Walnut Cabinet * Lamp Table * Serving Spray Painted Finish + Molded Stub Tenon & Groove dsmith Yo 17 / No. 101No. 101 October, 1995 E DETOR Ss COLUMN Publisher Donald B. Pee Rater Tory J. Stroman Assistant Bstors Tox Garbis Mak Willian Senior Mntrates David Kreglige Cinder Dink Ver Seg Mustrator rch Lage (CREATIVE RESOURCES Creative Dineotor’ Ted Krall Photographer tngland ectronie Publishing Doighe M Like “Hlectronic Cra Glowacks lec. Comunication Geren Calpe ‘Geaphie Design Cherg1T. Cytor ‘AIRCULATION SeletpiaNougr Sil amy Dow tegen en Sher eager i Newitnd Mirek Bus CORPORATE SERVICES stapler Sense. lohan” aad Asistononce: Ken Grit” ONS WOODSMITHMAILORDER Dacor. Ba Bk Arr Coty re Mastol Car Come otciee et Nyce RC ssi oy es Se Ta Siethn, chetcabs Stnacary. cer be woopsmrmSTORE Dae Leen ss rat dae Set ene Stns alae otf age el re seat as — Sue Fee bonsen Anta ef se to Mode Bs pea inten USA Sawdust he way 1 ook ait, woodworking i 2 series of comnected steps that leads to a final goxl, Usually, this goal is fictional, good-looking reve offumiture. Bot tha’s ct what [find most rewarding, 1 ‘enjoy the whole process — from planning {o building and finishing the projet PLANNING. Aflerthe design is complete the fist thing Ido is figme out where Tra going to stat and how I lope to end. So yen before pens up apiece of wood sit down wit the plans and work out the procedure. Acinally, I bail it sever times tn my head. The geal is to ceme up with the best way to build a project before 1 make my fist out For instance, T bet there ae neatly. a dozen different ways you could built the seiving tray on page 24, Some are safer and mow efficientthan others, BatT know from experience that working. vith smal pieces canbe tricky. Andi cane tough to get them tof gether jl ph, 8 on fey Leelee coer i and tex pecs. The banks would iktnds se and the tet plas weal ee slime accurate cuts, BUILDING. But when the building be sins, there's @ subtle change in the. pme- ess Eatly on, consult the plans care fly. making sare of each meastrement. Bui dloceu'Etake long before I siaxt consulting the projed. Then instead of wing on pre ‘ise mumbets, I begin to get my measure tment tig from te project. ‘Of comme, there's alvays a litle room foremor sl I'm not \rorking with "and? easements And the difference be tween agood fit and a sborpy firisprobably ‘only a few thoasaniths of an inch, So ‘offen, I won't try 10 of apiees "dead on! the firs time. Instead, Ill mak wp on ¢ pee fy ming tal wt, And ‘hen the pieces finally side together — ‘ell, thats What woodworkingyis all about “Take the Walnut Cabinet on pase 6, for example. Building the plywood case is prety straightforward, Inst follow the di mensions inthe plans. But asthe base, the loots, and the top are added, #’s more im: portant that the pieces tthe case. Noe thal the measuretnenis match dhe pans, FINISHING. When the projec buat, theres one inal stepinthe fingh: ing. A finish can make or break a projec, ‘which is probably why T ean be a ithe re- Ihctan to try something nev. So when Kent, our Senior Projest De- sgver, suawested ve pant the base of the Tap table on pape 18, Twas skeptical To rie, wbod and sat mic abo ae wel ait and water. Maybe ite besause Ive spent so nnch time stipping paint offold furniture tat it seems like @ oiime to paint a new peoe. Butwhen Kent matea "mock-ap" of ‘what the finish would foo ike, 1 yas sar ‘pised and impressed. The elase-smooth finish looked sea, OTHER NEWS To celebite our 106th ise Ist month, Wwe decided to have an open house, Frankly, 1 didnt how wh to expect, But 1 oetainy didnt expect over 30) peopl 10 altend. We had vistors from as faraway 2s ‘Ausra. And sabscibers from Califonta to Alabama planned theitvacations aronnd the open howse Tam deeply appreciative of this show of support. And I wanted to extend a special {Taks to all who attended he oven house, tothose who worked har! to make ita si es5, and tol our readers who have made 100 ists of Woodmith possible. NEWINDEX.Atfheopen howe, afew of you reminded me that it has heen a couple Sear sine weve offered an index Peowaner Well, we got busy, and now there's a new aid compte index of woodworking profes and information fromissues 110) of Woodsmith and isaws 123 of Shop- Notes, The price of this index is $495, ‘which inclades shipping and handling. To onder you can cals PANDA 7OID fax tus of 515282 0447, or wite to us at PO. Box 842, Des Moines, IA 50304, Well be shad to send i ight out 0 you. NEWNAME, Speaking ofnevs, ve havea new corpomite name — August Flome Pub- Hone 4 many oy know, we resety launched a new gardeving magazine Called Garden Gate. To refietthisnewade tion, I thought a name change seemed appropriate. After all, while we plan to Keep piodicing the best woodworking hiagnes nthe ruaket (Vondith & ‘StopNotes), | hope to Took to other areas that will help readers interested in improv- ing theirhomes and enjoying hobbies. 3 jodsmith. No. 101A LOOK Contents FEATURES ‘Walnut Cabinet... 6 Its the detaiis that count: ball-tipped hinges, quarter-round molding, and decorative feet are just a fen ofthe many features in this classic walnut cabinet Molded Stub Tenon 14 You don't need an expensive router bit to make this joint. It can be made with the tools in you-shop and a simplejig. We'll walk you through the procedure step-by-step. Lamp Table 18 With its Shaker-style ines, this lamp table willfit well in @ variety ofsettings. And tts easy to build. We've even included a quick shop-madefigfor tapering the legs Spray Painted Finish 22 Get a smooth painiedfinish —without any expenswespray equipment. Well recommend which paint to use and show you hoy to prepare the surface for professional results Serving Tray. a 24 This tay has several designfeatures wefind appealing: a maple panel that contrasts with a narrow cherry frame, some sculpted handles, and simple euroedfect. Reader’s Jig 30 Need an extra hard? This assembly ie. sent in by Roger Balling ofSanta Ana, California, uses asimple cam lock- ing system to help you hold case pieces during assembly. DEPARTMENTS Tips & Techniques 4 Shop Notes 17 Talking Shop 28 Sources 31 Waluut Cabinet Moliled Stub Tenon Painted Finish page L4 No. 101 WoedsmithFROM FELLOW WOODWORKERS Tips & Techniques | MITER GAUGE WEDGE CLAMP. ‘board tight agamst the miter pieces. A wedge and ablock at- block to hold different sizes of id the block. gauge when i's standing on tached to the miter gauge bar. stock. see Fig. 2. On one end. s¢ the jig. position your 1 mol 3 = % ees 2 : see th TRUNNION ADJUSTMENT | n my Saw holes bigeer, I made the bolts blade with the miter gauge skt. smaller. Simply remove a bol. | + In my shop, doubles ear But. on my contactor-style sa. grind offthe threads just below | pet tape gets used a lot. But thatmesntmovingthetrannion the head, and reinstall tin the | Could never find my seisors (he casting that holds the saw, see deal below. “ARer | hen it eume time fo cul itt blade). The problem sas the grinding all the bolts, you | length, To sohe thisprablem,[ mounting holes in thetrunnion should fave the room needed | Keepasinalewdued