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HCN i) aaa 2G) Bitrate TO cr = 5 nen Motor 2H. niov/zzov, single-phase + Precision ground cast ron table ‘with wings measures 27" 40" + Atbor: th’ + Abor speed! 3850 RPM Capacity: 34" @ 90" 2%." Rip copacity: 30" 12"L ‘Quick change tiving knife + Cast iran trunnions newotstonitcuus ‘App hippng weight $4 G0715P nmoovcron ss 10" CONTRACTOR- 10" STYLE TABLE SAW with Riving Knife Motor HP, 10Vf220V, single-phose Precision ground cast ron ta Tobie sie. 27x40» Aroor i Motor 3 Prcison ground cos with Riving Knife & Cast Iron Router Table H® or 5HP. 2201 sngle-phose se wlth wings: 27 48" Motor: 2HP, NOVI220V, single-phase, TEFC Precision giound cost ion fable size: 17 sa, Table tit: 10" 45° R Cutting capocttyfhvoat: 16" Max, cutting height: 12" Blode sae: 131%" Ls" 1") Blade speeds: 1700 & 3500 FPM (Quick rleose blade tension lever Approx, shipping weight: $42 Ibs. cauoes ewe aubeD Anan FENCE, MER GAUGE GW BADE 60513? ame: 2 TABLE SAWS 10" CABINET TABLE SAW with Riving Knife & Extension Rails Notor 9H 2209, ele pote « = e Precision ground cast ton table Tobie dre wih extension: 7x 7482 stron F9BI8| ‘Ato speed: 4200 RPM «bor W + Arbors!” * Arbor speed: 4300 RPM Copoaily: 3" 90, 27" @ 45" cutng Max. depth of cut: 3" 907 2 @ 45° Rip copocty 36°. 12L + Approx sipping | Copaaty: Max. copacity 80" ie weight sa2ios | Sete BL Max. dado wid" i Max. depth of ‘Approx. sipping weigh: 6720s. (eso cur sa 90" 2ie as + Apprex. nipping weight: 546 bs. a CARDED BLADE (GIOZBRLWX 5 HP $1 14" BANDSAW Motor % He, Now220v, single-phase, TEFC Procson ground cost ion tabla sae 14"sq, Tobie it 15° 45° ea Cutting capactytoat: 13" Max. cutting hekant 6 SS a Blade sia: 9247-93" L ae Gee w) Bade speed: S000 FM Cast von tome eA Steel open fame stond | = ‘Approx. shioping weight = Yesins cantcrusce | io Mer Gao al \ novseroipouet | 60580 \ aa og. $395.00 - $3750 fam | - PRICING Cop, |G1O29RLW 3 HP 137500 ULTIMATE 14" BANDSAW 1-800-523-4777 F283 29800 19" HEAVY-DUTY EXTREME SERIES BANDSAW: Motor 3HP, 220¥ single hose, TEC Precision groun Motoe 1 HP, nowr220y single hase, TEFS Precision ground cost on tbe sz0: 14g, Tooke LaSE robles 2010310 uti capaci robots Las ee Cuting copactytoot 8 Mex eutng helt ox cuteg lg 12 Ble 92 Blo so: MLC 1) nN fade peed: TaD 8 FP Approx. shipping weight 440 os. exe RESAW FENCE inewoe 96 bs. GosssP fier (GO51AX 125000 INOW SHIPPING] "TO CANADAL LE Mrs 2 snge phase Cac eee Cate secs c04 ru Sea eee pele eaees Sl) ‘Max. ploner cutting height: 8° erg weep Pte LS: " wena oS (GO634XP wn £ 60633 ore aner 499600 f 606342 sa. cumesieAo Mode. 247600 (Eg > 8" JOINTERS Motoe 348.2201 sngepoxe. 1 Precison gun catren‘ed samo Pah ee Ne el + ac ebbetng dept Gitenecd aa:s = Cutarhoos = speed 6000 RPM Guts per mince: 20.000 ‘Apptox shipping welght £00 bs. locas (60656P irooucr0Ry 0 GO656PX 10" DRUM SANDER + Motor Vs HP. NOM, single-phase * Conveyor motor: Yak New! * Max sanding wth: 10" + Mex. weikgsece height 2. + Nin wonepioce helt Yt Voarioble feed speeds: IO FPM + oust por Approx shipping weight 20 es ss sownsie ‘MAN SPORT Hanes FORMOBUNY GONG nsa00W ad TS __12" JOINTER/PLANER 1 COMBINATION MACHINE ~ Wew! oa (60706 219500 SALE zs SU | ud ey TEFC, 8450 RPM Stoptional port Impeller 13)" Height: 68¥." Bulf-n emote ‘control sultch Approx. shioping ‘weight: 210 Ibs G0703P woo 12" x 60" SHORT BED JOINTER with Spiral Cuttethead Motor! SHP, 220 single phase, TEFC Precision gtouns cos! ven table 20.15" x60" ea Fence:Sivx3IM Aun ocr Suteneod da. si YY Cuttethead spoect 2950 0PM Bevel Jottings a 50% 135" Mk. depth feu Approx. nipping woh 6321bs 15" DISC SANDER with Stand Motor Ws HP, 220. single-phase, “ 1720 RPM Hew! aren nro New cee ste 15 Cast ten table S20: 1220 fae tit = 45+ Floot to table height: 375" Dust pot 24" Approx. shipping woh 22 Ios, eaves oui MOTOR BRAKES STORAGE CABINET Win se GOTIY wn ge e4{i ea] Lt ("See CYCLONE DUST COLLECTOR Motor: I¥eHP, 110V/220V, single-phase, Air suction capacity: 775 CFM Stotic pressure at rated CFM: 108° Intake port: 6 with included Huge Pre tnreases on MatSile& Labor Overseas a New! (TZ 15" PLANERS Motor 3HP, 2201 single-ohose Precisen ground cost on tle 825 isan Min. stock thicknese = Mn. stock longs Max. cutting aeptn + Feed ote 16 FPA & E S = 3s ee ‘Approx. shipping > 60453? wreoo IC G0453Px 1 HP WALL MOUNT DUST COLLECTOR Motor: 1H, HOvI2z0Vsngle-phose SPECIAL WALL MOUNT DESIGN ‘Amps: 17 Bog sue (la. x dept Tare Bosonced seal rode finimpeler ‘Arsucton cpa asocrM. Max, static pressure: 72° Approx shipping \welght 51 bs sexe secu indsaw Blade Organizer 17 Weekend Project: Desk Clock 24 Sheet Goods Rack/Cutoff Station 28 Cover Project: Cedar Glider 36 Scrollsawn Potpourri Box {60 Toy Truck Two-fer: Lowboy and Sidedump 70 Shaker-Inspired Bench SKILL BUILDERS 20 Routing Large or Odd-Size Holes 48 Get the Most from Your Biscuit Joiner '55 Picture Framing Secrets from a Pro (67 How to Prevent Too-Deep Driling TOOLS &M 23 Wise Buys: Band Clamps 26 How to Ch Tension Bandsaw Blades 38 Shop Test: Biscuit Joi 68 Best Buys in Benchtop Tools No ned tobreak the bank on floorstanding tools ‘when some Benchtop versions prove plenty capable 74 All About Walnut 77 Shop-Proven Products Compact ils and dives hybrid rsh nae. DEPARTMENTS 6 Sounding Board 8 Shop Tips 80 Ask WOOD 88 What's Ahead RIALS July 2011 Issue 205, i € MAG. 5 eacN i ey woodmagazine.com wood magazine. com E YOUR ‘Memorial Flag Case Plan woodmagazine convflagcase American-Made Saw Blades woodmagazinecom/frresthlades U.S.