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THEARTOFWOODWORKING

HOMEWORI$HOP
 I
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WORKSHO
GPU I D E I
HARDWARE
ANDINLAYS I
Bed bolt covers Escutcheone Federal-otyle inlayo
t

M I
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CATCUTATING
BOARD
FEET
0rdering lumber bytheboard foot I
NUMBER OFBOARD FEET Because theboardfootisa unitof measurement that
IN4 TINEAR
FEET()F offersa standard wayof totaling thevolume of stock
I
DIFFERENT
SIZEBOARDS regardless of dimensions, it is commonly usedwhen
dealing withlumber. Asshownat left,thestandard
I
1"x 12"x 12"= 1otandard board foot boardfootis equivalent to a piecethatis 1 inchthick,
12 inches wideand12 inches long.Tocalculate the
I
number of boardfeetin a particular pieceof wood,
1-by-3=lboardfoot
multiply itsthreedimensions together. Thendivide I
theresult by I44 if thedimensions areall in inches,
1-by-6=2boardfeet or by 12 if onedimension is expressed in feet.Forthe
I
standard board, theformulais:
I " x 7 2 "x 1 2 "+ 1 4 4= I ( o r1 "x 1 2 "x I ' = L 2= 7 ) . I
Soif youhadan8-foot-long 1-by-3, youwouldcal-
1-by-12=4boardfeet culatetheboardfeetasfollows: 1 x 3 x 8 + 12 = 2 (or I
2 boardfeet).Otherexamples areshownin theillus-
tration.Remember thatboardfeetarecalculated on
t
thebasisof nominal ratherthanactualsizes.
2-by-4 = 22/z board feet I
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2-by-6=4boardfeet I
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THEARTOFWOODWORKING

CLNSIC
AMERICAN
FURNTTURE
 THE ART OF WOODWORKING

CIASSIC
ANAERICAI
FURNITURE

TIME-LIFE
BOOKS
ALEXANDRIA,VIRGINIA
ST.REMYPRESS
MONTREAL
 r
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THE ART OF WOODWORKING was produced by
ST.REMYPRESS
THECONSUTIANTS t
JonArno is a consultant,cabinetmaker,and freelancewriter who I
Publisher KennethWinchester livesin Tioy,Michigan. He conductsseminarson wood identifi-
President / ChiefExecutiveOfficer FernandLecoq
President/ ChiefOperatingOfficer PierreL6veilld
cationand earlyAmericanfurnituredesign,and is the authorof
TheWoodworkers VisualHandbook,publishedby RodalePress. I
SeriesEditor
SeriesArt Director
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FrancineLemieux
Mike Dunbar builds fine furniture at his workshop in
Portsmouth,New Hampshireand offersWindsorchairmaking
t
SeniorEditor Marc Cassini seminarsacrossNorthAmerica.He is a contributingeditorof
Editor Andrew Iones AmericanWoodworkerand author of FederalFurniture and I
Art Directors lean-PierreBourgeois,Michel Gigudre MakeAWndsor ChairWth MichaelDunbar,bothpublished
Designers FrangoisDaxhelet,Jean-GuyDoiron
FrangoisLongp16
by The ThuntonPress.
I
PictureEditor ChristopherJackson GilesMiller-Mead taught advancedcabinetmakingat Montreal
Writers fohn Dowling, AdamVan Sertima
Contr ibuting IlIustrators GillesBeauchemin,Michel Blais,
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Zealand,he hasworked asa restorerof antique furniture.
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Administrator NatalieWatanabe ClassicAmericanfurniture.
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 CONTENTS

6 INTRODUCTION L04 QUEENANNE SECRETARY

106 Anatomy of a
T2 CTASSICAMERICAN QueenAnne secretary
FURNITURE STYLES 109 Making the deskunit
1 1 6 Making the drawers
22 PEMBROKETABLE 1 1 9 Building the pigeonholeunit
24 Anatomy of a Pembroketable 12T Making the fall-front
26 Making the leg-and- 1 3 0 Making the bookcase
rail assembly 1 3 5 Making the doors
30 Preparingthe siderails
4 I Making the drawer I4O GLOSSARY
43 Making the top
I42 INDEX
48 FOUR-POSTERBED
50 Anatomyof a four-posterbed I44 ACKNOWTEDGMENTS
52 Tirrning the bedposts
59 Making the end boards
66 Pencilposts

70 WINDSOR CHAIR
72 Anatomy of a sack-back
Windsor chair
74 Making the spindles
80 Making the bow and arm
84 Making the seat
88 Making the legs,arm posts,
and stretchers
94 Assemblingthe chair
103 A milk paint finish
 INTRODUCTION

Dr. Iohn Kassayon

WINDSOR
FURNITURE
deceptivelywell-engineeredfurniturestylewhosepartsareassembled mainly
fromwoodensticks, Wndsorrepresents oneof history's
mostinnovative and I
recognizable furnituredesigns. TheWindsorfamilyof furnitureconsists of stools,
chairs, cradles,
stands,andtables.
basicforms,suchascomb-backs,
Chairsarethelargest
step-downs,
categorywith
andthesack-back
eightdifferent
version, whichis
r
featured beginningon page70.Chairsalsospawned ninederivatives thatinclude I
stools, rockingchairs,writingarmchairs, andchild-sized chairs.
Theoriginof Wndsorsisancienthistory.Theirantecedents canbeattributed to I
theEgyptians, wheretombdrawings of the18thDynastydepictworkmensittingon
threeJegged hand-hewn
Wndsoris something
stoolssocketed
of anenigma,
to a plankseat.Thereason
but themostlogicalexplanation
for thename
is thatthey
r
werenamedduringthefirst decade of the 18thCenturyaftertheEnglishtown I
of Windsotwhosebeechtreesprovideda plentifrrlsupplyof rawmaterialfor legs
andotherturnedparts. I
Windsorchairsimprovedon thetraditionaljoiner'schairsof theperiodby
eliminatingtheneedto glue-upseatframes. In aWindsorchair,theseatis a solid I
plankservingasthefoundationfor thelegsandstretchers andfor thespindleback.
Thatsimplicityandstrenghof designis no doubtoneof thekeysto thechair's I
undyingpopularityandlongevity.
Windsorchairmakingstarted asa cottage industryin England duringthe1720s, I
but soonbecame animportantfactory-based operation,employing hundreds of
workers, centeredin thetownof HighWycombe. AlthoughthefirstWndsorsin I
Americawerechairsimportedfrom England,Philadelphia chairmakersalmost
immediately capitalizedon thispopularnewform of easilymadeseating. Their
one-manshopsexpanded intolargefactories.
Englishchairmakerstookadvantage of thephysical properties
of differentwoods
for differentcomponents of thechairs,usingashfor bentparts,beechfor turnings,
andelmfor seats. TheirAmerican counterparts usedhickoryredoakor ashforbend-
ing,maplefor turnings,andpinefor seats. Windsors weretraditionallypaintedgreen,
butothercolorssuchasblue,mustardandredwerealsoused.Thepaintconcealed the
differentwoodcolorsandservedto protectthewoodoutdoors,whileconveying a
unifyingwholeness to thepiece.ManyEnglishchairsweresimplydip stained.

Nowretired,Dr.JohnKassay taughtfurnituredesign for 30yearsat San

FranciscoStateUniversity.
HisBookof Shaker Furniture, published
bythe
University
ofMassachussettsPress,
isconsideredoneof theforemostreference
boolcs
onShaker preparing
style.Heiscurrently a similarbookonWndsor
furniturefor thesamepublisher.
He livesin SanBruno,Califurnia.
ET
r l INTRODUCTION
l l
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GregoryWeidmantalksaboutthe
t
I APPEALOF
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FEDE,RAL
STYLE
A s a graduatestudentat theWinterthurMuseumProgramin EarlyAmerican
f\ Crliut., I wasprivilegedto work with the country'fpremierecollectionof
Americanfurniture,includingthe bestexamples of the stylesmostpopularwith
cabinetmakers today-QueenAnneandChippendale. Evenin thissetting,though,
I wasalways drawnto theneoclassicalpieces of thelaterFederaland Empireeras.As
curatorof the MarylandHistoricalSocietyin Baltimore17 yearslater,I am still
studyingandwritingaboutthosewonderfulpiecesthat I foundsoappealing.
TheFederalera in Americabeganwith independence from England. Thispolitical
I changealsousheredin a newperiodin the arts.The Federalstylerepresented an
I-. estheticrevolutionoverthe popularChippendale and Rococostyles.The promi-
3
II nentfeatures of the earlierperiods-florid,naturalistic carving,asymmetryin
in casefurniture-were all derivedfrom
I
r'.U
ornament,andarchitectural
a hodgepodge
massiveness
ofhistoricalandcontemporary sources. Federal furniturereplaced
theseartisticexcesses with a clean,linearstylethat lookedbackto jllst onesource
of inspiration-AncientClassicism.
The greatneoclassical architect/interior designerRobertAdamintroducedthe
I new styieto the Englishgentry,and ftrrnituredesigners GeorgeHepplewhite and
ThomasSheratonpublishedhighlyinfluentialbooksthat popularizedits ancient
GreekandRomandecorative motifs.
"Hepplewhite"
In theUnitedStates, thisnewstyle-sometimes alsoreferred to as
"sheraton"-was Althougheachmetropoli-
or theheightof fashionby themid-1790s.
tanareadeveloped its owndistinctive form of Federal style,therewerecertainbasic
thatdefinedit. Thepieces
characteristics in general arelightanddelicate, with atten-
uatedelements suchastaperedlegs.Surface areflat andlinear,relyingon geomet-
of veneerandbandingin contrasting
ric patterns woodsto achieve themainesthetic
effects.Ornamentation is primarilyinlaidandpatterned stringingand pictorial
motifs.Decorative elementsarederivedfrom ancientclassical sources:
columns,
shells,urns,swags, leaves andvines,with onedistinctively Americanmotif:thepatri-
oticeagle,symbolof thenewnation.
Byabout1810,Federalstyle beganto evolveintoLateNeoclassical or Empiretaste,
whichwasevenmorecloselyinspiredby archaeological discoveries.Actualpieces of
"klismos"
ancientfurnituresuchas chairs,banquetingcouches, andtripod stands
werereproduced by cabinetmakers. Not until the lB40sandtheadventof romantic
Victorianrevivalstyles wasthetastefor theClassicalsuperseded in theAmericanhome.

GregoryWeidmanis Curatorof theMaryland

HistoricalSociety homeofAmerica's
in Baltimore,
largestcollectionof Federal
furniture.
 INTRODUCTION

Norm Vandalexplains

QUEENANNE'S
LINE OFBEAUTY
f nrnut.riulobjectssuchasfurniture,I believe beautyisbornfrompleasing pro-
I portionandtheharmonious relationship between curvedandstraightlines.
Straightlinesimpartstructure, mass,andsolidity.Curvedlineslendmovement,
elegance, andgrace. Tome,QueenAnne-style furniturepresents theperfectunion
of straightandcurvedcomponents. Simplelines,gracefulcurves, unpretentious
decoration, anddelicate proportionall contributeto someof themostbeautiful
expressions in Americanfurniture.
QueenAnneisa namegivento a styleof furniturefirstproduced in theAmerican
Colonies in theearlyto mid l8th Century. Assigning periodsor historicalepochs
to furniturestyles, however, issolelyusefulfor discussions abouttheirorigins.This
stylesawonlyembryonic development duringthereignof QueenAnneherself, yet
it remains immensely popularto thisday.Indeed, whileI amcertainlynotan 18th
Centurycabinetmaker, mostof thepieces I'veproduced in myrural,one-man shop
havebeenin thiselegant style,andtheyhaverangedfromfaithfulreproductions of
periodpieces to modernadaptations.
Whatarethehallmarks of Queen Annefurniture? Themostprominent featureis
thecabrioleleg,a sculptured, three-dimensional formbasedonanimalmotifs.Other
essential characteristicsincludethescrolled apronsoftables, chairsandcase pieces;
thevase-shaped splatsof chairbacks; thescrolled pediments of highchests andsec-
retaries;thearch-panel doorsofsecretaries andcupboards; andtheshellcarvings on
chaircrests, dressingtables,andothercase pieces.Virtuallyallof theseelements are
dependent on thecurve,on theS-shaped "line
so-called of beauty."
In becoming familiarwith anystyleof furniture,youeventually recognize how
styleis evolutionary, howit develops andchanges with theaccretion of newideas.
All designisin constant flux at anyof itsstages. I takegreatpleasure in examining
furniturefor vestiges of theQueenAnnestyle,bothin periodpieces andin new
designs fromtheshopsof contemporary craftsmen. I don'task"IsthispieceQueen
Anne?" "What
butrather aretheQueen Annecharacteristics of thisparticular piece,
anddo anyotherelements contribute to or conflictwith theeffective beautyof its
design?" In thisway,theoldis constantly blended with thenew-a stockpot in the
kitchenof ideas.

Norm Vandalbuildsreproduction furniture in his

Roxbury,Vermontshopand teaches literatureat s
nearbyhighschool.
He is theauthoro/QueenAnne
Furniture,publishedby TheThuntonPress.
I
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CLASSICAMERICANFURNITURESTYLES r
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At{NE
OUEEI{ I
Spanning mostof thefirsthalfof
the 18thCentury, theQueen Anne SECRETARY I
stylewasbothinfluentialand (page 1o4)
original, characterized byrefined, A desk-bookcaae combination
with a veneeredfall-front;
I
flowinglineswithoutexcessive dec- featu rea d ovetailed cornere
oration. Inchairandtablemaking, and drawera I
thestylespawned an important
innovation: thecabriole leg.Queen I
Annedesigns migrated to America
afterbecoming wellestablished
Lar6e braaa
t
in England. Thestyleeventually
f o u n da h o m ei n P h i l a d e l p ht ihae,
baak plate
with bail t
colonies' mostimportant cabinet-
makingcenter. Queen Annefurni- I
tureremained popular in America
longafterit wassuperceded in I
England bytheearlyGeorgian style.
I
t
AUEENANNE t
CHAIR
r
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Curved
chair baak
CARDTAELE I
Padded Top folda in half and aide raila
alip aeat foid inward to move leae cloeer
to1ether
t
r
I
Cabriole
Ieg
r
Thehighboyaboveexemplifies
I
theharmonybetyveen straight
linesandfluid curvestypical
r
of QueenAnne-stylefurniture I
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I
I CLASSICAMERICANFURNITURESTYLES
I
I
CHIPPENDALE
t CHINE1E
NamedafterBritishmastercarver CHIPPENDALE CHAIR
I a n df r r r n i t r t rdee s i s n eTr h o m a s Feat.ureda clean rec-
C h i p p e n d a lteh,i ss t y l ee m e r g e d Lan4ularlook wlLhliqhlt
I i n t h e s e c o n dh a l fo f t h e 1 8 t h 4eometrtc freLwork
Century.It is oftenthoughtof as
I QueenAnnedressed up withorna-
m e n t a t i osnu c ha ss h e l cl a r v i n g s .
I intricate fretwork, piecrust edging,
a n do t h e re l e m e n tosf r o c o c o r
I Chinese d e s i s n T h e s t v l ef l o u r -
i s h e di n t h e A m e r i c a n cabinet-
I m a k i n gc e n t e r o s f B o s t o nN, e w
Y o r kN , e w p o rat .n dP h r l a d e l p h i a ,
I w i t he a c hc e n t e d r e v e l o p i ni g
ts
o w ns i g n a t u r eP.h i l a d e l p h i a
I C h i p p e n d aw l ea st h e m o s te x t r a v -
a g e n ti n i t s c a r v e dd e t a i lw
, h i l ei n
I N e wY o r kt h e s t y l ew a sm o r e
restrained l n. B o s t o nt ,h e b o m b e -
I shapedchestwaspopular.Newport
h e l p e dp o p u l a r r zaeu n i q u e l y
I A m e r i c a fno r m :t h e b l o c k - f r o n t .

t FeaLured a tilttnq
top and l,ripod leqe

I 9ATINWOOD
Kosette pull
COMMODE
I Thebombbehape thell
wao typtcal of I;he carving
I DoeLonoLyle

t
I
I nff$ay\
"ru# ,EFhr",
q<;,^r Cdhb
-lgr'-
I
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I
ELOCK-FRONT
I CHE?T
An Americanadaptton
of the Chippendale
atyle
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CLASSICAMERICAN FURNITURE STYLES r
r
FEDERAT
PTRIOD
I
Afterthe Revolution, American furniture
makersbeganto distance themselves WORKTAELE I
fromBritishinfluence. Endeavoring to Thou1hdelicate in appearance,
createa newstyle,theyturnedto the the table waa solid enouqhto
eupport a heavymarble top
T
classicaldesigns of ancient Greeceand
Rome.Forthis reason. Federal furni- I
tureis oftencalled"Neoclassical." More
austerethanChippendale, Federalpieces I
typicallymimicked the linesandfeatures
of antiquity,suchascolumns, animal CARDTAELE I
claws,reeding, fluting,andthe lyre.
Despiteeffortsto achieve indepen-
dence,however, American cabinetmak-
ersremained underBritishinfluence.
Thedesigns of Englishmen George
Hepplewhite andThomas Sheratonwere I
widelycirculated andcopiedin America,
although someNewWorlddesigners I
attempted to Americanize the British
stylesby incorporating the eagleand I
otheroatrioticmotifs.
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Designedtofit belowa recessed window
I
theaptly namedwindow seat,lilcethe PHYFE ARMCHAIR
oneshownabove"wasa popularFederal Marked by a I
theraton-etyle
period daign. Thecross-latticepattern
of theraisedendsis typicalof thebest-
reatanqular baak I
and deliaately
knownFednal daigner,DuncanPhyfe. Fluting croaaed back alata
r
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NUI I N I T U I { ES T Y I - I ] S
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MIKROR
I iemple'ltke cr:lumns
are typtcal ner:classt
cal infiuenoes
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Hinged
I writing
eurface
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I
I PEMEROKE TABLE
2 2 )
I Qaqe
litr:t.apered t6:4e
of i.lue )EYMOUKDE1K
1,.a,ia a r a cha racf.erictl t:
\ An AmencanadapLattonof
I ai' i,.: c h d eotq ner.
r t1.i Taperedleg Hepplewhtt.eand 5 herato n et.yleo
G eo r4 c rl c c p| c.wlt tf t:.:
I lor aaaJ at.orede. f irt
tiliqe.) leavaa oen r;a Braes feet
iroPPt:d dc,ivn Tapered leg
t
 CLASSICAMERICAN FURNITURESTYLE,S

AMERICAN
COUNTRY/C()t()NIAt
Usinglocalwoodspecies andunsophis-
ticated construction methods, colonial
America's oioneers adaoted traditional Four-poater bed
country designs fromEngland to produce (pase 4O)
For qutckdieaeeembly,
s i m p l ep, r a c t i c faul r n i t u rken o w a
ns
the bedpoatofeature
American Country. round mortiee-and'
Although moresophisticated styles tenona LhaLcan be
supplanted thesedesigns in prosperous taken aparL; the aide
colonial towns, rusticfurniture prevailed ratlaare attached to
the poeLawif,hknock-
ontheever-advancing frontier. Withits
down hardware
simplicity, durability, andeconomy, tra-
d i t i o n aAlm e r i c aCno u n t rfyu r n i t u r e
s a p p e at lo 2 0 t h - C e n t u r y
c o n t i n u et o
f urniture makers, particularly thoseliv-
i n si n r u r aAl m e r i c a .

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Back slat r
I
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Rueh seat I
I
An ingeniousresponse to cramped
conditions, thechairtableshown
Ladder-back chair I
Theeeat in the example
aboveservesdoubleduty. With the
tilted-uptopagainsta wall, thepiece
ahownia madeof ruah,
but cane,eplint,and
I
canvaataPe qeata were
canbeusedasa chair.Loweringthe
top transformsit into a table. also commonlyproduced t
I
I
t CLASSICAMERICAN FURNITURESTYLES
I

I CUPBOARD
ANDHUTCH
Variatione
on thie
I de6qn werecom-
monly made in
I America between
1730and 1B4O
t
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I Wrought-iron
etrap hinge
I
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I
Taverntable
I Lowrectan4ular
or circular table
I with atretchere
and t.urnedle7a
I
I
Trestle table
I A larqe tabletop eupported by le4e and a trea-
t[e; tuak or prnnedtenonojotn le4ato the
I treetle, allowin4eaeydreaaeembly

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CLASSICAMERICAN FURNITURESTYLES I
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WINDS(1R
I
TheWindsorchair(page70) is often
CONTINUOU9-ARM CHAIR 9pindle
classified withAmerican Country furniture
Feat.ureaa einqlecontinuoua I
because itssimpleandprecise joinery arm made of ateamed wood
andfunctional elegance harken backto aupported by turned Braaing I
thecraftsmanship of a bygone era.But epindleeand arm poete atiak
theWindsor is neither American norrural. I
Firstmadein late17th-Century England,
it is oneof themostenduring andpopu- I
l a ro f a l l c h a i rd e s i g n T
s .h eW i n d s o r
f a m i l ya l s oi n c l u d esst o o l sc,r a d l e s , I
stands, andtables.
A l t h o u gthh eW i n d s ocrh a i rh a s I
spawned countless variations, virtually
all versions feature a solidseat,which t
anchors separate assemblies of turned
legsanda spindle back. t
I
OVAL- t
EACK
CHAIR I
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Many of theelementsof thecomb-back
Wndsorchairshownabovewereriven
I
andshaped from greenwood.Thechair I
wasmadeby North Carolinawood-
workerDrewLangsner.
I
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I CLASSICAMERICAN FURNITURESTYLES
I
t
r REGIONAL
STYTES
Liketheearlysettlers fromEngland, addedtheirowninfluence to thecat-
I newcomers to America fromother alogof earlyAmericanstyles.Mixed
partsof theworldbrought theirunique intotheblendwereNorthAmerican
I cabinetmaking traditions
withthem. versions of national
stylesbuiltin the
Fromthe Dutchwhofounded New former French andSpanishcolonies.
I Amsterdam to theZoarite Germans Thepieces shownherearea brief
whosettled in 0hio,thenewarrivals sampling of regional
styles.
I
NEWMEXICANCHAIR
I Made bv 7paniah
"Carpinier'oo," Frame-and-panel
thia aonatruation
r chatr reflecte both
9panieh and naLtve-
Americaninfluencea;
I extenaivechip carvinq
eerved to li4hten
I the lookof the heavy
timber uaedin the
a99empty.
I
I
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I FRENCH
PROVINCIAL ARMOIRE
I A popularconLinental
deei4nfound throu4h-
I out Lheformer French
colonieain America,
particula rly Louieiana
T
ZOAR
I CHAIR
A aimplecountry chair,
I baeedon modeleori4inally
made rn Germany,Auetria and
"Lwo-board
I OERMANSAWBUCKTABLE
A typical Oermandeai4nfound in manyreqionoof
)witzerland; often called a chair"

Fennoylvania:euch a eturdy deaiqn that.many

I 2OO-year-oldexampleoremainin uaablecondition

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CLASSICAMERICAN FURNITURE STYLES I
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SHAKER
ROCKINOCHAIR I
TheShakers werea ouritanical Hae eteam-bent rear le4aand aolid-woodrockers;
religious sectthatprospered in the the tape oeatinq ia availablern a variety of colora
and patterne. Aleo made in a ladder-backvereion
t
1 8 0 0 sm , a i n l iyn N e wE n g l a n d ,
NewYorkState,andthe Midwest. I
Theylivedin isolation fromsociety
BLANKET CHEST
on self-suff icientfarms.Shaker
Foretonn4blanketa I
furniture is practical, functional, andqutlta
andaustere-without extravaga nce I
or ornamentation-but attractive in
y .h a k edre s i g p
i t ss i m p l i c i tS nr i n - I
ciplescontinue to insprre modern
funiture makers. I
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I
PIE'AFE
I
Traditionally
uaed to atore I
baked4ooda;the
pierced-tin door I
panelakept the
LikeotherShakerpieces,thedrop-
leaftableshownaboveowesits
contents freah
whilepreventinq
I
verminfrom enter-
beautyto itscleanlinesand com-
pletedevotiontofunction.With its
in4.Adjuotable I
ahelveaadded
leavesextended,
people.
thetablecanseat
When theentiresur-
flexibility t
four
face is not needed,
the leaves
canbe
droppeddownand thetablestored
I
compactlyup againstawaII. I
5TEP?TOOL
Aaaembled
withthrough
I
dovetatla,theae mini-
atepladdere enabled I
Shakere to reach the
top ahelveaand dooraof I
floor-to- ceilin4 casework:
three- and four-otep ver-
sionawerealao common
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I CLASSICAMERICAN FURNITURESTYLES
I
I
t Mlsst0N MI)9ION ARMCHAIR
Ouatav )Lickley eoughLto cre-
TheMission styleis anoffshoot of
I theArtsandCraftsmovement that
ate eimple,durableand com-
fortable furniture:Lhiopiece
evolved in England asa reaction to feat urea aLratqhtfo rward, rec'
t thestylistic excesses of theVictorian Liltneardeot7ne,expoeedjotnery
perrod andto thedecline in crafts- and modeet materiale
t manship caused bytheIndustrial
Revolution. Ledbydesigners like
I Gustav Stickley, American furniture
makers adopted preindustrial work
I methods to create functional, un-
adorned f urniture.Mission-style
I pieces featured exposed joints,native
woodspecies (often oak)anda gen-
I erally morerusticlook.Mission fur-
n i t u r eg r e a t l iyn f l u e n c emda j o r
t architects suchasCharles andHenry
Greene andFrank Lloyd Wright
t
OREENEAND
GREENECHAIR
Deoignedby CharleeOreeneaL the turn
I ^[ rt-- tn+b.-A+,,.,. "hte Chair ie
Lypicalof furniture madefor houeeebuilL
t by LheOreenebrotherein ?aeadena,California;it
featured ouperbcraf|amanahtpand reaLrained
decorationwtf,ha htnLof )rtent al tnfluence
I
I
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ARTS AND
I CRAFTS
|]:
OAKTABLE q.-P ll
ll[--..-"-.."---{l :1
I The eolid, handcrafted
atreLcher borrowo iLo deoiqn l t v t l
-T
y--.-_--.------.

I from the oturdy undercar-

rtage of a farm hay waqon ilu ll -
l l a D l l
l l - l l
I -
llvll -
t 9TICKLEY
-
l l vll
ROCKING CHAIR
t Durlt from aoltd
oak, thie chatr fea-
llv
t:l]
ll -

I Lurea inlatd floral ilv

h____=_J tl
mol,ife on the back
slate than enrich
I an otherwtgeaus'
tere piece
ROLL.TOPDE9K
Made of oak and marked
I by an abeence of adornment

I
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I PEMBROKETABLE
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t hePembroke tableisthought
I to haveoriginatedin themid-
in a table-mounted
edges
routerto shape
ofthe top andleaves.
the
Rule-joint
t 18thGntury whenLadyPembroke
commissioned thegreatGeorgian
hinges arethenrecessed
sidesof thepanels
intotheunder-
to complete thecon-
I cabinetmaker andmastercarver nection.Theleaves aresupported in
ThomasChippendale to fashiona their extendedpositionby fly rails
I smallcasualtable forher.Theexam- attached to thesiderailswith knuckle
plefeaturedin thischapter, howev- joints(page32).
I er,hasmorein commonwith the Anotherof thetable's functionalfea-
neoclassical
designs of Sheraton and turesisthedrawerthatslidesunderthe
I American Federal furniture,which top. Perfectfor storingutensilsand
flourishedin thefollowingcentu- linens,thedrawerismadewith through
I ry.Is gracefirl
blend of straightlines dovetails. Theendgrainof thesidesis
andgentlecurvescontrasts sharply Thelegsof thePembroke tablefeature concealed by a falsefront, whichis
I withtheintricateandornateroco- stripsof dark banding,framed by curvedto matchthecurvedrail at the
codesigns of Chippendale. thin string inlay of a lighter wood. table'sotherend.
I Theearliestversions of thispiece In keepingwith thetable'sstraight
werebuilt at a timewhenspace wasat a premiumin most andelegant lines,thelegsaresimplytapered on four sides
t homesandfurniturehadto occupyaslittleroomaspossible. (page
ThePembroke tablemeetsthischallenge
26).Narrowstripsof bandingnearthelegs'bottom
in a coupleof inge- ends(page27)adda decorative touch.
I niousways.First,thetable'stopis flankedby twoleaves that Thejoineryusedto assemble thetableis sturdyandrela-
canberaisedup whentheentiretablesurface is needed and tivelysimple.Therailsarefixedto thelegswith blindmor-
t thenloweredwhenit is not,allowingthetableto bestored tise-and-tenoffi
compactly in acorneror hallway. Theleavesareattached
(page33),reinforced by woodencorner
to the blocks.Thedrawerrailsattachto thelegswith twodifferent
topwitha hingedjointknownasarulejoint.Asshownbegin- joints:dovetailed
I ningon page43,matching coveandround-over
half-laps
bitsareused tenoniointson thebottom.
atthetopandtwin mortise-and-

t
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I Madefrom mahoganywith contrastingwalnut
inlayaroundthe legs,
the Pembroke table
and maple
shown at left is
I piece
an elegant offurniture
includingdropleaves
with several
useful
features,
on thesidesand a drawerat oneend.

I 23
I
 I
I
ANATOMYOF A PEMBROKETABLE
t
nyr he Pembroketable consistsof ing edgesof theleavesareshapedwith opposite,thesejoints featureinter-
I
I threemainsections: a top,theleg- a matchingcove,forminga seamless
and-railassembly, and a drawer.The joint when the leavesare in the up
locking fi.ngersfixed togetherby a
woooenDrn.
I
top is attachedto a leafon eachside position.Theleaves aresupportedby Eachsiderailismadeup of fourindi-
with a hingedrulejoint. Theedgesof fly railsthat swingout from the side vidualboards. First,the knucklejoint
I
the top areroundedoverandthe mat- rails on knucklejoints. As shown betweenthe longoutersiderail piece I
I
Kule-jointhinge I
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Wood
Drawer
oide -
button I
Tnn
'"r runner
drawer rail
I
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I
thort outer
eide rail piece
I
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Lon4outer
oide ratl piece t
lntay
I
I

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I PEMBROKETABLE
I
I nerblocksarescrewed to adjoiningrails edges ofthe rails;thebuttonsarescrewed
and the fly rail is cut and assembled.
t Then,the short outersiderail pieceis
sawnto sizeand the stationarvDieces
at thebackendofthe tableto keepthe
cornerssquare.
to theunderside
page47,pocket
of thetoo.Asshownon
holescanalsobe used.
I areface-elued to theinnersideiail.the The top is attachedto the railswith The dovetailed draweris supported
assembly is thenjoinedto thelegswith wood buttons,whichfeaturea lip that by woodenrunnersscrewed flushwith
I blindmortise-and-tenons. Woodencor- fits into a groovecut alongthe inside thebottomedgeof thesiderails.

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T
I LIST
CUTTING

I ITEM OUANTITY THICKNESS WIDTH IENGTH

Gorner
blocks 2 3" 3"
I Dlawer:Flontandback 2
J

%' z%', 1A'/a',

I lront
False 1 rv;' 2'/"', r4,/;'
Sides 2 %r 2%', 18'
I rails*
Drawer 2 %' 3" r6%'
Runners 2 31, 1' 2I'
I Bottom I Y^' t4' 17Y4'
Endrail* 1 4%', 3', r6%'
I
Flyrails 2 1" 4%', L0y,'
I lnnersiderails* 2 1', 4%" 32',
Leaves 2 ,/8,
10" 4t"
I Legs 4 T%' I%' 29Y4'
Shortoutersiderailpieces* 2 1" 4%', 7t%'
I longoutersiderailpieces* 2 1" 4%', 1.6%',
I Top 1 v;' 20' 4T'

* N o t eD
: i m e n s i oin sc l u dtee n o no r h a l f - l al pe n g t h s .
I
 I
I
MAKING THE LEG-AND-RAILASSEMBLY
I
tl" h. legsof a Pembroketablehavea TAPERING
THELEGS I
l- delicatelook that beliestheir stur-
diness.Theyaretapered,with a simple
I
bandedinlay aroundeachleg about
3 inchesfrom thebottom.Thebandine
I
includesa %-inch-wide dark strip--
in this case,walnut-which contrasts
T
with themahogany. A thin stripof maple
framesthewalnut.On somePembroke
I
tables,the inlay wasusedto mark the
transitionto a second,steepertaper
I
at the bottom of the leg.Traditionally,
legswith a doubletaperweretaperedon
I
the two insidefacesabovethe banding
and on all four sidesbelowit. Thever-
I
sionshownin thischapterfeatures a sin-
gletaperon eachface.
I
Oncethesiderailsareassembled, they
arejoinedto thelegswith mortise-and-
I
tenons(page33).So,too,istheendrail,
but it must first be bandsawed into a
t
curvedshapeto complement thecurved
drawerfront at the oppositeendof the
I
table(page36).Thedrawerrailsarefixed
to thelegswith twin mortise-and-tenons
r
and dovetailedhalf-laps(page34).
I
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t
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'l Making a taperjig
I
I C u ty o u rl e gb l a n ktso s i z er, e f e r r i nt ogt h ea n a t o mi yl l u s t r a t i o n p a g e 2 4 .
M a r ka l i n ea l l a r o u neda c hb l a n k5 i n c h efsr o mt h et o pe n dt o d e f i n e t h es q u a r e
I
section to whrch therailswillbejoined. Thenoutline a %-inch square onthebottom I
A fly rail holds up one of the leavesof endof theblankto define thetaper. Tomakethecutonyourtablesaw,usea shop-
the Pembroketableshownabove.The m a d ej i g .C u tt h eb a s ef r o m% - i n cphl y w o o m d ,a k i n igt l o n g earn dw i d e trh a nt h e
knucklejoint that attachestheJly rail to blanks. Seta blankonthebase, aligning corresponding taperlinesat thetopandbot-
t
the siderail is designedto stoppivotirtg t o mw i t ht h ee d g eo f t h eb a s eC. l a m tph eb l a n ki n p l a c ea n dp o s i t i ot nh eg u i d e
oncethefly rail opensto a 90" angle.A blocks against it. Screw theguideblocks to thebase, thenfasten twotoggle clamps
I
recesscarved into the curved edgeofthe t o t h el o n g ebr l o c kP. r e stsh et o g g l cel a m pds o w nt o s e c u rteh eb l a n kt o t h ej i g ,
(above).
I
lly rail providesa convenienthandhold. tightening thenutsontheclamps witha wrench Remove thebarclamps.
I
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TABLE
T
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I Q Cutting
r.J Release
theremaining
thetoggle
tapers
clamps, turnthe
I blankto theadjacent
it, thistimeusinga wedge
side,andreclamp
between the
T longguideblockandthetapered
theblankto compensate
partof
forthecutyou
justmade.Markthe location
I r) cuttingthefirsttaper
of the
on theguide
broadendof thewedge
I L eutttheedgeof thejig basewiththeblankagainst thebladeandposition therip blocksoyoucanreposition thewedge
fenceflushagainsttheopposite Tosupport
edgeof thebase. theblankduringthecut, properly forthe remaining twocuts
(above).
I mounttwofeatherboards
sideoftheblankbysliding
to thesawtable,oneoneachsideof theblade.
thejigandworkpiece thetable,making
across
Taperthefirst
sureneither
Thentaperthesecond
the blank.Reoeat the orocess
sideof
forthe
I handis in linewiththe blade(above).(Caution:
Bladeguardremoved forclarity.) r e m a i n i sn igd e s .

t INTAY
BANDING
INSTALLING ONTHELEGS
I 'l Setting uptheroutertable
I T oc u td a d o eisn t h el e g sf o r i n l a y
I banding ona router table,install a Tq-inch
straight bit in a routerandmountthetool
I in a table.Adjustthecutterfora /a-inch-
deepcut.Next,attachanextension board
I to the mitergauge. To ensure thatthe
dadoes areparallel to theendsof theleg,
I themitergaugemustbesetto theappro-
priateangle.Holdthetapered partof the
I legf lushagainst themitergaugeexten-
s i o nw h i l eb u t t i n g
t h eh a n d l e
ofa try
I square against the leg'ssquare portion.
Adjustthemitergauge sothemiterbaris
I parallel to thebladeof thesquare (/eff).

