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WoodSmith Issue 100 en PDF
WoodSmith Issue 100 en PDF
Sawdust
Editor
Executive Editor
Managing Editor
Donald B. Peschke
Douglas L. Hicks
Terry J.Strohman
I t's still hard to believe that this is the
100th issue of Woodsmith. To me, it
just doesn't seem that long ago that I was
The Readers' Gallery isn't the only thing
special about this issue. We've also in-
cluded three special projects.
Assistant Editors Jon Garbison working on the first issue. I guess time CLASSIC WORKBENCH. The last time we
Mark A. Williams does fly when you're having fun. featured a traditional workbench was in
Creative Director TedKralicek READERS' GALLERY. To help celebrate Woodsmith issue No. 50. But this time, in-
Senior Illustrators David Kreyling our 100th issue, I wanted to do something stead of a "European-style" bench with an
Cinda Shambaugh special. Something a little different. open base, we took a different approach.
DirkVerSteeg So a couple issues back I asked readers We designed a classic cabinet style
Illustrator Erich Lage to send in photographs of Woodsmith pro- workbench. (It reminds me of the kind of
Photographer Crayola England jects they had built. To say that I was bench you might have seen in a turn-of-
Electronic Graphics Chris Glowacki pleased with the response would be an un- the-century woodworking shop.)
Design Director Ken Munkel derstatement. I can't remember the last Besides offering plenty of storage for
Senior Designer Kent Welsh time I had so much fun opening the mail. various tools and accessories, this bench
Shop Manager Steve Curtis Every day we received dozens of entries. also features a solid maple top. And an
Shop Asst/Facilities Steve Johnson
(There's one day's worth shown at the bot- easy to install, bolt-on woodworking vise.
tom of this page.) And every day I was im- As I said before, this bench has an old
CIRCULATION pressed by the quality and variety of the fashioned feel to it. So we wanted to photo-
Sw6serijotionMancw7ers:SandyBaum,TroyJ.Dowell, graph it in an old fashioned setting (see
Paige Rogers • Assistant Subscription Managers:
projects being built.
Shane Francis, Julie Greenlee • Newsstand Manager: But best of all, it didn't seem to matter if the photos on the front and back covers).
Kent A. Buckton a person had been a woodworker for 22 The trick was finding the right setting. But
PUBLISHING SERVICES years (like Mary Ellen Hampton), or they we found it right here in Des Moines: the
Mgr: Gordon Gaippe • Graph. Artist: Cheryl L. Cynor were building their first woodworking pro- woodshop at Living History Farms. (Living
CORPORATE SERVICES ject. All of them seemed to share a genuine History Farms is an open air museum that
Planning Director: Jon Macarthy • Controller: Robin
love of woodworking. And that's some- tells the story of Midwestern agricultural
Hutchinson 'Account.: Laura Thomas • Bookkeeping: thing I'm proud to be part of. and rural life.)
Holly Lucas • Production Mgr.: Carol Quijano • Info. All in all, we received hundreds of photo- DOVETAIL CHEST. The other "old fash-
Serv. Mgr.: Joyce Moore • Elec. Pub. Coord.: Douglas graphs. Many more than we could ever ioned" project in this issue is the dovetail
M. lidster • Network Adm.: Nick Thielen • Admin. hope to put on two pages. So we picked chest on page 18. It features traditional
Assistants: Cheryl A. Scott, Julia Fish* Receptionist:
Jeanne Johnson • Build. Maint: Ken Griffith photos that represented a wide variety of hand-cut joinery and a shellac finish.
Woodsmith projects. Congratulations to THREE-BOARD SHELF. Also, check OUt
WOODSMITH MAIL ORDER those people whose projects appear on the three-board shelf on page 28. It's a sim-
pages 16 and 17. And to everyone who sub- ple weekend project with a unique mount-
Art Dir.: Cindy Jackson • Catalog Prod. Mgr.: Bob
Baker • Inv. Control/Prod. Mgr.: Mark Mattiussi mitted photos — thank you. ing system.
• Proj. Supplies: Linda Jones • Tech. Supp: Dave Stone
• System Operator: Tammy Aldini
CUSTOMER SERVICE
Manager: Jennie Enos'Team Leader: Karla Cronin
• Customer Service Reps.: Jennifer Murphy, Joy
Krause, Sara Kono, Anna Cox, Lonnie Algreen,
Adam Best, Kristi Andrews
SHIPPING DEPARTMENT
Supr: Nancy Johnson • Fulfillment Gloria Sheehan,
Chuck Carlson, Sylvia Carey, Larry Prine
WOODSMITH STORE
Manager: Dave Larson • Assistant Manager: Paul
Schneider»Sa£es Staff: Wendell Stone, Pat Lowery
• Office Manager: Vicki Edwards
Contents
FEATURES
Classic Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sturdy and solid — nothing on this workbench is fragile.