(Canada Flag ntarsia Plan woodmagazine convflagintasia State Quarters Display Plan woodmagazine com/quartermap America’s Best Workshops Issue woodmagazine com/ambestsopsi0. Presidential Dollars Display Plan wontmagazncmiOog Made-in-Chicago Clamps woodmagazineconagjdamp Vv ] Vist 000’ Facebook page at . facebook.com/woodmagazine and clickthe ke" button near te top of the page. Wellrewardyou with pans forthe ine rack shown af pus you'l get excsvediscouns and ways To win woodworking stuf. Gota woodworking question that can't wat? Post tat woodmagrine.convforums and get quick ‘answers from your fellow woodworkers Poste New Latest Post re) Woodworking sor 33077 42 minutes 090 Po: ° tetmrer ie by natea282 Front Porch 14195 ates [2 mioutes 200 Rockers a byanne mall project ° 49757 Satay Entertainment centeratone 4 Finishing and Refinishing soos as08 2 290 z Sree Ret ernment ers ane Refumiare 4 asia iat: aor cores Nour 890 = © Mientras te cares Dy marten at Wo. Nao) anos INNUVALIVE PRUDULIOS SINCE 1989! Ea 10" TABLE SAWS with Riving| Knife Fre « whe fom ped + 3HP, 220, single pose motor + Coston table size 27x 40%" Fete eS gee nee t (W1820) 50" \WI819 10"Table Saw “2 ‘Wi820 10"Table Saw VARIABLE SPEED PLANER/MOULDER with Stand + Noto: 2H, 2200s «D ale hose * Pron ponder kon be wh ngs 26472 TOW ‘© Max. culting width: 7° ifs Max pony nt 71 “Max. moulding dept: ¥ We tee caren extn selection ff moulding knives Mor this machine! wisi2 Planer/Moulder SLIDING TABLE and ROUTER TABLE ATTACHMENTS for ae & W1820 wise wise ads «Pa ron be sae 2 x20" + Universal ota eur lei: 7° x9 + Mos. cross cut 4 10" SLIDING TABLE SAW = 5HP,220N, single phase moto T ‘Precision pound enstron able. eves or smonsures 47° 40" wit exiension St? + Siang tole measures 69° x 121s" wisi 10" Sliding Scoring blade eliminates Table Saw ross grain fearout 3 HP LOW PROFILE CYCLONE DUST ~ D> + Moto: 3 HP, 220, sngle-hose, loss, 3450 RPM . es on capacity FM Filer: 02-2 microns vor + 55 go. sil collection i rum wi costes Onty 80" Talt! Wiss x i Gore gg Dust Collector = 8" JOINTER with Parallelogram Adjustable Beds ‘+ SHP,220V, sinle;phse, TEFC moor « Pecision ground east Ion parallogram fqn tole moasute 8" x 76% + outameads: (WI7A1) 4 HSS knives (WI7A1S) sol gy 2 Bullen Mobile Base WITAI 8" Jointer — WITS with Spiral Cutterhead OUTSTANDING SHOP FOX’ ACCESSORIES agp ADJUSTABLE MOBILE BASES JOINTER Pals MERE ar asia as asin ome Seton ives in prot abigament ey tie! ‘1210 Polyeatbonat jg for 4-8 ointrs wt rive D260 Minitab dae W121 Sted jg fora 8 joiters WHS ives WIRI2 Carbide ora" jinters wiearbide or SS kes int? catidegfor Ibex Dista ‘i oe ee mer Ss Note ae En see Ca FENCE Tony ur Stet Contacton en Sion Bi Angle Dean Mears WIT16 Aume asic Fone wind S7 Bets W1720 A sl Fee wl ti craty als ep cing ac 259A tatesion Ki sll mode) 22464 36 Excarsion Bas (fs all modes) W172 79 ras legs ence noticed) W172 Setot 3 pode coated set metal ings WOODSTOCK INTERNATIONAL, INC. IS ALSO HOME TO THESE OTHER FINE BRANDS: 'STEELEX*, PRO-STICK", PLANER PAL”, JOINTER PAL", BOARD BUDDIES”, PARROT VISE", ROMAN CARBIDE* ROUTER BITS AND SHAPER CUTTERS. : VISIT OUR WEBSITE OR CALL TOLL FREE TO FIND AN AUTHORIZED DEALER NEAR YOU. aehacumehersreec ise eee eS AY eens better Homes and Gardens: sedan July 2017 Whats the most important rule 28, No.3 Tssue No, 205 Rey tise > sensi reser Ry er i ng, comenieeseacth Soewunen ane Gates ‘nocagerDncer Hosier vane Sealine Coffee cup on ‘GREG SELLERS MARGAREY CLOSNER ‘eyeand hearing ‘ite ee fas pbs Phoarapher JASON DOANELLY, SCOTT LITLE, JY WILDE Contig liao TM CAML, LORNA JOHNSON, ROXANE LeMONNE Conubutng Catan JM HERVEY Dict Response Aer {ATLANTA Nia Meta. 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Plan Prey Download these woodworking plans atthe prices shown, orhave them malled Eisenmann ee Pret ee Peer etree tain Calltoll free 1-888-636-4478 ene ern Sounding Board ur bulletin board for letters, comments, and timely updates A light? A table? Make mine a lighted table liked two recent WOODes magazine | from issue 200 (October 2010) and the | “The electric cord for the light hides in a {or the inspiration! bruce Dikeman, Colorado Springs, Col. into one. The resulting table at right isa__ built my table trom curly cherry with hybrid of the Luminous Display Pedestal quilted maple veneer to cover the panels. pices mach hat combined them | Halableiniaue 199 epee 2010, | grove none ofthe back lee. Tass | a So Article updates Issue 201 (November 2010) WA few dimensions on the Drop-Dovin Battery Dispenser were listed Incorrectly on page 32. ‘These drawings show the correct dimensions. Issue 202 (December/ January 2010/2011) The copper cap for the ‘Gumball Machine on page 53 should be ¥" 1D. DOS Nc) for woodworking advice: 1 Subscription assistance (Wo order pastisues and artis: Postyourwondorin question one, sting, _—_Tocotact us about your WOOD subscription, vist For pasties of 000 magazin in pintoron tos turing dst cleo, on one ofcur woodmagazine.comservice, Or wit to W000 DVD-ROM, er newstand-ry sues or dowicdeble nln forums at woodmagazine.com/forums. agains, PO, Bo.37439, oon, 1A SO037-043% ates, st woodmagazinecom/sore mal wdmeustseryscisfufllment.com. dude Wo contact ou editors: yurname ard dtressitappeassonyourmagazne MLUpdetes to previously published projects: Send your comments va emalto abel renewal oti aoe, Foran up-to-date listing of angesin mensions \woodnailewocdmagatinecom;owiteo and bying-uide sources om ive I though ody W000 masaine 176 Locust 15221, Tofindpastartides: nto woedmagazin com/editorial Des Moines a 0308, ‘Se ourindex at wootmagazineconvinder. WOOD magazine uy 2017 More tips for building better birdhouses In my studies a a wildlife and plant biologist, Ihave researched all aspects of making homes for birds and have built many birdhouses to keep them safe and healthy. On page 79 of issue 202 (DecemberiJanuary 2010/2011) you lst appropriate opening sizes for birdhouses, but like to suggest some additional details. First, build birdhouses from lumber at least thick to provide insulation from extreme temperatures. In adltion to the opening, borea few small ventilation