet ween the lamps. Another method usss 4 beard and 5, sev Fig, 5. Wedues are pushed un derthe board to apply pressure to the: ing. It good way topatpresste ona stub thorn area that you can/tget to tick, Bat whet ifyoar clarpe are too chor? This is often the ease when gluing edging to the (op or boom ofaloag panel. In that situation there's ancther litle tick: ile to clamp a short board across the swidih ofthe panel, see Fig. 6.This ats like an anchor so can use shorter carps and ‘ill get good reauls, f sgatohonget Se Convex Bourd. A convex boowd applies clanpingpressurcabngihefitllenghoftie edgniguidhjusthwoclamps, FINISHING UP ‘The Ind step to finishing off the eding is totrimit Tush with theface ofthe plywoed. This is the point whon the edging stats to ‘blend with the plywood. FLOCK tame, IP there's only a sll amount ofedging hat needs to be trimmed, Tilsautby using ablock plane, see Fig. 7.1t ‘empves most ofthe wood to get the edving closetotheplywood Note:I find ithetpsto jhold theplane at an angle as you make your Double Wedges. Two wedges wed ingetior exertequalpressurconiteelging, Use exira airs at stbborn spots so egnigwillstck ‘eit. Thisprodaces a nt with a slicing action ‘and seduces the chanes of trout SCRAPER. To set he edging flush with the plywood, sometimes ifs just as fast to luce a cabinet sotaper, [use just the eid of the serapet and push oF pll it along the ‘edge, sce Fig. 8. Try to keep the scraper level so-vou don't gcage the plywood. FIUSHTRIV BT. If there's lot oPedeing totrim, the quickest way is to use o roster Clamp Anchor. iow: Tongest lamps are 0 short clanp a board ie plywood is.an ‘anchor id use shorier clamps. andfiu trimbit, ce ig, 9. The flushtrim Dit leaves a nice clean edge. But the only problem is trying to keep the router from tipping. A simple solation isto clam awide ‘board (o the plywood for more suppor. Note: Refer topage 30for areader} abo trims edging flush Finally, lightly sand the edging to dean ‘up any mais and fo rake sure the edging i flash over ite entte length, SP peisscasonais | Block Plane. To te'ppreventtearowt.hld the Bloskplane atanangle make ashoar- Ing cut along the edeing, Scraper. To keep the soraper fro Boizine thephwooduseyeurindexfingaras guide. dvd hold evel to heap the caging spuare Lal Flush Trin Bit. Tuequickest way to trim allotofedging lenithafhush trim bit. Clamp board w one sidafor mere raster support. No. 94 ‘Wooxlsmith aCOMMENTS AND QUESTIONS Talking Shop ZERO-CLEARANCE + Azero-clesrance inset in the iablo avy prevents marrow or thin workpieces fiom tipping info theblade opening. Andfor mostcatsissaertouse ard pro- doves clearer cuts with ss chipoutthan the "actors" insert "Buta zero-clearance insert car. clo prevent the sav blade from being tiled very fat, soo Deail a. Because the opening fas "aro clearance’ on citer Side of the blade, it will tind agaist a blade tha’ ted, Tf you try to tum on a tbe say ‘with the blade bind agent the insert, you cca cause damageto the inset, tho lade, or youself. ve sce a INSERTS saw bladobent thisway) UNDERCUT, There is away to, snodily a shop made zeroclear ange inset to allow the blade 10 tilt Iesby"eheving” thebottom of the cpening, see Detail b. To 4o this, run tho insont over aV- ‘groove bitin the router tab ‘This will alow he bladeto tik (slightly). But to tlt the blade more tan aboat 20°, the inset should be replaced with one tha Tas awider opening. ‘Note: Wherever 1 changeblas, insu, othe saw blate ange, T make 2 point of checking that the blade spans freely beforeturningon the saw. ee aor PLASTIC RESIN GLUE + When bling the Pry Door capoge 2 deed ou plate Shoforthcjomts, spe ee ae eee ee ecu Fir fshighlyvateresis tant The Doorean gt rac on removed on, 20 through san mes and weeny ands fhe oe wil old. Tideena rence eee dee Tatdwae sis, Thaws abou the. cane as yelow Wood Wore. gorse fo mien se Sones Senatl under wed stations pte ly eg tha ee ty Gus diferat fom alow fe, Htc ain ghas come fe ee mined with eterbefore sing Tole: When exed othe oo roo eosistengy the shi sould fe tke a bea fost, se Hoe a0 aoe See ee on i eee ‘speoi will also work) to get the > comect amoun's of powder and ‘waler. And ascrap sick of wood to sir it all toget quan. Too of ifs ‘guessing game tying to