Even the metal vise features heavy wooden jaws, so it has Classic Workbench page 6
a wide clamping surface and holds a pair of bench dogs.
Laminated T o p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
There are two tricks to building aflat laminated bench top:
laying out the boards properly and gluing them up. We've
included some tips, techniques, and a simple jig for making
this process as easy and accurate as possible.
Readers* G a l l e r y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Many readers responded to our request for snapshots of the
projects they've built from past issues. Here's your chance
to see the work of some fellow woodworkers. -•**,
Dovetail Chest page 18
Dovetail C h e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8
This heirloom chest is just a box with a lid — and a sliding
tray inside. It'll give you a chance to use some traditional
woodworking techniques and an old-fashioned finish.
Hand-Cut Dovetails 24
If you've never cut dovetails by hand (or if you need a quick
"refresher course"), here's our simple step-by-step method.
Tips & T e c h n i q u e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shop Notes 30
S o u r c e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FROM F E L L O W W O O D W O R K E R S
Remove existing
base and install
auxiliary base
* Masonite base
Insert
Insert
t
Straight
~" bit Profile bit
Va" Masonite
auxiliary base
SECOND: Cut out
circle and drill
clearance holes
QUICK TIP
Class& Workbench
The base of this workbench does more than support the top. The trays and
drawer store a shop's worth of tools — within easy reach.
ost shops can always use more storage cabinet already filled with tools. When you com-
space. So why not build a workbench bine the two, you end up with a "rock-solid" work-
where the base not only supports the top but also bench capable of handling most any project.
provides space inside for your hand and power To hold these projects on the bench, there's a
tools? That's the idea behind this workbench. metal woodworking vise attached to one corner
And to make it easy to use this storage space, with a thick, maple-block covering the front jaw.
a drawer and two trays ride on full-extension A pair of dog holes in the block line up with the
slides to keep your tools accessible. holes in the bench top so bench dogs can be used
Then there's the top. This laminated, hard ma- to hold big projects. And the vise is easy to install.
ple top adds considerable weight to a storage Just four lag screws hold it in place.
Made from
strips of 8/4 hard maple
glued face-to- face
BASE:
Outside case is made from
cherry hardwood and plywood
Interior framing and
drawers made from maple
hardwood and plywood
NOTE:
Complete cutting diagram
and materials list on page 13
CROSS SECTION
END VIEW
———— 22%" —————
VISE DETAIL The Record #52V2 ED vise with
CROSS SECTION wood jaws has an open capacity of 9%"
Solid steel
handle
Drawer
_ Ball catch
for doors
Wood
Note: Drawer and trays spacer
are mounted with full-
extension drawer slides _ Quick-release lever allows ^- Vise mounted with (4)
vise to open and close freely V2" x 3" lag screws
wood knobs
Frame and
panel doors Trays- HARDWARE LIST
Frame and
panel back • (1) Record #52V2 ED Vise (8) #4 x 1/2" Fh Woodscrews
• (2)#14x2" RhWoodscrews (4) 1/4" x 3" Lag Screws
• (4) 1/2" x 3" Lag Screws (4)V4" Washers
. (4) 1/2" Washers (20) #8 x 13/4" Fh Woodscrews
• (4) 1V4"-dia. Wood Knobs (36) #8 x 11/4" Fh Woodscrews
Hardwood • (2pr.)2" x1 3 /s" Ball-tipped (16) #8 x 1" Fh Woodscrews
kickboard Hinges (3 pr.) 16" Full-Extension
- 19V2"-
• (2) Ball Catches Drawer Slides
MOUNTING
R)Ci£A7 O. CROSS SECTION a.
VERTICAL (TOP VIEW) CROSS
STIFFENER SECTION
(SIDE VIEW)
K. l_KUii iCtllUIH
(SIDE VIEW)
^ \ \ iltl
\V-N
•«-7!4-*-
#8x 13/4"
ft
Fh woodscrt w fi? Miter
NOTE: Glue kickboards to
^ fit around case
and screw
stiffeners to
backs of stiles ^ f^ ll
TRAY SIDE
a. TOP END VIEW
VIEW
Size groove
SIDE to match
plywood v / J~
L^' I
V2"
I
TRAY FRONT
' FRONT/BACK-
CROSS j
f b - sECTION
(T<M> VIEW) ',
/
Center 1 W-dia \ \ '• P
knob on width
of door stile, K
\\1
V
x '> J ^/P
see Fig. 13.