holes in the bottom or top of the sides, The interior surface the entry hole needs to be rough So the birds, particularly young ones leaving the nest, can get a good foothold while climbing out Locate the birdhouses propely, keeping in mind exposure to wind, rain, sun, and the birds’ preferred habitat. For example, Bluebirds like vide open fields, while wrens prefer bushy areas, And for best results, maintain the houses to ensure wasps and house sparzows stay out, and clean out okt nests and parasites at the end of ‘Most importantly, protect the houses from predators, as many animals enjoy the easy meal of bid eggs or babies. For more info, goto tinyur.com/34rksk. Lance Care, Vagina ttt of Marne Scene, lovee Pon Reformulated: = Type tPA, No Foaming * Dries Natural Color + deal Clamp Time + Indoor/Outdoor Use For A Free Catalog O To Find Your Local Woodcraft tore, iit wooderaft.cm Apollo TrueHVLP™ 835 & 1035 Power Series Unites Stats, contwesoenginerHULP prods tat meet the nah [LP sites in aorta and ately coves for user comet and oval dri, Recognising Weodra as & woedworking tl nds leader Agel has ‘reatad these HVLP Systems bund with unique accessory packages exclu fr Woodert Bhp ‘We ETL Ceri for Nort Arca) Power Saris Specifications #1035; 4 Stage Trtine, 20 Ture 7.0 1035 8a 91035 8235.2 Exclusive Accessory Packages ‘Apolo TrueNV.P™ 1095 (152658) 101, 13mm & 1 Sr Nese Mazes Cait Tem cl RS Raa SV [ed Shop Tips Helping you work faster, smarter, and safer Top Shop Tip Press-on, peel-off to transfer patterns ve found a method for transferring patterns to wood that doesn't destzay the paper pattern or make a mess of the wood. ‘The solution lies with a kitchen product called Glad Press'n Seal®. (Find it with the aluminum foil and plastic wraps) Simply peel a length of the film off the roll, press it—sticky-side down—to the paper pattern, and trace the pattern with a ball-point pen or a fine-point felt-tip marker. Then peel the film from the pattern, press it onto the wood blank, and ‘cut away. When you'e finished, just peel off the film, No need for solvents or scraping Henry lech Vist, Cat Bown einstein ‘lad Press Seal plastic wrap REVO For sendingin ths sues Top Shop Tip, Henry gets a pair of 60" Bessey K-Body REVO. \VARIOs, along with 24” and 40" pairs of Bessey K-Body REVOs, Attaboy, Henry! Your tips earn cash, tools! WOOD magazine sy 201 Nothing fishy about these hardware bins Here's my take on a low-dough hardware storage system. This cabinet has hardboard drawers that ride in 4" slots, Sardine tins (thoroughly cleaned and any sharp edges filed, of course) double-face-taped to the drawers hold the hardware. OF course, if you don't like sardines as much as do, you could substitute mint tins or inexpensive plastic food-storage containers. —Serge Duclos, Deon, Que ‘continued on page 10 Sardine tin Attach tins to rowers wth Soubie faced Carpet tape We hareboare Grawer woodmagazine.com FREE Ductwork Plan Plus Save $100 when you purchase any S-series Tempest™ cyclone! Offer expires 8/31/11 Use Code WOODTS Nanofiber eats the ,competition’s dust! (FREE with any Tempest Cyclone!) The best value in dust collection is now the cleanest. (Our Tempest Cyclone Dust Collectors now include Nanofiber filtration 28a FREE upgrade (a $54 value). Industry leading, Merv 15 rated 'Nanofiberfitration combined with our cyclonic separation process captures 99.98% of wood chips and dust particles to below 1/2 micron, You achieve near surgical quality air and cleaner tools, while practically eliminating dust clean up forever! What's more, Tempest Cyclones never clag, require almost no maintenance and come with a5 year warranty. = 25 HP - 1450CFM -$995 ‘ TSSHp-soocem.gr1a5 Askabout our solutions for smaller TEOHp. 1eo0ceM.gisos_ Shops starting at only $295, = 2.0 HP - Portable* 1025CFM - $895: FREE Shipping ‘SAVE on any system you buy! PSI offers a varlety of discounts and offers on dust collectors too numerous to list here, We're your complete resource for everything you need to get the job done right! To get the ‘best deal on the system sized perfectly for your shop and number of tools, call Bill at (215) 676-7606 x16. Penn State Industries Top Quality, Great Prices, and Expert Advice! 1-800-377-7297 » www.pennstateind.com Tips Make a slim scraper from scrap Here's a quick, disposable seraper that works great for cleaning up give squeeze-out, Bandsaw a "deep kerf in a angle. Then scrap-stock "handle" at approximately a 1 epoxy a utility knife blade into the ker. Stan Ledman, Mople Gow, Min. | le MORON NCCT OTL ACLU Pe ac SN 0 UM Crate 1 8 TA 0 ASEAN IL J all Today for Catalog outa te Wl 406 TTT =, sity knife blade epoxted int ert =. Tiny table gets a grip on small parts ‘The Smaller the part you drill on your drill press, the more important it is to clamp it for safety and accuracy. Ironically the smaller the part, the more difficult it Is to clamp to the table, My solution, this -beam fixture, provides a tiny table to position and clamp most any small part, My drill-press auxiliary table has T-track already installed, so the slots on the fixture allow it to move in two dimensions; but you could also simply clamp the base of the fixture to your table. Hot glue a hardboard top to the fixture fora sacrificial surface that can be pried off once it's damaged. Len Urban, Rancho Mirage, Colt Sacifcll hardboard top \ 10 WOOD magazine july 2011 Smart and safe small-part square-up When making boxes or small cabinets, squaring up small parts can be way too dangerous on the jointer. Instead, use this trick: Clamp a jointer plane upside down in your bench vise together with a shop-made wooden fence. Then joint the piece as you would with a power jointer—by running it against the fence and across the plane aad de. Alinco Joiner plane py Screw eyes driving you nuts? Use a nut