et ate the amount of give that should be mixed up for any pro- Jeo So, tobe on the safe side, 1 alia) is tnote Hn Mink teed. This way, I Won" mun out ofsloe afterthe thitd enon on a foorenon ascenbly, ‘Note’ Thought 16 ounces of ‘Weldwood brand plastic resin lus, bat eight ounces would lave been enough forthe Door, eA aS WORKING TIME Becanse the iixture begin: fo set up fast (from five to fificen minutes), tlhe glue must be applied ee ne Sick (0 spread ‘eelly ‘on the workpiece, And to allo the sive to dry completey, is a good idea to ‘eave the assersbly clamped for at lead twelve hours. Finally, be sure to dean up any squeeze-out tigi away with “About ihe tine the Entry Door ‘yasnearingcomolion etd ‘Tl op even after beng in \watefothoue Stongerthan thewoedtcell Sandsandcrapes ‘asily. Nomixingtequired” It sounded to good to be tmue. So sent away for sam- ale se paoate le availble, see phctoat ee both Bxcel and GovillaGhie) ‘Tetame out this new hbo — are tall. Wo in have been using it for yeas. ea ~ eee oie eae ina anngp siueezeour ‘wasn'ta problem, ‘oew" products, the cost is ‘high. Bui formy next catdoor project MM be sure t keep polyurethane ghein mind, a wet mg. Be- ‘cue ifs plastic, the stuffean be areal painto scrape orsand later ‘en. Any residue will pel a coat of finish ike a vinyl eancoat, surethanteglne—isninew T decided to do some tet- Unfortuately, ike many’PRATURE PROJECT Raised Panel — Entry Door — A well-designed door has a strong frame and panels thatjit as tight i nter as they do in summer *e Wanted tobuild an entry dace foralong ime — ahont jakt years. Thats how long ifs been sinee we renovated the carias tuilding, During this tenovation, I aot to watch Ken Munkel build and inal seven slid ck dors cole hips realy in pressed me about Ken's work, He bint cistom doors th old fashioned way using simple, stiongjoinery. And le could do itwithoutalot offincy (ie, expensive) woodworking took. Basically, jnsta fable ay, renter, and dill pes. Tyiass0 impresed by Ken’ oraftsmmanshipthat! Hired him should fit tight in the to design projec for Woodemitl Of course, I also wanted kimto showmehowtobuildadoct Bulsomehow,we'veboh The problem is panels eapand and stayed too busy to find the tine. shrink from season t0 season. Reveatly, there's been another "home inprovement pro- _Withtraditional ised panels, dry winter airwill case the je” noing on around here — we've been adding ono our panel to shrink. This can lonsen the seal between the panel office hnilding. Oneprojest scheduled wasantpdaiedeatry andthe frame-and lt cold air nf the house ‘way. AndT got othinking it would be ageod time to design With this doar, we paid special attention to the panels. ‘They\ve been desianed 20 they can ex ed enity door nt have a strong ou! affecting the sel, eferto pu pe. But many doors these days get their sitength fiom 10\ any harverto take Infact, this dooriscasetto assem dowels oreven lig bolts. Instead, this dcorisbuilt with large than a more traditional frame and pane! door mortises and tenoss, se left photo below. This traditional INSTALLING THE DOCR. Even when the door is complete, {int doesnt need dowels. Its already plenty strona yore still not done-with the proc. The door also needs to ANUS. There's another important design consideration. be hung in place, To hep with his, weve incuded an article A door ako has fo proted apzins the weather The panels to show you how, refer'o page 28 Frame. While many doors usejoineny that Panels, fer thfiame tus been glued wp, mast be reinforced with dowels, atrame on the panels are secured with strips ofmola- this deor is joined with simple ing, And snllte traditional panels, these ‘mortise and tenon. ‘panels will ip a tht seal, Installation. The lis sich instatationis te easiest — adting the tance and dead oli, ut bejere this can happen, the door has ole rinmed ostze auihunziaplace, No.94DESIGNING THE DOOR afew Bull aid garel door shoulda. Fy b ig. IS the sume joinery used | V | to build an inset cabinet door — only ona larger scale. And I found that designing an ents dexter. ou low Sew niles 2 F = CONBCNENTS Basal, ll Fame and panel entry doors have th sane corn ponents, Thats an outer frame with top {nl bottom rls and vertical sles, see Fig 