I
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I 27
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PEMBROKE
TABLE
I
t
r) Routing
I
thedadoes
Z. Position
gauge
the legagainstthe miter I
extensionsothe bottomendis
3%oinchto therightof thebit.Toensure I
allthedadoes willbealigned,
butta stop
blockagainst theendof thelegandclamp
it to theextension.
I
Tocutthefirstdado,
holdthelegflushagainst theextension I
andstopblock,andfeedthelegandmiter

r ) 1 )
gauge acrossthetableintothebit.Turn I
theblankto theadjacent sideandrepeat
to routtheremaining dadoes(/eff). I
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Gluing thebanding
Usinga hardwood darker thanthe
I
pieceof banding
leg,cuta rectangular
evei'y dado.Sawthebanding sothegrain
for I
willbeparallel withthegrainof theleg I
whenthepieces aregluedin place; they
shouldbethesamewidthasthedadoes,
butabout%inchlonger ood3/rc inchthick.
I
Spread glueontwopieces
themin dadoes onopposite
of banding,
sidesof the
set I
l e ga n ds e c u rteh e mi n p l a c ew i t ha C I
clamp(righil.Oncethe adhesive has
c u r e dr,e m o vteh ec l a m pa n dt r i mt h e
endsofthebanding flushwiththelegby
I
running
router
theadjoining
tableagain
dadoes across
asin step2. Glueband-
the I
ingintothesedadoes,
ingflushwiththe legsurface.
thensandtheband- T
I
28 I
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T PEMBROKE
TABLE
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Kerfingthelegsforthestringing
I f, Installing thestringing
Toaccentuate the inlaybandingonthe legs,installnarrow stripsof woodcalled r.,l Makethestringing from%-inch-
stringingbetween thebanding andtheleg.Formaximum effect,choose a species
that thick,%-inch widewoodstrips. Usinga
I is lighterthanthewoodyouhaveselected forthetable.Usingthe sameprocedure you b a c k s aiwna mini-mite b ro x( l i k et h e
followed in step2, cutslotsforthestringing alongtheedgesof thebanding-but this k i n du s e di n d o l l h o u s e - b u i l dci nugt ) ,
I time,witha%-inchupcutspiralstraight bit in therouter.
Cutalltheslotsat thebottom thestrips to fit in theslots. Cutandfit
edgeof thebanding first,thenreposition
thestopblockto routtheremaininp slnis onepieceat a time,mitering theends
I at 45'. Applyglueto thepiece,insertit
intoitsslothbove)and tapit intoplace
I w i t ha w o o d em n a l l e tO. n c ea l l t h e
stringing is installed andtheadhesive
I hascured, sandthepieces f lushwith
the legsurfaces.
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Insteadof beingcut to fit into a
I dado in a leg,the commercialinlay
veneersshownat left areglued to
I the sidesof a taperedlegblank.
t
I 29
t
 I
PREPARING
THE SIDERAILS I
t
MAKING
THESIDE
RAILS t
1l Marking
-
joints
theknuckle I
I B u t tt h e m a t i n ge n d so f t h e f l y r a i l
a n dt h e l o n go u t e rs i d er a i l p i e c et o g e t h - I
e r . m a k i n gs u r et h e b o a r de d g e sa r e
a l i g n e d .U s er e f e r e n c el e t t e r st o l a b e l I
t h e p i e c e st ,h e nm a r ka s h o u l d el irn eo n
e a c hb o a r da b o u t1 i n c hf r o mt h e i rm a t - I
i n ge n d s ;u s ea t r y s q u a r et o e n s u r et h e
linesareperpendicular to the boardedges t
T o c o m p l e t teh e j o i n to u t l i n eu, s ea t a p e
measure t o d i v i d et h e b o a r d si n t o f i v e I
e q u a ls e g m e n tasc r o s st h e i rw i d t h ,c r e a t -
i n ga g r i do f f i n g e r sa n d n o t c h e o s nthe I
boardends.Markthe wastesections-or
n o t c h e s - w i t hX s ( r i g h t )s o t h e f l y r a i l I
w i l l h a v et h r e en o t c h e a s n dt h e m a t i n s
nipnp turn nntnhpc I
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t
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I
r) Sawing thefingers
t
L To cutthefingers at theendof thefly
railonyourbandsaw,startbysawing out
I
thewasteat bothedges of thepiecewith
twointersecting cuts.Toclearthewaste
I
between thef ingers, nibble at it withthe
b l a d ep, i v o t i nt gh ep i e c ea s n e c e s s a r y
I
to avoidcuttingintothe fingers(left).
Onceall thefingers arecut,test-fit the
I
jointandmakeanynecessary adjustments
w i t ha c h i s e l .
I
I
30 I
t
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I PEMBROKETABLE
I
I thepinholes
Q Drilling
r./ Assemble eachof theknuckle joints,
I thenmarkthecenter of thefingers onthe
topedgeof the longrailpiece.Borethe
I holeforthewooden pinonyourdrillpress.
I n s t aal l % - i n cbhi ti n t h em a c h i naen d
T c l a m pa b a c k u p a n etlo t h et a b l eS . et
t h eb o a r dosnt h ep a n e la, l i g n i nt gh e
I centermarkdirectly under thebit.Clamp
a boardagainst thebackfaceof thestock,
I thensecure rt to thebackuo oanelasa
fence.Drillrightthrough thestock(/eff,).
I lf the bit is notlongenough to penetrate
to theotheredgeof theboards, turnthe
I s t o cokvea r n dc o m o l e tteh e h o l ef r o m
t h eo t h esr i d e .
t
I
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T
I
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I Fine-tuning joints
theknuckle
lf theshoulders
andfingers
of theknuckle wereleft
lornts
I s q u a r et ,h e f l y r a i l sw o u l db i n da g a i n stth e s i d er a i l sw h e nt h e y
w e r ee x t e n d e dT.o p e r m i t h e j o i n t st o p i v o t m , a r ka l i n eo n t h e
I i n s i d ef a c eo f e a c hf l y r a i la n d s i d er a i l p i e c ep a r a l l et lo t h e
s h o u l d elri n ea n d o f f s e t% i n c hf r o mi t . C l a m po n ef l y r a i l
I inside-face up on a worksurfacewith a backupboardbetween
t h e r a i la n dt h e t a b l e .S t a r tb y u s i n ga c h i s e l t h es a m ew i d t ha s
I t h e f i n g e r sa n d n o t c h e st o r o u n do v e rt h e e n d o f t h e f i n g e r s .
T h e np o s i t i o tnh e t i p o f t h e c h i s e b l l a d eo n t h e o f f s e tl i n e ,c e n -
I t e r e do n a n o t c h ,a n g l i n gt h e t o o ls o t h e c u t w i l l e n d a t t h e
o r i g i n aslh o u l d el irn e .H o l d i ntgh ec h r s ewl i t ho n eh a n dt,a p i t
I w i t h a w o o d e nm a l l e t o b e v etl h e s h o u l d e rR. e p e afto r t h e
remaining notches(right).Beuelthe notchesthe samewayon
I t h e l o n gr a i lp i e c e b, u t l e a v et h e f i n g e r s q u a r e .

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PEMBROKE
TABLE I
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t
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Cutting thefly railsto lengh Routingfingerrecessesin thefly rails
R e f etro t h ea n a t o mi vl l u s t r a t i o n pivoting
Tofacilitate thefly rails,cutfingerrecesses intotheunderside of their I
(page24)to marktheS-shaped cutting curvedends.Installa pilotedcovebit in a router,
mountthetoolin a table,andsetthe
lineonthef ly rails,thendesignate the depthat %inch.Toprovide
cutting a bearingsurface
fortherails,fashion a fenceforthe I
wastewithXs.Feedthestockacross the stockto rideagainstontheinfeed sideof thetableanda guardforthebit froma ply-
bandsawtablebbovd,making certain woodblockandclearacrylic. Attachtheguardandfencetogether andclampthemto I
n e i t h ehra n di s i n l i n ew i t ht h eb l a d e .
Makematching cutsonthemating ends
thetable.Press
bbove);
thestockagainst
maketherecess
thepilotbearing
about4 inches
asyoufeedeachrailacross
longandcenter it ontherail'scurved
thetable
end. r
of theshortouterrailpieces, ensuring
t h a tt h e r ew i l l b ea s u f ifc i e n t llya r g e t
gap-about% inch-between theiwo
boards fora handhold. I
I
] Gluing upthesiderails
/ Assemble theknuckle joints, insert- I
inglengths of %-inch dowelintotheholes
through thefingers, andcuttheinnerside I
r a i lp i e c etso l e n g t hF. o re a c hs i d er a i l ,
spread glueonthecontacting surfaces of r
theboards andclamptheouterrailpieces
t o t h e i n n e r a i l ;d o n o ta p p l ya n yg l u e t
o n t h ef l y r a i ls i n c ei t m u s tb ef r e et o
pivot.Makesureto leavea %-inchgap t
between thefly railandthe shortouter
siderailpiece. Alternate theclamps across I
thetopandbottomedgesof theassem-
b l y ,s p a c i ntgh e m3 t o 4 i n c h e as p a r t . thor| outer
I
Tighten theclampsevenly(right)until eide rail piece
adhesive squeezes outof thejoints. I
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TABLE
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Cutting therailtenons
I Thenextstepin making therailsis to cutthetenons that withthedadoheadandbuttthefenceagainst theendof the
w i l l f j t i n t ot h e l e gm o r t i s e S
s .t a r b
t yd r i l l i n a
g t e s tm o r t i s e board. Feed therailfacedown,holding thestockflushagainst
I (page 3 7 ) ,t h e no u t l i n e
t h et e n o n os nt h ee n d so f t h er a i l s , thefenceandthemitergauge extension. Turntherailoverand
usingthetestmortise asa guide.Cutthetenons onyourtable repeat thecutontheothersidebbove), fittingthetenonin the
I sawfittedwitha dadohead;adjustthewidthof the headto t e s tm o r t i saen dr a i s i ntgh eb l a d eus n t i tl h ef i t i s s n u gC . ut
slightlymorethanthetenonlength-about 3,4 inch.Setthecut- tenoncheeks at theotherendandreoeat foreachsideand
I tingheight at onethird thestockthickness. Attach anauxiliary endrail.Next,fliptherailonedgeandadjust thebladeheight
fenceto thesaw'sripfenceandanextension boardto themiter t o t r i mt h et e n o ntso w i d t hA. g a i nt ,e s t h et e n o nu n t i li t f i t s
I gauge. Toposition thefence, aligntheshoulder lineontherail snugly in thetrialmortise.
I Preparing therailsforthetop
Q
J Onceallthetenons arefinished, you
I willneedto cuta groove along theinside
faceof therailsto accommodate thewood
I buttons thatwillsecure thetabletoo in
place. Leave thedadoheadonyourtable
I saw,adjustitswidthto %inch,andset
thecutting height at aboul% jnch.Position
I t h ef e n c ea b o u t % i n c hf r o mt h eb l a d e s .
Feedtherailsintothedadoheadinside-
I facedownandwiththetopedgepressed
against thefence(left).Alsocuta groove in
I t h ee n dr a i lb l a n ka t t h i st i m e T
. h i sw i l l
e n s u rteh a ta l lt h eg r o o v easr ei d e n t i c a l .
I (Caution: Bladeguardremoved forclarity.)
I
I
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 t
PEMBROKETABLE I
I
PREPARING RAILSANDENDRAIL
THEDRAWER I
'l
Cutting thetopdrawerrail I
I C u tt h e t o p d r a w erra i lt o l e n g t ht,h e n
o u t l i n et h e d o v e t a i l ehda l f - l a otsh a t w i l l I
. 1 o i tnh e e n d so f t h e r a i l t o t h e f r o n t l e g s
o f t h e t a b l e .O f f s e t h e o u t l i n et o w a r dt h e I
b a c ke d g eo f t h e r a i ls o t h e d o v e t a w il ill
b e c e n t e r eodn t h e l e gw h e nt h e r a i l ' sb a c k I
e d g ei s f l u s hw i t ht h e b a c kf a c eo f t h e l e g
( s t e p2 ) . C u t o u t t h e d o v e t a i l so n y o u r I
b a n ds a w ,m a k i n gt w o i n t e r s e c t i ncgu t s
a l o n ge a c he d g eo f t h e o u t l i n e s( / e f f ) . I
T h e n u s ey o u rt a b l es a wf i t t e d w i t h a
d a d oh e a dt o c u t a w a yo n e - h a ltfh e t h i c k - I
n e s so f t h e d o v e t a i lfsr o mt h e i rb o t t o m
Iace (inset). I
I
I
t
I
I
I
I
Cutting thedovetail
sockets in thelegs
I
Secure a frontlegupright in a bench vise
a n du s eo n eo f t h ed o v e t a i l ehda l f - l a p s
I
y o uc u t i n s t e p1 t o o u t l i n teh em a t i n g
s o c k eot n t h e l e g ' st o ne n d .M a k es u r e I
t h et o ne n do f t h el e si s f l u s hw i t ht h e
benchtop; thiswrllsupport therouter base
I
plateasyoucutthesocket. Alsoensure
thatthedovetail shoulder is butted against
I
t h ei n s i d e d g eo f t h el e ga n dt h er a i l ' s
backedgeis f lushwiththe backfaceof
I
t h el e ga sy o um a r kt h el i n e sI.n s t a al l
/ " - i n c hu p c u t - s p i rsat rl a i g hbti t i n t oa
I
router andadjust thecutting depthto the
thickness of thedovetail. Routthesocket
I
withinthemarked outline, thensquare the
corners andpareto thelinewithstraight
I
a n ds k e wc h i s e l sa ,sn e e d e d R.e p e at ot
cutthesocketin theotherfrontleg(right).
I
I
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t
I
I PEMBROKETABLE
I
I n<' Cuttins
twintenons
in
r-,1 the bottomdlawerrail
I T h e b o t t o md r a w e r a i l i s j o i n e dt o t h e
l e g sw i t h t w i n m o r t i s e - a n d - t e nj ooinn t s .
I C u tt h e t e n o n sa t t h e e n d so f t h e r a i lo n
y o u rt a b l es a w .I n s t a lal d a d oh e a d% i n c h
I w i d e ,t h e ns e t u p a t e n o n i njgi g i n t h e

t m i t e rs l o t .M a r ka t w i nt e n o na t e a c he n d
o f t h e r a i la n ds e tt h e c u t t r n gh e i g h at t
% i n c h .L a yo u t t h e t e n o n ss o t h e b a c k
I edgesof the railand legwill align(step4).
C l a m pt h e r a i le n d - u pi n t h e j i g , p l a c i n g
I a s h i m b e t w e e nt h e t w o t o p r e v e ntth e
d a d oh e a df r o mc o n t a c t i nt gh e j i g .S h i f t
t t h e j i g s i d e w a ytso a l i g no n eo f t h e t e n o n
m a r k sw i t ht h e d a d oh e a d T . o m a k et h e
I c u t , p u s ht h e j i g f o r w a r df ,e e d i n g the
s t o c ki n t ot h e b l a d e sS . h i f tt h e j i g t o
I l i n e u p t h e d a d oh e a dw i t h t h e w a s t e
a d l o i n i ntgh e t w i nt e n o n sm , a k i n gs e v e r a l
I p a s s e su n t i l y o u h a v ec l e a r e da w a yt h e
excesswood (right).Repeatthe cut at
I t h e o t h e re n d o f t h e r a i l .

I
I
I
I
I
I
I
I
0utlining
thedouble
I mortises
inthelegs
I S e t o n eo f t h e l e g si n s i d e - f a cuep o n a
w o r ks u r f a c et,h e n p l a c et h e b o t t o m
I d r a w erra i lo n i t , a l i g n i ntgh e b a c ke d g e
o f t h e r a i lw i t ht h e l e g ' sb a c kf a c e .W i t h
I t h e e n do f t h e r a i la t t h e a p p r o p r i a t e
h e i g h ot n t h e l e g ,o u t l i n et h e t w i n t e n o n s
w i t ha p e n c i l( l e f t ) .P r e p a rteh e e n d r a i l
I @ a g e3 6 ) a n d d r i l lo u t t h e r a i lm o r t i s e s
i n t h e l e g s( p a g e3 7 ) b e f o r ec h i s e l i ntgh e
I doublemortisesin the legs(page3&.
I
I 35
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PEMBROKETABLE I
I
f, Cutting thecurved faceoftheendrail t
r-,f Outline thecurved outside faceof theendrailontheedges
sothelegswillextend %inchbeyond therailwhenthetableis I
a s s e m b l eTdh.e ns, t a n d i nagt t h es i d eo f t h eb a n ds a wt a b l e ,
settheraildownonedge. Aligntheblade justto thewaste side I
of thecuttinglinenearthecenter andholdthetwoendsto feed
thestockacross thetable;makesureneither handis in Iinewith I
theblade. Onceonewaste piecefallsaway, turntherailoverand
cut the opposite end(right). I
I
Veneering theendrail
l f y o ue
r n dr a i l w a m s a d ef r o mg l u e d - uspt o c ky,o um a y I
needto applya pieceof veneer to theoutside faceto conceal
anyglueslinesthatmightbevisible. Follow thesameproce- I
d u r e sy o uw o u l du s eo nt h ef a l l - f r o notf a s l a n t - t odpe s k .
Maketheveneer patternandsetup a vacuumpress(page123). I
F o rt h em o d esl h o w ni n , s e rt th eh o s ei n t ot h en i p p l e
i nt h e
bottomof the pressbag.Thenplacetheplatenin thebagand I
i n t ot h ep l a t e snl e e v e
s l i d et h en i p p l e S.e t h ee n dr a i lo na
worksurface, applytheglue,andlaytheveneer ontherail. I
Place a pieceof waxpaperovertheveneer, restthecaulontop,
andplacetheassembly atoptheplaten. Sealthebag,turnon t
thepumpandleave theassembly underpressure fortherec-
ommended lengthof |ime(below). Mostvacuum presses will I
shutoffwhentheappropriate pressure hasbeenreached,
I
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I
36 I
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I TABLE
PE,MBROKE
I
t UPTHELEGS
GLUING ANDRAILS
I therailmortises
1t 0utlining
-
inthelegs
I U s eo n eo f t h e r a i lt e n o n sy o uc u t
I ( p a g ej 3 ) t o o u t l i n et h e l e n g t ha n dw i d t h
nf ihe mnriisoc \l:rl hv hnldrno thp e hppk
I
i b ! i i v v i i e v i r

o f t h e t e n o nf l u s ha g a i n stth e i n s i d e
f a c eo f o n eo f t h e l e g s ;m a k es u r et h a t
I t h et o pe d g eo f t h e r a i li s a l i g n e w d i t ht h e
t o p e n do f t h e l e g .M a r kt h e l e n g t ho f t h e
I m o r t i s eT.o o u t l i n et h e m o r t i s w
e i d t h ,h o l d
t h p p d o p n f i h p t p n n n f l r r c . h: s : i n s t t h c
I i n s i o ef a c eo f t h e l e ga n d m a r kt h ec h e e k s
of the tenon(rtght).ExIendthe linesalong
I t h ef a c e( s h o w n i n t h e i l l u s t r a t i oans d o t -
t e d l r n e s )R. e p e afto r t h e r e m a i n i nsgi d e
I a n de n d r a i lm o r t i s e sR. e m e m b et hr a t
t h e o u t s i d ef a c eo f t h e l e g ss h o u l de x t e n d
I b e y o n dt h e e n d r a i lb y a b o u t' l i n c h .

r
I
I
t
t
t
I
I
I
I
I r ) D r i l l i ntgh er a i lm o r t i s ei sn t h el e g s
/ , ,
I 4 - U s ea m o r t i s r nm g a c h i n ea s s h o w n
o r i n s t a l l am o r t i s i nagt t a c h m e on nt y o u r
I drill nrcqs Clamn nnc nf lhp lcqsto thc
f e n c ec e n t c r i nt ph e m o r t i soeu t l i n eu n d e r
I t h ec h i s eal n db i t .A d l u stth ed r r l l r ndge p t h
t o % i n c h m o r et h a nt h e t e n o nl e n g t h .
I M a k ea c u t a t e a c he n d o f t h e m o r t i s e
h e f o r ed r i l l i n po r r tt h e w a s t ei n b e t w e e n
I ( l e f t ) R e o e atth e n r o c e d u rteo c u t t h e
r e m a i n i nm go r t i s e s .
I
I 37
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PEMBROKETABLE
I
I
I
I
I
I
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I
I
I
n Chiselins thedoublemortises for the bottomdrawerrail
r - , f C l a m pa l e gi n s i d e - f a cuep t o a w o r ks u r f a c eT. h e n ,s t a r t -
I
i n ga t o n ee n do f t h e d o u b l em o r t i s o e u t l i n eh, o l da m o r t i s i n g
c h i s e sl q u a r et o t h e i n s i d ef a c eo f t h e l e ga n ds t r i k et h e h a n d l e
I
with a woodenmallel(left).Usea chiselthe samewidthas the
m o r t i s easn d b e s u r et h a tt h e b e v e l e sdi d ei s f a c i n gt h e w a s t e .
I
C o n t i n um e a k i n gc u t sa t i n t e r v a losf a b o u t% i n c h u n t i ly o u
r e a c ht h e o t h e re n do f t h e o u t l i n eU . s et h e c h i s etl o l e v e o r ut
I
t h e w a s t et o t h e r e q u i r ed e p t h( a b o v eC ) .h o po u 1t h e r e m a i n i n g
d o u b l em o r t i s etsh e s a m ew a y .T e s t - f itth e j o i n t sa n dw i d e no r
I
d e e p e nt h e m o r t i s ew s i t h t h e c h i s e l a, s r e q u i r e d . I
t
Gluinethe legsto the siderails
I
-1lT
T e s t - a s s e m bt hl ee l e g sa n ds i d er a i l s ,
f i n e - t u n i nagn yi l l - f i t t i njgo i n t sw i t ha
I
c h i s e l ,i f n e c e s s a rS y .a n da n ys u r f a c e s
t h a t w i l l b e d i f f i c u l t o a c c e s so n c et h e
I
t a b l ei s a s s e m b l e N d .e x t s. p r e a d
o n t h e c o n t a c t i n sg u r f a c e sb e t w e e n
glue
one
I
o f t h e s i d er a i l sa n di t sc o r r e s p o n d ilnegg s ,
t h e nf i t t h e j o i n t st o g e t h e rt a
, p p i n gt h e m
I
i n t of i n a lp o s i t i o w
n i t h a w o o d e nm a l l e t ,
i f r e q u i r e dU. s et w o b a rc l a m p st o s e c u r e
r
t h e l o i n t sA. l i g n i ntgh e b a r sw i t ht h es i d e
r a i l ,l a yt h e a s s e m b loy n i t s s i d eo n a
I
w o r ks u r f a c ew i t h o n ec l a m pu n d e rt h e
r a i la n do n eo n t o p . P r o pt h e t a p e r e dp o r -
I
t i o n o f t h e l e g so n w o o db l o c k st o k e e p
t h e a s s e m h l v l e v c l P r n t e c t i n st h p s t n . k
I
w i t h w o o dp a d s t, i g h t e nt h e c l a m p se v e n -
l y u n t i la t h i ng l u eb e a ds q u e e z eosu to f
I
the joints0ight).Repeatfor the remaining
s i d er a i la n d l e g s .
t
I
3B I
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t PEMBROKETABLE
I
T
I
I
I
I
t
t
r
I
I
I
I
I
I
I f, Gluingtheendrailanddrawer rails
r,/ Oncethegluebonding thelegsto thesiderailshas
I cured,
remove theclamps andsettheassemblies f latona
worksurfacewiththeirmortises facingup.Test-fit and,if
jointsanddoanyrequired
I necessary,
sanding.
correct
Spread
anyillJitting
glueonthecontacting surfaces between
I theendanddrawer
drawer
railsandthelegs, thenfit thebottom
railandendrailintooneof thesiderailassemblies
(above).
Position theotherleg-and-railassembly ontop
I andsettheframework uprightonthefloor.Finally, fit the
I topdrawer railintoplaceandclamptheassembly GtepO.

I Installing theclamps
I Usethreebarclamps to secure thejointsbetween the
endanddrawer railsandthelegs.Protecting thestockwith
I w o o dp a d si,n s t a o t h ee n dr a i la n dt w o
l l n ec l a m pa l o n g
morealong thedrawer rails.Tocheckwhether theassembly
I is square,
immediately
measure thediagonals
aftertightening
between
theclamps
opposite
(/eff).
corners
Theyshould
I beequal;if not,theassembly
theproblem, installa barclampacross
is out-of-square.
the longer
Tocorrect
of the
I t w od i a g o n aT
suring
l si .g h t etnh i sc l a m pa l i t t l ea t a t i m e ,m e a -
asyougountilthetwodiagonals areequal.
I
I 39
I
 I
PEMBROKETABLE I
I
Making
thecorner blocks
I
I
/ Attach
a t r i a n g u l caor r n ebr l o c kt o
e a c hi o i n tb e t w e etnh c e n d r a i la n d t h e
I
s i d er a i l s t; hr sw i l l r e i n f o r cteh e b a c kc o r -
n e r so f t h e t a b l ea n dk e e pi t s q u a r eT. o f i t
I
t h e b l o c k si n t ot h e t a b l ec o r n e r sm, a k ea
4 5 " m i t e rc u t a t e a c he n do f t h e b l o c k s
I
a n d m a r kf o u rp o i n t so n t h e l o n ge d g e .
t w o n e a re a c he n d . N e x t ,b o r ep o c k e t
I
h o l e st h r o u g ht h e b l o c k sf o r t h e s c r e w s
t h a tw i l ls e c u r teh e mt o t h e r a i l s I. n s t a lal
I
Z,-inch F o r s t n ebri t i n y o u rd r i l lp r e s sa n d
c l a m pa b a c k u pp a n etl o t h e m a c h i n e
I
t a b l e .S e c u r e t h e b l o c ki n a h a n d s c r e w
a n d d r i l la s h a l l o wh o l et o r e c e s tsh e
I
s c r e wh e a d R . e p o s i t i ot h n e b l o c kt o b o r e
t h e n e x th o l e t, h e nt u r nt h e b l o c ka r o u n d
t
i n t h e h a n d s c r etw o d r i l lt h e h o l e sn e a r
t h e o t h e re n d .R e p e atth e p r o c e sw s i t ha
I
s m a l l ebr r a d - p o i nbti t t o b o r ec l e a r a n c e
h o l e s( / e f f )F. i n a l l yw, r t ht h e b l o c kt o p -
I
f a c ed o w no n t h e t a b l e ,d r i l la c o u n t e r -
b o r e dh o l et h r o u g ht h e m i d d l eo f t h e
I
s u r f a c et :h r sh o l ew r l le n a b l ey o ut o f a s -
t e n t o t h e b l o c kt o t h e t a b l et o p .
I
I
I
I
I
I
I
I
I
t
I
lnstalling
thecorner
blocks
S n r p : d o l r r pn n i h o n n n i : r ' i i n o c r r r -
I
f a c e sb e t w e e tnh e f i r s t b l o c ka n dt h e
r a i l s h, o l dt h e b l o c ki n p o s i t i oang a i n s t
I
t h e r a i l sa n d s c r e wi t i n p l a c e R
for the secondblock(rrght).
. epeat
I
I
40 I
t
I
I
MAKINGTHEDRAWER
t
t
f) uild thedrawerfor your Pembroke
t D tubl. as you would for a Queen
AnnesecretaryQage116)usingthrough
t dovetailsto join the pieces.
UseZ-inch
plywoodfor the drawerbottom. The
I Pembroke tabledraweralsogetsa false
front which is curvedto match the
I shapeof the endrail anddrawerrails.
To install the drawer,start by fas-
I tening runnersto the side rails, as
shownbelow.Slidethe drawerinto its
I openingand clampon the falsefront,
then tracethe curveofthe top drawer
I rail ontothetopedgeof thefilsefront
(page42) and cut the profile of the
I front. You can applywax to the run-
nersto help the drawerride smoothly
Supported by runnersfastenedto thesiderails,thePembroke table
I asit is openedandclosed.
drawershownaboveis assembled with throughdovetails.Thefalse
I front curvesto matchtheprofileof theendrail and drawerrails.

I THEFRAME
REINFORCING
t 1l lnstallins -
thedrawer runners
I S i z et h ed r a w erru n n e r sc ,u t t i n g
I thema fewincheslonger thanthedraw-
er. Drillthreeholesthrough theedges
I of eachone,locating oneholeneareach
e n da n do n ea t t h em i d d l eH. o l d i nagn
I edgeof therunner against thesiderail
andoneendagainst the bottomdrawer
I rail,screwit in place(left).Thetopface
b ef l u s hw i t ht h e
o f t h er u n n esrh o u l d
t toofaceof thebottomdrawer rail.

I
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 I
PEMBROKETABLE I
I
r) Sawing thecurueofthefalsefront
I
I gtaethedrawer intoits opening I
t n t h et a b l ea n dc l a m ot h ef a l s ef r o n t
blankto thedrawer
drawer at itsfullyclosed
front.Holding
position,
the
use
I
a pencilto tracetheprofile
drawer railontothetopedgeof the
of thetop t
blank(lefil.Cutthe curveof the false I
frontonthe bandsawasyoudid the
e n dr a i la n dg l u ev e n e et o
r t h ef r o n t I
face,if desired(page36).
I
I
r
t
I
I
I
I
I
I
I
I
T
I
I
t
? lnstalling thefalsefront I
\ - t W i t ht h ed r a w esrt i l li n t h et a b l e ,
spread glueon thecontacting surfaces
between thedrawer frontandthefalse
I
f rontandclampthetwotogether,
woodpadsto protectthe stock(right).
using I
T i g h t et nh ec l a m pesv e n luyn t i l ag l u e
beadsqueezes outof thejoint.
T
t
A '
+L
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I
I
I MAKINGTHETOP
I
With the sidesdown, the top of the
I Pembroke table appears to be circular.
Once the leavesare raised,however,
I the top's distinctive shape, with ellip-
tical endsqnd sides,becomesappar-
I ent. Similar - shaped t abletops w ere
used on Federal-period card tables.
I The leavesare hinged on a rule joint,
which is shapedon the router table.
I Once thejoint is completedand the
hinges located, the curved profile of
I the leavesis cut on the band saw.

I
I
I
t
I THET()P
SHAPING
I
I
I
t
I
I
I
I
I
I
I
I
I 1 Routingtheedgesofthetabletop
I Clampthetabletop to a worksurfacewiththeedgeto be depthin at leasttwopasses.Asyoumakethecut,press the
I shaped off thesurface.
extending Installa pilotedround-over bit pilotagainst
thestockthroughoutthepass(above).
Fora
thecutting
bitandadjust depthto allowyouto reach thefinal smooth finish,makeyourfinalpassa slowandshallow
one.
I
I 43
I
 I
PEMBROKETABLE
I
t
r) Routing
I
the covein the leaves
L l n s t a l la p i l o t e dc o v eb i t i n t h e I
r o u t ea r n d m o u n t h e t o o li n a t a b l e .
A l i g nt h e f e n c ew i t ht h e b i t p i l o tb e a r i n g I
s ot h e w i d t ho f c u t w i l l e q u a ol n e - h a lt fh e
c u t t e rd i a m e t e rC. l a m pa f e a t h e r b o atrod
t h e f e n c eo n t h e i n f e e ds i d eo f t h e b i t t o
t
h o l dt h e w o r k p i e cfel a t a g a i n stth e r o u t e r I
t a b l e .S e tt h e d e p t ho f c u t s h a l l o wt o
start;makeseveralpassesto reachyour I
f i n a ld e p t hg r a d u a l l yF.e e dt h e l e a fi n t o
t h e b i t , p r e s s i ntgh e e d g eo f t h e w o r k - I
piecefirmlyagainstthe fence(left).After
e a c hp a s s t, e s t - f i t h e p i e c e su n t i lt h et o p I
a n dt h e l e a fm e s hw i t h a v e r vs l i s h ts a n
betweenthe two. I
r
I
t
I
I
t
I
Attaching
theleaves
to thetop I
J o i nt h e l e a v e st o t h e t o p b y i n s t a l l
i n gr u l e - j o i nhti n g e so n t h e u n d e r s i doef I
t h e n i e c e sS . e tt h e t o n a n d l e a v e fsa c e
d o w no n a w o r ks u r f a c et,h e n m a r kl i n e s I
a l o n gt h e s h a p e de d g e so f t h e t o p i n l i n e
w i t h t h e s t a r to f e a c hr o u n d - o v ecru t , I
k n o w na s t h e f i l l e t ( i n s e t ) I. n s t a l lt h r e e
h i n g e sf o r e a c hl e a :f o n e i n t h e m i d d l e I
o f t h e j o i n ta n d o n e 5 i n c h e sf r o me a c h
e n d .W r t ha p a p e rs h i m i n s e r t e db e t w e e n
t h e l e a fa n dt o p , p o s i t i o n a h i n g el e a f
t
a g a i n stth e t o p a n dt h e o t h e ra g a i n stth e I
l e a fa t e a c hh i n g el o c a t i osno t h e p i n i s
alignew d i t h t h e f i l l e t l i n e ,t h e no u t l i n e I
t h e h i n g eC . h i s eol u t t h e m o r t i s e su,s i n g
a w i d e r - b l a dteo o l t o c u t t h e m o r t i s e s I
f o r h i n g el e a v e sa n d a n a r r o w ecrh i s e lt o
c u t t h e s l o t sf o r t h e p i n s ( r i g h t ) .S c r e w
ihp hinopc in nl:nc
I
t
44
I
I
I
I PEMBROKETABLE

I
I
I
I
I
I
I
t
I
I
I
I
I
I theprofile
0utlining ofthetop
E n l a r gteh e g r i ds h o w ni n t h e i n s e t
I to produca e c u t t i n gp a t t e r nf o r s h a p i n g
t h e p r o f i l eo f t h et o p ;o n es q u a r e q u a l s
I 2 i n c h e sT. r a c et h e p a t t e r no n t oa p i e c e
o f % - i n c hp l y w o o od r h a r d b o a radn d
I c u t o u tt h et e m p l a t e o n y o u rb a n ds a w .
Thensetthe top face-down on a work
I surface a n de x t e n dt h e l e a v e sM. a r ka
l i n ed o w nt h e m i d d l eo f t h e t o p a n d
I p o s i t i o tnh e t e m p l a t eo n i t ; a l i g nt h e
s t r ai s h te d s en f t h e n a t t e r nw i t ht h e
I c e n t e r l i naen dt h e a d j o i n i ncgu r v e d
e d g ew i t ht h e e n do f t h e t o p . U s ea p e n -
I cil fn trarp tho nrrrvod nrnfilp nn ihe tnn

R e p e aat t t h e r e m a i n i ncgo r n e r (sa b o v e ) .