driver Using large fingers to install small screw eyes into picture frames can be frustrating at best, and painful at worst. For me, a set of nut drivers works well to drive the hardware ober Marchant, Data, a, continued on page 12 u The Possibilities are Endless icine isis een ome) Sere ENE pee cette ere een recat Seog a blanks to choose from, you have over Sent erates Pero ey prune co rere) alford eres as errr en nee erat RT OM UR LULL Free Pen Turning DVD! a N INS EASY STEPS a Yerhndraepey op Tips Tool stop ends chuck mishaps ‘To provide both a visual reference and a guard that prevents 2 turning tool from catching i spinning chuck jaws, welded a diameter steel rod to the end of my tool rest Asa beginning turner, this has added both safety and peace of ming, —Femath Cook Ptsbargh, Ni Put some extra spring in your grip Often when you need to place a spring clamp, you only have one hand to spare. But with failing hand strength, I've found it increasingly difficult to open spring clamps. ‘one-handed. The solution: Before starting a glue-up, use both hands to place the required number of clamps on a scrap of wood. With the clamps near their maximum capacity, as shown below, they are much easier to use one-handed, Le Urban, Rancho Mirage, alt Wel rod ~ welded toteal est | WOOD magasine uy 2011 AAPL SA a euetie 3 aC ean PA esa eautoas v Fast Shipping GOTO WWW.ROCKAUTO.COM Scissor-lift support cuts need for a third hand This adjustable-height support serves as an extra hand. I's | motion, the scissor action lets me adjust the support to the especially useful for joining two parts where clamps would | perfect height, and the wing nut locks it firmly in pl get in the way. With the lock nuts just loose enough to allow Chaves Top pas Al parts 4" plywood woodmagazine.com 3 BORNE %& food Products, Inc. QUALIZER SLIDES TABLE SLIDES mE IA @IUC ico o0l Made to order Table Apron Kits. W SOURCE FOR TABLE SLIDES Great Ideas for Your Shop Divide and conquer Bandsaw Blade | toring blades of various widths and tooth counts for his 14" ‘bandsaw presented a problem for Howard Lang of Wilmington, North Carolina, so he designed an organizer we knew you'd lave. Use 2x4 stock for the angled spaces, 14" hardboard for the dividers, and %" plywood for the back. Customize the holder to house as many blades as you normally store (we made ours to hold eight blades, sizing ‘the angled spacers 1" thicker than the width of your blades. Cut the spacers and dividers to shape, with a 1" radius on the corners, where shown at right. Glue and clamp the pieces together, keeping the edges flush. (A brad nailer speeds up the process and allows you to skip the clamping) For Jong bandsaw blade, coil a blade, measure the diameter, and make the length of the dividers (front to back) 2" longer than the blade’s measured diameter and the height 1" taller than, the radius. Cut the back at least 14" wider and 3" taller than the assembled blade holder. Drill mounting holes, and attach the holder to the back. Then, screw the assembled organizer to your shop wall. 2h. wood stews Project deg te rd E Lang, Wilninglon, N.C. "ANGLED SPACERS For a FREE video on coiling a bandsaw blade, go to woodmagazine.com/coilblade “ WOOD magazine uy 201) GES Gin HOW CAN THE BEST GENERAL PURPOSE SAW BLADE GET EVEN BETTER? Eee a Kerf Designs For Every Table TET mere Introducing the Premier Fusion saw blade in both Thin and Full = SP Pg Cee eRe eet ees ec Er @ 7 Ceo teed ee UR a Nee ne Rana ee A a a Kerf combines the advanced Premier Fusion features See Cr ree tO Cr eter ee cme eR Relea cen Tue Ty Rete es ac aera ree es caie ee nce} blade on the marketwith a radical news ee en ea ee Re A Ree eae td a glass-smooth, chip-free top and bottom See em sae neko cct i) Mer acer nec Cee ge tenure Re vane Carbide, superior anti-vibration design’ and ene eure retry Cer ater te rd Re eet etc! Chose from four blades in the Full Kerf Premier « y Peco eC ere eC <<] de ore ora agence ren ater Te Caer Meese) Cte Pn ‘Lt Cit Sad i be ge eee ca Le ce /re@Ue) orto find a dealer near you visitor cal: 1-800-472-7307 eer ei ers CE tec ora ec) ea Ru Ean ell * : Sepitmy!SSUES 1.202 x ; Issues 1-202 bra naan ie te The easy searchable index takes you instantly to 305 920 1625 TU a ce (acy Weekend Projects ST toy 250 570 810 Shop Projects CO Tay Skill-building Techniques Order online at woodmagazine.com/DVDlibrary or by phone at 888-636-4478 Special pricing for owners ofthe 25-year collection! ca Crisscross Clock 1 Begin by cutting the body to size F orawing 1 rom a 1-thtck blank laminated together). | Play out the four plug holes [Drawing | Map andaiill the "holes "deep. | Cut four %«-tong segments from a’ | woodmagazine.com birch dowel, and glue them into the holes [Photo (If you don’t have a of cherry (or two ¥'-thick pieces | dowel, use a5" plug cutter to make plugs from any light-colored wood.) Using a crosscut blade on your Diablesaw, cut four ¥s"-deep horizon- tal kerfs in the body [Drawing 1] A simple technique for the ink makes this clock'a quicker bi than you might expect. AfFrom 4"-thick walnut stock, make hs 316" blank for the inlay. After ripping test strips to get the perfect fit in ‘the grooves, rip four strips and crosscut slightly longer than the grooves. Glue the strips into the grooves, and sand flush when dey. wv Weekend Project ‘Cut the four vertical grooves | circle cuter (fyou don't own acutter | §¥Cut the top to size and chamier the Drawing 1] with the same crosscut | that size, seepage 20 for tips on cutting | Pfour bottom edges (Drawing 2). Sand blade. Glue inlay strips into these | large holes by other methods) | the top smooth and glue the top to the ‘grooves, let dry, and sand them flush. | "J/Draw the arch as shown, cut it at_ body, centered in all directions. ‘Lay out the centerpoint for the clock | # the bandsaw