1. Adaninefainethatincliatesteinnet rails afd verucal mullons, These frames hold the panels n plac OUTERTRANE The design forthe outer frame savspretty mushthe same rom doce to door These peces are wider than the n- net flame pieces to give the doce strength fd naidiy. We alen bas to accomnpecats Tuudare svclas ic handleset and igen INNERFRAME, Dut ile the cutee suays he same, the inter fame ds more flexible, The number and size of panels can change, And there area number Df window eptons too, se¢ box below - DESIGN DETAILS. Fer ths Entty Door we arte by Sting ihe ype of Wood Ma: Hogany, redwood, orponderosa pine reall dood choices Bute desided on White cok Hissvongand stands up wellto the weather, Anolter design dea we Watitel ink | BOTTOM AAI clude was @ small window. Its simply larger version of peep hole, Adin # win dow meant the door would lave tee pa als across the width, (We wanted the Wine bye F 4 Sone wig ees ee dau Pee eal dow centered) This aetully worked to our sdvantage. Narrow panels expand and con- the bottom As for the widih, [built tright tract ess dhan wider panels, 136). You want to avoid trinsming the lang DOOR SZE. Since adoorhasto fititsopen- edges ofthe door ifyau ean help & s ilkjustany size, Ourdeor _ MINORCIANGES. [fy our open But lke any inset door, this door starts changes. Measure the opening and simply out alittle oversize. !added 1” tothe length add any extra width or length to the outer ofthe door with mostofthe "extr" being at frame. (But f your opening is smaller, be ‘The look of a frame and panel door is easy to change. Just rearrange the inside pieces (the innerrails, mullions, and pane's), The oor wil sll be strong because the outer frame provides most ofthe strength. Glassallows a number of design options. A big panel can“open up” the look ofa door (Example A). Smaller ones just let in light (8). But ifyou want the most security and ee) eee ay ental Cee Dy Anptier thing to considers the position of the innor rail, When it lines up with the Tockset or handles, ifs called alockrail (A, B, and C), This is mostly vistal. Inthe lock il were close to the lockset butnot aligned itwould look out of place ‘careful about making the frame smaller, es- pecially the siles, soe Guidelines in Fig 1). MAJOR CHANGES. I? your opening wont | hold a 36" 2 80" doce, youl need 10 make J 30" x 80" to fita standard opening. standard door, theremaystill bea fewminor some more changes. Sart with the overall dimensions and work ftom there, Just keep ‘within the guidelines show in Fig. 1, and ‘you shoulda'thave any problems, 4 WoodsmithDOOR FRAME ‘Wilt typical ratte and pabedjoinery, fue holis tle panele i g1boves, Ts ‘means thal all he pretes have to be assem bled at thesame tine, Wetooka different approach, The fame canbe built and assernbled before making the panels. So yon doa't have to mess with the panelsiwhen sluinaup the frame. MORMSEATENON. To hold the door ‘frame (ogethet, we decided to rely en com- Thom mottiseandienon{oins, eer 2.10S all prety straightforward — exceot for the bottom ial. thas double tenons. BOTTOM RAIL Thebottomralismafeex- trawiteto add strength and rigidity to the frame, see Fig. 2d Joining thebottom railto the stiles would require wide mortises (and tenons). But with mottises this wile, the Siles are (00 weak aid tem 1 bow out So ‘when dilling the motises in each stile, 1 dalled double mentises insead, se Fiz. 3. DEEP MCRTISS Like, eversthing eke with thisdoor, the moitise and tenons come in lage sives_In fact the trowises in the ailes eH" wide and 314" deep. ‘Note: Dailling the mottises in the door fame requires an exttelong Forstnes bit, seepaze 3 frst. (A ang brad pot also won ROUNDED TENONS. Usually after dean- ing the mortises, T sare the ends with a chisel. But squaringend arsinon deep mor- tises isnt eacy, expecially with white oak And doingeishteenwould have boon teal chow, So instead, Trounded the tenoasto fi the monies, se detailsin Fig, 2. While tounding the tenons is. easier, there are sill got of them to do, This 18 ‘Deetty slow soing with a file 0 ris, So 1 ame up with ashortcat onthe routertahe, see pa 15. DSIELY When asambling te fiom, ifs 20! to end up bath square aed flat Th seit nich Gaser ithe suace youre ‘yorkingon isflatioo.1used'ancdsolidcore