/' \
=
_* 1
NOTE:
Keep a '
clearance
around doors,
i
DOOR
STILE
f- •
^ ———— ,
Mortise hinge
int0 D0th door
anci front frame
\
see detail a.
15 Rout pocfcet
in bench strip CROSS SECTION
for vise jaw
n
9Vis"
Do not use
alignment dowels
in first two holes
Top edge I
Front
strip (Ato.7.)
17 Laminated
Top
FRONT VIEW NOTE:
Before mounting top to base CROSS SECTION '-*'
Install top so it's centered rout Vs" chamfer (SIDE VIEW) chamfer-^
side-to-side on cabinet around bottom edges
washer
~- VA" x 3" lag screw
NOTE:
Chamfer
top edge
of face block
with vise
closed
Laminated Top
Building a laminated top may keep track of the direction, I'll
seem a little intimidating at first. mark an arrow on the board
You have a lot of boards to cut pointing to the crook.
and fit together. But you don't BOW. When you've identified
have to be a magician to get a the crook, you can sort the
solid, tight-fitting top if you boards to minimize bow. Bow is
know a few tricks. It only takes warpage along the edge from
two steps: laying out the boards end-to-end, see Fig. 2. Unlike
so they're compatible with each crooked boards, you can usually
other and gluing them together pull a bowed board straight.
to avoid any gaps. That's because you're straight-
ening the board across its thick-
LAYOUT ness (not across the width).
Like drawing and discarding Here again, arrange your
playing cards to get a better boards so the "bows" oppose
hand, the boards in a laminated each other. I'll put my straight-
top need to be sorted for the est boards on the outside to help
best fit and appearance. This pull the rest of the bowed pieces
means checking each piece for straight. Note: While rearrang-
crook and bow but also arrang- ing the boards for bow, remem-
ing the workpieces so the top looks its best. "pull" a crooked board straight. So do you ber to keep the crooks opposed.
CROOK. The maple boards I used all had discard all the boards with crook? Well, if APPEARANCE. With the pieces sorted for
a little crook and bow. But when trying to there's more than Vs" of crook, I'll cut it into crook and bow, you still need to consider
assemble a laminated top, the crook of a shorter pieces for another project. how the boards will look when glued to-
board can cause you more trouble than its Boards with less than Vfc" of crook can be gether. Small blemishes will be sanded out
bow. So I checked for crook first. used — if they've been sorted first. I ar- when the top is leveled. But for larger de-
Crook is warpage across the width of a range them so the crooks oppose each fects you should shuffle the boards again.
board running from end-to-end, see Fig. 1 other, see Fig. 1. This way when the pieces LABEL PIECES. Once you have the boards
and the Shop Tip below. It can be difficult to are forced flat, the crook is canceled. To arranged for crook, bow, and appearance,
How much crook is there? It's stretch the string from end-to-
not always easy to tell. A simple end and tape it in place. Then at
way to measure crook is to use the center measure the gap be-
a string and some tape. Just tween the string and the board.
Gallery
O ver the years, a lot of readers have sent
us photos of projects they've built from
Woodsmith. Plus, we've received hundreds more
since I announced this gallery in the Sawdust Oak Rocking Chair (Issue 84)
column a couple of issues ago. Tom Baker
Of course, we couldn't include every photo. San Diego, California
What you see here is a sampling of the crafts- Editor's Note: Tom used black
manship and ingenuity of our readers. Some fol- walnut to build his oak rocker.
lowed our plans closely; others adapted them
quite a bit. We hope you enjoy seeing these
completed projects as much as we have.
Saw Cabinet (Issue 47)
David Kerski
Eden Prairie, Minnesota
"This photo was taken in
my library because my
shop was too small."
Classic Roadster
(Issue 51) Garden Bench (Issue 93) Rocking Horse (Issue 65)
Frank Pino Bill Kilpatrick William Murray
Edwardsville, Kansas Enniskerry, County Wicklow, Ireland London, Ontario
Heirloom Cradle
(Issue 48)
Robert Kubiak
Omro, Wisconsin
Curved-Front Table (Issue 77)
Mark Hoecker
Charlotte, North Carolina
Dovetail Chest
The charm of this small chest is created with
two "old" woodworking techniques: cutting dovetails by hand
and brushing on a few coats of shellac.