I
I
Cutting theprofileof thetop
I f,
r-,/ Unscrew the leavesfromthe top and
u s ey o u rb a n ds a wt o c u t t h e c u r v e dp r o -
I f i l e i n t oe a c ho f t h e t h r e ep i e c e sC. u tj u s t
to the wastesideof yourcuttingline (left),
I f e e d i n gt h e s t o c kw i t h b o t hh a n d sa n d
keeping y o u rf i n g e r sc l e a ro f t h e b l a d e .
I S a n dt h e c u t e d g e st o t h e l i n e .

I
I 45

I
 I
PEMBROKE
TABLE I
t
I
I
I
t
I
I
t
T
t
T
--4 ----------liD
., %..- I
b I
@'
=--[9
f-f6-j
l.--t-'-...-/i I
\ vt=-/ I
Installing thetop
I
A

tilJljljllililijillliliJlli iltilllilljJjlliillJlJjJ
L,f Thetop is fastened to the tablerails
I
llii{llJ llitlljlllil with woodbuttons:screwed to the top,
t h e b u t t o n sf e a t u r el r p st h a t f i t i n t o
grooves cut intothe rails(page33), pro-
I
5HO7Tt? v i d i n ga s e c u r ec o n n e c t i ownh i l ea l l o w -
i n gf o r w o o dm o v e m e nR t . e i n s t atlhl e
I
Uoingoteel tabletop faetenere
r u l e - j o i nhti n g e si n t h e t o p a n d l e a v e s ,
Commercial eleelIableNopfaoten-
and placethe top facedownon a work
I
ere worklikewoodbutf,one:They are
ecrewedto LheIoV from underneath surface.Makea buttonfor every6 inch-
a n d g r i pa q r o o v ec u Xa l o n q l h e es of rail lenglh (pageJ33,).Spacing
I
ineideface of Ihe raile.Secauee t h e ma b o u t6 i n c h e sa p a r ta n d l e a v i n a g
commercial fasNeners arethinner % - r n c hg a p b e t w e e ni h e b o t t o mo f t h e
I
than lippedwoodbutLons, Lhe g r o o v easn dt h e l i p p e de n d so f t h e b u t -
qroove does noNhaveLo
' ,,.'1:, tons,screwthe buttonsin place(above).
I
be cuL wilh a dado blade t 0 n c ea l l t h e b u t t o n sa r ea t t a c h e dd,r i v e
(pa4e33):you can uoea
a s c r e wt h r o u g he a c hc o r n e b r l o c ki n t o
T
etandardsaw bladeor a
t h et o p .
Lhree-winq ololLi n4 c utt er I
in a table-mounled router.
Tnenattrc nrnncr f-e -
n a, ', - t o n ,

make ihe qroovea liLile

I
farLherfrom lhe Lopthan you
wouldwith lhe woodbuttono,
H-frb'P1"@w I
t
t
I
I
I
I PEMBROKETABLE
I
I
I
t
P()CKET.HOLE JIG
t Youcanusepocketholeswith
screws asan alternative to wood
I buttons forattaching a tabletop to
thesideandendrails. Theholes are
I drilledat an angle,anda pocket-
holejig (left,tofl, shop-built from
I %-inch plywood, makes simplework
o f b o r i n tgh e h o l e so n y o u rd r i l l
t press.Forthejig, screwthetwo
sidesof thecradle together to form
I a n L . T h e nc u t a 9 0 ' w e d g e from
eachsupport bracket sothatthe
I widesideof thecradle willsitat an
angleof about15"fromthevertical.
I Screwthe brackets to thejig base
andgluethecradleto ihe brackets.
I Tousethejig,seata railin the
c r a d lw
e i t ht h es i d et h a tw i l lb e
I drilled facingup.Drilltheholesin
twostepswithtwodifferent bits:Use
I a Forstner bittwicethediameter of
thescrewheads fortheentrance
I holesanda brad-point bit slightly
larger thanthediameter of thescrew
I shanks fortheexitholes. (Thelarger
brad-point bitallows forwoodexpan-
I sionandcontraction.)
To beginthe process, installthe
I b r a d - p o ibnitt a n d ,w i t ht h ed r i l l
pressoff, lowerthe bit withthe
I feedlever,thenposition thejig
andworkpiece to centerthe bot-
I tomedgeof theworkpiece on the
bi| (inset). Clampthejig to the
I tableandreplace the brad-point
bit withthe Forstner bit.
I F e e dt h e b i t s l o w l tyo d r i l lt h e
holesjustdeepenough to recess
I thescrewheads. Then,installthe
brad-point bit andborethrough the
I workpiece to complete the pocket
holes(/eft,bottom).
I
I
I
T 47

I
I
I

I
I
I FOIIR-POSTERBED
r
I
I
't T t ,'
| h. four-posterbedis a dramatic asmuchas3 inchesthick.Boxsprings,
I I and imposingpieceof furniture however, couldbelaidon narrowcleats
that descends from the canooybedsof fastened to theinsideof therails,sothe
I the Byzantineand medieval'periods. railsthemselves couldbereduced to a
Once,onlyheadsof familiescouldoccu- mereI inchthick,astheyaretoday.
I py a bedwith a full canopy;otherscon- Themostprominenifeature of the
r tentedthemselves
or unadornedbeds.
with half-canopybeds, bedareitsfourposts,
over6 feet
eachstanding well
tall.Giventhe36-inchcapac-
Theuseofa canopied bed,then,was ityof thetypicallathe, turningthepbsts
I certainlya mark of status,but it alsocon- canseem tobeanintimidating prospect.
veyedsomepracticalbenefitsaswell. But,asshownon page50,youcandivide
I The heavilyquilted draperythat hung eachpostintofourmanageable segments
from the frameworkof boardscalled andturn themseparately. Byintroduc-
I testersprovidedprivacy,a rare com- ing decorative elements likebeadsand
moditvin a daywhenbedroomsserved covesadjacent to the joint linesthe
I asfamilyliving andentertainingspaces. breaks arenot noticeable andtheoosts
Thefoldsof fabricalsoshutout the cold Twosections of a bedpostare appear to besolidturnings.
I winterdraftsthat werecommonand.in beingfitted togetherwith a long Likemostbeds,theonefeatured in
summer,the drapeswerereplacedby mortise-and-tenon knownasa tangthischapter hasrailsthatareattached
I light nettingto keepinsectsat bay. joint. Locatedto coincidewith decora-
to thepostswithknockdown hardware
Statusand utility aside,Americans tiveelements on theposts,thejoints
for quickdisassembly. Youcanusebay-
I havealwayssimplylikedthe look of the arevirtuallyinvisible.Thisoneis onetbrackets(page63)thathookthe
four-poster. In its undrapedform, the notgluedtogether, railsontothepostsor bedbolts(page59)
but assembled
I stylehasbeenan Americanfavoritefor dry so the bedcan beeasilydisas-to drawtherailsandpoststogether by
almost200years. sembled and transDorted. means of a boltandtappednut.Since
I Theonlyrealchange in four-poster thepostsaregluedto theheadboard and
design relatively
occurred recently,
withtheadvent ofboxsprings footboard,allbutoneof thetangjointsconnecting thepostseg-
I andspringmattresses. Before, a mattress
wasplaceddirectly mentstogether areleftdry.Thisallowsthepoststo betaken
onaplatformof ropestretched tightlybetweenthebedrails.To apartwithout compromising thebed's structure.
Withthetesters
I resistthetensionof thecords,therailshadto bequitestout- in placeon theposts,thewholeassembly isveryrigid.
I
I
I
Whethertheyaregracedby a canopyof hanging
I draperyor left bare,theuprightsand testers
of a
four-posterbedareimpressive. Themahoganybed
I shownat left alsofeaturesa sunriseheadboard.

I 49

I
 t
BED
ANATOMYOF A FOUR-POSTER r
I
I
End tester
'1"
I
x 1%"x 63". FiLaover aide teatera with
half-tapathat are not qlued,but drilledand
held in place by tenon at bottom end offinial
I
I
I
n
t l

U
I
-
Poat I
Turnedin four indivtdualeectione
connecLedby tan4 jointe; vaee
aectionaare qluedLoqeLher,but
Side tester (paqe 65) I
1"x1%"x 86". Keataon
other tanq jointa are left.dry for
dieaooembly.Gluedto end rarl
top end of poot: has half-
lap at each end Lhat
Headboard
(pase61)
t
and to either headboardor foot' acceptaa matchtn7cut
board;joined to aide rarla with
knockdownhardware.Hole ia
in end teetera. Holedrilled
1"x213/o"x5B";
tenona at both
I
through eachend for tenon
drilled inLo top end to accept endeare qlued
Lenonat bottom end of finial
at bottom end offinial
f,o Poe'e I
I
Footboard
1"x 11%"x 58": tenon I
at eachend ia qlued
into a poet morDige
I
Tenon(page 59)
t
3/a"x 1%"x 3"; 7lued
int;o morLiaern poot I
I
I
I
I
I
I
End rail
I
'1"
x 5%"x 58"; haa a
Cleat (page 62)
1"x 1%"x BO". )uppor-to box Lenonat each end Bayonet braaket
1ide-rail
1"x5'/r'xBO";
I
epringand mattreaa; faa- whichis gluedto poot Qaqe 63) joined to poete wrth
tened to inaideface of atde 9ecurea side knockdownhardware
I
ratle flush with boLtomedqe ratle to poete for easy dieaeeembly
I

I
I
t
t FOUR-POSTER
BED
I
I
FINIAT-TESTER-BEDPtlST
ASSEMBTY
t FOOTBOARD
P(IST AITERilATE
DESIGN:
Finial ienon; Finial PE1{CIt
POST
I t/o"diameter
(pase57) A (page
66)

I Ll )
I End tester
Vaae
T .=:
I
I
I Bead
(pase 54)
I
t
t
I
t
I Top vaae eection;
3/+"diameter mortiae
3"
t
Tan6joint,
I ATTERNATIVE HEADBOARDPOST
@ase56)
FINIAT
DESIGNS (bottom
section)
I
I 13/o"
II
12"
I Urn finial Z3/^tl
.-l
I
I
I
Pommel
(pase 52)

3 % "x 3 % ' !
I
16v"
F l
I Acorn finial
I
I i
f
6%"
I
I
 I
TURNINGTHE BEDPOSTS I
I
f urningthebedposts of a four-poster and tenons.Seethe anatomyillustra- I
I bedmayappearto be a daunting tionson page51for detailsof theposts'
challenge,but theprojectis manageable diameters andthelocations of thevar- I
ifbrokendowninto itscomponentparts. iouselements. Each6-foot-longpost
Thedesignof thepostsis simple;each is turnedin four individualsections, I
onecomprises onlya fewrecurringele- allowingfor the 36-inchlimit of most
ments,suchaspommels,beads,vases, lathes.Sincethe sectionsareioinedbv I
tangjoints,remember to allowfor the
2-inch-long tenonswhencuttingyour I
Thepommel,or bottomsection,of a blanksto length.
four-posterbedpost is turnedwith the Althoughthebottomsections ofthe I
helpof a storypoleand calipers.A story footboardandheadboard oostsaredif-
polecanseryeasa shop-made turning ferent,thefourpostsareotherwise iden- I
guide.Cutfrom a stripof plywood,it tical.To helpkeepthem uniform,turn
includes keydimensions and diome- theirmatchingsections oneafteranoth- I
tersaswellqsthelocationof decorative er,ratherthanproducingan entirepost
elements likebeads.A Frenchcurveis beforemovingon to thenextone.Start I
a gooddesigntoolfor drawingon the with the bottom sections(below),and
pole.Thecalipersareusedto checkthe moveup,turningthevasesections(page I
sizeof theblanksasturningproceeds. 55) next and the fintals(page57)last.
I
MAKING
THEPOMMET
SECTI()NS I
I
?ommel , Lowerpommelhne
I
I
I
I
I
t
I
I
'l Defining thepommels t
I C u tt h ef o u rp o m m e l - s e c tbi loann ktso s i z et,h e no u t l i n e theoutside of theblanks,runa pencilalongthearmto mark
the pommels-the transitions between theturnedandsquare thelowerpommels (above,
/eff).Mountoneof theblanks I
segments of the posts.Setthestockon a worksurface and between centers onyourlatheandadjust themachine'sspeed
c l a m pt h ep i e c etso g e t h ewri t ht h e i re n d sa l i g n esdoy o uc a n to slow.Startingabout%inchoutside thelowerpommel line, I
m a r ka l lt h ep o m m e al st t h es a m et i m e A . l t h o u gt h eu p p e r turna V-groove intothecornersof theblankwitha skewchis-
pommels onthe headboard postsarehigher thanonthefoot- el (above,
right).Deepen thegroove untilit runscompletely I
boardposts, the lowerpommels areat thesameheighton all aroundtheworkpiece. Toavoidkickback, cutwiththepoint
fourpieces. Holding theedgeof a carpenter's square against of thebladewiththebevelrubbing against thestock. I
I
52 I
I
I
t BED
FOUR-POSTE,R
I
I r) Shaping
thepommel
. a ^
Z - O n c ey o u h a v ef i n i s h e dt h e V - g r o o v e .
I w i d e ni t g r a d u a l l cy u, t t i n gw i t ht h e l o n g
p o i n to f t h e c h i s e lp o i n t e df o r w a r dR . oll
I t h e c h i s e fl r o ms i d et o s i d ew h i l er a i s
i n s t h e h a n d l es o t h e b e v ecl o n t r n u e s
I ' ' ' b . . -

r u b b i n ga g a i n stth e e d g e so f t h e g r o o v e
w a l l sa s y o u c u t t h e m ( l e f t ) .T u r n o f f
I t h e l a t h ea f t e re a c hc u t t o c h e c kt h e s h a n e
o f t h ep o m m e l .
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I Turning partofthepost
thecylindrical
na<l (ahnvc n 2 q ^ ^ ^ d^ rl ^u-l ^l B + L^
I Onno tho nnmmpl
Y " " " " " '
rq finichod rrsc: rnrrohins-nrrisnrroo

o f t h e p o s tb e l o wt h e p o m m e l .
t o t u r n t h e c y l i n d r i c ap lo r t i o n
lpff) mzkp crrnnpqqivplv dponpr
r*-)c) Lllc

H o l d i n gt h e g o u g ew i t ha n o v e r h a ngdr i p ,b r a c ei t o n t h e t o o l
I r e s t .C u tv e r yl i g h t l yi n t ot h e b l a n k m , a k i n gs u r et h e b e v e il s
r u b b i n ga g a i n stth e s t o c ka n d m o v i n gt h e g o u g es m o o t h lay l o n g
I t h e t o o lr e s t A s t h e p o u p eb e p i n rso r r n d r nt hs e c o r n e rosf t h e
I
t 53
I
t h e h a n d l eo f t h e t o o ls l i g h t l yw i t h e a c hp a s s ,
b l a n k ,r a i s i n g
u n t i lt h e e d g e sa r ec o m p l e t e lryo u n d e da n dy o uh a v ea c y l i n d e r .
Adjusthe position o f t h e t o o l r e s ta s y o u p r o g r e st so k e e pi t
c l o s et o t h e b l a n ka n d p e r i o d i c a lcl yh e c kt h e d i a m e t eor f t h e
bottomsegmentof the postwith calipers(above,ilghil.
 I
F O U RP O S T E R
BED I
I
I
I
I
I
I
I
I
I
I
t
I
I
I
Turning
thebead
U s ea p e n c i tl o o u t l i n et h e b e a d
I
b e t w e etnh e l o w e rp o m m eal n dc y l i n d r i -
n:l cpnfinn n
u rf tLhr rpL n
p vnJsL t,
+h^- -^r,^
Llltrll llldnU
-
d
jllifiltfiijittltrtltilfiiifii]fiIjfillilll
ttiltllllljtuljlllJfillfii1 t
V - c u ta t e a c hl i n ew i t h a s k e wc h i s e l .
S w i t c ht o a s p i n d l eg o u g et o f i n i s ht h e 1HO?TI? I
b e a d .B e g i n n i nagt t h e c e n t e r - o rh i g h -
e s t p o i n t o f t h e b e a d ,h o l dt h e g o u g e
Using preeetcalipero t
7inceyouareIurn-
f l a t a n d p e r p e n d i c u ltaort h e p o s ts o i t s
b e v e il s r u b b i n gR . a i s et h e h a n d l ea n d
inqthe variouE - I
secttons of lhe
m a k ea d o w n h i lcl u t - w o r k i n gf r o ma
h r g hp o r n t o a l o wp o i n t - r o t a t i n tgh e
bedVooboto dif-
ferenLdiame-
I
t o o l i n t h e d i r e c t i o no f t h e c u t a n d lero,you can
a n g l i n g t h eh a n d l ea w a y( a b o v d . f h e opeedup f,he '... . jl j
\if,
.
I
g o u g es h o u l df i n i s ht h e c u t r e s t i n g on ?roce6sby adjue|- \.. N
i t s s i d e .R e p e afto r t h e o t h e rs i d eo f t h e inqoeVaralecalipere \ I
b e a da, n g l i n a g n dr o l l i n tgh et o o li n t h e for eachteature of Ihe
o p p o s i tder r e c t i o nR. o u n dt h e s h o u l d e r s blanks.ForIhe Iurninqehown I
o f t h e b e a db y b l e n d i n g i t i n t ot h e t u r n -
at righl,onepairie adjusledfor
i n g .O n c et h e b e a di s f i n i s h e dc.o n t i n u e
the thickerparLof Ihe cylindrical
eeq' I
menl,anolheris selfor lhe beadbelowit,
t u r n i n gt h e b o t t o ms e g m e not f t h e p o s t
u n t i lr t h a st h e s h a p es h o w no n p a g e
and a third io adjueLedfor Nhenarrow seclion
near the bottom of Nheworkpiece,Thiswill save
I
5 ' ] . R e n e atth e n r o c e stso t u r n b e a d s youthe lroubleof coniinuallyreadjuetinq
a t t h e u p p e rp o m m elli n ea n df o r b o t h of calipero.To
a oinqlepair
avoidconfueinqlheeetlings,attach a
I
p o m m e los f t h e r e m a i n i npgo s t s . numbered sLrioof LaoeLo eachinsNrumenl.
I
I
54 I
I
I
I FOURPOSTERBED
I
I THEVASESECTI()NS
TURNING
I 1t Makins
-
cuts
sizinq
I 0 n c et h e l o w e rp o m m esl e c t i o n o sf
I t h e f o r r rn o s t sa r ed o n e t. u r nt o t h e v a s e
cpniinnc. F:r'h nnc.l h2s thrpp v2qp qtro-

I m e n t s o: n ea t t h e t o p o f t h e p o m m esl e c -
t i o n a n dt w o m o r ea b o v ei t . A l t h o u g thh e
I b o t t o m m o sotn e i s t h e w i d e s ta n d t h e
n e x to n er r ni s l o n p e s t h e v a s e sa r eo t h -
I e r w i s ei d e n t i c aaln d h a v es i m i l a cr o n -
t n r r r sT h e va l s nf e a t r r r ae t e n o na t t h e
I b o t t o me n da n da m a t c h i n m g ortise atthe
tnn Tn nrndrrep e v:sp irrrn iho qpompni

I i n t oa c y l i n d e (r p a g e5 3 ) ,t h e nm a k ea
s e r i e so f s i z i n gc u t sw i t h a p a r t i n gt o o l .
I H o l d i ntgh e p a r t i n tgo o lw i t ha n u n d e r h a n d
s r i n p d o p - r r n n n t h. p- t. n- , nl r -I v^ )^1 +, l- d^l ;) ^c ^ +L lLl ^t r

I h a n dl e s l i g h t l sy o t h e b l a d ec u t si n t ot h e
c y l i n d e rC. o n t i n uteo r a i s et h e h a n d l eu n t i l
I tho eut rp:ehcc ihp rpnrrirpd d'onlh (lpft)

E a c hc u t s h o u l dp e n e t r a tteo t h e f i n i s h e d
I diamotpr nf thp nnct :t th:t nnint nhpek

y o u rp r o g r e swsi t h c a l i p e r p s eriodically.
I T w i s t h e t o o ls l i g h t l yf r o ms i d et o s i d ea s
y o um a k et h ec u t t o m i n i m i zfer i c t i o na n d
t t o p r e v e ntth e b l a d ef r o mj a m m i n g .

I
I
I
I
I
I
I
thevasesmooth
Planing
I U s ea s k e wc h i s etlo s m o o t h t h ev a s eH . o l d i n teh et o o lw i t h
r) Roughing
outthevase a n u n d e r h a ngdr i pa n dw i t ht h e l a t h et u r n e do f f ,s e tt h e b l a d eo n
I . a ^
Z - O n c ey o ur a v ef i n i s h e d a l l t h e s i z i n gc u t s .u s ea r o u g h i n g thetoolrestsothat its longpointis abovethe blankand its bevel
g o u g et o c l e a ro u t t h e w a s t eb e t w e e nc u t s .F o l l o wt h e s a m e i s i n c l i n e idn t h ed i r e c t i oonf t h ec u t ;t h i si s a b o u 6t 5 " t o t h ea x i s
I p r o c e d u ryeo uw o u l du s et o t u r n a c y l i n d e rh, o l d r n tgh e t o o l o f t h ew o o d S . w i t c ho n t h e l a t h ea n dr a i s et h e h a n d l es l i g h t l y ,
w i t ha n o v e r h a ngdr i pa n da l w a yw s o r k i n ign a d o w n h i d l li r e c - bringing the cuttingedgeof thechiselintocontactwiththe stock.
I t i o nt o a v o i dt e a r o u (t a b o v e J) .o i n i n gt h e s i z i n gc u t sw i l l c r e a t e Movethe bladealongthe tool rest(above), lettrngits bevelrub;
a t a p e ra l o n gt h e l e n g t lo' f t h e w o r k p i e c eU.s ea s p i n d l eg o u g e d o n o ta l l o wt h e h e e lo r l o n gp o i n td i g i n t ot h ew o o dT . h ec e n t e r
I t o r o u n do v e rt h e e n d so f t h e v a s e . o f t h ec u t t i n ge d g es h o u l dp r o d u cae s e r i e os f t h i ns h a v i n g s .

I
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FOUR_POSTER
BET) I
I
MAKING
THETANG
J()INTS I
1t Turnins
-
thetenons I
I O r c ey o uh a v et r r n e da l l t h ev a s e si .t
i s t r m et o p ' o d u c et 1 er a n gj o r n t sS. r a r b ty I
t. -r r" "" 'nb i nl ep n o n as l l h en n l t o m
e r d so f L h e
t i r u nq e n , a r a l ev : s e < o r - i i n n 5a n d I n i a l b a f k . I
M a r kt h et e n o ns h o u l d e2r r n c h efsr o mt h e
e n do f t l ^ ew o r k p , eecb y l ^ o l idr g a p e r c t
a g a i n st ht es p i n nn g b l a n kT. h e n h, o l d i n g
a p a r t i n tgo o lw i t ha n u n d e r h a ngdr p , I
m a k ea s e " i eos' s i zr p c r . t st o d e f i n e the
tenon(pzgp55). Usea ,oughing gougeto I
c l e a ro r t t h e w a s t eb e t w e e trh e c u t s .A s
t h et e n o nb e g i n tso t a k es h a p ep, e ro d i c a l i y I
c h e c kt w i t l ^c a i p e r ss, t o p p i nw g l ^ e nt h e
t e n o ni s I i n c hi n d i a m e t eFr .i n a l l yu,s ea I
s k e wc h i s e[l o r n d e r c utLh es h o u l d esrl r g h t -
l y ;t h i sw i l e n s u r teh a tt h e b o t t o me n d so f I
t h ev a s es e c to n ss i t f l u s ho n t h es e c t i o n s
b e l o ww i t h o uwt o b b l i n gH. o l dt h ec h i s e l I
edge-up s o i t s l o n gp o r n ta n d b e v e al r e
a l i g n ew d i t ht h es h o u l d el irn e ,T h e ns l o w l y I
rarse a n dt w i s t h e h a n d l es,l i c i n g deeper
i n r ot l - es l - o u l d ears t l e c u t t r r ge d g ea p - r
n r o a c n e' \se l e n o t ( r t p h l J .
t
i ' r r b r i ! /

t
I
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I
r ) B o r i n tgh em o r t i s e s
I
Z . R . r o u . t h e b l a n ka n d t o o l r e s t ,a n d a d j u s t h e l a t h et o
t s s l o w e sst p e e d l. V o u n at l - i n c hd r r l lb r t i n a J a c o bcsh u c k
t h e b e du n t i t h e b i t m e e t st h e c e n t e o r f t h e w o r k pe c e .T h e n
t u r no n t h e l a t h ea n dt u r nt h e h a n d w h e teol a d v a n cteh e t a i l -
r
a n da t t a c ht h e c h u c kt o t h e l a t h et a i s t o c k l.V o u ntth et e n o n -
e n do f t h e b a n ki n t h e h e a d s t o cakn ds l i d et h et a i l s t o cakl o n s
s t o c ks o t h e b i t b o r e ss t r a i g hitn t ot h e e n do f t h e b l a n k( a b o v e ) ;
h p s r r r pl n h n l n t h e w o r k n i p r ^ p . , t p a d v :ttn p < , t a rni f t n p n
v yn
r r o ru :L lr vr rn n
r'
t
I
,56 I
I
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I BED
FOUR-POSTER
I
I TUR N I N
TGH EF I NIA T S
I thefinials
1I Shaoins
I T h ef i n i a l sa t t h et o p o f t h e b e d p o s t s
t c o m b i n ev a s e sa n d b e a d sA. f t e rt u r n i n g
t h e s ee l e m e n t ss,e p a r a tteh e t o p e n do f
I t h e f i n i a lf r o m t h e w a s t ew o o du s e dt o
h o l dt h e b l a n kb e t w e e cne n t e r sT. o a v o i d
I m a r r i n gt h e f i n i a l ' sr o u n d e d
t o p , u s ea
s k e wc h i s e lt o p a r to f f t h e w o r k p i e c e .
I H o l d i ntgh et o o lw i t ha n u n d e r h a ngdr i p ,
m a k ea s l i c i n g c u t w i t ht h e l o n gp o i n otf
I t h e b l a d ea s y o uw o u l dr o u n da p o m m e l
@age53).Makea seriesof deeperV-cuts
I (right).Beforethe finishedturningbreaks
l o o s ef r o mt h e w a s t es, u p p o ritt w i t ho n e
I f r e eh a n d ,k e e p i n ygo u rf i n g e r sw e l lc l e a r
o f t h e t o o l r e s ta n d b e i n gc a r e f unl o tt o
I g r i pt h es p i n n i nw gorkpiece.

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r) Smoothing
I L f o remoue
thefinial
anytool marksleft on the
I f i n i a l sb yt h es k e wc h i s e ls, a n dt h e i rs u r -
f a c e ss m o o t hY . o uc a n d o t h e j o b b y
I h a n d ,s e c u r i ntgh e s t o c ki n a b e n c hv i s e
a n d u s i n ga s a n d i n gb l o c k .B u t a d i s k
I s a n d e lri k et h e o n es h o w na t l e f tw i l l
m a k eq u i c kw o r ko f t h e t a s k .H o l d i n g
I t h e f i n i a lo n t h e s a n d i n tga b l e e , a s ei t
i n t ot h e d i s ka t a n a n g l eo f a b o u t4 5 " .
l i g h tp r e s s u r e
r o, t a t et h e f i n i a l
I Applying
u n t i li t i s s m o o t h .
I
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FOUR-POSTER
BED I
I
PREPARING
THEPOSTS
FOR
THEENDBOARDS
ANDRAILS I
'l Laying outthemonises I
I Thebedoosts areioined to theend
b o a r dasn di a i l sw i t ht l i n o m o r t i s e - a n d - I
tenons. Toensure thatall themortises
l i n eu p ,m a r kt h e mo nt h ep o s t isn a s i n - t
glesetup. Clamp theposts together with
theirendsaligned andplacetheassem- I
blyona worksurface. Holding theedge
of a carpenter's square against thestock, I
m a r ko n o n ep o s ta t a t i m e .M a r kt h e
mortise length-3 i nches-across the I
pommel; eachheadboard posthasthree
mortises, including twofortheheadboard t
andonefortheendrail,whileeachfoot-
boardposthastwo-oneforthefootboard I
andonefortherail,Next,markthemor-
tisewidth-% inch;centerthe mortise I
outline onthepommels. Usethesquare to
alignall themortise lengthmarks(/eff). t
I
I
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t
I
r) Drilling themortises
1 youcancutthemortises in theoosts I
byhandwitha chisel andmallet, or usea
routerf ittedwitha mortising bit.Butcon- t
sidering thedepthof themortises-1%
inches-ahollow chiselmortiser, likethe I
oneshownat rightor a drillpress with
a m o r t i s i nagt t a c h m e nwti,l ld ot h ej o b I
mostquickly andaccurately,
m a c h i nfeo l l o w i nt g
Setupthe
h em a n u f a c t u r e r ' s r
directions. Forthemortiser shown, install
a s/e-inch bit andplaceoneof theposts I
onthetable,centering a mortise outline
underthecutter.Buttthefenceagainst I
thestockandadjustthe hold-down to
secure thepostwhilestillallowing youto I
slidetheworkpiece freely along thefence.
M a k ea c u ta t e a c he n do f t h eo u t l i n e , I
thena series of staggered cutsin between
(right)Io complete themortise. t
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58 I
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MAKINGTHEENDBOARDS
I
I rl*1 he sunrisemotif of the headboard it takeslongerto set,allowingmoretime
I featuredin this chapteris a popular for adjustment afterit hasbeenapplied.
I design,particularlyin AmericanCountry Jointhe siderailsto the postswith
furniture.rv\hatever designyou choose, commercial bayonetbrackets(page63)
I however, theprimarychallenge in making or bedbolts(photo,right).Bedbolts are
the endboardsfor a bed is cuttingthe stronger,but thebracketsaresimplerto
I piecessymmetrically. Theboardsaretoo installand comeapartwith only a few
unwieldyto do thejob accurately on the mallettaps.
I bandsaw.Youwillbe muchbetteroff
shapingtheboardswith a routerguidedby
I templates, asshownstartingon page61. Tofacilitatedisassembly,bedpostsare
Whenthetimecomesto gluetheend usuallyanachedto thesiderailswith
I boardsand railsto the bedposts(page knockdown hardware,suchasthebed
64),lry to enlistthe aid of an assistant boltshownat right.Theboltextends
I or hvo to help you maneuverthe stock throughthepostinto therail and is
andthesixlongbarclampsyouwill need. threadedinto a crossdowelinstalled
I Formaximumflexibilityat glue-up,use in therail. Theboltheadis concealed
whiteglueratherthanyellowadhesive; by an embossed brasscover.
I
I THETEN()NS
CUTTING
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'l Sawing thetenoncheeks
I I Youcancutthetenoncheeks in theendboards andrails asthickastheendboards andrails.Test-fit thetenonin one
witha router or a radialarmsaw.lf youdothejobona table of thepostmortises, raising thedadoheadandmaking addi-
I saw,asshownhere,youwill needto setup an auxiliary table tionalcuts,asnecessary, untilthefit is snug.0ncethe blade
orworkwitha helper to keepthelongworkpieces steady asyou heightis set,position thefencefora ll,-inch-wide cut and
I feedthemacross thetable.Startbyinstalling a dadoheadon c l a m oa f e a t h e r b o at or dt h ef e n c ea b o v teh ed a d oh e a d .
thesaw,adjusting it to itswidestsetting.
Attacha highauxil- H o l d i ntgh ew o r k p i e cf leu s ha g a i n st h
t ef e n c ea n dm i t e r
I iaryfenceandan extension boardto themitergauge. Holda gauge extension, andflatonthetable,feedit intotheblades
carpenter'ssquare against thefenceandextension to ensure to definethetenonshoulder. Thenshiftthestockawayfrom
I thattheyareperpendicular to eachotherandadjustthemiter thefencebythewidthof thekerfandmakeanother passto
gauge, if necessary (above, /eft).Setthecuttingheightat cleartheremaining waste. Turntheworkpiece overto cutthe
I about%inchandmakea cutacross eachfaceof a scrapboard cheekonthe otherside(above, right).
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FOUR-POSTER
BED I
I
r) Markingtheedgesof thetenons I
L O n c ea l l t h e t e n o nc h e e k sh a v eb e e n
c u t , m a r kt h et e n o n se' d g e su, s i n gt h e i r
t
p o s tm o r t i s eass a g u i d e O . utline single
t e n o n so n t h e e n dr a i l sa n df o o t b o a r dt h; e
I
h e a d b o a rsdh, o w na t r i g h t ,h a st w ot e n o n s .
S e tt h e p o s to n a w o r ks u r f a c ew i t h i t s
I
m o r t i s efsa c i n pr r na n d o o s i t i otnh e m a t -
i n gp i e c eo n t o p ,a l i g n i ntgh ee n do f t h e
r
b o a r dw i t ht h e m o r t i s e sT.h e nl i n eu p t h e
b l a d eo f a c o m b i n a t r os n quarw e i t ho n e
I
e n do f a m o r t i s ae n d ,h o l d i n tgh e h a n d l e
o f t h e s q u a r ea g a i n stth e e n do f t h et e n o n
I
a n dt h et i p o f t h e b l a d ea g a i n stth es h o u l
d e r ,m a r kt h e t e n o ne d g ea c r o s tsh e c h e e k
I
w i t ha p e n c i lO . u t l i n teh e r e m a i n i nt e
gnon
edgesthe sameway tight), markingthe
I
wastewith Xs as yougo.
I
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I
Finishing
thetenons
C l e a trh e w a s t ea d j o i n i ntgh e e d g e so f t h et e n o n su s i n ga W i t ht h e t o o l ' sb a s ep l a t ef l a t o n t h e w o r k p i e c ae n d f l u s h
I
r o u t e fri t t e dw i t ha b o t t o m - p i l o tfel u
ds h - t r i m m i n
bg r t .C l a m p
t h e s t o c kt o a w o r ks u r f a c ea n d a l i g nt h e c u t t e rw i t ht h e e d g e
a g a i n st th e s t o pb l o c k e, a s et h e b i t i n t ot h e s t o c ku n t i lt h e
p i l o t b e a r i n gr e a c h e tsh e t e n o ns h o u l d e rF. e e dt h e r o u t e r
I
o f a t e n o n .T h e nb u t t a s t o pb l o c ka g a i n stth e r o u t e b r a s ep l a t e a l o n gt h e e n do f t h e b o a r ds, t o p p i n g
w h e nt h e b a s ep l a t ec o n -
a n dc l a m pi t t o t h e w o r k p i e c el f. t h e r ei s a s e c o n dt e n o no n t h e t a c t sa s e c o n ds t o pb l o c k( i n s e t o) r t h e b i t r e a c h e tsh e e d g e
I
s a m ee n d o f t h e s t o c k a , s i n t h e h e a d b o a r cd l,a m pa s e c o n d
s t o pb l o c kt o p r e v e ntth e r o u t e fr r o mc u t t i n gi n t ot h e t e n o n .
o f t h e w o r k p i e c (ea b o v e )C. l e a nu p t h e e d g e so f t h e t e n o n
w i t ha c h i s e l .
r
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-a
I FOUR.POSTER
BED
I
I THEENDBOARDS
SHAPING
I 1 Making theendboard templates
I Shape thecurved profiles of thehead-
I andfootboards witha routerguidedby
t e m p l a t e sM. a k et h et e m p l a t ef sr o m
I %-inch plywood, tracing thecontours of
theboards'top edges, as illustrated on
I page51, on theplywood. Butinstead of
producing templates thatspanthefullend
I boards, markonlyone-half the patterns
o n t h ei e m p l a t efsr,o mo n ee n dt o t h e
I m i d d l en; o to n l yw i l lt h et e m p l a t ebse
easier to maneuver, butbyusinga single
I pattern to outlinebothhalves of each
board, youwillensure thattheyaresym-
I metrical. Cuteachpattern one-half as
l o n ga st h ee n db o a r dp, l u sa b o u 1 t2
I inches. Onbothsidesof thetemplate,
markoneendof theendboard, thenthe
I middle, andtracethecurved pattern in
between. Cutthe pattern on yourband
I s a w t, h e ns m o o t thh ec u t e d g eu, s i n ga
spindle sander (righilor a sanding block.
I
I
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J
I
I r") Marking theendboard stock
L Setthestockface-uo on a worksur-
I f a c ea n dm a r kt h e m i d d l eo n t h et o p
e d g eT. h e nc l a m pt h et e m p l a toen t o p ,
t a l i g n i ntgh ee n dm a r kw i t ht h ee n do f
theworkpiece andthetwomiddlemarks.
I R u na p e n c ial l o n g
t h ec u te d g eo f t h e
template to outlinethe pattern on the
I endboardstock(/eft).Thenturnthetem-
plateoverandrepeat theprocess to mark
I theotherhalfof theworkorece.
t
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FOUR_POSTER
BED I
I
theendboards
I
Q Shaping
r.,l Cuttheendboards onyourbandsaw,
leaving about1/sinchof wastealongthe
I
cuttinglines.Reclamp theworkpiece and
template to a worksurface asin step2,
I
e n s u r i ntgh a tt h ee d g et o b e s h a p e d
e x t e n dosf f t h et a b l eb y a f e wi n c h e s .
I
flush-trimming bit in
Install a top-piloted
yourrouter, adjusting thecuttingdepth
I
sothepilotbearing willbelevelwiththe
I
t e m o l a taen dt h ec u t t ew r i l lt r i mt h e
entireedgeof thestock.Starting at one
endof theboard, holdtherouter flaton
I
t h et e m o l a taen de a s et h eb i t i n t ot h e I
stockuniilthebearing contacts thepat-
tern.Thenfeedthetoolsteadily along the
I
edge,moving against thedirection of bit
rotation andpressing thebearing against
thetemplate (right).Onceyoureachthe
I
e n do f t h et e m p l a t e
t h et e m p l a toev e a
s t, o pt h ec u t .T u r n
r n dc l a m pi t t o t h e
t
otherhalfof theendboard, thenrepeat
thetrimmingprocess. Smooth theedges
I
of thestockwith12O-grit sandpaper.
I
THESIDERAILS
PREPARING
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1 Fastening hookplates t0 therails
I
I lf youareusingbayonet brackets to attach thesiderailsto w i t ht h ee n do f t h er a i l ,h o l di t i n p o s i t i oann dt a pi t w i t ha
theposts, startbyfixinga hookplateto theendsof therails. malletto markthe baseof the hooks on thewood.Holdthe
I
Clamp a railtoa worksurface, center a plateontheend,and chiselperpendicular
to theendgrainof therailandcutrecess-
t h eo u t l i n e esforthe hooks(above).
o u t l i niet w i t ha p e n c iTl .h e nc h i s eal m o r t i swei t h i n Thenscrewtheplateto therail,mak-
to a depth equal to the plate thickness. 0nce the plate is flush ingsurethatthehooks willbepointing down.
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62 I
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I FOUR-POSTER
BED
I
t r) Fastening catchplates to theposts
L me placement of thecatchplates on
I thebedposts determines theheight ofthe
mattress; thebottom of theboxspringis
I customarily 8r/zinches above thef loor.lt
is alsocrucial to locate theplates sothe
t inside facesof therailshugtheedges of
theboxspring; fora 60-inch-wide box
I spring/mattress setin a bedof thedimen-
sionsprovided on page50, centrethe
I plateontheedgeof thepost.Markthe
edges of therailonthepostandoutline
I thecatchplateon the post?ighil,cen-
teringit between railmarks. Chisel the
I platemortise asyoudid in step2, then
h o l dt h eh a r d w airnep o s i t i oann do u t l i n e
I t h eh o o ko p e n i n gosnt h es t o c kU . s ea
chiselandmalletto cut recesses in the
I postforthehooks, thenscrew thecatch
olateto theoost.
I
I
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I
I
I
I
I
I
t) Fastenins
thecleats
to thesiderails
I <'
r . , l 0 n c e a l l t h e b a v o n ebt r a c k e t a sre
I i n s t a l l e dc,u t t h e c l e a t st h a tw i l l s u p p o r t
t h e b o xs p r i n gt o t h e l e n g t ho f t h e s i d e
r a i l s .S p r e a dg l u eo n t h e c o n t a c t i nsgu r -
I f a c e sb e t w e etnh e s i d er a i la n dc l e a t t, h e n
I c l a m pt h e c l e a ta l o n gt h e i n s i d ef a c e
o f t h e r a i l ,f l u s hw i t ht h e b o t t o me d g e ;
m a k es u r et h e e n d so f t h e t w o p i e c e s
I a r e a l i g n e dN. e x t d , r i l lp i l o th o l e st h r o u g h
t h e c l e a ta n d i n t ot h e r a i l ,s t a r t i n g
I e s i n f r o mt h e e n d sa n d s p a c i n g
2 inch-
the
I r e m a i n i nhgo l e s8 i n c h e sa p a r t F
drivea screwinto eachhole (lefil,
. inally,