ror blade forany adjustment, | tuck under the end! ofthe roll ! Keich King | (Shamp edge in) t0 cut the tape. } solution, Instead of making the Crooksille, Ohio Guy Mile Charlottesville, Virginia ) tie witha sot in one end, I f works lke a small squeegee t0 / spread an even eet of ue acos the jomt Then when ‘youre done.justthrowitavay. & ‘ind aay treoos fa brow tot Pest =—— And best fil they free apoyo nea “arth Sith epee Reading, Penneylvania, 4 Woodsmith No. 101SAWHORSE INSERTS. KEYHOLE SAW ‘1 built the sayhorses featured ‘in Woodsmithissne 97, bat was aalitle reluctant to ase them. 1 didn'twanito" shew-up"the tp with my si. So hefore porting themto werk, [added areplace- able ingot to take the abuce. ‘This insert is simply a 1¥2"-x 142" squate plex: of crap stock that sis on the top of the san Tone: tSheldin plaxeby aceu- pk of34" x 112! cas. When crewed to the top, the deus form ada forthe inset to jo. Touire worried about fing the sces when making a cat, imply glue or carpet tape Teens clip need ‘Duval Mss Simcoe, Nordh Carolina nseicap be. eleoat ROUTING HANDLES. +] Fike fo make my own hran- les, Ent routiig the elgct on srnallpiccesis difficult and da seus Soto ply a [male Tose asuppot bead, fst xt ont your blank and gine itto the board. Ones the glue dries, rout the inside and outside handle blanks first and then of the handle blank. Fe gle fhe to Inget support tilly, make arp caton deable oad made ftom a piece of sawio separate the finished han- Sara. This vay, ca Keep 4 dle rom the suppor board. ‘200d grip on the workpiece s | ‘onal Whitsel Tn it pastthe ronterbt Onirchoille, Pennsylania Gp Hark» scrap pice Tek werioieos Sey +A keyok sa works pal to cat holes in tight places, But in- stead of buyingote, made my ow, Allyou need isa sabre sew ‘blade and a wooden or plasic {ike handle, sie photo above. Forvvooden handles sharpen the shank end ofthe lade to a Bl fore yu dive the onto the Blade, Forplastic haniles, heat the blade andpnsh tintothehandle ‘with apair ofits. Safety nove: ‘The hot blede can cause burns. Brad Burns Wapakoneta, Olio JOINTER ADJUSTMENTS ‘When | gota tapered efge af: plywood —with the comers ant eis ke ye en eee ointer, Tkiew] hada problem, metal framing :quares will also ‘owner's manaal suggested do the job.) checking the infeed and ouifeed Just seta square on ech te lables (6 make sure they were BIC 90 their edges touch, sxe parallel with each other. Aneasy drawing, Then check for g ‘wayto checkthisiswith accu- between the edges. A zap in ple of shopmade "squanes’, —_cetes the tables aren't parallel, ‘To make these squares, Tse Wayne. Reaty rectangular pieces of MUthike Buckley, Washington Sei ae Woodsmith 5© ATURE PROVE CT Walnut Cabinet An ogee base, built-in molding, and doors with two goodfaces. k Te’s this attention to details thai makes for a classic-looking cabinet, | | | | | | | seation to deta, Tha’s what ses this he joint gies you a stonger door, Theses more Sebinet apart fiom Your werage project surface ateafor the el to hod the door ictails axe obvious. Others you'd Theply they're pointed out to you. ‘unique. It'safact of lifethatthin hardwood plyy ‘ba oad example Instead cfa only has one goal face. Sa what do yon do phinpleceofbtock forthe cabint tored on there the inside face of door (ice the onec onthe eat fn ogee profile ext ito the front and wide prccos_ ne) willbe exposed each time #6 oped? The an ‘Andto atemsiben the mierjoinswedtojoin thew sve iso cover twit verse. edges a ich picasa spline added atbeth From comets. tothe overall hikes oflaepanel, but cst ‘A chest look a the doots teas the molded aids (othe aypearanoe ofthe door: sib tenonjoint used to held thea fosethes Typ- When you conine these details wat the beanty cally, molding ts added after the door is shied to- of walnut, yoa end up with aproject that looks good father. But making the molding an integral partof ix nos any roominyoar home 6 Woodsmith No. 101 SsConstruction Details peor a Polen is sa deg gia EXPLODED VIEW een, soettoy " Zz conten Bes, poate Beremeiae J itiatctetae® No. 101 ‘WoodsmithCASE ‘To build this twodeor walnut cabinet, [ started with the case. Its basically a large sywvood box with an adjustable shelf added WWike midi forsouse. TOPBCTIOM PANEL. Ivo of the nisin pass oft plywood ox ate the op and tompanes. These are W-thickpieces of ‘walnit plywood sino ded by fourwide Ships of said bantwood molding Since both pancls ax identical ( for some mounting hokes drilled im the top ‘eae Tater), Linade them atthe same tie, Todo this statby cuttingthe plywood up- per and lower panels (A, B) (a finalize “ithe mse et foe the eis of next sep is to cover the elges of these pants ih molding But sometnes it can be alitile difficult to get molding aligned perfecdy with the edzes, Expecislly ‘when youre using widepicces. (Mine Wott 14" ite) To help me do that, [cut aa'- ‘wide tongiie on each eige of the Plywood panes, 62 Fig. la, “The importa thing is og thetonges ceniered on the thickness of the plywood. Otherwiee the two surfaces wonte flask when the molding is installed. An easy way to do thisis oflip thepancl over aflereach pass, That Way you're cutting from both sides until he tongue is centered on the panels edge. MOLDING. Onoethe tongues are ent son «an add the molding. These are jstpieves of M-tiek stockplaned to match the ply- ‘Wood thickness. Althoush theyre cutto fi al widdh (54%), [ kel them ext lon ‘Late, this extra stock will come in hardy ‘whenmiteringthe molding tofitaroundthe ‘edge ofeach piew to accept the tongue on the edges ofthe panel, see Figs. 2 and 2a, Now the back molding (C) canbe cut s1o0ves in the side molding pees (added panels, Then cut a centered veanthe to finished length. it's the same length as next), sce Fig. 2b, Then gluethe backmold- ihe tr the plywood panels (2814"). A stub tenon is ing to theplywoodpanel. ‘Once the back molding is attached, the cent on each end of this piece to fit the dame. courtesink shank | aunts ‘sr af ouroagee NOTE: Cartes gooye on ab mosang Grosse Banus ACK MOLI Marea ct gu fen on baokimoling Woodsmith.canbe cut nest, ee Fig, 2 This melding is alile different than theback rnoiting. Yon don't have to cut stub tenons. Instead, the fronts ands sides pieocse ance itera roan the cower panel Tree teton igtgi fine and dry ace, Nest, the ‘molding pass are sifered on One end they time et sh wh tebe || molding. Nowsine and clamp the front and se olin pees oe pane. RABEETED EDGE. With the molding in salle, Tent rabhas around the top and bot tom panels, see Fig: 3 ‘These rabhets are all a 1 dc a he mabe on the back ofthe panels" wide and therabbets [AE J sama | | atiestoneaa sects tiie [oe een sce Figs, 3a and 2, You need the extn, ‘width fora decortiveprofile added nex. HOGEPKOSILE: Now to soften the edges sft top and bottom panels, a decorative profile & anton the font and sides, se Fi 4, Dont werry about the back edge, Since you dont sei, set square) “This profil s ceaied with a 32" ound- over bitinthe rower table, ae Fig. 43, Bu ‘oui have fo ase the fence when making ‘the cat Thats because theres not en Socket on the workpiece