Y ou don't want to rush hand-cut dovetails.
They require careful, deliberate work. That
doesn't mean they have to be perfect. After all,
Come to think of it, applying the finish to this
chest is rewarding too. I wanted it to match the
"antique" character of the chest. And what better
hand-cut dovetails aren't going to be machine- way than to use an "antique" finish?
precise — especially with wide panels. But that Shellac has been used on furniture a long time,
fits the charm of this chest perfectly. and its color adds a natural warmth that's hard to
There's something to be said for a few quiet get from an off-the-shelf stain.
hours in the shop. Working without the roar of a Of course, many woodworkers think of shellac
router or breathing the clouds of dust. Okay, so as a "delicate" finish. And while it may not match
the pace is a little slower, and the process takes a the durability of polyurethane, a lot of antiques
little longer. This is one time to throw out the finished with shellac have put up with years of
schedule. If you can put yourself in the right wear. And it's not difficult to apply either. For step-
frame of mind, the process is its own reward. by-step instructions, see the box on page 23.
EXPLODED VIEW
NOTE:
All panels are
glued up from BASE
solid wood END
BASE
FRONT Dovetails cut by hand,
see a/t/c/e on page 24
LID-
TRIM
FRONT
TRIM
BOTTOM-
BASE
Sliding Tray. Like the case, the sliding tray inside the
chest is joined with hand-cut dovetails. This tray sits on
simple supports glued into the front and back of the case. END VIEW
CROSS SECTION
Wide pin
at top is
covered by
trim molding
later, see
next page
NOTE:
Cut 3/a"-deep To apply pressure,
groove for bottom clamps should be
in all case pieces positioned over tails
Rip chamfer on
top, outside edge
of base blanks
CROSS SECTION
TRIM
FRONT/BACK V?
SHELLAC
When choosing a finish for this chest, I Though any alcohol will work, I dissolve
wanted a warm, "aged" color. But instead of shellac in denatured alcohol. Shellac is
trying to mimic an old finish, I decided to mixed in "pound cuts" — the number of
use the real thing: shellac. pounds of flakes to a gallon of alcohol. For
For this chest, I applied one coat of or- this chest I used a 2 Ib. cut. But I only mixed
ange shellac. The orange shellac gives the up a pint of each grade (which requires 4 oz.
wood its warm color — and it doesn't blotch of shellac flakes). And don't worry about be-
like a normal stain will. But more than one ing precise. Just get it in the ballpark.
coat makes the wood too dark. Shellac doesn't dissolve like Kool-Aid. It
So to keep the color lighter but still add takes several hours or more. Pour the flakes
more protection, I applied two more coats of into a non-metal container. (The shellac re-
another "grade" of shellac: blonde shellac. acts to metal.) Then pour in the alcohol and
(Shellac comes in several grades, see page stir it. Let it set a bit Then stir it again. It's ish too much with the brush. The shellac
31.) Actually, this isn't a different type of a good idea to strain the shellac a few times dries fast, so you can apply another coat af-
shellac. It has just been purified more, so before using it, see photo. ter about three hours. Note: If the shellac
there's not much color. Before applying the first coat of shellac, I seems to be drying too quickly, then thin it
Shellac comes ready-to-use or in flakes sanded the dovetail chest to 220-grit be- a little with more alcohol.
that must be dissolved in alcohol. (See page cause the soft grain of pine tends to raise I sanded the first coat lightly with 400-grit
31, for sources.) Once dissolved, it begins when shellac is applied. paper. Then after the two coats of blonde
to slowly deteriorate. So, I use the flakes and To apply shellac, I use a natural bristle shellac were applied, I rubbed out the finish
mix my own. This way, I know it's fresh. brush. The only trick is not to work the fin- with 600-grit paper.
MATERIALS SUPPLIES
A Front/Back (2) 3/4X18V*-36 G Trim Front/Back (4) 1/5x3/4-40 rgh. • (1 pair) 3" No-mortise Hinges
B Ends (2) 3/4x181/4-16 H Trim Ends (4) 1/4 x 3/4 - 20 rgh. • (1) 15" Brass Chain
C Bottom (1) I Lid(1) 1V16X18-38 • (2) #8 x 5/&" Brass Rh Screws
D Tray Supports (2) 3/4 X 3/8 - ; J Tray Front/Back (2) 3/4 x 31/2 - 24
E Base Front/Back (2) 1 Vie x 3 - 40 rgh. K Tray Ends (2) 3/4 X 3'/4- 143/8
F Base Ends (2) 1Vi6 x 3 -20 rgh. L Tray Bottom (1) 1/4x1314-231/8
'/////. ty '//////
'/, '/// ^'/////, ////
'////////, ////;/ ////
V x 8"- 96" (Two boards @ 6.6 bd. ft. each)
Hand^Cut Dovetails
A step-by-step approach to cutting dovetails in wide panels.