I
I 63
I
 t
FOUR_POSTER
BED I
t
UPTHEBEDPOSTS
GLUING ANDENDB()ARDS I
'l
Gluingthe bedpost vase I
I sections together
A l t h o u g thh e j o i n t sc o n n e c t i ntgh e p o m - I
m e l s e c t i o nas n df i n i a l so f t h e p o s t st o
t h e v a s es e c t i o nasr en o tg l u e d t, h e t a n g
j o i n t sb e t w e etnh e v a s es e c t i o n m
t
s u s tb e
g l u e dt o g i v et h e p o s t sa d e q u a t rer g r d i t y . t
S o r e a da d h e s i voen t h e t e n o na n d i n t h e
m o r t i s eo f t h e t a n gj o i n ta n do n t h e c o n - I
t a c t i n gs u r f a c ebs e t w e e tnh e t w o p i e c e s ,
t h e ns e c u r et h e m i n a b a rc l a m p ,p r o t e c t - I
i n gt h e s t o c kw i t h w o o dp a d s .l f t h e p o s t
b e g i n st o d i s t o r at s y o ut i g h t e nt h e c l a m p , I
r e p o s i t i oi nt i n t h e j a w su n t i li t r e m a i n s
straight.Keeptightening(right)unlil a I
g l u eb e a ds q u e e z eosu t o f t h e j o i n t .
I
t
I
r) Gluingthe poststo the endboards I
L S e t t h ee n d b o a r d sw i t ht h e i rr e s p e c -
t i v ee n dr a i l sa n d p o s t so n a w o r ks u r f a c e , I
a n dt e s t -ift t h e m o r t i s e - a n d - t e nj ooinn t s
b e t w e etnh e m .U s ea c h i s e tl o p a r ea w a y I
w o o df r o ma n yr l l -rft t r n g l o r n t sA. p p l yg l u e
t o t h e c o n t a c t i n sgu r f a c e osf the posts I
a n de n db o a r das n dr a i l sa, n du s ea n o n -
marring dead-bloh wa m m etro t a p t h e t
j o i n t st o g e t h e ri f. n e c e s s a rSy e. c u r ethe
n ri eu nu ou sJ uv rvirt Lh i lfr nu rur rr lr nu ni loE p
p
^r--^^
n l; p^ ^t r L ^.
lolllp) UI I
pioht q , h n r i p r h:r e l:mns rrcpd in nairs

a s s h o w na t l e f t .P o s i t i otnw oc l a m p s I
a c r o s st h e e n d b o a r ds o t h e h a n d l e - e n d
j a w sr e s ta g a i n sot p p o s i t e
+^ir ^+^^^ ^t +L^ ^r^*^^
p o s t sa n d t h e I
tdil Jtup) ur L|tr Ltdttp5 n- ,v o_ r, l a n Prntor.i

t h e p o s t sw i t hw o o dp a d sc u t a s l o n ga n d I
w i d ea s t h e p o m m e sl e c t i o n su: s e p l y -
w o o dp a d st o p r o t e c t h e f a c e so f t h e
^-f, L^^-!^ ^^f, -^ir^ Ti:hipn
I
trru uudru> dilu rdilJ. rrb...-.. nnp of ihp

c l a m p su n t i lt h e t a i l s t o p sm a k ec o n t a c t . t
R e p e awt i t ht w o m o r ec l a m p sa c r o s tsh e
e n dr a i l a n dp a r t i a l lt yi g h t e na l l f o u r I
c l a m p st,h e nt u r nt h e a s s e m b loyv e ra n d
i n s t a ltlh e r e m a i n i nfgo u rc l a m p sT. i g h t e n t
a l l t h e c l a m p s( l e f t )u n l i la t h i n g l u eb e a d
s o r e e z eos r t o f t h e i o i n t s . I
I
64 I
I
I
I FOUR-POSTER
BED
I
I MAKING
ANDINSTALLING
THETESTERS
I 1 Notching theendsofthetesters
I Oncethebedposts, endboards, and
t r a i l sa r eg l u e du p a n da s s e m b l ei tdi,s
timeto preDare thetesters thatconnect
I thetopendsof theposts. Useyourtable Miter 4au4e
exLengion
s a wt o c u t t h e h a l f - l a pt sh a tj o i nt h e
I testers, lnstalla dadohead,adjusting it
to itsmaximum width,andsetthecutting
r h e i g hat t o n e - h atlhf es i o c kt h i c k n e s s .
Screwan extension boardto the miter
I p a r r s eP.o s i t i ot n
h er i nf e n c ef o ra w i d t h
of cut equalto thewidthof thetesters,
t t h e nc u t e a c hh a l f - l a ipn t w op a s s e s .
S t a r tb ya l i g n i ntgh ee n do f t h e b o a r d
I withthedadoheadand,holding theedge
of thetesterflushagainst themitergauge
I e x t e n s i ofne,e dt h es t o c ki n t ot h ec u t .
Makethesecond passthesameway,but
I withtheendof the boardflushasainst
Ihefence(right).
I
I
I
I
I
I
I O Installing
L Borea holethroush
thetesters
thecenter of each
I half-lap
yourdrillpress
at theendoflhetesters,
f ittedwitha bitthesame
usrng

I d i a m e t earst h ef i n i a tl e n o n s% i n c h .
To prevent tearout, borethe holesin two
I steps:Startbydrillinghalfway
thestock,thenturnthetesteroverand
through

I c o m p l e th e eh o l ef r o mt h eo t h esr i d e .
(Youcanalsoassemble thetesters and
I d r i l lt h et w oh o l e as t t h es a m et i m ew i t h
a p o r t a bdl er i l lT. h i sw i l le n s u rteh a t h e
I holeslineup perfectly.) Install thetesters
at onecorner of thebedat a time.Sliothe
I f i n i atl e n o nt h r o u gthh eh o l ei n t h ee n d
testerand,holding thesidetesterover
(left),fit thetenonthrough
I the bedpost
itsholeintothemortise in theoost.
I
I 65
I
 I
t
PENCILPOSTS
I
hetaperedoctagonal
bedpost, known execution.The bevelsthat createthe
I
f
I asa pencilpost,is a popularalter- octagonmust be laid out so the eight I
nativeto theturnedversionfeaturedin sidesareequalasthe posttapersfrom
the previoussection.Insteadof being baseto tip. Althoughthelayoutmethod I
shaoedin individualsectionsthat are shown below is straightforward,it
then assembled, pencilpostsaremade
from a singlelengthof solidor face-
demandsprecisedrafting. t
gluedlumber-first taperedon ajoint- I
er (page67)andthenby hand (page68).
To avoidtearoutasyou shapetheposts,
makeyour blanksfrom 3/,-inch-thick
With its solid, squarebasegiving
way to an octagonalsectionthat
I
stockwith straightgrain;if you choose
to glueup thinnerboardsto makeup
gradually tapersto a narrow tip, the
pencil post shown at right offersboth
I
the blanks,makesurethe wood grain strengthand refinement.The curved
I
of theoiecesrunsin thesamedirection. bevelsthat mark the transition between
Shapingthe octagonalsectionsof
the postsis a challengeof designand
the squareand octagonalsegments
are known as lamb's tongues.
I
I
MAKING POSTS
PENCIL I
I
I
I
I
I
I
I
r
I
taper (ahaded area)
I
I
1 0utlining thetapers
I Fora bedofthedimensions shown on page50,marka line square thatpassesthrough eachof itsfourcorners. Then,with I
forthestartof thetaperall around from
theblank20 inches the a penciland ruler,
draw a second squarewhose corners meet
(inseil.
bottom end.Thenoutline theoctagonal
thetopend.Startbycentering
taperonthecenter
a lYq-inch squareontheend
of where
shape
thecircleandcenter lines
willbecut byfirsttapering
intersect fhe octagonal
thestockto thedimensions of
T
you planing
withsides
square
parallel
to theedges
to thestock's side.Extendthesidesof the thefirstsquare drew,thenby
of thestock,thendrawverticalandhorizon- square downto theremaining
thecorners
sidesof thesecond
of that
square. Mark
I
pencil
tal linesthrough
Nextusea comDass
thecenter, eachbisecting thesquare'ssides. thefirstcutsbyusinga
to drawa circlefromthecenterof the
andlongstraightedge
thetaperlinesfromtheendto thestartline(above).
to extend I
I
66 I
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I FOUR-POSTER
BED
I
t
t
I
t
I
I
I
t
t
t
t r) Setting upandstarting thetaper
L nn easywayto taperthe postsis witha jointer. Setthe f e n c e a l i s nt h e t a n e rs t a r tl i n ew i t ht h e f r o n to f t h e o u t f e e d
I machine fora shallow
about4 inches
cutandposition
ofthecutterhead.
thefenceto expose
Forthisoperation,
only
alsoadjust
tableT
terhead
. o s t a r te a c hp a s sc, a r e f u l llyo w e trh e b l a n ko n t ot h e c u t -
w h i l eh o l d i n gi t f i r m l ya g a i n stth e f e n c e( a b o v e M
). ake

I t h eg u a r d
o u to f t h ew a yT. h e nh, o l d i ntgh eb l a n ka g a i n st ht e s u r eb o t hh a n d sa r eo v e rt h e i n f e e ds i d eo f t h e t a b l e .

I
I
I
I
I
I
I Tapering the posts
Q
I r - , 1 F e e dt h e l e s a c r o s st h e c u t t e r h e a d
w i t ha p u s hb l o c k ,p r e s s i ndgo w no n t h e
I t r a i l i n ge n do f t h e s t o c kw h i l eh o l d i n gi t
flushagainstthe fence(/eft).Keepyour
I l e f th a n da w a yf r o mt h e c u t t e r h e a dM. a k e
a s m a n yp a s s e a s s n e c e s s a ruyn t i l y o u
I h a v et r i m m e dt h e s t o c kt o t h e t a p e ro u t -
l i n e ,r e p e a t i ntgh e p r o c e stso s h a p et h e
I r e m a i n i nfga c e s l. f y o u rm a r k i n gasr ec o r -
r e c t ,y o us h o u l dm a k et h e s a m en u m b e r
t o f p a s s eosn e a c hs i d e .C l e a nu p t h e t a p e r
a t t h e s t a r tl i n eu s i n sa b e l ts a n d e r .
t
I 67
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FOUR-POSTER
BED I
I
BEVELING
TAPERS
I
I
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t
I
I
r
I
I
I
I
t
I
'l Layingoutthebevels
I Toformtheoctagon, bevelthecornersof thesquaretaper. post,measuring fromeachcorner of thesquare to eitherside.
I
Thebevelis alreadyoutlinedontheendof eachpost,butit Thenusea pencilanda longstraightedge to connect each
mustalsobemarked onthesidesof thestock.Takingthedimen- markwithitscorresponding pointontheoctagon drawnat the
I
sionsfroma pieceof full-size
poststock,anddrawing onscrap t o pe n do f e a c hp o s tO
. n c ea l l e i g hbt e v elli n e sa r em a r k e d ,
plywood, outlinesquares asyoudid in stepI (above,left). drawa curved lamb's tongue at eachcorner, joining thebevel
I
Transferyourmeasurement-equal to thebevelwidth-tothe markswiththetaperstartlinehbove,right).
t
Roughing outthebevels
I
Tosecure theoosts. usethreewood
blocks. CutV-shaoed notches intoan
I
edgeof eachone,thenplacetwoof the
blocksundertheworkpiece to support it
I
andclamponeontop between theother
two:oosition twoof theblocks around the
I
square portion of the post.Thenusea
drawknife to shapethetapered portion of
I
thepostsintooctagons, beveling onecor-
n e ra t a t i m e .H o l d i ntgh ed r a w k n iof en
I
thestockbevel-side down,pullthetool
toward thetopendof thepost(righil.fhe
I
depthof cutdepends on howmuchyou
tilt thehandles; thelower theangle, the
I
shallower thecut.Takea lightshaving,
always following thewoodgrain.
I
I
68 I
I
I
t FOUR-POSTER
BED
I
I thebevels
Q Smoothing
r-,f Onceall the bevels havebeencut,
I u s ea b e n c hp l a n e
toflattent h ee i g h t
sidesof theposts'tapered section.Adjust
I thetoolto a verylightcutandworkfrom
thetaperstartlinetoward thepost's top
I endto levelthesurface (righil.fo auoid
tearout, workwiththewoodgrain.Repo-
I sitiontheoostin thewoodblocks asnec-
essary to f latten theremaining sides.
I
I
I
t
I
I
I
I
I
I
I
I
I
I
I
I
I
Shaping thelamb's tongue
I Tocomplete thepencilposts, switch
f er i n gt h el a m b ' s
b a c kt o t h ed r a w k n i b
I tongues to theirfinalshape. Workasyou
didin step5, smoothing outthetransition
I between thetongues andthebevellines
(left).Onceyouarefinished draw-knifing,
I smooth thesurface using a sanding block.
I
I 69
I
I
I
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t
t
I

I
I
I \AINDSORCHAIR
I
I
I
T n. Windsorchairis a the seat at whateverangles
I I incontrasts.
study Origi- suit its user.All of the chair's
nallydesigned asan artless parts are joined with round
I furnishing,it is now con- mortise-and-tenons-afairly
sideredto be a sophisticated simplejoint to produce.Some
I example of modernchairmak- woodworkerscontend that
ing.Thesimpleelements of a one of the benefitsof making
I Windsor-the sculptedseat a Windsor chair with green
and the hand-shaped legs, lumber is that you can take
I stretchers, arm posts,and advantage of the hygroscopic,
spindles-beliethe precise or moisture-absorbing charac-
I engineering requiredto assem- ter of wood. dryrngthe leg
By
bleit. Anddespiteitsrelative- tenonsprior to assembly and
I ly lightweight components, the fitting them into
"wet"
mor-
Windsorchairis verystrong tisesin theseat,a snugjoint will
I anddurable. Thetop of a Windsorchairseatis traditionally becomeeventighter.Oncethe
Firstmadein ruralsouth- sculptedby hand. With shapingtoolslike joint is assembled, the tenon
I ernEngland, Windsorchairs thespokeshave, inshave,and drawknife,it is will absorbmoisturefrom the
cameto NorthAmericain the possibleto customize theseatfor its user. woodsurroundingthemortise,
I mid-18thCentury. Perhaps as swellingthetenonandshrink-
aresultof itspracticaldesign andunsophisticated construction, ingthemortise. Otherchairmakers choose insteadto usesea-
t thestylequicklyflourished with America's pioneerhome- sonedwoodfor theseat,whichwill belesslikelyto crackasit
steaders.Thefoundation of allWndsorchairs-whether the dries,andreinforce thejoineryin otherways. Thejointsin the
t sack-back version featured in thischapter,
thecomb-back with chairfeatured in thischapteraregluedandmanyof them-
its highbackest,or thecontinuous-arm type-is thesolid- suchastheleg-to-seat joints-are furtherstrengthened by
I woodseat.Traditionally cutfroma
"green"(or
freshlyfelled) wedges inserted in kerfscutin theendof thetenons.
log,theWindsor's seatrepresented animportantinnovation A finaladvantage of buildinga Windsorchairis thatthe
I in chairmaking.In earlierstyles, thebackof thechairwasan entireprocess canbedonewith handtools.Althoughthelegs
extension of thelegs.Thismeantthattherearlegshadto be andstretchers canbeturnedonalathe(page89),theycanalso
I bentto providecomfortable seatingandwereattached to the beshaped-along withthespindles-using a drawknife (page
seatframewith relatively complex joinery. 76)andashop-built shavinghorse (page7B).Theseatcanbe
I Thelegsof a Windsorchairarenotbent.Instead, theback cutwithabowsaw (page84),thenshavedandadzed to itsfin-
andlegassemblies areindependent, anchored separately to ishedshape.
I
I
Thesack-back Windsorchairshownat left wasfinishedwith milk paint, a
t traditionalfinishfor AmericanCountryfurniture.,fuailablein powdered
form and mixedwith waterto a paint-likeconsistency, milk paint reflects
I thesimplicityof the Windsorchair;it is bestappliedby brush.

I 7T

I
 I
I
ANATOMYOF A SACK-BACKWINDSORCHAIR
I
anyof the round mortise-and-
I
tenonjointsthathold a Windsor
chairtogetherarereinforcedby wedges.
I
As the illustrationat right shows,the
top endofthe legs,armposts,andspin-
I
dlesareallkerfedprior to assembly;the
wedgesthat fill the kerfsexpandthe
t
tenons,ensuringthat theyfit snuglyin I
theirmortises.
Buta Windsorchairis morethanthe
sumof its parts.Forstrengthandcom-
t
fort, it alsorelieson the interactionof
its variousassemblies. The legsand
I
for example,work against
stretchers,
eachotherto supportthe weightof its
I
user.The backassembly, with its bow,
arm,andspindles, functionsin a similar
I
manner.Thelegssplayout to the sides
and arerakedforwardandbackward-
I
providinga broad,stablebasefor the
chair.As with all enduringdesignsthe
I
seatis tilted back slightly,making I
the chairmorecomfortable.
The threeviewsof the sack-back
Wndsor presented on page73 provide
t
you with the criticalangles, spacings,
and dimensions.More dimensions
I
appearin the cuttinglist belowand I
throughoutthechapterwhereeachpart
of thechairis made.
As you prepareyour stock,keepin
I
mind that you will not be ableto cut I
someof thepartsto theirfinishedlength
until youbeginfinalassembly. Thespin-
dles,for example,shouldall be left at
I
LIST
CUTTING
their maximum possiblelength-22
inches-until youhavebentthearmand
t
bow,andtest-fitted thespindles against W.ORDIAM
them.In thesameway,sizethestretch-
PIECE OTY. THICKNESS
I
Arm I %' 2', 44',
ers only after test-fittingthe blanks I
betweenthe legs. Armposts 2 IYo' 11',
ARr
Bow I
4
%u

17'
I
Legs !3/o'

Seat 1 2', 16' 20' I

3/ou 22',
Longspindles 7
Smallspindles 4 3At II%' I
Middle
stretcher 1 T%' 17' I
Sidestretchers Ivi' I4Yz'
t
I
I WINDSOR CHAIR
I
I
Side view Front view
I 1ocketa in
arm for lonq
apindlee
I apaced 2'/o
incheoapart
I
I
I
I
I
I
I
I
t
I
t
I
I
t
Top view
I
I thort apindlee
apacedequally
I betweenlon1
opindleand
arm poet
I
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I
I
I
 I
MAKING THE SPINDLES I
I
indsorchairmakingstartswith a it is stronger,
because thebreakfollows proneto cracking thana board,which I
freshlycut log. Becausegreen thewoodfibersratherthanshearing maycupor check.
woodis swollenandlubricated with them,asa sawmilldoes.And second, Ifyou haveaccess to a woodlot,you I
moisture,it iseasy andbend.It
to cleave woodseasons betterif it isshaoedwhile canfellyourowntreesusinga chainsaw.
isalsolessworkto shape.Splittingwood stillgreen.A chairspindle, foiexample, Otherwise, youmaybeableto obtain I
fromalogoffersotheradvantages. First, will season morequicklyandbe less greenlogsfroma sawmill,a localfire-
wood supplier,or your local roads I
department. Youcanmakean entire
chairfromhardwoods likehickorywhite I
ash,or oak;butmanywoodworkers also
usesoftwoods suchaspoplarandpine I
for theseat,whichareeasierto shape
with handtools. I
Theprocess described onthefollow-
ing pagesfor riving,or splitting,a log I
into spindleblanlscanalsobeusedto
producearm,leg,andstretcher blanks. I
I
Oncea loghasbeencut into manage- I
ablelengths,it is time to split it.
Driving an iron wedgeinto theendof t
thelogwith a sledgehammer, asshown
at left,will separate
thewoodftbers I
alongthegrain. Weareyeprotection
whenyou strikemetalagainstmetal. I
I
PREPARING
THESPINDLE
BLANKS
I
1 Spliftinga boltintoquarters
I Onceyouhavefelleda logand I
trimmedoff the branches, sawit into
workable lengths,calledbolts.Forbest I
results,usea chainsaw.Splittheboltsin
hall (photo,abovd,usinga sledgeham- I
merandironwedges; wearsafetygoggles
throughout theoperation. Tocleave the I
halves intoquarters,standthe pieceup,
markthe centeron the endanddrivea t
wedgeintothe mark.Continue driving
thewedgetighl untilthe boltsplits. I
t
I
t
I
I
74 I
t
I
t WINDSORCHAIR
I
I
t
I
I
I
t
I
I
t
I
r) Rivinga quarterboltintoblanks
I I Onceyou h a v es p l i ta b o l ti n t oq u a r t e r sr i,v ee a c hp i e c ei n t o h i c k o r yd, o g w o oodr e l m . H o l d i n g
t h e f r o ei n o n eh a n dw i t ht h e
s p i n d l eb l a n k sO. u t l i n e
t h e b l a n k so n t h ee n do f t h e b o l ta n ds p l i t bladeoffsetfromtheoutline,strikethe bladewiththe club (above,
I iI (above,left),thenrivethe blankswith a froeand a f roeclub ilghil.fwislthe froebackandforth,anddriveit in deeper.0nce

t m a d ef r o ma n 1 B - i n c hl e n g t ho f d e n s eh a r d w o o sdu, c ha s m a p l e , t h e w a s t eb r e a k so f f, r e p e atto m a k et h e r e m a i n i ncgu t s .

I
I
I
I
I
I
I
I
I
I
I
-) Debarkins
theblanks
I <.
r - J R e m o v eb a r kf r o my o u rb l a n k su s i n ga d r a w k n i f o en a i n b o t hh a n d sw i t ht h e b e v e dl o w n ,p u l l t h et o o lt o w a r dy o u
h o r s e( p a g e/ B ) . S e c u r e
s h o p - b u i sl th a v i n g t h e w o r k p i e cbea r k t o s h a v eo f f t h e b a r k( a b o v e )T. u r nt h e p i e c ea r o u n dt o d e b a r k
I s i d eu p u n d e rt h e h o r s e 'csr o s s b aTr .h e n ,h o l d i n gt h e d r a w k n i f e t h e o t h e re n d .

I
I
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 I
WINDSORCHAIR I
I
SHAPING
THESPINDLES I
ANATOMY
OFSPINDLE t
-/,."
dta. +i i

)/
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Rough-shaping thespindles
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I Secure a s p i n d l eb l a n ki n y o u rs h a v r nhgo r s ea n d u s ea d r a w k n i fteo s h a p e
t h e s t o c ki n t oa t a p e r e dc y l i n d e rF. o rb e s tr e s u l t st,h e g r o w t hr i n g so n t h e e n d
I
'/ "
dia. '>i !-
Long epindle
g r a i no f t h e b l a n ks h o u l db e r o u g h lvye r t i c aS
Holding
l . t a r tb y s q u a r i nagn ds i z i n gt h e b l a n k .
t h e d r a w k n i foen t h e b l a n kb e v esl i d ed o w n ,p u l lt h e t o o lt o w a r dy o u ,
t
a l w a y sf o l l o w i n tgh e g r a i n( a b o v e )K. e yd i m e n s i o nasn d d i a m e t e rfso r t h e s e v e n
l o n gs p i n d l eas n df o u rs h o r ts p i n d l eyso u n e e df o r a c h a i ra r ep r o v i d eidn t h e
I
i l l u s t r a t i oant l e f t .T u r nt h e b l a n ke n d - f o r - e nadn d r e p o s i t i oi nt i n t h e s h a v i n g
h o r s ef r e q u e n t lsyo y o uc a ns h a p ei t u n i f o r m l yP. e r i o d i c a cl l hy e c kt h e p i e c e ' s
t
k e yd i a m e t e rwsi t hc a l i p e ros r a s h o p - m a dgea u g el i k et h e o n es h o w no n p a g e7 7 .
( l f y o up r e f e ry, o uc a nt u r nt h e s p i n d l e o sn a lathea , s s h o w no n p a g e8 9 . )
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r) Evening
I outthe spindles
L O n c ea l l t h e s p r n d l eas r er o u n d e d a n dt a p e r e du, s ea s p o k e s h a vt oee v e no u t
I t h e i rs u r f a c e sA. d j u s t h e s p o k e s h a vf oer a v e r ys h a l l o w
c u t . H a n d l et h e t o o la s y o u
d r dt h e d r a w k n i f ea,l w a y sw o r k i n gw i t h t h e g r a i n( a b o v ea)n d r e p o s i t r o n i tnhge w o r k -
p i e c ea s n e c e s s a rF
I y .o r mt h e t e n o n sa t t h e b o t t o me n d so f t h e s p i n d l e w
r e f e r r i ntgo t h e a n a t o m yi l l u s t r a t i oonp p o s r t e .
s i t ha k n i f e ,
Q
S m o o t h i nt hges p i n d l e s
r - . 1 U s ea h a n ds c r a p etro g i v et h e s p i n -
t d l e sa s m o o t hf i n i s h G. r a s p i ntgh et h i c k
e n d o f t h e s p i n d l ei n o n eh a n da n d ,
t jiiilIi ffi dr{il ffi tulil tiJill, iiiji$ ,u{lr,itrjdi d, bracing t h e t h i n e n do n a w o r ks u r f a c e ,
u s ey o u ro t h e rh a n dt o d r a wt h e s c r a p e r
I a l o n gt h e s u r f a c e( a b o v e )W . o r kr n t h e
1HO?Tt? ,r:
d r r e c t i o on f t h e p r a r na n d r o t a t et h e
I ShoV-madesizinggau6e // -/ -)t
spindle f r e q u e n ttl oy k e e pi t u n i f o r m .
A ehog-made oizingqauge -'//
I alloweyouto meaeure trhe
diamelersof chaireVin- {,r-,2
I dleeae youohapethem.
Soreholesinlo a wood
ecrap,eizingLhemaccordinq
I to NhesVindleo' keydiameters. Dnlla
'/,.,-inch-diameLer
holeinto the qaugeLo
I checkNhetenon aI Lhe boLLomend of Lhe
e p i n d l e ea, n d a 7 / , , - i n c h - d i a m e t h
ear l ef o r t h e
t f , o Ve n d o f l h e o p i n d l e s . Y o cua n a l s o c h e c ka k e y
d i a m e l e r a l o n gL h e l e n q l h o f t h e e p i n d l e ob y b o r -
I i n q a h o l et h r o u g h L h e q a u q ea n d e l i p p i n gI h e b l a n k
introf,he hole.Ihe blankis lhe correcl diamet,erwhen iL
I j a m e i n N h eh o l ea I L h e a p p r o p r i a t ep o i n l a l o n qi t o l e n g f , h .