door, buta shet ofpiywood wil aso work. TWO STAGES. Thisfoorfimeislange and heavy, and thew ae aletofointe to AtTo- ‘ether, So I assembled itn two stages Fig] gis fhs vale and pliers pad clanped them ogetiea soe Fig 4. (used pase man glue, refer (o pase 22) 1 hanged these frame pices it setions be {eae | didnt have clamps longenongh But Twas concerned that the tenons tight not line up with the mortises inthe stiles So to avoid this, T added the sties "dy" to the fit aosombsy to hold the als inplaco, sco Fig 4 When the fist assembly was diy, = moved the stiles, adel glie, and clamped the stiles back in pl Dil a ios We deoper tia length tena Nore: (22 701 gh S35) am tt Fo No. 94 Woodsmnich.PANEL ASSEMBLY ‘While te frame is drying, workcan begin, con the panels. These panels were our big- scsi design challenge. The trick was to get thejointhetween eachframeznd panel tight ‘encugh to keep out coli air and moieture. But nottoo tight — the wood aill as to be able to expand and contract ‘With frarre and paveljoinery, the panels Sit in grooves in the frame, They “float” in these grooves so the wood can expand and contractwith changes in humidity. Unfortu nately, 2 the wood moves, the fit the panel and the frame can widen row, ove near box atright PANELS, Instead of a beveled border aronnd each panel, this Eniry Door hs raised panels with flat borers, see far box at tight, This ‘vay, the panels can fit tight agains the molding and sill he fight as the wool ex ands and contract ACKTORACK There's ancther differ ‘ence. Most raed parels ate made from a singlepiece cf wood ora glies-up panel. But ‘we made our panels out of two pieoss in ead ofjust one, Let me e«piin. Rather than a L¥sMhiek parel two Ye! panels are st backsto-back. This allows the anels to move independent of each ether ‘The outside panel can expand or contrat at a different rte than the inside one. “TWO SETS OFPANELS. What you end up making are two ses of identical panels. So instead of eight panels to build, there ane sixteen, (There are actually nine panel ‘openings, bot I puta piece of elas in the ‘enet opening, eee bax on page 27) NAKINGTHEPANELS, A mised panelwith alt borders simple to make. Fist ct the panel blanksto fie epenings inthe Fearne see Fig. 5.T mademine M6" shorter and Yat ‘aiower to allow for expansion and con- traction, se Fig, Sa The next step is to ait the flat border around one side ef each panel. To-do this, I tused « dado blade and out the bordcr in a serissofpasses, see Fiz. 6, A When a door is irst built ¢ beveled panel may fit tight in the frane. But as ‘the panetshitnks, agap can develop. ee era eee Heal sh A The panels on this door aren't bevelod tall, Sone matte: howmuch the panels Slriak, the seal will still be tight Finally: chamfer the shoulders of the raised fied on exch pane), ae Bg. 7 MOLDING To hold the panels in place, Tused sal sigs of molding oneach Side ofthe back- to-ack panels, Et the inside and outside taps are applied differently. The inside is ‘led and naled to the ftame. Bur the out Sileisjnst mailed DRAINACESOLUTIONS IFWe would have shied borh stips, any moisture that scoped ‘behind the sips would have beentrapped ean seep into the groove. And once it Sete ete owe provide a way forit to drain cut Co ee Fist, the etrips are catto size, Then a shaul-ovis adeeove eto hehe joint ine between the frame and the molding stiips) The last step is to round over the tS Site Sethe mal jte: Siivethe molding strips are only Vi"x 54 theres not much wood to hold on to, To keep my fingsts sa, I used sone speed stups ven Working withthe ing Stps, se page 14, Shop Tip: the tast thing you wantto hap- pen i$ £0 come up short on molding. So make plenty of ex, When insalling the Stipe, stat with the longest panel opening. | wie ents er gue anda ncn hing (0 ane Ifapiece ends up too short, you can use it inasmalieropening ater. ‘Now the panels and molding sips are ready to be set in the frame. Each piece is attached a particular way depending on whether ifs on the inside or the outside. Start with the inside ofthe door facing wp. INSIDEMOLDING. The inside moking installed Mint. The molding sips axe ink tered at exch end, and getting them to fit tight can betricky. Fortips on mitering thin strips, sce pase 15, iT