or with a jigsaw, and \pply three coats of aerosol lacquer insert [Drawing 1, and bore the hole | sand it smooth. Finish-sand all surfaces. | For polyurethane, sanding between sing #3" Forster bit or am adjustable Coats with a 320-gtit sponge ® Projet design: Sehlabaugh & Sons Mustations: Roxanne LeMoine Source ‘lock movement: pa 120023 5285 pls sping and anding Siabough&Son 8003469663, shsorscom PN se grooves ‘i deep His00y (front view) "wsdeep Orient the grin of all four plugs inthe same direction, When dry trim the plugs witha block plane and sand them flush. Bhowrtove0 view lock movement 18 WOOD magazine uy 2017 ‘Clinic Large Holes in 5 Easy Steps Boring big or odd-size holes just got a whole lot easier using this simple method. any times when making trays, shallow bowls, or ‘locks, the need arises to cut large holes. Often the holes are odd-size diameters or irregularly shaped. As youll seein the steps below, a router, pattern bit, and. shop-made template will cut these holes accurately every time, 1. Mark the workpiece Cutan MDF orhardboard template tothedesredholeshapeusing a Using double faced tape or hotmelt glue, attach the template tothe Jigsaw, srlzaw, rere cutter Sandsawn edges smooth: Now, hold workpiece Take care agning twit the marked layout ne {he template on the workpiece and mark the hole location as shown. 4. Rout the hole Chucks pattem bitin your route sts dpthsothe its earing 4 Contacts the template and out round the empate's elena clockwise direction, smoothing the roughed-out edge of the bored hole. 2. Rough-out the hole 5. Complete the hole Using a dill press and 1" Forstner bit setjustless than the finished the hole can be routed tofinished depth with the template in place, hhole depth, hog out as much material from the hole as you can. reset the bit depth and complete routing the hole. fthebit won't Be sure to leave the layout line to relocate the template on the. safety reach hefnshed depth th he template in place remove tn workpiece. template, eset the bit depth and complete the holes shown at top. 20 WOOD magazine uy 2017 Think Fast! When mien ey for speed Think Instant Bond! ‘Although our core Titebond” Wood Glue product line is Titebond Instant Bond is a two-part bonding system Pee Sano ee eee ee oe ke we realize there isa growing need for faster, and in __ seconds for intial cure. 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Every workshop should have at least one band damp—alo known as sap or web camp for puling together joints on Our Expert Tests projects that prove dificult for standard bar or pipe camps, such 2s frames, chairs, cases, columns, or any odd-shaped project. They all come with corner blocks for supporting angled joints, but you also can use these clamps without them. just be aware that ‘without corner blocks, glue squeeze-out seeps into the nylon bbands and can be difficult to remove, ‘Bob Sounders, owner of Prarie Rose Woodworking Studio LEE VALL! Expert test-drive: This low-cost clamp work ike the ratcheting tie-downs | use to secure cargo to my pickup truck But instead of rubber-coated metal hooks on the ends of the 16-long nylon band, is secured to the ratchet at one end with the other end loose t pull through the ratchet before tightening, It comes with four 90° nylon comer brackets that clip onto the band and work great for square glue-ups, For odd angle, l use Lee Valleys accessory varable-angle corners (4-pack, #50K5701, $12.95, shown in the photo) because they adjust from 30° to 180"—the only ones with {his much flexibility. My advice: Buy the band clamp (#1710.02) itself fr $9.95, then get the variable corners, Tolearn more: 800-871-8158, leevalley.com Expert test-drive: CCraftsman’s easy-to-use band clamp has a one-handed ratchet ing mechanism (with rubber overmolded handles) that frees up imy other hand to adjust the comer blocks as | tighten it. The 16-iong nylon band pulled out easily winen | depressed the release button, and automatically locked when Ilet go. The band’s metal end hooks onto a magnetic rod that prevents the hook from coming loose while setting it up. The corner blocks adjust from 60° to 180", but | wish Craftsman would sel extra blocks for clamping up projects with more than four corners, Tolearn more: 800-383-4814, craftsman.com BESSEY, #VAS-23, Expert test-drive: (Of the seven clamps | tested similar to this one, | prefer the Bessey lis handle closely resembles those on my Bessey K-Body parall-jaw clamps and fits my hand preety ts 23-long nylon band was longest in the test, and although | might never nee all that length, it's nice to have it available ina ight, easy-to-use reel that never gets in the way. And the metal hasp proves easy to couple and elsconnect. With swiveling jaws that snugly ft 60° to 180° angles, the corner biocks have open “pockets” inside the comers to Keep glue squeeze-out from getting on them, Tolearm mor 800-828-1004, besseytools.com 2 Drea prey ener et ad es Mobil Sheet-goods Rack/Cutoff Station - ] his compact unit packs loads of lumber into only 18" of width. Castets let you swivel one end to load up sheet goods from, your driveway, then swivel the other to olfload sheets into your shop. The shorts rack side doubles as a simple panel saw, right, maximizing shop space even more. You can make it in a few hours froma single sheet of 4' plywood, one 2x6, and seven Dds, Build up the base Start by cutting and assembling the 24 base with #83" flathead ‘wood screws, a5 shown in the Exploded View on page 25. Add the 26 to the "sheets" side of the base Keeping the bottoms ofthe base members flush. Cut a 16796 piece of # plywood to serve as the top ofthe base. Use a jigsaw to notch the ends and attach ito the base with #82" flathead wood screws. The protruding ends actas both a clamping surface anda spacer between the spinning blade