Plus, some techniques for assembly and a few troubleshooting tips.
TROUBLESHOOTING
It's a good feeling when those pins finally add an auxiliary base to your router and rout The idea is to cut an even kerf through
slide into the tails. But sometimes the joint them flush, see page 30. the gap, see Fig. 1. Then glue a spline in the
isn't quite perfect GAPS BETWEEN DOVETAILS. Gaps are a kerf to "patch" it, see Fig. la.
PROTRUDING TAILS* PINS. One common much bigger problem. For instance, you GAPS AT BASELINE. There's another pos-
problem is when either the tails or pins stick might have a gap between a tail and a pin (or sible gap you might run into: a gap along the
out. But this is easily corrected with a little between several tails and pins). This can be baseline of the tails. Here the cut was too
sanding, see the box on page 21. And if fixed, but once again, you'll need to get out deep. The solution is to use wedges to fill the
there's too much to sand off quickly, you can your hand saw. gaps, see Fig. 2.
To fill baseline
gap, glue in—
wedges and
trim flush
Three
Board
Shelf
This evening project
makes use of a unique,
invisible hanging system.
NOTE: Do not
e
rout bullnose profile
on these edges
Vi* squares
Router \
fence ~\ \ "~
J^V]
NOTE:
Strike 12" NOTE:
radius from Rout slot in
center of shelf Raise bit to cut multiple passes
through auxiliary base
Shop Notes
DOVETAIL JIG
• The timing couldn't have There's a block to guide the saw, the sides for cutting the tails. end of the workpiece and start
been better for receiving a dove- and a clamping bar to hold the And has two angled kerfs for on the pins, see Fig. 3. For more
tail jig design from Jeffrey jig in place. cutting the pins. on cutting dovetails, refer to
Kern of Benicia, California. We Once you've decided on the Then glue and screw the page 24. The only thing critical
were just getting started on the dovetail angle (I used 14° for the guide block to the clamping bar, here is to make sure the saw
dovetail chest. And his jig helps dovetail chest on page 18, and 9° see Fig. 2. But don't cut off the blade stays tight against the
keep the saw aligned with the for the drawer on page 11), it's waste just yet. It keeps all the guide block on the jig.
lay-out lines when making the easy to build the jig. Start with pieces of the guide block posi- You cut the tails the same way.
cuts. (Refer to page 24 for more the guide block, see Fig. 1. Both tioned correctly on the clamp- Except this time, you'll use the
on laying out dovetails.) the sides and kerfs use the same ing bar until the glue dries. bevel on the side of the block to
The jig consists of two pieces. angle. The block is beveled on To use the jig, clamp it to the guide the saw, see Fig. 4.
Use kerfs to
GUIDE guide saw when
BLOCK #8x1VSFh cutting pins
Waste woodscrew
GUIDE
i
BLOClC\ END VIEW
'- t
CLAMPING
BAR
Remove waste from guide
block after the glue dries
Angle ofj
dovetail
TRIMMING DOVETAILS
• On page 21 we show a tip for- bit and your router, see Fig. 1. lem, I made an auxiliary base to can reach the pins and tails. To
trimming dovetails flush with a But first you have to replace raise the router up so it doesn't make the base stable, it's cut ex-
belt sander. This works fine the existing router base with a hit the dovetails. tra long (mine was 11"). And for
when there isn't much material different one. That's because 3
This auxiliary base is simply added control, there's a block at
to remove. But if the pins and the edge of a regular base runs a /4"-thick piece of stock with a one end for a handle.
tails are cut a little long, there's into the pins or tails before the wide rabbet cut on the bottom, To use the jig, adjust the bit
a quicker way to do the same bit can get near enough to trim see Fig. 2. The rabbet provides height so it trims the pins or tails
thing. All you need is a straight them flush. To solve this prob- the clearance needed so the bit flush, see Fig. 3.
Sources
Woodsmith Project Supplies prove the versatility of a work-
S U P P L I E S
Final Details
Hand-CutDovetails Page 24
Cutting dovetails by hand isn't
just for the experts. You can create
a tight-fitting joint with our step-
by-step instructions.