aed and mild the inside stips in plae, se Fig. §.Te do this, [sed Franke ins Titebond If Ife act completely water proof like plasie resin, but if water 10 fant and much easierto use Also fo spliting the sips when naifing then Bos, a god de to pred th les forthe brads. “The challenge here is getting the stips flush with the inside face ofthe frame. My solation vins to set them on spacer blocks, ee Fig. $b. (Inst bo mir you dont alu of rail the stips to the spacer blocks.) PANELS Onve the inside suips ate come sete, the panels can be installed, see Fig. 9. Fant fo cee «pond sel between the ‘inside and ontside ofthe door. But the pan- els sil cede to be able to move. ‘aside panels n place These pecs: are not alied. Thee jst Tocwaeaflesiblezei,{ wedsilisonized Now, taskeseh panel inplace the cen- nailedinplace. This), waercan aint aonjlic caulk. But a bead of cailk need: ter, soo. 9. Do this atths top and bottom underneath the molding. a For the glass panel inthe door, Fused an in sulated pane to prevent beat foss. An insu Jated pane is simply tivo pleaes of giass that sandwich an alummurn channel, see draw- ing. This type of pane masi he pecial or dered at 2 local ghas store are geldor ‘Note: Since insulated pars ‘square and cant be ext, Tonfesed my pane ‘smaller than the opening in the fraine, ‘This insures the glass Will fit ‘The aks pane | ordered was made of safety alas, Instead of breaking into large, Jagged pieces, it shatters into small, harm inside elge of the insite panel, = Fig. 9, Net lpped he dor over and fanaa Ikalongthe inside comer ofthe mod- ing stup, se Fig. 9. Then] setthe inside and fess pieors, (Code restictions require sifet) glass for any entry door.) ‘The lass panel is installed pretty much Tike the wood pane’s. There are only cou. little cushioning, And icant be just nailed inplase.So to po- sition the panel, | surrounded it with some Stall rubber sjaces. (Tbought thei when ‘erdering the gass) ‘Als0, 10 create a 2ood seal, | applied the Sliconized acpvTic caulk fo both the inside and the outside of the glass, sce drawing only. This kocpsthe panels center but stil ddlows them io expand and contract atthe sis. (Be sure fo prediil fhe holes) ‘OUTSIDEMGLDING. Ihelststepistonsil the outside molding in place, se Fig. 10. Aine Spacer ifene ‘4 ar No. 94 ‘Woodsmith. SERRE ERREC AN TOU RK — Installing an Entry Door ‘When inating any inst cabinet door, the seal isto end up with a consistent gap be= tween the door and the cabinet An entry goris the same, But an entry door suite abitlawger and the opening ititsin is tobe ontofsquare To. make the job more manageable, T break it into three ces. First, I trim the door to fit the opening, Then I mount the Ikinges and hans the door, Andfinally Tadd the handle and Tock FITTING THEDOOR There's more than. one way to fit a doorto its opening, Ifan old doors being replaced, then use it ar a termplate, cee box on next ‘page. I thew isnt a doorto copy, thea work from the existing jamb, see Fg 1. The Jambisthe wooden frame aronndthe door) ether Way the goal sto find out where the doorneeds tobe trinamed READING THRJANB To fi needs fo be trimmed from the docr, yon. need to "tead thejamb," see Fig, 1. This in- ‘elves a couple thins, Measuring the width and height of the opening. at sever loea- tions. And cheeking to see just how plumb ‘and sqtare the jamb really's (or isnt). SELLING MEGAP, Wah histfomtion, the doorcan be ext to fit hejanmb, But yout dont want an exact fit, On the top, bottom, and bande side, I shootfor about an ¥4"zap. But the Side with the hinges sa little different I think hinges look best ithey're mortised flash, SoT holdthe aves ‘of the hinge parallel and ease the gap betiveen them, referto Fi. 5a, This gap becomes the gap on the hinge side ofthe door, CULENGTO WIDTH. Whealaying ofthe door, L work on the width fist. [builttie doorto thecor- rest width, so there shouldnt be mach to trim off Gan). BEVELING THEEDGE, Butevenifiie door js the posfect width, IM still cat abovel on the handic edge, se Tigs 2 and. Without abeve, the oualde comer ofthe doorwill ib agus the jamb as elses. Buta 9-7" bevel allowsinst enonsh slearince And the a at the fuside- comers still only an V4. Note: Ifyon find the door need: a lot of ‘material