and the cutoffs stowed DDehind. Use aclamp-on straightedge to guide your saw. ‘WOOD magazine hy 2017 ENDS AND DIVIDER sw Cutouts on Giger only Stack up the rack Cut the ends and divider to 13-474: ‘Then, lay out and cut the angle on each, where shown in the Endsand Divider drawing, Set aside the angled cutoffs for later. Lay ont the radius on the top of each end and the divider and jigsaw them to shape: On the divider only, measure from the top and crosscut the divider down to 4394 Jigsaw the notches for the 24 supports where shown, then trae the cutout locations onto the end pieces for later reference ‘With the base sitting flat on your workbench, attach the ends to the base, flush tthe bottom edges and snug agains the notches in the base top (The tends protrude from the front ofthe base fo prevent saving into the horizan- talsupports when used as a cutoff stati Se photo on pre 24) Crosscut the four horizontal sapports to it between the ends, Mark the location ofthe divider at SO" on each as ‘well a on the base top. Install the horizontal supports and the divider, positioning i wsing the marks. ‘woodmagazine.com a EXPLODED VIEW 5 sive easter From the angled cutoffs you st aside, cout 3/4454" ier pleces to fit under the protruding edge of the base tp, where shown: Install the four support blocks on the “shorts” side to serve s supports for breaking down sheet goods, Now load ‘er up tucker avay in the cornet, and enjoy the extra space you've created. Project design: Kevin Boyle INurratons Roxanne LeMolne: Lorna johnson For enlargeable versions of these drawings go to ‘woodmagazine.com/cutoffstation * Wex2FH. ‘wood sreu BASE Van ex wexaixst LOCK SUPPORT fax3FH. wood screw Cutting | Diagram [SE Sahoo een Greece Vax 96"Pine 24) 25 V Right Results Match your bandsaw blade to the job, then set up the saw for accurate cuts, time after time. speeds: We know we should ‘change them for different tasks, but we usually don't. However a litle extra effort to change those blades will reward you with better cuts and longer lasting equipment. Here's how to best match the blade to the job at hand. Blade basics ‘As you shop for blades, it helps to know some of the essential terms (sce below): WM Gullet: a chip-clearing gap between the teeth, 1 Pitch: the spacing of teeth, expressed in teeth-persinch (TP. B= blades are like drill-press Rake angle: the angle of the tooth face relative to the blade body. Set: the pattern of bending teth to the Jeftor right to create a ker wide enough to Keep wood from pinching the blade body as you cut Next match the blade pitch to the workpiece thickness. The thinner the stock, the greater the TPI you can use You want at least three teeth in the wood atany one time asthe blade cuts, but no ‘more than 12, top right. (To resaw pieces ‘more than 6° wide, just slow the feed rate) More teeth leave smoother sur- faces, but have smaller gullets. that inhibit chip clearing ENCARTA) With 11 saw teeth in the wood as the blade cuts this blade pushes the limits ofits chip- clearing ability Match the blade to the task For this job fr Finecuteand ight | -¥,10-14 4p, curves instock, Seeidtoo thinner than andar tooth Scrollworkinstock | W246 ¢pi, about thick ondord tooth General-purpose | W,6ti,skip tooth works curves a ‘Smooth straight | Wr 14tpi, erosscutsandrips | standardtooth ‘Resawing maximum. | W'-¥"% 3 tpi hook sidtnhardwoodsar | or skp oot ‘green woo * Saw ip may Tit maximum blade width For general rules on the best TP! for everyday jobs, see the chart above. To ‘match a blade to curved cuts, refer to the chart below. For resawing, install the widest blade that fits your saw as spec fied in the manual PES es STANDARD SKI VARIABLE ree IT Tightest HooK 2 a ae w 7 na ‘lesring chips better, 26 ‘Aitemate-zet blades spread the work to ease cutting thick stock. Raker teeth cut cleaner by spacing compromises on both. Hook teeth prove most aggressive, but dull faster. Standard blades cut aggressively, while skip-toath blades clear chips to make smooth cuts. Variable-tooth Find the tightest curveto bbecut, then choose ablade rnovwiderthan shown to the rightof that radius. WOOD magazine uy 2017 Creates blade hump leas Stresses the aw frame SEENON ome ON Flattens rubber Distorts whee! bearings strains welds inde Constant tension on an idle bandsaw blade creates stresses that lead to premature wear, vibration, and broken blades. Detension ifthe saw wil situnused for more than a day. Turn up the tension With too little tension, bandsaw blades will stall inthe wood or drift off the cut line, But too much tension stresses the saw, as shown above, and shortens blade life. You can buy expensive (though Now set the guides With the blade tensioned and the saw unplugged, loosen the upper and lower pairs of guide blocks and back off both thrust bearings. (Spin the blade wheels by hand to center the blade if you've changed blades) Place paper spacers between the loos- ened upper guide blocks or bearings, and press the blocks and spacers against the blade body, rig. Tighten the guides in place while pressing them against the blade, and repeat for the lower guides. ‘Now advance the upper thrust bearing until the blade just clears I, fr right. Tighten the thrust bearing in postion, repeat forthe lower thrust beating, and youre ready to cat. # Wiriten by Bob Wilson. woodmagazine.com accurate) tensioning gauges, but ten- sioning needn't be that precise. Instead, set the tension one of these three ways: Whe builtin tensioning scale. These typically indicate more than the actual tension, but they're sufficient for Paper spacers supply just the right clearance ‘between guide blocks or bearings and the body of the blade, moderate thumb pressure presses the blade against a square placed 4" away, Increase tension one full urn andre most jobs. IF you notice blade