forthe bearing to ride st @) SONOS Me is te 1, t file, the lax aepto completing the top and bbotiom panels is dallng a sees of mount- ing holes, Hew is whete the upper aid Jowerpanels differ. To hold he cabinet top added later, youl need eishit mare lols in thetpper panel (A), se exploded view and ‘etcils 4? and" on previons page. : i SIDES. NowyouYeready 3 addthesides 4 ee Leut two Satthiek plywood sides (F) to a | finished size of 12" x 30M, se Fig, §. But before they can be insaled, here a a Cone ple ofthingsto do. Firs, on the font edge ofeach sidepiece athin stip ofhardwood, side edging (), is sttached to cover the plies, see Fig. 5a ‘This edging isa Y2"thick piece of slid wale ntct the same Jeng and thickness a2 the sides and glued flush with the eds. Neat thew’sa¥4'-widex Yédeep tabi! ‘at on the back edge of the sides, sce Fi 5b. This mbbet is used fo hold the back panel added later. ASSANBLY Now the sides pieces can be ‘used to join the top and bottom panels fo form the exe These pieces axe simply sled and screyed toscher. on SHELFHOLES. Before moving on tothe | Repel tinh backpanel Iwaned to duly" mount. | Meee” Thles in the sides for shelf pins that are insulled lacs, we Fiz. 6, To help mede tat, @ si Mesnictenplae sere fa. Srr py se the template in the case to dil the holes Ithelpe Heep the holes aligned so the shelf docant rock. | 0) See oxents To aiihdes ‘satorpite. No. 101 ‘Woodsmith 9CASE covmUED Aer glingup the sas, do nextatepisto Sold te bark We sluwli sp yrecteanel Suroundedby apairolsiks and wis, sized {oft the ening inthe back of ie cae. Biyepenhawasa wiles 304th) GME. [ suited by cuttng the Lane picass thesfiles(H) an rails) tofine ‘hed width Qi, se Fig. 7. Thon to fn ished kwh G04" and 2612. ‘Next shallow groove, centred onthe ene el gate finepias. 16 cut ‘oat the tickaes ofthe lyvood panel thatwlbeaddedlaen se hig. $0 8 “Then stub tenonscan be cut on the ends offheralstofitin bess groves, Steck ap on thethiclnes ofthe tenon by makings teal passes and fiping tho werlpis be: Someone Soha 9 BACK Pasi With i fae pieos com et, the back patel J) 8 cue est. This thick pece of phyinod s ato fr in the fea ype! ns 2542 3 0) Mer ‘hung the fame petes and backpanel oe Seti hessenbled ck cobetned th cas Tas glue and see in plans, Si versie eae es CABINET TOP. The cabire. Op i alded ei one the back imple [sate a Ile ligerthan te top ofthe ease to over- Tang the ont and se ess ter indecently The top consist of {thickly ood center panel () C3 * 204) fury by ee orale toanerthe ples so Fig 10 MOLDING Whats aide usual isthe ml isn tallthe samesize, Themoldi ‘on the front and sides of the cabinet is yode aude peor onthebackis al wie, je entra Wi th is forronting 2 decorative eyroueo ven ge onthe font side pes. nse you don rout the back, T out the ack molding (1) iol Jeng fist lueditto the centerpanel, ove) and then: Sefigs land a Now therestof he moldingpecescanbe tex rae ‘GROSS. SECTION Tent VE FROME VEN, added, First, I mitered the front mol (M1) to ithe length ofthe center panel an Sliedkinprace New, mieronechd ofeash Side molding (N) with the opposite end trimmed flush wih, the back edge. Then glue and clap the sideriezes to thepanel Usedadebleds fo cat ianon on enaschais‘To complete the cabinet top, Tused 24" roundover bitin the ronterableto ronttte front and side edges, see Figs 11 and 11a. Since the cabinet top is a large pice, T clamped a featherboardto my router table to help stabilize the panel INSTALLATION, Now you'rereadyto lve and scien thefop tothe ease, see Exploded ‘View. To do this, center the top from side- torside, and keep the back edge of the top ‘lush with the back edge ofthe case, ‘BASE. Once the top = glued and sewed jn phe, the case is almns! complete. All thal'sTeft is adding the base, Its made from thiee pieses of solid stock mitered at the omers. And cut into the face ofeach piece isadeconttivepiofike CLEATS But before you can tuild the base pieces, three hardwood cleats 4 front cleat(O), and two side cleats (P)have to beattached tothe bottom panel, sce Fig 12. ‘They hold the base to the cabinet. These denis are "x "pieces of dockslued and screwed to the bottom, see Fig. 2s and ex ploded view, detail’ ‘The interesting thing is where you pos'= toa theckas They setback Ftromthe outside edge, This gives you a ¥4" reveal ‘when the bese pieces are installed. FAS RRONTASIDES With the cleats i place, thebase front and sidee can be added next, They're made from %-thickcpioces of ‘walnut ratered to Hit aigund the bottom of the cise, sce Fig, 12, “ite the Non! mlding (MD, the base front (Q) is natered at both ends. And the ‘basesides (R)aremiteredatoneendand citto length fash wi edge. "Tosttengthen the miferedjomt, [added aWlthick hardboard. Maconite) spline, eTig. 3, But the Steep kerf isnt com tered on the miter, see Fig. 134 This way, the spline is hidden withthe buss insaled ‘Wit the base mitered toi, you can et 4. decorative pattem on the front and side Tees se Fig, M, (Referto page 7 forthe NOTE: Feit roundoveror Tt ed S658 OMY pattem) For atip on entinsths base, refer {o page 17. Now atserrble the Ine pleces ané_slue them to tho cleats, refer to es ploied view, deal 'e? BRACES Filly, io stenstieathebuck oftiebase, Ladies pai ofiangleshaped braces (S),see Figs. I2and 15, These are {Wick plexes of tock, glued and screwed tb the bottom panel and base sides. isa ‘rd aase baton r Woodsmith:DOORS & SHELF To match the paneled construction used to ‘nulld the back ofthe ezbinet, 2 pair of par led doors rae othe fot But wats a fide unusual here the joinoy. Hs a molded phases that has a‘decoro- side ez. STILESSRAILS To build. the doom, 1 started with the frames (ses and rails the width of all these peces is the same is simple. ust mensire between the op and otompanelson the cabinet andthensub- ‘tact 1 for clearance, seo Fig. 16 (My sles wore 3044") Butfiguringoutthe ength ofthe tails Upisabitmore complicated Fete youll need 9 (ake 0 ac- count the width ofthe stiles, the Stub tenons on the ras the asra- sgalinthe middle, and 38% clearance between the dbars, ee Figs. 16 and 7 (My ails were 10}4"long ‘Once the stiles and rails ao out tofinishedlonath, the molded stub tenon ointis cut next This joints atTitle more involved than your typical stub tenon. But Hike the igegofmakingtheroundoveranin- ‘egal part of the frame rather than adding the molding later. For more on cutting this joint, referto the aricleon page 4 PLYWOOD FaneL. After" completing the fame pieces, the nex step i to add a door panel (V). Ths oversized pice of thick Plywood wills eutto fri the opening be fren the fame picocs, sce Fi. Tike pabelis oversizedbecause before ac tually doinany cuting, Veovered the back side of the plywood witha piece of flesble- tack veneer. That vay. the panel will ook the veneer and the plywood to final size 1016" x 2554") atthe some time ASSEMBLY. Now you can assemble the doors. For additional strength, the plywood panel s glued inthe frame, Simply apply en ‘even fl of glue to the tenons on the tals andalo in the grooves ASTAAGAL de STOP. At thispoint,theastra- gal and stop can be