trimmed ofPis width, remove an ‘equcl amount from both sides. Thi will fy the es even, cle are several ways fo tim a door, A saa willttim anf bevel the Jong edge cleanly bat requires a shagp blade and some fad work. A cieular saw and 2 Sight cedzc-willalsowork, see Fis 4.To seta rela fively cle cut, nse a sharp, thin kerb. "TRIMMING ue TOR. When the dh bs been established, shock the top edue.Ithe jamb ion oquar, tim the doorjast encugh So il match the jamb, Otlenwise, leave it alone, (Wien crosscutting, scare the eat fis to redice chipout) Remember, the goal is.a consistent a all aroand the doc, CUTTINGTO TENGE Now that three of the sidesfitthe opening, the lad step (0 cermsscut the door to length. I do this atthe bottom, where 1"bultin’ an extra ‘Note! I bevel the hovomedge ofthe door juste the handle else, ae Tig 3, Abevel helps the bottom fit ‘tight against the ‘weathersipping, while Keeping the 44" ap onthe inside Tac, z Tine: Tain top stDocr Raa SECOND: Thin ag axe! 28 Woodsmith. No.94MOUNTING THE HINGES ‘Afterthe door is triramied to fit the opening, ifs tine Wadd the hinges. I mount tiem (0 the door fis, then work on the jamb. Doorhinges are located 5-7" rom the top and 7-11" stom the bottom, see Fig. 5. The middie hinge is centered between them. ‘Toholda doorthishesvy, lused 4x4 ball tearing hinges, The ball bearings allow the door © open and close smoothly. POSMMONINGTHEHINGES, Set the binge ‘en the door so the leafs set back % from the outside fave, see Fig, Sa. Trace around the hinge, Then rout out the mortise and ‘Suite up the comers with a chisel ‘To orale the hinges on the jamb. you ‘eouldjust measure them out Butto be sate, ‘et the door in place and shitn the top and bottom to create an i6'gap, see Fig 6 Then transfer the position of te monises to the jamb, and rout and squave the meetises, All thats left is 1 mount the hinges and hang the door, But it’s important to get the hoves for the hinges perfectly centered. To do this, Vused a Vie Bit see ADDING THEHANDLESET The last sep is to mount the hancleset This involves cling holes for the evlinders and atches. And cutting shallow mortses for the plates. Note: You may need to pirchase some special hole saws, se page 3 Follow the insinictions and use the tr ples that come with the handleset, But don'etry w dill the holes for the lack and dead bolteylinders al the way through the door, see Fig. 8 — at eas! notin one pass When the mandrel bit cuts through, stop and finish the hole rem the other side. This ‘way you won't tear out either face Also, mount the latch and dead bolt first A’ Our handlaset inelided a handle latch ‘and use them to position the stike plate and dead holt Installation involved drill: mortises in the jamb, se Fig 9 Ding holes ard cutting sallow mortises. ‘GHOSS SECTON so} motes SaTE EH) coer peng ‘ojamb fo. CROSS SECTION orvenp Mangelbt REPLACING AN OLD DOOR The eases way t fita door to iis jamb 1s 0 use the existing oor. The old door serves as & template to mark the new one, But before you remove the ‘ld door, take Agond lookathow it fits, Is it rubbing against the jamb 3 s on the door when miming the new de Size 10 the new door, maki Now set the olf door on the new one, Transfer the overall any adjustments you noted Also match the bevels on the side and hortom ofthe door. You can aso use the oid dloor to mark the position of the hinges, But the handle, dead tol, and latch plates should be marked trom. the ‘amb afte the door is hung, Sop ol new ocor snaceoestorpe No. 94 Woodsmith 29READER § JIG | Flush TrimJig Here's ajig that you can use to trim plywood edging perfectly flush every time. ingflushonplywood 1 make adjastmenislateron flush timbit Butifs | cut both pars ofths guide (B and C) eady asyeu from the sameboard. Butone pies shorter than the otber. WI gether, i forms a “step” for bit clearance, potcaretul, the bit might gous Next, | cut the handle from 34 thick We had a ot of edging that nec stock and screwed ito the guide support, immed flush on our Cornet Cabinet (see see Fig. 1b. 6), That$ why we ot excited when we ASSEMBLY. When assembling thei the ‘eived thisjig desgn from Steven Wocd importantthing isto align theguide with the ‘of Cheshire, Connecticut Tt lets you Thatway the guide sin ‘quick’y rin