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WINDSORCHAIR
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t
Eridge
2" x 10"x 35" I
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Eench
t
3"x10"x72"
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t
Foot bar t
Erace
Adiuetment hole 1'1"x3'/2"x13" I
Pivoting arm Pivoting t
aeaembly lag bolt
I
Leg
2"x4"x19/2"
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A SHAVIilGHORSE withangled joints,reinforced
T half-lap backof thebenchandscrewit in place t
Theshaving horsegripsstocksecurely byscrewsandbracestighil. CutIhe fromunderneath. Thenscrewthebridge
in placewhileit isshaped withdraw- twobracestrom2-by-4stockto fit to the riser(page79, above,right)and I
knivesandspokeshaves. Simpleto between the leg'soutside edgesand thefrontof thebridge io the bench.
build,thetypicalshaving horsefeatures screwthemto the legs.To bevelthe I
a bench, an inclinedbridge,anda piv- bottoms of the legssotheysit flat and
otingarmassembly. Bystepping down level,settheshaving horse on a flat I
ontheassembly's footbar,youcanlock surfaceandbutta squareboardup
yourworkpiece in positionbetween the againstall foursidesof eachlegto I
bridgeandtheassembly's crossbar. markcuttinglinesaroundthem(page
To buildtheversion shownabove, 79, above,/eft).Sawthe bottomsof I
startwith the bench, which canbe the legsflat,thencutthetopsof the
hewn from halfa log10 to 12 inches legsflushwiththebench. I
in diameter,orcutto length from rough Next,sawtheriserandthebridge to
3-by-10lumber. Makethelengthof size;therisershouldbecut andbev- I
the benchto suityourneeds. eledsothatthebridge is inclined
at an
Next,cut the legsfrom2-by-4 angleof about15'to thebench. Locate I
stockandattachthemto the bench the riserabout30 inchesfromthe
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I WINDSORCHAIR
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N e x tb, u i l dt h ep i v o t i nagr m .T h e bly.Cutdadoesin thefootbarto match lagscrews. Donottightenthescrews
t a s s e m b cl yo n s i s tosf t w oa r m s a, in thearms,fit thepieces
thenotches immediately; leavethemloose enough
notchedcrossbar,anda footbar together,
andreinforce thejointswith soyoucanslipthecrossbar in place. Do
I (right)Thecrossbar is joinedto the screws.
Withthefootbarattached. slio notglueor screwit, butleavethebar
armswiththrough roundmortise and thearmassembly undertheshaving freeto pivot.Onceit isconnectedto the
I tenons, whilea bridlejointconnecis horseandscrewit in placewiththe arms,f inishtighteningthelagscrews.
thefootbarto thearms.Cutthearms
I from2-by-4stockandboretwocoun-
tersunk holes through eachoneforlag PIVOTINGARMAS?EMELY
I screws. Makeadditional holes through
the armsaboveandbelowthe f irst
I soyouwill beableto adlustthe posi-
tionof the assembly laterto accom-
I modate thrcker stock.To oreoare the
armsfor the bars,cut a roundmor-
I tisethrough themat thetopendand
a notchat the bottom.
I Next,cut thecrossbarto length,
making it about3 inches longer than
I the width of the bench.Cutround
tenons in bothendsanda V-shaped
Lag screw
I notchin themiddleof thebottom edge
to holdyourstock.Setthecrossbar
I asidefor now.Next,cut thefootbar,
m a k i n igt s l e n g t h
t w i c et h a to f t h e
I crossbar to provide anoctagonal-shaped
footrestoneachsideof thearmassem-
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I
MAKING THE BOW AND ARM
I
-l- h. arm and bow of the sack-back 83is shop-made from ABSpipe.Besure source,it is safestto do your steaming
I
I Windsoranchorthechair'sback-
rest,tying the spindlesinto a strong
to makethesteamer longerthanthebow
and arm,and sealit tightlyto keepthe
outside,If you areusinggreenwood,
l5 to 20 minutesof steamingshould
t
and comfortablestructure.The grace-
ful curvesofboth piecesareachieved
steamfrom escaping.Includea small
drain hole at one end and olacethe
makethe piecesufficientlypliableto
bend arounda form. Air-driedlum-
t
throughsteambending,a process that steameron a slightincline,however,to berrequirestwiceasmuchsteaming. It
maywell be the most challenging part allowthe condensed steamto run out. will takeabout one weekfor a bent
I
Ifyou areusinga gas-powered steam pieceof l-inch-thickstockto dry.
of makingthe chair.
Thetwo essentialelementsof wood-
I
steamingarea steamgeneratorand an I
enclosedsteamer. Theversionshownin
thephotoat right anddescribedon page I
I
The arm of a sack-backWindsorchair
is extractedfrom a steamingjig with a
t
pair of tongs. The steamingprocess
leavesthe wood pliable for about a
I
minute-long enough to bend thepiece
around a form. Becauseof the intense
t
heatproduced, always wear work gloves
when handling steamedwood.
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ANATOMY
OFA BOWANDARM I
r
22" (from end to middle)
I
',,>,,
dia.
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, l

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22'/r" (from end to mtddte)
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%" dia. I
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I WINDSORCHAIR

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I PREPARING
THESTOCK
I 1I Squarine
thebowandarm
I D r a w k n i fteh e b o wa n da r m r o u g h ltyo
I c,izp (naop 74) lhon rrc.p: hon.h nlanp

to scuare t h eo i e c eas n df l a t t e nt h e i rs i d e s .
I Secure t h e b l a n kb e t w e e b n e n c hd o g so n
y o u rw o r k b e n c hS.t a r t i n g a t o n ee n d o f
I t h e s t o c k g. u i d et h e p l a n ea c r o s tsh e s u r -
f a c et o t h e o t h e re n d :k e e pt h e s o l eo f t h e
I t o o lf l a t o n t h e w o r k p i e caen da p p l ym o d -
eratedownwardpressure(right).Planethe
I a r mu n t i li t i s I b y I i n c h e sf ;o rt h e b o w .
r e f e rt o t h e a n a t o m iyl l u s t r a t i oonp p o s i t e .
T
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r ) S h a p i ntgh eb o wi n t oa c y l i n d e r
I L Secu,ethe b o wb l a n ki n y o u rs h a v i n g h o r s ea n ds t a r t
s h a p i ntgh e p i e c ew i t ha d r a w k n i f e B.r a c i ntgh e e n do f t h e
I s t o c ka g a i n syt o u rc h e s t d , r a w k n i fteh e b l a n ki n t oa c y l i n d e r
( l e f t )w
; o r kw i t ht h e w o o dg r a i nt h r o u g h o uAt .s s h o w ni n t h e
I diagram o p p o s i t em, a k et h e f i n a ld i a m e t eor f t h e b o wI i n c h ;
i t s h o u l dt a p e rd o w nt o I i n c hs t a r t i n ga b o u tB i n c h e sf r o m
I e a c he n d .A s y o uw o r ko n t h et h i n n eer n do f t h ew o r k p i e c e ,
r e p o s i t i otnh e b l a n ki n t h e s h a v i n g
h o r s es o t h a t l e s ss t o c k
I e x t e n do sut f r o m u n d e rt h e c r o s s b a Sr .w i t c ht o a s p o k e s h a v e
to givethe bowa smoothersurfacetinish (above), handlingit
I a s y o ud i d t h e d r a w k n i f e .

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WINDSORCHAIR I
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B u i l d i nag b e n d i njgi g
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BENDING
JIG I B u i l da b e n d i ntgi g l i k et h eo n es h o w n
at leftto bendthe bowand arm of a sack-
I
b a c kW i n d s ocr h a i r .C u t t w o p i e c e so f
%-inchplywoodto the desiredcurveof the
I
b o wa n d a r m ,t h e ns c r e wt h e m t o g e t h e r
t o m a k et h e f o r m .M o u n t h e f o r mo n a
I
% - i n c hp l y w o o d b a s ea n d m a r kt h e c e n t e r
o f t h e f o r mn e a ri t s t o p e d g e T . h e nc u t
t
t h e s t o pb l o c kf r o m h a r d w o oadn d s c r e w
i t t o t h e h a s e a n d h o r et h e t w o Z - i n c h -
t
d i a m e t edr o w e lh o l e si n t ot h e b a s e T . he
s p a c eb e t w e e nt h e b l o c ka n dd o w e l sa n d
t
t h e f o r ms h o u l de q u a tl h e t h i c k n e sosf
t h e w o r k p i e cpel u st h e w e d g e su s e dt o
I
6 qc.rrrp it in nlanp Fin:llv nron:ro tho

d o w e l sa n d w e d g e st,h e nc l a m pt h e b a s e
I
to a worksurface.
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Securing
thebowaround
theform
O n c et h e w o r k p i e chea sb e e ns u f fi c i e n t l ys t e a m e dr.e m o v e
I
i t f r o mt h e s t e a m e(rp a g e8 0 ) a n dp l a c ei t o n t h e b e n d i n g
A l i g nt h e m i d d l eo f t h e b o ww i t ht h e c e n t e rm a r ko n t h e f o r m
1ig.
I
a n d c l a m pt h e s t o c kt o t h e m i d d l eo f t h e f o r mb y t a p p i n g
w e d g e si n p l a c e .P u l lo n ee n d o f t h e w o r k p i e cteo w a r dt h e Maintaining
thebendwithstring
I
f o r mf i r m l ya n d s t e a d i l yu n t i l i t c o n t a c t st h e s i d eo f t h e f o r m . T i ea l e n g t ho f s t r i n gt i g h t l yb e t w e etnh e e n d so f t h e b o w
Insera t d o w e li n t ot h e h o l ei n t h e b a s ea n d t a p i n a w e d g e ( a b o v e ) a nbde g i ns t e a m i n tgh e a r m .0 n c et h e a r m i s r e a d y I
t o s e c u r et h e b o wi n p l a c e .R e p e afto r t h e o t h e rs i d eo f t h e f o r b e n d i n gy, o uc a n r e m o v e t h e b o wa n d b e n dt h e a r m a s i n
w o r k p i e c e( a b o v e )W . o r kq u i c k l yt o c o m p l e t teh e b e n d . s t e p2 . T h es t r i n gw i l l k e e pt h e b o wb e n tu n t i l i t d r i e s .
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I WINDSORCHAIR

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A SHOP-MADE PIPE STEAMER
I An economical anddurable wood (DETAIL)
STEAM 1OUKCEFTTTING
steamer liketheoneshownbelow MachirtenuL
y?u'
I canbefashioned from2-by-4s and (ineide eream

e rSp i p ea n df i t -
4 - i n c h - d i a m eAt B
I tings,Thedevice features support
racksinsidethe pipeanda remov- 7[aeLtc hoae
t ablecapat eachendforeasyaccess. to Iteamer
Thesteamsource is a watercancon-
I nected to thesteamer bya lengthof
plastichose:thewaterin the can couplinq Kubber 1aokeL
I is heated bya propane-fired cooker.
(Thissetupshould onlybeusedout-
I doors). Thesteamsource should asshown. Theseboltswillsupport onbothsides to makeanairtight seal.
havea removable, screw-type cap. woodinsidethesteamer to preventit Nowgluebothhalves of thepipeto an
I Tobuildthesteamer, startwitha fromlyingin condensed water.(The ABST connector. Drilla %-inch drain
lenghof schedule 80 ABSpipelonger zinccoatingwillprevent
theboltsfrom holeat oneendto release moisture
I thanthebowandarm.Cutit in half stainingthewood). Drillthe holes andexcess pressure. Thengluea
anddrilla series of holes through both below thecenterlineof thepipeto connectorpipecutfrom1%-inch ABS
I pipehalves to accommodate %-inch provideroomforthewood.Install the pipeto thespouiof theT connector.
zinc-coated machine boltsandnuts bolts,usingsteelandrubber washers Next,cut a lengthof plastichose
I thatwillconnect thesteamer to the
watercan;thef ittingsrequired for
I Kemovableend cap thewatercanendareshownabove.
(Thefittingsforthesteamer endof
I thehoseareidentical, exceptthatan
ABSendcapis usedinstead of the
T watercancap;theendcapisglued
andscrewed to theconnector pipe.)
I Makesurethef ittingsareairtight.
Lastly,builda 2-by-4frameto sup-
I portthesteamer. Naila smallsupport
blockat oneendsothesteamer will
I restona slightincline andtheexcess
waterwillrunoutof thedrainhole.
I To usethesteamer, carefullycon-
nectthe gascooker to a propane
I tank.Fillthe watercan,attachthe
capandhoseto it, andsetthecanon
I thecooker. Secure theremovable end
capsonthesteamer, lightthecooker,
I andletthesteamer buildup steam.
' '"(-"" (Caution: Donot let the steamer or
aaa cooker
I tanK steamsourcebecome pressurized.)

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I 83
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MAKINGTHE SEAT I
I
rla he seatof a sack-back Windsor Thefinal stepis to boremortisesinto t
I chairisbestcut from a singleplank. the seatfor the legs,spindles,and arm
As shownin thephoto at left,theblank posts(page90).Asshownin the anato- I
is roughedout by hand with a frame mv illustrationbelow.the arm oost
sawor bowsaw.Then the seatis given mortises arethelargest:%inchin diam- I
its basicshapeusinga varietyof hand eter;thelegmortisesare%inchin diam-
tools-the edgesareroundedoverby a eter,while the spindlemortisesmust I
drawknife(page85),the top surfaceis be drilledwith a %-inch-diameter bit.
scooDedout with an adze and an Referto the diagram for the seat's I
inshave(page86),andsomefinaltouch- dimensionsand for the location and
esareetchedwith a veiner(page87). spacingof the mortises. I
I
SEATDIMENSIONS
ANDANGLES
I
OVERHEAD
VIEW
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A framesawcutsa Windsorchair
seatblankfrom a pineplank.
I
Theblankwill beshapedlater
with a varietyof hand tools.It t
couldalsobecut on a bandsaw.
T
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'IDEVIEW I
16" I
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I WINDSOR CHAIR
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I THESEAT
SHAPING
I 1
0utliningthetopsurfaceof theseat
I S a wy o u rs e a tb l a n kf r o ma p i e c eo f
I 2-inchlhick pine(page84), thenoutline
the areato be scooped out. Startby mark-
I i n gt h e c e n t e ro f t h e b l a n k ' sf r o n te d g e .
N e x t ,m a r ka l i n e2 k i n c h e si n f r o me a c h
I s i d eo f t h e b l a n kt;h e l i n e ss h o u l db e p a r -
allelto the frontedgeand4% inchesaway
I f r o mi t . D r a wa c u r v e dl i n et h a tj o i n st h e
t w os i d em a r k sa n dp a r a l l e ltsh e s i d e sa n d
I backedgeof the blank (lefil. Finally,draw
t w o c u r v e dl i n e st h a t c o n n e ctth e s i d e
I m a r k sa n d t h e c e n t e rm a r ka t t h e f r o n t
e d g eo f t h e b l a n k t; h e s el i n e si n d i c a t e
I w h e r et h e t o p s u r f a c eo f t h e s e a ts l o p e s
towardthe frontedgeand are represented
I b y t h e d o t t e dl i n e si n t h e i l l u s t r a t r o n .

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I r) Rounding overtheblank
I L Clu^otheblankin a viseandusea drawknife to roundover encounter a knotin thewood,cutaround it gradually,
rather
itsedges. Tobegin, smooth thecircumference of theblankand thantryingto hackthrough it witha stroke.
single Then usethe
I (above,
f ei t ht h eg r a i n
r o u n do v e ri t su n d e r s i dpeu, l l i n tgh ed r a w k n iw
lf you
drawknifeto formthe flat
edgeof theblank,angling
lip
the
on the
cut at
topsurface
about40'
along
the front
right).
/eff);repositton theblankin theviseasnecessary. bbove,
I
I 85
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WINDSOR CHAIR
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n<' Dishins
outtheseat
I
r . , l O n c et h e c i r c u m f e r e n coef t h e s e a t I
h a sb e e ns h a p e d r, o u g ho u t t h e w a s t e
f r o mt h e t o p s u r f a c eu s i n ga g u t t e ra d z e .
W e a r i n gs t e e l - t o e db o o t s ,s t e po n t h e
I
e d g e so f t h e b l a n kt o h o l di t s t e a d ya n d I
c h o po u t t h e s i t t i n ga r e af r o mo n es i d eo f
the outlineto the other(lefil.f ry to cuI I
w i t ht h e g r a i n ,u s i n gs h o r ts t r o k e sM
. ake
s u r ey o u rf e e ta r en o t i n t h e p a t ho f t h e I
b l a d eC . ontinuu e n t i ly o u h a v ec u t a b o u t
% i n c hd e e pi n t h e c e n t e ro f t h e s e a tw i t h t
a g r a d u asl l o p ef r o mt h e c e n t e ru p t o t h e
s i d e sa n df r o n ta n d b a c ke d s e s . t
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Smoothing
theseat
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Securethe seatbetweentwo bench
d o g so n y o u rw o r k b e n c hp,r o t e c t i ntgh e
I
s i d e sw i t h w o o dp a d s .S t a r tw i t h a n
i n s h a vteo s m o o t ht h e r o u g hs u r f a c el e f t
I
b yt h e a d z e W
t o ps u r f a c e
. o r k i n fgr o mo n es i d eo f t h e
t o t h e o t h e r ,h o l dt h e i n s h a v e
I
w i t h b o t hh a n d sa n d p u l l i t t o w a r dy o u ;
alwaysfollowthe grain(righil.Usea con-
I
vexspokeshave,
smoothness
or travisher, to refinethe
of the seat(photo.page7 l).
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86
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I WINDSOR CHAIR
I
t thelip
f, Shaping
r-,f Thelip at thefrontedgeof theseat
I h a sa s l i g h d t o w n w a rbde v e lW . orking
on onesideof theseat'sfrontedgeat a
I t i m e ,u s ea s m a l d l r a w k n i ft e
o c u tt h e
lip (right).Formaximum comfort, the
I t r a n s i t i obne t w e et nh ed i s h e do u tD o r -
tionof theseatandthebevels should be
I smooth andgradual. Thesameshould be
trueof thetransition between thebevels
I andthef latsection around thecircumfer-
thelip
t enceof theseat.Finish
witha sookeshave.
smoothing

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Carving
thechannel
I U s ea % - i n c vhe i n etro c a r v et h e c h a n -
nelthatseparates theseat'sscooped-out
I topsurface fromtheflatsection around
its circumference (left).Thisis a deco-
I rativegroove designed to sharpen the
r h ec u r v e a
t r a n s i t i obne t w e et n
oortions of theseat.
d n df l a t

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I
MAKINGTHELEGS,ARM POSTS,AND STRETCHERS
I
tlt h. legs,stretchers, andarm postsof guideto producethe turnings.Referto
I
I aWndsorchaircanbeshaoed with theillustrationbelowfor dimensions.
a drawknife,but manywoodworkers usecalipersto checkkeydiametersas
and I
work with a latheinstead,usinga story
polefor eachcomponenl(page52)asa
thework progresses. Startby turningthe
legsand the arm posts.But beforeyou
I
you haveto bore
canturn thestretchers.
the leg mortisesin the seatand test-fit
I
A handbracefixed with a spoonbit
boresa mortisein onesidestretcher
thelegsin place.By measuringtheexact
distancebetweenthelegswith the chair
I
of a sack-backWindsor chair.The
mortisewill housea tenonof the
test-assembled, the stretcherscan be
sizedwith precision.
I
middlestretcher. Themortisemust
beangled;a spoonbit enables you
The tenonsthat join the pieces
together-at thetop endsof thelegs,the
I
to start drilling theholestraight bottomsof the arm posts,and at both I
for thefirst'/ inch before
tilting the endsof the stretcheri-are taperedto
toolto thecorrectangle. lock the tenonsinto their mortises. I
t
ANATOMY
OFTHELEGS,
ARMPOSTS,
ANDSTRETCHERS I
LEG
SIDE
MIDDLE STRETCHER I
ARMPO9T 5TRETCHER
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t
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t
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Note: All dimeneione are
dia meters, etaept where
I
apeaified ao length.
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t
88
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t W I N D S O RC H A I R
t
I THELEGSANDARMPOSTS
TURNING
I 'l Shaping
I
thelegsandarmposts
I l V o u nitn e b l a r k b e t w e e cne n t e r so n
I y o u rl a t h ea n d u s ea r o u g h r nggo u g et o
p r o d u cteh et u r n i n gR. e f etro t h e a n a t o '
I m y i l l u s t r a t i oonp p o s i t feo r t h e l o c a t i o n s
a n dd i a m e t e rosf d e c o r a t i veel e m e n t lsi k e
I h e a n sa n dc n v p qO n c ev o ua r es a t i s f i e d
| u U v v l J . v | | ! v ,

w i t ht r e t u r n r n g s' sh a p ef.o r mt h et a p e r e d
I I e n o na t t h e a p p r o p r i a Leen d ( r i g h r )O . r
t h e l e g sa , s s h o w nt,h et e n o ns h o u l db e
I 2 , / i n c h e sl o n g t, a p e r i n fgr o m 1 i n c ht o
, / ' n c h i n d i a m e t e rM . a k et h e a r m p o s t
I t e n o n s1 i n c h l o n g ,t a p e r i n g f r o m / , ,I o
/ , l n c hi n d i a m e t e F r .r n a l l yt u, r na s h a L
I I n wp r o o v e o n e a c hl p st o i n d i c a t e the
l o c a t i o no f t h e s t r e t c h e r tsh; i sg r o o v e will
I d o ub l ea s a d e c o r a t i veel e m e n t .

I
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I r ) S m o o t h i nt hget u r n i n g s
I Z R . r o u . t h e r o o lr e s ta n d f o l d a
n i e c eo f 8 0 - s r i ts a n d n a o ei nr t h i r d st o
I p r e v e nt th e p a p e frr o ms l i p p i n gS. w i t c h
o n t h e l a t h ea n d h o l dt h e p a p e ra g a i n s t
I . o r kw i t ht h e g r a i na l o n g
t h e t u r n i n gW
thp lpnorh nf ihp nipco:c mrrnh 2q nnq-

I s i h l e/ i e f l ) b e i n pc a r e f r rni o t t o r o r , n d
o v e rt h e d e c o r a t i veel e m e n t os n t h e
, , +L U^ ^ - ^
I cJ Lt n
UnL 'k\ . s
u 'i uopn
q:ndino n upr rr iU^Uf l, L; ^c l^l iy l
p

. o r kw i t h p r o -
v e n tb u r n r n tgh e w o o d W
Prs-

I o r o q q i v o l v f,i ,n,p, r, ,n : n p r c

you reach224 griL

,
r * Y - , - . i t o p p l n gw n e n

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I 89
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WINDSORCHAIR I
I
TUR N I NTG
H EST E T C H E R S I
'l
l
Marking
-
thelegandspindle I
I mortises on theseat
B e f o r ey o u c a n t u r n t h e s t r e t c h e r sy,o u I
n e e dt o b o r et h e l e g m o r t i s e si n t ot h e
s e a t ,t e s t - f i t h e l e g si n t h e m o r t i s e sa,n d t
m e a s u rteh e d i s t a n c ebse t w e e tnh e l e g s .
S t a r tb y m a k i n ga t e m p l a t eo f t h e s e a t I
f r o m l - i n c h h a r d b o a r dr e, f e r r i ntgo t h e
a n a t o m yi l l u s t r a t i oonn p a g e8 4 f o r t h e I
d i m e n s i o nosf t h e s e a ta s w e l la st h e l o c a -
t i o n a n d s i z eo f t h e l e ga n ds p i n d l em o r - I
t i s e s .D r i l la h o l et h r o u g ht h e t e m p l a t ea t
e a c hm o r t i s em a r k ,t h e ns e tt h e s e a to n a I
w o r ks u r f a c ep, o s i t i o n t h e t e m p l a t ea t o p
it, and marktheholes(right). I
I
I
t
I
I
r) Drilling
thelegmortises
t
t ^ ,
4 , - C l a m pt h e s e a td o w na n df i t a h a n d
b r a c ew i t ha s p o o nb i t t h e s a m ed i a m e t e r
t
a st h e s m a l le n do f t h e l e gt e n o n sU . s ea
straightedg aen da s l i d i n gb e v e l t oh e l p
I
y o ud r i l lt h ec o m p o u n d - a nhgol el e sT. h i s
w i l l e n a b l et h e l e g st o s p l a yo u t f r o mt h e
I
s i d eo f t h e s e a ta t t h e p r o p ear n g l ea n d
be angled-or raked-towardthe frontor
I
b a c ko f t h e c h a i r .P o s i t i otnh e s t r a i g h t -
pdsp anrnqq fhc cp:f ai tf
_ _ _ ._ . . , t ec o r r e csl p t a y
I
a n g l eo f 1 0 5 " ,o r 1 5 ' f r o mt h e p e r p e n d i c -
u l a r( p a g eB ) . f h e n a d j u s t h e s l i d i n g
I
b e v etlo t h e r e q u i r e rda k ea n g l ew , h i c hi s
I 0 0 " f o r t h e f r o n tl e p sa n d I I 5 " f o r t h e
I
r e a rl e s s .o r l 0 o a n d? 5 ' f r o mv e r t i c a l .
P o s i t i otnh e s l i d i n gb e v e l o nt h e s t r a i g h t -
t
e d s e T h e n c e n t e trh p h i t o n t h e m o r t i s e
m a r ka n db e g i nd r i l l i n gk,e e p i ntgh e h a n d
I
b r a c ep a r a l l et o
l t h e s t r a i g h t e d gaen dt h e
b i t l i n e du p w i t ht h e s l o p eo f t h e b e v e l
t
(lef). Repeatthe procedureto borethe
r e m a i n i nlge gm o r t i s e s .
I
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90 I
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I WINDSOR CHAIR
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f
thelegmortises
Tapering
: O n c ea l l t h e l e gm o r t i s ehs a v eb e e n
d r i l l e d r. e m o v teh e s p o o nb i t a n d i n s t a l l
I a t a p e r e dr e a m e rT. h i sd e v i c ew i l l g i v e
t h e l e g m o r t i s e sa t a p e r e ds h a p et h a t
I m a t c h e st h e c o n i c asl h a p eo f t h e l e g
t e n o n s l,o c k i n gt h e l e g st o t h e s e a t .
I S e c u r et h e s e a ti n a v i s e ,t h e nt a p e r
e a c hl e gm o r t i s es, t e a d y i ntgh e h a n d
t braceagainstyourchest(above). Period-
i c a l l yt e s t -ift t h e l e g si n t h e i rm o r t i s e s ,
I r e a m i ntgh e h o l e su n t i lt h e f i t i s s n u g .

I thesplayandrakeofthelegs
,{ Checking
r+
I Testjitthefrontlessin theirmortises
a n dc h e c kw h e t h et hr e i rs p l a ya n dr a k e
I angles areuniform. Tohelpyougauge
rakeangle,placea straightedge
the
across
I t h el e g st;h eb o a r ds h o u l db e p e r f e c t l y
lavol /lpff) Roncaf fnr the ro:r looc lf

I a n yo f t h e a n g l e sa r eo f f s l i g h t l yy, o u
c a nc o m D e n s aftoer m i n o ri n a c c u r a c i e s
I w h e nt h e t i m e c o m e st o t u r n a n d i n s t a l l
thp circinhcrs (naoe Q2)
r1r'
\Fvbv

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WINDSORCHAIR
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t
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t
I
f, Sizingthe sidestretchers
.-,1 Set the seat-and-leg assembly on a worksurfaceand mea- I
s u r et h e d i s t a n c eb e t w e e tnh e f r o n ta n d r e a rl e g so n o n es i d e
(above), aligning your tape measure with the stretcher grooves I
fi Turning
thesidestretchers
y o ut u r n e di n s t e p1 . R e p e aot n t h e o t h e rs i d eo f t h e s e a t .T o
t h e l o n g eor f t h e t w o m e a s u r e m e nat sd,d 1 %i n c h e sf o r t h e \ , f C u tt h es i d es t r e t c h ebrl a n ktso l e n g t h
your piece
a n dm o u not n e t
t e n o n sa t e a c he n da n da n a d d r t i o n a %l i n c ht o h o l dt h e l e g s between centers on lathe. Shape the witha rough-
i n t e n s i o nw h e nt h e c h a i ri s a s s e m b l e dB.y s i z i n gb o t hs t r e t c h - inggouge, referring to theanatomy illustratron on page88 for I
e r sa c c o r d i ntgo t h e l o n g e m r e a s u r e m e nt ht ,e r a k ea n g l eo f t h e keydiameters. Finish byturning thetenons at theendswitha
t w o l e g sw i l le q u a l i z e . sprndle gouge(above). Repeat fortheothersidestretcher. I
I
Turningandsizingthe middlestretcher
/ S i n c et h e m i d d l ea n ds i d es t r e t c h e r s
t
a r ea s s e m b l ebde f o r eb e i n gg l u e dt o t h e I
l e g s ,y o uc a n n o td e t e r m i n teh e l e n g t ho f
t h e m i d d l es t r e t c h ebr y m e a s u r e m e n t . I
I n s t e a dc, a l c u l a t ei t s l e n g t hS
. t a r tb y c u t -
t i n g a b l a n ks e v e r ai ln c h e sl o n g etrh a n
y o u n e e da n dt u r n i t o n y o u rl a t h e ;u s e
t
t h e i l l u s t r a t i oonn p a g e8 8 a s a g u i d e T . o I
d e t e r m i nteh e s t r e t c h e r l' e s n g t hs, e c u r ei t
i n a v i s ea n dm a r ki t s m i d d l eT. h e nm e a - I
s u r et h e d i s t a n c ebse t w e e tnh e f r o n tl e g s
a n dt h e nt h e r e a rl e g sa, l i g n i nygo u rt a p e I
w i t ht h e t u r n e ds t r e t c h egrr o o v e sa;d dt h e
r e s u l t st o g e t h ear n d d i v i d eb y t w o .A d d
another2/, inchesfor the tenonsand %
r
i n c ht o p r o v i dteh e p r o p ear m o u not f t e n -
s i o n .A d j u s at s e to f c a l i p e rtso o n e - h a l f
t
y o u rg r a n dt o t a la n dm a r ko f f t h i sd i s t a n c e
fromthe centermarkto eachend (right).
t
C u tt h e s t r e t c h et ro l e n g t ha n dt u r n a I
t e n o na t e a c he n d .
t
92
I
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I
t WINDSORCHAIR
I
I Drilling themiddle stretcher
mortises inthesidestretchers
I Todetermine theangle of themortises to
b ed r i l l e di n t h es i d es t r e t c h efrosrt h e
I middlestretcher, youhaveto measure the
angleformedbythelegsat onecorner of
I t h ec h a i rO . n c et h em i d d l e s t r e t c h ei sr
ready,placea straightedge onthework
I surface alongonefrontandrearlegof the
c h a i ra, n da n o t h earl o n gt h ef r o n tl e g s .
I Adjust a sliding bevel to theangle formed
bythetwoboards(left).Secure theside
I stretchers in a viseandboreeachhole
w i t ht h e h a n db r a c ea n ds o o o nb i t
I (nhnfn
t r , e . v t
neop RR)

I
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I
a
I
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I
I Assembling thestretchers
Q
J Spread gluein themortises in theside
I s t r e t c h ear sn do nt h em i d d l es t r e t c h e r
t e n o n sI .n s e rt th et e n o n isn t ot h e i rm o r -
I tisesandpress the pieces f rrmlytogeth-
e r b yh a n dT. h e nh, o l d i ntgh em i d d l e
I stretcher f irmly,tapthebackof theside
stretcher mortise witha dead-blow ham-
I m e rt o s e a t h et e n o nf u l l yi n t h e m o r -
tise(right). Turntheassembly overand
I repeat theprocedure. Makesuretheside
stretchers arebothaligned in thesame
I vertical andhorizontal planes.

I
I 93

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 I
I
THE CHAIR
ASSEMBLING
T
i\ lthoughthestretchers aregluedto Oncethelegsarefixedto theseat,the
t
A thelegsandthelegsaregluedto the top ends of the legs are kerfed and
seatin separate steps,theseprocedures wedges areinsertedinto thecutsto rein-
I
mustbe completed in quicksuccession forcethejoints (page96).Thearm posts
for the chairto be symmetricalandwell areinstallednext,thenthearm is setin
I
balanced. To makeglue-upgo easier, place,fastenedto the arm postswith
test-fitall thejointsandcorrectanyill- round mortise-and-tenons. The final
I
fitting ones,then labelthe legsbefore stepsof the assembly areinstallingthe
applyinganyglueto thepieces. spindlesand thebow (page9B).
I
I
THELEGS
GLUING TOTHESEAT
ANDSTRETCHERS I
t
T
I
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t
I
I
Oncethestretchers havebeenglued
I
to the legsand the legsfixed to the I
seat,it is time to trim the legsto the
samelength.Thetechnique
aboveinvolvescuttingfour wood
shown I
blocksfrom a singleboard,then
notchingoneof themtofit arounda
I
Ieg.Placetheblockaroundthefirst I
Iegto becut, then,holdingtheleg
firmly with onehand,cut it to length I
with aflush-cuttingsaw.Oncethe
first legis trimmed,removethe I
notched blockand replaceit with
oneof theremainingblocks. Position
thestretchelmortises in thelegs
I
the notchedpiecearoundthenext 1 Drilling
legandcut it. Continuein thesame I Witfrthechairtest-assembled, posrtion
thesidestretchers on the Iegsand
wayuntil all four legsarecut. marktheirlocations. Thenremove thelegsfromtheseatandsecure onein a vise.
I
thelegsarerakedto thefrontandbackof thechair,thestretcher mortises
Because
in thelegsmustbeangled. Adjusta slidingbevelto thecorrectangle, to
referring
t
theanatomy on page73. Forthefrontlegstheangleis 15"fromthe
illustration
vertical;forthe a spoonbit in a handbrace,
rearlegs,it is 20".Install settheslid-
I
ingbevelonthebenchtop, andkeepthebracealigned withthebevelbladeasyou
drilleachmortisebbove),
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t
94 I
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t WINDSORCHAIR
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I
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I
I
I
I
I
I
I r) Gluing upthelegsandstretchers
I L IestliI the lessandstretchers
t o g e t h etrh, e ns p r e a gd l u eo n t h e
I s t r e t c h et er n o n a
sponding
s n di n t h e i rc o r r e -
mortises in thelegs. Working
t ona flatsurface, fit thepieces
u s ea d e a d - b l ohwa m m et o
together;
r s e at h e
I tenons f ullyin the mortises (above).

I
I
I
I
I
I Q Gluing thelegsto theseat
r-,1Sincethe legtenons will protrude
t beyond thetopsurface of theseatwhen
youdrivethemintotheirmortises, set
I theseatupsidedownonwoodblockson
yourworksurface.Fitthelegsintotheir
I mortisesbyhand,thenf inishthejobwith
hammer(left).
the dead-blow
I
I 95
I
 a
WINDSOR CHAIR I
I
thelegtenons forwedges I
1l Kerling
-t Thelegtenons in theseatarewedged,
tightening thejointsandensuring thatthe t
s i l ln o tl o o s e nK.e r tf h et e n o n s
t e n o nw
bystriking a f irmerchiselwitha hammer; I
to avoidsplitting theseat,orient theslots
s ot h e ya r ep e r p e n d i c utloatrh eg r a i n
I
of theseattighil. Cutthe kerfsto a depth
slightly below thetopof theseat. I
I
f, Tappingin thetenonwedges
r
r-,1 Cut hardwood wedsesto f it intothe
k e r f s ;m a k et h e m t h e - s a m ew i d t h a s
t
t e n o n sb, u t a f e w i n c h e sl o n g e ra, n d n o I
I
t h i c k e rt h a n Y oi n c h a t t h e b r o a de n d .
Coatthe wedges withglueanddrivethem
i n t ot h e s l o t sa s f a r a s t h e yw i l l g ow i t ha I
hammer(below).Let the glueset,then
trim the wedgesevenwith the end of the
I
t e n o n su s i n ga f l u s h - c u t t i nsga w .N e x t ,
u s ea w i d e ,s h a l l o wc a r v i n gg o u g et o
I
s l i c et h e t e n o n sf l u s hw i t ht h e s u r f a c e
of
the seat;strikethe gougewith a wooden
I
m a l l e t( i n s e t )F. i n a l l yt,r i m t h e l e g st o
the samelength(photo,page94),
I
t
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96 I
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I WINDSOR CHAIR
I
t INSTALLING
THEARM
I 1 Marking thearmpost
I mortises onthearm
I Install thearmposts asyoudidthelegs,
referring to theanatomy illustration(page
I 73)forIheangles at whichtheposts splay
outto thesidesandraketo thefrontof
t t h es e a tD . r i l tl h ec o m p o u n d - a nmgol er -
tisesforthepostsin theseat,thensetthe
I o o s t si n o l a c eO. n c et h ea d h e s i vhea s
s e t ,p o s i t i ot nh ea r mo nt h ep o s t sa n d
I m a r kt h el o c a t i oonf t h ep o s t e n o nos n
thearm(left).f,Aake suretherewill be
I at leastY,inchof solidstockall around
t h e h o l e sr;e p o s i t i ot hnea r ma n dt h e
I posts,if necessary.