aided. the astragalisa ‘decorative molding attached to the sile on the left-hand door, see Fig. 17. Ithides the ‘exp normally foundberween tive doorsana Cabinet. And the Sop, attiched tothe astra gal, holds the lefi-hand door closed after Youive closed the right hand ane. Since the astagal QV) is 2 fairly small peceohnoldingtc workwith{ fouditeas 4et (and safer) fo cutitout ofan extra wide piece of ¥thick stock. All ittakesare three e25) steps onice your workpiece 1s cut to match the length ofthe doorstile. (My as tragal was 70388) Fi vide mabbet cut 1A" there's deep cn one edge, see Fig. 17a. Next, 0 Ya" roundover is muted to erate a beaded sce Fig. 17b, Then it ean be ripped gal othe sie on Compared to the astraeal, making. the (244), but their lengths vary. good from either side with the doors open. stop (X) is simple. I's justa Va"awide strip Determining the length ofthe stiles(T) With an oversized panel, [could trimboth ripped from the edge ofa 44'-thick board. roe AG) a. iz] ~% aa cant oe oon nee Mo ee THRO Mncaeyd ener oo 12 Woodsmith No. 101Tie stop is cut alse shorter than the astra seal O04"), Tus is For clearance between the fnpand bottom rane’ when the Tooris ‘lose, Thea its sly ghied othe take the atingal ida oki 1. ‘SULLEDeferchanging hedooms lade a sef(3). Its upece ofd4tek pymood thats auttc ft se te ease, see Fig. 18. Added to the fronts osu of shelf mold- ing @)thatcovers the edge ofthe plywood, seeFip. BaTohold the shelin the cabinet shelf pins are installed in the holes pre ‘viously dulled in the once sides, HINGES, ARer installing the shelf, the doois can be hung on the cabinet There's hothing tieky bere, but you do wantaVis” jepaiie epanitorometie cons Shep ip: One way to do thisisto xetthedoorsin the cantar uses cote efpennies or Spacers when racing the hinge Tocaion Tetsted by cuting atmovdes inthe door tofitthe hinges and screwed themin place ‘Then setihe dootsin the opening. ad trans- fer the hinge location onto the case sides. i, mortise an opening in the sides and sctew the hinges to the case, sce Fig. 19. KNOB & CATCHES. Finally b complete the cabinet, Tadded the rst ofthe hardware: a pair ofball catches and apairofbmss knobs, see Figs. 20and 21. "The knobs are simply centered on the stiles, and the ball catches are positioned be- hind the right-hand door. You don't need any catches for theleti-hand door. Thestop fon the astrazal holds it closed. MATERIALS case: A Upper Panel (1) 34 ply - 1084x2842 B LowerPanel (1) 34 py. - 1024228 © Back Madang (2) 4x 194-2814 1D Front Melding (2) 44x 134-3112 E Side Molding (4) 4x 134 «1398 F Caso sides (2) Sli ply - 12x30 G Sde Edgng tH 14%¢34-30V H Boot stiso @) 34x21 3010 V Beck Faib@) 4x22 25% 2 Gack Fonel(1) ve ply. -2510 125% Top & BASE: i Corter Panel (1) 94 ple «1344 x30 L Back Molding (1) 1434-2004 CUTTING DIAGRAM Wee ES (49 8) aN om (M Front Melding (1) Vex ¥4- 31% N Sue neting (2) Yan%4- 1378 © Frontciest(1) P Se Coats (2) @ Base Front} R Base Sides 2) S Braces) DooRS T Dec Stlesid) suxza-20%4 U Dos Pais 8) Yax2%-10%4 Vox Farels@) Va ply - 100A x 2558 Wasaga 1) 40x94. 20% X Siop() xan 2068 She) Hap 1O'2x267% 1 Sher Mataing (1) 12 x39 = 287% is 2 396,45 2d % =a SUPPLE + (2) Ball Catches (2pan 214" Ball Tp Hinges (2)1" Brass knots (@)SnetSugparis (20) #8x2" FhiNocdscrows (18)28x 114" FhWoedecrows © (33)98x 1" FhWocdscrews HOTE: Actions) Shes cabo at font pinned No. 101 ‘WoodsmithWOODW ORKING TECHNIQUE There are several ways to join frame pieces (siles and sails) together on 4 paneled door. But one of my favortes is 2 molded stub tenoa joint (ike the doors used ‘onthe walaut eabinet on pase 6). T's an eas) Way to add a decorative profile (a quarter rong} fo the inside edze on frame and ppanel door Now [know they make special routerbits ‘you can nse fo eit sini joints, Bhtadding a profleto the stiles and mils it too diff- ‘alt, Allthat’ reqaited aw afew more steps ‘and some catcfal planning, Then you can ‘4 the samme results without spending alo, ‘of money. To do this, [simply use my table SIM a Tou ‘anda shopmadejig. (we the box below. IZING, Thefirststepio making’ perfect {joint isto make sureyourstilesand rails are ‘ent to finished sae. This nt only meane ‘The weet to fitting 2 molded stab tenon Joint isto usea simple, shop-madig. I fits ‘over the frame pleses and can he ed two {was Fist, gtides your chisel when cit- fing the niters on the molded edac, we photo below right. Ard by flipping the jig ‘ve, i ean also help when renving the ‘wast fom the molded edge on the tes Molded Stub Tenon The “built-in” molded edge replaces the decorative molding you typically add to a door frame tenia ae toe as (ei ier eaten oe Oro ‘peetier fiah die ees TROCVES crs ent the stiles and can fietelan aes etimureoro aa Hee ie as val We oem ae the plywood, we Buttoallowforthebuilt-in molding on the Bee teeta cen ae tikes ne UO tas Us een aig aa ere “The is & easy to make and consists of thee pals. Jas give a spacer between to ide tals and cota miter on one end, se= drawing, This forms a pocket forthe frame Pieces to fit ato. The depth ofthis pocket ‘@¥2)iseaua tothe distance fem the edae of your sie or all to the shoulder of the molded edge Spacer metotas shoe tics strergthens the door frame onoe the ply= ‘wood pane! is ged in place, Shop Tip: When cutting the groove onthe frame pieces, I like to use a np blade. The teeth are around flat an top, soiteutsa flat bottomed groove, _Tousethe igto miterthe molded ete, simply, s4 it over your frame pisce and clampitinplae: The anglehelps anide your Chisel to cu 45? mites, ‘By turning the jig over it canbe used to Youillhavetostopshor ofthe the profilebexause the diameter ofthe bit (29 won't lt you get into tight comers. But ts sim leo finish dhe Gut Tustuse a Chisel 10 clean up the eomer Note: [left the straightedge in place to help guide my cise 1 By oN we SNS AEN eS us ein we Sk short of cmp anicean wine “a No. 101 ‘Woodsmith ”WEEKEND PROUECT Lamp Table There’s nothing complicated about this table. You can build it in « weekend. And its classic, clean Tines will fit a variety of settings. ‘ome projects are appealing Hpecause of the details cf their design: hand-catjoinery, applied molding, or graceful ‘auives. Tis Hip table, on the other hand, stands out because cf ats sinphiity But simplicity of design isn't something that originated with ‘usbyany means, Thie table wa, ingpired by an eafiee group of woodworkers: the Shakes, The Shakers were masters of good proportionsand clean, un adored lines, And we tried © include both these qualities in the desien of this table IGNDETAILS There isnt anything complicated or chow: about this tebe, Tedoesn'vhhave any drawersorapplied molding. And to give tile legs a light sracefil appearance, their in- Side faces are slightly tapered. ‘The design isn't the only thingsimpte about this table, te ‘lao easy to build. The legs and aprons are joins mortise and tent mortises are aut on the router table; the tenons on the table saw. And the legs are tapered with a shophuilijig, so they're notrickatall PAINTED FINE dar ‘other design tick inspined by he Shakers They souetines ‘sed diferent types of dad contstto apiece of ture, Orthey painted patofthe project and lef the rest natal Tine natural contest added i torvstto the desizn, Soinstoad ofgiving the wtole tabiea cearfinish, Ldrssed up thebaseby painting iDlack, sa te article on pase 22, Taebiack realy ial the ich ele ofthe chest bp. 18 Woodsmith No. 101 ee EEETOP VIEW Both inside feos ig fpered—/ SIDE VIEW Yet chentor anpse and lotr edges) Construction Details The aprons snags ace ‘awa wh rise stub tenon fens. MATERIALS & SUPPLIES 5 besa) Naxtin-25% B Aponsis) MxSA-12 © Toni) 442 16-15 +) Figure-B Fasteners (@)#8% 12" Flathoad Woedsorawe:LEGS. ‘There's nothing complicated about ths tbl, You stat by raking the es ‘Then connectiher with aprons, and finally add at CUrIO SZE, To begin work on the legs (A). | sated with 945g and mppel fur tanks 12" square and 2514" long, see Fig 1. Ifyou can't get ahold of siods you can laminate two pieces of "thick sick. But i is a bit more work And if jong to paint the base, youl jintline, havea vi ‘Note: Becanse Iwas planuing to paintthe base, I didn tneed to use the sime wood as the top (cherry). Instead, Tused hand ma- le, but you could ako use soft maple, pop- lr or alder — anything that has asmooth, slesed grain surface. Toconpkte the legs there are two more steps. First, cut ncrtises dat the tenons on the aprons will ft into, Then taper the legs ‘MORTISES. To bezin, I id ont the mor- tiselocationsonthe itsidefaces of eachleg, seeFig land theLege, ~ onpase19.The thing to keep in mind here is the mortises on these legs, aron't centered; they‘ 14" ftom tous edge, i hs Peat ‘wanted the aprons Corto the front atte legs. ee All th morse ao openended. This Jowed me rout themon th router table sg? susigtbieand astopblock, see Fig 9 Formote on ti, so poge 17) But besa the two mortises on each leg are fist they dont use the same sem. The ‘oater uble fence needs tobe change ater the Sst set of monices. oc tie fst mordse on cach leg, the fence shouldboseti2!fromths mide odes ofthe bit se Pg. 2a, Per the other set of Inortses; youll teed io move the nce. ‘gan, the mage numbers ut this time, the H"isthe dotaoe Fomib outside ofthe bio the ouside ele ofthe work: picce, eg. 2h. Nov te complete the montce, all thats Je fferyou to dois squae up theends with chisel sep 3. TAPERS. Chee pots weet vp, soucinepet You wen tnee ee teanuipe teers Tova tneed made foes the 0b wll 2 Toca the tapers fst themvoat onthe ieade fies ofthe ley, eo a 1 (lize sin aja mats on) Then to cathe pers Tue aj hat Pete ae aay ate tlecy theboxbelon. ane Building the Jig. Tis plywood jig lets ‘Jou taper nw faces oft lee, The bod) onthe Jiginatches the lengte and angle ofthe tee ‘Per, The cleat supports the workpiece, Uningihe Jig. First, layout the the kgs. Then set the aigledface againstheripfeice witht cleat onan fporelore eat rd foun are inde, anti set «Weg in the jg 80 the in- frond as «Sten ‘Side facesoftte leg are outandidawn Next ‘sete force so the Blade altans witt the lay-outmarks, Cutthe first aper-Tten ro- tate the lee 90° and cul the second per. 7 20 ‘Woodsmith No. 101| APRONS With teers compete, Leumed ate ou tue buraprons @) Tega ty our ting them to size GY2"x 12"), sce Fig. 4. ENGNG. The mestsiep is cue nots thatare centered on the ends of the aprons, sa Fig 4. To do ts fused a ago blade ete at ey oe ee Batge wit a backing board euppons the workpicees and prevents chipout. Though tke novice ae effete xe eur eedte ceed oo gosta the da blade, Tippmg tepee between rece, unl he tons fhe moviaes. ‘Next. you want the length ofthe tenon to rat ie orice. Todo hs Leta sho der at the bottom of the tenon by standing. Sagres on sign ae 6s ed of the blade (44) eos ‘right, but cheek pe “ASSEMBLY, Once the tenons have been cal thease canbe semble Todo ti, first glue up two sub-assermblies: two legs Slug, ‘Thenjoin the aes cine coenogaean a FASTENERS, Tholectetepisiopmperctho Ise Tovataching htop, used ours ee tee ae fue ee cee ce ‘tase. They allow the panel ‘0 expand and contract with changesin humidity. To install the figure-Sfastencrs, ill vo Me! holes, 44" deep in bo ofthe aprons, see Fig. 7a, Thicholeis offeet 4" toward then side ofthe apron and acts az ashallowmer- tise for the fastencr, With the holes drilled, fe fasteners sinply suewed in place, 6 TOP To complete the tble, all thats left is to build the top (©), The tap of this table sa sgluedup panel that's cut 16" square, see Fig. &. Once itwas cutto size, Irlieved the edges by routing a Vid'chamfr around the top andbotiom, se Fig, 8 ‘The top should be centered on the base. Anewy Way to do this i to fist mark oem ‘terlines on the outside ofthe aprons (B) and the bottom fice ofthe top (C), see Fig. 9 Next lay the tep Tae down and set thebase ‘on its0 the grain on the top mano perpen dicular with theaprons thathave the flgure= fasteners, Then line ypthe centerlines and Screw the two together, ‘Note: Ifvou're planing to paint the base olthislanp table. like did rermovethe top from thebace before you begin, a ee ie: wpnee ant wore ‘WoodsmithFINISHING “TECHNIQUE e ee Spray Painted Finish To create a smoothfinish, you need to choose the right aerosol paint and prepare the surface carefully. I ‘o get a smooth painted finish, yon _PAINISELECTION ‘There are two types of after a couple of days. This makes the paint might think youd need expensive sonaypaintyoulliindatyourlocalhardware alitleincomvenieat to work with. eiuiprent. Not so Topaintihebas ofthe siox-enamelandlacqper Botha spriyed _Resideshe Sow drying quality ofexam- lamp table on page 18, all [used was spay onthe ste way. The big differences how ck [Ne alzo nan into problems with the sc the kind that comes in a ean Just soon yon ean apply the xeond ccat fad coat adhering to the fir, The second i, ad paint wlan. Ensiel paints cy sowly. So coat often wrinkked and cracked Ue the ‘Well, its net quite shat easy. But Wo whenyyoute applying the second coa, the Skin of an alligaion — even whi T was things Will make your job mich easie and fits: cat has tobe eter slightly tacky or withinthe “window oftime thatwasrecom- sive you thebest reals; choosing heriaht completely dry. Ustally, thedivetions we- mended on the can. paint andpreparingthe surface carfilly. ommend thet you recoa within an hoaror TACQUER. On the other hand, Ive found Jaorper-basel spray pain ie easy to use Lae dries quiet. It dics to the {ouchin12 minutesand oan be handled a teranhour. Bur the dtestions say you can ‘eel tat anytime And the salve ia the pitt softens the coat below it, so the two Goals “et! together. I havent mi info any ‘wrinkfing problems with Lacquer ‘To he far, shonid mention that enamel is probably fonaher than lacquer. If youre plasning to paint a project that vail have to putupwithplenty ofabuce lis oudoorfir- niture, youll probably watt (0 use ent} pint instead oflaoque, But for afurniture rope, like the Lamp table on page 18 fc- ‘quez provides plenty of protection, And its ‘mich easier to work sith Salty Note: Aword of caution when us- {ng spray paints. Whethor yon nso enamel of Iacquerbased paint, make sue there's pkty ofgood