deflec- tion, try one of the following methods. W The deflection test. First set the blade tension using the built-in gauge and raise the upper guide as high as It will go. Then stand a square 4" from the blade, and push the center of the blade with your thumb, as shown ‘above, Under moderate pressure, the blade should just touch the square. BW The “flutter” test. With the guide locks or bearings withdrawn from the blade, tension the blade using the built-in gauge. Turn on the saw and release tension a half-turn at a time until the blade visibly flutters. Now Increase the tension until the flutter Ing just stops; then add a quarter toa half-turn of the tensioning knob. THRUST BEARING REMAINS IDLE = i} | } } | WI Watch a bandsaw tensioning video at woodmagazine.com/ bladetension 27 Cee eee) PROJECT HIGHLIGHTS 1 Approximate materials cost: $130 for cedar, $28 for glider harcware (ee Souree), and $42 for ruts, bolts, washers, and screws. Suitable for use on the porch, deck, or lawn, it back, relax, and enjoy summer JCrosscut the legs (A) to length, then “Set your tablesaw blade 11%" above evenings with a friend in this lay out the notch to receive the arm — the table and position the tip fence ‘comfy glider. To build it, you need rail (C) [Drawing 1}. On one leg only, lay 2! from the outside of the blade, Make repeated passes to cut the notch in each leg (A) [Photo B). Bandsaw or jigsaw the and “two-by” cedar out the three points that define the boards, screws, and the simple swinging curve and draw the curve [Photo Al. hardware sourced on page 34. PSE nots tainto Je _ manearas Build two side frames for the seat ‘On the clearest areas of 1%'thick dimensional cedar, lay out parts A-K Tonge an Hae amet ae 4; Shop Tip, opposite page). Crosscut and. rip the pieces to rough lengths and fin- a thin scrapalong one ished widths, Set aside all parts but the rch and flex ctthe legs (A) for now. raw the arch along the crap, 28 = Establish the shoulder of the notch first, ‘then remove the remaining material wth repeated passes over the biade. curve in one leg and sand it smooth. Using this leg as a template, transfer the curve to the other legs. Cut the curves, then stack and clamp all four legs together to sand them to final shape. Start with 100-geit sandpaper and end. with 150 grit. LEG (Left leg shown) Location Loca on ane xsi ol ane ‘ariage bol, “rimmed | Bong “riled af ‘assembly, ext SE cariage bot, “wrnmed | 2 Tong aE a ‘Overhang the arm rll C)2" past the front {ace ofthe front leg (A). Make two mirrored legal assemblies (A-C). Crosscut the lower rails (B) to fin- ed length [Drawing 2). Set your tablesaw miter gauge to 15° and miter- cut the arm rails () to finished length. Quick Tip! Save time and improve ‘accuracy, eave your miter gauge set ‘at 15° for cutting several more pieces in the next few steps. Lay out and cut the ‘curve at the front end of each arm rail Screw each lower rail between to legs (A), then glue and screw the arm rails in place [Photo] Note: For the screw joints om this project «aril Yi" countersunk pilot holes before driv= ing the screws. Also use « glue suitable for ‘outdoor applications: type Il or HI yellow (YAY or a polvuretiane gue. Retrieve the center seat rll (D). Lay out the 15° angleat the back, and the curve on the top edge [Drawing 3, Photo DJ At the tablesaw, miter-cut the end of Beer sioe ‘EXPLODED VIEW wim eat LAY OUT A FLOWING CURVE = Fioxa thin scrap between the rearmost three points, them use the front point and the ‘Corner of the blank to form the frant curve. SHOP TIP Create clear stock, even when it’s knot Careful layout of parts minimizes keots that can weaken your project ox detract from is appearance In Photo A, the knots fa into waste areas of the leg (A) blank, yielding a clear workpiece the rail, then cut the top edge with a jigsaw or bandsaw, and sand the top edge to 150 grit Glue and screw a side assembly (E-G)t0. leg assembly (AC), Make two mitrored assemblies, Use the center seat rail (D) as a tem- plate to lay out the curved shape of the end seat rails (E) and the angled end of the end-rail braces (F) [Drawing 3}. Miter-cut the ends of these pieces. Then ‘cut the curves in the end seat rails and sand them to shape. Finish-sand the seat rails and end-rail braces, With the miter gauge still at 15°, iter-cut the uprights (G) to length, [Drawing 2]. Glue and screw an end seat rail (E) to an end-rail brace (F), flush at the front and bottom. Glue and screw an upright to this assembly with its end flush to the bottom edges of the rail and brace. Repeat this process to create a microred assembly (E-G) for the oppo- site side of the glider. Screw and glue each side assembly to a leg assembly (A-©) [Photo E) Be With a squaring brace clamped to the pieces, drive a 2)" deck screw through the back ral (into the end-all brace Add a place to sit 7] Cut the back rails (H) and front rail (1) to size [Drawing 4]. Join the side assemblies (A-G) by screwing aback rail to each end-rail brace (F, flush at the back (Photo). Cut the lower spat fillers () to finished length [Orawing 5] and tise them as spacers to” position the ‘upper back rail [Photo 6], outs" rounhoverson the front bot tom edge and ends ofthe front rl (1) [Drawing 4], then screw it to the ends of the end seat ails (F),Serew the center eat ral (D) between the front and back (1) rails, centered on thle lengths, and fash ‘with thelr top edges ‘QPlace a 4'-thick scrap between the ovver spat fillers (J) and center this sembly on the length of the back rails (H) [Photo H]. Screw through both back Position a lower splat filler J) at each end between the back rails (H), then drive 3" deck screws to secure the upper back rail rails into the splat fillers and then remove the serap. Aesetermine the length of the upper splat fillers (K), measure from the top face of