I
t
I
I
t
t
I
I
I
r) Boring themortises forthearmposts
I L Clamo thearmto a worksurface with
a b a c k ub p o a r du n d etrh es t o c kt o p r e -
I venttearout. Toguideyouasyoudrillthe
t mortises in thearm,adjusta slidingbev-
el to thesamerakeangleusedto bore
thearmpostmortise in theseat.Usinga
I handbrace fittedwitha spoonbit,start
d r i l l i ntgh em o r t i swei t ht h et o o la t a 9 0 "
I angle T .h e nt i l t t h eb r a c e
t o t h es u r f a c e
b a c kk, e e p i nigt a l i g n ew d i t ht h eb e v e l
I bladeto control therakeangle(right); Ihe
splayanglecanbeeyeballed byreferring
I to thearmpost.Oncebothmortises are
taperthemasyoudidthelegmor-
t bored,
tisesin theseat(nase91).
\rsbe r

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WINDSOR CHAIR
I
r
I NS T AL L T
I NHGES P IN D L E S
I
'l Marking thecenter spindle I
I location onthearm
D r i ltlh es p i n d lm
e o r t i s ei nst h es e a ta; l l I
theseholesareat 90"to theseatsurface.
Thenfit thearmontothearmoosts and I
insert thecenter spindle intoitsmortise
in theseat.Adjust theposition of thearm I
p o s t sa n da r m ,i f n e c e s s a u r yn,t i lt h e
assembly is symmetrical. Thenholdtng t
thecenter spindle against thearm,mark
its location onthetopface(right). I
I
I
I
r) Marking
L spindle
theremaining
locations
I
Adjusta setof calipersto thedistance
b e t w e etnh ec e n t esr o i n d l a e n dt h e
t
adjacentones(page73) andmarktheir I
locations onthearm(below). Repeat for
t h er e m a i n i nl ogn gs p i n d l eM
shortspindles sothegapbetween
s .a r kt h e
them
I
andthearmoostsiseoual. I
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98 I
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I
I WINDSOR CHAIR
I
|l
Q Boring thespindle
t r-J mortises in thearm
Clampthearmto a worksurface, center-
i n ga b a c k u b p o a r du n d etrh eh o l ey o u
I w i l lb ed r i l l i n gA.l s oi n s t a al l s p o o b
n i ti n
I a h a n db r a c a e n da s m a l l c l a moont h e
e d g e os f t h es t o c ki n l i n ew i t ht h eh o l e
t markto prevent
a sy o ud r i l l A
thewoodfromsplitting
. d j u sat s l i d i n bg e v et lo t h e
backward slantof thespindles, placeit
I o nt h et a b l ea, n da l i g nt h eb i tw i t ht h e
bevelbladeto borethe holes(rueht).
I
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I
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T
I
I
I
t Gluing
spindles
thearmposts
totheseat
and

I S l i pt h es p i n d l ei sn t ot h e i rm o r t i s ei ns
thearm.Thebottom endsof thespindles
I should b ea l i g n esdo9 t o 1 0 i n c h eos f
eachlongspindle extends above thearm;
o o o o o
I shave thespindles
necessary.
to improve
Next,gluethearmpoststo the
thef it, if

I seat.Spread
dletenons
someadhesive
andin theirseatmortises,
onthespin-
and
t onthetopendsof thearmpostsandin
theirmortises inthearm,thenfit thespin-
I dleassembly ontotheseat(/eft).Usea
dead-blow hammer to tapthearmbetween
I e a c ho f t h es p i n d l et o
andarmoosttenons
s s e a t h es p i n d l e
fullvin theirmortises.
I
I 99
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 I
WINDSOR CHAIR I
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t
t
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I
thearmposts andshoftspindles
I
f, Wedging
r.,/ Thetooendsof theshortspindles andbothendsof thearm
postsarewedged in theirmortises.
Starting withthechairright-
I
sideup,chiselkerfsintothetopendsof theshortspindles and
armposts, making thecutsperpendicularto thewoodgrainof the
I
arm,thentapa wedgeintoeachcuI(left);followthesameproce-
dureusedfortheleglenons(page 96).furnthechairoverand
I
endsof thearmposts
repeai
hbove).
to wedgethetenons
Trimthewedges
at thebottom
andtenons flushwiththeseatsurface.
t
T
THEBOW
INSTALTING I
1l Markine thebowendsonthearm
I Position
-
thebowonthearmandsoin- I
dlessoitsendsextend below thearmby
thesameamount on bothsides. Tohold I
thebowsteady whileyoumarkits location
o nt h ea r m ,t h r e a di t i n a n do u to f t h e t
spindles (right). Drilla holeat each
marked point,centering thebit between I
thp pdooc nf thp arm Thon ianpr ihp

holes(page9l) to ensure
a snugfit. I
I
I
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I
I
100 I
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I
t WINDSOR CHAIR
I
t r) Boring thecenter spindle
I Z- mortise through thebow
M a r kt h el o c a t i oonf t h ec e n t esrp i n d l e
I onthebow,thendrilla holeat yourmark,
usinga handbraceandspoonbiI (right).
t Angletheholeto matchtheslantof the
s o i nlde .
I
I
I
I
I
I mortises
Q Drilling theremaining spindle
I r-J Referring to theanatomy
on page73, usea pencil
illustration
anda setof
I c a l i p e tr os m a r kd r i l l i npgo i n tosnt h e
(below).
bowfortheremaining spindles
I T h e nd r i l tl h eh o l e s .

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t 101
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 I
WINDSOR CHAIR I
I
Gluingthe bowto thearmandspindles
I
't/l Spread gluein thespindle mortises in
thebowandin themortises forthebow
I
in thearm,Fitthebowin position, tapping
downalongitslenghwitha malletto seat
I
the piecefully(ilghil.Installwedges in
thetopendsof thespindles, repeating the
I
p r o c e d uur es e df o rt h es h o r st p i n d l e s
@age100. Makesurethekerfsareper-
I
pendicular to thegrainofthebow.Trimthe
wedges andspindles f lushwiththebow.
I
I
I
f,
Wedging the endsof the bow
r . , l O n c et h e g l u es e c u r i n tgh e b o wh a s
t
c u r e d f, i n i s ha s s e m b l i nt g
h e c h a i rb y
w e d g i n gt h e e n d so f t h e b o w .S e tt h e
I
c h a i ru p s i d ed o w no n a w o r ks u r f a c e ,
clamping d o w nt h e a r ms o t h e e n d so f
I
t h e b o we x t e n do f f t h e t a b l eb y a f e w
i n c h e sT. h e nk e r ft h e e n d so f t h e b o w
I
a n d g l u e i n w e d g e st,a p p i n gi n e a c h
o n e w i t h a h a m m e r( b e l o w ) .
I
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t
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t02 I
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I
I
AMILKPAINT FINISH
I
t rl- he traditionalfinishfor Windsor occursbetweenthelacticacidin the milk
I chairsis milk paint,whichis thin and the lime,which is a base;lime is
I enoughto allowwood grainto show not simply addedasa thickener.Skim
through.Youcanbuythepaintin pow- milk isusedbecause thefat in wholemilk
I deredform and mix it with wateror with thecuringprocess,
interferes reduc-
makeyour own by followingthe recipe ing the paint'sdurability.Buttermilkor
I presentedbelow.The blend provided thewheyfrom cheese-making weretra-
wasusedin colonialtimesasan interi- ditionalsubstitutesfor wholemilk.
I or wall paint,whichyieldeda flat,lus-
terlessfinishthatcanbestained, oiled,or
I waxedoncethe surfaceis dry. To pro-
ducea semigloss sheen,eggwhiteican A milkpaintfinishis beingbrushed
I be addedto the recipe.Their usehasa ontoa sack-back Windsorchair.
longtraditionin painting;eggtempera Thetransparency of milk paint, com-
I paintswereusedby someof the great paredto otherpaints,alongwith its
Renaissance masters. tendencyto varyslightlyin hueacross
I Theabilityof milk paintto produce a surface,complements thehand-
a finishthat is both durableand mois- sculptedcontoursof theWindsorchair.
I ture-resistant is somewhatof a mystery, Thedarkgreenshownat right is a
but it is known that a chemicalreaction traditionalcolorfor Windsors.
I
I A MILKPAINT
PREPARING FINISH
I
I
I
I
I
I
I
t
I
I
I Combining andapplying theingredients
addmoreplaster Testthe painton a scrappieceand
t To makeaboul2 quartsof milkpaint,weargloves
cupsof skimmilkintoa container (above). Sprinkle
andpour3
2 ounces let it dry.Todeepen
of Paris.
the hueof thefinish,addmorecoloring.
of slaked limeintothemilkandmixfor3 minutes. Thenstirin Letthepaintsitfor t hour,thenbrushit on,stirring frequent-
I 16 ounces of plaster of Paris. Addcoloring, suchasartist's pig- ly.Sincemilkpaintraises thegrainof thewood,sandthesur-
t mentsor earthpigments usedforcoloring cement, or powdered facelightlybetween
c h a l kl i k et h ek i n du s e di n c h a l kl i n e sT. ot h i c k etnh es o l u t i o n , of varnish,
coatsfora smooth
oil,orwaxto protect
shellac,
finish.Adda thin layer
thef inish.
I
I 103
t
I
I
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t
I A]\TNESE,CRETARY
QTIE,EN
I
t
I
-l- h. secretary, a bookcase and Anotherusefi.rlcomponent of the
I l- slant-top deskcombination, deskis thelockablelid. Thissafe-
I evolved in BiitainandAmericain guards thecontents ofthe pigeon-
the18thGnturyandhasbeenpop- holes,whileprovidinga quickway
I ulareversince.By settinga book- to hideclutterbehindthefall-front.
caseatop a slant-topdesk,the Both the deskand bookcase
t secretary embodies
tionshipbetween
thecloserela-
booksandwrit-
derivemuchof theirstrenghfrom
half-blinddovetails. Cuttingthese
t ing.Until the19thCentury,
werean expensive
books
andsometimes
jointsby hand(page109)is time-
consuming, but well worth the
I rarecommodityto be treasured. effort,considering thehand-crafted
A secretary offeredanidealwayto appearance youwill obtain.The
I keepa preciouscollectionsafely drawers canbemadewiththrough
behindglass, onlyanarm'sreach Theweightof thefall-front in thesecretary dovetails cutwith a commercial jig
I away.TheQueenAnneversion fea- shownaboveis borneby a pair of supportscalled andarouter(page 116),and theend
turedin thischapterismoreelegant Iopers.In thedownposition,thefront becomes grainof thetailshiddenwith false
I thanthestolidfurniturethathall- a leather-Iinedwriting surface.Theremovable fronts.Youcanalsousehalf-blind
markedthe 17thCentury, but it is pigeonhole unit issetatopthedeskunit. dovetails to attachthedrawerfronts,
I lessornatethansomeof theincar- therebydispensing with falsefronts.
nationsthatfollowed it, suchasChippendale-style secretaries. Theveneer appliedto thefall-front(page121)addsa dec-
I Thedeskhalfof thepiecehasseveral usefulfeatures. The orativeflairto thedesk,becoming thefocusof theentirepiece.
veneered fall-frontcanbelowered to become a largewriting Thesecretary shownopposite usesbookmatched veneer, but
"pigeonhole" Thisnetworkof
t surface andrevealthe
dividers,compartments, anddrawers
unit. otherattractive
servedasa primitive do a lot ofveneering,
optionsareshownonpage124.Ifyou planto
consider buyinga vacuumpress(page
I precursor to today's laptopcomputers. Completely portable, 124);otherwise, usea shop-made veneerpress(page125).
theunit enabled clerksin bygonedaysto taketheirofficesand Thedesignandconstruction ofthe base(page128)and
I informationwith themwhentraveling.Youcanadaptthe crownmolding(page134)mayappearcomplicated, but the
pigeonhole designshownon page108,addingor removing time-tested methods presented arenotdifficultto master and
I compartments, adjusting theirspacing, or incorporating more areimportantto accommodate theinevitable woodmove-
drawers to fit yourneeds. mentatthesewlnerablelocations.
I
I
I
I Madefrom mahoganywith a clearlacquerfinish, the
QueenAnnesecretary shownat left marrieselegance
I with
case
usefulness,
to create
a
crowning
single,
a slant-topdeskwith a book-
strikingpieceoffurniture.

t
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 I
ANATOMYOF A QUE,ENANNE,SECRETARY I
r
I
ToP
DESK
UNIT 109) Jotned Lo eidee wiLh I
half-blind dovetaile

Top of drawer seation

I
Front edqe to hin4ed to fall-fronL:
Eack panel ende ftt tnto qroove in carcaee etdee I
Ftl,etnto rabbetecut alonqback
ed7eeof carcaaepanele I
Duet frame (page 112)
9upporLe drawer. AaEembled
wtth plaLe jotnta; etde ptecee fiL
I
Drawer divider
tnT,oqrooveg tn carcaoe aideo
I
Aaeembledand fixed Loper (page 115)
to dustframe below 9upporte fall-front when tn down poeitron. I
Dowel4lued tnLo tnatdeface altdea tn elot
in loper houeinq: ptecejotned Lo fronL end
with eltdinq doveLail conceale end qrain
I
I
Loper houeing

9ide
Featuree slot Lhat. qutdee loper; t
t.op edqe ftte tnto qroove tn under-
Joined to
top and
etde of drawer eectton Lop
t
bottom Leather inlay
with half- I
blind dove-
tailo I
t
I
I
Fall-front (page 122)
Hin4ed Lo Lop of draw-
er eecLion;servee ao
I
wntin4 eufface in down
Ease
(pase 12o) poetLton.0utetde face I
ie veneered;tneide face
Eottom
JoinedLo aideewil,h
featurea leaLher inlay I
half'blinddovetatla
Layered t
base
molding Eracket I
feet
Olued1,o
moltiinq
I
I
False front
Drawerbottom
FiLgtnto 7rooveern
Olued Lo
drawer front
I
front, back, and eidee
Front
I
t
I QUEENANNE SECRETARY
I
t , hemajorcompoucuts of theQueen huuridity,the framesareglLred to the ftrll,vadjustable; the,vsiton pinsthatcan
. Annesecretary areshorvr.r in explocl- sidesonlynearthefront;screu,s driven be inserted at anyheightin the sides.
I edforrr in thissection. Themostelab- throughelongated holesreinforce this Theglass doorsthatgracethebookcase
oratepart-the deskrmit (poge106) is connection. Thefall-frontisflxedto the anclprotectits contentsarehingedto
I essentiallya carcaselvith drawers, a f-all- unitu,ithbutthinges. Toease thestrain thesidepanels.
fbr thepigeonhole on thehingeswhenthefall-frontis let Thepigeonhole unit (pnge108)is a
I fi'ontandanopening
unit.All thecornerjointsfbr thecarc.lse, down,a pairof boards,callediopers, srrallercarcase ll ith threedrau,ers
anda
I thebookcase, anclthedrarvers aredove- slideout to providesupport. series of i,erticaldividels. Theunit rests
tailed.Thedrarvels aresupported b,vdust Thebookcase (below)is anothersol- atopthedralversection of thedesk,lvith
fl'arresattaclieclto
thesicles.Toallorvfor id-panel withshelves,
cal'case a backpan- stripsof moldingconcealing the gap
I nrlrlcln"ror,etr-tent
asa resultof changes in el,andcrownmolding.Theshelves are betleen thetrvo.
I
I (page130)
BO0KCASE ToP
AtLachedLo bookcaee
wiLhwoodbutLone
I
I Layered crown moldinq (page Ea)

I Eack rail
TenoneaL endsftt tnLamorLteeetn etdee.Face
i a n r n - r o 1 r . na r r n r y m n 4 a fe w o o d b u f t o n o f o r
I Lop; boLLom edge te rabbeted for back panel

I -S5
Eack panel
FitE tnLorabbeLecuLalong
fl $f-;- backed7eoor carcabppaiet,

Front facing rail

I Frovidea baEe for moldin4;
joined to sidea with plaLejointe
I o o Shelf
eupporE
BOOKCASEGLASS
I Ftte tnto
aleevetneert-
D00R(page135)
o w

I o o
ed in hole
dnlbd in
o o
etde panel
I
I o u door frame

I 9ide
Jotned to
I baltltam with
half'blrnd
doveLaile
I Bottom rail
Gluedto backed7eof bot-
I tom panel;Lop edqete rab'
Rail
TenoneaL
beLedfor backpanel
ende fit. int.o
I Eottom ettle morLteee
JotnedLo eideewiLh
t half'blinddovetatle

I t07
I
 I
QUEENANNE SECRETARY
I
I
I
I
I
I
dadoeacut t
acroao dividera

Drawer
I
Aaaembledwith
rabbeta at front t
and dadoeaat
back; bottom I
I
I
I
t
CUTTING
LIST
I
W w w I
BUREAU:
FallFront 1 Molding
frameback 3t
2 3 0 2 Drawersupports ,l Bn 9y,
1 Panel 3,6 LO/4 29'l 2 lVlolding
framesides 3/
2 r7'l 6 Arches 'lz
\lz
lX 3t/" t
2 Rails % 2 % 1 4 6 Bracketfeet % 3 8 3 Drawerfronts 3 8rl.
2 Stiles lo 2% 33X BUREAU:
DeepDrawers
3A
3 Drawerbacks )
)lz
1 2 3 8
I
BUREAU:
Carcase 4 Upperfrontandback 4t5/a 15% 6 Drawersides 3 8%
2 Sides /o 17% 38 4 Uppersides 3/
4\5/a 17 3 Bottoms ' 1 2 8 8 I
% 10,a 33)6 3A 5 75'A B00KCASE:
1 Top 2 Upperfalsefronts Carcase
1 Bottom 3/4 17U 33rA 2 Upperdrawerbottoms ta i5 16rt 2 Sides 3/o 8% 35/4 I
I BackPanel /4 32Y' 37Y, 2 Middlefrontandback % 5t'la 32% I Top 3l lr% 38
1 Writingsurface /, LT\A 32\A 2 Middle
sides 3l 5t'/ro 17 1 Bottom % 8Y, 32rA I
2 Lopers lo 33/o 17 1 Middlefalsefront 3A 6 32V I Frontfacingrail 3A 3Yo 33
2 Loperhousings lo 331 17 2 Lowerfrontand back -/4
6t5Au 3231" I Backrail % 3 31tt I
6 Dustframestiles lo 2 32y, 2 Lowersides 3A 6t5/ta 17 I BottomRail % 2 31rl
6 Dustframerails % 2 l3v, 1 Lowerfalsefront 3A 7 33% 1 Molding
framefront % 2 3 6 b I
1 Crossrail 31 4 r3y, 2 Drawerbottoms Y^ 3r% 16h 2 Molding
framesides ,a 2 11
1 Drawerdivider lo 2 15% BUREAU:
Shallow
Drawer front(builtup)
1 Molding r% l% 3531
I
1 Muntin / 0 2 5 % 31Va 29\A 2 Molding
sides IU 1Y4 10%
BUREAU:
Base
2 Frontand back
2 Sides % 311ls 17 1 Backpanel y^ 29y, 323/o
I
% ,a 35%
1 Molding
front
2 M o l d i nsgi d e s /o ',4 I8%
1 Falsefront
1 Drawerbottom
%
74
3%
28% 16'i
29% B00KGASE:
Doors
4 Stiles "4 2 31%
I
3/o 3
1 Moldingbasefront
2 Molding
basesides
,l 3
35/o
19',4
BUREAU:
Pigeonhole
Unit
2 Topand bottom 2 81n 32tt
4 Rails
1 Glass-stop
molding
31
% % r 9 2
2 I2'l
t
',4 l2'/* 275A
1 Molding
framefront % 2 3 4 B Dividers
andsides v 8Y, 10% 2 Glasspanes I
I
r08 t
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I
t MAKINGTHE DESKUNIT
I
I rla he carcases of the deskunit and
I bookcase form the two main parts
I In keepingwith thetwin
of the secretary.
requirementsof elegance and usefulness,
I both piecesareassembled with one of
themostattractive-andsturdy-joints
I availableto the woodworker:the half-
blind dovetail.The stepsshownbelow
I and on the following pagesfeaturethe
connectionbetweenthe too and sides
I of the deskunit; but the sime proce-
duresapplyto thejoints at thebottom of
I the both the deskand bookcaseunits.
Oncethe dovetailshavebeencut,you
I canmoveon to makingthe dustframes
(page112)andtheloperhousings. The
I carcase is thenassembled (page113)and A platejoinercutsa slotin thestileof a dustframe;a stopblockdampedin placeholds
the back panelis nailedin place(page theworkpiece squareto thetool.A woodbiscuitandgluewill beaddedto thesemicir-
I 115).Thefinal step,oncethe gluehas cularcut and thenfitted into a matingslotin a rail. Quickandeasyto make,the
joint will bestrongandinvisible,enablingtheframeto supporta drawer.
t cured,is installingthe lopers. resulting

I CUTTING
HALF.BtIND
D()VETAILS
t 1 Marking thepinsinthesides
you
I Once have gluedupthepanels and
I cutthemto therightsize,marktheirout-
sidefaceswithanX.Secure oneof theside
I panels upright in a vise,thenseta cutting
gauge to abouttwo-thirds thethickness of
I thesidesandmarka lineacross theendto
indicatetheendof thetails.Thelineshould
I becloser to theoutside thantheinside face
of thepanel.Adjustthecuttinggauge to the
I stockthickness andscribe a lineontheinside
faceof thesideio marktheshoulder line
I of thetails.Next,usea dovetail square to
outlinethepinsontheendsof theside;
I thewidepartof thepinsshouldbeonthe
insidefaceof thepanel(/eft).Thereareno
t strictguidelinesforspacing dovetailpins,
butforstockof thedimensions orovided on
I page108,I%-inchevenly spaced pinswith
%-inch tailsanda half-pin at eachedge
I willmakefora strong andattractive joint.
Tocomplete themarking, extend thelines
I onthepanelendto theshoulder lineon
its insideface.Markthewastesections
t withXsasyougo.

I
I
I 109
I
 I
QUE,ENANNE SECRE,TARY
I
I
r) Cutting the pins
I
L L e a u i n g t hsei d ep a n e li n t h e v i s e ,
c u t a l o n gt h e e d g e so f t h e p i n sw i t ha
I
dovetailsaw(lef), workingyourwayfrom
o n ep a n e e l d g et o t h e o t h e r (. S o m ew o o d -
I
w o r k e rp s r e f e tro c u t a l l t h e r i g h t - h a n d
e d g e sf i r s t ,t h e na l l t h e l e f t - h a n e
dd g e s . )
t
H o l dt h e p a n e sl t e a d ya n da l i g nt h e s a w
b l a d ej u s tt o t h e w a s t es i d eo f t h e c u t t i n g
I
l i n e ;a n g l et h e s a wt o w a r dt h e w a s t et o
a v o i dc u t t i n gi n t ot h e p i n s .U s es m o o t h ,
I
e v e ns t r o k e sa, l l o w i n tgh e s a wt o c u t o n
t h e p u s hs t r o k eC . o n t i n uteh e c u t j u s tt o
I
t h e s h o u l d elri n e ,t h e nr e p e atto s a wt h e
p i n sa t t h eo t h e re n do f t h e p a n e l .
I
I
I
I
t
I
t
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I
I
I
t
I
I
a< Chiseline
outthewaste
r J S e tt h e p a n e li n s i d e - f a cuep o n a w o r ks u f a c ea n dc l a m p a w a ya t h i n l a y e ro f w a s t eC . ontinuu e n t i ly o ur e a c ht h e s c r i b e d
I
a g u i d eb o a r dt o i t , a l r g n r n igt s e d g ew i t ht h e w a s t es i d eo f t h e
s h o u l d elri n e .S t a r t i n g
a t o n ee d g eo f t h e s t o c k ,h o l dt h e f l a t
l i n eo n t h e e n do f t h e b o a r dt,h e nr e p e atth e p r o c e sw
r e m a i n i nw g a s t es e c t i o n sP. a r ea w a ya n ye x c e s w
s i t ht h e
s a s t ef r o m
I
s i d eo f a c h i s eal g a i n st th eg u i d eb l o c k ; t h e b l a d es h o u l db e
n o w i d e rt h a nt h e n a r r o w e spta r to f t h e w a s t es e c t i o nW . i t ht h e
b e t w e etnh e p i n s ,c o m p l e t i nw g o r ko n o n ew a s t es e c t i o nb e f o r e
m o v i n gt o t h e n e x t .P r e s st h e f l a t s i d eo f t h e c h i s e a
l g a i n stth e
t
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ing awaythe lastsliversof waste(insef).Thenpareawayany
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I s e c t i o nw i t h X s .

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I t h a nt h e s a w ,m a k e sf o r e a s i e rm , o r ea c c u
r a t e .c u t t i n gS . ecure t h e p a n e sl o t h e
t r i s h t - h a nedd g e so f t h e t a i l sa r ev e r t i c a l .
S a ws m o o t h layn de v e n l a y l o n gt h e e d g e s
t o f t h et a i l s s. t o n n i nast t h es h o u l d el irn e .
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a l o n gt h e f r o n te d g eo f t h e p a n e sl o t h e
d a d ow i l ls t o p2 i n c h e s h o r to f t h e e d g e .
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Foreachdustframe,routa stoppeddado r) Makingandgluingupthedustframes
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platecontacts the stopblock.Squarethe t h e s h a n k so f t h e f a s t e n e ryso uw i l l u s et o a t t a c ht h e f r a m e st o t h e c a r c a s e sides.
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(photo,page109)at eachcornerof the frames,assemble the jointswith woodbiscuits
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d u s tf r a m ef o r t h et w o n a r r o w edrr a w e r si n , c l u d et h e c r o s sr a i l ( p a g eJ 0 6 ) .
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I d o v e t a itLn a d d a n i e c et o t h e f r o n te n d o f e a c ho n et o h i d e f a c en f t h e r r n n e r m o ds u t s tf r a m et o a c c o m m o d a l h ee l o n e r
t h e e n d g r a i n .T h e nr o u tt h e , u , - i n c h - w isdl oe t si n t h e h o u s - h n r r q r n pSsn r e a bp d' l" r" r e"r ' n r h es l o t sa n dp r o o v e tsn. e nf i t t h e
I i n g sf o r t h e l o p e rd o w e l sM . a k et h e L - s h a p eddr a w e dr i v i d e r d r r s ft r a m e st o g e t h e u r .s i n sc l a r n n lso s e c r r r e ' hder a w e r
a n d a t t a c hi t t o t h e c r o s sr a i lo f t h e m i d d l ed u s tf r a m ew i t ha d i v i d e rt,h e l o p e rh o u s i n g sa .n dt h e f r a m e si n p l a c e P . "otecr
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QUEENANNE SECRE,TARY
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Fittingthe lopersin place
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I t h ef r o n te n dw i t ha s l i d i n g d o v e t a iTl .h e n
s l i d ey o u rb l a n k si n t ot h e r rs l o t sb e t w e e n
I t h e h o u s i n gasn dt h e s i d ep a n e l sa. n c
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I t o p p a n eo l f t h e d ' a w e rL , n i ta: l s om a r k
t h e l o c a t i o on f t h e h o u s i n sgl o t so n t h e
I l o p e r sC. u tt h e l o p e r tso l e n g t ha n dd r i l la
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I s l o to u t l i n el;o c a t et h e h o l es o t h e f r o n t
e d g eo f t h e f a l l - f r o nwt i l l p r o l e cat b o u 2 l
I t o 3 i n c h e sb e y o n d t h e l o p e rw h e ni t i s
f u l l ye x t e n d e (dl e f t ) C. u tt h e d o w e l s1 l
I i n c h e sl o n g t, h e ns p r e a dg l u ei n t h e d o w e l
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MAKING THE DRAWERS
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Thedeskunit drawersareassembled
I
with throughdovetails,thena falsefront
isgluedto thedrawerfront to conceal
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theendgrain of the taik. Thechamfer
cut aroundtheperimeterof thefake
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front shownaboverecallsthetraditional
practiceofbevelingtheendsand edges
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UPTHEDRAWERS
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template
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1 Routing thethroughdovetail ioints
I Sizethedrawer partsto fit theiropenings in thedeskunit, drawer sideswillmatch.Installa top-piloted dovetail bit in the
thenjointheboards withdovetails, cuttingthepinsin thefront routerandcutthetailsbyfeeding thetoolalongthetopof the
I
andbackof thedrawer, andthetailsin thesides. Tocutthe template andmoving thebit in andoutof thejig'sslots(aboue,
jig
witha routerandthe shownabove,
dovetails screwthepin- left).Keepthe bit pilotpressed against thesidesof theslot
I
andtail-boardtemplatesto backup boards, thensecure oneof throughout.Repeat to routthetailsat theotherendof theboard
thetailboards(drawersides) endup in a benchvise.Protectingandrntheotherdrawer sides.Thenusethecompleted tailsto
I
thestockwitha woodpad,clampthetailtemplate thepinsonthedrawer
to thework- outline frontsandbacks. Secure a pin
piecesotheunderside of thetemplate is buttedagainstthe boardin thevise,clampthepin-board templateto theboard
I
endof the board.
thedrawer
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sidesotheiailsat theotherendandin theother in place.Routthe pinswitha straightbiI (above,
thestopblock
right).
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I QUEENANNE SECRETARY
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t r) Preparing the drawers
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T h e b o t t o mo f e a c hd e s ku n i t d r a w efri t s
I i n t oa g r o o v ea l o n gt h e i n s i d eo f t h e
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I c l a m pt h e u n i ts e c u r e l yp ,r o t e c t i nt h ge
s t o c kw i t h w o o dp a d sa n d a l i g n i n g the
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routew r i t h a p i l o t e dt h r e e - w i nsgl o t t i n g
I c u t t e ra n d m o u n t h e t o o lt n a t a b l e .
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bearrng b u t t e da g a i n stth e w o r k p i e c e ,
(right).Continue
I feedthe drawerclockwise
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I r e t u r nt o t h e s t a r t i n gp o i n t .U s ev e n e e r e d
plywood f o r t h e b o t t o ma n dc u t t h e p a n e l
I t o f i t t h eo p e n i n g .

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s m a l ln o t c h e si n t h e p a d ss o t h e yo n l y
I c o n t a ctth et a r l sS. preaa d t h i n ,e v e nl a y
e r o f g l u eo n a I t h ec o n t a c t r nsgu r f a c e s .
I t h e na s s e m b lteh e d r a w e r as n d i n s t a l l
t w o b a rc l a m p sa c r o s tsh e p r n b o a r d s .
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- ^-^il -*^,,^r ^r -r,,^ -nilppzps
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T h et w o r e s u l t s h o ud b e t h e s a m e .l f
t n o t ,r r s t a lal n o t h ebr a rc l a m pa c r o stsl - e
l o n g eor f t h e t w o d i a g o n a l s ,e t t i n gt h e
c l a m pj a w so n t h o s ea l r e a d iyn p a c e .
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INSTALTING
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Chamfering the endsandedgesof thefalsefronts
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u n i t ,s u b t r a c t i n}g4 'i,n c hf r o mt h e l e n g t ha n dw i d t h .T o c h a m f e r
t
t h e p e r i m e t eorf t h e f a l s ef r o n t s i,n s t a lal p i l o t e d4 5 " c h a m f e r -
i n gb i t i n a r o u t ea r n d m o u n t h e t o o l i n a t a b l e .A l i g nt h e r) Positioning thefalsefronts
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f e n c ew i t ht h e b i t ' sp i l o tb e a r i n ga n da d j u s t h e h e i g h o t f the
b i t t o c u t a l l b u t l . i n c ho f t h e f a l s ef r o n t ' se n d sa n de d g e s .
L Seteachdrawerface-upon a worksurfaceanddrivetwo
b r a d si n t ot h e d r a w efrr o n t ,l e a v i n tgh e i rh e a d sp r o t r u d i n g .
t
C l a m pt w o f e a t h e r b o a rtdost h e f e n c e o , n eo n e a c hs i d eo f t h e M a k es u r et h e b r a d sa r en o t l o c a t e d w h e r et h e d r a w e pr u l l
b i t , t o s u p p o rtth e s t o c k .( l n t h e i l l u s t r a t i oanb o v et,h e f e a t h e r - w i l l b e i n s t a l l e dt h, e ns n i po f f t h e h e a d sa n d i n s t a ltl h e
I
boardon the outfeedsideoJlhe-fencehasbeenremovedfor
c l a r i t y .T) o r e d u c et e a r o u tc, h a m f etrh e e n d sb e f o r et h e s i d e s .
d r a w e irn t h e d e s ku n i t .C a r e f u l lpyo s i t i o tnh e f a l s ef r o n to v e r
t h e d r a w e (r a b o v e ) . 0 n cyeo ua r es a t i sife dw i t ht h e p l a c e m e n t ,
r
F e e dt h e w o r k p i e caec r o s tsh e t a b l ew i t ha p u s hs t i c k ,u s i n g p r e s sf i r m l y ;t h e p o i n t e de n d so f t h e b r a d sw i l l p u n c hi m p r e s -
yourleft handto pressthe stockagainstthe fence(above). s r o n si n t ot h e b a c ko f t h e f a l s ef r o n t .
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n Gluinson thefalsefronts
r - . 1 R e m o v et h e d r a w e ra n d s p r e a da
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thinlayeo r f g l u eo n t h e b a c ko f t h e
f a l s ef r o n t .P l a c et h e f r o n ti n p o s i t i o n ,
t
w i t ht h e t w o b r a d sr n t h e i ri m p r e s s i o n s .
Hnld the asspmhlv tnocther rrsinoh:r
I
c l a m p sa l o n gt h e t o p e d g eo f t h e f r o n t
a n dd e e p - t h r o a t C e dc l a m p sa l o n gt h e
I
h o t t o me d s e .n r o t e ctth e s t o c kw i t hw o o d
p a d sw h e r en e c e s s a rTyi.g h t e nt h e c l a m p s I
e v e n l yu n t i lt h e r ea r en o g a p sb e t w e e n
the falsefrontand Ihe drawer(rtghD.
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BUILDINGTHE PIGEONHOLEUNIT
I
I Thepigeonhole unit is madetofit
betweenthetopsof thedeskand drawer
I sections
of thesecretary. Moldingcanbe
tackedin placeto hide thegapbetween
I thetwo carcases,as shown at left. You
canalso omit the molding, leavingthe
I pigeonholeunit removable.
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I THEUNIT
MAKING
I 1 Rough-cutting thearches
I Referring to theanatomy illustration
I of the pigeonhole unit (page10&, ouI-
linetheshape of thearches ona piece
I of %-inchplywood, cut it out,andsmooth
theedges to fashion a template thatyou
I jie
will useto makea routing btep 2).
Before assembling thejig,usethetem-
I plateto outlinesixcopies of theshapeon
yourarchstock.Cutoutthearches to
I within%inchof yourcutting linesusing
the bandsaw.To keepthe bladefrom
I bindingin the kerfs,makea series of
release cutsthrough thewaste,stopping
I %inchfromthe lines.Thensawalongthe
wastesideof the lines,feeding thework-
I piecewithbothhands(righ).I'liake sure
thatneither handis in linewiththeblade.
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QUEENANNE SECRETARY
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r) Shaping
C- to complete
thearches
the routing jig, prepare a guidepiecewitha tablein linewith,andalmost touching,
thebit.Totrimthe
t
holdthejigwithbothhands
n o t c ht o f i t t h ea r c hb l a n k s y ocuu t i n s t e p1 , a n df a s t e ni t
to theiemplate, centering the notchoverthearchoutline. thetemplate
archesto finalshape,
at oneendof thearchpattern
andpress
againstthepivot
t
Screwtwotoggleclamps to theguidepieceandsecure the bar.Thenpivotthejig andblankintothebit.Oncethetem-
firstblankto thejig. Next,installa top-piloted flush-cutting platecontacts the pilotbearing,shapethearchbyguiding the
I
bit in yourrouter, mountthetoolin a table,andadjustthe cutteralongit, starting
withthebearing pressed
bit heightsothe pilotbearing will rideagainst thetemplate. endof thepattern, ridingit along
thetemplate,
againstone
andstopping
I
To complete thesetup,clampa picket-shaped pivotbarto the whenit contacts the opposite end(above). t
Gluinguptheunit
I
Cutthepartsof thepigeonhole unit I
to sizeandprepare themforassembly. In
thetopandbottom,
dividers andrabbets
cut dadoes forthe
forthesides;in the
I
middletwodividers, cut dadoes forthe
drawer supports.Spread glueonthecon-
I
tactingsurfaces
securely;
andclamptheassembly
reinforcethejointswithfinishing
r
nails.Makesixcurved
f it in the middlecurves
clamping blocks
of thearches.
to r
Whentheunitis ready,
andapplyadhesive
remove theclamps
to thestraight edges of
I
thearches, thenclampthemto theunit,
usingthecurved clamping blocks to dis-
I
tributethepressure (left).Refer-
squarely
ringto the anatomy(pagel08),make
I
threedrawers forthepigeonhole
beting thedrawer
unit,rab-
frontsforthesidesand
I
dadoing thesidesforthebacks.
pullto eachdrawer front.
Attacha I
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MAKING THE FALL-FRONT
I Once theframe for thefall-front has been
I assembledand hinged to the deskunit,
the leather top can beglued to the inside
I face. The leather should be cut slightly
larger than the recess.Usecontactcement,
I hide glue, or thick wallpaperpaste to
anach the material to the surface.Trim it
I to sizewith a craft knife, then smooth it
down with a hand roller, as shown at left.
I The leathershould be treatedwith glycer-
ine saddlesoaDoncea year.
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I THEFRAME
PREPARING
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I 1 Shaping theframeedges
I C u tt h ef o u rf r a m ep i e c efso rt h ef a l l - f r o fnrto ma s i n g l e pilotbearingandclamptwofeatherboards to thefence,oneon
thesecuts,shapeoneedgeof the eachsideof thebit,to supporttheworkpiece.Feedthestock
I board.
board.
Butbefore
Install
making
a piloted 45'chamfering bitin yourrouter, mount facedown(above), finishingthepasswitha pushstick.(lnthe
ofthebitsoit willcuta illustration, thefeatherboard ontheoutfeedsideof thefencehas
I thetoolin a table,
%-inch-wide
andadjust theheight
bevelintothestock.Alienthefencewiththebit beenremoved forclarity.)
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QUEENANNE SECRETARY
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t
r) Preparing theframeforthepanel
I
L me fall-front panelsitsin a groove
cutaround theinside edges of theframe.
I
Install a piloted three-wing slotting cutter
in therouter andalignthefencewiththe
I
bit'spilotbearing. Adjust thebit height so
thetopedgeof thecutteris centered on
I
theedgeof thestock.Sincethegroove
willhaveto accommodate boththeoanel
I
andtheveneer gluedto it,youwillneed
at leasttwopasses to routa sufficiently
I
widegroove. Feed thestockasin step1,
r r d r ntgh eu n c h a m f e reeddg ea l o n g the
I
f e n c ef;i n i s ht h ep a s sw i t ha p u s hs t i c k .
Thenturnovertheworkpiece andrepeat
t
to widenthegroove (right). Now,cutthe
fourframepieces to length, mitering the
I
ends.Oncetheveneered panelis ready,
theframewillbeassembled usingplate
I
joints.(Thef inished frame, along withthe
veneered panel, isshown on page104.)
I
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A VARIETY
OFVENEERED
PANETS I
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5lip matah Eook match Herringbone I
Often ueed to dramatic effecL; A repeatinqpathern in whichadjoin- Veneerfiqure runo diaqo-
reduceedietortion cauoed by
liqht refraction problemowhen
ing eheetoof veneerappear1;oradi-
ate from the joint; bef,ween
Lhem,
nallyoff each eheeL,creaL-
inn a zinzaz effert
t
book-matchin4 likethe paqeoof an openbook
r
r
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End-to-end Eutt-and-book match Reverae-diamondmatch
I
A mirror-imagepattern fea- CommonlyuaedwiLhbutt, crol;ch, FeaLureefour aheeta of
turin4 flat-cut veneerewiLh and etump veneerato create an veneerthat appear to I
promtnent landacape fi4 ure unfoldin4. circuIa r effecL .Aht/?rnp a+ rha ron+pe

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I QUEEN ANNE SECRETARY
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t THEVENEERED
MAKING PANEL
t pattern
theveneer
1l Creatins
-
I C o v etrh e o u t s i d e f a c eo f t h e f u l l J r o n t
I p a n ew l i t hv e n e e rY. o uc a n b u yr e a d y -
matched s h e e t sa n dg l u et h e md o w na s - i s
I o r m a k e o u ro w nm a t c h r, e f e r r i ntgo o n e
y
o f t h e p a t t e r n si l l u s t r a t e d
o n p a g eI 2 2 ;
I the secretary featuredin this chapteruses
a butt-and-boo mka t c h T . o a p p l ym o r e
I t h a no n es h e e o t f v e n e etro a p a n efl a c e
with a veneerpress(page124),Iapethe
I sheetstogetherandgluethem downas a
u n i t .S t a r tb y a l i g n i n tgh e s h e e t se d g et o
I e d g eo n a w o r ks u r f a c eg,o o d - s i duep ,t o
p r o d u ca e v i s u a l l iyn t e r e s t i npga t t e r nT. h e
I combined l e n g t ha n dw i d t ho f t h e v e n e e r
s h o u l de q u atl h ed i m e n s i o n o sf t h e p a n e l .
I 0nce you havea satisfactory arrangement,
tapethe sheetstogetherusingveneer
I Iape (left).