ventilation. Tor verspray, yo can crete atempos drop by hanging a shest of pasic from the ceiling. Bot mos of all, protect your lines by wearing arespirtor SURFACE TREPARATION. Choosing the paintiv only the ftstepoftheprocess, You fko have fo prepare the surface carfilly. Paint oily Tooks as good a6 the suite that it coves. It doesnt hide soraches or dents. Instead, t ac- centutes them, Unlike the feature ani olor of wood (which help to bide seratches), the single color ofpainton allt, smooth eur {aco causes anyblemishosto Painting supplies To patil a project lhe the lamp table, yout meet: automotive spot puiy and a plastic spreader. welliry sand- paper anda spray bot. te, sandablo primer, gloss pati, aud some erylic clear coat. 1 ‘also found teat a trig per handle and a lacy ‘susan came in handy, ‘see Sources page 3 really stand out So dont get fooled into thinking, pantwillide sloppy workmanship. ‘Yea cant bypass careful sanding andrely onthepaint to makeevery- thingdisappear. Infact, you'll probe ably need to prepare the surface beticrthan you nommally would, 2 Woodsmith No. 101SiS Neola The scowt to acting a emooth inichishav- iug a crrooth surfaco to apply the paint to Sobeforcyoushakoupthateanofpaial you hnave spend some tne prepating the t= face. This means yon need to sand fill,and pimethewoodthorougtly. SIND & FILL Skat by. Sanding nt the scratches and iling in dents and chipont, se Sep 1.Tuse an antomotive slaritg & gopuy (mien) Tepe a A adhere to wood and wont shrink, painted finish requires a smooth €y Nest, spray on a coat of sartable FRME Wie vood hss Don ka, fice Bag ysandng igre. prover aston, eeengpasee The el cro ate ag line any dems and deep scratches goal isancver, weicont But ooutrxs abate forthe paint, Note: Tused asandable piney, aio mole eth pret and int were compatible, I used the came Brandforbothe FILL. With the peimex on, youll be ableto se ay Scratches you might have missed. And you may findthe areas you slleceatict are alitle righ, So ilthese areasagzin be- fore going on, see Step3. SAND. The next sep isto sand pain, soe Sep 4) But the primer "oad: up? rela saitdbape quichly. So fiom now on when sanding mat ipod wih warble and said eveything with wel dey paper: The primer will cawe any missed gy iWherthe putty s completely dry, the iin aceon Oaeeiey aetna Meare eves a an S leienta re oe ad Jilled earlier may not be perfecty smooth. To a this mst water OF theproject and imer fo the wood in some id pity to these ares said it with 200-grit wed Ay sa Tals wanted 0 mike sie the den and 22D OUD! Gob ouph et es sevaichos had been filled completely Repeat this procese of filling, and priming att the surface Thet lightly sand ome more tine with 400. aritwel/dry paper to get it ely smoath PAINT. Toparathehasccfticlanptbl, L spuyed on four cous ef sess hequet pant, se Sep 6, Theres nothing magic bout the nomber: [just wanted to be sire the suface was covered well Nest, I rubbed out” the baze one last time with 400grit sandpaper, sxx Step 7. Again you wanktousealightionch, When ge After sand ‘anotler cot of f Now sooth, Sanding the pai, the sandpaper cn easly primer dicts oe Or ut thiough fotle primer—ortothewool, $5 Whenallthe hemishosaregone sand four canis of@ gloss paint, spraying tion Note: The pain’ will dull as you sant ery Highth with 400 gritwotdry paper. “with the saree tochnigne as the printer. Thats okay The gloss will etn when the clear coat is applied next. CLEARCOAT The ket sep isto gray on seven coas of an acylic ekar eval sce Sip 8. Thisadds exteapotection othe fie island gives mare depth, Also, the dear ‘oat determines thefinal gloss ofthe finish Soifven wanta highelossfinish nse alos ear cat. But fyeu'l Hike to tone dawn the les, like I did on the amp table, chocse a Satin clea coat, did oto sand ub ut he dea coat at all, The teason fOr this is Siiple. ‘Whea sanding its oo easy to sand through 9 Wheuthe last ocat of paints dry, a Toadddepthand protectionto the fin- thepaot Gaideventie pine) atisox Mf cut omicis ant min ane” O in teledcer k ovoph mneete news. Sowhat you cold end upwith salot seed toberemoved. Sover lighth rubout clear coat. Aeain, Feprayed on four coats, ofextra work D thepaintwith 100 gritwoiry sandpaper. But this imo, | sod satin instal of gloss withautomotive alacing & spo! patyy. and sage, keep thoftrstcoat light No. 101 Woodsmith 23 rsWERKE NDS BR OLE CT Serving Tray is ray served up a couple interesting challenges. shaping the sculpted handles on the ends, and creating a smooth lip around the inside edge ofthe tray St projets, liko this serving tray, ean be nat as rewarding as larger once, The scale may’ not be quite the same, but theke are all cnty of crc out — expecially When you're trying to come up with aprocedure that works well and makes the building process 28 simple as possible HANDLES One challenge onthistraywasehan- ing the handles. [did't ant to just ale thernto the end pieces, the joint line would have been too distracting, So these handles had fo be sculpted the sate: block of wood thatthe ends are cut from, But looking at the block and "seeing" the handles (ike a sculstoc would), I teaized that a Jot of cutting and routing had to be done on some fairly namo pieces. ‘The solution? Indead of working with two cepa rate blanks (one foreach end piece), stated out ‘with only one wide blank This vay, bo handles could be shaped safely. Then Laer, they could be cto finisted size fromthe blank, ROUTED CVE, This ra provided anotherlitle challenge: the ronted oove slong theinside edge. wanted the coveto end up perfetly Aish with the plywood pane. This not only looks better its ako easier to Keepclean, But which do you esiab- lish fist — the position ofthe cove or the panel? Thegau by routingthe eove. Then I could shea ‘up on the location ofthe panel by asing my table sawanda few testpieces.Ididitihisway because the fence on my fable saw leis me "ne tune” 2 ce etter than the fence on my renter table 4 Woodsmith. No. 101 |TRAY ENDS. Blank for tray ends 1 started work: on the serving tray by ent: ‘ting out and shaping the end pieces, which also serve as the handles. “Aqiuslly, these twoetd pisces sat out as one wide blank, see duawing above. This makes these pieces mich easiet and safer to hold when you're routing them. centering Waste 7 mo ‘The next step isto eut the end pieces to ‘width and complete the handles. ‘Withtheawerotted, aowyon caneutthe ‘endipieosstofinal width fromthe blank: To do his, setthefonce 136" fromtho blade and ‘ip ope end piece from the blak. Thea flip tie blank around and tip the other pve, eee Cm) ‘Thefirstthing thar needstobe donewith the blank to create a cove along thebot- tam edge of each sido, co Fig. 1, This wil formic bottomedge ofthe handles. ‘To tout thecovg Tusedarouertable with a¥4! core box bit ised 96"above the table. ‘Se the router fence so the cut is #4" wide, Then make a pas along both edges, se Fig. la, Then to incteax the width of the ‘cave, move the router fence slighily away fromthebitand make acouplemore passes. Repeat thisprocedareuntilthecave isalull ‘Ye! wide. Thea sand it smoeth, seethe