the upper back rail (H) to the top of an upright (G). Cut the upper splat fillers to this length, then set them. aside, From thick stock, rip and cross cut the narrow splats (L) to size, with a 15* bevel on one end [Drawing 5]. Rout 14" round-overs on the front faces, except for the bottom ends. Glue and screw a narrow splat to the front edge of each, upright (G) and lower splat filler (). Retrieve the upper splat fillers and glue and screw them in place [Photo Back it up ‘Cut the spats (M) to size (Materials Us] and cut fourteen "thick spac. Screw through the narrow splats (into the upper splat fillers (C), ‘then tae-screw through the upper back rall(H) into the ‘WOOD magazine uy 2017 Tinted area: () Zk meee EXscarrais/enp-raierace = A... pe Sold line area: (6) against the clamps and lexit tthe high the assembly and cat each splat individually. ers, Clamp six splats together with their bottom edges flush and spacers between them [Photo4}. Flex a thin strip to lay out the atc along the top of the assembly [Drawing 5). Cut the arc, then set the pieces aside and repeat the process for the 8 round-overs ‘Aclamp on each side of the splat dry assembly marks the ends of the arc. Place a thin scrap intof the ac; then trace along the scrap. Unclamp remaining six plats, Rout %” round-overs, around both faces except the bottom ‘edges, then sand the splats to 150 grit. }Clamp a scrap below the lower back rail (H) to support the splats (M) and spacers for one side of the glider [Photo snd drive serens along the lines, K]. Screw the splats in place [Drawing 5). Repeat to secure the remaining splats Using an 8"Jong 4" drill bit found at home centers) bore two holes through, each leg (A), centered on their thickness [Drawing 1; Shop Tip, opposite. Secure a el Gicrraam (Right arm is. mirror image) Wood magas iy 2001 BUSS Ls - Stack the end rails (f) and cross rails 5} as ‘you screw them in place, keeping their ends {ind faces flush. 5%" carriage bolt in each upper hole with a flat washer, lock washer, and nut. Rip and crosscut the front slat (N) rand the slats (O) to size [Drawing 4, Materials List]. Rout" round-overs on the top faces, and sand them to 150 grit. Cut ten ¥e!-thick spacers to use when Installing the slats, Starting with a "lock washer eat washer (liderbracket ‘woodmagazine.com SHOP TIP Cuta length of Scrap to use as a guide when drilling with a long bit. By keeping the bit parallel to both the face of the block and the bottom ledge, you'll drill straight and true through the leg (A), tend seat rail (), and end-rail brace (F). spacer at the rear, alternate spacers and slats to check the fit. Serew the slats in place, centering the front slat on the length of the front rail (D. ‘om T'-thick stock, cut the arms (P) to size [Drawing 6]. Lay out the points for the curve on the inside edge and flex a thin scrap to connect the 3 dackscrew points. Lay out the rounded corners Where shown and cut the arms to shape. ‘Then rout %" round-overs on both faces. Sand the arms to 150 grit, then screw them in place. Make a base Cut the legs (Q), end rails (R), cross rails (S), and feet (1) to size [Drawing 7, Set the legs upside down on your bench and screw an upper end ral between each pair of legs. Stack the cross rails on the upper end rails, and screw them in place [Photo LJ, then add the lower end rails 33 Decermera foot one lngand vrew them in place [Drawing 7. Fp the base ‘over and dill the holes in the upper end rails (R) for the glider hardware. Feed a 1421s" carriage bolt through each hole in the upper end rails (), then add a fender washer, glider bracket, flat washer, lock washer, and nut. With a hacksaw, cut off the excess bolt length, label hidden areas. Cutting Diagram Place the seat (A-P) over the base and, using the same combination of hard- ware as before, secure the legs (A) to the slider brackets [Drawing 1. Cut the bolts flush with the nuts using @ hacksaw. [Remove the hardware, splats (M), Fand slats (N, O), and apply a finish. Quick Tip! For best appearance, ‘make reas- ax 74% 96" Cedar (2x8) 10:7 bf) ‘Vx 50x 72 Cedar (2x6) (bd) Vex 51472" Cedar (296) 6b fe) ‘ax Sx 72" Codar 2x6) (ba) 13x51 96" Cedar (296) Sd fe) 2 needed) Plane or esa tthe thickness lated nthe Materials ist, ‘Wax 54 172" Cedar (26) (6 bf) 34x74 96" Cedar (138) (53 baat) needed) : @: 4x74 x60 Cedar (38) 3 ba.) (needed) 54% 74 60" Cedar (18) 33 Bd FL MORE RESOURCES FREE PLANS 1 Get free plans for constructing squaring braces, and a fairing stick for drawing curves at: ‘woodmagazine.com/brace ‘woodmagazine.com/fairing, FREE VIDEO Learn how to use a faring stick at ‘woodmagazine.com/fairingvideo. == sembly easier, as you remove each slat and splat, label Is location on the back face, where it wil be hidden when rein- stalle. (We applied Cabot Wood Toned Deck and Sting Stain no, 9202, Cedar, using a "wide foam brush, then wiped off the excess, and allowed ft {0 cry overnight) Reassemble the glider fol Towing your labels, and rock on. # Pode by Crag Ruegvegger vith Jl Mertz Proje eg tt ete Monson Lor som Find more outdoor furniture project plans at: woodmagazine.com/outdoor a les aa C4 1° loners aw isc Camis ww <2 DP eertersetral Uv" 19 E endseaais Wh ai Wir C2 Fe endralbvaces 0 24° ca Supt 2 ee He backs 2 aS tomate 4 an 2 lowerspat es 12" 25° 2 16 upperslatiles V9 23 ae LL narow spats 8 ce spas xe Dw Cw N fonesit 2K STAC Oss wae SoH Cs Pas ros me C2 fe kegs we aT A eodnais U2 ae ce Sosa Ys wwe 1 feet woe wee "arsine ion Sets ntacin Materials keys. Supplies: 225 decks etwas (2, Jefender washes lock waters 12; 6° hex (02,1520 carage bots 4 3" caiage bots es 54 caoge bots Bits: round ove outer bit Yoo its, courtesink. Source “lider bracket hardware: No 5833052798, RoclerHacnare, 8203279488, rclercom, 'WoOD magazine jy 2017

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