I
I
I press
upa vacuum
Setting
I F e a t u r i nags e a l e dv a c u u mb a ga n da
5 - c f m( c u b i cf e e t p e r m i n u t e v) a c u u m
p u m p ,t h e p r e s ss h o w ni n s t e p3 c a n
I e x e r tp r e s s u rger e a t etrh a n 1 , 0 0 0p o u n d s
persquarefoot.The pressworksby with-
I d r a w i n gm o s to f t h e a i r f r o mt h e b a g :t h e
r e s u l t i nogu t s i d ea i r p r e s s u rsee c u r etsh e
I v e n e e rT. o s e t u p t h e p r e s sc, u t t h e p l a t e n
a n d c a u lt o t h e s a m es i z ea s y o u rs u b -
I s t r a t ep a n e lt i g h ) . f h e p l a t e ns h o u l db e
I m a d ef r o mm e d i u m - d e n sfi it by e r b o a rodr
p a r t i c l e b o aar d t l e a s t% i n c ht h i c k .C u t
I t h e c a u lf r o ma n yt y p eo f m a n u f a c t u r e d
b o a r d( o t h e trh a np l y w o o da)t l e a s t% r n c h
I t h i c k .T o p r e p a rteh e p l a t e nr, o u n do v e r
i t s c o r n e rtso a v o i dt e a r i n gt h e b a g ,t h e n
I c u t a g r i do f g r o o v e Is i n c hd e e pa n d
w i d ea c r o s si t s s u r f a c es, p a c e d4 t o 6
I i n c h e sa p a r t .F i n a l l yb, o r ea ' l ' - i n c hh o l e
2 i n c h e sf r o mo n ee n do f t h e p l a t e na n d
I centereb
sleeve
detween i t s e d g e sS . l i pt h e
s u p p l i e dw i t h t h e p r e s si n t ot h e
I holeT
nection
. h es l e e v e w i l l e n s u r ea t i g h tc o n -
w r t ht h e v a c u u mh o s e .
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I t23
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QUEEN ANNE SECRETARY
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/) Veneerins the nanel
r - , 1 U s et h e v a c u u mp r e s st o g l u et h e v e n e e d r o w nt o t h e t h e s u b s t r a t eP. l a c ea p i e c eo f w a x p a p e ro v e rt h e v e n e e r ,
I
p a n e l ,f o l l o w i n tgh e m a n u f a c t u r e ri 'nss t r u c t i o n sF.o rt h e m o d -
e l s h o w n ,i n s e r t h e h o s ei n t ot h e n i p p l ei n t h e b o t t o mo f t h e
r e s tt h e c a u lo n t o p ,a n d p l a c et h e a s s e m b layt o pt h e p l a t e n .
S e a lt h e b a g ,t u r no n t h e p u m pa n d l e a v et h e a s s e m b luyn d e r
t
p r e s sb a g .T h e np l a c et h e p l a t e ni n t h e b a ga n ds l i d et h e n i p -
p l e i n t ot h e p l a t e ns l e e v eS. e tt h e s u b s t r a tpea n e lo n a w o r k
p r e s s u rfeo r t h e r e c o m m e n d el de n g t ho f t i m e ( a b o y e )M
v a c u u mp r e s s ew
. ost
s i l l a u t o m a t i c a lsl yh u to f f w h e nt h e a p p r o -
I
p r i a t eo r e s s u r e
c r r r f : n p : n n l v t h p o l r r o e n d l a v t h o v, o- n
, ,p-o-r , t.a-ny e - s r ouep 0 n h a sb e e nr e a c h e d . I
I
I
Assembling
thefall-front
Oncetheveneerhasbeensecured,
I
remove t h e t a p ea n dg e n t l ys a n ds u r f a c e s
t h a t w i l l b e d i f f i c u l t o r e a c ha f t e rt h e
I
f r a m ei s g l u e dt o g e t h e rR. e a d yt h e f r a m e
piecesfor platejoints (page109), apply-
I
i n gt h e g l u ea n d w o o db i s c u i t sa t t h e
m i t e r e de n do f t h e b o a r d sD . on o ti n s e r t
I
a n ya d h e s i vien t h e p a n e g l r o o v e st h; e
p a n e lm u s t b e f r e et o m o v e .T o p r e v e n t
I
t h e w o o db i s c u i t sf r o m e x p a n d i n b gefore
e v e r y t h i nigs p u t t o g e t h e ra, s s e m b lteh e
I
f r a m ea s q u i c k l ya s p o s s i b l ef i,t t i n gt h e
f ramespiecesto the panel (right).V,'lilh
I
w o o dp a d sp r o t e c t i ntgh e f r a m e ,s e c u r e
t h e p l a t ej o i n t sw i t h b a rc l a m p s .
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I QUEEN ANNE SECRETARY
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VENEER PRESS Theoress in theillustrationisassem- collars, thentapping thecollars into
I Madefromplywood, hardwood, and bledwithopenmortise-and-tenon theholesin thetoprailsfromunder-
sixf-inch-long pressscrews, theinex- joints(inset),butthroughdovetails n e a t hS. l i ot h et h r e a d esde c t i o n s
I pensive shop-built veneer press shown canalsobeused.Whichever joinery intothecollars andreattach themto
below willworkaswellasa commer- method youuse,reinforce eachjoint theswivelheads.
I cialmodel. Thedimensions orovided withglueandthreescrews. To usethe press, applytheglue
o ni l ly i e l da p r e s s
i n t h ei l l u s t r a t i w Nowcutthepieces forthebaseand andlaytheveneer tape-side up on
I c a p a b loef v e n e e r i npga n e lus pt o caulto size.Botharemadefromtwo thesubstrate. Settheoanelonthe
1 6 b y2 9 %i n c h e s . pieces of %-inch plywood face-glued baseof thepress, veneered-face down
I Startbycuttingtherailsandstiles andscrewed together.Toassemble witha stripof waxpaperbetween
fromhardwood. Borethreeequidis- the press,setthetwoframes ontheir theveneer andthebase.Starting in
I tantholesthrough themiddleof each sidesona worksurface andscrew the the middleof the panelto prevent
toprail,sized slightly larger thanthe baseto thebottomrails,drivrng the adhesive frombecoming trapped,
I diameter of the oressscrewcollars fasteners t h ep r e s cs l a m p os n ea t a
fromthebottomof therails. t i g h t e n
youwillbeusing. Next, jointherails Attachthepressscrews to thetoprails timeuntila thingluebeadsqueezes
I andstilesintotworectangular frames. by removing the swivelheadsand outfromunder theoanel.

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I Kail
1'l"x3"x1B'/."
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1tile
I 1/,"x3"x12"

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I Open mortiae-
ana-tenon JotnE

I
Baee
I 1 / . 'x 1 6 x 2 9 ' 1 "

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QUEENANNE SECRETARY
I
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ATTACHING
THEFALL-FRONT
T()THEDESKUNIT
I
1I Makins
-
thehinsemortises I
I U s ey o u rt a b l es a wt o c r , ra - i n c h -
w i d c r : h h p t ( n a p p 5 Q ) a l n n o t h p c . i d p qn f t
L h ef r a m e B . e g i rw i t ha s h a l t o w d e p t ho f
c u t . i n c r e a s i nt hgeo e p t hb y i n c nw i t h I
e a c hn a s sl n t i l t h e f a l l - f r o n tb' so t t o m
e d g ei s i n c ha b o v et h et o p o f t h e d r a w I
e r u n i tw h e nt h ef a l l - f r o ni ts i n p o s i t i o n .
0 n c ey o ua r es a t i si fe dw i t ht h e f i t , l a yt h e I
f a l f r o n tv e n e e r - f a cdeo w no r t h e l o p -
e r sa n d b u t t t h e b o t t o me d g ea g a i n s t I
t h e t o o o f t h e d r a w esr e c t i o nP. o s i t ' o n
a n do u t l i n et h e t h r e eh i n g e o snthe I
^;^^^- ^^^;^ +L^ -;t:t^ -^: ^^^ ^^^f,
prtrLq)-uilg iltItc ililuutv d|u uilu cdLtl

n e a rt h es r d e s c e n t e r i ntgh eh i n g ep r no n I
t h e s e a mb e t w e etnh ef a l l J r o nat n dt h e
c a r c a s eT.o c u t t h e h i n g em o r t i s e s . I
instaa l l , 1 - i n csht r a i g hbti t i n y o u r o u t e r .
s e tt h e c u t t i n gd e p t ht o t h e h i n g el e a f I
t h i c k n e s sa ,n dc u t o u tt h ew a s t ei n s i d et h e
o u t l i n eU. s ea c h i s e la. c a r v i nggo u g ea. n o I
a woodenmalletto pareto the line (left).
T e s lf i l I n e h i n p e si n t h e i rm o r t i s easn d I
u s et h ec h r s etro d e e p e n o r w r d e na n yo f
+h^ -^^^^^^^ l{ ^^^^^^^-,, I
I
I
I
Attaching thefall-front to thedeskunit
I
!
Z - S e tt h e h i n g e sn t h e r "n o r t i s e sr nt h e
d e s ku n i ta n dm a r kt h es c r e wh o l e st,h e n
I
d r r l l n , l n t h n l e s z n d q c r e r , t\ h
r p hinop lpavpc.

i n p l a c el.e a v i ntgh ef a s t e n e a r s i t t l el o o s e .
I
M a r kt h ed r r l l r ndge p t ho n t h ed r i l lb l t b y
w " a p pn g a s t r i po f m a s k i n tga p ea r o u ' r d ir.
I
Next,extendthe lopersandsetthe fal
f r o n rt r p o s i t i o ns .l r p p , ntgh ef r e eh i n g e
I
l e a v eisn t ot h e i rm o r t i s e sM. a r kt h es c r e w
h o l e sd, r i l lp i l o th o l e sa, n ds c r e wt h e
t
h r n g etso t h ef a l l - f r o ntth, e nf i n i s ht i g h t e n -
inga I the screws(right).lf youareusing
I
brassscrews.be carefulrot to overtighten
t h e mo r t h e yw r l lb r e a kl.t i s a g o o di d e at o
I
d r i v ei n a s t a n d a rw
t h ep i l o th o l e .
d o o ds c r e wf i " s tr o t a p
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I QUEI:NANNE SECRETARY
I
t INSTALLING
THEFALL-FR()NT
L()CK
I 'l
t
0utlining
-
thelockfaceplate
I O p e nt h e f a l l - f r o nt to i t s d o w np o s i -
I t i o na n dp l a c et h e l o c kf a c ed o w no n t h e
t o p f r a m ep i e c es o t h e k e ys h a f tw i l l b e
I c e n t e r eb d e t w e etnh e s l d e st;h e l o c k
s h o u l da l s ob e f l u s hw r t ht h et o p e d g eo f
I t h e p a n e l l. f t h e k e ys h a f ti s o f f - c e n t ear ,s
i s t h e c a s ew r t ht h e l o c ks h o w ny, o uw i l l
I n e e dt o u s ea t a p em e a s u raen da t r y
s q u a r et o m a r kt h e m i d d l eo f t h e f a l l - f r o n t
I and alignthe keyshaftwith iI (left).Drill
t h e h o l ef o r t h e k e ys h a f ta n d i n s e rtth e
I s h a f t h r o u g ht h e h o l e .O n c et h e l o c ki s
p r o p e r lpyo s i t i o n e tdr,a c et h e o u t l i n eo f
I t h e l o c kf a c e p l a t et h, e ne x t e n dt h e l i n e s
o n t ot h e t o n e d c eo f t h e f a l l - f r o n t .
I
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t
r) -) Installins
I Routing the lockmortise
L S t a r tb y u s r n ga c h i s e tl o c u t a s h a l l o wm o r t i s ef o r t h e
<'
thestrikenlate
J F i t t h e k e yi n t ot h e l o c k .T o l o c a t et h e s t r i k ep l a t ef o r t h e
I f a c e p l a tlei p i n t h et o pe d g eo f t h e f a l l - f r o nN t . e x t i, n s t a lal
s t r a i g hbt i t i n y o u rr o u t e rs, e tt h e c u t t i n gd e p t ht o t h e f a c e -
b o l t ,t u r nt h e k e yt o e x t e n dt h e b o l ta n d u s ea p e n c i tl o c o a t
t h e e n do f t h e b o l tw i t hg r a p h i t eR. e t r a ctth e b o l ta n ds w i n g
I p l a t et hi c k n e s sa,n dc u t a m o r t i sw
I J s et h e c h r s etlo s c r . a rteh e. n r n e r q
e i t hi n t h e m a r k e d outline.
a r d n a r et n t h e l i n e T o
t h e f a l l ' f r o ntto t h e c l o s e dp o s i t i o nE. x t e n dt h e b o l ta g a i n stth e
u n d e r s i doef t h e c a r c a steo p t o m a r ki t s l o c a t i o nA. l s oe x t e n d
I c u t t h e m o r t i s ef o r t h e l o c kh o u s i n gm
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t h e b o l ta g a i n stth e e d g eo f t h e t o p p a n e a l n d m a r ki t s s i d e s
o n t h e t n n ( a h n v e )P o s i t i o tnh e s t r i k en l a t eo n t h e c a r c a s e
I f e r y o u rm e a s u r e m etnot t h e m o r t i s eT. h e nJ S ea c a r v , n g
g o u g et o c u t t h e f i n a lm o r t i s e( a b o v e T ) .e s t -i ft t h e l o c ki n t h e
t o p ,c e n t e r i ni gt s o p e n i n og n t h e p e n c im l a r k sO
p l a t e t, h e nc u t a s h a l l o wr e c e s fso r i t a n da d e e p em
. u t l i n teh e
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I c a v i t ya n du s et h e c i i s e lo r g o u g et o d e e p e o
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t h e b o l t .F i n a l l ym , a r kt h e p l a t e ' ss c r e wh o l e sb, o r ea p i l o t
h o l ea t e a c hm a r k ,a n df a s t e nt h e p l a t ei n p o s i t i o n .
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QUEENANNE SECRETARY
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Thebonomofthe
I
desk
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unit sitson a base
I
supportedby
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I
corner.Thebottom I
edgesofthe carcase
areconcealedby
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I
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to thecarcase.This I
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t I C u ta b o a r dl o n g ear n dw i d e rt h a ny o u
w i l l n e e df o r t h et h r e ep i e c e o sf molding.
l n s t a l la R o m a no g e eb i t ( i n s e t )i n y o u r
I r o u t ea r n d m o u n t h e t o o li n a t a b l e .A l i g n
I t h e b i t ' sp i l o tb e a r i n gw i t ht h e f e n c ea n d
a d j u s t h e c u t t i n gh e i g h t o l e a v ea f l a t
I l i p n o m o r et h a n% i n c ht h i c ko n t h e e d g e
of the stockabovethe molding.Mounttwo
I f e a t h e r b o a rodns t h e f e n c ea n d o n eo n
t h e t a b l et o s e c u r et h e w o r k p i e c e( l.n t h r s
I illustration t h, e f e a t h e r b o a or dn t h e o u t -
f e e ds i d eo f t h e f e n c eh a sb e e nr e m o v e d
t f o r c l a r i t y .T) u r no n t h e t o o l a n d f e e d
ihp c.innk lriohf I f n r-nmnlptp thp n:c.s

I m o v et o t h e o u t f e e ds i d eo f t h e t a b l ea n d
p u l lt h e s t o c kt h r o u g ht h e e n do f t h e c u t .
I M a k es e v e r apl a s s e si ,n c r e a s i nt g h ew i d t h
o f c u t % i n c ha t a t i m e .R i pt h e m o l d i n g
I s t r i p sf r o mt h e b o a r do n y o u rt a b l es a w ,
t h e nc u t t h e mt o l e n g t hm . i t e r i n gb o t h
I e n d so f t h e f r o n tp i e c ea n dt h e f r o n te n d
o f t h e s i d ep i e c e s .
I
I
I
I r) Gluinu g pt h eb a s e
I L C u t t h er a i l so f t h e m o l d r n fgr a m ea n d
m o l d i n gb a s et o l e n g t hm , itering b o t he n d s
I o f t h e f r o n tp i e c e sa n dt h e f r o n te n do f
t h es i d en i e c e s . n mtiht e b a c kr a i lf o rt h e
I b a s eJ. o i nt h e c o r n e r os f t h e f r a m e sw i t h
p l a t ej o i n t s( p a g e1 0 9 ) a n d c l a m pt h e m
I a s y o ud i d t h e d u s tf r a m e s( p a g e1 1 2 ) .
N e x tg, l u et h e m o l d i n g b a s et o t h e u n d e r -
I sideof the frameso the sidesof the base
e x t e n db e y o n d t h e f r a m eb y a b o u t1 i n c h .
I Thencut the bracket feeton yourbandsaw.
S p r e a dg l u eo n t h e c o n t a c t i nsgu r f a c e s
I b e t w e e tnh e m o l d i n gp i e c e st,h e b r a c k e t
f e e t ,a n dt h e m o l d i n gb a s et.h e nf i t t h e
I p i e c e st o g e t h ear n dc l a m pt h e a s s e m b l y ,
protecting the stockwith woodpads(left).
I O n c et h e a d h e s i vhea sc u r e d ,r e m o v e
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the

t u n i tb y s c r e w i nt gh e m o l d i n fgr a m et o t h e
c a r c a s teh r o u g he l o n g a t esdc r e wh o l e s .
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MAKING THE,BOOKCASE
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t
Ad.jrtstoltla slrclvcs give tlrc book-
cosesecliotto.l-thcsecretarygre(tter I
.flexiLtility, erurblirtgyott to odnpt to
,Jl,i ttt ilit Itt't'I : rtI trl ot qrl tlzr'.sprtct' I
rnostelficierrtly.The solid brass
slrcl.f'strpports slnwrt ttt rigltt cttrt I
Itc slippedirrto urtyof the sleetes
rtlont t/it'..lrir'f,lt,'/s, pcrrrr i t t i rrt I
tlrcshclvcs to Lterrroturted ot urry
lrciglrtirr tlrc boLtkcttse. I
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PREPARING
THESIDEPANELS
FORADJUSTABLE
SHELVING I
- ./ I
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Drilling
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holesforshelfsupports
I C u tt h e s i d ep a n e l so f t h e b o o k c a steo w i d t ha n d l e n g t h , a n di n s t a lal s t o pc o l l atro m a r kt h ed r r l l r ndge p t he q u atl o t h e I
t h e ns e tt h e m i n s i d e - f a cuep o n a w o r ks u r f a c eT. h ec o m m e r - s l e e v el e n p t hS i a r t i n pa t e i t h e re n d o f o n eo f t h e i i g ' sr a r l s .
c i a lj i g s h o w na b o v ee n a b l e ys o ut o b o r et w o p a r a l l erlo w so f
h o l e si n t h e s i d en a n e l sa t 1 - i n c hi n t e r v a lasn de n s u r etsh a tc o r -
p l a c et h e a p p r o p r i a bt eu s h i n gi n t h e f i r s th o l eo f t h e b u s h i n g
r ^ a r r i e(rT h eh r r s h i nkpe e n st h e h i t n e r f e c t lsvn r r a rteOt h e w o r k -
I
r e s p o n d i nh go l e sw i l lb e p e r f e c t al yl i g n e dC. l a m pt h e1 i gt o t h e
e o g e so f o n ep a n e lt:h e h o l e sc a n b e a n yd i s t a n c fer o mt h e p a n -
p i e c e .H) o l d i ntgh ed r r l a l n dc a r r i e rb,o r et h e h o l e D . r i la
l series
o f e v e n l ys p a c e dh o l e sa l o n gb o t hr a i l s .R e m o v teh e j i g a n d
t
e l e d g e sb. u t a b o u t2 i n c h e sr n w o u l db e b e s tf o r t h e s e c r e t a r y .
F i ta n e l e c t r i d
c r i l lw i t ha b i t t h e s a m ed i a m e t ear s t h e s l e e v e s
r e p e afto r t h e o t h e rs i d ep a n e lc. a r e f u l lpyo s i t i o n i nt hge l i g s o
t h a tt h e h o l e sw i l lb e a l i g n ew d i t ht h o s ei n t h ef i r s tp a n e l .
t
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QUEENANNE SECRETARY
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I r) Mountingthesleeves
andsupports
L f o tnslall without
thesleeves dan-
I $ # f f i * u . r i , i i i l h $ f f i ' 4 fffiiiliiii
fi$ '[iuiru :" bo"i' nb s i. h' p m r r q p : q l p p v p - c . p t t i n on r r n r ^ h

P l a c ea s l e e v eo n t h e e n do f t h e p u n c h
I 1HO?Tt?
rl
rl
a n dp u s hi t f i r m l yi n t oo n eo f t h e h o l e s
i n a s i d en a n e l( a h o v p )l n s e r a t sleeve
I A ohop-made i n t oe a c hh o l e y o u d r r l l e d . 0 n cyeo u
jig
ohelf-drilling h a v er r s t a l l e d a l l t h e s l e e v e sr ,n s e r t
I T h eT ' e h a p e d1 i qe h o w n \ s h e l fs r r n n o r il ns l ot h es l e e v east e a c r
h e r ew i l le r a b l ey a L l a : s h e l fl o c a t i o n( i n s e t ) .
N
I d'i,lla'ow of evenly u???.",1,
h o l e ea e a c c t - a t e l y a s w i L \ \ N
a c o m m e r c i aj il q . f ' l a k et h e j i q
I from'-by-3 etoc\. be'tq carel"
:\

L o b c r e wL h e f e n c e a n d a r m
I L o q e L h e ra f , a p e r f e c t 9 0 " a n q ' e
M a r k a l i n ed o w n L h e m t d d l eo l t h e a r m
I a n d d r i l l h o l e ea t Z - i n c hi n f , e r v a lael o n q
i t w i t h L h e s a m e b i t y o u w o u l du e e l o r
I L h e s l e e v e eT. o u s e L h ej i q , c l a m p i t rL o a
L h e e i d e p a n e lw i t h L h e f e n c e b u I t r e d
I a g a i n e t e i L h e re n d o f L h e p a n e la n d L h e
m a r k e dc e n L e r l i n e2 i n c h e si n f r o m i l o e d q e
I F i l ,y o u r d r i l l b i L w i l h a a l o p c o l l a r ,b o r eL h e
h o l e Ea, n d r e V a o i L i o L n h ej i q f o r e a c h n e w r o w
I
I
I 131
I
 I
QUEENANNE SECRETARY
t
I
ASSEMBTING
THECARCASE
I
1 Gluing upthesides, bottom, andrails I
I Cuttheremaining pieces of thebook-
casecarcase to size-the bottom,the I
rails,andthe backpanel.Next,sawa
rabbet alongthebackedges of thesides I
andbottom forthebackpanel. Cutblind
tenonsat bothendsof the backrail (page t
59 anddrilla matching mortise(page58)
o n t h e i n s i d ef a c eo f e a c hs i d ep a n e l . I
Witha platejoiner,makeslotsfor biscuits
in thefrontandbottom rails,andmating I
onesin thesides. Usehalf-blind dovetails
(page109)Iojointhesidesto thebottom I
of thebookcase, cuttingthe pinsin the
sidesandthetailsin the bottom. Then I
spread glueon the contacting surfaces
of all thepieces, inserting woodbiscuits I
whereappropriate, andf it themtogeth-
er. Protecting the stockwithwoodpads, t
installtwobarclampsacross eachside,
positioning theclampjawsonthefrontand I
backrails,theninstall twomoreclamps
across the backandbottomrails.Tighten I
theclampsevenly (left)untila thinglue
beadsqueezes outof thejoints.Finally, t
nailthebackpanel(page115)in place.
I
I
t
I
I
r) Routing a groove forthetoppanel
L to attachthetop panelto thebook-
I
caseusingwoodbuttons, asshownin
t h i ss e c t i o ny,o uw i l l n e e dt o r o u ta
I
groove forthe buttons
thecarcase.
alongthetopof
Fityourrouterwitha pilot-
I
ed three-wing slotting cutterandsetthe
tool'scuttingdepthto locatethegroove
I
aboulYzinchbelowthe top edgeof the
carcase. Starting nearonecorner, guide
I
the routeralongthe top edge(right). I
Movethetoolin a clockwise direction,
keeping the baseplateflatandthe bit's I
pilotbearing pressed against thestock.
t
r32 t
I
I
t QUEENANNE SECRETARY
I
t
t
I
t
I
I
I
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I
Making
thebuttons
I Vn, rinrill nppd tn n l : n p , ru u i n n d h r t t n n e v p n r 6 i n r - h p s a l n n o t h p
P'uuu c u t o f f t h e b u t t o n sa b o u tI I i n c h e sf r o mt h e e n d s( i n s e f ,T) .o
t n n p c p e n f ' h e c a r c . : s eC r r ts e v p r a l h v - l - i n r : hb l t r o n s f r o m m a k eh o l e si n t h e b u t t o nfso r i n s t a l l a t i ouns, ea n L - s h a p ecdo r n e r
I : c i n o p h n : r d . m : L p t n p i h i c k n p c q n f t h p s r n a k e- lful o' I- r +L ^U r1fi,l ^t r E
^-^
OP
j i g f a s h i o n efdr o ma s c r a po f I - i n c h p l y w o o a d n dt w o p i e c e so f
. l a m pt h ej r gt o y o u rd r i l lp r e s st a b l ea n ds t e a d tyh e b u t
t oetweerLnebottonof the grooveand Lie top edgeof the carcase. w o o dC
l e s sI i n c h .C u ta r a b b etto f r t t h eg r o o v a e t e a c he n do f t h e t o n sw i t ha h o l d - d o wm n a d ef r o ms c r a pw o o d .D r i l t h r o u g ht h e
s n t h e u n r a b b e t epdo r t i o nos f t h e b u t t o n s( a b o v e ) .
t b o a r dt,h e nr i p t h e b o a r dr n t o1 - r n c hs t r i p so n y o u rb a n ds a wa n d c e n t e r o

I
I Attaching
thetop
C l t h e b o o k c a steo p t o s i z e ,t h e . t
I s h a n ei t s e n d sa r d e d g e so n a r o u t e r
I a b l e( p a g eJ J 8 ) , u s r n ga d e c o r a t t v e
I m o l d i n gb r t .S e it h e t o p o u t s i d e - f a c e
d o w no n a w o r ks u r { a c a e n dp o s i t i o n
tie
I c a r c a soen l o n . F i t t h e r a b b e t eedn do f a

t w o o db u t t o ni n t ot h e g r o o v ei n o n eo f t h e
s i d en a n e l a s n di r s e r ta n o t l e r r t ot h e
p r o o v ier t h e b a c kr a i la b o u 6 t inches
I a w a yD . r i l la p i o t h o l et h r o u g thh eh o l e
i r t i e b u t t o ra n di r t o t h et o p .L h e ns c r e w
I t h e b u t t o n si n p a c e ( l e f t ) l,e a v i n g
a l-
r n c hg a pb e t w e etrn e l i p p e de n d so f t h e
I b u t t o n sa n dt h e b o t t o no f t h e g r o o v e .
t I n s t al t h e r e m a r n r nbgu t t o n ss.o a c ; n g
t h e me v e r y6 i n c h e s .
I
I
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 I
QUEENANNE SECRETARY I
I
MAKING
ANDINSTALLING
CR()WN
MOLDING I
'l
t
Making
-
themolding
andattaching
theframe I
I F i x e dt o t h e u n d e r s i doef t h e b o o k c a steo p a n d f l u s h
a g a i n stth e c a r c a s et h , e c r o w nm o l d i n gc o n s i s tos f t h r e el a y e r s I
( i n s e t )C. u tt h e m o l d i n gf r a m ep i e c e st o l e n g t hm , i t e r i n gb o t h
e n d so f t h e f r o n tp i e c ea n dt h e f r o n te n d o f e a c hs i d ep i e c e . t
C r e a t teh e b u i l t - u p m o l d i no g n t h e r o u t etra b l ea sy o ud i dt h e
b a s em o l d i n g( p a g e1 2 9 ) ,u s i n gt w o d i f f e r e not g e eb i t sf o r t h e I
narrow a n dw i d e rp i e c e sC. u tt h e m o l d i n gt o l e n g t hm , itering
t h e p i e c e as sy o ud i d t h ef r a m eS . t a r tb y i n s t a l l i nt g
h em o l d i n g I
f r a m eF . o rt h e s i d ep i e c e sd,r i l la n e l o n g a t ehdo l et h r o u g e ha c h
b o a r dn e a rt h e s t r a i g het n d ;t o a l l o wf o r w o o dm o v e m e nst ,p r e a d t
g l u eo n o n l yt h e f i r s t2 i n c h e so f t h e t o p f a c ea t t h e m i t e r e d
e n d .N o w ,s e tt h e b o o k c a st eo p - d o w o n n a w o r ks u r f a c e and I
positioo n n es i d ep i e c eo n t h e u n d e r s i doef t h e t o p . i n s t a l al
b a rc l a m pt o s e c u r et h e m i t e r e de n d a n d d r i v ea w o o ds c r e w t
t h r o u g ht h e e l o n g a t ehdo l ea n d i n t ot h e t o p t o f i x t h e b a c ke n d
( l e f t ) .R e p e afIo r t h e o t h e rs i d e ,t h e ni n s t a ltl h e f r o n tp i e c e
s p r e a d i nggl u ea l o n gi t s e n t i r el e n g t h .
r
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r ) A p p l y i ntgh em o l d i n g
f - l l e c r o w nn o d r n gr sf a s t e n e tdo t h e b o o k c a sien t w os t e p s : I
T h ew i d e rs t r i p sa r ea t t a c h e fdi r s t ,f o l l o w e d b yt h e n a r r o w e r
p i e c e so n t o p .S p r e a da t h i n l a y e ro f g l u eo n t h e b o t t o mf a c eo f I
t h e w i d e rs t r , p s t, a k n g c a r en o l L og e t a n yg l u eo n t h e e d g e s
s i n c et h e m o l d t n sg h o u l do n l yb e f i x e dt o t h e m o l d i n fgr a m e , I
a n d n o tt o t h e c a r c a s eS. e tt h e s t r i p so n t h e m o l d i n gf r a m e ,
e d g e sf l u s ha g a i n stth e b o o k c a s em, a k i n gs u r et h a tt h e m i t e r e d t
e n d sb u t tt o g e t h ecr l e a n l yb e f o r ec l a m p i n g t h e m o l d i n gi n
p l a c eO . n c et h e a d h e s i vhea sc u r e dr, e m o vteh ec l a m p sa n d t
r e p e a t h e p r o c e s fso r t h e n a r r o w em r o l d i n gs t l p s ( r i g h t ) .
C u t t i n gw o o dp a d sw i t h c o n v e xc u r v e sm a t c h i n tgh e c o n c a v e I
p r o ifl e o f t h e m o l d i n w g i i l n o to n l yp r o t e ct th es t o c k b, u ta l s o
h e r pd i s t r r b u ct e, a n p i n gp r e s s u reev e n l y . I
I
134 I
I
I
I MAKINGTHEDOORS
I
t An escutcheon isfastenedto oneof the
doorsof thebookcase shownat left.On
I thispiece,thekeyand escutcheons are
purelydecorative. Thedoorsareactually
I heldshutbyspringJoaded catches
installedon the insidefacesof thestiles
I nearthe bottom of thedoors.
I
I
I
I
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I MAKING DOORS
FRAME.AND.PANEL
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t thetenonin therails
1 Gutting
I Startmaking theframe-and-panel doorsof the bookcase in a testmortise(step4), thenrepeatthe process on the
I bycuttingblindtenonsat theendsof all therails.To dothe otherendof the boardandontheotherrailshbove,left).To
jobon yourtablesaw,installa dadoheadslightly widerthan cutthetenonshoulders, setthecuttingheightat about%
I thetenonlength. woodfenceandnotchit inch.Then,withtherailfaceflushagainst
Attachan auxiliary the mitergauge
by raisingthedadoheadintoit. Setthewidthof cut equal andtheendbuttedagainst thefence,feedtheworkpiece
I to thetenonlengthandadjustthecuttingheightto about intothe blades. Turntherailoverandrepeat thecut on the
one-thirdthethickness of thestock.Holdingtherailflush otherside(above, right).Cutthe restof the tenonshoulders
I againstthe mitergaugeandthefence,feedthestockface- thesameway.Fashion molding
integrated ontheinsideedges
downintothe blades to cut onetenoncheek. Turnthe board of the doorframeson a routertable(page129) usinga pilot-
I overandmakethesamecut on theotherside.Checkforf it e d m o l d i nbgi t .
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I 135