first lupin thebax below. FIRST: at hap on bands 3 s Hontie acosit it roundover bt ‘Now lay out the shape of'the handle on both pieces, se dmavingabove and the sec- ‘ond tip in the box below. Then this shape: ‘can be cut out with a band sa, soe Fig, 2 ‘The oaly problem here is the picwe can rockwhen making heent.So used adowel to ald stability, se the tid tp in the box below. Dont try tocutrightto the fine with the band saws itworks better to sand up to itimstend. (iused a dram sander), ‘Nov to complete the handle, rout a 34 roundever along the top edge, sce Fig. 3, But the handle is toothin o ride againstthe ‘ening, so you'll need to use the fence eda, dowel wth sandpaper Try se ss Finis to hea sandpaper arciind a dowel. Ing sds togotior and use a compass. Sanding. To smd aroued cove quiet Liging oit ares. When (pine out the Adding support. To add support to a ‘and consitenily, Ivirap adhesive backed ares, [found iteasiestto clamp the oppcs- ‘small workpiecewith arouiedcove, Iwed tape to hota a dowel in the cove. Woodsmith. T 3SIDES & FEET RE With the handles complete, its time to male the skles and add some feet. (Creating the two 20“long, side pieces ie simply amatierofripping themto match the final width ofthe end pieces see Fig. 4 and the drawing above. ‘The next sep i to make feet forboth the ce J didn't really want square feet for the tray, so I cut 4 small curve on the inside edge ofeach. ‘The fist top for ewating acurve is sik ing an are. The ares have a %" redius and TRAY SOE ane ee, Test — EF ‘Next, Iersated« lip around the fray by routing a 94° coved long the taside edge othe tray pieces. ‘To dothis I nsed the roster able with a 4" core box bit, sve Fig. 8. Simply raise the ‘bit 98" above the table and then setthe fence tomakea Whwideent,seeFig Sx Now.yon ‘ray reer sie and end pieves, sex Fig. 5. Cutting them to sia is as easy as outing the side ‘pices. Infact, the fence seting is the sare. Jost stat with exta Tong blanks, and when they've been tipped to width, you ean cat the blanks to make eight 4-Jong feet. ‘With the feet cot to sz, they're ready to be glned and clampedtothe sdesand ends, ‘When sloing the feet, they shoald be Mosh with te ends and with the outside fase of «ach piece, And pay attention to the wood _graintop,Iesbestiftle feet ben” ino the Side and end pieces as mich as possible so the joint line is noticeable. are centered $4? away rom: the ends ofthe Dicoes. But seitinga compass exactly on the ‘edge is abit of ablancing act, To make this ‘easier, I clamped the opposing pieces (o- aethorto draw the ares, see Fig. 6, ccan rout the cove onesch tray pies. ‘Aller the cow has been routed, there's sfil one more thing to do, Andtiat’s trout a Tew ted pieces wilt the same cove, sxe drawing above left. These test pieces will help later when you need to postion a ‘arvove that will be cat in the tray pieoes. When the ares are all laid oot, cut the ave foreah foot. se Fi. 7, (Apa. todo used a band sawto remove the waste DeOpiieacdie eaenoa ea a drum sander) 42 cora bow bit ‘To mabe the tex picees frst cut afew blanks from scraps The blanks don't need to match the ie orshape ofthe endpicces, butyou do want them big enough t0 work with safely, Mater, youl be ripping. a sroove on the tale av) Then simply rout the cove dong, one edge of each blank 2% Woodsmith No. 101e PANEL & ASSEMBLY TRAY PANE, (a. \ oat sede rabbe! ound pan ‘in neti emake te plywood a fre PPT oncunion thick plywood to finished size, ssethe draw- ‘ing above. (Lused maple plywood and cut it 12" wide and 18" log.) TRAY SDE may ED Test pieces = Now ifs timeto cuta groove in the side ‘and end pieces to accept the panel, ‘Theides is talocatethe smavesathe op cof the panel is Sush with the bottom of the cove, see Fig. 10. And to act up the ent, ‘youll use the test pieces you niade eatiet, Brpucontorinos co the boom Dfaach poe tonalp ath signee ‘The last step i to miter Ue ends ofthe tray pleces before assembling the tray. ‘Nommlly, wien fmniteringpreceswith atable sins, [use the mir gauge st to the proper ansle, Bui forthis tay, [tied the Wade 45° instead, se Fe. 11 This way, all the pieces can be laid face down, and the ‘The panelfitsintoagroovethabwill be cur Jaterin the sie and end pieces, sce the next seties of seps below. But since saw blades ‘can vary in thickness, t's a good ideato cut atest Kerf in a somp block, se drawn; ‘Thenvouean catthetongueenthepivwcod Wo termiecss A cz raising the saw blade to match the length ofthe tongae oa the panel. (Ac: fnally, Teut the groove Vo! deeper so the tongue wouldn't boitom ont) Then set the ripfence 4" fromthe blade andeutagroove in oncofthe tes pieces. Now testthelit with Sat by aise tt uri tongue ig torin coro book ‘panel tofityour su blade’s kerfexactiy, “To ereate tho ¥4!»wide tonanc on the ply- ‘wood pane, used a bbe bitin he router tbl, soc Fig. 9.1 snuckup onthefinalthick ness ofthe fongue until t fit the Kerf in the serap block, see Fig. 9, the panel, see Fig. 10a, Ifthe panel sticks above the cove, move the fence away fromm theblade. Otherwise, mave closer ‘Now when you have the sip fence posi- tioned conectly, out the grooves on all the tray pieces, se Fig, 10. Handles on the ends dont getin the way There's another thing that’s diferent. Co atthe tay pees 10 Feng, you Teed to rrarkthemoff thepanel so they're perfectly centered. To do this, T drew ceaterlines on the hottom of the plywood panel and the tray pieces, Then dry assemble exch piece around the panel, centeine io centerline, and mark where éach piece should be cut, Aterthetmy pieces are mitered, you can s2lue them around the plywood panel, see Fig. 12 Filly, to protect the serving tray in case af spills Tapphed a couple af coats ‘ofa satin polyurethane. a No. 101 Woodsmith aCOMMENTS & QUESTIONS * Mos woodworkers know that hig humdi cases wood 0 ‘expand. But here in Jowa, the high hornidity: duving the sam= fection and mist This fetion mals a wotkpicoe sick to. a tistdl table instead of sling Srootily — the sume wey your Shit sie to your back Tre ned alet ofprodics to rethoefiftion, Carag talon om tach and furai- Tame sf. But the problemis, they leavea reside fn thew, and they don lst Si har long. Pas they Go very lite anything, to prot the sutfice of the mal ftom ni. ‘So we use three different prod- ‘ucts in our shop: Speed. TypCete, an Boeshield 9 (Skepase 31 for sours) IY STESD. Tike othe iy Speed for a longlasing fist Tehueet ie stale on te table sav, bend sav, and dal press ables. Pat of the. reason why it sweats so well is whit it mide From. iy Speed 4 specal raphe wae vith the consi featy of oath pase. ‘Med in With the was are snl ster Meds. ‘These Mees ABRASIVE PADS: are a molybdemim compound used for reducing fiction. (At Teast thats what Farris Machin- cry Ine, the supper, told me) Phe other thing, ike adscat ily Speodis how ts aplied. It reminds me of waxing tay eat Youvipe ion. Letithaze ove. Then buitit oft This prunes fas litle time and elf, But is saisly- ingo look back and se the sl- verflesk: where Pveput dow a eat of protection TOPCOTE Another product I usin theshop tokep eliminate