the eds tthe sametimethe bitis A The handle on the jig holds the router The reason | liked Steve's design is bo- trimming the edging Mush steady while trimming. the edging flush ses a Vertcal guide thai mounts First align the guide withthe bearing as along the lengthofthe plywood. Fowler, so phe, The sk y as pessible and draw a line 19 mark es the router and Keeps the bit perpen Figs 2 und 2a. Then n= FEATURE YOUR JG ] cular b the edging athe sane tine Be a issinple An ethejig hastobe turned over be. | jj20Uve buch origi igand w aus ee (A) eas your ror yoyo scev edb | 18s Sued fase. Atached to this is the vertical guide sided earettapetokeep the eden place. | 224, sees (yandguide suppor (©) wihhabandle wetip A Thenattich hepuideto theless | ?200Grand Ave, Des Moines 1AS015 Daualtornppore sete 1 Meet ce re if we publish well end ou SIO) used my enstng outer Rass as a nents (0 the jig are neoded, | 214 aul ee plate formarking the mounting holes onthe loosen the mounting serav= that hold on es ae ees iene osobane Ityoutve built an or . $300) Include orliee Dellead exteneers Ce eee iots ee ; : ile a hile overiza se Fg. 1a This way sized ols until he lsh im bk cus the | SXPlamnowstsused Andpleaseinclude youn shiftherouronticigifyosrecd edgingmshvith thephywoad. a [*etymephorenumber, | fal Se ie] |] 2 a) iil ovenied holes in — ‘Base for acumen |, Usesquace — Jo sign bring ‘Hn gh wth AES cp oF Guia Support aa Aaa 3M 4 eae sa = s = ceee sey / 2. arta” )| |e pon Coblaes eon see, RS 30, Woodsmith No. 94| | PROJECT SUPPLIES Sources local paint and hardware stores. inclades the handle and dead Plastic Resin gle, such as | Pe, ssn at el ft bon ee Acompletshardwarekitforthe finished with two coats of Gen are availbleat home centers or is inexpensive — about $8 for ‘Comet Cabinet, shown on page zal Finishes! Royal Finish. This local locksmith ib, of powder. And i's com- 8 vue from oodsniti vipngvamneh savalaleftom CLASS If youinciu ashy monly avalable m hardware FrojectSupplies Tiskthasal ith Proect Supplies panel in you Door, twill need stores and home centers. roolerensyouTine/pins andthe soaes ization" toe sty alae te ge 7 Thew are so pelynetimne Sete Wo4-4003-602 Royal Finish (Ourpanel was ako insulated.) ghies curently avaiable: Excel pe) Le ‘Top Coat Gatin)...§11.66 quart Ttcan be ordered through a o- and Gorilla Give. Thoy/r a bit cd glas sor, And while more expensive than plastic 1G Bait Fuk etesion LAWN 0M finite pidkupsoneray rein Bas Siegert 4c, Biers 1p crete a pattem for outing ber blocks fr setiig the sls Gori Glve 5199 for 1 ce. : Magnetic Catches the mumbers forthe Lawn Sigh, inthe door frame. ‘Both are avalahlethrongh mail i ‘AdjistableLegLeveler you can enlarge the numbers FINISH.There are a mamber order sources, sxe below. YieDia OakDowel with aphoiocopierto 44a. swe of fishes to apply to an entry ) utd. Sa Dove Be TH-Oryon can orderfull- door. A door that wil be pro- YytDia. OakDovrel terns avalable from texted by aporch or awning ean HINGE BIS 32) Clot Pole Sockets sib Projet Supplies. get by with a water ral. | When elias pilothaesfor 84-100 Comer Wous00 3595 Law neservative, This finish | hiiges, is easy to dil them (Cabinet Hardware Kit... $8995 Patteras.. tio Tookt “natural” and fs easy to | off-center Thiscantowthe ‘Note: Most of the fiatdware ‘Note: I apply_and maintain. We hinge outofalienment when | lied abete see ape eee ete eiiien oe Guy Doe el / fromthe mal ordersenmesbe- routing the numbers, sce coats of General Fishes! Out- at ing theComer Cabinet Tow The adusabe eg leider sures below dor One sames low. | and ae Futy Deo svcd and closet po are va oor te direct sun | thie fxbitsio auto- @ rie as ee } haniware stores ‘Tobuildthe EnyDoon shown Here you have to nike a dec | hokestor he door ROUIER sm To shape the on page 23, youll med soe Sionbetweenpaintandsgarvar | Vix bits are available edging onthe Comer Cabin, sper oo} an hardyare, mB. alas onge.Sparvar_| doug ue fey lo Me used a comer beading bit, — TOOLS. Todailth:deepmor- nish looks better, but it also | der sources, sxe box ‘This router bit isn't as common tives, you'll need a long Font- needs to te recoated or refin- | Woodsmith Project ce Haters bait malate ner bt, se oumes ele. (Aish mee often ete rangh the mail