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QUEEN ANNE SECRETARY
t
t
r) Preparing therailsforglueup
I
Z- me corners of thetenonshoulders
mustbe mitered to mateproperly with
t
thestiles. Remove theauxiliary fence from
thetablesawfenceandinstall a crosscut
t
or combination blade. Settheblade angle
:
to 45",makea testcut in a scrapboard,
andchecktheresult witha combination
s q u a r eA.d j u stth ef e n c ep o s i t i oann d
I
b l a d eh e i g hst ot h ec u t i s a sw i d ea n d
d e e pa st h ew i d t ho f t h ee d g em o l d i n g .
I
(Thebladeteethshouldjustprotrude
beyond thetenonshoulder.) Tomakethe
I
cuts,holdthepieceflushagainst thefence
andmitergaugeasyoufeedit edgedown
I
i n t ot h eb l a d eR. e p e at ht ec u t so nt h e
endsof eachmolded edgeof theremain-
t
ingrails(left).
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Notching
thestiles
L e a v et h e t a b l es a wb l a d ea n g l e da t 4 5 " , m e a s u rteh e w i d t h the45" cut andeachendof thestilewitha bandsaw(above,
t
of eachrail,andmarka lineonthemolded edgeof itsmating /eff).Smooth
thecutedgeusingthetablesaw.Leaving therip
stilea conespondingdistancefromtheend.Cutintothemolded fencein place,
holdthestileflushagainstthemitergauge,and
T
edgeat theline,making certainthatthecutwillnotmarthe slidethestockbackandforthacross the blade(above,
righD.
faceof thestile.Sliceoff mostof thestripof moldingbetween Repeat theprocess
forallthestiles.
T
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r36 I
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I
I QUEEN ANNE SE,CRETARY
I
I mortises
Cutting inthestiles
Useoneofthetenonsyoucutinstep1
I a s a g u i d et o o u t l i n i n gt h e m o r t i s eos n
ihp pdops of thp stiles
I pacipr .l:mn
Tn m:kc thp ioh

a l l i h p c . t i l p s t, n o p t h c r f a c p

t o f a c ew i t ht h e i re n d sa l i g n e dI.n s t a lal
I mortisina g t t a c h m e notn y o u rd r i l l p r e s s
a n dc l a m po n es t i l et o t h e f e n c e c, e n t e r -
I i n gt h e m o r t i s oe u t l i n eu n d e tr h e c h i s e l
a n d b i t . M a k et h e d r i l l i n gd e p t hl . i n c h
I m o r et h a nt h e t e n o nl e n g t hm ; a k ea c u t a t
e a c he n do f t h e m o r t i s eb e f o r eb o r i n go u t
I t h e w a s t ei n b e t w e e n( / e f t ) .R e p e at h e
p r o c e d u rteo c u t t h e r e m a i n i n m g ortises.
I
I
t
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t
t
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I Gluingupthe doors
f,
r - , 1T e s t - a s s e m btl he e d o o r sa n d u s ea c h i s e lt o p a r ea w a y c o n t a c t i nsgu r f a c eosf t h e l o i n t s R
. e a s s e m btlhee d o o r sa n ds e t
I s o m ew o o df r o m a n y o v e r l yt i g h t j o i n t .O n c ey o u a r es a t i s f i e d e a c ho n eo n t w o b a rc l a m p sa, l i g n i n g t h e b a r sw i t h t h e r a i l s .
w i t h t h e f i t , s a n da n ys u r f a c etsh a t w i l l b e d i f fi c u l tt o r e a c h U s i n gw o o dp a d st o p r o t e c t h e s t o c k ,t r g h t e nt h e c l a m p s
I w h e nt h e d o o r sh a v eb e e ng l u e du p ,a n ds p r e a d g l u eo n a l l t h e ( a b o v eu) n t i la t h i n g l u eb e a ds q u e e z eosu t o f t h e j o i n t s .

t
I t37
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 t
QUEENANNE SECI{ETARY I
I
INSTALLING
THED()ORS I
'l
I
Preparing forglass
thedoors I
I C i a s sp a n e l sl i e i n r a b b e tasn da r e
h e l di n p l a c eb y t h i ns t r i p so f m o l d i n g . I
C l a m po n ed o o rf r a m et o a w o r ks u r f a c e ,
t h e ni n s t a lal p i l o t e d - i n c hr a b b e t i nbgr r I
i r y o u rr o u t e ' a n os e tt h e d e p t ho f c u tt o
t h ec o m b i n etdh i c k n e sos' t h e g l a s sa n d I
t h e m o d r n g .H o l dt h e t o o lf i r m l yw i t h
b o t hh a n d sw h i l er e s t r ntgh e b a s ep l a t e T
o r t h ef r a m en e a ro 1 ec o r n e rt,n e ng u i d e
the hit into lhp insidpedsp of lhp dnnr I
M o v et h e r o u t e cr o c k w i s ae l o n gt h e
r h e p i l o tb e a r i n g
e d g e si / e I l ) ,k e e p i n g I
p r e s s eadg a i n st th es t o c kS . q u a r teh ec o r
n e r sw i t ha c h r s eal n da w o o d e n mallet. I
R e p e af to rt h e s e c o n d o o r .
r
I
I
I
I
I
I
t
I
r ) M a k i n gt h em o l d i n g
L C u ta o o a r dl o n g etrh a ny o l w i l l n e e d I
f o r t h e m o l d i n gt ,h e ni n s t a lal : / , - i n c i
c o v eb i t i n y o u rr o u t e ra n d m o u n t h e t o o l t
i n a t a b l eA . l i g nt h e b i t b e a r i nw g i t ht h e
f e n c ea n d a d j u s t h e c u t t e rh e i g h t o I
s h a n et h e b o t t n mr - n r n eO" f L h es t o c k .
M o u na t f e a t h e r b o aorndt h et a b l ei n l i n e I
w i t ht h e b i t t o s e c u r et h e s t o c kd u r i n g
t h e c u t .T u r no n t h e t o o la n df e e dt h e I
s t o c k f, i n i s h r ntgh e p a s sw i t ha p u s h
s t i c k .S h a p et h e o t h e re d g eo f t h e b o a r d t
t h e s a m ew a y ( r r g h t )R . r pt h e m o l d i n g
f r o mt h e s t o c ko n t h e t a b l es a wa n dc u t t
t h e m o l d i n tgo l e n g t hm , i t e r i ntgh e e n d s
a t 4 5 ' C u La n df i r o n ep i e c ea t a t i m e . I
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r38 t
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I QUEENANNE SECRETARY
I
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t
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t
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I
-) Installins
thedoorcatches
I <
r . J B e f o r ei n s t a lnr g t l ' e g a s s .m o u n t h e d o o r so n t h e b o o k i n p o s i to n a g a i n sitt s d o o rs t i l e ,t h e nm o v ei t t o w a r dt h e b a c k
c a s ea , t t a c h i ntgh e mw i t h h l n g e st h e s a m ew a yy o uf a s t e n etdh e n a n ehl v i n c r a n dm a r kt h es c r e wh o l e sD. r r lal n i l o th o l ea t
I f a l l - f r o ntto t h e d e s ku n t ( p a g e1 2 6 ) .f t i s e a s i etro i n s t a ltlh e e a c hm a r ka n ds c r e wt h e c a t c hi n p l a c e R . e p e atth e m a r k i n g
d o o rc a t c h e w s i t h o ut h e g l a s si n p l a c eT. h eb a l lc a t c h e s h o w n (above, left) andfastening process for the othercatch.To install
I a b o v ef e a t u r ea c a t c hf a s t e n etdo t h e b o t t o mp a n eol f t h e b o o k - t h e s t r i k ep l a t e i. n s e r itt s s c r e w se,n g a g ei L w i t ht h e c a t c h ,a n d
c a s ea n da s t r i k eo l a t es c r e w e tdo t h e i n s i d ef a c eo f t h e d o o r c o s et n e d o o r t: h e t i p so f t h e s c r e w w s r l .r n a r kr m p r e s s ' o trsn
t s t e s ;t w o s p r i n g - i o a d b ea
d l l si n t h e c a t c hc a p t u r e
t h es t r i k e t h e d o o rs t r l e .D r r l la p i l o th o l ea t e a c hm a r ka n df a s t e nt h e
p a t ew h e nt h e d o o ri s c l o s e dA. s s e m b lteh e c a t c h e sh, o l do n e c t r r k o n l : t p t n t n p d n n r . P\ C^ ^p g^o^t + +l U^l - +L lLl g^ U^ L+I hC^l - ^p ltO^L, g^ (t rau hv vnwv, p rt it tot ht Ll )
I
I
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t
theglass
Securing
I Unscrew t h e d o o r sf r o mt h e b o o k c a s e
a n ds e to n ed o o ri n s i d ef a c eu p o n a w o r k
I crrrf:np Spr : drnn of clp:r olstins cam.

n n r r n d p v p r v f p r n ri n e h p q : l n n o i h p r : h h p i
I Cardboard
i n t h e d o o rf r a m et o p r e v e nt it e g l a s sf r o m
ralllinq Spl lhp ol:c.c.:nd rhp mnldino in
I p l a c ea n d .s t a r n L g 2 r n c h efsr o n I h ec o r
n e r sd. r r l nl i l o h
- o l eas t6 r n c h , n t e r v a l s
I t h " o r r pt h e r r o l d i n a
p n di n t ot h ef r a m e .
T a c kd o w "rrh e r r o l dr g w t h b r a d su. s i n g
I : nipnp nf e:rdhn:rd tn nrntpei thp oL:cq

f r o mt h e h a m m e(rl e f t ) . I of i n i s ho f f t h e
t q p . r p ' : ' r r r' up, i n, JsL tu ," r l ltL h" Lc d
J '
u un g 1 5 .

I
I 139

I
 I
I
GLOSSARY
I
A-B-C.D Clearancehole: A hole bored in a E-F.G-H-I-I I
Adze: An ax-like tool with a curved workpieceto allow free passage
of the Escutcheon:A metal plate installed
blade used to carve out concave shankof a screw. around a keyholefor decoration and I
surfaces,such aschair seats. protectionof the surroundingwood.

Auxiliaryfencs A wooden attachment

screwedto the rip fence of a table saw
or other machine,to prevent damage
to the metal fence.
Basemolding: A decorativeframe made
from molded stock that supports the
bottom ofa desk.
Corner block A triangular block of
wood screwedto an inside corner of a Falsefront A pieceof wood installed
t
table'sleg-and-railassemblyto reinforce
and squarethe joint.
over a drawer front, usuallyto conceal
the end grain ofthe sides.
t
Counterbore: To drill a hole so the Featherboard:A board with thin, flexi- I
head of a screwor bolt will sit below the "feathers"
ble fingersor along one end,
wood surfaceand be concealedwith a clamped to the fenceor table of a sta- I
wood plug. tionary tool to hold the workpiece

Bead: A rounded, convex shapecut in Countersink: To drill a hole so the head

wood, usually for decorationi seecove.
Bending form: A jig used to bend
steamedwood.
Bookmatching: In veneering,a decora-
tive pattern in which successive
veneers
cut from the samelog are arrangedside-
by-sideso as to mirror eachother's
image like pagesof an open book.
Bow: The curved upper rail of a sack-
back Windsor chair.
Brad-point bit: A drill bit featuring a
sharpenedcenterpointand two cutting
spurs on its circumference;produces
cleanerholesthan a twist bit and does
not tend to skateon the surfacewhen
starting a hole.
Carcase:A pieceof furniture with a box-
like construction;madefrom solidpanels.
Caul: Used in veneering or gluing
up carcases,a board placed between
clamps and the workpiece to distribute
clamping pressure.
of a screwwill lie flush with or slightly
below the wood surface.
Cove:A concavedecorativeprofile cut
in wood, usuallyalong an edge;seebead.
Crown or cornice molding: Molding
attachedto the top of a pieceof furniture.
Cuttinglist A list of the dimensionsof
the lumber neededfor a specificproject.
Dado.:A rectangularchannel cut into
a worKplece.
Dovetailed halfJap joint: Used for
joining the top drawer rail of a table to
the legs;the half-lap at the end ofthe
rail is cut in a dovetail shapeto lock
the joint in tension.
Dovetail joint: A method of joinery
using interlocking pins and tails; the
name derivesfrom the distinctive shape
cut into the endsofthe joining boards.
Drop-leaf tabls A table with a narrow
top and hinged leavesthat fold down
securely. I
Fillet In a rule joint, the short, flat surface
at the top ofthe rounded-overportion I
of the joint; the pins of the rule-joint
hingesare alignedwith the fillet. I
Finial: An ornament-usually turned I
or carved-projecting from the upper
cornersof a pieceof furniture.
I
Flyrail A short wood piecethat swings
out from a table side rail to support I
a drop leaf.
t
Froe: An L-shapedtool with a beveled
blade that is struck by a club to rive, or
split,greenwood.
I
Glass-stopmolding: Decorativestrips I
of wood usedto hold a pane of glassin
placein a door. I
Green wood: Freshlycut, unsea-
sonedwood.
I
Half-blind dovetail: Similar to the
I
through dovetailjoint, exceptthat the
pins are not cut through the entire I
thicknessof the workpiece,thus con-

Chamfer: A bevel cut along the edge

when not in use. cealingthe end grain of the tail boards. r
of a workpiece. Dust frame: A flat frame used to
support deskdrawers.
Inlay A decorativestrip of metal, hard-
wood or marquetry that is glued in a
I
CheelcIn a mortise-and-tenonjoint, that
part of the tenon parallelto the wood
groove cut into a workpiece.
t
grain and perpendicularto the shoulder.
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140 I
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t K-r-M-N-O-P-Q
Kerf, A cut madein wood by a sawblade.
I its top edge.
Kickback The tendencyof a workpiece
I to be thrown back in the direction of the
saw operator by a moving blade or cut-
I ter on a woodworking machine or tool.
Knuckle joint: A joint consistingof
I interlocking fingersfixed togetherby a
wooden pin; enablesa fly rail to pivot
.t awayfrom a table side rail.
I Lamb's tongue: On a pencil-postbed,
the shapeat the bottom ofthe octagonal
I portion ofa bedpost.
Loper: On a slant-top desk,a board that
I slidesout of a housing to support the
fall-front in the horizontal position.
I splayangle.
Mortise-and-tenon joint A joinery tech-
I nique in which a projectingtenon on one
board fits into a mortise on another.
t Mortise: A rectangular,round, or oval
hole cut into a pieceof wood to receive
I a matching tenon.
I Neoclassicism:An l8th-Century design
movement inspired by the estheticprin-
I ciplesof classicalGreeceand Rome.
Pigeonhole: A framework of small
I dividers and drawersin a desk:some-
times removable.
I Shoulder: In a mortise-and-tenonjoint,
Pilot bearing: A cylindrical metal collar
I either aboveor below the router bit's
cutting edgethat rides along the work-
pieceor a template,guiding the bit
I during a cut.
I Pilot hole: A hole bored into a work-
piece to accommodatea nail shaft or
I the threadedpart of a screw;usually
slightly smallerthan the fastenerdiam-
I eter.The hole guidesthe fastenerand
preventssplitting.
I Plate joint A method of joining using
oval wafersof compressedwood that fit
I into slotscut in mating boards.
I
I
I
I t41
t
Pocket holq An angledhole bored into
the faceof a workpieceand exiting from
Pommet A rounded shoulderproduced
on the lathe;servesto separatesquare
and cylindrical sectionsof a workpiece.
R.S
Rabbet A steplike cut in the edgeor end
of a board; usually forms part of a joint.
RaiL A board running alongthe bottom
edgeof a tabletopto which the legscan
be attached;also,the horizontal member
of a frame and panelassembly;seestile.
Rake angle: The angleat which a chair
leg or post deviatesfrom the vertical when
viewed from the side of the chair: see
Reveal:The gap betweenthe outside
surfacesofa table rail and the adjoining
legs;servesa decorativepurpose.
Riving: The techniqueof splitting wood
from a freshly felled Iog with a sledge-
hammer and wedgesto separatethe
wood along the fibers.
Rule joint A pivoting joint commonly
usedin dropJeaf tables;featuresmating
concaveand convexprofiles cut into the
edgesofthe tableleafandtop.
the part ofthe tenon perpendicularto
the cheek.In a dovetailjoint, the valleys
betweenthe pins or tails.
Sliding dovetail joint A joinery method
in which a dovetailedslide on one oiece
fits into a matchinggroovein the oiher.
Splay angle The angleat which a chair
leg or post deviatesfrom the vertical
when viewedfrom the front of the chair:
seerake angle.
Steambending: The techniqueofsoft-
ening wood for bending by subjectingit
to steamand heat,and then bending it
around a curved form.
Stile: The vertical member of a frame-
and-panelassembly;seerail.
Stopped dado: A dado that stops before
crossing the full width or thickness of
a workpiece.
Substrate:A piece of plyr,voodor
solid wood used as the foundation
for veneeror leatherthat coversthe
surfaceof a desktop.
T-U-V.W.X.Y-Z
Template A pattern cut from plywood,
hardwood, or particleboard used to
produce multiple copiesof a part.
Tenon: A protrusion from the end of
a board that fits into a mortise.
Tester: A light framework that joins the
tops ofthe bedpostsin a four-posterbed,
often usedto hang a canopyor drapery.
Through dovetail joint A method of
joining wood at the cornersby means
of interlocking pins and tails,both cut
through the thicknessof the workpiece.
Travishen A type ofspokeshavedesigned
for smoothing concavesurfaces.
Urn: A decorativeelementturned in
spindle work; often part of a finial.
Veneer: A thin layer of decorative
wood usedto dressuD a more common
speciesofwood.
Wood button: A small, square-shaped
block with a rabbet at one end that
is used to securethe top of a piece
of furniture.
Wood movemenfi The shrinking or
swelling of wood in reaction to changes
in relative humidity.
 t
I
INDEX
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I
Pagereferences in italicsindicatean Cutting lists Hardware,fr ont endpaper
illustration of subjectmatter.Page
references in bold indicatea Build It
Pembroketables,25
Secretaries, 108
Bedbolts,59
Escutcheons, 135
I
Yourselfproject. Windsor chafts,72 Locks,127
Highboys I
A-B.C D-E-F QueenAnne,12
Adzes,backendpaper Desks Hutches I
Americancountry/colonialstyles, Federalperiod,15 Americancountry/coloniaI, 17
16-19 Mission style,2l
SeealsoSecretaries I-I-K
I
SeealsoFour-posterbeds;Shaker
style;Windsor
Armoires,19
chairs Drop-leaf tables,20
Escutcheons, 135,front endpaper
lnlays,front endpaper
Commercial veneers.29
I
Arts and craftstables,21 Federalperiod style,14-15 Pembroketables,27-29
Beds.SeeFour-posterbeds SeealsoPembroketables Inshaves,backendpaper I
Bendingjigs,82 Finishes Iigs
Biscuitjoints, 109 Milk paint, 70, 103 Bendingjigs,82 t
Blanketchests,20 Four-posterbeds,16,48-50 Drill presspocket-holejigs,47
Block-frontchests,l3
Board feet,front endpaper
Canopies,49
End boards,59-62,64
Routers,119-120
Shop-madeshelf-drillingj igs
t
Gluing up,64 (ShopTip), 131
Bookcases. SeeSecretaries
Build It Yourself Posts,51,52-56,64 Shop-madesizinggaugesfor I
Pipesteamers,83 finials,51,57 spindles(ShopTip), 77
Pocket-holejigs,47 mortises.58 Tablesawtaper jigs,26 t
Shavinghorses,78-79 pencilposts,66-69 Ioinery
Veneerpresses, 125 tang joints,49,56 Half-blind dovetails,109-1I 1 I
Cabriolelegs,12 Siderails,62-63 Knucklejoints,25,30-31
Card tables,12, 14
Chairs
Testers,
Tools,52
51,65 Platejoints,109
Rulejoints, 43
r
Americancountry/colonial,16,18
Chippendale,l3
usingpresetcalipers
(ShopTip), 54
Tangjoints,49,56
Throughdovetailjoints, l16 r
Federalperiod, 14 Frame-and-panel construction Kassay, lohn,6-7
Missionstyle,2l Glass-panel doors,135-1i9 Keyed-tenon stools,l6 t
QueenAnne,12 Frenchprovincialarmoires,19 Knucklejoints,25,30-i1
Shaker,20
SeealsoWindsorchairs
Furniture styles
Americancountry/colonial,16-19 L-M-N.O
t
four-posterbeds,48-69 Ladder-back chairs.l6
Chair tables,16
Chests Windsorchairs,70-103 Langsner,Drew I
Chippendale,13 Chippendale,l3 Windsorchair,18
Shaker,20 Federalperiod, 14-15 Locks I
ChineseChippendalestyle,I3 Pembroketables,15,22-47 Secretaries, 127
Chippendale, Thomas,23 Mission style,21 Logs I
Chippendalestyle,13 QueenAnne,12 Splitting,74
Commodes
Chippendale,13
secretaries.
Shaker,20
104-139 Lumber
Board feet,front endpaper
t
Continuous-armchairs.18 SeealsoCutting lists
Cornercupboards,17 G-H Milk paint, 70, 103 I
Crown molding, 134 Germansawbucktables,19 Mirrors
Cupboards Greene,Charles Federalperiod,15 I
Americancountry/colonial,17,19 Chairs,2l Missionstyle,21
Piesafes,20 Greeneand Greenechairs,2l
Half-blinddovetails.109-1
11
Neoclassical
periodstyle
style.SeeFederal I
New Mexicanchairs,19
Oval-backchairs,l8
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t42 t
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I
P-Q Cuttinglists,108 Through dovetailjoints, 116
I Paint,70, 103
Pembroketables,15,22-25
Deskunits, 106,109
assembly, 113-115
Tools
Adzes,backendpaper
Cornerblocks,40 bases,128-129 Inshaves,backendpaper
I Cutting lists,25 drawers.116-118 Sharpening, backendpaper
Drawersr23r 4l dustframes.I 12 Spokeshaves, backendpaper
I falsefronts, 42 fall-fronts,105,121- 124,126-127 Turning bedposts,52
runners,4l half-blinddovetails,109-1 11 usingpresetcalipers(Shop
I Endrais,34-36
drawerrarls,34,35
leathertops,121
locks,127
Tip),54
Vacuumpresses, 36, 123-124
veneer,36 lopers,l15 Trestletables,I Z
I Gluing up,37-40 platejoints, 109
Joints throughdovetailjoints, Jl6 v-w-x-Y-z
I knucklejoints,25,30-31 veneer,105,122-124,125 Vacuumpresses, 36,123-124
rail-to-leg,25 |oinery,105,109-I 11, 116 Vandal,Norm, l0-11
I Leaves, 23,44-45 Pigeonholeunits, 105,119-120 Veneers
Legs,23,26-27 Settees,14,18 lnlays,29
I doublemortises,35
dovetailsockets,34
Seymourdesks,l5
Shakerstyle,20
Patterns,122
Vacuumpresses, 36,123-124
inlay,27-29 Sharpening, backendpaper Veneerpresses, 125
I rail mortises,37,i8 Shavinghorses,78-79 Weidman,Gregory,8-9
Siderails,30-33 Shelves Window seats,14
I fly rails,32 Bookcases, 130-131 Windsorchairs,18,70-73
tenons,33 shop-madeshelf-drillingjigs Arms,80-82
I Tops,43-46
rule joints, 43
(ShopTip), l3l
ShopTips,46,54,77, 131
posts,88-89,97
spindlemortises,98-99
using steeltabletopfasteners Spindles Bows,80-82, 100-102
I (ShopTip),46 Shop-madesizinggauges Cutting lists,72
Phyfe,Duncan, 14 (ShopTip),7Z Gluingup, 94,95-96,99,102
I Phyfearmchairs,14 SeealsoWindsorchairs Legs,88-89
Piesafes,20 Spokeshaves, backendpaper splayand rakeangles,73,91
I Pipesteamers,83 Steambending,S0 stretchermortises,94
Platejoints,109 Bendingjigs,82 stretchers, 88,92-93
t QueenAnne style,I l, 12
SeealsoSecretaries
Pipesteamers,83
Stickley,Gustav,2l
trimming,94
Milk paint, 70, 103
Stickleyrocking chairs,21 Seats,7l,84-87
I R-S.T-U Stools legmortises,90-9I
Riving greenwood,,74-75 Americancountry/colonial,16 Spindles
I Rocki-n[chairs Shaker,20 blanks,74-75
Mission styLe,2l Styles.SeeFurniture styles installing,98-102
I Shaker,20
Roll-topdesks,2I
Tables
Americancountry/colonial,16,17
shaping,T6-77
shop-madesizinggauges
Rulejoints,43 Chippendale,13 (ShopTip),7Z
I Sack-back Windsorchairs. Federalperiod, 14-15 Wood
SeeWindsorchairs Germansawbuck,19 Board feet,fr ont endpaper
I Sawbucktables,l9 Mission style,2l Green.74-75
Secretaries,
12,104-105 QueenAnne,12 SeealsoCutting lists
I Bookcases, 107 Shaker,20 Zoar chairs.19
assembly, 132-133 Tangjoints,49,56
I crown molding, 134
doors,135-139
Thverntables,17
Teatables,l3
t shelving,130-131
shop-madeshelf-drillingjigs
(ShopTip), r31
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ACKNOWTEDGMENTS
Theeditorswishto thank thefollowing
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CLASSICAMERICAN FURNITURESTYLES I
Winterthur Museum,Winterthur, DE

PEMBROKETABLE
I
AdjustableClampCo.,Chicago,IL; Albert Constantineand SonInc.,Bronx,NY; AmericanTool Cos.,
Lincoln, NE; Black& Decker/EluPowerTools,Towson,MD; CMT Tools, Oldsmar,FL; Delta I
InternationalMachineryiPorter-Cable,Guelph,Ont.; GreatNeckSawMfrs. Inc. (BuckBros.Division),
Millbury, MA; LesRealisationsLoeven-Morcel,Montreal, Que.;Sears,Roebuckand Co., Chicago,IL;
StanleyTools,Division of the StanleyWorks, New Britain, CT; Tool Trend Ltd., Concord,Ont.;
I
Vacuum PressingSystemsInc., Brunswick,ME; WainbeeLtd., Pointe Claire,Que./DE-STA-CO,
Troy, MI; The Woodworker'sStore,Rogers,MN I
FOUR-POSTERBED
AdjustableClamp Co., Chicago,IL; AmericanTool Cos.,Lincoln,NE; CMT Tools,Oldsmar,FL; ;
Delta InternationalMachinery/Porter-Cable,Guelph,Ont.; GreatNeck SawMfrs. Inc. (Buck Bros.
DMsion), Millbury, MA; Jean-Pierre
Masse,Montreal,Que.;PackardWoodworks,Tryon, NC; RecordTools,
Inc.,Pickering,Ont.; RyobiAmericaCorp.,Anderson,SC;Sears,Roebuckand Co.,Chicago,IL; Stanley
t
Tools,Division of the StanleyWorks, New Britain, CT; WoodcraftSupplyCorp.,Parkersburg,
WV
I
WINDSORCHAIR
AdjustableClamp Co., Chicago,IL; Anglo-AmericanEnterprisesCorp., Somerdale,NJ; Mike Dunbar,
Portsmouth,NH; GreatNeck SawMfrs. Inc. (Buck Bros.Division), Millbury, MA; Drew Langsner,
I
Marshall,NC; LeeValleyTools,Ltd., Ottawa,Ont.; Olde Mill CabinetShoppe,York, PA; StanleyTools,
Division of the StanleyWorks, New Britain, CT I
QUEENANNESECRETARY
AdjustableClamp Co., Chicago,IL; Albert Constantineand Son Inc., Bronx, NY; AmericanTool Cos.,
t
Lincoln,NE; CMT Tools,Oldsmar,FL; DeltaInternationalMachinery/Porter-Cable, Guelph,Ont.;
GreatNeckSawMfrs. Inc. (BuckBros.Division),Millbury, MA; David Keller,Petaluma,CA; LeeValleyTools, I
Ltd. Ottawa,Ont.; LesRealisations
Loeven-Morcel, Montreal,Que.;Sears,Roebuckand Co.,Chicago,IL;
Steiner-Lamello
VacuumPressing
A.G. Switzerland/Colonial
Systems
SawCo., Kingston,MA; Tool Trend Ltd., Concord,Ont.;
Inc.,Brunswick,ME; WainbeeLtd.,PointeClaire,Que./DE-STA-CO, Troy, MI
I
Thefollowingpersonsalsoassisted
in thepreparationof this book: t
LorraineDord, SylvieGirard, SolangeLaberge,GenevidveMonette,David Simon. t
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PICTURE CREDITS
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Cover RobertChartier
6,7 Ron Levine
8,9TomWolff
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10,11RobertHolmes
14,16Courtesyof The HenryFrancisdu PontWintherthurMuseum I
18 Martin Fox
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W O R K S H OGPU I D E
SHARPENING
SP()KESHAVES
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I Honing thebladeof a metalspokeshave
To removethe bladefromthe spokeshave,
I l o o s e tnh es c r e wi n t h e m i d d l eo f t h e h a n d l e .
Sharpening thebladeof a woodenspokeshave Set up a benchstoneon a worksurface;a
I R e m o vteh e b l a d ef r o mt h e h a n d l eb y p i n c h i n g t h e t a n g st h a t p r o t r u dteh r o u g h w a t e r - l u b r i c a tdeida m o n ds t o n ei s s h o w n
t h e h a n d l ea n dp u s h i n tgh e md o w n w a r dF.o rs h a r p e n i ntgh,e b l a d ei s h e l dw i t h a b o v eI.n s t a l l t h e b l a d ei n a c o m m e r c i a l
I the tangsfacingdown.To preventthe tangsfromcatchingon yourworksurface, h o n i n gg u i d e .L u b r i c a t teh e s t o n ew i t h
setyoursharpening stoneatopa woodblockto provide the necessary clearance. w a t e ra n dt h e n ,h o l d i n tgh e h o n i n gg u i d e ,
I H o l d i n tgh e b l a d eb yt h e t a n g ss, e ti t s b e v efll a to n t h e s t o n eB . e c a u steh e b l a d e s l i d et h e b l a d eb a c ka n d f o r t hf r o me n dt o
i s l o n g etrh a nt h e w i d t ho f y o u rs t o n e h, o l dt h e c u t t i n ge d g ed i a g o n a l a l ys y o u e n da l o n gt h e s h a r p e n i nsgu r f a c eA. p p l y
I s l i d et h e b e v e bl a c ka n df o r t ho n t h e s t o n e R . e p e awt i t ht h e b l a d ea n g l e dt h e m o d e r a tper e s s u rwei t ht h e b e v etlo u c h i n g
o t h e rw a y .R e p e aat g a i nw i t h t h e b l a d eh e l ds t r a i g hbt b o v e ) . 0 n c e t h es h a r p e n - t h e s t o n eT. h e nr a i s et h e a n g l eo f t h e b l a d e
I i n g i s c o m p l e t et u
, r nt h e b l a d eo v e ra n d h o n et h e f l a t s i d et o r e m o v teh e b u r r a f e wd e g r e easn dc o n t i n u eu n t i ly o uf o r ma
f o r m e db y t h e s h a r p e n i npgr o c e s s . s e c o n d a rbye v e l - o rm i c r o b e v e l .
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SHARPENING
ANINSHAVE SHARPENING
ANADZE
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I H o n i na g na d z e
S e c u r et h e a d z ei n a b e n c hv i s e ,a s s h o w n
I H o n i na gni n s h a v e a b o v eW . r a pa s h e e to f e m e r yp a p e ra r o u n d
C l a m pt h e i n s h a vteo a w o r ks u r f a c seo t h ec u t t i n ge d g ei s f a c i n gu p ,a s s h o w n a d o w ew l h o s ed i a m e t ecr l o s e l ym a t c h e s
I above.Usea slipstone to honethe edge.Startwith a rough-grit stoneand progress t h e c u r v eo f t h e a d z eb l a d eH . o n et h e c u t t i n g
t o a f i n e ro n e .W o r kw i t ha c i r c u l am r o t i o nu n t i la u n i f o r ms h i n ed e v e l o posn t h e e d g eu s i n ga b a c k - a n d - f o rmt ho t i o na l o n g
I b l a d eG . i v et h e f l a ts i d eo f t h e b l a d ea f e ws t r o k etso r e m o v a e n yb u r r .O n c et h e t h e l e n p t ho f t h e h e v e l H o n et h e f l a t s i d e
b l a d ei s s h a r pp, o l i s ht h e b e v ew l r t ha l e a t h esrt r o pa n dp o l i s h i ncgo m p o u n df i,n - o f t h e b l a d ew i t h a s l i p s t o n teo r e m o v ea n y
I i s h i n gw i t ha f e wp a s s eosn t h e f l a ts i d eo f t h e b l a d et o r e m o v teh e b u r r .l f t h e b u r r .l f t h e a d z eh a sa k n i f e - e d g eh,o n e
inshavehasa knife-edgebeveled on bothsides-honebothsides. bothsides.
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