Fiction is Topco This is a pioduet with aTefloataseafor- hula thet you spray_on yoar fools, I reminds me ofa vezeta- He shortening. you spray in a pan to keep food feomsticking Since ZzpCot is an acre, its s convenient way of geting nioa diffiiltoreachatea. For Instance, Tuse i on te planer bed became the spray exsily coversthe whole surface, and T dont havetoworry about miss- ing'a spa. [also fee fon Some ‘ofimy hand tool die my com- bination aqua) topeevent st, easly sts into all hese nooks and crannies. Touse 2opcote, simply spray Talking Shop FRICTION REDUCERS & RUST INHIBITORS itonand letit, er auey seconds, Then for the best resulis, just rab it ont lightly wih a clean cath Ahoogh «second catisrecommended, The found a single agplication fs ust ally enoash. TTopcoteiscasyto apply and fd tre it Selsey — exe cept for a couple of thngs Fins, alt tle more expensine tha pase prod uc. And second, it dlocant seem to lst as long once it's been applied. Shop Caution: When spray- ing socls lke TepCoro, the thing to be cael wih isthe overspmy Hit cs onthe sho feoriteabecane Sipps. BOESHIELD TS, While Xity ‘Speed or TopCoie does provide Some nis protetion them’san- other product bei sited for thejob: Bowshild 79. Ws de- ed to profect metal pats fiom moistine. So its ideal for those shop tcols that dot set tise al thar oRen, Beoshield ix an serosal prod- uct produet that’ composed of a elveat and paraffin wax. By spraying on alight flmand then wiping it off i eat be used 10 protect and fubvicate the tools ase every Butto protect yourtools fora long stetch (ike ever the same inet), eimply gray acoat on and letitset — don buff ou. This docskeave astichy film. Sowhen youtrereadytowethetoo, sim ply wipe t down with asdvent. * Youve mentioned abrasive pads in previous tssues, ant The seen them in local hard- ware stores. Conyeut toll mea Title abeait thera? “Abnsive pads (Hike Scotch Brite, Bear Tex, and. ScutFRte) work well whenyou. fe smoothing outa fish between coms, I'you typically use steclwol or 2a (or finer) sandpaper between coats your might van! to aie these pods ty Abrasive pads have some, disivetalvanvages atk sandpaper thes pals dent clog up with dred finish Thats beewise the srall dbrac sive patisles anebonded ita an open ich ofinictlacking fibers, instead ofbving zlued to aheavy paper backing And theres another benef Abrasive pads are flexible, $0 theycan conformtotheshape of ‘the surface, which makes rold- ings and enrved parts of pro- {eas mc easier to werk 00, eto at left. © Abrestroparsaloohavean af vantage over tralitional sist ‘Woo! Sted wool leavestiny sliv= ers behind, which is a problem, cesperially when you're working th water-based finishes. The slivers can mst when the next coat af fri i applied, On the other hand, the bers that make up the dbmasive pads ae syithetic. As you rub the pad cers the workpiece, the fi BS ea les 2 fiesh abrasive patticles. ee el off, but ary missed particles rent goingtonistand discalor ‘Abrsivepads come in avari- ety of "grits” and are anally olor coded, But since different companies produce different abmsivepads, they're not stand. andized, Tike sandpaper and steel wool. However, there's iflen asteel wool equivalent in the product information. nie sy) 28 ‘Woodsmith No 101BOG HOLES + In the lastisie, we featured a workbench completewith holes fForround bench dogs. Buk what ifyon want to add dog holes to an existing bench? The Found that whether you add holes during the building pivoes or after the top is com plete, there are twe steps: laying bt the holes and driling them. tavour, To hy cit the deg holes, start by determining the distance between them. At most, this distance should beslightly ks than the opening, capacity ofyourvise, se Fig. 1. However, when laying oat the holes on ny bench top| wanted ‘oavoid tnmingthe vise handle a mumberoftimes hen ading- ingittohold apiece. Sol usta hen Of course, you dont nosd a visctouse bench dogs. Withihe benchtop Ibuiltinthe laisse, used Wonder Dogs in addition toavise seeF'z, 1 OnaWonder Dog, the soww is mock shorter than on a vise the dog holes caaitbe rach ary apartthan 4", (The Tength the seww cn the Wonder Dog ttarcks) LOCATION Spacing ist de onlything you need to cousider. ‘You ako lave to determine the ‘specific location ofthe holes. In tions are the parts of the vi Avoid duilliag holes in the vise screw, guide tds, and caniage. But there are other. things that can get inthe way, The base that the bench top sis on, any dmwers, or even 4 cabinet te ‘demeath the bench are all ob- stuctions that can prevent you fromgetting abench deg seated ‘fully inits hole — orback out i Te 1 0g ten Tere NOTE Spacing alowe. fit auch of Wonder Dp the dop ispasied in toofar. DRILLING. When the holes are laid oy the pent epi to dell thom, fon aucbailding the op, this nt a problem: you can drill the {fos befor the to is assembled. Bi when the top ie already but, too bigto ws the dil pes, 20 ‘you have to dll thy hand. The tick here is keeping the holes pesca bit long enough to drill all the way through the top. But there's. Jn eaysclion. You cin sea inand dill gtige anda spade bit to dil the holes, sso phot. Note: Formore on the spade bit and dil guide Ive wel inthe aS, se page 52 ‘When drilling the holes, you ‘want to prevent the bit from "lowing ou” the boom sie, Todothis, {set the depth ofthe suite so just the tip of the bit reals through the bottom. se Fig 2. Then flip the bench top ‘aver and complete the bales by duiling fromthe opposite side, To complete the dog hls, 1 advo rove a 4" chamnferanound the top and botomedges. Spa ‘oe HORSEPOWER RATINGS m Recently, I've been looking to ing @ table sav, and Fre rin ‘across advertisements that say 4 saw "develops three horse power.’ What does this mea ‘and how car Lfind out how powerful a motor actually is? ‘Whea 4 motor is pushed to iis Jimat, say by cutting through a hart knot, the motor, dws ‘more amperage than under nor mal conditions. Just before it falls, the motor-willbe drawing, ee eae ad oma ing its maxim horsepower. ‘The most % can develop. OF course, it will only be able to adnan this for a short potiod oftimebeforethe motor stalls or fhe citosit beaker kicks off This is what manufacturers mean when they say a motor "develops Shp” ct can abo be refered {0 a8 a motor’ "peak horsepower”) Technically, the anufactnrers ae tight, Bat in my opinion, its miseading Theyre trying 1 get you £0 compare apples to oranges. “Mest table saw motors use a continuousduty —horepower tating, This is the amount of power 4 suv produces uiider onmaluse — isthe poweryou vill workwith most ofthe time, To compare motors, check their idenification plates. You ‘an Took atthe honeposver ra ing, but often is let off of saws {hat advertise their developed horsepower, But yon can sill compare them by checking the amperge ratings ‘Gencraly sealing, the Higher the anpetage the more power {he motor produces, So one ‘motor develops 3hpand another 18 qconfinucus-daty Thp motor and both draw about the sae merge, you can be prety sare that bosh motor: produce aibcutthe same power, No. 101 Woodsmith 29