onder sources int bit wil also work ¥ ficbite. One for Nos: Titedbelow ‘Als, oat handleats wil ee WATERPROOF GLUES. | SS ondscrows Another for FINISH Webuiltwwoverions quire 14". and 21¢%dia. Anentry doorrequiresa strong, | Nos. 8,9, and 10saews, attic Come: Cabin secpage link avs, Thos ae avalable waerprofsine Onpare20,ve | Wf 808 SOSNos 5 1B. One Wis let unstained: The at local hardware stows. about a couple different | and 6-Vix Bit... $895 ther Was staned with Min- HARDWARE To sill the types of gues plastic sin alae | W94-1505-500Nos, 8.9, Was Sie Blue and Winer oot versed faltering ada nev bred ofahes male | and 10Vs Bi... 5998 White Pastel stains, available at hinges. Our handleset, which frompolyurethane. WOODSMITH PROJECT SUPPLIES MAIL ORDER SOURCES ORDEREYMAIL ORDER BYPHONE | _ Sim hurware we spptes may befoun ti ejolowing te es bl st Rafat sions orl ee Hae cal eek aap aa ea ree | mh hat eornes wit order line. Open Monday | AnBstCon, Trgdlaas The Moher | ‘caunent issue, The oder form throughFriday, 7AM(o7PM| 222°" Ra OE | includes infortation on ses Central Time. petal wae oe a Vr | tax a wel as sipping and efor cling, plese ave| tae REL lida ‘handling. ceges. a VISA, MasterCard, ot ae eecbis——LongRominerdit 7 mere iene ee ia onlerfarm isnot scover Cant ready. oie. Make Wena Sent aval ae Bora esos ke er at the right for 1-800-444-7527 es a s Hote Bay ai Geometry more information on specific > nla Gowp nebo ) | shares and aay plicable Note Pricessubjectio Ora | | salestax. change der Ociober, 1994 l No. 94 Woodsmith 31 enFinal Details Lawn Sign Corner Cabinet A Unique design ana some simple weet That's all jt takes to tare c Tunber into a distincive Lawn Sign, See page 16. | Raised Panel Entry Door ais apraoheal project wih a wilque dosign seepage 6. ‘Several compartments ifr solutions ‘o a variety ofstoraze preblans. ‘32 weshow low to build a custom A Cankrasiing cobvrsofsiai re A Shop-made drawer pulls are door tn a home workshop. few wols and ate. an Intenesting eck. Witheatt easy to nate ana theyvearcattroc- Some basic tesirlques ar? all thats rested. hiding the grain ofthe wood, te way In eomiplet he Cabinet, 2 Woodsmich No.94Sneak Preview [Mere Agesttie a increments of Ys” for fect fittingjoints ; We're offering you a special early opportunity tp order our all-new Box mint Jig to be featured in the fall Woodanaith Shop Catalog. As 2 part ofthis special offer we forward your ‘odor 0 you right away. Chances are you'll have yours in tho shop before Anyone else even sees it With an adjustable key slot and © feplaceable backing stipthis isthe fi Tost sosurate way 10 create bot joins. The Box ointhig atacte étoyour miter gage makes it folroo! to et up and Greate perfect fitting box joints on your outer ble ortable saw. The micro-adjust feature allows you to "diakin’ perfect Jilhing ointsby adjustingthekey position in increments of kssthan Ya", Cne of the Knobs lets you to match the key to the blade, and the second to set the spacing between the pins, The settings can easly belocked inwith twoknobson therear of thelig Withthe pontionehekeylocked the jig won't "ereep" while you're work fng nomaterhow any ceawersocbones you're making The hefty solid aluminum body gives you plenty of st our ‘workpiece whether youte planning to tse it with your ronter table or table sus. The unique plastic replaceable onthe Tes, / Acuatable mitt key stows ral ing iy ung BaXjOI stole from ver arecth Pa, Remar Kea he trough the BotStIon te galter chen hace Ot orgs hn Create Expert Box Joints Using Our Box Joint Jig Apr este theigta he dar ce and specing ofthe pins and als, One krob ‘niche te Fey tothe la, da th cond Tb te espasngbivee tapi backing strip backs “upyour workpiece 10 eliminate. chip- out, Complete detailed inge- Ge or atch ing the Ba Joint sali force included ‘Aluminum Box Jota Jig €7-4502-658, Replecemeni 74802487... ence Clear Aadzad Mami | Becking Seip: UBM Pa Cope lly arse bad ar realy tase Miers Aajant Fandtion Ore il flston of he kno micve a kay ts Tie adusatleweth Rey potions he work: ‘lce tote ss ar ct aor datases A MserecesaseresOfpie aul at ‘eget efor tog Topreventthekeyon he Rox ointlisfrom “roping” once it dusted a fal oF plaste bobelocistsscwrelp place Dre real pf fing box Jct,